xvs1100 v-star 1100 (99-00) service manual

–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


√ √ √ √ √ √


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–


CHKADJ

NOTE:



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.


–22–


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–


123456

Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly

112121

Remove the parts in the order listed.Drain


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–


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–


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–





CABLE ROUTING SPEC







–14–





CABLE ROUTING SPEC




guard clamp.



body.

–15–

CABLE ROUTING SPEC



–16–


CHKADJ

NOTE:

EB300000











Replace. √ √


√ √ √ √




√ √ √ √ √

7 * Front brake


√ √ √ √ √ √


8 * Rear brake


√ √ √ √ √ √





√ √ √ √

11 * Tires


√ √ √ √







√ √ √ √ √


–17–


CHKADJ

NOTE:




18 *Rear shock




√ √


√ √ √ √ √ √








√ √ √ √ √ √

EAU03541



–18–


WARNING

CAUTION:











8. Connect: leads

–19–


a

b

a

b

EAS00184









–20–


NOTE:




–21–


12345678

9


11111111

1




–22–


EAS00510






1 Surface plate



–23–


123456


112121




6 Nm (0.6 mkg)

27 Nm (2.7 mkg)

30 Nm (3.0 mkg)



–24–


12345678



1–

1/11

1/1111




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–


9101112131415


1111111



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–





CABLE ROUTING SPEC







–14–





CABLE ROUTING SPEC




guard clamp.



body.

–15–

CABLE ROUTING SPEC



–16–


CHKADJ

NOTE:

EB300000











Replace. √ √


√ √ √ √




√ √ √ √ √

7 * Front brake


√ √ √ √ √ √


8 * Rear brake


√ √ √ √ √ √





√ √ √ √

11 * Tires


√ √ √ √







√ √ √ √ √


–17–


CHKADJ

NOTE:




18 *Rear shock




√ √


√ √ √ √ √ √








√ √ √ √ √ √

EAU03541



–18–


WARNING

CAUTION:











8. Connect: leads

–19–


a

b

a

b

EAS00184









–20–


NOTE:




–21–


12345678

9


11111111

1




–22–


EAS00510






1 Surface plate



–23–


123456


112121




6 Nm (0.6 mkg)

27 Nm (2.7 mkg)

30 Nm (3.0 mkg)



–24–


12345678



1–

1/11

1/1111




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–


9101112131415


1111111



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



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



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



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


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


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


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


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


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


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


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


Item Standard

Lubrication chart:

Left crankcase Right crankcase


2-11

Cylinder head tightening sequence:

Crankcase tightening sequence:

2-12


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


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


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


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


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


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


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


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


2-25

4 Middle drive shaft5 Drive axle6 Connecting rod big end

1 Camshaft2 Crankshaft3 Main axle


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.




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


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


INSPADJ

EB300000


PERIODIC MAINTENANCE/LUBRICATION INTERVALSEVERY

NO. ITEM CHECKS AND MAINTENANCE JOBSInitial

(1,000 km)

6,000 kmor

6 months(whichevercomes first)

12,000 kmor


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)


√ √

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


12,000 kmor


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.


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.


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


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


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.


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)


4. Check:engine idling speedOut of specification Adjust.


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”.


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.


4 6 mm


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


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.


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)


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


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.


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.


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.


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.


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.


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.


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


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


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.


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.


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)


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


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


Charging method using a constant-voltage type charger


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






3-45

REPLACING THE HEADLIGHT BULB/ADJUSTING THE HEADLIGHT BEAM

INSPADJ

CAUTION:

a

b

a

b




7. Connect: leads

EAS00184









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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1


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


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


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


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


Disconnect

DisconnectRefer to “INSTALLING THE ENGINE”.

Disconnect


64 Nm (6.4 mkg) 64 Nm (6.4 mkg)

ENGINE REMOVAL ENG

LEADS, SHIFT PEDL AND CLUTCH CABLE

4-4


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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.


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


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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


89

101112

Timing chain tensioner/gasketCamshaft sprocketCylinder headDowel pinsCylinder head gasket

1/11121


Refer to “REMOVING/INSTALLING THECYLINDER HEADS”.


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


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”.


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


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”.


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.


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.


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


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Removing the rocker arm andcamshaftCylinder headsStopper plateCamshaft bushingCamshaft /dowel pinUnion bolt /gasketRocker arm shaftsRocker armsLocknutsValve adjusters

11

1/11/12222


Refer to “CYLINDER HEAD”.


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


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


4-20


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


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


Refer to “CYLINDER HEADS”.Refer to “ROCKER ARMS ANDCAMSHAFT”.Refer to “REMOVING/INSTALLING THE VALVES”.


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


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


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


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


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


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.



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


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


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


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)


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


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”.


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


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



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


67

Dowel pinsCrankcase cover gasket

21


New

10 Nm (1.0 mkg)

CLUTCH ENG

4-40


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


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


151617

Thrust washerClutch housingLong clutch push rod

111


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)


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)


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.


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


123456789

Removing the generator and starterclutch.RotorDowel pinsSpringsWoodruff keyShaftStarter idler gearCirclipStarter clutch drive gearStarter clutch assembly

166111111

Remove the parts in the order listed


Refer to “REMOVING/INSTALLINGTHE GENERATOR.”

Refer to “INSTALLING THEGENERATOR.”

175 Nm (17.5 mkg)

12 Nm (1.2 mkg)


GENERATOR AND STARTER CLUTCH

4-49


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.


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


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.


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


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 .


4-52


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


123456

Removing the shift shaft and stopperlever.Engine oil

Left crankcase coverRotor assemblyShift shaftCirclipTorsion spring (stopper lever)Stopper leverCirclipTorsion spring (shift shaft)

111111


Refer to “ENGINE OIL REPLACEMENT”in CHAPTER 3.


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


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”.


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


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


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”.


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


1

2345678

Removing the crankshaft andconnecting rodCrankshaft assembly

Oil pump drive sprocketBearingNuts (connecting rod caps)Connecting rod boltsConnecting rodsConnecting rod capsPlain bearings

1

1144224


Refer to “REMOVING/INSTALLINGTHE CRANKSHAFT”.


Refer to “INSTALLING THECRANKSHAFT”.

48 Nm (4.8 mkg)

Refer to “REMOVING THE CONNECTINGRODS/INSTALLING THECRANKSHAFT”.


4-60

CRANKSHAFT AND CONNECTING RODS

4-61

A

B


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


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


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.


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


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.


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


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


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”.


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


1

23456789

Removing the middle drive piniongearSepalate the crankcase

Bearing retainer

Spring retainersSpring seatDamper springDamper camsNutBearingShim(s)Middle drive pinion shaft

1

21121111


Refer to “CRANKSHAFT ANDCONNECTING ROD.”Refer to “REMOVING THE MIDDLEDRIVE SHAFT ASSEMBLY/INSTALLINGTHE MIDDLE GEAR ASSEMBLY ANDADJUSTING THE BACKLASH”.


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


12345

6

789

Removing the middle drivenpinion gear.BoltsCirclipsBearingsDriven yokeNut

Drive yoke

Bearing housing/O-ringWashersCollar

32211

1

1/131


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


1011

121314

Collapsible collarMiddle driven shaft

Oil sealBearingBearing

11

11


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. . . . . . . . . . . . . . . . . . . . . .

5-1


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.


NOTE:

10 Nm (1.0 mkg)

CARBURETOR CARB

CARBURETIONCARBURETOR

5-2


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


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)”.


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.

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


123456

Removing the front wheel and brakediscs

Brake calipersFront wheel axle pinch boltFront wheel axleFront wheel assemblyCollarsBrake discs

211122



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



Disassembling the front wheelOil sealsBearingsCollar

221



123

6-2

6-3


WARNING

NOTE:

NOTE:

NOTE:

WARNING

EAS00521

REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.



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


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.


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


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.


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


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


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


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


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


1234

Removing the muffler and brakecaliperMufflerMuffler stayBrake hose holderBrake caliper

1111


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


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



DrainRefer to “FINAL GEAR OIL REPLACE-MENT” in CHAPTER 3.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.Loosen


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

6-12



Rear wheel disassemblyDisassembling the rear wheelLock washersClutch hubDampersO-ringsOil sealBearingSpacerBearing

21621111



12345678

62 Nm (6.2mkg)

6-13


WARNING

NOTE:

NOTE:

EAS00562

REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.


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


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


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


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


1234

Removing the front brake padsRetaining boltBrake caliperBrake padsPad spring

1121



Refer to “REPLACING THE FRONTBRAKE PADS”.

23 Nm (2.3 mkg)


FRONT AND REAR BRAKESFRONT BRAKE PADS

6-17


1234576

Removing the rear brake padsMufflerMuffler stayBrake hose holderCaliperCoverClipsPad pinsPad springBrake pads

1112212



Refer to “REPLACING THE REARBRAKE PADS”.

Refer to “REAR WHEEL AND BRAKEDISC”.

40 Nm (4.0 mkg)


EAS00578

REAR BRAKE PADS

6-18


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


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.


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


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


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.


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


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


Drain


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 BRAKE MASTER CYLINDER

6-23


Disassembling the front brakemaster cylinderDust bootCirclipMaster cylinder cupSpring

1111



1234


6-24


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


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)


EAS00586

REAR BRAKE MASTER CYLINDER

6-25


Disassembling the rear brake mastercylinderMaster cylinder bootCirclipMaster cylinder cupSpring

1111



1234


6-26


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


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


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.


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)


6-29


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.



4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.



6-30


WARNING

CAUTION:

WARNING

CAUTION:

EAS00610

INSTALLING THE REAR BRAKE MASTERCYLINDER1. Install:copper washers (New)brake hose

Union bolt30 Nm (3.0 mkg)


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)



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.





6-31


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


123456


112111




30 Nm (3.0 mkg)

23 Nm (2.3 mkg)

6 Nm (0.6 mkg)


FRONT BRAKE CALIPERS

6-33


Disassembling the front brakecalipersPad springBrake caliper pistonsDust sealsCaliper piston sealsBleed screw

12221



Refer to “REMOVING THE FRONTBRAKE CALIPERS”.

12345


6-34


12345

Removing the rear brake caliperMufflerMuffler stayBrake fluidBrake hose holderUnion boltCopper washersBrake hoseCaliper ass’y

11211


Drain


Refer to “REMOVING/INSTALLINGTHE REAR BRAKE CALIPER”.


40 Nm (4.0 mkg)

30 Nm (3.0 mkg)


ESA00616

REAR BRAKE CALIPER

6-35


Disassembling the rear brake caliperCoverClipsPad pinsPad springBrake padsCaliper pistonsDust sealsPiston sealsBleed screw

122122221



Refer to “DISASSEMBLING THE REARBRAKE CALIPER”.

123456789


6-36


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


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


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.



6-39


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


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)



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.



6-40

CAUTION:

WARNING





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.



6-41


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


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)



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.


6-42

CAUTION:

NOTE:


4. Bleed:brake system


Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” 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


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”.


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


Disassembling the front forkCap boltO-ringSpacerSpring seatFork springDust sealOil seal clipDamper rod boltCopper washerDamper rod/rebound springOil seal

111111111

1/11


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


Seal spacerOuter tube bushingInner tube/inner tube bushingOil lock pieceOuter tube

11

1/111


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.



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


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



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)


1213141516

Throttle grip assemblyHandlebar holders (upper)HandlebarCable guideHandlebar holders (lower)

12112


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.


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.


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.


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.


4 6 mm

6-58


12345678


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




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


9101112131415


1111111


7 Nm (0.7 mkg)

1st

110 Nm (11.0 mkg)

2nd52 Nm (5.2 mkg)18 Nm (1.8 mkg)


STEERING HEAD CHAS

6-60

STEERING HEAD CHAS

WARNING

NOTE:

WARNING

EAS00677

REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.


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


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


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”.


7 Nm (0.7 mkg)

REAR SHOCK ABSORBER AND SWINGARM CHAS

REAR SHOCK ABSORBER AND SWINGARMRIGHT SIDE COVER AND BATTERY BOX

6-64


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


7 Nm (0.7 mkg)


LEFT SIDE COVER AND TOOL BOX

6-65


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.



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

6-66


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


WARNING

NOTE:

CAUTION:

NOTE:

EAS00694

REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.



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


WARNING

NOTE:

EAS00702

REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.



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


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


NOTE:

CAUTION:

EAS00698

INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Install:swingarmRefer to “INSTALLING THE SWINGARM”.

2. Lubricate:spacersbearings


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


6-71


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


123

4

Removing the final drive assemblyand drive shaft.

Rear wheel assembly

CollarDrive shaft assemblyFinal drive pinion gear assembly

Final gear assembly

111

1




Refer to “DISASSEMBLING THE FINALDRIVE ASSEMBLY/ALIGNING THEFINAL DRIVE PINION GEAR AND RINGGEAR”.


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


Disassembling the final gear.Bolts (bearing housing)Nuts (bearing housing)

Bearing housing/O-ringRing gearShim (s)Thrust washer

26

1/1111


Working in a crisscross pattern, looseneach bolt and nut 1/4 of a turn. After allthe bolts and nuts are loosened, removethem.


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.


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.


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


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.


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


7-6

WARNING

CAUTION:

NOTE:


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.


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


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.


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


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


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.


EAS00743

7-11


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


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


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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Sta

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Sta

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Sta

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Eng

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sw

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36 38

Dio

de60

ELECTRIC STARTING SYSTEM ELEC

EB803000

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

7-14


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


2. Battery


Open-circuit voltage12.8 V or more at 20 C

Is the battery OK?

YES



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


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)


1) battery cover2) rider’s seat3) fuel tank4) steering head side covers5) left side coverTroubleshoot with the following specialtool(-s).


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


Are the tester readings correct?

EAS00760

Tester positive probe

black/yellowTester negative probe

sky blue

2

1

Nocontinuity


EAS00759

7-17

YES

Replace the starterrelay.

NO

Battery positive terminal red/whiteBattery negative terminal blue 2

EAS00750



YES


NO


EAS00751



YES


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



YES


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.


EAS00761

7-18

EAS00766

NO

The starting systemcircuit is OK.

YES

YES


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?


EAS00764

12

1234567891011


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



Disassembly the pats in the order listed.

Refer to “Assembling the starter motor.”



For assembly, reverse the disassemblyprocedure

10 Nm (1.0 mkg)



7-19

STARTER MOTOR

7-20


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.


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


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


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


2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.


Is the battery OK

YES



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)


1) battery cover2) rider’s seat3) left side coverTroubleshoot with the following specialtool(-s).

Engine tachometer90890-03113


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.


LIGHTING SYSTEM ELEC

7-26

49464 7 8 25 27 4844 50 52

Aux

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Pas

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itch

Mai

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Bat

tery

Mai

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eter

ligh

tH

igh

beam

indi

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Hea

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Dim

mer

sw

itch

Tail/

brak

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ight

fuse

Ligh

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itch

39

EB805000

LIGHTING SYSTEMCIRCUIT DIAGRAM

7-27



YES


NO

YES



NO


NO

EAS00749

3. Main switch



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


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


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).


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


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.


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).


1

B

1

4


7-30

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.


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).


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).


1


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


YES


NO

YES



NO


NO

EAS00749

3. Main switch



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)


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).


EAS00738

7-34


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.


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.


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


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).


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).


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).


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


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).


12


NO

2. Neutral switch



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


7-38

Set the main switch to “ON”.Measure the voltage (12 V) of brown andblack/red at the meter assembly coupler.


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


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


2. Battery



Is the battery OK?

YES


Recharge or repla-ve the battery.

NO

EAS00749



YES


NO

3. Main switch

EAS00750



YES


NO


NOTE:

YES NO


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


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).


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


YES

7. Wiring

Properly connect orrepair the fuel pumpsystem’s wiring.

21


EB803023 EB808021

7-43


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



Is the battery OK?

YES NO

EAS00739



EAS00749



YES


NO

3. Main switch

EAS00751



YES


NO

4. Neutral switch


NOTE:

YES NO


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


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).


EAS00738

7-46


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


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.


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


1) rider seat2) fuel tank3) air filter case4) left side coverTroubleshoot with the following specialtool(-s).


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?


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–





CABLE ROUTING SPEC







–14–





CABLE ROUTING SPEC




guard clamp.



body.

–15–

CABLE ROUTING SPEC



–16–


CHKADJ

NOTE:

EB300000











Replace. √ √


√ √ √ √




√ √ √ √ √

7 * Front brake


√ √ √ √ √ √


8 * Rear brake


√ √ √ √ √ √





√ √ √ √

11 * Tires


√ √ √ √







√ √ √ √ √


–17–


CHKADJ

NOTE:




18 *Rear shock




√ √


√ √ √ √ √ √








√ √ √ √ √ √

EAU03541



–18–


WARNING

CAUTION:











8. Connect: leads

–19–


a

b

a

b

EAS00184









–20–


NOTE:




–21–


12345678

9


11111111

1




–22–


EAS00510






1 Surface plate



–23–


123456


112121




6 Nm (0.6 mkg)

27 Nm (2.7 mkg)

30 Nm (3.0 mkg)



–24–


12345678



1–

1/11

1/1111




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–


9101112131415


1111111



1st2nd

52 Nm (5.2 mkg)18 Nm (1.8 mkg)

110 Nm (11.0 mkg)

7 Nm (0.7 mkg)

STEERING HEAD CHAS

xvs1100 v-star 1100 (99-00) service manual

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