Yamaha TDM850 Service manual

EB000000
TDM850 ’96
SERVICE MANUAL
1996 by Yamaha Motor Co., Ltd.
First edition, March 1996
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a
basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
Without such knowledge, attempted repairs or service to this model may render if unfit to use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha
dealers and will, where applicable, appear in future editions of this manual.
PARTICULARY IMPORTANT INFORMATION
This material is distinguished by the following notation.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander, or a person inspecting or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This 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 each section.
It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by
corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal
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 by a
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 marks 6 . 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 of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the
exploded diagram and the job instruction chart.
2
1
4
3
6
8
5
7
EB003000
1
GEN
INFO
3
2
ILLUSTRATED SYMBOLS
SPEC
Illustrated symbols 1 to 9 are printed on top
right of each page and indicate the subject of each
chapter.
4
INSP
ADJ
ENG
5
6
COOL
CARB
7
1
2
3
4
5
6
7
8
9
General information
Specifications
Periodic inspections and adjustments
Engine
Cooling system
Carburetion
Chassis
Electrical
Troubleshooting
8
CHAS
ELEC
10
Illustrated symbols 10 to 17 are used to identify
the specifications appearing in the text.
11
12
10
11
12
13
14
15
16
17
13
14
9
TRBL
SHTG
15
16
17
18
19
20
21
24
22
23
25
Can be serviced with engine mounted
Filling fluid
Lubricant
Special tool
Torque
Wear limit, clearance
Engine speed
Ω, V, A
Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18
19
20
21
22
23
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply lightweight lithium soap base grease
Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply a locking agent 24
and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Replace
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
INSP
ADJ
3
ENG
4
COOL
5
CARB
6
CHAS
7
ELEC
8
TRBL
SHTG
9
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-3
1-3
1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the right side of the steering head.
NOTE:
The vehicle identification number is used to identify the motorcycle and may be used to register the
motorcycle with a licensing authority.
EB100030
ENGINE SERIAL NUMBER
The engine serial number 1 is stamped into the
crankcase.
NOTE:
The first three digits of the engine serial number
indicate the model type; the remaining digits are
the unit production number.
MODEL LABEL
The model label 1 is affixed to the frame. This information will be needed to order spare parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
1. Remove all dirt, mud dust, and foreign material
before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling the motorcycle keep
mated parts together. This includes gears, cylinders, pistons, and other mated parts that
have been “mated” through normal wear.
Mated parts must be reused as an assembly or
replaced.
4. During the motorcycle disassembly, clean all
parts and place them in trays in the order of disassembly. This will speed up assembly time
and help assure that all parts are correctly reinstalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all replacements. Use oil and/or grease recommended
by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals and O-rings should be replaced when an engine is overhauled.
All gaskets surfaces, oil seal lips and O-rings
must be cleaned.
2. Properly oil all mating parts and bearing during
reassembly. Apply grease to the oil seal lips.
1-2
IMPORTANT INFORMATION
GEN
INFO
LOCK WASHERS/PLATES AND COTTER PINS
1. All lock washers/plates 1 and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or nut
flat(s) after the bolt or nut has been properly
tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) and oil seal(s) with their
manufacturer’s marks or numbers facing outward. (In other word, the stamped letters must
be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings dry. This causes damage to the bearing
surfaces.
2 Bearing
CIRCLIPS
1. All circlips should be inspected carefully before
reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When
installing a circlips 1 , make sure that the sharp
edged corner 2 is positioned opposite to the
thrust 3 it receives. See the sectional view.
4 Shaft
1-3
CHECKING OF CONNECTIONS
GEN
INFO
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two or
three times.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed above
when checking the wireharness.
For a field remedy, use a contact revitalizer available on the market.
Use the tester on the connector as shown.
1-4
HOW TO USE THE CONVERSION TABLE
CONVERSION TABLE
HOW TO USE THE CONVERSION
TABLE
METRIC TO IMPERIAL
All specification data in this manual are listed in SI
and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC
**mm 2 mm MULTIPLIER
0.03937
=
0.03937
=
GEN
INFO
Metric unit Multiplier Imperial unit
IMPERIAL
**in
0.08 in
1-5
Torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
Weight
kg
g
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lit (liter)
lit (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/mm
55.997
kg/cm2
14.2234
Centigrade 9/5+32
(_C)
lb/in
psi (lb/in2)
Fahrenheit
(_F)
SPECIAL TOOLS
GEN
INFO
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly.
Using the correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.
Tool No.
90890-01083
90890-01084
Tool name/How to use
Slide hammer bolt
Weight
These tools are used to remove the
main axle assembly cover.
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
level in the float chamber.
90890-01325
90890-01352
Radiator cap tester
Adapter
This tester is needed for checking the
cooling system.
90890-01362
90890-01382
Flywheel puller
Crankshaft protector
These tools are used to remove the A.C.
magneto.
90890-01367
90890-01374
Fork seal driver weight
Adapter
These tools are used when installing the
fork seal.
90890-01326
90890-01465
T-handle
Damper rod holder
These tools are used to loosen and
tighten the front fork damper rod
holding bolt.
90890-01403
Ring nut wrench
This tool is used to loosen and tighten
the steering ring nut.
1-6
Illustration
SPECIAL TOOLS
Tool No.
Tool name/How to use
90890-01701
Sheave holder
90890-03081
This tool is used to hold the rotor when
loosening and tightening the rotor bolt.
Compression gauge
90890-03094
This gauge is used to measure the
engine compression.
Vacuum gauge
90890-03112
This gauge is needed for carburetor
synchronization.
Pocket tester
90890-03113
This instrument is invaluable for
checking the electrical system.
Engine tachometer
90890-03141
This tool is needed for detecting
engine rpm.
Timing light
90890-04016
This tool is necessary for checking
ignition timing.
Valve guide remover, installer and
reamer (5.5 mm)
90890-04019
90890-04108
These tools are used to remove, install
and rebore the valve guide.
Valve spring compressor
Attachment
90890-04086
These tools are needed to remove and
install the valve assemblies.
Universal clutch holder
90890-06754
This tool is used to hold the clutch when
removing or installing the clutch boss
nut.
Ignition checker
This instrument is necessary for
checking the ignition system components.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-85505
Tool name/How to use
Yamaha bond No. 1215
This sealant (bond) is used on crankcase
mating surfaces, etc.
1-8
GEN
INFO
Illustration
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2-4
2-11
2-15
GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . . . . 2-18
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Model:
TDM850
Model code:
4TX1
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,165 mm, 2,200 mm (D, DK, SF, N, S)
790 mm
1,285 mm
805 mm
1,475 mm
165 mm
2,900 mm
Basic weight (With oil and full fuel tank): 229 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Liquid-cooled 4-stroke, DOHC, 5 valve
Forward-inclined parallel 2-cylinder
0.849 L
89.5 67.5 mm
10.5 : 1
1,200 kPa (12 kg/cm2, 12 bar) at 300 r/min
Electric starter
Lubrication system:
Dry sump
Oil type or grade:
Engine oil
API Standard:
API SE or higher grade
Oil capacity:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
3.5 L
3.6 L
4.2 L
2-1
GENERAL SPECIFICATIONS
Item
Standard
Air filter:
Dry type element
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
20 L
3.1 L
Carburetor:
Type/quantity
Manufacturer
BDST38/2
MIKUNI
Spark plug:
Type
Manufacturer
Spark plug gap
DPR8EA-9/X24EPR-U9
NGK/NIPPONDENSO
0.8 X 0.9 mm
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio
1st
2nd
3rd
4th
5th
Spur gear
67/39 (1.718)
Chain drive
42/17 (2.471)
Constant mesh 5-speed
Left foot operation
37/13 (2.846)
37/20 (1.850)
30/21 (1.429)
27/23 (1.174)
28/27 (1.037)
Chassis:
Frame type
Caster angle
Trail
Diamond
24.5
103 mm
Tire:
Type
Size
Manufacturer
Type
SPEC
front
rear
front
rear
front
rear
Tubeless
110/80 ZR18
150/70 ZR17
BRIDGESTONE/PIRELLI/MICHELIN
BRIDGESTONE/PIRELLI/MICHELIN
BT54F/MTR03/MACADAM90X
BT54R/MTR04/MACADAM90X
2-2
GENERAL SPECIFICATIONS
Item
Standard
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High speed riding
front
rear
Brake:
Front brake
Rear brake
type
operation
type
operation
180 kg
0 90 kg
225 kPa (2.25 kg/cm2, 2.25 bar)
275 kPa (2.75 kg/cm2, 2.75 bar)
90 180 kg
225 kPa (2.25 kg/cm2, 2.25 bar)
275 kPa (2.75 kg/cm2, 2.75 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
275 kPa (2.75 kg/cm2, 2.75 kg/cm2)
Dual disc brake
Right hand operation
Single disc brake
Right foot operation
Suspension:
Front suspension
Rear suspension
Telescopic fork
Swingarm (monocross)
Shock absorber:
Front shock absorber
Rear shock absorber
Coil spring/Oil damper
Coil spring/Gas-oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
149 mm
144 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
T.C.I. (digital)
A.C. magneto
GT12B-4
12 V 10 AH
Headlight type:
Quartz bulb (halogen)
Bulb wattage quantity:
Headlight
Auxiliary light
Tail/brake light
Flasher light
Meter light
Indicator lights
Neutral
Turn
High beam
12 V 55 W 2
12 V 5 W 1
12 V 5/21 W 2
12 V 21 W 4
12 V 3.4 W 1
12 V 1.7 W 2
12 V 3.0 W 1
12 V 3.4 W 1
12 V 3.4 W 1
12 V 3.4 W 1
* Load is total weight of cargo, rider, passenger and accessories
2-3
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Cylinder head:
Warp limit
Cylinder:
Bore size
Taper limit
Out of round limit
Intake
Exhaust
0.03 mm
89.500 89.505 mm
89.6 mm
0.05 mm
0.03 mm
Camshaft:
Drive method
Camshaft cap inside diameter
Camshaft outside diameter
Camshaft-to-cap clearance
Cam dimensions
“A”
“B”
“C”
“A”
“B”
“C”
Limit
Timing chain (right)
25.000 25.021 mm
24.967 24.980 mm
0.020 0.054 mm
35.95 36.05 mm
27.95 28.05 mm
7.9 8.1 mm
35.95 36.05 mm
27.95 28.05 mm
7.9 8.1 mm
35.85mm
27.85mm
35.85 mm
27.85 mm
Camshaft runout limit
Cam chain:
Cam chain type/No. of links
Cam chain adjustment method
82RH2015/138
Automatic
0.15 0.20 mm
0.25 0.30 mm
Valve, valve seat, valve guide:
Valve clearance (cold)
IN
EX
Valve dimensions:
Head Dia
“A” head diameter
0.03 mm
Face Width
IN
EX
Seat Width
25.9 26.1 mm
27.9 28.1 mm
2-4
Margin Thickness
MAINTENANCE SPECIFICATIONS
Item
“B” face width
“C” seat width
“D” margin thickness
Stem outside diameter
Guide inside diameter
Stem-to-guide clearance
Standard
Valve spring:
Free length
Set length (valve closed)
Compressed pressure
(installed)
it
Tilt lilimit
Direction of winding
(top view)
Limit
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
2.06 2.46 mm
2.06 2.46 mm
0.9 1.1 mm
0.9 1.1 mm
0.8 1.2 mm
0.8 1.2 mm
5.475 5.490 mm
5 460 5
475 mm
5.460
5.475
5.500 5.512 mm
5.500 5.512 mm
0.010 0.037 mm
0.025 0.052 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
5.445 mm
5 43 mm
5.43
5.55 mm
5.55 mm
0.08 mm
0.10 mm
0.01 mm
IN
EX
0.9 1.1 mm
0.9 1.1 mm
1.6 mm
1.6 mm
IN
EX
IN
EX
37.29 mm
37.29 mm
30.39 mm
30.39 mm
35.2 mm
35.2 mm
SSS
SSS
10.0 11.6 kg
10 0 11
6 kg
k
10.0
11.6
SSS
SSS
SSS
SSS
2.5_/1.7 mm
2.5_/1.7 mm
Clockwise
Clockwise
SSS
SSS
Stem runout limit
Valve seat width
SPEC
IN
EX
IN
EX
IN
EX
2-5
MAINTENANCE SPECIFICATIONS
Item
Piston:
Piston to cylinder clearance
Piston size “D”
SPEC
Standard
Limit
0.065 0.085 mm
89.420 89.435 mm
0.15 mm
4.5 mm
1 mm
IN side
20.002 20.013 mm
19.991 20.000 mm
20.043 mm
19.975 mm
Type
Dimensions (B T)
End gap (installed)
Side clearance (installed)
2nd ring:
Barrel
1.0 3.5 mm
0.30 0.45 mm
0.035 0.070 mm
0.7 mm
0.12 mm
Type
Dimensions (B T)
End gap (installed)
Side clearance (installed)
Oil ring:
Taper
1.0 3.5 mm
0.30 0.45 mm
0.035 0.070 mm
0.8 mm
0.12 mm
2.00 2.85 mm
0.2 0.7 mm
0.026 0.050 mm
0.09 mm
Measuring point “H”
Piston off-set
Piston off-set direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston rings:
Top ring:
Dimensions (B T)
End gap (installed)
Connecting rod:
Oil clearance
2-6
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Crankshaft:
153.6 154.4 mm
64.75 65.25 mm
0.160 0.272 mm
0.8 1.0 mm
0.020 0.038 mm
0.035 mm
0.5 mm
0.1 mm
Balancer:
Balancer drive method
Gear
Clutch:
Friction plate thickness
Quantity
Clutch plate thickness
Quantity
Warp limit
Clutch spring free length
Quantity
Clutch release method
2.9 3.1 mm
9
1.9 2.1 mm
8
55 mm
6
Outer pull, rack & pinion pull
2.8 mm
0.1 mm
53 mm
Transmission:
Main axle deflection limit
Drive axle deflection limit
0.08 mm
0.08 mm
Shifter:
Shifter type
Guide bar bending limit
Guide bar
0.1 mm
4TX 00
#142.5
#60
5EI85-2/3
Y-2
#70
1.4
0.9
#45
0.8
0.9
0.8
2.0
Assembly width “A”
Crank width “B”
Runout limit “C”
Big end side clearance “D”
Small end free play “F”
Journal oil clearance
Carburetor:
I.D.mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet 1
Pilot air jet 2
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw
(M.J)
(M.A.J)
(J.N)
(N.J)
(P.A.J.1)
(P.A.J.2)
(P.O)
(P.J)
(B.P.1)
(B.P.2)
(B.P.3)
(P.S)
2-7
MAINTENANCE SPECIFICATIONS
Item
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Fuel level
Engine idle speed
Intake vacuum
Standard
(V.S)
(G.S.1)
(G.S.2)
(Th. V)
(F.L)
Fuel pump:
Type
Model/manufacturer
Output pressure
Lubrication system:
Oil filter type
Oil pump type
Tip clearance
Side clearance
Bypass valve setting pressure
Relief valve operating pressure
Cooling system:
Radiator core size
Width/height/thickness
Radiator cap opening pressure
Reservoir tank capacity
<From low to full level>
Water pump
Type
Reduction ratio
SPEC
Limit
1.7
#75
0.8
#130
15.8 16.8 mm
1,050 1,250 r/min
36.0 38.7 kPa (270 290 mmHg)
Vacuum type
4NX/MIKUNI
10 kPa (0.1 kg/cm2, 0.1 bar)
Paper type
Trochoid type
0 0.12 mm
0.03 0.08 mm
39 78 kPa (0.4 0.8 kg/cm2,
0.4 0.8 bar)
343 441 kPa (3.5 4.5 kg/cm 2,
3.5 4.5 bar)
0.17 mm
0.15 mm
300/180.6/27 mm
75 105 kPa (0.75 1.05 kg/cm2,
0.75 1.05 bar)
0.3 L
0.2 L
Single suction centrifugal pump
44/44 38/27 (1.407)
2-8
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Part to be tightened
g
Camshaft cap
Cylinder head
Cylinder head cover
Coolant drain bolt (cylinder body)
Spark plug
Connecting rod
Rotor
Camshaft sprocket
Timing chain tensioner
Radiator
Delivery hose (crankcase-cylinder)
Oil pump assembly
Oil baffle plate
Drain bolt (oil pan)
Oil strainer
Stay (relief valve)
Oil filter cover
Ring nut (exhaust pipe)
Exhaust pipe (CO test)
Exhaust pipe and frame
Exhaust pipe and muffler
Muffler
Crankcase
Balancer shaft
Balancer holder
Chain cover
Drive sprocket cover
Oil tank case 2
Engine bracket
Crankcase cover (left)
Starter clutch
Clutch spring
Clutch boss
Main axle bearing housing
Drive sprocket
Drive axle cover plate
Shift cam stopper lever
Shift fork guide
Shift arm
Shift rod
Shift pedal
Stopper bolt
Part name
Flange bolt
Nut
Bolt
Bolt
Bolt
—
Nut
Flange bolt
Flange bolt
Bolt
Flange bolt
Bolt
Bolt
Screw
Flange bolt
Bolt
Screw
Flange bolt
Flange bolt
Flange bolt
Nut
Bolt
Flange bolt
Screw
Bolt
Flange bolt
Flange bolt
Flange bolt
Screw
Flange bolt
Flange bolt
Flange bolt
Flange bolt
Flange bolt
Flange bolt
Bolt
Screw
Nut
Screw
Nut
Bolt
Bolt
Flange bolt
Flange bolt
Nut
Bolt
Bolt
2-9
Thread
size
M6
M10
M6
M6
M6
M12
M9
M12
M7
M6
M6
M10
M6
M6
M6
M14
M6
M6
M10
M6
M8
M6
M8
M8
M10
M10
M6
M8
M6
M6
M6
M6
M6
M8
M6
M6
M6
M20
M6
M18
M6
M6
M6
M6
M6
M8
M8
Q’ty
y
16
6
2
8
1
2
4
1
4
2
4
2
2
6
2
1
4
1
1
1
4
2
1
1
2
6
12
11
2
4
2
5
2
2
1
3
6
1
3
1
5
1
2
1
2
1
1
Tightening
torque
Nm
mSkg
10
40
10
10
10
18
48
130
24
10
7
21
10
6
10
35
7
10
30
10
20
10
24
20
24
40
12
24
12
10
5
5
10
24
10
10
8
70
12
70
10
10
12
12
8
22
22
1.0
4.0
1.0
1.0
1.0
1.8
4.8
13.0
2.4
1.0
0.7
2.1
1.0
0.6
1.0
3.5
0.7
1.0
3.0
1.0
2.0
1.0
2.4
2.0
2.4
4.0
1.2
2.4
1.2
1.0
0.5
0.5
1.0
2.4
1.0
1.0
0.8
7.0
1.2
7.0
1.0
1.0
1.2
1.2
0.8
2.2
2.2
Remarks
Stake
Use lock washer
Use lock washer
SPEC
MAINTENANCE SPECIFICATIONS
Part to be tightened
g
Stator coil
Starter motor
Thermo switch
Thermo switch housing
Part name
Screw
Flange bolt
—
—
Crankcase tightening sequence:
2-10
Thread
size
Q’ty
y
M6
M6
M6
PT1/8
3
2
1
1
Tightening
torque
Nm
mSkg
7
10
28
15
0.7
1.0
2.8
1.5
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item
Standard
Limit
Steering system:
Steering bearing type
Angular bearing
Front suspension:
Front fork travel
Fork spring free length
Spring rate
Stroke
Optional spring
Oil capacity (per fork tube)
Oil level
Oil grade
149 mm
505 mm
6.4 N/mm (0.64 kg/mm)
0 149 mm
No
0.515 L
130 mm
Fork oil 01 or equivalent
500 mm
Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring rate
Stroke
Optional spring
Swingarm:
Free play limit
Front wheel:
Type
Rim size
Rim material
Rim runout limit
Rear wheel:
Type
Rim size
Rim material
Rim runout limit
Drive chain:
Type/manufacturer
No. of links
Chain slack
(K1)
(K1)
47 mm
(K1/K2) 144 mm/69 mm
(K1/K2) 136 mm/65 mm
(K1/K2) 260 N/mm (26.0 kg/mm)/182 N/mm
(18.2 kg/mm)
(K1/K2) 0 30/30 47 mm
No
end
side
1 mm
0.3 mm
radial
lateral
Cast wheel
18 MT3.00
Aluminum
1 mm
0.5 mm
radial
lateral
Cast wheel
17 MT4.00
Aluminum
1 mm
0.5 mm
525HV/DAIDO
114
40 50 mm
2-11
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Front disc brake:
Type
Disc outside diameter thickness
Disc deflection limit
Pad thickness
inner
Pad thickness
outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Dual
298 4 mm
5.5 mm
5.5 mm
15.8 mm
33.96 + 30.23 mm
DOT 4
0.2 mm
0.5 mm
0.5 mm
Rear disc brake:
Type
Disc outside diameter thickness
Disc deflection limit
Pad thickness
inner
Pad thickness
outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Single
245 5 mm
5.5 mm
5.5 mm
14 mm
42.8 mm
DOT 4
0.15 mm
0.5 mm
0.5 mm
Controls:
Brake lever slack (at lever pivot)
Brake pedal height
Brake pedal slack
Clutch lever slack (at lever end)
Throttle cable slack
0 mm
29 mm
0 mm
10 15 mm
3 5 mm
2-12
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Thread
size
Part to be tightened
g
Upper bracket and inner tube
Upper bracket and steering stem
Steering stem and ring nut
Inner tube and under bracket
Horn bracket and brake hose holder
Brake hose holder and under bracket
Front brake hose union bolt
Cowling stay and frame
Meter and cowling stay
Handlebar and grip end
Front master cylinder
Upper bracket and handlebar holder (upper)
Upper bracket and cable holder
Upper bracket and cable guide
Engine mount (rear-upper)
Engine mount (rear-lower)
Engine bracket and frame
Engine bracket and engine (upper)
Engine bracket and engine (rear-lower)
Pivot shaft and nut
Rear shock absorber and swingarm
Rear shock absorber and frame
Chain case and swingarm
Chain protector
Swingarm and brake hose guide
Rear fender cover and swingarm
Fuel cock and fuel tank
Fuel tank bracket and fuel tank
Fuel tank bracket and frame
Fuel tank (rear) and frame
Ignition coil and frame
Vacuum pump stay and vacuum pump
Vacuum pump stay and frame
Fuel cock and frame
Tail cover and frame (front)
Battery box and frame
Coolant reservoir tank and frame
Rear fender and frame
Taillight bracket and frame
Taillight
Rectifier/regulator and cowling stay
Side cover and frame
Rear fender stay and taillight bracket
Sidestand
Sidestand bolt and locknut
Footrest bracket and frame
Rear footrest bracket and frame
Rear master cylinder and frame
Footrest bracket and footrest
Footrest and footrest tab
Brake pedal and brake shaft
Front wheel axle
Rear wheel axle and nut
Front brake caliper and front fork
Rear brake caliper and caliper bracket
M8
M22
M25
M10
M6
M6
M10
M8
M6
M16
M6
M8
M6
M6
M10
M10
M8
M10
M8
M14
M10
M12
M6
M6
M6
M6
M6
M6
M8
M8
M5
M6
M6
M6
M6
M6
M6
M6
M8
M6
M6
M6
M8
M10
M10
M8
M8
M8
M10
M8
M6
M16
M16
M10
M10
2-13
Tightening
torque
Nm
mSkg
23
108
16
30
10
10
30
30
7
26
9
23
7
7
89
64
30
60
30
90
64
64
7
7
7
7
7
7
16
16
4
7
7
7
7
7
7
7
23
7
7
7
16
46
39
30
30
23
64
16
8
58
107
40
40
2.3
10.8
1.6
3.0
1.0
1.0
3.0
3.0
0.7
2.6
0.9
2.3
0.7
0.7
8.9
6.4
3.0
6.0
3.0
9.0
6.4
6.4
0.7
0.7
0.7
0.7
0.7
0.7
1.6
1.6
0.4
0.7
0.7
0.7
0.7
0.7
0.7
0.7
2.3
0.7
0.7
0.7
1.6
4.6
3.9
3.0
3.0
2.3
6.4
1.6
0.8
5.8
10.7
4.0
4.0
Remarks
See “NOTE”
MAINTENANCE SPECIFICATIONS
Thread
size
Part to be tightened
g
Caliper bracket and swingarm
Brake disc and wheel hub (front and rear)
Driven sprocket and rear hub
Bleed screw and brake caliper
Rear brake hose union bolt
Front wheel axle pinch bolt
Brake hose joint and brake hose
Chain puller and locknut
Front fender and front fork
Brake hose joint and front fork
Rear brake caliper and brake hose joint
M10
M8
M10
M8
M10
M8
M10
M8
M6
M6
M10
SPEC
Tightening
torque
Nm
mSkg
35
20
60
6
30
19
14
16
9
10
40
3.5
2.0
6.0
0.6
3.0
1.9
1.4
1.6
0.9
1.0
4.0
Remarks
NOTE:
1. First, tighten the ring nut approximately 48 Nm (4.8 mSkg) by using the torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
2-14
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Standard
Limit
Voltage:
12 V
Ignition system:
Ignition timing (B.T.D.C.)
Advancer type
10 at 1,150 r/min
Electrical type
192 288 Ω at 20C/Blue/Yellow –
Green/White
TNDF33/NIPPONDENSO
Ignition coil:
Model/manufacturer
Minimum sspark
ark gap
ga
Primary winding resistance
Secondary winding resistance
J0300/NIPPONDENSO
6 mm
3.4 4.6 Ω at 20C
10.4 15.6 kΩ at 20C
Spark plug cap:
Type
Resistance
Resin type
10 kΩ
Charging system:
Type
Model/manufacturer
Normal output
Stator coil resistance
A.C. magneto
LNZ29/NIPPONDENSO
14 V 25 A at 5,000 r/min
0.23 0.35 Ω at 20C/W-W
Rectifier:
Model/manufacturer
Withstand voltage
SH650A-12/SHINDENGEN
240 V
Battery:
Specific gravity
1.320
Constant mesh type
SM-13/MITSUBA
0.8 kW
0.01 Ω at 20C
12.5 mm
570 920 g
28 mm
0.7 mm
5 mm
27 mm
9768042/JIDECO
100 A
4.2 4.6 Ω at 20C
T.C.I.:
Pickup coil resistance/color
T.C.I. unit model/manufacturer
Electric starter system:
Type
Starter motor:
Model/manufacturer
Output
Armature coil resistance
Brush overall length
Spring force
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
2-15
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Horn:
Type
Quantity
Model/manufacturer
Maximum amperage
Plane type
1
YF-12/NIKKO
2.5 A
Flasher relay:
Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage
Semi transistor type
FE246BH/NIPPONDENSO
No
75 X 95 cycle/min
21 W
2 + 3.4 W
Starting circuit cut off relay:
Model/manufacturer
Coil winding resistance
Diode
G8R-30Y-F/OMRON
180 X 270 Ω at 20C
Yes
Thermostatic switch:
Model/manufacurer
2EL/NIHON THERMOSTAT
Thermo unit:
Model/manufacturer
11H/NIPPON SEIKI
Fuse
30 A
1
15 A 1
15 A
1
7.5 A
1
7.5 A
1
30 A
1
15 A
2
7.5 A
1
Circuit breakers:
Type
Amperage for individual circuits
Main fuse
Headlight fuse
Signal system fuse
Ignition fuse
Radiator fan fuse
Reserve fuse
Reserve fuse
Reserve fuse
2-16
GENERAL TORQUE SPECIFICATIONS
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasteners
with standard I.S.O. pitch threads.
Torque specifications for special components or
assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications
call for clean, dry threads. Components should be
at room temperature.
A : Distance across flats
B : Outside thread diameter
A
(Nut)
B
(Bolt)
10 mm
General torque
specifications
Nm
mSkg
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
2-17
SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication point
Lubricant type
Oil seal lips
O-ring
Bearing
Crankshaft (big end)
Piston surface
Piston pin
Cylinder
Piston ring, oil ring
Connecting rod bolt
Crankshaft journal
Balancer (bearing/shaft)
Camshaft, camshaft cap
Valve stem (IN/EX)
Valve stem end
Water pump impeller shaft
Oil pump assembly (inner)
Oil strainer assembly
Push rod
Idle gear surface
Starter clutch ball
Primary driven gear
Transmission gear (wheel/pinion)
Axle (main/drive)
Shift cam
Shift fork, guide bar
Shift shaft assembly
Shift boss (inner)
2-18
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
CHASSIS
Lubrication point
Lubricant type
Steering bearing and bearing race (upper / lower)
Front wheel oil seal (right / left)
Rear wheel oil seal
Clutch hub oil seal
Clutch hub fitting area
Rear brake pedal shaft
Sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever bolt, sliding surface
Clutch lever bolt, sliding surface
Rear shock absorber (lower)
Swingarm pivot bearing
Pivot shaft
Thrust cover (inner)
2-19
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1
2
3
4
5
6
Oil pump (for pumping oil to the oil tank)
Oil pump (for lubricating the engine parts)
Oil strainer
Oil filter
Drain bolt
Oil tank
2-20
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
5
6
Front balancer
Oil strainer
Oil pump
Relief valve
Oil pump (for pumping oil to the oil tank)
Oil pump (for lubricating the engine parts)
2-21
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
5
6
Camshaft
Rear balancer
Main axle
Drive axle
Drain bolt
Front balancer
2-22
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Cylinder head
Rear balancer
Crankshaft
Drain bolt
2-23
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Drive axle
2-24
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
Throttle cable
Right handlebar switch lead
Brake hose
Main switch lead
Clutch cable
Left handlebar switch lead
Horn lead
Starter cable
Coolant reservoir hose
Headlight lead
11
12
13
14
15
Meter light lead
Thermo switch lead
Fan motor lead
Ignition coil (left) lead
Ignition coil (right) lead
A Fasten the right handlebar switch lead with a plastic band.
B Fasten the left handlebar switch lead with a plastic band.
C 50 mm
2-25
CABLE ROUTING
D
E
F
G
Fasten the horn lead with a plastic band.
60 mm
Fasten the brake hose with plastic bands.
Fasten the coolant reservoir hose with a plastic
clamp.
H Fasten the right handlebar switch lead, meter light
lead and headlight lead with a plastic clamp
I Fasten the wire harness with a plastic clamp..
SPEC
J Fasten the wire harness, right handlebar switch lead,
meter light lead and headlight lead with a plastic band.
K To the throttle position sensor.
L Fasten the wire harness and ignition coil (left) lead
with a plastic clamp.
M Fasten the wire harness, right handlebar switch lead,
main switch lead and fan motor lead with a plastic
clamp.
2-26
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
Front flasher light (left) lead
Main switch lead
Starter cable
Left handlebar switch lead
Spark plug lead
Carburetor breather hose
Fuel hose
Vacuum hose (#2)
Coolant reservoir hose
Sidestand switch lead
11
12
13
14
15
16
17
18
19
Neutral switch lead
A.C. magneto lead
Air filter case breather hose
Carburetor heater hose
Speedometer cable
Brake hose
Wire harness
Flasher relay lead
Fuel hose 5
2-27
SPEC
CABLE ROUTING
A Fasten the left handlebar switch lead and main switch
lead with a plastic clamp.
B To the air filter case.
C Fasten the coolant reservoir hose, A.C. magneto
lead, neutral switch lead and sidestand switch lead
with a plastic clamp.
D Fasten the rear flasher light (left) lead with a plastic
clamp.
SPEC
E Fasten the sidestand switch lead, neutral switch lead
and A.C. magneto lead with a plastic clamp.
F Fasten the sidestand switch lead and air filter case
breather hose with a metal band.
G Pass the air filter case breather hose over the carburetor heater hose.
H Pass the speedometer cable through the guides.
2-28
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
Starter motor lead
Fuel tank breather hose
Spark plug lead
Right handlebar switch lead
Clutch cable
Brake hose
Throttle cable
Headlight lead
Meter light lead
Carburetor heater hose
Vacuum hose (#1)
12
13
14
15
16
SPEC
Coolant reservoir breather hose
Carburetor breather hose
Rear brake switch lead
Battery positive lead
Battery negative lead
A Pass the battery positive lead and battery negative lead through the
guide.
B Fasten the wire harness coolant reservoir hose and flasher relay lead
with a plastic clamp.
C Pass the carburetor breather hoses through the metal band.
2-29
CABLE ROUTING
D Pass the carburetor breather hoses and vacuum
hose (#1) through the guide.
E Pass the vacuum hose (#1) through the guide.
F Fasten the coolant reservoir hose with a plastic
clamp.
G Fasten the wire harness, right handlebar switch lead,
meter light lead and headlight lead with a plastic
clamp.
H Fasten the right handlebar switch lead with a plastic
clamp.
I Fasten the throttle cables with a plastic clamp.
SPEC
J Pass the coolant reservoir hose over the throttle
cables.
K Fasten the wire harness, right handlebar switch lead,
meter light lead and headlight lead with a plastic band.
L Pass the clutch cable through the guide.
M Pass the carburetor air vent hose through the guide.
N Pass the coolant reservoir breather hose, fuel tank
breather hose and carburetor breather hoses through
the guide.
2-30
CABLE ROUTING
O Pass the fuel tank breather hose through the hole of
the frame bracket.
P Pass the coolant reservoir breather hose and fuel
tank breather hose through the guide.
Q Pass the rear brake switch lead through the guide.
R Fasten the wire harness and rear flasher light (right)
lead with a plastic clamp.
SPEC
S Fasten the wire harness with plastic clamps.
T To the engine.
U Fasten the coolant reservoir breather hose with a
plastic clamp.
V To the starter relay.
W Pass the carburetor breather hoses through the
guide.
2-31
CARBLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
Headlight lead
Wire harness
Meter light lead
Throttle stop screw cable
Vacuum hose (#1)
Carburetor air vent hose
Carburetor breather hose
Starter motor lead
Battery positive lead
Battery negative lead
Coolant reservoir breather hose
12
13
14
15
16
17
18
Coolant reservoir hose
Vacuum hose (#2)
Fuel hose
Carburetor breather hose
Cylinder head breather hose
Air filter case breather hose
Throttle cable
A Fasten the meter light lead, headlight lead and wire harness with a
plastic clamp.
2-32
SPEC
B Fasten the wire harness and coolant reservoir hose with a plastic
clamp.
C Pass the starter relay lead through
the guide.
CABLE ROUTING
D Fasten the taillight lead with a plastic band to the taillight bracket.
E 50 mm
F Fasten the carburetor breather hoses with a plastic
clamp.
G Fasten the wire harness with a plastic clamp.
H To the front flasher light (left).
I To the headlight.
J To the meter light.
K Fasten the headlight lead with a plastic clamp.
L To the auxiliary light.
SPEC
M Fasten the meter light lead and headlight lead with
plastic clamps.
N Fasten the meter light lead, headlight lead and front
flasher light lead connector with a plastic clamp.
O To the front flasher light (right).
P Fasten the meter light lead, headlight lead, starting
circuit cut-off relay lead and front flasher light (right)
lead with a plastic clamp.
Q To the rear brake switch.
2-33
SPEC
INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . . . . 3-1
COWLINGS, SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . 3-3
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
3-6
3-13
3-15
3-16
3-18
3-19
3-20
3-22
3-23
3-25
3-25
3-26
3-27
3-27
3-28
3-28
3-29
3-32
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE ADJUSTMET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(HYDRAULIC BRAKE SYSTEM)
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN SLACK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
3-33
3-33
3-34
3-35
3-36
3-36
3-37
3-37
3-38
3-39
3-41
3-41
3-43
3-44
3-45
INSP
ADJ
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .
LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-47
3-49
3-49
3-50
3-50
3-50
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-51
3-51
3-52
3-53
3-58
3-58
3-60
3-60
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
INSP
ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These
preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service
life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in
service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this
entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
ITEM
ROUTINE
BRAKE-IN 6,000 km
1,000 km
or
12,000 km
6 months
12 months
or
Valves*
Check valve clearance.
Adjust if necessary.
Spark plugs
Check condition.
Clean or replace if necessary.
Air filter
Clean.
Replace if necessary.
Carburetor*
Check idle speed / synchronization / starter operation.
Adjust if necessary.
Fuel line*
Check fuel hose and vacuum pipe for cracks or damage.
Replace if necessary.
Engine oil
Replace (Warm engine before draining).
Engine oil filter*
Replace.
Brake*
Check operation / fluid leakage / See NOTE.
Correct if necessary.
Clutch
Check operation.
Adjust if necessary.
Swingarm pivot*
Check swingarm assembly for looseness.
Correct if necessary.
Moderately repack every 24,000 km or 24 months.***
Wheels*
Check balance / damage / runout.
Replace if necessary.
Wheel bearings*
Check bearing assembly for looseness / damage.
Replace if damaged.
Steering bearings*
Check bearing assembly for looseness.
Correct if necessary.
Moderately repack every 24,000 km or 24 months.**
Front forks*
Check operation / oil leakage.
Repair if necessary.
Rear shock absorber*
Check operation / oil leakage.
Repair if necessary.
Cooling system
Check coolant leakage.
Repair if necessary.
Replace coolant every 24,000 km or 24 months
Drive chain
Check chain slack / alignment.
Adjust if necessary.
Clean and lube.
Fittings / Fasteners*
Check all chassis fittings and fasteners.
Correct if necessary.
Sidestand*
Check operation.
Repair if necessary.
Sidestand switch*
Check operation.
Replace if necessary.
*
**
***
EVERY 42,000 km or 42 months
EVERY 500 km
: If is recommended that these items be serviced by a Yamaha dealer.
: Lithium soap base grease.
: Molybdenum disulfide grease.
3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INSP
ADJ
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
3-2
COWLINGS, SEAT, TAIL COVER AND FUEL TANK
INSP
ADJ
COWLINGS, SEAT, TAIL COVER AND FUEL TANK
COWLINGS
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Q’ty
Cowlings removal
Side cowling (left and right)
Meter panel
Damper
Wind shield
Inner panel
Front flasher light lead
Front flasher light (left and right)
Auxiliary light lead coupler
Headlight lead coupler
Front cowling
Headlight unit
Remarks
Remove the parts in the order below.
2
1
1
1
1
4
2
1
1
1
1
Disconnect
Disconnect
Disconnect
For installation, reverse the removal
procedure.
3-3
COWLINGS, SEAT, TAIL COVER AND FUEL TANK
INSP
ADJ
SEAT, TAIL COVER AND FUEL TANK
16 Nm (1.6 mkg)
Order
Job name/Part name
1
2
3
4
5
6
Seat, tail cover and fuel tank removal
Side cowling
Seat
Taillight lead coupler
Tail cover
Side cover
Fuel hose (RES)
Fuel hose (ON)
1
1
1
2
1
1
7
8
Fuel tank breather hose
Fuel tank
1
1
Q’ty
Remarks
Remove the parts in the order below.
Refer to “COWLINGS”.
Disconnect
NOTE:
Set the fuel cock (fuel tank side) to “OFF”
before disconnecting the fuel hoses.
For installation, reverse the removal
procedure.
3-4
AIR FILTER CASE
INSP
ADJ
AIR FILTER CASE
AIR FILTER CASE
Order
Job name/Part name
1
2
3
4
Air filter case removal
Side cowling, seat, side cover and fuel
tank
Cylinder head breather hose
Air filter case breather hose
Carburetor clamp
Air filter case
Q’ty
Remarks
Remove the parts in the order below.
Refer to “COWLINGS, SEAT, TAIL
COVER AND FUEL TANK”.
1
1
2
1
Loosen
For installation, reverse the removal
procedure.
3-5
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
The valve clearance should be adjusted when
the engine is cool to touch.
The piston must be at Top Dead Center (T.D.C.)
on compression stroke to check or adjust the
valve clearance.
1. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case
Refer to “AIR FILTER CASE”.
2. Drain:
Coolant
Refer to “COOLANT REPLACEMENT”.
3. Disconnect:
Hose 2 1
Hose 3 2
Coolant reservoir hose
(from radiator side)
Fan motor lead coupler
4. Remove:
Radiator 1
3-6
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
5. Disconnect:
Thermo unit lead 1
Thermo switch lead 2
Ground lead 3
Thermostatic valve housing 4
6. Remove:
Spark plug caps
Spark plugs
Cylinder head cover
7. Remove:
Timing plug 1
Straight plug 2
O-ring
8. Check:
Valve clearance
Out of specification Adjust.
Valve clearance (cold):
Intake valve:
0.15 0.20 mm
Exhaust valve:
0.25 0.30 mm
Checking steps:
Turn the crankshaft counterclockwise with a
wrench.
Align the T.D.C. mark a on the rotor with the
align mark b on the crankcase cover when #1
piston is at T.D.C. on compression stroke.
NOTE:
TDC on compression stroke can be found when
the cam lobes are opposite each other as shown.
3-7
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
S Measure the valve clearance using a feeler
gauge 2 .
NOTE:
S Record the measured reading if the clearance is
incorrect.
S Rotate the crankshaft 270_ counterclockwise
and check the clearance of piston #2.
NOTE:
Make sure that the camshaft lobes are opposite
each other when the piston is at TDC on the compression stroke.
9. Adjust:
S Valve clearance
Adjustment steps:
S Loosen the timing chain tensioner cap bolt.
S Remove the timing chain tensioner 1 , timing
chain guide (upper) 2 , timing chain guide (exhaust side) 3 and camshaft caps.
NOTE:
Remove the camshaft cap bolts in a crisscross
pattern from the outside working inwards.
S Remove the camshaft (intake and exhaust 1 ).
NOTE:
Attach a wire 2 to the timing chain to prevent it
from falling into the crankcase.
3-8
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
Remove the valve lifters 1 and the pads 2 .
NOTE:
Place a rag in the timing chain space to prevent
pads from falling into the crankcase.
Identify each valve lifter 1 and pad 2 position
very carefully so that they can be reinstalled in
their original place.
Select the proper pad using the pad selecting
table:
Pad range
Pad Availability:
25 increments
No. 120 1.20 mm
Pads are available in
0.05 mm increments
No. 240 2.40 mm
NOTE:
The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface.
Round off the last digit of the installed pad number to the nearest increment.
Last digit of pad
number
Rounded value
0 or 2
0
5
(NOT ROUNDED OFF)
8
10
EXAMPLE:
Installed pad number = 148
Rounded off value = 150
NOTE:
Pads can only be selected in 0.05 mm increments.
3-9
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
Locate the rounded-off value and the measured valve clearance in the chart “PAD
SELECTION TABLE”. The field where these
two coordinates intersect shows the new pad
number to use.
NOTE:
Use the new pad number only as a guide when
verifying the valve clearance adjustment.
Install the new pads 1 and the valve lifters 2 .
NOTE:
Lubricate the valve lifters and pads with molybdenum disulfide oil.
Valve lifter must turn smoothly when rotated with
a finger.
Be careful to reinstall valve lifters and pads in
their original place.
Install the new pads so that the side with the pad
number faces up (toward the valve lifter).
Install the camshafts (exhaust and intake), the
timing chain and the camshaft caps.
10 Nm (1.0 mkg)
NOTE:
Lubricate the cylinder head mating surfaces cam
lobes and camshaft journals.
Install the exhaust camshaft first.
Align the matching marks.
Turn the crankshaft counterclockwise several
turns so that the installed parts settle into the
right position.
Refer to “CAMSHAFT” in CHAPTER 4.
3-10
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
INTAKE
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 0.04
0.05 0.09
0.10 0.14
0.15 0.20
0.21 0.25
0.26 0.30
0.31 0.35
0.36 0.40
0.41 0.45
0.46 0.50
0.51 0.55
0.56 0.60
0.61 0.65
0.66 0.70
0.71 0.75
0.76 0.80
0.81 0.85
0.86 0.90
0.91 0.95
0.96 1.00
1.01 1.05
1.06 1.10
1.11 1.15
1.16 1.20
1.21 1.25
1.26 1.30
1.31 1.35
1.36 1.40
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215 220 225
150 155 160 165 170 175 180 185 190 195 200 205 210
155 160 165 170 175 180 185 190 195 200 205 210 215
160 165 170 175 180 185 190 195 200 205 210 215 220
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220 225 230
175 180 185 190 195 200 205 210 215 220 225 230 235
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
VALVE CLEARANCE (cold):
235 240
0.15 0.20 mm
240
230
215
220
225
235 240
220 225
225 230
230 235
235 240
240
Example: Installed is 175
Measured clearance is 0.27 mm
Replace 175 pad with 185 pad
Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
EXHAUST
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 0.04
0.05 0.09
0.10 0.14
0.15 0.19
0.20 0.24
0.25 0.30
0.31 0.35
0.36 0.40
0.41 0.45
0.46 0.50
0.51 0.55
0.56 0.60
0.61 0.65
0.66 0.70
0.71 0.75
0.76 0.80
0.81 0.85
0.86 0.90
0.91 0.95
0.96 1.00
1.01 1.05
1.06 1.10
1.11 1.15
1.16 1.20
1.21 1.25
1.26 1.30
1.31 1.35
1.36 1.40
1.41 1.45
1.46 1.50
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215 220 225
140 145 150 155 160 165 170 175 180 185 190 195 200
145 150 155 160 165 170 175 180 185 190 195 200 205
150 155 160 165 170 175 180 185 190 195 200 205 210
155 160 165 170 175 180 185 190 195 200 205 210 215
160 165 170 175 180 185 190 195 200 205 210 215 220
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220 225 230
175 180 185 190 195 200 205 210 215 220 225 230 235
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
VALVE CLEARANCE (cold):
235 240
0.25 0.30 mm
240
230
205
210
215
220
225
235 240
240
Example: Installed is 175
Measured clearance is 0.37 mm
Replace 175 pad with 185 pad
Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
3-11
235 240
210 215
215 220
220 225
225 230
230 235
VALVE CLEARANCE ADJUSTMENT
INSP
ADJ
Recheck the valve clearance.
If the clearance is still incorrect, repeat all the
clearance adjustment steps until the specified
clearance is obtained.
10. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of their
removal. Note the following points.
11. Install:
Chain guide (exhaust side)
Chain guide (upper)
Timing chain tensioner
Refer to “CAMSHAFT” in CHAPTER 4.
12. Install:
Cylinder head cover
Spark plugs
3-12
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
CARBURETOR SYNCHRONIZATION
INSP
ADJ
CARBURETOR SYNCHRONIZATION
NOTE:
Valve clearance and idling speed should be adjusted properly before synchronizing the carburetors.
1. Place the motorcycle on a level surface.
NOTE:
Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand
under the motorcycle.
2. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3. Remove:
Vacuum hose 1 (#1 carburetor) 1
Vacuum hose 2 (#2 carburetor) 2
4. Attach:
Adapters
Vacuum gauge 1
Engine tachometer 2
(to #1 spark plug lead)
Vacuum gauge:
90890-03094
Engine tachometer:
90890-03113
5. Start the engine and let it warm up for several
minutes.
6. Check:
Engine idling speed
Out of specification Adjust.
Refer to “ENGINE IDLING SPEED ADJUSTMENT”.
Engine idling speed:
1,050 1,250 r/min
3-13
CARBURETOR SYNCHRONIZATION
INSP
ADJ
7. Adjust:
Carburetor synchronization
Adjustment steps:
Synchronize carburetor #1 to carburetor #2 by
turning synchronizing screw 1 until both
gauges read the same.
Race the engine for less than a second, two or
three times and check the synchronization
again.
Intake vacuum at idle speed:
36.0 38.7 kPa (270 290 mm Hg)
NOTE:
The difference between both carburetors should
be 0.67 kPa (5 mm Hg) or less.
8. Check:
Engine idling speed
Out of specification Adjust.
9. Stop the engine and detach the measuring
equipment.
10. Adjust:
Throttle cable free play
Refer to “THROTTLE CABLE FREE PLAY ADJUSTMENT”.
Free play:
3 5 mm
At throttle grip flange
11. Install:
Fuel tank
Side cover
Seat
Side cowling
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3-14
IDLING SPEED ADJUSTMENT
INSP
ADJ
IDLING SPEED ADJUSTMENT
NOTE:
The carburetor synchronization should be adjusted properly before adjusting the idling speed.
1. Start the engine and let it warm up for several
minutes.
2. Attach:
Engine tachometer 1
(to the #1 spark plug lead).
Engine tachometer:
90890-03113
3. Check:
Engine idling speed
Out of specification Adjust.
Engine idling speed:
1,050 1,250 r/min
4. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case
Refer to “AIR FILTER CASE”.
5. Adjust:
Engine idling speed
Adjustment steps:
Turn the pilot screw 1 until it is lightly seated.
Turn out the pilot screw for the specified number of turns.
Pilot screw: 2.0 turns out
3-15
IDLING SPEED ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
INSP
ADJ
Turn the throttle stop screw 2 in or out until
specified idling speed is obtained.
Turnning in:
Idling speed is increased.
Turnning out: Idling speed is decreased.
6. Adjust:
Throttle cable free play
Refer to “THROTTLE CABLE FREE PLAY ADJUSTMENT”.
Free play:
3 5 mm
At throttle grip flange
THROTTLE CABLE ADJUSTMENT
NOTE:
Engine idling speed and carburetor synchronization should be adjusted properly before adjusting
the throttle cable free play.
1. Check:
Throttle cable free play a
Out of specification Adjust.
Free play:
3 5 mm
At throttle grip flange
2. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case
Refer to “AIR FILTER CASE”.
3-16
THROTTLE CABLE ADJUSTMENT
INSP
ADJ
3. Adjust:
Throttle cable free play
Adjustment steps:
First step:
Loosen the locknut 1
Turn the adjuster 2 in or out until the specified
free play is obtained.
Turnning in:
Free play is increased.
Turnning out: Free play is decreased.
Tighten the locknuts.
NOTE:
If the free play can not be adjusted here, adjust it at
the throttle grip side of the cable.
Final step:
Loosen the locknut 3 .
Turn the adjuster 4 in or out until the specified
free play is obtained.
Turnning in:
Free play is decreased.
Turnning out: Free play is increased.
Tighten the locknut.
WARNING
After adjusting, turn the handlebar to the right
and left, making sure that the engine idling
speed does not change.
4. Install:
Air filter case
Refer to “AIR FILTER CASE”.
Fuel tank
Side cover
Seat
Side cowling
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3-17
SPARK PLUG INSPECTION
INSP
ADJ
SPARK PLUG INSPECTION
1. Remove:
Spark plug caps
Spark plugs
CAUTION:
Before completely removing the spark plug,
use compressed air to clean the cylinder head
cover areas to prevent dirt from falling into the
engine.
2. Inspect:
Spark plug type
Incorrect Replace.
Standard spark plug:
DPR8EA-9 (NGK)
X24EPR-U9 (NIPPONDENSO)
3. Inspect:
Electrode 1
Wear/Damage Replace.
Insulator 2
Abnormal color Replace.
Normal color is a medium-to-light tan color.
4. Clean:
Spark plug
(with spark plug cleaner or wire brush)
5. Measure:
Spark plug gap a
Use a wire gauge.
Out of specification Adjust.
Spark plug gap:
0.8 0.9 mm
6. Install:
Spark plug
18 Nm (1.8 mkg)
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
3-18
IGNITION TIMING CHECK
INSP
ADJ
IGNITION TIMING CHECK
NOTE:
Carburetor synchronization, engine idle speed
and throttle cable free play should be adjusted
properly before checking the ignition timing.
1. Remove:
Timing plug 1
2. Attach:
Timing light
Engine tachometer
(to the #1 spark plug lead)
Timing light:
90890-03141
Engine tachometer:
90890-03113
3. Check:
Ignition timing
Checking steps:
Start the engine and let it warm up. Let the engine run at the specified speed.
Engine speed:
1,050 1,250 r/min
Visually check the stationary pointer a is within the firing range b on the A.C. magneto.
Incorrect firing range Check rotor and pickup assembly.
NOTE:
The ignition timing is not adjustable.
4. Install:
Timing plug
3-19
COMPRESSION PRESSURE MEASUREMENT
INSP
ADJ
COMPRESSION PRESSURE MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1. Check:
Valve clearance
Out of specification Adjust.
Refer to “VALVE CLEARANCE ADJUSTMENT”.
2. Start the engine and let it warm up for several
minutes.
3. Stop the engine.
4. Remove:
Spark plug caps
Spark plugs
CAUTION:
Before completely removing the spark plug,
use compressed air to clean the cylinder head
cover areas to prevent dirt from falling into the
engine.
5. Attach:
Compression gauge 1
Adapter
Compression gauge:
90890-03081
6. Measure:
Compression pressure
Above the maximum pressure:
Inspect the cylinder head, valve surfaces, and
piston crown for carbon deposits.
Below the minimum pressure:
Squirt a few drops of oil into the affected cylinder
and measure again.
Refer to the table below.
3-20
COMPRESSION PRESSURE MEASUREMENT
INSP
ADJ
Compression pressure
(With oil applied into cylinder)
Reading
Diagnosis
Higher than
without oil
Worn or damaged
pistons /piston
rings Repair
Same as without oil
Defective ring(s),
valves, cylinder
head gasket or piston is possible Repair
Compression pressure (at sea level):
Standard:
1,200 kPa (12.0 kg/cm2, 12.0 bar)
Minimum:
1,000 kPa (10.0 kg/cm2, 10.0 bar)
Cylinder difference:
100 kPa (1.0 kg/cm2, 1.0 bar)
Measurement steps:
Crank over the engine with the throttle wideopen until the reading on the compression
gauge stabilizes.
WARNING
Before cranking the engine, ground all spark
plug leads to prevent sparking.
Repeat the previous steps for the other cylinders.
NOTE:
The difference of compression pressure between
the highest and lowest cylinder compression
readings should be 100 kPa (1 kg/cm2, 1 bar) or
less.
7. Install:
Spark plugs
Spark plug caps
3-21
18 Nm (1.8 mkg)
ENGINE OIL LEVEL INSPECTION
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
NOTE:
Position the motorcycle straight up when inspecting the oil level.
1. Place the motorcycle on a level surface.
NOTE:
After idling the engine for 15 minutes, be sure the
motorcycle is vertical, then check that the oil level is between the maximum and minimum marks.
Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable
stand under the motorcycle.
2. Inspect:
Oil level
Oil level should be between the maximum a
and minimum b marks.
Oil level is below the minimum mark Add oil
up to the proper level.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classification:
API STANDARD:
API “SE” or higher grade
CAUTION:
Do not put in any chemical additives or use
oils with a grade of CD a or higher.
Be sure not to use oils labeled “ENERGY
CONSERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Be sure no foreign material enters the crankcase.
3. Start the engine and let it warm up for several
minutes.
4. Turn off the engine and check the oil level
again.
NOTE:
Before checking the oil level, wait a few minutes
until the oil settles.
3-22
ENGINE OIL REPLACEMENT
INSP
ADJ
ENGINE OIL REPLACEMENT
1. Start the engine and let it warm up for several
minutes.
2. Stop the engine and place an oil pan under the
drain bolt.
3. Remove:
Oil filler plug 1
4. Remove:
Drain bolt (with gasket) 1
Oil filter drain bolt (with gasket) 2
Drain the crankcase and oil tank of its oil.
5. If the oil filter is to be replaced during this oil
change, remove the following parts and reinstall them.
Replacement steps:
Remove the oil filter cover 1 and oil filter element 2 .
Check the O-rings 3 , if cracked or damaged,
replace them with a new one.
Install the oil filter element and oil filter cover.
Oil filter cover (M10):
10 Nm (1.0 mkg)
6. Install:
Gaskets New
Drain bolt
Oil filter drain bolt
3-23
35 Nm (3.5 mkg)
30 Nm (3.0 mkg)
ENGINE OIL REPLACEMENT
INSP
ADJ
7. Fill:
Crankcase
CAUTION:
The engine should be filled with oil in two
steps. First fill the engine with 3.2 liters of oil.
Then start the engine and race it five or six
times. Stop the engine and fill it with oil to the
specified level.
Oil quantity:
Total amount:
4.2 L
Periodic oil change:
3.5 L
With oil filter replacement:
3.6 L
8. Install:
Oil filler plug
9. Inspect:
Engine (for oil leaks)
Oil level
Refer to “ENGINE OIL LEVEL INSPECTION”.
10. Check:
Oil pressure
Checking steps:
Slightly loosen the oil gallery bolt 1 .
Start the engine and keep it idling until oil starts
to seep from the oil gallery bolt. If no oil comes
out after one minute, turn the engine off so it will
not seize.
Check oil passages, oil filter and oil pump for
damage or leakage.
Start the engine after solving the problem(s)
and recheck the oil pressure.
Tighten the oil gallery bolt to specification.
Oil gallery bolt:
10 Nm (1.0 mkg)
3-24
CLUTCH ADJUSTMENT/ AIR FILTER CLEANING
INSP
ADJ
CLUTCH ADJUSTMENT
1. Check:
Clutch cable free play a
Out of specification Adjust.
Free play:
10 15 mm
At clutch lever end
A
2. Adjust:
Clutch cable free play
B
Adjustment steps:
Loosen the locknut(s) 1 .
Turn the adjuster(s) 2 in or out until the specified free play is obtained.
Turnning in:
Free play is increased.
Turnning out:
Free play is decreased.
Tighten the locknut(s).
A Handlebar side
B Engine side
AIR FILTER CLEANING
1. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case cover 1 .
2. Remove:
Air filter element 2
CAUTION:
The engine should never be run without the air
filter element, otherwise excessive piston
and/or cylinder wear may result.
3-25
AIR FILTER CLEANING/
CARBURETOR JOINT INSPECTION
INSP
ADJ
3. Inspect:
Air filter element
Damage Replace.
4. Clean:
Air filter element
Blow off dust from the outer surface of the element with compressed air.
5. Install:
Air filter element
Air filter case cover
NOTE:
Make sure the element is properly seated in the filter case.
6. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of their
removal.
CARBURETOR JOINT INSPECTION
1. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case
Refer to “AIR FILTER CASE”.
2. Inspect:
Carburetor joints 1
Cracks /Damage Replace.
Refer to “CARBURETOR” in CHAPTER 6.
3. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of their
removal.
3-26
FUEL LINE INSPECTION/
BREATHER HOSE INSPECTION
INSP
ADJ
FUEL LINE INSPECTION
1. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
2. Inspect:
Vacuum hoses 1
Fuel hoses 2
Cracks /Damage Replace.
Loose connection Connect properly.
NOTE:
Drain and flush the fuel tank if abrasive damage to
any components is evident.
3. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of their
removal.
BREATHER HOSE INSPECTION
1. Remove:
Side cowling
Seat
Side cover
Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Air filter case
Refer to “AIR FILTER CASE”.
2. Inspect:
Breather hose 1
Cracks /Damage Replace.
Loosen connection Connect properly.
3. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of their
removal.
3-27
EXHAUST SYSTEM INSPECTION/
COOLANT LEVEL INSPECTION
INSP
ADJ
EXHAUST SYSTEM INSPECTION
1. Inspect:
Exhaust pipes
Mufflers
Cracks /Damage Replace.
Gaskets
Exhaust gas leaks Replace.
2. Check:
20 Nm (2.0 mkg)
Exhaust pipe nut 1
Exhaust pipe bolt 2
24 Nm (2.4 mkg)
Muffler bolt 3
24 Nm (2.4 mkg)
Bolt (exhaust pipe and muffler) 4
20 Nm (2.0 mkg)
COOLANT LEVEL INSPECTION
NOTE:
Position the motorcycle straight up when inspecting the coolant level.
1. Place the motorcycle on a level surface.
NOTE:
Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand
under the motorcycle.
2. Inspect:
Coolant level
Coolant level should be between maximum a
and minimum b marks.
Coolant level low Add soft water (tap water)
to proper level.
3-28
COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT
INSP
ADJ
CAUTION:
Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you
can’t get soft water.
COOLANT REPLACEMENT
1. Remove:
Side cowling (right)
Seat
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid
and steam may be blown out under pressure,
which could cause serious injury. When the
engine has cooled, open the radiator cap by
following this procedure:
Place a thick rag or a towel over the radiator
cap. Slowly rotate the cap counterclockwise to
the detent. This allows any residual pressure
to escape. When the hissing sound has
stopped, press down on the cap while turning
counterclockwise and remove it.
NOTE:
Position the motorcycle straight up when replacing the coolant.
2. Place the motorcycle on a level surface.
NOTE:
Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand
under the motorcycle.
3. Remove:
Water pump drain bolt (with gasket) 1
Cylinder drain bolt (with gasket) 2
Radiator cap 3
Drain the radiator and engine of its coolant.
4. Disconnect:
Coolant reservoir hose 4
3-29
COOLANT REPLACEMENT
INSP
ADJ
5. Install:
Gaskets New
Drain bolt 1
10 Nm (1.0 mkg)
Cylinder drain bolt
10 Nm (1.0 mkg)
6. Connect:
Coolant reservoir hose
7. Fill:
Cooling system (radiator and engine)
(to specified level a )
Recommended coolant:
High quality ethylene glycol
anti-freeze containing corrosion
inhibitors for aluminum engines
Coolant and water mix ratio:
50% – 50%
Radiator capacity
(including all routes):
1.7 L
Reservoir tank capacity:
0.3 L
From lower to upper level:
0.2 L
NOTE:
Put the sidestand down so the motorcycle leans to
the side and fill with coolant. To help dissipate the
coolant throughout the cooling system, hold the
motorcycle in the upright position for a few seconds. Then lean it back to the side and continue
filling with coolant.
Handling notes for coolant:
Coolant is harmful and should be handled with
special care.
WARNING
If coolant splashes in your eyes:
Thoroughly wash your eyes with water and
see a doctor.
If coolant splashes on your clothes.
Quickly wash it away with water and then
with soap.
If coolant is swallowed.
Quickly make the patient vomit and take him
to a doctor.
3-30
COOLANT REPLACEMENT
INSP
ADJ
CAUTION:
Hard water or salt water is harmful to the engine parts. Use boiled or distilled water if you
can’t get soft water.
Do not use water containing impurities or oil.
Take care that no coolant splashes onto
painted surfaces. If it does, wash it away with
water immediately.
Do not mix different types of ethylene glycol
antifreeze containing corrosion inhibitors for
aluminium engines.
8. Install:
Radiator cap
9. Fill:
Coolant reservoir 1
(to upper level mark)
10. Install:
Coolant reservoir cap
11. Start the engine and let it warm up for several
minutes.
12. Stop the engine and inspect the level.
Refer to “COOLANT LEVEL INSPECTION”.
NOTE:
Wait a few minutes until the coolant settles before
inspecting the coolant level.
13. Install:
Seat
Side cowling (right)
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3-31
COOLANT REPLACEMENT/
COOLING SYSTEM INSPECTION
INSP
ADJ
COOLING SYSTEM INSPECTION
1. Inspect:
Radiator 1
Hose 2 2
Hose 3 3
Cracks /Damage Replace.
Refer to “RADIATOR” in CHAPTER 5.
3-32
FRONT BRAKE ADJUSTMENT
INSP
ADJ
CHASSIS
FRONT BRAKE ADJUSTMENT
1. Adjust:
Brake lever position
(distance a from handle grip to front brake lever)
Adjustment steps:
Turn the adjuster 1 while pushing the front
brake lever forward until the desired lever position is obtained.
Direction b
Direction c
Distance a is the largest
Distance a is the smallest
WARNING
After adjusting the front brake lever position
(distance), make sure align the mark on the adjuster with the mark on the brake lever.
CAUTION:
Make sure that the brake does not drag after
adjusting it.
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake system. This air must be removed by bleeding the
brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in
loss of control and an accident. Inspect and
bleed the system if necessary.
3-33
REAR BRAKE ADJUSTMENT
INSP
ADJ
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification Adjust.
Brake pedal height:
29 mm
Below top of footrest.
2. Adjust:
Brake pedal height
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 2 in or out until the specified
pedal height is obtained.
Turnning in:
Height is decreased.
Turnning out:
Height is increased.
WARNING
After adjusting brake pedal height, visually
check the adjuster end through the hole a .
The adjuster end b must be visible within this
hole.
Tighten the locknut 1 .
CAUTION:
Make sure that the brake does not drag after
adjusting it.
WARNING
A soft or spongy feeling in the brake pedal can
indicate the presence of air in the brake system. This air must be removed by bleeding the
brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in
loss of control and an accident.
Inspect and bleed the system if necessary.
3. Adjust:
Brake light switch
Refer to “BRAKE LIGHT SWITCH ADJUSTMENT”.
3-34
BRAKE FLUID LEVEL INSPECTION
INSP
ADJ
BRAKE FLUID LEVEL INSPECTION
NOTE:
Position the motorcycle straight up when inspecting the fluid level.
1. Place the motorcycle on a level surface.
NOTE:
Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand
under the motorcycle.
2. Inspect:
Fluid level
Fluid level is under “LOWER” level line a Fill to proper level.
A
A Front
B Rear
Recommended fluid:
DOT 4
NOTE:
When inspecting the fluid level in the reservoir on
the handlebar, make sure the master cylinder top
is horizontal.
B
CAUTION:
Brake fluid may corrode painted surfaces or
plastic parts. Always clean up spilled fluid immediately.
WARNING
Use only the designated quality fluid. Otherwise, the rubber seals may deteriorate causing leakage and poor brake performance.
Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical reaction leading to poor brake performance.
Be careful that water does no enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and
could cause vapor lock.
3-35
BRAKE PAD INSPECTION/
BRAKE LIGHT SWITCH ADJUSTMENT
INSP
ADJ
A
BRAKE PAD INSPECTION
1. Activate the brake lever or brake pedal.
2. Inspect:
Brake pad
Wear indicator 1 almost contacting the brake
disc Replace brake pad as a set.
Refer to “FRONT AND REAR BRAKE” in
CHAPTER 7.
B
A Front
B Rear
BRAKE LIGHT SWITCH ADJUSTMENT
NOTE:
The brake light switch is operated by movement of
the brake pedal.
Proper adjustment is achieved when the brake
light comes on just before the brake begins to take
effect.
1. Check:
Brake light operation
Incorrect Adjust.
2. Adjust:
Brake light operating timing
Adjustment steps:
Hold the main body 1 of the switch with your
hand so that it does not rotate, and turn the adjuster 2 in or out until the operating timing is correct.
3-36
Turnning in:
Brake light on later.
Turnning out:
Brake light on sooner.
BRAKE HOSE INSPECTION/
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
INSP
ADJ
BRAKE HOSE INSPECTION
1. Inspect:
Brake hoses 1
Brake pipe 2
Cracks /Wear/Damage Replace.
WARNING
The brake pipe must not be disassembled. Do
not loosen the bolts 3 .
2. Check:
Brake hose clamp
Loosen Tighten.
3. Hold the motorcycle on upright position.
4. Check:
Brake hoses
Activate the brake lever or pedal several times.
Fluid leakage Replace the hose.
Refer to “FRONT AND REAR BRAKE” in
CHAPTER 7.
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)
WARNING
A
Bleed the brake system if:
The system has been disassembled.
A brake hose has been loosened or removed.
The brake fluid has been very low.
The brake operation has been faulty.
A loss of braking performance may occur if the
brake system is not properly bled.
1. Bleed:
Brake system
B
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to spill any
fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .
A Front
B Rear
3-37
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/
SHIFT PEDAL ADJUSTMENT
INSP
ADJ
d. Place the other end of the hose into a container.
e. Slowly apply the brake lever or pedal several
times.
f. Pull the lever in or push down on the pedal.
Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the lever or
pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or pedal limit has been reached, then release the lever or pedal.
i. Repeat steps (e) to (h) until all air bubbles have
disappeared from the fluid.
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 mkg)
NOTE:
If bleeding is difficult, it may be necessary to let the
brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.
k. Add brake fluid to proper level.
Refer to “BRAKE FLUID LEVEL INSPECTION”.
WARNING
Check the operation of the brake after bleeding the brake system.
EB304080
SHIFT PEDAL ADJUSTMENT
1. Check:
Shift pedal position
The top of the shift pedal 1 should be aligned
with the crankcase 2 .
3-38
SHIFT PEDAL ADJUSTMENT/
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
2. Adjust:
Change pedal position
Adjustment steps:
Remove the drive sprocket cover 1 .
Loosen both locknuts 2 .
Turn the shift pedal link 3 in or out to obtain the
correct pedal position.
Turnning in:
Shift pedal is raised.
Turnning out:
Shift pedal is lowered.
Tighten both locknuts.
Install the drive sprocket cover.
DRIVE CHAIN SLACK ADJUSTMENT
NOTE:
Before checking and/or adjusting, rotate the rear
wheel several revolutions and check slack at several points to find the tightest point. Check and/or
adjust the chain slack with the rear wheel is in this
“tightest” position.
CAUTION:
Too little chain slack will overload the engine
and other vital parts; keep the slack within the
specified limits.
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place, and hold
it in an upright position.
NOTE:
Both wheels should be on the ground without a rider on the motorcycle.
3-39
DRIVE CHAIN SLACK ADJUSTMENT
INSP
ADJ
2. Check:
Drive chain slack a
Out of specification Adjust.
Drive chain slack:
40 50 mm
3. Loosen:
Caliper bracket bolt 1
Axle nut 2
4. Adjust:
Drive chain slack
Adjustment steps:
Loosen both locknuts 3 .
Turn the adjusters 4 in or out until the specified slack is obtained.
Turnning in:
Slack is decreases.
Turnning out:
Slack is increases.
NOTE:
Turn each adjuster exactly the same amount to
maintain correct axle alignment.
(There are marks a on each side of the swingarm. Use them to check for proper alignment.)
Tighten the axle nut and caliper bracket bolt to
specification, while pushing the chain tight.
Axle nut:
107 Nm (10.7 mkg)
Caliper bracket bolt:
35 Nm (3.5 mkg)
Tighten the locknuts.
3-40
DRIVE CHAIN LUBRICATION/
STEERING HEAD INSPECTION
INSP
ADJ
DRIVE CHAIN LUBRICATION
The chain consists of many parts that work with
each other. If the chain is not maintained properly,
it will wear out rapidly.
Therefore, form the habit of periodically servicing
the chain. This service is especially necessary
when riding in dusty conditions.
This motorcycle has a drive chain with small rubber O-rings between the chain plates. Steam
cleaning, high-pressure washes, and certain solvents can damage these O-rings. Use only kerosene to clean the drive chain. Wipe dry, and thoroughly lubricate it with SAE30 50W motor oil.
Do not use any other lubricants on the drive chain.
They may contain solvents that could damage the
O-rings.
Recommended lubricant:
SAE30 50W motor oil or chain
lubricant suitable for O-ring
chains.
STEERING HEAD INSPECTION
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place.
2. Elevate the front wheel by placing a suitable
stand under the engine.
3. Check:
Steering assembly bearings
Grasp the bottom of the front forks and gently
rock the fork assembly back and forth.
Looseness Adjust the steering head.
3-41
STEERING HEAD INSPECTION
INSP
ADJ
4. Remove:
Starter cable holder 1
Cable guide 2
Handlebar holder (upper) 3 (with plugs)
Handlebar 4
5. Loosen:
Upper bracket pinch bolts 1
6. Remove:
Handle crown nut 2
Upper bracket 3
7. Adjust:
Steering head
Adjustment steps:
Remove the special washer 1 , ring nut (upper) 2 and rubber washer 3 .
Loosen the ring nut (lower) 4 .
Tighten the ring nut (lower) using the ring nut
wrench 5 .
NOTE:
Set the torque wrench to the ring nut wrench so
that they form a right angle.
Ring nut wrench:
90890-01403
Ring nut (initial tightening)
48 Nm (4.8 mkg)
Loosen the ring nut (lower) 4 completely, then
retighten it to specification.
Ring nut (final tightening)
16 Nm (1.6 mkg)
WARNING
Do not overtighten.
3-42
STEERING HEAD INSPECTION/
FRONT FORK INSPECTION
INSP
ADJ
Check the steering head by turning it lock to
lock. If it binds, remove the steering stem assembly and inspect the steering bearings.
Refer to “STEERING HEAD” in CHAPTER 7.
Install the rubber washer 3 .
Install the ring nut (upper) 2 .
Finger tighten the ring nut (upper) 2 , then
align the slots of both ring nuts. If necessary,
hold the ring nut (lower) and tighten the ring nut
(upper) until their slots are aligned.
Install the special washer 1 .
NOTE:
Make sure the special washer tabs sit correctly in
the slots.
8. Install:
Upper bracket
Handle crown nut
108 Nm (10.8 mkg)
Upper bracket pinch bolts
23 Nm (2.3 mkg)
Handlebar
Handlebar holder (upper) bolts (with plugs)
23 Nm (2.3 mkg)
Cable guide
Starter cable holder
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
FRONT FORK INSPECTION
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
1. Place the motorcycle on a level place.
3-43
FRONT FORK INSPECTION/
FRONT FORK ADJUSTMENT
INSP
ADJ
2. Check:
Inner tube 1
Scratches /Bent/Damage Replace.
Oil seal
Excessive oil leakage Replace.
3. Hold the motorcycle in an upright position and
apply the front brake.
4. Check:
Operation
Pump the front fork up and down for several
times.
Unsmooth operation Repair.
Refer to “FRONT FORK” in CHAPTER 7.
FRONT FORK ADJUSTMENT
WARNING
Always adjust each fork to the same setting.
Uneven adjustment can cause poor handling
and loss of stability.
Securely support the motorcycle so there is
no danger of it falling over.
Spring preload
1. Adjust:
Spring preload
Turn the adjuster 1 in or out.
Turnning
in a :
Spring preload is
increased.
Turnning
out b :
Spring preload is
decreased.
Adjuster position:
Standard: 3
Minimum: 1
Maximum: 5
2 Setting position
CAUTION:
Grooves are provided to show the adjusting
level.
Always keep the adjustment level equal on
both forks.
Never turn the adjuster beyond the maximum
or minimum setting.
3-44
FRONT FORK ADJUSTMENT/
REAR SHOCK ABSORBER ADJUSTMENT
INSP
ADJ
Damping force
1. Adjust:
Damping force
Turn the adjuster 1 in or out.
Turnning
in a :
Damping force is
increased.
Turnning
out b :
Damping force is
decreased.
Adjuster position:
Standard: 4 clicks out
Minimum: 5 clicks out
Maximum: 0 clicks out
*: From the fully turned-in position.
CAUTION:
Always keep the adjustment level equal on
both forks.
Never turn the adjuster beyond the maximum
or minimum setting.
REAR SHOCK ABSORBER ADJUSTMENT
WARNING
Securely support the motorcycle so there is
no danger of it falling over.
Spring preload
1. Adjust:
Spring preload
Coarse adjustment (top)
Turn the adjuster 1 “S” or “H”.
Adjuster position:
Rider only = S
Rider and passenger = H
3-45
REAR SHOCK ABSORBER ADJUSTMENT
INSP
ADJ
2. Adjust:
Spring preload
Fine adjustment (bottom)
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 2 in or out.
Turnning
in a :
Spring preload is
increased.
Turnning
out b :
Spring preload is
decreased.
Measurement length c :
Standard: 61 mm
Minimum: 59 mm
Maximum: 63 mm
Tighten the locknut.
Lock nut:
70 Nm (7.0 mkg)
CAUTION:
Always tighten the locknut against the spring
adjusting nut and tighten the locknut to the
specified torque.
Damping force
1. Adjust:
Damping force
Turn the adjuster 1 in or out.
Turnning
in a :
Damping force is
increased.
Turnning
out b :
Damping force is
decreased.
Adjuster position:
Standard: 20 clicks out
Minimum: 10 clicks out
Maximum: 0 clicks out
*: From the fully turned-in position.
CAUTION:
Never turn the adjuster beyond the maximum
or minimum setting.
3-46
TIRE INSPECTION
INSP
ADJ
TIRE INSPECTION
1. Measure:
Tire pressure
Out of specification Adjust.
WARNING
Tire inflation pressure should only be
checked and adjusted when the tire temperature equals the ambient air temperature. Tire
inflation pressure and suspension must be
adjusted according to the total weight of the
cargo, rider, passenger and accessories
(fairing, saddlebags, etc. if approved for this
model), and according to whether the motorcycle will be operated at high speed or not.
NEVER OVERLOAD THE MOTORCYCLE.
Operation of an overloaded motorcycle
could cause tire damage, accident or injury.
Basic weight:
With oil and 229 kg
full fuel tank
Maximum
load*:
Cold tire
pressure:
180 kg
Front
Rear
Up to 90 kg
load*
225 kPa
(2.25
kg/cm2,
2.25 bar)
275 kPa
(2.75
kg/cm2,
2.75 bar)
90 kg Maximum
load*
225 kPa
(2.25
kg/cm2,
2.25 bar)
275 kPa
(2.75
kg/cm2,
2.75 bar)
High speed
riding
225 kPa
(2.25
kg/cm2,
2.25 bar)
275 kPa
(2.75
kg/cm2,
2.75 bar)
*: Load is the total weight of cargo, rider, passenger, and accessories.
2. Inspect:
Tire surfaces
Wear/Damage Replace.
Minimum tire tread depth:
(front and rear):
1.6 mm
1 Tread depth
2 Side wall
3 Wear indicator
3-47
TIRE INSPECTION
A
B
INSP
ADJ
WARNING
It is dangerous to ride with a worn-out tire.
When a tire tread begins to show lines, replace the tire immediately.
Do not use tubeless tires on a wheel designed for tube type tires only. Tire failure
and personal injury may result from sudden
deflation.
A Tire
B Wheel
Tube type wheel
Tube type tire only.
Tubeless type
wheel
Tube type or tubeless
tire.
Be sure to install the correct tube when using
tube type tires.
WARNING
After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co.
Ltd. for this model. No guarantee for handling
characteristics can be given if a tire combinations other than the approved is used on this
motorcycle. The front and rear tires should always be of the same manufacture and design.
FRONT TIRE:
Manufacture
Size
Type
BRIDGESTONE
110/80 ZR18
BT54F
PIRELLI
110/80 ZR18
MTR03
MICHELIN
110/80 ZR18
MACADAM
90X
Size
Type
BRIDGESTONE
150/70 ZR17
BT54R
PIRELLI
150/70 ZR17
MTR04
MICHELIN
150/70 ZR17
MACADAM
90X
REAR TIRE:
Manufacture
3-48
TIRE INSPECTION/WHEEL INSPECTION/
CABLE INSPECTION AND LUBRICATION
INSP
ADJ
NOTE:
For tires with a “DRIVE” mark 1 :
Install the wheel with the “DRIVE” mark pointing
in direction in which the wheel will rotate.
WARNING
After mounting a tire, ride conservatively for a
while to give the tire time to seat itself properly
in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle.
WHEEL INSPECTION
1. Inspect:
Wheels
Damage/Bends Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel.
CABLE INSPECTION AND LUBRICATION
WARNING
Damaged cable sheaths may cause corrosion
and interfere with the cable movement. Replace damaged cables as soon as possible.
1. Inspect:
Cable sheath
Damage Replace.
2. Check:
Cable operation
Unsmooth operation Lubricate.
Recommended lubricant:
Engine oil
NOTE:
Hold cable end up and pour a few drops of lubricant into the cable sheath.
3-49
LEVER AND PEDAL LUBRICATION/SIDESTAND
LUBRICATION/REAR SUSPENSION LUBRICATION
INSP
ADJ
LEVER AND PEDAL LUBRICATION
Lubricate levers and pedals at their pivoting
points.
Recommended lubricant:
Engine oil
SIDESTAND LUBRICATION
Lubricate the sidestand at pivoting points.
Recommended lubricant:
Engine oil
REAR SUSPENSION LUBRICATION
Lubricate the rear suspension at pivoting points.
Recommended lubricant:
Molybdenum disulfide grease
3-50
BATTERY
INSP
ADJ
ELECTRICAL
BATTERY
7 Nm (0.7 mkg)
23 Nm (2.3 mkg)
30 Nm (3.0 mkg)
7 Nm (0.7 mkg)
8 Nm (0.8 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
Battery removal
Seat
1
2
3
4
5
6
Remarks
1
1
1
1
1
1
Brake hose guide
Rear master cylinder
Rear brake switch
Battery negative lead terminal
Battery positive lead terminal
Battery assembly
Refer to “Battery removal”.
For installation, reverse the removal
procedure.
3-51
REMOVAL
INSP
ADJ
REMOVAL
WARNING
Immediately after removing the battery leads,
securely cover the terminals with the covers
1 to prevent the battery leads from being
shorted.
1. Remove:
Seat
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
2. Remove:
Negative terminal cover 1
Positive terminal cover 2
WARNING
First disconnect the negative lead 1 , then disconnect the positive lead 2 .
3. Remove:
Battery assembly
NOTE:
Slide the battery assembly around the right side of
the shock absorber and then pull it outward to remove.
4. Remove:
Battery negative lead 1
Battery positive lead 2
Battery 3
Battery box 4
3-52
INSPECTION
INSP
ADJ
INSPECTION
NOTE:
Since the MF battery is a sealed type battery, it is
not possible to measure the specific gravity of the
electrolyte in order to check the charge state of the
battery. Therefore the charge of the battery has to
be checked by measuring the voltage at the battery terminals.
CAUTION:
This is a sealed type battery. Never remove
the sealing caps. If the sealing caps have
been removed, the balance will not be maintained and battery performance will deteriorate.
Charging time, charging current and charging voltage for the MF battery are different
from those of general type batteries. The MF
battery should be charged as explained in
“CHARGING METHOD”. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when
charging the battery.
WARNING
Batteries generate explosive hydrogen gas.
Always follow the following preventive measures:
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or open
flames (e.g., welding equipment, lighted cigarettes, etc.)
DO NOT SMOKE when charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
3-53
INSPECTION
INSP
ADJ
1. Check:
S Battery condition
Volt meter
Battery condition checking steps:
S Connect a digital voltmeter to the battery terminals.
Open-circuit voltage
Tester (+) lead battery (+) terminal
Tester (–) lead battery (–) terminal
(V)
13.0
NOTE:
The charge state of an MF battery can be checked
by measuring the open-circuit voltage (i.e. the
voltage when the positive terminal is disconnected).
Relationship between the open-circuit voltage
and the charging time at 20_C
12.5
12.0
11.5
Open-circuit voltage
12.8 V or higher
Open-circuit voltage (V)
5 6.5
10
Charging time (hours)
S This varies depending on the temperature, the state of charge
in the battery plates and the electrolyte level.
14
13
12
11
10
CAUTION:
0
100
75
50
30 25 20
Condition of the charge in the battery (%)
Open-circuit voltage (V)
17
16
15
14
13
12
11
10
0
S If it is impossible to set the standard charging
current, be careful not to overcharge.
S When charging the battery, be sure to remove
it from the motorcycle. (If charging has to be
done with the battery mounted on the motorcycle, be sure to disconnect the wire at the
negative terminal.)
S Never remove the sealing caps of an MF battery,
S Make sure that the charging clips are in full
contact with the terminal and that they are
not shorted together. (A corroded clip on the
charger may cause the battery to generate
heat in the contact area. A weak clip spring
may cause sparks.)
Ambient temperature
20_C
18
10
20
30
No charging is
necessary.
S Check the condition of the battery using the following charts.
Example:
S Open-circuit voltage = 12.0 V
S Charging time = 6.5 hours
S Charge condition of the battery = 20 30%
S Charging method for MF batteries
Charging method
Ambient
temperature
20_C
Charging
Charging time
60 Time (minutes)
40
50
Check the open-circuit
voltage
3-54
INSPECTION
INSP
ADJ
Before removing the clips from the battery
terminals, be sure to turn off the charger’s
power switch.
The open-circuit voltage variation for the MF
battery after charging is shown below. As
shown in the figure, the open circuit voltage
stabilizes about 30 minutes after charging
has been completed.
Therefore, wait 30 minutes after charging is
completed before measuring the opencircuit
voltage.
WARNING
Do not quick charge the battery.
3-55
INSPECTION
INSP
ADJ
Charging method using a variable-current (voltage) type charger
Charger
AMP meter
Measure the open-circuit
voltage prior to charging.
Connect a charger and AMP
meter to the battery and start
charging.
YES
Make sure that the current is
higher than the standard
charging current written on
the battery.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
NO
By turning the charging voltage
adjust dial, set the charging voltage at 20 25 V.
Adjust the voltage so that the
current is at the standard charging level.
YES
Monitor the amperage for 3 5
minutes to check if the standard
charging current is reached.
NO
Set the timer according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps.”
If the current does not exceed
the standard charging current
after 5 minutes, replace the
battery.
If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
R12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
3-56
INSPECTION
INSP
ADJ
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and
AMP meter to the battery
and start charging.
YES
Make sure that the current
is higher than the standard
charging current written
on the battery.
Charge the battery until the battery’s
charging voltage is 15 V.
NO
This type of battery charger cannot
charge the MF battery. A variable voltage charger is recommended.
NOTE:
Set the charging time at 20 hours (maximum).
Measure the battery open-circuit voltage after leaving the battery unused 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.
Charger
AMP meter
Volt meter
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
3-57
INSPECTION/INSTALLATION/FUSE INSPECTION
INSP
ADJ
2. Inspect:
Battery terminal
Dirty Clean with a wire brush.
Poor connection Correct.
NOTE:
After cleaning the terminals, grease them lightly.
INSTALLATION
1. Install:
Battery assembly 1
NOTE:
During installation, be sure the projection a on
the battery box aligns with the grommet on the
frame.
Pass the battery leads through the cable guide
2.
2. Install:
Positive terminal cover 1
Negative terminal cover 2
NOTE:
Connect the battery positive lead first and then
the negative lead.
After connecting the leads, securely cover the
terminals with the covers.
FUSE INSPECTION
CAUTION:
Always turn off the main switch when checking or replacing the fuse. Otherwise, a short
circuit may occur.
1. Remove:
Seat
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3-58
FUEL INSPECTION
INSP
ADJ
2. Inspect:
Fuses 1
Inspection steps:
Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to “Ω 1”
Pocket tester:
90890-03112
If the tester indicates ∞, replace the fuse.
3. Replace:
Blown fuse
Replacement steps:
Turn off the ignition.
Install a new fuse of proper amperage.
Turn on the switches to verify operation of related electrical devices.
If the fuse immediately blows again, check the
electrical circuit.
Description
Amperage
Quantity
Main
30A
1
Head
15A
1
Signal
15A
1
Ignition
7.5A
1
Fan
7.5A
1
WARNING
Never use a fuse with a rating other than specified. Never use other materials in place of a
fuse. An improper fuse may cause extensive
damage to the electrical system, malfunction
of lighting and ignition and possibly cause a
fire.
4. Install:
Seat
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3-59
HEADLIGHT BEAM ADJUSTMENT/
HEADLIGHT BULB REPLACEMENT
INSP
ADJ
EB305021
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:
Headlight beam (vertically)
Turn the adjuster 1 in or out.
Turnning in:
Headlight beam is
lowered.
Turnning out:
Headlight beam is raised.
2. Adjust:
Headlight beam (horizontally)
Turn the adjuster 2 in or out.
Right headlight:
Turnning in:
Headlight beam is to the
right.
Turnning out:
Headlight beam is to the
left.
Left headlight:
Turnning in:
Headlight beam is to the
left.
Turnning out:
Headlight beam is to the
right.
HEADLIGHT BULB REPLACEMENT
1. Remove:
Cover 1
2. Disconnect:
Headlight leads 1
3. Unhook:
Bulb holder 2
4. Remove:
Bulb
WARNING
Keep flammable products and your hands
away from the bulb while it is on, as it will be
hot. Do not touch the bulb until it has cooled
down.
3-60
HEADLIGHT BULB REPLACEMENT
INSP
ADJ
5. Install:
Bulb New
Secure the new bulb with the bulb holder.
CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous
flux will be adversely affected. If oil gets on the
bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
6. Hook:
Bulb holder
7. Connect:
Headlight leads
8. Install:
Cover
3-61
INSP
ADJ
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER . . . . . . . . . . . . . .
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-3
4-5
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4-6
4-7
4-8
4-9
4-11
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
VALVE AND VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15
4-16
4-17
4-21
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
4-24
4-24
4-27
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29
4-29
4-30
4-31
4-31
4-32
CRANKCASE COVER (LEFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
ENG
A.C. MAGNETO AND STARTER WHEEL GEAR . . . . . . . . . . . . . . . . . . . . .
STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.C. MAGNETO AND STARTER WHEEL GEAR . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37
4-37
4-38
4-39
4-39
4-40
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP COVER AND OIL PUMP DRIVEN GEARS . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-41
4-41
4-42
4-43
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
OIL HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BALANCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-46
4-46
4-47
4-49
4-50
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-52
4-52
4-53
4-54
4-55
4-60
TRANSMISSION, SHIFT CAM AND SHIFT FORK . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-63
4-64
4-65
4-66
ENGINE ASSEMBLY
ENG
ENGINE OVERHAUL
ENGINE ASSEMBLY
LEADS
10 Nm (1.0 mkg)
Order
Job name/Part name
1
2
Leads disconnect
Side cowling, seat, side cover and fuel
tank.
Battery negative lead
Battery positive lead
3
4
5
6
Starter motor lead
1
Startor coil lead/pickup coil lead coupler 1/1
Neutral switch lead coupler
1
1
Clamp
Q’ty
Remarks
Disconnect the parts in the order below.
Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3.
1
1
WARNING
Disconnect the negative lead first and
then disconnect the positive lead.
Immediately after removing the battery
leads, securely cover the terminals with
the covers 1 to prevent the battery
leads from being shorted
Disconnect
Disconnect
For connecting, reverse the disconnection
procedure.
4-1
ENGINE ASSEMBLY
ENG
DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER
12 Nm (1.2 mkg)
70 Nm (7.0 mkg)
24 Nm (2.4 mkg)
5 Nm (0.5 mkg)
24 Nm (2.4 mkg)
20 Nm (2.0 mkg)
20 Nm (2.0 mkg)
Order
Job name/Part name
Q’ty
Drive sprocket and exhaust
pipe/muffler removal
Air filter case
Carburetor assembly
Radiator assembly
Thermostatic valve assembly
1
2
3
4
5
6
7
8
9
Remarks
Remove the parts in the order below.
Refer to “AIR FILTER CASE” in CHAPTER 3.
Refer to “CARBURETOR” in CHAPTER 6.
Refer to “RADIATOR” in CHAPTER 5.
Refer to “THERMOSTATIC VALVE”
in CHAPTER 5.
Drive sprocket cover 1
Shift arm
Drive sprocket cover 2
Nut/Lock washer
Drive sprocket/Drive chain
Exhaust pipe/Muffler
Exhaust pipe gasket
Clutch cable
Spark plug caps
1
1
1
1/1
1/1
1/1
2
1
2
For installation, reverse the removal
procedure.
4-2
ENGINE ASSEMBLY
ENG
ENGINE ASSEMBLY
10 Nm (1.0 mkg)
89 Nm (8.9 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
30 Nm (3.0 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
64 Nm (6.4 mkg)
Order
Job name/Part name
Q’ty
Engine removal
1
2
3
4
5
6
7
8
9
10
11
Remarks
Remove the parts in the order below.
NOTE:
Place suitable stand under the frame and
engine.
Starter motor
1
Vacuum hose
Breather hose
Bolt
Bolt
Bolt
Engine bracket (left)
Engine bracket (right)
Plug
Bolt
Bolt
Engine assembly
2
1
2
1
1
1
1
2
1
1
1
4-3
Refer to “STARTER MOTOR” in CHAPTER 8.
= 45 mm
= 25 mm
= 60 mm
= 230 mm
= 115 mm
Refer to “INSTALLATION”.
ENGINE ASSEMBLY
ENG
10 Nm (1.0 mkg)
89 Nm (8.9 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
30 Nm (3.0 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
64 Nm (6.4 mkg)
Order
12
13
Job name/Part name
Q’ty
Engine stay (left)
Engine bracket (lower)
Remarks
1
1
For installation, reverse the removal
procedure.
4-4
ENGINE ASSEMBLY
ENG
INSTALLATION
1. Install:
Bolt 1 X 6
NOTE:
Do not fully tighten.
2. Tighten:
Tighten the bolts in the order below.
1
2
3
4
5
6
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
1
2
3
4
5
6
3. Install:
Shift arm 1
30 Nm (3.0 mkg)
30 Nm (3.0 mkg)
64 Nm (6.4 mkg)
89 Nm (8.9 mkg)
60 Nm (6.0 mkg)
30 Nm (3.0 mkg)
12 Nm (1.2 mkg)
NOTE:
Align the punched mark a on the shift shaft with
the slot on the shift arm.
The top of the shift pedal 1 should be aligned
with the crankcase 2 .
4-5
CAMSHAFT
ENG
CAMSHAFT
CYLINDER HEAD COVER
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Cylinder head cover removal
Side cowling, seat, side cover and fuel
tank
Air filter case
Remove the parts in the order below.
Refer to “COWLINGS, SEAT, TAIL
COVER AND FUEL TANK” in CHAPTER 3.
Refer to “AIR FILTER CASE” in
CHAPTER 3.
Refer to “COOLANT REPLACEMENT”
in CHAPTER 3.
Refer to “RADIATOR” in CHAPTER 5.
Refer to “CARBURETOR” in CHAPTER 6.
Refer to “THERMOSTATIC VALVE” in
CHAPTER 5.
Coolant
Radiator
Carburetor assembly
Thermostatic assembly
1
2
3
4
5
Breather hose
Spark plug cap
Bolt
Cylinder head cover
Cylinder head cover gasket
Remarks
1
2
1/6/1 = 68/27/58 mm
1
3
For installation, reverse the removal
procedure.
4-6
CAMSHAFT
ENG
CAMSHAFT
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
20 Nm (2.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Q’ty
Camshaft removal
Spark plug
Plug/O-ring
Timing chain guide (upper)
Timing chain tensioner/Gasket
Camshaft sprocket
Timing chain guide (exhaust)
Camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
2
2/2
1
1/1
2
1
4
8
1
1
Remarks
Remove the parts in the order below.
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal
procedure.
4-7
CAMSHAFT
ENG
REMOVAL
1. Remove:
Timing plug 1
Straight plug 2
2. Align:
“T” mark
(with stationary pointer)
NOTE:
Turn the crankshaft counterclockwise and align
the “T” mark a with the stationary pointer b
when #1 piston is at TDC on compression stroke.
The #1 piston is in compression stroke TDC
when the cam lobes are turned away from each
other.
3. Remove:
Timing chain guide (upper) 1
4. Loosen:
Camshaft sprocket bolts 2
5. Loosen:
Tensioner cap bolt 1
6. Remove:
Timing chain tensioner 2
7. Remove:
Camshaft sprockets 1
NOTE:
Attach a wire 2 to the timing chain to prevent it
from falling into the crankcase.
4-8
CAMSHAFT
ENG
8. Remove:
Timing chain guide (exhaust)
Camshaft cap 1
NOTE:
Remove the camshaft cap bolts in a crisscross
pattern, working from the inside to the outside.
CAUTION:
The bolts (camshaft caps) must be removed
evenly to prevent damage to the cylinder head,
camshafts or camshaft caps.
INSPECTION
1. Inspect:
Cam lobes
Pitting/Scratches /Blue discoloration Replace.
2. Measure:
Cam lobes length a and b
Out of specification Replace.
Cam lobes length limit:
Intake:
a 35.85 mm
b 27.85 mm
Exhaust:
a 35.85 mm
b 27.85 mm
3. Measure:
Runout (camshaft)
Out of specification Replace.
Runout (camshaft):
Less than 0.03 mm
4-9
CAMSHAFT
ENG
4. Measure:
Camshaft-to-cap clearance
Out of specification Measure bearing diameter (camshaft)
Camshaft-to-cap clearance:
0.020 0.054 mm
Measurement steps:
Install the camshaft onto the cylinder head.
Position a strip of Plastigauge 1 onto the
camshaft.
Install the dowel pins and camshaft caps.
10 Nm (1.0 mkg)
NOTE:
Tighten the bolts (camshaft cap) in a crisscross
pattern from innermost to outer caps.
Do not turn the camshaft when measuring clearance with the Plastigauge.
Remove the camshaft caps and measure the
width of the Plastigauge 1 .
5. Measure:
Outside diameter (camshaft) a
Out of specification Replace the camshaft.
Within specification Replace camshaft case
and camshaft caps as a set.
Outside diameter (camshaft):
24.967 24.980 mm
6. Inspect:
Timing chain
Stiffness/damage Replace the chain and
the sprockets as a set.
4-10
CAMSHAFT
ENG
INSTALLATION
1. Install:
Exhaust camshaft 1
Intake camshaft 2
(with camshaft sprocket temporarily tighten)
Dowel pins 3
NOTE:
Install the camshaft with the punch mark a facing
upward.
2. Install:
Camshaft caps
10 Nm (1.0 mkg)
NOTE:
Install the camshaft cap with the arrow mark a
embossed facing timing chain of the engine.
Tighten the camshaft cap bolts in a crisscross
pattern from the inside to outwards.
Do not install the bolts at b marked place in this
stage.
CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, camshaft caps and camshaft will result.
3. Install:
Camshaft sprockets
Installation steps:
Turn the crankshaft counterclockwise until the
“T” mark a on the A.C. magneto is aligned with
the stationary pointer b on the crankcase cover
(left) when #1 piston is at TDC.
Fit the timing chain onto both camshaft sprockets
and install the camshaft sprockets on the camshafts.
NOTE:
When installing the camshaft sprockets, start with
the exhaust camshaft to keep the timing chain as
tense as possible on the exhaust side, and set the
match marks c to be parallel with the case surface on the corresponding sides.
“I”: Intake side
“E”: Exhaust side
4-11
CAMSHAFT
ENG
CAUTION:
Do not turn the crankshaft during the camshaft installation. Damage or improper valve
timing will result.
Make sure that marks d and e are aligned after
the crankshaft is rotated twice and the piston is at
TDC.
4. Install:
Timing chain guide (exhaust)
5. Install:
Timing chain tensioner
Installation steps:
Remove the tensioner cap bolt 1 , washer 2
and springs 3 .
Release the timing chain tensioner one-way cam
4 and push the tensioner rod 5 all the way in.
Install a gasket 6 . New
Install the timing chain tensioner.
Timing chain tensioner:
10 Nm (1.0 mkg)
Install the springs 3 and washer 2 .
Install the tensioner cap bolt 1 .
Cap bolt:
20 Nm (2.0 mkg)
6. Turn:
Crankshaft
Counterclockwise several turns
7. Check:
A.C. magneto “T” mark
Align with the crankcase stationary pointer.
Camshaft punched marks
Align with the camshaft cap embossed marks.
Out of alignment Adjust.
8. Tighten:
Camshaft sprocket bolts.
24 Nm (2.4 mkg)
4-12
CYLINDER HEAD
ENG
CYLINDER HEAD
40 Nm (4.0 mkg)
21 Nm (2.1 mkg)
10 Nm (1.0 mkg)
60 Nm (6.0 mkg)
10 Nm (1.0 mkg)
60 Nm (6,0 mkg)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Q’ty
Cylinder head removal
Exhaust pipe
Camshaft
Union bolt
Copper washer
Oil delivery pipe
Clip
Vacuum hose
Cylinder head
Cylinder head gasket
Dowel pin
Remarks
Remove the parts in the order below.
Refer to “ENGINE ASSEMBLY”.
Refer to “CAMSHAFT”.
1
2
1
2
2
1
1
2
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
4-13
CYLINDER HEAD
ENG
INSPECTION
1. Eliminate:
Carbon deposit
(from combustion chamber)
Use rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damaging
or scratching:
Spark plug threads
Valve seat
2. Inspect:
Cylinder head
Scratches /Damage Replace.
3. Measure:
Cylinder head warpage
Out of specification Resurface.
Cylinder head warp limit:
Less than 0.03 mm
Warp limit measurement and resurfacement
steps:
Hold a straight edge and a thickness gauge to
the cylinder head.
Measure the warpage.
If the warpage is out of specification, resurface
the cylinder head.
Place a 400 600 grit wet sandpaper on the surface plate, and resurface the head using a figureeight sanding pattern.
NOTE:
Rotate the head several times to avoid removing
too much material from one side.
INSTALLATION
1. Install:
Dowel pins
Cylinder head gasket New
Cylinder head
Nut 40 Nm (4.0 mkg)
Bolt 10 Nm (1.0 mkg)
NOTE:
Apply the engine oil onto the nut threads.
Tighten the nuts in a crisscross pattern.
4-14
VALVE AND VALVE SPRING
ENG
VALVE AND VALVE SPRING
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Q’ty
Valve and valve spring removal
Cylinder head cover
Cylinder head
Valve lifter
Adjusting pad
Valve cotter
Valve retainer
Valve spring
Stem seal
Valve spring seat
Exhaust valve
Intake valve (center)
Intake valve (left and right)
Remarks
Remove the parts in the order below.
Refer to “CYLINDER HEAD COVER”.
Refer to “CYLINDER HEAD”.
5
5
10
5
5
5
5
2
1
2
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal procedure.
4-15
VALVE AND VALE SPRING
ENG
REMOVAL
1. Remove:
Valve lifters 1
Pads 2
NOTE:
Identify each lifter 1 and pad 2 position very
carefully so that they can be reinstalled in their
original place.
2. Check:
Valve sealing
Leakage at valve seat Inspect the valve
face, valve seat and the valve seat width.
Checking steps:
Pour a clean solvent a into the intake and exhaust ports.
Check the valve seating.
There should be no leakage at the valve seat 1 .
3. Remove:
Valve cotters 1
NOTE:
Attach the valve spring compressor 2 and attachment 3 between the valve spring retainer
and cylinder head to remove the valve cotters.
Valve spring compressor:
90890-04019
Attachment:
90890-04108
4-16
VALVE AND VALVE SPRING
ENG
INSPECTION
1. Measure:
S Stem-to-guide clearance
Stem-to-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification Replace valve guide.
Stem-to-guide clearance:
Intake:
0.010 X 0.037 mm
<Limit>: 0.08 mm
Exhaust:
0.025 X 0.052 mm
<Limit>: 0.10 mm
2. Replace:
S Valve guide
Replacement steps:
NOTE:
Heat the cylinder head in an oven to 100_C to
ease guide removal and installation and to maintain correct interference fit.
S Remove the valve guide using the valve guide
remover 1 .
S Install the valve guide (new) using the valve
guide installer 2 and valve guide remover 1 .
S After installing the valve guide, bore the valve
guide using the valve guide reamer 3 to obtain
proper stem-to-guide clearance.
Valve guide remover, installer and
reamer (5.5 mm):
90890-04016
NOTE:
Reface the valve seat after replacing the valve
guide.
4-17
VALVE AND VALVE SPRING
ENG
3. Eliminate:
Carbon deposit
(from valve face)
4. Inspect:
Valve face
Pitting/Wear Reface the face.
Valve stem end
Mushroom shape or diameter larger than rest
of stem Replace.
5. Measure:
Margin thickness a
Out of specification Replace.
Margin thickness:
0.8 X 1.2 mm
6. Measure:
Runout (valve stem)
Out of specification Replace.
Runout limit:
0.01 mm
NOTE:
Always replace the guide if the valve is replaced.
Always replace the oil seal if the valve is removed.
7. Eliminate:
Carbon deposit
(from valve face and valve seat)
8. Inspect:
Valve seat
Pitting/Wear Reface valve seat.
9. Measure:
Valve seat width a
Out of specification Reface valve seat.
Valve seat width:
Intake: 0.9 X 1.1 mm
Exhaust: 0.9 X 1.1 mm
4-18
VALVE AND VALVE SPRING
ENG
Measurement steps:
Apply the Mechanic’s blueing dye (Dykem) b to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and onto
the valve seat to make a clear pattern.
Measure the valve seat width. Where the valve
seat and valve face made contact, blueing will
have been removed.
If the valve seat is too wide, too narrow, or the
seat is not centered, the valve seat must be refaced.
10. Lap:
Valve face
Valve seat
NOTE:
After refacing the valve seat or replacing the valve
and valve guide, the valve seat and valve face
should be lapped.
Lapping steps:
Apply a coarse lapping compound a to the
valve face.
CAUTION:
Be sure no compound enters the gap between
the valve stem and guide.
Apply molybdenum disulfide oil to the valve
stem.
Install the valve into the cylinder head.
Turn the valve until the valve face and valve seat
are evenly polished, then clean off all compound.
4-19
VALVE AND VALVE SPRING
ENG
NOTE:
To obtain the best lapping result, lightly tap the
valve seat while rotating the valve back and forth
between your hand.
Apply a fine lapping compound to the valve face
and repeat the above steps.
NOTE:
Be sure to clean off all compound from the valve
face and valve seat after every lapping operation.
Apply the Mechanic’s blueing dye (Dykem) b to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and onto
the valve seat to make a clear pattern.
Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
11. Measure:
Free length (valve spring) a
Out of specification Replace.
Free length (valve spring):
37.29 mm
<Limit>
35.20 mm
12. Measure:
Compressed force (valve spring) a
Out of specification Replace.
b Installed length
Compressed force:
10.0 X 11.6 kg at 30.39 mm
4-20
VALVE AND VALVE SPRING
ENG
13. Measure:
S Spring tilt a
Out of specification Replace.
Spring tilt limit:
2.5_/1.7 mm
INSTALLATION
1. Install:
S Stem seal New
S Valve
S Spring seat
S Valve spring
S Valve retainer
(into cylinder head)
NOTE:
S Make sure that each valve is installed in its original place, also referring to the embossed mark
as follows:
Intake (right/left): “3LD:”
Intake (middle): “3LD.”
Exhaust “3LD”
S Install the valve spring with the larger pitch a
facing upwards.
b Smaller pitch
4-21
VALVE AND VALVE SPRING
ENG
2. Install:
Valve cotters 1
NOTE:
Install the valve cotters while compressing the
valve spring with the valve spring compressor.
Valve spring compressor 2 :
90890-04019
Attachment 3 :
90890-04108
3. Secure the valve cotters 1 onto the valve stem
by tapping lightly with a piece of wood.
NOTE:
Do not hit so much as to damage the valve.
4. Install:
Pads 1
Valve lifters 2
NOTE:
The valve lifters must move smoothly when rotated with the finger.
Each valve lifter and pad must be reinstalled in
their original position.
Refer to “VALVE CLEARANCE ADJUSTMENT” in
CHAPTER 3.
4-22
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Q’ty
Cylinder and piston removal
Cylinder head
Joint
O-ring
O-ring
Dowel pin
Cylinder
Cylinder gasket
O-ring
Circlip
Piston pin
Piston
Piston ring set
Remarks
Remove the parts in the order below.
Refer to “CYLINDER HEAD”.
1
1
1
4
1
1
2
4
2
2
2
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal
procedure.
4-23
CYLINDER AND PISTON
ENG
REMOVAL
1. Remove:
Piston circlips 1
Piston pins 2
Pistons 3
NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag to prevent the piston
pin clip from falling into the crankcase cavity.
Put identification marks on each piston head for
reference during reinstallation.
Before removing the piston pin, deburr the clip
groove and pin hole area. If the piston pin groove
is deburred and piston pin is still difficult to remove, use the piston pin puller 4 .
Piston pin puller:
90890-01304
CAUTION:
Do not use a hammer to drive the piston pin
out.
INSPECTION
1. Inspect:
Cylinder and piston walls
Vertical scratches Rebore or replace cylinder and piston.
2. Measure:
Piston-to-cylinder clearance
Measurement steps:
1st step:
Measure the cylinder bore “C” with a cylinder
bore gauge.
NOTE:
Measure the cylinder bore “C” in parallel to and at
right angles to the crankshaft. Then, find the average of the measurements.
4-24
CYLINDER AND PISTON
ENG
Cylinder bore “C” 89.500 X 89.505 mm
Taper limit “T”
0.05 mm
Out of round “R”
0.03 mm
“C” = Maximum D
“T” = (Maximum D1, or D2) – (Maximum D5
or D6)
“R” = (Maximum D1, D3 or D5)
– (Minimum D2, D4 or D6)
If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as
set.
2nd step:
Measure the piston skirt diameter “P” with a micrometer.
a 5.5 mm from the piston bottom edge.
Piston size P
Standard
89.420 X 89.435
mm
Oversize 2
0.50 mm
Oversize 4
1.00 mm
If out of specification, replace the piston and piston rings as a set.
3rd step:
Calculate the piston-to-cylinder clearance with
following formula:
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.065 X 0.085 mm
<Limit>: 0.15 mm
If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as
set.
4-25
CYLINDER AND PISTON
ENG
3. Measure:
Side clearance
Out of specification Replace piston and
rings as a set.
NOTE:
Eliminate the carbon deposits from the piston ring
grooves and rings before measuring the side
clearance.
Side clearance:
Top ring:
0.035 X 0.070 mm
2nd ring:
0.035 X 0.070 mm
4. Position:
Piston ring
(into cylinder)
NOTE:
Push the ring with the piston crown so that the ring
will be at a right angle to the cylinder bore.
a 5 mm
5. Measure:
End gap
Out of specification Replace.
NOTE:
You cannot measure the end gap on the expander
spacer of the oil control ring. If the oil control ring
rails show excessive gap, replace all three rings.
End gap:
Top ring:
0.30 X 0.45 mm
2nd ring:
0.30 X 0.45 mm
Oil ring:
0.20 X 0.70 mm
4-26
CYLINDER AND PISTON
ENG
6. Inspect:
Piston pin
Blue discoloration/Grooves Replace, then
inspect lubrication system.
7. Measure:
Piston pin-to-piston clearance
Measurement steps:
Measure the piston pin outside diameter a .
If out of specification, replace the piston pin.
Outside diameter (piston pin):
19.991 X 20.000 mm
<Limit>: 19.975 mm
Measure the piston inside diameter b .
Calculate the piston pin-to-piston clearance with
following formula:
Piston pin-to-piston clearance =
Bore size (piston pin) b –
Outside diameter (piston pin) a
If out of specification, replace the piston.
Piston pin-to-piston clearance =
0.002 X 0.022 mm
<Limit>: 0.07 mm
INSTALLATION
1. Install:
Piston rings
NOTE:
Be sure to install rings so that “T” mark is located
on the upper side of the rings. Oil the pistons and
rings liberally.
4-27
CYLINDER AND PISTON
ENG
2. Install:
Piston pins 1
Pistons 2
Piston circlips 3
NOTE:
Apply engine oil to the piston pins.
Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
Before installing the piston, cover the crankcase
with a clean rag to prevent the piston from falling
into the crankcase.
3. Position:
Top ring
2nd ring
Oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Oil ring end (lower)
c Oil ring end (upper)
d 2nd ring end
4. Install:
Dowel pins
O-rings New
Cylinder gasket New
Cylinder
NOTE:
Install the cylinder with one hand while compressing the piston rings with the other hand.
Pass the timing chain and timing chain guide (intake) through the timing chain cavity.
4-28
CLUTCH
ENG
CLUTCH
CRANKCASE COVER (RIGHT)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.
Crankcase cover (right) removal
Engine oil
1
2
Clutch cable
Crankcase cover (right)
1
1
3
4
5
6
7
8
9
Gasket
Dowel pin
Circlip
Plain washer
Pull lever
Torsion spring
Plain washer
1
2
1
1
1
1
1
NOTE:
Loosen the bolts in a crisscross pattern.
For installation, reverse the removal
procedure.
4-29
CLUTCH
ENG
CLUTCH
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job name/Part name
Clutch removal
Clutch spring
Pressure plate
Plain washer/Bearing
Pull rod
Friction plate
Clutch plate
Clutch boss nut
Lock washer
Clutch boss
Thrust plate
Spacer/Bearing
Clutch housing
Thrust plate 2
Thrust plate 1
Q’ty
Remarks
Remove the parts in the order below.
6
1
1/1
1
9
8
1
1
1
1
1/1
1
1
1
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal
procedure.
4-30
CLUTCH
ENG
REMOVAL
1. Straighten the lock washer tab.
2. Remove:
Clutch boss nut 1
Lock washer 2
Clutch boss 3
NOTE:
Loosen the clutch boss nut 1 while holding the
clutch boss 3 with the universal clutch holder.
Universal clutch holder:
90890-04086
3. Remove:
Spacer 1
Bearing 2
NOTE:
Install 6 mm bolts 3 onto the spacer. Then remove the spacer by pulling.
INSPECTION
1. Measure:
Friction plate thickness
Out of specification Replace friction plates
as a set.
Measure at four points.
Thickness:
2.9 3.1 mm
<Limit>: 2.8 mm
2. Measure:
Clutch plate warpage
Out of specification Replace clutch plate as
a set.
Use a surface plate and feeler gauge 1 .
Warp limit:
Less than 0.1 mm
3. Measure:
Free length (clutch spring) a
Out of specification Replace springs as a
set.
Free length (clutch spring):
55 mm
<Limit>: 53 mm
4-31
CLUTCH
ENG
4. Inspect:
Dogs
(on the clutch housing)
Pitting/Wear/Damage Deburr or replace.
Clutch housing bearing
Wear/Damage Replace clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic operation.
Clutch boss splines
Pitting/Wear/Damage
boss.
Replace
clutch
NOTE:
Pitting on the clutch boss splines will cause erratic
operation.
INSTALLATION
1. Install:
Clutch boss 1
Lock washer 2 New
Clutch boss nut 3
70 Nm (7.0 mkg)
NOTE:
Tighten the clutch boss nut while holding the
clutch boss with the universal clutch holder 4 .
Universal clutch holder:
90890-04086
2. Bend the lock washer tab along a flat side of the
nut.
3. Install:
Friction plates
Clutch plates
NOTE:
Mount friction and clutch plate alternately.
Lubricate the friction plates with engine oil.
4-32
CLUTCH
ENG
4. Install:
Pressure plate
NOTE:
Align the punched mark a on the clutch boss with
the punched mark b on the pressure plate.
5. Install:
Clutch springs 1
Clutch spring bolts 2
8 Nm (0.8 mkg)
NOTE:
Tighten the clutch spring bolts in stage, using a
crisscross pattern.
6. Install:
Dowel pins
Gasket New
Crankcase cover (right)
10 Nm (1.0 mkg)
NOTE:
Install the pull rod so that the splines a are toward
the back, then install the crankcase cover (right).
7. Install:
Plain washer 1
Torsion spring 2
Pull lever 3
Plain washer 4
Circlip 5 New
NOTE:
Align the punched mark a on the clutch pull lever
shaft with the mark b on the crankcase cover.
4-33
CRANKCASE COVER (LEFT)
ENG
CRANKCASE COVER (LEFT)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
5 Nm (0.5 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Crankcase cover (left) removal
Engine oil
1
2
3
Drive sprocket cover 1/2
Shift arm
Crankcase cover (left)
4
5
6
7
Gasket
Dowel pin
Circlip
Plain washer
Remarks
1/1
1
1
NOTE:
Loosen the bolts in a crisscross pattern.
1
2
1
1
For installation, reverse the removal
procedure.
4-34
SHIFT SHAFT
ENG
SHIFT SHAFT
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Refer to “CLUTCH”.
Refer to “CRANKCASE COVER (LEFT)”.
Shift shaft removal
Clutch
Shift arm
Shift shaft
Circlip
Plain washer
Torsion spring
Stopper level
Bearing retainer
Torsion spring
1
1
1
1
1
1
1
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
4-35
SHIFT SHAFT
ENG
INSPECTION
1. Inspect:
Stopper lever 1
Roller turns roughly Replace.
Bends/Damage Replace.
2. Inspect:
Torsion spring (shift shaft) 1
Torsion spring (stopper lever) 2
Wear/Damage Replace.
3. Inspect:
Shift shaft 1
Shift pawls 2
Bends/Wear/Damage Replace.
INSTALLATION
1. Install:
Return spring 1
Bearing retainer 2
Stopper lever 3
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
NOTE:
Be sure the stopper lever roller fits into the shift
cam segment.
4-36
A.C. MAGNETO AND STARTER WHEEL GEAR
ENG
A.C. MAGNETO AND STARTER WHEEL GEAR
STATOR COIL
7 Nm (0.7 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Refer to “CRANKCASE COVER (LEFT)”.
Stator coil removal
Engine oil
1
2
3
4
5
6
Crankcase cover (left)
Stator coil lead/Pickup coil lead
Crankcase cover (left)
Gasket
Dowel pin
Clamp/Pickup coil
Stator coil
Remarks
1/1
1
1
2
1/1
1
For installation, reverse the removal
procedure.
4-37
A.C. MAGNETO AND STARTER WHEEL GEAR
ENG
A.C. MAGNETO AND STARTER WHEEL GEAR
130 Nm (13.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
1
2
A.C. magneto and starter wheel
gear removal
Rotor
Shaft
1
1
3
4
Starter idle gear
Starter clutch
1
1
5
6
7
Plate washer
Woodruff key
Starter wheel gear
1
1
1
Refer to “REMOVAL” and
“INSTALLATION”.
NOTE:
After reassembling the starter clutch stake
the top of the bolts.
For installation, reverse the removal
procedure.
4-38
A.C. MAGNETO AND STARTER WHEEL GEAR
ENG
REMOVAL
1. Remove:
Bolt (rotor) 1
Washer 2
NOTE:
Loosen the bolt (rotor) 1 while holding the magneto with the sheave holder 3 .
Do not allow the sheave holder 3 to touch the
projection on the rotor.
Sheave holder:
90890-01701
2. Remove:
A.C. magneto 1
NOTE:
Remove the rotor 1 using the rotor puller 2 and
crankshaft protector 3 .
Fully tighten the tool holding bolts, but make sure
the tool body is parallel with the magneto. If necessary, one screw may be backed out slightly to
level tool body.
Flywheel puller:
90890-01362
Crankshaft protector:
90890-01382
INSPECTION
1. Check:
Starter clutch operation
Clutch operation checking steps:
Install the starter wheel gear to the starter clutch,
and hold the starter clutch.
When turning the starter wheel gear clockwise
A , the starter clutch and the wheel gear should
be engaged.
If not, the starter clutch is faulty. Replace it.
When turning the starter wheel gear counterclockwise B , the starter wheel gear should turn
freely.
If not, the starter clutch is faulty. Replace it.
4-39
A.C. MAGNETO AND STARTER WHEEL GEAR
ENG
2. Inspect:
Starter wheel gear 1
(contacting surfaces)
Pitting/Wear/Damage Replace.
INSTALLATION
1. Install:
Starter wheel gear 1
Woodruff key 2
2. Install:
Plate washer
Rotor 1
Washer
NOTE:
Clean the tapered portions of the crankshaft and
rotor.
When installing the magneto, make sure the
woodruff key is properly seated in the key way of
the crankshaft.
3. Install:
Bolt (rotor) 1
130 Nm (13.0mkg)
NOTE:
Tighten the bolt (rotor) 1 while holding the magneto with the sheave holder 2 .
Do not allow the sheave holder 2 to touch the
projection on the rotor.
Sheave holder:
90890-01701
4-40
OIL PUMP
ENG
OIL PUMP
OIL PUMP COVER AND OIL PUMP DRIVEN GEARS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q’ty
Oil pump cover and oil pump driven
gear removal
Engine oil
1
Oil pipe
O-ring
Oil pump cover
Gasket
Dowel pin
Collar
Gasket
Circlip
Oil pump driven gear
1
1
1
2
1
1
2
2
Remarks
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
For installation, reverse the removal
procedure.
4-41
OIL PUMP
ENG
OIL PUMP
6 Nm (0.6 mkg)
6 Nm (0.6 mkg)
Order
1
2
3
4
5
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Oil pump removal
Oil pump assembly 1
(For pumping oil to the oil tank)
Gasket
Dowel pin
Oil pump assembly 2
(For lubricating the engine parts)
Gasket
1
1
1
1
1
For installation, reverse the removal
procedure.
4-42
OIL PUMP
ENG
INSPECTION
1. Inspect:
Oil pump driven gears
Wear/Cracks /Damage Replace.
2. Measure:
Tip clearance a
(between the inner rotor 1 and the outer rotor
2)
Side clearance b
(between the outer rotor 2 and the pump
housing 3 )
(between the inner rotor 1 /outer rotor 2 and
the pump housing 3 )
Side clearance c
Out of specification Replace the oil pump assembly.
Tip clearance a :
0 0.12 mm
Side clearance b :
0.03 0.08 mm
Side clearance c :
0.03 0.08 mm
3. Check:
Oil pump operation
Unsmooth Repeat steps 1 and 2 or replace
defective parts.
4-43
OIL TANK
ENG
OIL TANK
OIL HOSE
21 Nm (2.1 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Refer to “ENGINE ASSEMBLY”.
Oil hose removal
Engine oil
1
2
3
4
5
6
7
Remarks
Engine
Union bolt
Copper washer
Oil delivery pipe
Oil hose
O-ring
Oil pipe
O-ring
2
4
1
1
2
1
2
For installation, reverse the removal
procedure.
4-44
OIL TANK
ENG
OIL TANK
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Refer to “ENGINE ASSEMBLY”.
Oil tank removal
Engine oil
1
2
3
4
5
6
Remarks
Engine
Oil tank case (upper)
Gasket
Dowel pin
Oil tank case (lower)
Gasket
Dowel pin
1
1
2
1
2
2
For installation, reverse the removal
procedure.
4-45
OIL PAN
ENG
OIL PAN
OIL PAN
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Refer to “ENGINE ASSEMBLY”.
Refer to “OIL TANK”.
Oil pan removal
Engine oil
1
2
3
4
Engine
Oil hose
Oil filter cover
O-ring
Collar
Oil filter
1
2
1
1
5
6
7
8
Oil pan
Gasket
Dowel pin
O-ring /collar
1
1
2
2/2
NOTE:
Install the oil filter with the projection
towards the oil filter cover.
For installation, reverse the removal
procedure.
4-46
OIL PAN
ENG
BALANCER
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3.
Refer to “ENGINE ASSEMBLY”.
Refer to “CYLINDER AND PISTON”.
Refer to “SHIFT SHAFT”.
Refer to “A.C. MAGNETO AND
STARTER WHEEL GEAR”.
Refer to “OIL PUMP”.
Refer to “OIL TANK”.
Refer to “OIL PAN”.
Balancer weight removal
Engine oil
Engine
Piston
Shift shaft
A.C. magneto
1
2
3
Oil pump assembly
Oil tank
Oil pan
Plate
Rear balancer holder/Dowel pin
Rear balancer shaft/O-ring
Remarks
2
1/2
1/1
4-47
Refer to “INSTALLATION”.
OIL PAN
ENG
10 Nm (1.0 mkg)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
4
5
6
7
Job name/Part name
Rear balancer weight
Front balancer holder/Dowel pin
Front balancer shaft/O-ring
Front balancer weight
Q’ty
Remarks
1
1/2
1/1
1
Refer to “REMOVAL” and
“INSTALLATION”.
For installation, reverse the removal
procedure.
4-48
OIL PAN
REMOVAL
1. Remove:
Plate 1
2. Remove:
Rear balancer holder 1
Dowel pins
3. Remove:
Rear balancer shaft 1
Rear balancer weight 2
4. Remove:
Front balancer holder 1
Dowel pins
5. Remove:
Front balancer shaft 1
Front blancer weight 2
4-49
ENG
OIL PAN
ENG
INSTALLATION
1. Install:
Front balancer weight 1
Front balancer shaft 2
O-ring 3 New
Plate (balancer shaft)
12 Nm (1.2 mkg)
Installation steps:
Turn the crankshaft until the keyway a is
aligned with the embossed mark b on the
crankcase.
While holding the crankshaft, install the balancer weight and align the mark c on the front
balancer gear with the embossed mark d on
the crankcase.
Install the front balancer shaft.
2. Install:
Dowel pins
Front balancer holder 1
10 Nm (1.0 mkg)
3. Install:
Rear balancer weight 1
Rear balancer shaft 2
O-ring 3 New
Plate (balancer shaft)
12 Nm (1.2 mkg)
4-50
OIL PAN
ENG
Installing steps:
Turn the crankshaft until the keyway a is
aligned with embossed mark b on the crankcase.
While holding the crankshaft, install the balancer
weight and align the mark c on the rear balancer gear with the embossed mark d on the crankcase.
Install the rear balancer shaft.
4. Install:
Dowel pins
Rear balancer holder 1
10 Nm (1.0 mkg)
4-51
CRANKSHAFT
ENG
CRANKSHAFT
CRANKSHAFT ASSEMBLY
(M6)
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Refer to “BALANCER”.
Refer to “WATER PUMP” in CHAPTER 5.
Crankshaft removal
Balancer weight
Water pump
Timing chain
Cover plate
Lower crankcase
Dowel pin
Nozzle
Crankshaft assembly
Main journal bearing
Pin
Timing chain guide (intake)
1
1
1
1
1
1
6
1
1
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal procedure.
4-52
CRANKSHAFT
ENG
CONNECTING ROD
48 Nm (4.8 mkg)
Order
1
2
3
4
5
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Connecting rod removal
Nut
Connecting rod bolt
Connecting rod
Connecting rod cap
Connecting rod bearing
4
4
2
2
4
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal
procedure.
4-53
CRANKSHAFT
ENG
REMOVAL
1. Remove:
Cover plate 1
2. Remove:
Upper crankcase
Lower crankcase
Dowel pins
A
NOTE:
Loosen the bolts 1/4 turn each and remove them
after all are loosened.
Remove the bolts starting with the highest numbered one.
The embossed numbers in the crankcase designate the crankcase tightening sequence.
B
A Upper crankcase
B Lower crankcase
CAUTION:
Use a soft hammer to tap on the case half. Tap
only on reinforced portions of the case. Do not
tap on the gasket mating surface. Work slowly
and carefully. Make sure that the case halves
separate evenly.
3. Remove:
Crankshaft assembly 1
4-54
CRANKSHAFT
ENG
4. Remove:
Main journal bearings 1
NOTE:
Identify each plain bearing position very carefully
so that it can be reinstalled in its original place.
5. Remove:
Pin 1
Timing chain guide (intake) 2
6. Remove:
Connecting rod cap 1
Connecting rod 2
Connecting rod bearing 3
NOTE:
Identify each bearing position very careful so that
it can be reinstalled in its original place.
INSPECTION
1. Measure:
Runout (crankshaft)
Out of specification Replace.
Runout:
Less than 0.035 mm
2. Inspect:
Main journal surfaces
Crank pin surfaces
Bearing surfaces
Wear/Scratches Replace.
4-55
CRANKSHAFT
ENG
3. Measure:
Oil clearance (main journal)
Out of specification Replace bearing.
Oil clearance:
0.020 0.038 mm
<Limit>: 0.1 mm
Measurement steps:
CAUTION:
Do not interchange the bearings and connecting rod. They must be installed in their original
positions, or the correct oil clearance may not
be obtained causing engine damage.
Clean the bearings, main journals and bearing
portions of the crankcase.
Place the upper crankcase on a bench in an upside down position.
Install the upper half of the bearings 1 and the
crankshaft into the upper crankcase.
NOTE:
Align the projection a of the bearing with the
notch b in the crankcase.
Put a piece of Plastigauge c on each main
journal.
NOTE:
Do not put the Plastigauge over the oil hole in the
main journal of the crankshaft.
Install the lower half of the bearings into the lower
crankcase and assemble the crankcase halves.
NOTE:
Align the projection of the bearing with the notch
in the crankcase.
Do not move the crankshaft until the oil clearance has been completed.
4-56
CRANKSHAFT
ENG
Tighten the bolt to specification in the tightening sequence cast on the crankcase.
A
1 6 (M10):
40 Nm (4.0 mkg)
7 10 , 13 , 15 , 20 25 (M8)
24 Nm (2.4 mkg)
11 , 12 , 14 , 16 19 , 26 , 27 (M6)
12 Nm (1.2 mkg)
A Upper crankcase
B Lower crankcase
B
NOTE:
Lubricate the threads of bolts 1 6 with molybdenum disulfide motor oil.
Lubricate the threads of bolts 7 27 with engine oil.
Remove the lower crankcase and lower half of
the bearing.
Measure the compressed Plastigauge width d
on each main journal.
If oil clearance is out of specification, select a replacement bearing.
4. Measure:
Oil clearance (crank pin)
Out of specification Replace bearing.
Oil clearance:
0.020 0.038 mm
<Limit>: 0.1 mm
Measurement steps:
CAUTION:
Do not interchange the bearings and connecting rod. They must be installed in their original
positions, or the correct oil clearance may not
be obtained causing engine damage.
Clean the bearings, crank pins and bearing
portions of the connecting rods.
4-57
CRANKSHAFT
ENG
Install the upper half of the bearing into the connecting rod and lower half of the bearing into the
connecting rod cap.
Put a piece of Plastigauge a on the crank pin.
Assemble the connecting rod halves.
NOTE:
Do not move the connecting rod or crankshaft
until the oil clearance measurement has been
completed.
Apply molybdenum disulfide grease to the bolts,
threads and nut seats.
Make sure the “Y” marks on the connecting rods
face the left side of the crankshaft.
Make sure that the letters on both components
align to form a perfect character.
Tighten the nuts.
Nut (connecting rod):
48 Nm (4.8 mkg)
CAUTION:
When you reach 35 Nm (3.5 mkg), keep tightening until the final torque is obtained. Apply
continuous torque until the specified torque is
obtained.
Remove the connecting rods and bearings.
Measure the compressed Plastigauge width b
on each crank pin.
If oil clearance is out of specification, select a replacement bearing.
4-58
CRANKSHAFT
ENG
5. Select:
Main journal bearing (J1 J3)
Connecting rod bearing (P1 P2)
Selection of bearings:
Example 1: Main journal bearing
If “J1” on the crankcase is “6” and “2” on the
crankweb, then the bearing size for “J1” is:
Bearing size of J1:
Crankcase J1 – Crankweb J1 =
6 – 2 = 4 (Green)
BEARING COLOR CODE
1
Blue
2
Black
3
Brown
4
Green
5
Yellow
6
Pink
7
Red
Example 2: Connecting rod bearing
If “P1” on the connecting rod is “4” and “1” on the
crankweb, then the bearing size for “P1” is :
Bearing size of P1:
Connecting rod P1 – Crankweb P1 =
4 – 1 = 3 (Brown)
BEARING COLOR CODE
4-59
1
Blue
2
Black
3
Brown
4
Green
CRANKSHAFT
ENG
INSTALLATION
1. Apply:
Molybdenum disulfide grease
(onto threads of bolts and nut seats)
Engine oil
(onto crank pins and inner surfaces of connecting rod bearings)
2. Install:
Connecting rod bearings 1
Connecting rods 2
Connecting rod caps 3
(onto crank pins)
NOTE:
Align the projection of bearing with the groove of
the caps and connecting rod.
Make sure to reinstall each connecting rod bearing in its original place.
The stamped “Y” mark a on the connecting rods
should face towards the left of the crankshaft.
Be sure that the letter b on both components
align to form a perfect character.
3. Align:
Bolt head
(with connecting rod cap)
4. Tighten:
Connecting rod nuts
48 Nm (4.8 mkg)
CAUTION:
When you reach 3.5 Nm (3.5 mkg), keep tightening until the final torque is obtained. Apply
continuous torque until the specified torque is
obtained.
4-60
CRANKSHAFT
ENG
5. Install:
Timing chain guide (intake)
Pin
6. Install:
Main journal bearings
NOTE:
Align the projection a of the bearing with the
notch b in the crankcase.
Install each bearing in its original place.
7. Apply:
Engine oil
(onto inner surfaces of main journal bearings)
Sealant
(onto crankcase mating surfaces)
Yamaha bond No. 1215:
90890-85505
NOTE:
DO NOT ALLOW any sealant to come in contact
with the oil gallery or crankshaft bearings.
8. Install:
Dowel pin 1
9. Install:
Crankshaft assembly 1
(onto upper crankcase)
4-61
CRANKSHAFT
ENG
10. Install:
Lower crankcase 1
(onto upper crankcase 2 )
Place the lower crankcase assembly onto the
upper crankcase assembly.
A
CAUTION:
Before tightening the crankcase bolts, check
the following point:
Be sure the gears shift correctly when the
shift cam is turned by hand.
11. Tighten:
Lower crankcase bolt
(follow the proper tightening sequence)
Upper crankcase bolt
B
1 6 (M10):
40 Nm (4.0 mkg)
7 10 , 13 , 15 , 20 25 (M8)
24 Nm (2.4 mkg)
11 , 12 , 13 , 15 19 , 26 , 27 (M6)
12 Nm (1.2 mkg)
A Upper crankcase
B Lower crankcase
NOTE:
Lubricate the threads of bolts (No. 1 6 ) with
molybdenum disulfide motor oil.
Lubricate the threads of bolts (No. 7 27 ) with
engine oil.
Install a copper washer on bolts No. 18 , 21 , 23 ,
25 .
Install a lead holder on bolt No. 20 .
Tighten the bolts in the tightening sequence cast
on the crankcase.
12. Install:
Cover plate
4-62
10 Nm (1.0 mkg)
TRANSMISSION, SHIFT CAM AND SHIFT FORK
ENG
TRANSMISSION, SHIFT CAM AND SHIFT FORK
12 Nm (1.2 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Transmission, shift cam and shift
fork removal
Lower crankcase
Drive axle assembly/Oil seal
Circlip
Shift fork guide bar 2
Shift fork “R”
Shift fork “L”
Shift fork guide bar 1
Shift fork “C”
Shift cam
Bearing housing
Cover
Main axle assembly
Q’ty
Remarks
Remove the parts in the order below.
Refer to “CRANKSHAFT”.
1/1
1
1
1
1
1
1
1
1
1
1
Refer to “REMOVAL”, and
“INSTALLATION”.
For installation, reverse the removal procedure.
4-63
TRANSMISSION, SHIFT CAM AND SHIFT FORK
ENG
REMOVAL
1. Remove:
Drive axle assembly 1
2. Remove:
Shift fork guide bars 1
Shift fork “R” 2
Shift fork “L” 3
Shift fork “C” 4
Shift cam 5
3. Remove:
Bearing housing 1
(use the torx wrench)
4. Remove:
Cover 1
NOTE:
Attach the slide hammer bolt 2 and weight 3 into
the cover, then remove the cover by pulling.
Slide hammer bolt:
90890-01083
Weight:
90890-01084
5. Remove:
Main axle assembly 1
(Push out of clutch side)
4-64
TRANSMISSION, SHIFT CAM AND SHIFT FORK
ENG
INSPECTION
1. Inspect:
Shift fork cam follower 1
Shift fork pawl 2
Scoring/Bends/Wear/Damage Replace.
2. Inspect:
Guide bar
Roll the guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent guide bar.
3. Check:
Shift fork movement
(on its guide bar)
Unsmooth operation Replace the fork and
guide bar.
4. Inspect:
Shift cam grooves
Wear/Damage/Scratches Replace.
Shift cam segment 1
Damage/Wear Replace.
Shift cam bearing 2
Pitting/Damage Replace.
5. Measure:
Axle runout (main and drive)
Use a centering device and dial gauge 1 .
Out of specification Replace.
Runout limit:
0.08 mm
4-65
TRANSMISSION, SHIFT CAM AND SHIFT FORK
ENG
6. Inspect:
Gear teeth
Blue discoloration/Pitting/Wear Replace.
Mated dogs
Rounded edges/Cracks /Missing portions Replace.
7. Check:
Proper gear engagement (each gear)
(with its counterpart)
Incorrect Reassemble.
Gear movement
Roughness Replace.
116.6 116.68 mm
Main axle reassembling point:
Press the 2nd pinion gear 1 in the main axle as
shown.
8. Inspect:
Circlips
Damage/Looseness /Bends Replace.
INSTALLATION
1. Install:
Main axle assembly 1
NOTE:
Use a pin 2 to align the bolt holes in the bearing
housing with the holes in the lower crankcase and
install the main axle assembly.
2. Install:
Cover
Bearing housing 1
12 Nm (1.2 mkg)
NOTE:
After tightening the bearing housing bolts, tap the
outer edge of the bolt head with a punch 2 to prevent it from loosening.
4-66
TRANSMISSION,SHIFT CAM AND SHIFT FORK
ENG
3. Install:
Shift cam 1
Shift fork “C” 2
Shift fork “L” 3
Shift fork “R” 4
Shift for guide bars 5
NOTE:
Install the shift forks with the embossed mark to
the right and in sequence (R, C, L) beginning
from the right.
Install the shift fork guide bars with the tapered
end a toward the clutch.
4. Install:
Circlip 1
5. Install:
Drive axle assembly 1
NOTE:
The drive axle bearing pin must point to the front
side of the crankcase.
Be sure that the drive axle bearing circlips are inserted into the upper crankcase positioning
grooves a .
6. Check:
Transmission
Unsmooth rotation Repair.
NOTE:
Oil each gear and bearing thoroughly.
4-67
ENG
COOL
CHAPTER 5.
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTATIC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
5-4
5-5
5-6
5-6
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
COOL
RADIATOR
COOL
COOLING SYSTEM
RADIATOR
5 Nm (0.5 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Radiator removal
Coolant
Side cowling, seat, side cover and
fuel tank
Air filter case
1
2
3
4
5
1
1
1
1
1
Fan motor lead
Coolant reservoir hose
Coolant hose 3
Coolant hose 2
Radiator assembly
Remarks
Remove the parts in the order below.
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK” in CHAPTER 3.
Refer to “AIR FILTER CASE” in
CHAPTER 3.
Disconnect
Disconnect
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
5-1
RADIATOR
COOL
INSPECTION
1. Inspect:
Radiator core 1
Obstruction Blow out with compressed air
through rear of the radiator.
Flattened fin Repair/Replace.
2. Inspect:
Fan 2
Cracks /Damage Replace.
3. Inspect:
Radiator hoses
Crancks /Damage Replace.
4. Measure:
Radiator cap opening pressure
Radiator cap opens at pressure below the specified pressure Replace.
Radiator cap opening pressure:
75 105 kPa
(0.75 1.05 kg/cm2, 0.75 1.05 bar)
Measurement steps:
Attach the radiator cap tester 1 and adapter 2
to the radiator cap 3 .
Radiator cap tester:
90890-01325
Adapter:
90890-01352
Apply the specified pressure for 10 seconds, and
make sure there is no pressure drop.
5-2
RADIATOR
COOL
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Install:
Radiator assembly
7 Nm (0.7 mkg)
2. Fill:
Cooling system
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
3. Inspect:
Cooling system
Decrease of pressure (leaks) Repair as required.
Inspection steps:
Attach the radiator cap tester 1 to the radiator.
Radiator cap tester:
90890-01325
Adapter:
90890-01352
Apply 100 kPa (1.0 kg/cm2, 1.0 bar) pressure.
CAUTION:
Do not apply pressure that is more than the
specification mentioned above.
Measure the indicated pressure with the gauge.
5-3
THERMOSTATIC VALVE
COOL
THERMOSTATIC VALVE
THERMOSTATIC VALVE ASSEMBLY
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Thermostatic valve assembly
removal
Coolant
1
2
3
4
5
6
Remarks
Side cowling, seat, side cover and
fuel tank
Air filter case
Radiator assembly
Ground lead
Thermo switch lead coupler
Thermo unit lead
Coolant hose 1
Coolant hose 4
Thermostatic valve assembly
1
1
1
1
1
1
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK” in CHAPTER 3.
Refer to “AIR FILTER CASE” in CHAPTER 3.
Refer to “RADIATOR”.
Disconnect
Disconnect
Disconnect
For installation, reverse the removal
procedure.
5-4
THERMOSTATIC VALVE
COOL
THERMOSTATIC VALVE
28 Nm (2.8 mkg)
15 Nm (1.5 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Thermostatic valve housing disassembly
Thermo switch
Thermo unit
Ground lead
Thermostatic valve cover
O-ring
Thermostatic valve
Thermostatic valve housing
1
1
1
1
1
1
1
Refer to “ASSEMBLY”.
For installation, reverse the removal
procedure.
5-5
THERMOSTATIC VALVE
COOL
INSPECTION
1. Inspect:
S Thermostatic valve 1
Valve does not open at 80 84_C Replace.
Inspection steps:
S Suspend thermostatic valve in a vessel.
S Place reliable thermometer in a water.
S Observe thermometer, while stirring water continually.
1 Thermometer
2 Water
3 Thermostatic valve
4 Vessel
A CLOSE
B OPEN
NOTE:
Thermostatic valve is sealed and its setting is specialized work. If its accuracy is in doubt, replace it.
A faulty unit could cause serious overheating or
over-cooling.
ASSEMBLY
1. Install:
S Thermostatic valve housing 1
S Thermostatic valve 2
S O-ring 3
S Thermostatic valve cover 4
NOTE:
Install the thermostatic valve with the breather
hole a facing up.
2. Install:
S Thermo switch 1
28 Nm (2.8 mSkg)
S Thermo unit 2
15 Nm (1.5 mSkg)
CAUTION:
Be very careful when handling the thermo
switch and thermo unit. Replace parts that were
subjected to impacts or were dropped.
5-6
WATER PUMP
COOL
WATER PUMP
WATER PUMP
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
Water pump removal
Coolant
1
2
3
4
5
6
7
8
Remarks
1
1
1
1
1
1
1
1
Coolant hose 3
Water pump cover
O-ring
Water pump housing
Washer
Circlip
Impeller
O-ring
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
5-7
WATER PUMP
COOL
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
NOTE:
It is not necessary to remove and inspect the water pump if the coolant is not unusually low or if it
has no engine oil mixed in it.
Always replace the entire water pump.
1. Install:
Impeller 1
Circlip 2 New
NOTE:
After installation, check that the impeller shaft rotates smoothly.
2. Install:
O-ring 1 New
3. Install:
Water pump housing
Water pump cover
Coolant hose 3
5-8
10 Nm (1.0 mkg)
CARB
CHAPTER 6.
CARBURETION
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TPS (THROTTLE POSITION SENSOR)
ADJUSTMENT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-2
6-4
6-5
6-5
CARB
CARBURETOR
CARB
CARBURETION
CARBURETOR
CARBURETOR ASSEMBLY
Order
Job name/Part name
Q’ty
Carburetor assembly removal
Side cowling, seat, side cover and
fuel tank
Remove the parts in the order below.
Refer to ”COWLINGS, SEAT, TAIL
COVER AND FUEL TANK” in CHAPTER 3.
Refer to ”AIR FILTER CASE” in
CHAPTER 3.
Disconnect
Air filter case
1
2
3
4
5
6
7
8
Remarks
Throttle position sensor lead coupler
Carburetor heater hose (inlet)
Carburetor heater hose (outlet)
Throttle stop screw
Fuel hose
Starter cable
Throttle cable (pull)
Throttle cable (push)
1
1
1
1
1
1
1
1
From frame
NOTE:
After loosening the throttle cable locknut and
removing the carburetor assembly, remove
the throttle cables.
For installation, reverse the removal
procedure.
6-1
CARBURETOR
CARB
CARBURETOR
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Q’ty
Remarks
Disassemble the parts in the order below.
Carburetor disassembly
Carburetor heater hose
Float chamber
Needle valve
Float
Starter jet
Main jet
Pilot jet
Jet housing
Jet needle
Throttle valve
1
1
1
1
1
1
1
1
1
1
6-2
Refer to ”INSTALLATION”.
CARBURETOR
Order
11
12
13
14
15
16
Job name/Part name
Q’ty
CARB
Remarks
1
1
1
1
1
1
Needle jet
Pilot air jet 1
Main air jet 2
Diaphragm
Starter plunger
Pilot screw
For assembly, reverse the disassembly
procedure.
6-3
CARBURETOR
CARB
ASSEMBLY
CAUTION:
Before reassembling, wash all parts in clean
petroleum based solvent.
Always use a new gasket.
1. Install:
Main jet 1
Starter jet 2
Pilot jet 3
2. Install:
Valve seat
NOTE:
Make sure that projection a on the valve seat is
aligned with the slot b on the carburetor body.
3. Install:
O-ring 1
Diaphragm 2
4. Install:
Pilot screw 1
Pilot screw (turns out):
2.0
6-4
CARBURETOR
CARB
FUEL LEVEL ADJUSTMENT
1. Measure:
Fuel level a
Fuel level:
15.8 16.8 mm
Below the MIKUNI mark
Out of specification Adjust.
NOTE:
Adjust the float level by slightly bending the float
tang 1 .
Fuel level measurement and adjustment
steps:
Place the motorcycle on a level surface.
Use a garage jack under the engine to ensure
that the carburetors are positioned vertically.
Connect the fuel level gauge 2 to the drain pipe.
Fuel level gauge:
90890-01312
Loosen the drain screw.
Hold the gauge vertically next to the MIKUNI
mark 3 .
Measure the fuel level a with the gauge.
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT AND INSPECTION
NOTE:
Idle speed should be adjusted properly before
adjusting the TPS (throttle position sensor).
When installing the TPS (throttle position sensor), observe the display on the tachometer and
adjust the angle accordingly. Refer to the adjustment procedure below.
6-5
CARBURETOR
CARB
1. Adjust:
TPS (throttle position sensor) position
Adjustment steps:
Turn the main switch to ”ON”.
Disconnect the TPS (throttle position sensor)
coupler.
Reconnect the TPS (throttle position sensor)
coupler.
NOTE:
When the above procedure is commenced, the
machine switches to TPS (throttle position sensor) adjustment mode.
Loosen the TPS (throttle position sensor) screws
1.
Adjust the TPS (throttle position sensor) position.
NOTE:
The angle of the TPS (throttle position sensor) is
shown on the tachometer.
Adjust the angle of the TPS (throttle position sensor) as appropriate as shown below.
When the angle is correct, the tachometer
reads 4,000 rpm.
When the angle is too wide, the tachometer
reads 8,000 rpm.
When the angle is too narrow, the tachometer reads 1,000 rpm.
After adjusting the angle, tighten the TPS
(throttle position sensor) screws.
4 Nm (0.4 mkg)
NOTE:
To return to normal mode, start the engine or reset
the main switch.
6-6
CARBURETOR
CARB
2. Inspect:
S TPS (throttle position sensor)
Inspection steps:
S Disconnect the TPS (throttle position sensor)
coupler.
S Remove the TPS (throttle position sensor) from
carburetor.
S Connect the pocket tester (Ω
1k) to the TPS
(throttle position sensor) couplers.
Tester (+) lead Blue terminal 1
Tester (–) lead Black/Blue terminal 2
S Check the TPS (throttle position sensor) resistance.
TPS (throttle position sensor)
resistance:
3.5 X 6.5 kΩ at 20_C
(Blue – Black/Blue)
Out of specification Replace the TPS (throttle
position sensor).
S Connect the pocket tester (Ω
1k) to TPS
(throttle position sensor) coupler.
Tester (+) lead Yellow terminal 1
Tester (–) lead Black/Blue terminal 3
S Check the TPS (throttle position sensor) resistance while turning throttle slowly.
TPS (throttle position sensor)
resistance:
0 X 5 ± 1.5 kΩ at 20_C
(Yellow – Black/Blue)
Out of specification Replace the TPS (throttle
position sensor).
6-7
CARB
CHAS
CHAPTER 7.
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATIC WHEEL BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-3
7-5
7-5
7-6
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET . . . . . . . . . . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE DISC AND DRIVEN SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATIC WHEEL BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .
7-8
7-8
7-9
7-11
7-12
FRONT AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-13
7-13
7-14
7-15
7-18
7-20
7-22
7-22
7-26
7-28
7-30
7-31
7-31
7-32
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-33
7-36
7-37
7-37
7-40
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-46
7-46
7-48
7-48
7-49
CHAS
REAR SHOCK ABSORBER AND RELAY ARM . . . . . . . . . . . . . . . . . . . . . . 7-50
HANDLING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
NOTES ON DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
FRONT WHEEL AND BRAKE DISCS
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISCS
58 Nm (5.8 mkg)
19 Nm (1.9 mkg)
40 Nm (4.0 mkg)
20 Nm (2.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
NOTE:
Elevate the front wheel by placing a suitable
stand under the engine.
Front wheel and brake disc removal
1
2
3
4
5
6
7
8
9
Remarks
1
1
1
1/1
1
1
1
1
1/1
Speedometer cable
Pinch bolt (front wheel axle)
Cable guide
Brake caliper (left/right)
Front wheel axle
Front wheel
Speedometer gear unit
Collar
Brake disc (left/right)
Disconnect
Loosen
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
7-1
FRONT WHEEL AND BRAKE DISCS
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
CHAS
Remarks
Disassemble the parts in order below.
Front wheel disassembly
Oil seal
Clutch retainer
Meter clutch
Oil seal
Bearing
Spacer
Bearing
1
1
1
1
1
1
1
Refer to “ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
7-2
FRONT WHEEL AND BRAKE DISCS
CHAS
INSPECTION
1. Inspect:
Front wheel axle. Roll it on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent axle.
2. Measure:
Wheel runout
Over the specified limit Replace.
Rim runout limits:
Radial a : 1 mm
Lateral b : 0.5 mm
3. Inspect:
Wheel bearings
Bearings allow free play in the wheel hub or
wheel turns roughly Replace.
Oil seals
Wear/Damage Replace.
Wheel bearing and oil seal replacement steps:
Clean the outside of the wheel hub.
Remove the oil seals using a flat-head screw
driver.
NOTE:
Place a rag on the outer edge to prevent damage.
Remove the bearing 1 using a general bearing
puller 2 .
Install the new bearing and oil seal by reversing
the previous steps.
7-3
FRONT WHEEL AND BRAKE DISCS
CHAS
NOTE:
Use a socket 3 that matches the outside diameter of the race of the bearing and oil seal.
CAUTION:
Do not strike the center race 4 or balls 5 of
the bearing. Contact should be made only with
the outer race 6 .
4. Inspect:
Collar
Wear/Damage Replace collar and oil seal
as set.
5. Measure:
Brake disc deflection
Out of specification Inspect wheel runout.
If wheel runout is in good condition, replace the
brake disc(s).
NOTE:
Remove the brake caliper before inspecting the
brake disc deflection.
Maximum deflection:
0.2 mm
Brake disc thickness
Out of specification Replace.
Minimum thickness:
3.5 mm
Measuring point 1 3 mm
Replacement steps:
Remove the brake disc(s).
Install the new brake disc(s).
Brake disc:
20 Nm (2.0 mkg)
NOTE:
Tighten the bolts (brake disc) in stage using a
crisscross pattern.
7-4
FRONT WHEEL AND BRAKE DISCS
CHAS
ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
Note the following points.
1. Lubricate:
Bearings
Oil seals (lips)
Recommended lubricant:
Lithium soap base grease
INSTALLATION
Reverse the “REMOVAL” procedure.
Note the following points.
1. Lubricate:
Front wheel axle
Drive /Driven gear (speedometer)
Recommended lubricant:
Lithium soap base grease
2. Install:
Speedometer gear unit 1
NOTE:
Be sure that two projections a inside the wheel
hub mesh with the two slots b in the gear unit assembly.
3. Install:
Front wheel
Front wheel axle
58 Nm (5.8 mkg)
NOTE:
Be sure that the projection (torque stopper) a of
the gear unit housing is positioned correctly.
4. Install:
Pinch bolt
19 Nm (1.9 mkg)
Brake caliper (left/right) and cable guide
40 Nm (4.0 mkg)
7-5
FRONT WHEEL AND BRAKE DISCS
CHAS
STATIC WHEEL BALANCE ADJUSTMENT
NOTE:
S After replacing the tire and/or rim, wheel balance
should be adjusted.
S Adjust the wheel balance with brake disk
installed.
1. Remove:
S Balancing weight
2. Set the wheel on a suitable stand.
3. Find:
S Heavy spot
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel bottom spot.
c. Turn the wheel so that the “X1” mark is 90_ up.
d. Left the wheel fall and wait for it to rest.
Put an “X2” mark on the wheel bottom spot.
e. Repeat the above b., c., and d. several times
until these marks come to the same spot.
f. This spot is the heavy spot “X”.
4. Adjust:
S Wheel balance
Adjusting steps:
S Install a balancing weight 1 on the rim exactly
opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.
7-6
FRONT WHEEL AND BRAKE DISCS
CHAS
S Turn the wheel so that the heavy spot is 90_ up.
S Check that the heavy spot is at rest there.
If not, try another weight until the wheel is balanced.
5. Check:
S Wheel balance
Checking steps:
S Turn the wheel so that is comes to each point as
shown.
S Check that the wheel is at rest at each point. If
not, readjust the wheel balance.
7-7
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
CHAS
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
REAR WHEEL
107 Nm (10.7 mkg)
35 Nm (3.5 mkg)
40 Nm (4.0 mkg)
16 Nm (1.6 mkg)
Order
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
NOTE:
Rear wheel removal
Elevate the rear wheel by placing a suitable stand under the engine.
1
2
3
4
5
6
7
1
1
1
2
1
2
1
Brake caliper
Caliper bracket bolt
Rear wheel axle nut
Plain washer
Rear wheel axle
Chain puller
Rear wheel
Loosen
For installation, reverse the removal
procedure.
7-8
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
CHAS
BRAKE DISC AND DRIVEN SPROCKET
60 Nm (6.0 mkg)
20 Nm (2.0 mkg)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Brake disc and driven sprocket
removal
Collar (left/right)
Brake disc
Driven sprocket
Clutch hub
Rubber damper
Collar
Oil seal
Bearing
1/1
1
1
1
6
1
1
1
For installation, reverse the removal
procedure.
7-9
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
Order
1
2
3
4
Job name/Part name
Q’ty
CHAS
Remarks
Disassembly the parts in the order below.
Rear wheel disassembly
Oil seal
Bearing
Collar
Bearing
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-10
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
CHAS
INSPECTION
1. Inspect:
Rear wheel axle
Refer to “FRONT WHEEL AND BRAKE DISC”.
2. Measure:
Wheel runout
Refer to “FRONT WHEEL AND BRAKE DISC”.
3. Install:
Wheel bearings
Oil seals
Collars
Refer to “FRONT WHEEL AND BRAKE DISC”.
4. Measure:
Brake disc deflection
Out of specification Inspect wheel runout.
If wheel runout is in good condition, replace the
brake disc(s).
NOTE:
Remove the brake caliper before inspecting the
brake disc deflection.
Maximum deflection:
0.15 mm
Brake disc thickness
Out of specification Replace.
Minimum thickness:
4.5 mm
Measuring point 1 3 mm
5. Inspect:
Clutch hub 1
Cracks /Damage Replace.
Rubber dampers 2
Wear/Damage Replace.
7-11
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET
CHAS
6. Inspect:
Driven sprocket
More than 1/4 teeth a wear Replace
sprocket.
Bent teeth Replace sprocket.
b Correct
1 Roller
2 Sprocket
Driven sprocket replacement steps:
Remove the self locknuts and driven sprocket.
Clean the hub, especially on the surfaces in contact with the sprocket, using a clean cloth.
Install the new driven sprocket.
Driven sprocket:
60 Nm (6.0 mkg)
NOTE:
Tighten the self locknuts in stage, using a crisscross pattern.
STATIC WHEEL BALANCE ADJUSTMENT
NOTE:
After replacing the tire and/or rim, wheel balance
should be adjusted.
Adjust the wheel balance with brake disc and
hub installed.
1. Adjust:
Wheel balance
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
7-12
FRONT AND REAR BRAKE
CHAS
FRONT AND REAR BRAKE
FRONT BRAKE PAD
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
5
6
7
8
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Front brake pad removal
Cable guide
Pad cover
Retaining clip
Retaining pin
Pad spring
Brake pad
Pad shim
Bleed screw
1
1
2
2
1
2
2
1
Refer to “BRAKE PAD REPLACEMENT”.
For installation, reverse the removal
procedure.
7-13
FRONT AND REAR BRAKE
CHAS
REAR BRAKE PAD
40 Nm (4.0 mkg)
6 Nm (0.6 mkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Rear brake pad removal
Pad cover
Retaining clip
Retaining pin
Pad spring
Brake pad
Pad shim (left/right)
Bleed screw
Q’ty
Remarks
Remove the parts in the order below.
1
2
2
1
2
1/1
2
For installation, reverse the removal
procedure.
7-14
FRONT AND REAR BRAKE
CHAS
CAUTION:
Disc brake components rarely require disassembly. DO NOT:
Disassemble components unless absolutely
necessary.
Use solvents on internal brake components.
Use contaminated brake fluid for cleaning.
Use only clean brake fluid.
Allow brake fluid to come in contact with the
eyes, otherwise eye injury may occur.
Allow brake fluid to contact painted surfaces
or plastic parts otherwise damage may occur.
Disconnect any hydraulic connection otherwise the entire system must be disassembled, drained, cleaned, and then properly
filled and bled after reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.
Front brake
1. Remove:
Brake pads 1
NOTE:
Do not depress the brake lever when the wheel is
off the motorcycle otherwise the brake pads will
be forced shut.
Install new brake pad spring and shims when the
brake pads have to be replaced.
Replace the pads as a set if either is found to be
worn to the wear limit a .
Wear limit a :
0.5 mm
7-15
FRONT AND REAR BRAKE
CHAS
2. Install:
Pad shims New
(onto brake pads)
Brake pads New
Pad spring New
Installation steps:
Connect a suitable hose 1 tightly to the caliper
bleed screw 2 . Put the other end of this hose
into an open container.
Loosen the caliper bleed screw and push the pistons into the caliper with the finger.
Tighten the caliper bleed screw 2 .
Bleed screw:
6 Nm (0.6 mkg)
Install the pad shims on the brake pad.
Install the brake pads and pad spring.
NOTE:
The arrow mark a of the pad spring must point in
the direction of the disc rotation.
After installing the retaining clip, turn the retaining pin so that the heads of the retaining clips
face towards the center of the brake pad spring.
3. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
4. Check:
Brake lever operation
A soft or spongy feeling Bleed brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
Rear brake
1. Remove:
Brake pads 1
NOTE:
Do not depress the brake pedal while the caliper
is removed.
When pads replacement is required, also replace the pad spring and shims.
7-16
FRONT AND REAR BRAKE
CHAS
Replace the pads as a set if either is found to be
worn to the wear limit a .
Wear limit a :
0.5 mm
2. Install:
Pad shims New
(onto brake pads)
Brake pads New
Pad spring New
Installation steps:
Connect a suitable hose 1 tightly to the caliper
bleed screw 2 . Then, place the other end of this
hose into an open container.
Loosen the caliper bleed screw and push the pistons into the caliper with the finger.
Tighten the caliper bleed screw 2 .
Bleed screw:
6 Nm (0.6 mkg)
Install the pad shims 3 on the brake pad 4 .
NOTE:
The arrow mark a on the pad shim must point in
the direction of the disc rotation.
Install the brake pads and pad spring 5 .
NOTE:
The longer tangs b of the pad spring must point in
the direction of the disc rotation.
3. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
4. Check:
Brake pedal operation
A soft or spongy feeling Bleed brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
7-17
FRONT AND REAR BRAKE
CHAS
FRONT BRAKE MASTER CYLINDER
9 Nm (0.9 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
5
6
7
Job name/Part name
Front brake master cylinder removal
Brake fluid
Brake lever
Front brake switch lead coupler
Front brake switch
Union bolt
Copper washer/Brake hose
Master cylinder bracket
Master cylinder assembly
Q’ty
Remarks
Remove the parts in the order below.
Drain
1
1
1
1
2/1
1
1
7-18
Disconnect
Refer to “MASTER CYLINDER
ASSEMBLY”.
For installation, reverse the removal
procedure.
FRONT AND REAR BRAKE
Order
1
2
3
4
5
6
7
Job name/Part name
Q’ty
CHAS
Remarks
Disassemble the parts in the order below.
Front brake master cylinder disassembly
Adjuster
Spring
Plate
Boot
Circlip
Master cylinder kit
Master cylinder body
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-19
FRONT AND REAR BRAKE
CHAS
REAR BRAKE MASTER CYLINDER
7 Nm (0.7 mkg)
30 Nm (3.0 mkg)
23 Nm (2.3 mkg)
Order
1
2
3
Job name/Part name
Rear brake master cylinder removal
Brake fluid
Union bolt
Copper washer/Brake hose
Brake reservoir hose
Q’ty
Remarks
Remove the parts in the order below.
Drain
1
2/1
1
NOTE:
Remove from the master cylinder side.
4
5
6
7
1
1
1
1
Cotter pin
Clevis pin
Plain washer
Master cylinder
7-20
Refer to “MASTER CYLINDER
ASSEMBLY”.
For installation, reverse the removal
procedure.
FRONT AND REAR BRAKE
Order
1
2
3
4
Job name/Part name
Q’ty
CHAS
Remarks
Disconnect the parts in the order below.
Rear brake master cylinder disconnection
Boot
Circlip
Master cylinder kit
Master cylinder body
1
1
1
1
For assembly, reverse the disconnection
procedure.
7-21
FRONT AND REAR BRAKE
A
CHAS
MASTER CYLINDER INSPECTION
1. Inspect:
Master cylinder 1
Wear/Scratches Replace the master cylinder assembly.
Master cylinder body 2
Cracks /Damage Replace.
Oil delivery passage (master cylinder body)
Blow out with compressed air.
B
A Front
B Rear
A
2. Inspect:
Master cylinder kit 1
Scratches /Wear/Damage Replace as a
set.
B
A Front
B Rear
MASTER CYLINDER ASSEMBLY
WARNING
All internal parts should be cleaned in new
brake fluid only.
Internal parts should be lubricated with brake
fluid when installed.
Recommended brake fluid:
DOT 4
Replace the piston seals and dust seals
whenever a caliper is disassembled.
7-22
FRONT AND REAR BRAKE
CHAS
Front brake
1. Install:
Master cylinder 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
CAUTION:
Align the end of the holder with the punch
mark a on the handlebar.
Tighten first the upper bolt, then the lower
bolt.
2. Install:
Copper washers 1 New
Brake hose 2
Union bolt 3
30 Nm (3.0 mkg)
WARNING
Proper hose routing is essential to insure
safe motorcycle operation. Refer to “CABLE
ROUTING”.
Always use new copper washers.
3. Fill:
Brake reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid immediately.
7-23
FRONT AND REAR BRAKE
CHAS
WARNING
Use only the designated quality brake fluid:
otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical
reaction and lead to poor performance.
Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and
may result in vapor lock.
4. Air bleed:
Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
5. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
6. Check:
Brake level operation
A soft or spongy feeling Bleed brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
Rear brake
1. Install:
Copper washer 1 New
Brake hose 2
Union bolt 3
30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose on the master
cylinder, take care that the pipe touches the
projection a as shown.
WARNING
Proper hose routing is essential to insure
safe motorcycle operation. Refer to “CABLE
ROUTING”.
Always use new copper washers.
7-24
FRONT AND REAR BRAKE
CHAS
2. Install:
Clevis pin 1
Washer
Cotter pin New
3. Fill:
Brake reservoir
Refer to “MASTER CYLINDER ASSEMBLY –
Front brake”.
4. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
5. Check:
Brake pedal operation
A soft or spongy feeling Bleed brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
6. Adjust:
Brake pedal height
Refer to “REAR BRAKE ADJUSTMENT” in
CHAPTER 3.
7. Adjust:
Brake light switch
Refer to “BRAKE LIGHT SWITCH ADJUSTMENT” in CHAPTER 3.
7-25
FRONT AND REAR BRAKE
CHAS
FRONT BRAKE CALIPER
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Drain
Front brake caliper removal
Brake fluid
Cable guide
Union bolt
Copper washer
Stay
1
1
2
Refer to “CALIPER INSTALLATION”.
WARNING
The brake pipe must not be disassembled.
Do not loosen the bolts indicated by “ ”.
5
6
1
1
Brake hose and brake pipe
Brake caliper assembly
For installation, reverse the removal
procedure.
7-26
FRONT AND REAR BRAKE
CHAS
6 Nm (0.6 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q’ty
Remarks
Disassemble the parts in the order below.
Front brake caliper disassembly
Pad cover
Retaining clip
Retaining pin
Pad spring
Brake pad
Pad shim
Bleed screw
Brake caliper piston
Piston seal
1
2
2
1
2
2
1
4
8
Refer to “CALIPER DISASSEMBLY”
and “CALIPER ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
7-27
FRONT AND REAR BRAKE
CHAS
REAR BRAKE CALIPER
40 Nm (4.0 mkg)
14 Nm (1.4 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Drain
Rear brake caliper removal
Brake fluid
Brake hose
Brake hose joint
Copper washer
Brake caliper assembly
1
1
1
1
Refer to “CALIPER INSTALLATION”.
For installation, reverse the removal
procedure.
7-28
FRONT AND REAR BRAKE
CHAS
6 Nm (0.6 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Q’ty
Remarks
Disassemble the parts in the order below.
Rear brake caliper disassembly
Pad cover
Retaining clip
Retaining pin
Pad spring
Brake pad
Pad shim
Bleed screw
Brake caliper piston
Piston seal
1
2
2
1
2
2
2
2
4
Refer to “CALIPER DISASSEMBLY”
and “CALIPER ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
7-29
FRONT AND REAR BRAKE
CHAS
CALIPER DISASSEMBLY
NOTE:
Before disassembling the front brake caliper or
rear brake caliper, drain the brake hose, master
cylinder, brake caliper and brake reservoir of their
brake fluid.
1. Remove:
Pistons
Piston seals 1
Removal steps:
Using a wood piece 2 , lock the right side piston.
Blow compressed air into the hose joint opening
a to force out the left side piston from the caliper
body.
Remove the piston seals and reinstall the piston.
Repeat previous step to force out the right side
piston from the caliper body.
WARNING
Never try to pry out the piston.
Do not loosen the bolts 3 .
A
A Front
B Rear
B
7-30
FRONT AND REAR BRAKE
CHAS
CALIPER INSPECTION AND REPAIR
Recommended brake component
p
replacement schedule:
Brake pads
As required
Piston seal,
dust seal
Every two years
Brake hoses
Every two years
Brake fluid
Replace
p
only
y when
brakes are
disassembled.
WARNING
All internal brake components should be
cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort.
1. Inspect:
Caliper piston 1
Scratches /Rust/Wear Replace caliper assembly.
Caliper cylinder 2
Wear/Scratches Replace caliper assembly.
Caliper body 3
Cracks /Damage Replace.
Oil delivery passage (caliper body)
Blow out with compressed air.
WARNING
Replace the piston seals and dust seals whenever the caliper is disassembled.
CALIPER ASSEMBLY
WARNING
All internal parts should be cleaned in new
brake fluid only.
Internal parts should be lubricated with brake
fluid when installed.
Recommended brake fluid:
DOT 4
Replace the piston seals and dust seals
whenever a caliper is disassembled.
7-31
FRONT AND REAR BRAKE
CHAS
CALIPER INSTALLATION
1. Install:
Front brake
Brake caliper 1 (temporarily)
Copper washers New
Brake hose 2
Union bolt 3
30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose on the caliper
1 , take care that the pipe touches the projection a on the brake caliper.
NOTE:
Make sure that the damper of the brake pipe is in
contact with the front fender. If it’s not in contact,
loosen holding bolt B (left and right) and move the
brake pipe so that the damper contacts the fender.
Then tighten the holding bolt.
Rear brake
Brake caliper 1 (temporarily)
Copper washer
Brake hose joint 2
40 Nm (4.0 mkg)
Brake hose 3
14 Nm (1.4 mkg)
WARNING
Proper hose routing is essential to insure
safe motorcycle operation. Rear to “CABLE
ROUTING”.
Always use new copper washers.
2. Install:
Pad shims
(onto brake pads)
Brake pads
Pad spring
Retaining pins
Retaining clips
Pad cover
40 Nm (4.0 mkg)
Brake caliper
Refer to “BRAKE PAD REPLACEMENT”.
3. Fill:
Brake reservoir
Refer to “MASTER CYLINDER ASSEMBLY –
Front brake”.
7-32
FRONT FORK
CHAS
FRONT FORK
23 Nm (2.3 mkg)
24 Nm (2.4 mkg)
30 Nm (3.0 mkg)
9 Nm (0.9 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “FRONT WHEEL AND
BRAKE DISCS”.
Front fork removal
Front wheel
1
2
3
4
5
6
7
Cable guide
Front fender
Plastic band
Pinch bolt (upper bracket)
Cap bolt
Pinch bolt (lower bracket)
Front fork (left/right)
Remarks
1
1
4
2
2
2
1/1
Loosen
Loosen
Loosen
Loosen
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
7-33
FRONT FORK
CHAS
24 Nm (2.4 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Front fork disassembly
Cap bolt
O-ring
Washer
Fork spring
Dust seal
Retaining clip
Damper rod bolt/Gasket
Oil seal
Plain washer
Q’ty
1
1
1
1
1
1
1/1
1
1
7-34
Remarks
Disassemble the parts in the order below.
Drain the fork oil
Refer to “DISASSEMBLY” and
“ASSEMBLY”.
FRONT FORK
CHAS
24 Nm (2.4 mkg)
30 Nm (3.0 mkg)
Order
10
11
12
13
14
Job name/Part name
Q’ty
Inner tube/Piston metal
Oil lock piece
Damper rod/Damper rod spring
Slide metal
Outer tube
1/1
1
1/1
1
1
Remarks
Refer to “DISASSEMBLY” and
“ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
7-35
FRONT FORK
CHAS
DISASSEMBLY
NOTE:
Do not reuse the front fork protector that was removed from the outer tube.
When installing a new front fork protector, be
sure it is not twisted and will not come off easily.
1. Remove:
Dust seal 1
Retaining clip 2
Use a slotted-head screwdriver.
CAUTION:
Take care not to scratch the inner tube.
2. Remove:
Damper rod bolt
NOTE:
Loosen the damper rod bolt while holding the
damper rod with the T-handle 2 and holder 1 .
Damper rod holder:
90890-01465
T-handle:
90890-01326
3. Remove:
Damper rod
Damper rod spring
4. Remove:
Inner tube
Removal steps:
Hold the fork leg holizontally.
Clamp the caliper mounting boss of the outer
tube securely in a vise with soft jaws.
Pull out the inner tube from the outer tube by
forcefully, but carefully, with drawing the inner
tube.
CAUTION:
Excessive force will damage the oil seal
and/or the bushes. Damaged oil seal and
bushes must be replaced.
Avoid bottoming the inner tube in the outer
tube during the above procedure, as the oil
lock piece will be damaged.
7-36
FRONT FORK
CHAS
INSPECTION
1. Inspect:
Inner fork tube 1
Outer fork tube 2
Scratches /Bends/Damage Replace.
WARNING
Do not attempt to straighten a bent inner fork
tube as this may dangerously weaken the
tube.
2. Measure:
Fork spring free length a
Over specified limit Replace.
Fork spring free length (limit):
500 mm
3. Inspect:
Cap bolt
Bend/Damage Replace.
ASSEMBLY
1. Install:
Damper rod
CAUTION:
Allow the damper rod to slide slowly down the
inner tube until it protrudes from the bottom,
being careful not to damage the inner tube.
7-37
FRONT FORK
CHAS
2. Lubricate:
Inner fork tube (outer surface)
Recommended lubricant:
Fork oil 10W or equivalent
3. Install:
Piston metal 1 New
Damper rod 2
Oil lock piece 3
4. Tighten:
Damper bolt 1
30 Nm (3.0 mkg)
NOTE:
Tighten the damper rod bolt while holding the
damper rod with the T-handle and holder.
T-handle:
90890-01326
Damper rod holder:
90890-01465
5. Install:
Slide metal 1 New
Plain washer
Use the fork seal driver weight 2 and adapter
3.
6. Install:
Oil seal 1 New
Use the fork seal driver weight 2 and adapter
3.
Fork seal driver weight:
90890-01367
Adapter:
90890-01374
7-38
FRONT FORK
CHAS
NOTE:
Before installing the oil seal, apply the lithium soap
base grease onto the oil seal lips.
CAUTION:
Be sure that the oil seal numbered side face
upward.
7. Install:
Dust seal 1
Use the fork seal driver weight.
Fork seal driver weight:
90890-01367
8. Fill:
Fork oil
Each fork:
0.515 L
For oil 10W or equivalent. After
filling, slowly pump the fork up
and down to distribute oil.
Oil level:
130 mm
(from the top of inner tube fully
compressed without spring)
NOTE:
Place the fork on upright position.
9. Install:
O-ring New
Cap bolt 1
NOTE:
Align the end of the cap bolt rod with the hole in the
damper rod, then install the cap bolt rod and temporarily install the cap bolt.
7-39
FRONT FORK
CHAS
INSTALLATION
1. Install:
Front fork(s)
Temporarily tighten the pinch bolts.
CAUTION:
Make sure that the inner tube end is flush with
the top of the upper bracket.
2. Tighten:
Pinch bolts (lower bracket) 1
30 Nm (3.0 mkg)
24 Nm (2.4 mkg)
Cap bolts 2
Pinch bolts (upper bracket) 3
23 Nm (2.3 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
7-40
HANDLEBAR
CHAS
HANDLEBAR
23 Nm (2.3 mkg)
9 Nm (0.9 mkg)
26 Nm (2.6 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Q’ty
Remarks
Remove the parts in the order below.
Handlebar removal
Band
Clutch cable
Clutch switch lead coupler
Clutch switch
Left handlebar switch
Clutch lever
Grip end
Front brake switch lead coupler
Master cylinder bracket
Master cylinder assembly
Collar
2
1
1
1
1
1
2
1
1
1
1
7-41
Disconnect
Refer to “INSTALLATION”.
Disconnect
HANDLEBAR
CHAS
23 Nm (2.3 mkg)
9 Nm (0.9 mkg)
26 Nm (2.6 mkg)
Order
12
13
14
15
16
17
18
19
20
21
Job name/Part name
Q’ty
1
1
1
2
1
4
2
1
1
1
Right handlebar switch
Throttle cable housing cover
Throttle cable housing
Throttle cable
Throttle grip
Plug
Handlebar holder (upper)
Handlebar grip (left)
Clutch lever holder
Handlebar
Remarks
Refer to “INSTALLATION”.
Refer to “INSTALLATION”.
For installation, reverse the removal
procedure.
7-42
HANDLEBAR
CHAS
INSPECTION
1. Inspect:
Handlebar
Bends/Crancks /Damage Replace.
WARNING
Do not attempt to straighten a bent handlebar
as this may dangerously weaken the handlebar.
Handlebar grip (left) replacement steps:
Remove the handlebar grip.
Apply a light coat of an adhesive for rubber on the
handlebar end.
Install the handlebar grip.
NOTE:
Wipe off excess adhesive with a clean rag.
WARNING
Leave the handlebar intact until the adhesive
becomes dry enough to make the grip and
handlebar stuck securely.
INSTALLATION
1. Install:
Handlebar
Handlebar holders (upper)
23 Nm (2.3 mkg)
NOTE:
The handlebar holders (upper) should be
installed with the arrow mark a forward A .
Install the handlebar so that the widths of the
match marks b are equal.
Align the match mark c on the handlebar with
the top of the handlebar holder (lower).
CAUTION:
First, tighten the bolt on the front side of the
handlebar holder, and then tighten the bolt
on the rear side.
Check the handlebar by turning it from one
lock to the other. If there is any contact with
the fuel tank, adjust the handlebar position.
7-43
HANDLEBAR
CHAS
2. Install:
Throttle grip 1
Throttle cable housing 2
Throttle cables 3
Throttle cable housing cover
WARNING
Align the projection a on the throttle cable
housing with the hole b on the handlebar.
3. Install:
Right handlebar switch 1
NOTE:
Align the projection a on the handlebar switch
with the hole b on the handlebar.
4. Install:
Collar
Master cylinder assembly 1
Master cylinder bracket 2
9 Nm (0.9 mkg)
CAUTION:
Align the slit in the master cylinder bracket
with the punched mark a on the handlebar.
Tighten first the upper bolt, then the lower
bolt.
5. Install:
Clutch lever holder 1
NOTE:
Align the slit in clutch lever holder with the
punched mark a on the handlebar.
7-44
HANDLEBAR
CHAS
6. Install:
Left handlebar switch 1
NOTE:
Align the projection a on the handlebar switch
with the hole b on the handlebar.
7. Adjust:
Clutch cable free play
Refer to “CLUTCH ADJUSTMENT” in CHAPTER 3.
8. Adjust:
Throttle cable free play
Refer to “THROTTLE CABLE ADJUSTMENT”
in CHAPTER 3.
7-45
STEERING HEAD
CHAS
STEERING HEAD
LOWER BRACKET
108 Nm (10.8 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
1st
2 nd
48 Nm (4.8 mkg)
16 Nm (1.6 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Lower bracket removal
Front wheel
1
2
3
4
5
6
7
8
9
10
Front fork
Handlebar
Main switch lead coupler
Starter cable holder
Cable guide
Horn /Horn lead coupler
Brake hose holder
Steering stem nut
Plate washer
Upper bracket
Special washer
Ring nut (upper)
1
1
1
1/1
1
1
1
1
1
1
7-46
Remarks
Remove the parts in the order below.
Refer to “FRONT WHEEL AND
BRAKE DISC”.
Refer to “FRONT FORK”.
Refer to “HANDLEBAR”.
Disconnect
Disconnect
Refer to “REMOVAL”.
STEERING HEAD
CHAS
108 Nm (10.8 mkg)
7 Nm (0.7 mkg)
7 Nm (0.7 mkg)
1st
2nd
48 Nm (4.8 mkg)
16 Nm (1.6 mkg)
10 Nm (1.0 mkg)
Order
11
12
13
14
15
16
17
18
Job name/Part name
Q’ty
1
1
1
1
1
1
1
1
Plate seal
Ring nut (lower)
Plate washer
Lower bracket
Bearing (upper)
Rubber seal
Bearing (lower)
Dust seal
Remarks
Refer to “REMOVAL” and
“INSTALLATION”.
For installation, reverse the removal
procedure.
7-47
STEERING HEAD
CHAS
REMOVAL
1. Remove:
Ring nut (lower) 1
Use the ring nut wrench 2 .
Ring nut wrench:
90890-01403
WARNING
Support the lower bracket so that it may not
fall down.
INSPECTION
1. Wash the bearing and bearing races with a solvent.
2. Inspect:
Bearings
Bearing races
Pitting/Damage Replace.
Bearing race replacement steps:
Remove the bearing races on the head pipe using long rod 1 and the hammer as shown.
Install the new races.
NOTE:
Always replace bearings and races as a set.
CAUTION:
If the bearing race is not fitted squarely, the
head pipe could be damaged.
7-48
STEERING HEAD
CHAS
INSTALLATION
1. Tighten:
Ring nuts (lower and upper)
Tightening steps:
Tighten the ring nut (lower) 1 using the ring nut
wrench 2 .
Ring nut:
48 Nm (4.8 mkg)
NOTE:
Set the torque wrench to the ring nut wrench so
that they form a right angle.
Ring nut wrench:
90890-01403
Turn the steering stem left and right for several
times.
Loosen the ring nut completely and retighten it to
specification.
Ring nut:
16 Nm (1.6 mkg)
WARNING
Do not overtighten.
Check the steering stem by turning lock to lock. If
there is any binding, remove the steering stem
assembly and inspect the steering bearings.
Install the plate washer.
Install the ring nut (upper).
Finger tighten the ring nut, then align the slots of
both ring nuts. If not aligned, hold the lower ring
nut and tighten the other until they are aligned.
Install the special washer.
NOTE:
Make sure that the special washer tab is placed in
the slots.
7-49
REAR SHOCK ABSORBER
CHAS
REAR SHOCK ABSORBER
64 Nm (6.4 mkg)
64 Nm (6.4 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “COWLINGS, SEAT, TAIL
COVER AND FUEL TANK” in CHAPTER 3.
Rear shock absorber removal
Seat
1
2
3
4
5
6
7
8
Remarks
1
1
1
1
1
1
1
1
Self locknut
Plain washer
Bolt
Collar
Cap
Self locknut
Bolt
Rear shock absorber
For installation, reverse the removal
procedure.
7-50
REAR SHOCK ABSORBER
CHAS
HANDLING NOTES
WARNING
This shock absorber contains highly compressed nitrogen gas. Rear and understand
the following information before handling the
shock absorber. The manufacturer cannot be
held responsible for property damage or personal injury that may result from improper
handling.
1. Do not tamper or attempt to open the cylinder assembly.
2. Do not subject shock absorber to an open
flame or other high heat. This may cause
the unit to explode due to excessive gas
pressure.
3. Do not deform or damage the cylinder in
any way. Cylinder damage will result in poor
damping performance.
NOTES ON DISPOSAL
Shock absorber disposal steps:
Gas pressure must be released before disposing
of the shock absorber. To do so, drill a 2 3 mm
hole through the cylinder wall at a point 15 20
mm a from the end of the gas chamber.
WARNING
Wear eye protection to prevent eyes damage
from escaping gas and/or metal chips.
7-51
SWINGARM AND DRIVE CHAIN
CHAS
SWINGARM AND DRIVE CHAIN
3
7 Nm (0.7 mkg)
90 Nm (9.0 mkg)
35 Nm (3.5 mkg)
7 Nm (0.7 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “REAR WHEEL, BRAKE
DISC AND DRIVE SPROCKET”.
Refer to “REAR SHOCK ABSORBER”.
Refer to “ENGINE ASSEMBLY” in
CHAPTER 4.
Swingarm and drive chain removal
Rear wheel
Rear shock absorber
Drive sprocket
1
2
3
4
5
6
7
Remarks
1
2
1
1
1
2
1
Brake hose holder
Collar
Rear fender
Drive chain case
Caliper bracket
Cap
Pivot shaft
7-52
SWINGARM AND DRIVE CHAIN
CHAS
7 Nm (0.7 mkg)
90 Nm (9.0 mkg)
35 Nm (3.5 mkg)
7 Nm (0.7 mkg)
Order
8
9
10
11
12
13
14
Job name/Part name
Q’ty
Remarks
1
1
1
3
2
1
2
Swingarm
Drive chain
Chain protector
Collar
Thrust cover
Bush
Bearing
For installation, reverse the removal
procedure.
7-53
SWINGARM AND DRIVE CHAIN
CHAS
INSPECTION
1. Measure:
10 link length (drive chain) a
Out of specification Replace drive chain.
10 link length limit:
159 mm
NOTE:
For measurement make the chain tense by finger.
10 link length is a measurement between the insides of the 1 and 11 rollers as shown.
Two or three different 10 link length should be
measured.
2. Clean:
Drive chain
Place it in kerosene, and brush off as much dirt
as possible. Then remove the chain from the
kerosene and dry the chain.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the chain plates.
Steam cleaning, high pressure washes, and
certain solvent can damage these O-rings.
Use only kerosene to clean the drive chain.
3. Inspect:
O-rings (drive chain) 1
Damage Replace drive chain.
Rollers 2
Side plates 3
Damage/Wear Replace drive chain.
7-54
SWINGARM AND DRIVE CHAIN
CHAS
4. Lubricate:
Drive chain
Drive chain lubricant:
SAE 30 50W motor oil or chain
lubricants suitable for “O-ring”
chains
5. Inspect:
Drive chain stiffness
Stiff Clean and lubricate or replace.
6. Check:
Swingarm free play
Inspection steps:
Check the tightening torque of the pivot shaft
(swingarm) 1 securing nut.
90 Nm (9.0 mkg)
Check the swingarm side play A by moving it
from side to side.
If side play is noticeable, check the inner collar,
bearing, washer and thrust cover.
Side play (at end of swigarm):
0.3 mm
Check the swingarm vertical movement B by
moving it up and down.
If vertical movement is tight, binding or rough,
check the inner collar, bearing, washer and
thrust cover.
7-55
CHAS
ELEC
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTING A SWITCH SHOWN IN THE MANUAL . . . . . . . . . . . . . . .
SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8-2
8-2
8-3
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10
8-10
8-11
8-12
8-16
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-24
8-24
8-25
8-27
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-31
8-31
8-33
8-34
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS . . . . . . . . . . . . 8-44
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
ELEC
ELECTRICAL COMPONENTS
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Ignitor unit
Starting circuit cut-off relay
Rectifier / regulator
Main switch
Thermo switch
Thermo unit
Flasher relay
Starter relay
9
10
11
12
13
14
15
Fuse box
Battery
Rear brake switch
Sidestand switch
Neutral switch
Ignition coil
Horn
8-1
ELEC
SWITCH INSPECTION
ELEC
SWITCH INSPECTION
SWITCH INSPECTION
Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch.
Pocket tester:
90890-03112
NOTE:
Set the pocket tester to “0” before starting the
test.
The pocket tester should be set to the “ 1” Ω
range when testing the switch for continuity.
Turn the switch on and off a few times when
checking it.
INSPECTING A SWITCH SHOWN IN
THE MANUAL
The terminal connections for switches (main
switch, handlebar switch, engine stop switch, light
switch, etc.) are shown in a chart similar to the one
on the left.
This chart shows the switch positions in the column and the switch lead colors in the top row.
For each switch position, “
” indicates the
terminals with continuity.
The example chart shows that:
1 There is continuity between the “Black and
Black/White” leads when the switch is set to
“OFF”.
2 There is continuity between the “Red and
Brown” leads when the switch is set to “ON”.
8-2
SWITCH INSPECTION
SWITCH CONTINUITY INSPECTION
Refer to “SWITCH INSPECTION” and check for continuity between lead terminals.
Poor connection, no continuity Correct or replace.
* The coupler locations are circled.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Rear brake switch
Fuse
Engine stop switch
Start switch
Front brake switch
Main switch
Clutch switch
Horn switch
Lights switch
Dimmer switch
Pass switch
Turn switch
Sidestand switch
Gear position switch
8-3
ELEC
8-4
5 Main fuse
8 Starting circuit cut-off relay
9 Neutral switch
10 Sidestand switch
12 Ignitor unit
13 Ignition coil
14 Spark plug
45 Engine stop switch
47 Ignition fuse
4 Battery
1 A.C. magneto/Pickup coil
3 Main switch
IGNITION SYSTEM
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
ELEC
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK)
Procedure
Check:
1. Fuse (main and ignition)
2. Battery
3. Spark plug
4. Ignition spark gap
5. Spark plug cap resistance
6. Ignition coil resistance
7. Pickup coil resistance
8.
9.
10.
11.
12.
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
5) Air filter case
S Use the following special tool(s) in this troubleshooting.
Main switch
Engine stop switch
Neutral switch
Sidestand switch
Wiring connection
(entire ignition system)
Ignition checker:
90890-06754
Pocket tester:
90890-03112
1. Fuse (main and ignition)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace fuse(s).
2. Battery
INCORRECT
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
S Clean battery terminals.
S Recharge or replace the battery.
Open-circuit voltage:
12.8 V or more at 20_C
CORRECT
:
8-5
IGNITION SYSTEM
ELEC
:
3. Spark plug
Standard spark plug:
DPR8EA-9/X24EPR-U9
NGK /NIPPONDENSO
S Check the spark plug condition.
S Check the spark plug type.
S Check the spark plug gap.
Refer to “SPARK PLUG INSPECTION” in
CHAPTER 3.
Spark plug gap:
0.8 X 0.9 mm
INCORRECT
CORRECT
Repair or replace spark plug.
4. Ignition spark gap
S Disconnect the spark plug cap from spark
plug.
S Connect the ignition checker 1 as shown.
2 Spark plug cap
S Turn the main switch to “ON”.
S Check the ignition spark gap a .
S Crank the engine by pushing the starter
switch, and increase the spark gap until a misfire occurs.
MEETS SPECIFICATION
Minimum spark gap:
6.0 mm
Ignition system is good.
OUT OF
SPECIFICATION
OR NO SPARK
5. Spark plug cap resistance
S Remove the spark plug cap.
S Connect the pocket tester (Ω
spark plug cap.
1k) to the
8-6
IGNITION SYSTEM
S Check the spark plug cap for specified resistance.
ELEC
OUT OF SPECIFICATION
Spark plug cap resistance:
10 kΩ at 20_C
Replace spark plug cap.
MEETS
SPECIFICATION
Tester (+) lead Red/Black terminal 1
Tester (–) lead Orange (Gray) terminal 2
6. Ignition coil resistance
S Disconnect the ignition coil connector from the
wire harness.
S Connect the pocket tester (Ω
1) to the ignition coil.
Tester (+) lead Spark plug lead 1
Tester (–) lead Red/Black terminal 2
S Check the primary coil for specified resistance.
Primary coil resistance:
3.4 X 4.6 Ω at 20_C
S Connect the pocket tester (Ω
tion coil.
1k) to the igni-
S Check the secondary coil for specified resistance.
Secondary coil resistance:
10.4 X 15.6 kΩ at 20_C
OUT OF SPECIFICATION
BOTH MEET
SPECIFICATION
Replace ignition coil.
:
8-7
IGNITION SYSTEM
ELEC
:
7. Pickup coil resistance
S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester (Ω
100) to the
pickup coil terminal.
Tester (+) lead Green/White terminal 1
Tester (–) lead Blue/Yellow terminal 2
S Check the pickup coil for specified resistance.
Pickup coil resistance:
192 X 288 Ω at 20_C
(Green/White – Blue/Yellow)
OUT OF SPECIFICATION
MEET
SPECIFICATION
Replace pickup coil.
8. Main switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace main switch.
9. Engine stop switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace handlebar switch (right).
10. Neutral switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace neutral switch.
11. Sidestand switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace sidestand switch.
:
8-8
IGNITION SYSTEM
:
12. Wiring connection
S Check the entire ignition system for connections.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
CORRECT
Correct.
Replace ignitor unit.
8-9
ELEC
3
4
5
6
7
8
9
10
35
45
46
47
Main switch
Battery
Main fuse
Starter relay
Starter motor
Starting circuit cut-off relay
Neutral switch
Sidestand switch
Clutch switch
Engine stop switch
Start switch
Ignition fuse
ELECTRIC STARTING SYSTEM
8-10
ELEC
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of the
starter motor, starter relay, and the starting circuit
cut-off relay. If the “ENGINE STOP” switch and the
main switch are both closed, the starter motor can
operate only if:
The transmission is in neutral (the neutral
switch is closed).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand
is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the starter from operating when neither of these conditions
has been met. In this instance, the starting circuit
cut-off relay is open so current cannot reach the
starter motor.
When at least one of the above conditions has
been met however, the starting circuit cut-off relay
is closed, and the engine can be started by pressing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE 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
8-11
ELECTRIC STARTING SYSTEM
ELEC
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.
Procedure
Check:
1. Fuse (main and ignition)
2. Battery
3. Starter motor
4. Starting circuit cut-off relay
5. Starter relay
6. Main switch
7. Engine stop switch
8.
9.
10.
11.
12.
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
5) Air filter case
S Use the following special tool(s) in this troubleshooting.
Neutral switch
Sidestand switch
Clutch switch
Start switch
Wiring connection
(entire starting system)
Pocket tester:
90890-03112
1. Fuse (main and ignition)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace fuse(s).
2. Battery
INCORRECT
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
S Clean battery terminals.
S Recharge or replace the battery.
Open circuit voltage:
12.8 V or more at 20_C
CORRECT
:
8-12
ELECTRIC STARTING SYSTEM
:
ELEC
:
WARNING
This check is likely to produce sparks, so be
sure that no flammable gas or fluid is in the
vicinity.
3. Starter motor
S Remove the starter motor from the engine.
S Check the starter motor.
Refer to “INSPECTION AND REPAIR”.
DOES NOT MOVE
MOVES
S Repair or replace starter motor.
Refer to “INSPECTION AND REPAIR”.
4. Starting circuit cut-off relay
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the starting circuit cut-off relay coupler terminals.
Battery (+) terminal Red/Black terminal 1
Battery (–) terminal Black/Yellow terminal 2
Tester (+) terminal Blue/White terminal 3
Tester (–) terminal Blue/White terminal 4
S Check the starting circuit cut-off relay for continuity.
NO CONTINUITY
CONTINUITY
Replace starting circuit cut-off relay.
8-13
ELECTRIC STARTING SYSTEM
ELEC
:
5. Starter relay
S Disconnect the relay unit coupler from the wire
harness.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the relay unit coupler terminals.
Battery (+) terminal Red/White terminal 1
Battery (–) terminal Blue/White terminal 2
NO CONTINUITY
Tester (+) lead Red terminal 3
Tester (–) lead Black terminal 4
S Check the starter relay for continuity.
Replace starter relay.
CONTINUITY
6. Main switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace main switch.
7. Engine stop switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace handlebar switch (right).
8. Neutral switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace gear position switch
9. Sidestand switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace sidestand switch.
:
8-14
ELECTRIC STARTING SYSTEM
ELEC
:
10. Clutch switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace clutch switch.
11. Start switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace handlebar switch (right).
12. Wiring connection.
S Check the entire starting system for connections.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
Correct.
8-15
ELECTRIC STARTING SYSTEM
ELEC
STARTER MOTOR
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job name/Part name
Q’ty
Remove the parts in the order below.
Refer to “ENGINE ASSEMBLY” in CHAPTER 4.
Starter motor removal
Exhaust pipe and muffler assembly
1
2
Starter motor/O-ring
Starter motor lead
1/1
1
Disassemble the parts in the order below.
Starter motor disassembly
1
2
3
4
5
Front bracket
Washer kit
Rear bracket
Washer kit
Brush seat/Brush 1
6
Armature coil
Remarks
1
1
2
1
1/1
Refer to “ASSEMBLY”.
NOTE:
Be sure to remove the installation nut on
brush #1 first.
1
For assembly, reverse the disassembly procedure.
8-16
ELECTRIC STARTING SYSTEM
ELEC
Inspection and repair
1. Inspect:
Commutator
Dirty Clean it with #600 grit sandpaper.
2. Measure:
Commutator diameter a
Out of specification Replace starter motor.
Commutator wear limit:
27 mm
3. Measure:
Mica undercut b
Out of specification Scrape the mica to proper value using a hacksaw blade can be ground
to fit.
Mica undercut:
0.7 mm
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of commutator.
4. Inspect:
Armature coil (insulation/continuity)
Defects Replace starter motor.
Inspecting steps:
Connect the pocket tester for continuity check
1 and insulation check 2 .
Measure the armature resistances.
Armature coil resistance:
Continuity check 1 :
0.01 Ω at 20C
Insulation check 2 :
More than 1 MΩ at 20C
If the resistance is incorrect, replace the starter
motor.
8-17
ELECTRIC STARTING SYSTEM
ELEC
5. Measure:
Brush length a
Out of specification Replace.
Brush length limit:
5 mm
6. Measure:
Brush spring force
Fatigue/Out of specification Replace as a
set.
Brush spring force:
570 X 920 g
7. Inspect:
Bearing
Roughness Replace.
Oil seal
O-rings
Bushing
Wear/Damage Replace.
Assembly
Reverse the “Removal” procedure.
Note the following points.
1. Install:
Brush seat 1
NOTE:
Align the projection a on the brush seat with the
slot on the housing.
2. Install:
Shim 1
Armature coil 2
8-18
ELECTRIC STARTING SYSTEM
ELEC
3. Install:
Gasket 1 New
Yoke 2
Washer kit 3
Gasket 4 New
Front bracket 5
O-ring 6 New
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.
8-19
1
2
4
5
A.C. magneto/pickup coil
Rectifier/refulator
Battery
Main fuse
CHARGING SYSTEM
8-20
ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
CHARGING SYSTEM
ELEC
TROUBLESHOOTING
THE BATTERY IS NOT CHARGED.
Procedure
Check:
1. Fuse (main)
2. Battery
3. Charging voltage
4. Stator coil resistance
5. Wiring connection
(entire charging system)
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
S Use the following special tool(s) in this troubleshooting.
Engine tachometer:
90890-03113
Pocket tester:
90890-03112
1. Fuse (main)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace fuse(s).
2. Battery
INCORRECT
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
S Clean battery terminals.
S Recharge or replace the battery.
Open circuit voltage:
12.8 V or more at 20_C
CORRECT
:
8-21
CHARGING SYSTEM
ELEC
3. Charging voltage
Connect the engine tachometer to spark plug
lead #1.
Connect the pocket tester (DC 20 V) to the battery.
Tester (+) lead Battery (+) lead
Tester (–) lead Battery (–) lead
Start the engine, accelerate to about, 5,000
r/min then check the measured voltage.
Check battery voltage.
Charging voltage = measured
voltage – terminal voltage:
Difference of 0.5 2.5 V
MEETS SPECIFICATION
NOTE:
Use a fully charged battery.
Replace battery.
OUT OF
SPECIFICATION
Tester (+) lead White lead 1
Tester (–) lead White lead 2
4. Stator coil resistance
Disconnect A.C. magneto coupler from the
wire harness.
Connect the pocket tester “Ω 1” to the stator
coils.
Measure the stator coil resistance.
Tester (+) lead White lead 1
Tester (–) lead White lead 3
Stator coil resistance:
0.23 0.35 Ω at 20C
OUT OF SPECIFICATION
Replace stator assembly.
BOTH MEET
SPECIFICATION
8-22
CHARGING SYSTEM
:
5. Wiring connection
S Check the entire starting system for connections.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
CORRECT
Correct.
Replace rectifier/regulator.
8-23
ELEC
3
4
5
19
21
25
26
30
31
32
39
40
48
Main switch
Battery
Main fuse
Meter light
High beam indicator light
Headlight
Auxiliary light
Lights switch
Dimmer switch
Pass switch
Tail/brake light
Headlight fuse
Diode
LIGHTING SYSTEM
8-24
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
ELEC
TROUBLESHOOTING
HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT AND/OR METER
LIGHT DO NOT COME ON.
Procedure
Check:
1. Fuse (main and head)
2. Battery
3. Main switch
4. Lights switch/Dimmer switch
5. Pass switch
6. Wiring connection
(entire lighting system)
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
5) Air filter case
S Use the following special tool(s) in this troubleshooting.
Pocket tester:
90890-03112
1. Fuse (main and head)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace fuse(s).
2. Battery
INCORRECT
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
S Clean battery terminals.
S Recharge or replace the battery.
Open circuit voltage:
12.8 V or more at 20_C
CORRECT
3. Main switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace main switch.
:
8-25
LIGHTING SYSTEM
ELEC
:
4. Lights switch/Dimmer switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Lights switch/Dimmer switch are faulty, replace
handlebar switch (left).
5. Diode
S Remove the diode from the wire harness.
S Check for continuity as follows:
Terminal 1 – terminal 2
Tester (+) lead Terminal 1
Tester (–) lead Terminal 2
Continuity
Tester (+) lead Terminal 2
Tester (–) lead Terminal 1
No Continuity
NOTE:
When you switch the “–” and “+” leads of the digital pocket tester the readings in the above chart
will be reversed.
INCORRECT
Replace the diode.
CORRECT
6. Pass switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Pass switch is faulty, replace handlebar switch
(left).
7. Wiring connection
S Check the entire lighting system for connections.
Refer to “WIRING DIAGRAM”.
POOR CONNECTION
CORRECT
Correct.
Check condition of each circuit for lighting system.
Refer to “LIGHTING SYSTEM CHECK”.
8-26
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM CHECK
1. Headlight and high beam indicator light does
not come on.
1. Voltage
Headlight:
Tester (+) lead Yellow 1 or Green 2 lead.
Tester (–) lead Black 3 lead.
High beam indicator light:
Tester (+) lead Yellow 4 lead.
Tester (–) lead Black 5 lead.
B Meter connector
Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light couplers.
A When dimmer switch is “LO” position.
B When dimmer switch is “HI” position.
Headlight connector.
Dimmer switch
Headlight
Hi
Turn the main switch to “ON”.
Turn the lights switch to “ON” position.
Turn the dimmer switch to “LO” or “HI” position.
Check for voltage (12 V) on the “Green” and
“Yellow” lead at bulb socket connectors.
Lo
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
8-27
LIGHTING SYSTEM
ELEC
2. Meter light does not come on.
1. Voltage
Connect the pocket tester (20 V) to the bulb
socket coupler.
Tester (+) lead Blue terminal 1
Tester (–) lead Black terminal 2
Turn the main switch to “ON”.
Turn the lights switch to “ON” or “PO” position.
Check for voltage (12 V) on the “Blue” lead at
the bulb socket connector.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
3. Taillight does not come on.
1. Voltage
Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead Blue/Red terminal 1
Tester (–) lead Black terminal 2
Turn the main switch to “ON”.
Turn the lights switch to “ON” or “PO” position.
Check for voltage (12 V) on the “Blue/Red” OUT OF SPECIFICATION
lead at the bulb socket connector.
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
8-28
LIGHTING SYSTEM
ELEC
4. Auxiliary light does not come on.
1. Voltage
Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead Blue/Red lead
Tester (–) lead Black lead 2
1
Turn the main switch to “ON”.
Turn the light switch to “ON” or “PO” position.
Check for voltage (12 V) on the “Blue/Red”
lead at the bulb socket connector.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
8-29
LIGHTING SYSTEM
8-30
ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-31
ELEC
SIGNAL SYSTEM
3
4
5
8
9
17
20
22
23
24
28
Main switch
Battery
Fuse (main)
Starting circuit cut-off relay
Neutral switch
Tachometer
Neutral indicator light
Turn indicator light
Rear flasher light
Front flasher light
Horn switch
29
33
34
39
40
41
42
44
Horn
Turn switch
Flasher relay
Tail / brake light
Headlight fuse
Rear brake switch
Signal system fuse
Front brake switch
8-32
ELEC
SIGNAL SYSTEM
ELEC
TROUBLESHOOTING
S FLASHER LIGHTS, BRAKE LIGHT AND/OR INDICATOR LIGHTS DO NOT COME ON.
S HORN DOES NOT SOUND.
Procedure
Check:
1. Fuse (main, head and signal)
2. Battery
3. Main switch
4. Wiring connection
(entire signal system)
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
5) Air filter case
S Use the following special tool in this troubleshooting.
Pocket tester:
90890-03112
1. Fuse (main, head and signal)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace fuse(s).
2. Battery
INCORRECT
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
S Clean battery terminals.
S Recharge or replace the battery.
Open circuit voltage:
12.8 V or more at 20_C
CORRECT
:
8-33
SIGNAL SYSTEM
ELEC
:
3. Main switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace main switch.
4. Wiring connection
S Check the entire signal system for connections.
Refer to “WIRING DIAGRAM”.
POOR CONNECTION
CORRECT
Correct.
Check condition of each circuit for signal system. Refer to “SIGNAL SYSTEM CHECK”.
SIGNAL SYSTEM CHECK
1. Horn does not sound.
1. Horn switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace handlebar switch (left).
2. Voltage
S Connect the pocket tester (DC 20 V) to the
horn lead.
Tester (+) lead Black/White lead 1
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Push the horn switch.
S Check for voltage (12 V) on the “Black/White”
lead at the horn terminal.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to horn terminal
is faulty, repair.
:
8-34
SIGNAL SYSTEM
:
3. Voltage
S Connect the pocket tester (DC 20 V) to the
horn at the “Black” terminal.
Tester (+) lead Black lead 1
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Push the horn switch.
S Check for voltage (0 V) on the “Black” lead at
the horn terminal.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace horn.
Adjust or replace horn.
2. Brake light does not come on.
1. Brake switch (front, rear)
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace brake switch.
2. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead Yellow lead 1
Tester (–) lead Black lead 2
8-35
ELEC
SIGNAL SYSTEM
S Turn the main switch to “ON”.
S Turn brake lever is pulled in or brake pedal is
stepped down.
S Check for voltage (12 V) on the “Yellow” lead at
the bulb socket connector.
ELEC
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
3. Flasher light and/or turn indicator light does
not blink.
1. Turn switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Replace handlebar switch (left).
2. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
Tester (+) lead Brown terminal 1
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Check for voltage (12 V) on the “Brown” lead at
the flasher relay terminal.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to flasher relay
connector is faulty, repair.
:
8-36
SIGNAL SYSTEM
ELEC
:
3. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay lead.
Tester (+) lead Brown/White terminal 1
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Check for voltage (12 V) on the “Brown/White”
lead at the flasher relay terminal.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace flasher relay.
4. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
A
B
A Flasher lights
B Turn indicator light
At flasher light (left):
Tester (+) lead Chocolate lead 1
Tester (–) lead Frame ground
At flasher light (right):
Tester (+) lead Dark green lead 2
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Turn the turn switch to “L” or “R”.
S Check for voltage (12 V) on the “Chocolate“
lead or ”Dark green” lead at the bulb socket
connector.
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from turn switch to bulb socket
connector is faulty, repair.
This circuit is good.
8-37
SIGNAL SYSTEM
ELEC
4. Neutral indicator light does not come on.
1. Neutral switch
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Replace neutral switch.
2. Voltage
Connect the pocket tester (DC 20 V) to the
bulb socket coupler.
Tester (+) lead Brown terminal 1
Tester (–) lead Sky blue terminal 2
Turn the main switch to “ON”.
Check for voltage (12 V).
OUT OF SPECIFICATION
MEETS
SPECIFICATION
Wiring circuit from main switch to bulb socket
connector is faulty, repair.
This circuit is good.
8-38
8-39
42 Signal system fuse
37 Thermo switch
38 Radiator fan fuse
15 Thermo unit
18 Water temperature meter
36 Fan motor
5 Fuse (main)
3 Main switch
4 Battery
COOLING SYSTEM
ELEC
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
ELEC
TROUBLESHOOTING
S FAN MOTOR DOES NOT MOVE.
S WATER TEMPERATURE METER DOES NOT MOVE, WHEN ENGINE IS WARM.
Procedure
Check:
1. Fuse (main, signal and fan)
2. Battery
3. Main switch
4. Fan motor
5. Thermo switch
6. Thermo unit
7. Water temperature
8. Wiring connection
(entire cooling system)
NOTE:
S Remove the following parts before troubleshooting.
1) Seat
2) Side cowlings
3) Side covers
4) Fuel tank
5) Air filter case
S Use the following special tool in this troubleshooting.
Pocket tester:
90890-03112
1. Fuse (main, signal and fan)
NO CONTINUITY
Refer to “SWITCH INSPECTION”.
CONTINUITY
Fuse is faulty, replace it.
2. Battery
S Check the battery condition.
Refer to “BATTERY INSPECTION” in CHAPTER 3.
INCORRECT
S Clean battery terminals.
S Recharge or replace the battery.
Open circuit voltage:
12.8 V or more at 20_C
CORRECT
:
8-40
COOLING SYSTEM
ELEC
:
3. Main switch
INCORRECT
Refer to “SWITCH INSPECTION”.
CORRECT
Main switch is faulty, replace it.
4. Fan motors
S Disconnect the fan motor couplers.
S Connect the battery (12 V) as shown.
Battery (+) lead Blue lead 1
Battery (–) lead Black lead 2
DOES NOT MOVES
S Check the fan motors for operation.
Fan motor(s) is faulty, replace it(them).
MOVES
:
8-41
COOLING SYSTEM
ELEC
:
WARNING
5. Thermo switch
S Handle the thermo switch with special care.
S Never subject it to strong shock or allow it to be
dropped. Should it be dropped, it must be replace.
S Remove the thermo switch from the radiator.
S Connect the pocket tester (Ω 1) to the thermo switch 1 .
S Immerse the thermo switch in the water 2 .
S Check the thermo switch for continuity.
Note temperatures while heating the water
with the temperature gauge 3 .
BAD CONDITION
Replace thermo switch.
A THERMO SWITCH “ON”
B THERMO SWITCH “OFF”
GOOD
CONDITION
:
8-42
COOLING SYSTEM
:
6. Thermo unit
S Remove the thermo unit from the radiator.
S Connect the pocket tester (Ω 10) to the thermo unit 1 .
S Immerse the thermo unit in the water 2 .
S Measure the resistance.
Thermo unit resistance:
80_C: 47 X 53 Ω
100_C: 26 X 30 Ω
WARNING
S Handle the thermo unit with special care.
S Never subject it to strong shock or allow it
to be dropped. Should it be dropped, it
must be replaced.
BAD CONDITION
GOOD
CONDITION
Replace thermo unit.
7. Wiring connection
Check the entire cooling system for connections. Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
CORRECT
Correct.
Replace the temperature meter.
8-43
ELEC
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS
ELEC
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS
Revolution
(103 r / min)
Tachometer display
Engine speed
time
(seconds)
CIRCUIT DIAGRAM
If the needle of the tachometer shows the following pattern while the engine is running, the throttle
position sensor circuit is broken, shorted, or the
TPS (throttle position sensor) is locked. In that
case, it would be best to inspect it.
1 0 rpm – 3 seconds
2 3,000 rpm – 2.5 seconds
3 present engine revolutions – 3 seconds
The above pattern is repeated.
NOTE:
The needle of the tachometer keeps pointing to
“0” rpm for 6 seconds when the engine is not running.
If any trouble occurs in the TPS, the ignition timing signal transmitted from the TPS to the ignitor
unit is limited to the full-open state signal.
11 TPS (throttle position sensor)
12 Ignitor unit
8-44
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS
ELEC
TROUBLESHOOTING
IF THE TACHOMETER’S TPS (THROTTLE POSITION SENSOR) SELF-DIAGNOSIS OPERATES.
Procedure
Check:
1. TPS (throttle position sensor)
2. Wire harness
NOTE:
Use the following special tool(s) in this troubleshooting.
Pocket tester:
90890-03112
1. TPS (throttle position sensor)
Disconnect the throttle position sensor coupler
from the wire harness.
Connect the pocket tester (Ω 1) to the
throttle position sensor.
Refer to “TPS (THROTTLE POSITION SENSOR) ADJUSTMENT AND INSPECTION” in
CHAPTER 6.
Check the TPS (throttle position sensor) for
continuity.
BAD CONDITION
GOOD
CONDITION
Replace TPS (throttle position sensor).
2. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
NO CONTINUITY
CONTINUITY
Repair or replace wire harness.
Replace the ignitor unit.
8-45
ELEC
TRBL
SHTG
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-2
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . . . . 9-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE . . . . . . . . . . . . . 9-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMP-OUT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FRONT FORK OIL LEAKAGE AND FORK MALFUNCTION . . . . . . . . . . . 9-4
OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
INSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
FAULTY LIGHTING AND SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASHER DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASHER WINKS SLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASHER KEEPS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASHER WINKS QUICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN IS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5
9-5
9-5
9-5
9-5
9-6
9-6
9-6
TRBL
SHTG
STARTING FAILURE/HARD STARTING
TRBL
SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. If should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment
and replacement of parts.
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
Empty
Clogged fuel strainer
Clogged fuel tank drain hose
Deteriorated fuel or fuel containing water or foreign material
Fuel cock
Clogged fuel hose/vacuum hose
Carburetor
Deteriorated fuel, fuel containing water or foreign
material
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Deformed float
Groove-worn needle valve
Improperly sealed valve seat
Improperly adjusted fuel level
Improperly set pilot jet
Clogged starter jet
Starter plunger malfunction
Improperly adjusted starter cable
Air cleaner
Clogged air filter
Fuel pump
Faulty fuel pump
ELECTRICAL SYSTEM
Spark plug
Improper plug gap
Worn electrodes
Wire between terminals broken
Improper heat range
Faulty spark plug cap
Ignition coil
Broken or shorted primary/secondary
Faulty spark plug lead
Broken body
Full-transistor system
Faulty ignitor unit
Faulty pickup coil
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty neutral switch
Faulty start switch
Faulty sidestand switch
Faulty clutch switch
Starter motor
Faulty starter motor
Faulty starter relay
Faulty circuit cut-off relay
Faulty starter clutch
9-1
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED
PERFORMANCE/POOR MEDIUM AND HIGH SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Broken cylinder head gasket
Worn, damaged or seized cylinder
Improperly sealed valve
Improperly contacted valve and valve seat
Improper valve timing
Broken valve spring
TRBL
SHTG
Piston and piston rings
Improperly installed piston ring
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
Crankcase and crankshaft
Improperly seated crankcase
Seized crankshaft
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Carburetor
Improperly returned starter plunger
Loose pilot jet
Clogged pilot air jet
Improperly synchronized carburetors
Improperly adjusted idle speed (throttle stop
screw)
Improper throttle cable free play
Flooded carburetor
Electrical system
Faulty battery
Faulty spark plug
Faulty ignitor unit
Faulty pickup coil
Faulty ignition coil
Valve train
Improperly adjsted valve clearance
Air Cleaner
Clogged air filter
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to “Starting failure/Hard starting”. (Fuel system, electrical system, compression system and valve
train.)
Air cleaner
Clogged air filter element
Fuel pump
Faulty fuel pump
Carburetor
Diaphragm malfunction
Improperly adjusted fuel level
Clogged or loose main jet
9-2
FAULTY GEAR SHIFTING/
CLUTCH SLIPPING/DRAGGING
TRBL
SHTG
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “Clutch dragging.”
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Improperly adjusted shift rod
Bent shift shaft
Shift cam, shift fork
Groove jammed with impurities
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Jammed impurities
Incorrectly assembled transmission
JUMP-OUT GEAR
Shift shaft
Improperly adjusted shift lever position
Improperly returned stopper level
Shift fork
Worn shift fork
Shift cam
Improper thrust play
Worn shift cam groove
Transmission
Worn gear dog
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
Clutch
Improperly adjusted clutch cable
Loose clutch spring
Fatigued clutch spring
Worn friction plate/clutch plate
Incorrectly assembled clutch
Engine oil
Low oil level
Improper quality/(low viscosity)
Deterioration
CLUTCH DRAGGING
Clutch
Warped pressure plate
Unevenly tensioned clutch springs
Bent push rod
Broken clutch boss
Burnt primary driven gear bushing.
Bent clutch plate
Swollen friction plate
Engine oil
Improper oil level
Improper quality (high viscosity)
Deterioration
9-3
OVERHEATING/FAULTY BRAKE/
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION
TRBL
SHTG
OVERHEATING
OVERHEATING
Ignition system
Improper spark plug gap
Improper spark plug heat range
Faulty ignitor unit
Fuel system
Improper carburetor main jet (improper setting)
Improperly adjusted fuel level
Clogged air filler element
Compression system
Heavy carbon build-up
Engine oil
Incorrect oil level
Improper oil viscosity
Inferior oil quality.
Brake
Dragging brake
Cooling system
Faulty water temperature gauge
Faulty thermo unit
Incorrect coolant level
Faulty thermostatic valve
Faulty thermo switch
Clogged or damaged radiator
Faulty radiator cap
Seized impeller shaft
Inoperative fan motor
FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake
Worn brake pads
Worn disc
Air in brake fluid
Leaking brake fluid
Faulty cylinder cup kit
Faulty caliper seal kit
Loose union bolt
Broken brake hose
Oily or greasy disc/brake pads
Improper brake fluid level
FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION
MALFUNCTION
Bent, deformed or damaged inner tube
Bent or deformed outer tube
Damaged fork spring
Worn or damaged slide metal
Bent or damaged damper rod
Improper oil viscosity
Improper oil level
OIL LEAKAGE
Bent, damaged or rusty inner tube
Damaged or cracked outer tube
Damaged oil seal lip
Improperly installed oil seal
Improper oil level (too much)
Loose damper rod holding bolt
Broken cap bolt O-ring
9-4
INSTABLE HANDLING/
FAULTY LIGHTING AND SIGNAL SYSTEM
TRBL
SHTG
INSTABLE HANDLING
INSTABLE HANDLING
Handlebar
Improperly installed or bent
Steering
Improperly installed handlebar crown
Bent steering stem
Improperly installed steering shaft (Improperly
tightened ring nut)
Damaged ball bearing or bearing race
Swingarm
Worn bearing or bush
Bent or damaged
Rear shock absorber
Fatigued spring
Oil and gas leakage
Tires
Uneven tire pressures on both sides
Incorrect tire pressure
Unevenly worn tires
Front forks
Uneven oil levels on both sides
Uneven spring tension (uneven damping force
adjuster position)
Broken spring
Twisted front forks
Wheels
Incorrect wheel balance
Deformed wheel
Damaged bearing
Bent or loose wheel axle
Excessive wheel run-out
Frame
Twisted
Damaged head pipe
Improperly installed bearing race
FAULTY LIGHTING AND SIGNAL SYSTEM
HEADLIGHT DARK
Improper bulb
Too many electric accessories
Hard charging (broken stator coil wire, faulty rectifier/regulator)
Incorrect connection
Improperly grounded
Poor contacts (main or light switch)
Bulb life expires
BULB BURNT OUT
Improper bulb
Faulty battery
Faulty rectifier/regulator
Improperly grounded
Faulty main and/or light switch
Bulb life expired
FLASHER DOES NOT LIGHT
Improperly grounded
Discharged battery
Faulty turn switch
Faulty flasher relay
Broken wire harness
Loosely connected coupler
Bulb burnt out
Faulty fuse
FLASHER WINKS SLOWER
Faulty flasher relay
Faulty main and/or turn switch
Improper bulb
9-5
FAULTY LIGHTING AND SIGNAL SYSTEM
TRBL
SHTG
HORN IS INOPERATIVE
Faulty battery
Faulty fuse
Faulty main and/or horn switch
Improperly adjusted horn
Faulty horn
Broken wire harness
FLASHER KEEPS ON
Faulty flasher relay
Bulb burnt out
FLASHER WINKS QUICKER
Improper bulb
Faulty flasher relay
Bulb burnt out
9-6
TDM850 ’96 WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
COLOR CODE
B ......
Br . . . . .
Ch . . . .
Dg . . . .
G .....
Gy . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
L ......
Lg . . . . .
O .....
R......
Sb . . . . .
W .....
Blue
Light green
Orange
Red
Sky blue
White
Y ......
B/L . . . .
B/R. . . .
B/W . . .
B/Y . . . .
Br / L . . .
Yellow
Black / Blue
Black / Red
Black / White
Black / Yellow
Brown / Blue
Br / W . .
G/R . . .
G/W . . .
G/Y . . .
L/B . . . .
L/R . . . .
Brown / White
Green / Red
Green / White
Green / Yellow
Blue / Black
Blue / Red
L/W . . .
L/Y . . . .
R/B. . . .
R/W . . .
R/Y. . . .
Blue / White
Blue / Yellow
Red / Black
Red / White
Red / Yellow
A.C. magneto / pickup coil
Rectifier / regulator
Main switch
Battery
Main fuse
Starter relay
Starter motor
Starting circuit cut-off relay
Gear position switch
Sidestand switch
T.P.S. (throttle position sensor)
Ignitor unit
Ignition coil
Spark plug
Thermo unit
Meter assembly
Tachometer
Water temperature meter
Meter light
Neutral indicator light
High beam indicator light
Turn indicator light
Rear flasher light
Front flasher light
Headlight
Auxiliary light
Left handlebar switch
Horn switch
Horn
Lights switch
Dimmer switch
Pass switch
Turn switch
Flasher relay
Clutch switch
Fan motor
Thermo switch
Radiator fan fuse
Tail / brake light
Headlight fuse
Rear brake switch
Signal system fuse
Right handlebar switch
Front brake switch
Engine stop switch
Start switch
Ignition fuse
Diode