SERVICE MANUAL VMX1200 V-MAX 2001 (РУКОВОДСТВО ПО РЕМОНТУ VMX1200 V

SERVICE MANUAL VMX1200 V-MAX 2001 (РУКОВОДСТВО ПО РЕМОНТУ VMX1200 V
VMX12
2001
3LRD-AE1
SERVICEMANUAL
EAS00000
VMX12 2001
SERVICE MANUAL
© 2000 by Yamaha Motor Co., Ltd.
First edition, June 2000
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
@
@
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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 checking 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.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
1
EAS00008
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical system
9 Troubleshooting
ENG
5
6
COOL
CARB
7
8
CHAS
–
ELEC
9
Symbols 0 to G indicate the following.
0
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Symbols N to O in the exploded diagrams
indicate the following.
O
LT
H Engine oil
I Gear oil
J Molybdenum disulfide oil
K Wheel bearing grease
L Lithium soap base grease
M Molybdenum disulfide grease
New
N Apply locking agent (LOCTITE®)
O Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
CHASSIS
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
CARB
6
CHAS
7
–
ELECTRICAL SYSTEM
TROUBLESHOOTING
+
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION .................................................................1-1
VEHICLE IDENTIFICATION NUMBER .................................................... 1-1
MODEL CODE ......................................................................................... 1-1
IMPORTANT INFORMATION ........................................................................ 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-2
REPLACEMENT PARTS ..........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-3
BEARINGS AND OIL SEALS ...................................................................1-3
CIRCLIPS .................................................................................................1-3
CHECKING THE CONNECTIONS ........................................................... 1-4
SPECIAL TOOLS ........................................................................................... 1-5
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL CODE
The model code label 1 is affixed to the
frame. This information will be needed to order
spare parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment. Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1-2
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium soap base grease.
Oil bearings liberally when installing, if appropriate.
1 Oil seal
CAUTION:
@
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
@
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-3
IMPORTANT INFORMATION
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
@
@
4.
•
•
•
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
@
@
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
@
@
1-4
SPECIAL TOOLS
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/Function
Valve guide remover (5.5 mm)
90890-01122
This tool is needed to remove and
install the valve guide.
Valve guide reamer (5.5 mm)
90890-01196
This tool is needed to rebore the new
valve guide.
Coupling gear/middle shaft tool
90890-01229
This tool is needed when removing or
installing the coupling gear nut.
Final gear backlash band
90890-01230
This tool is needed when measuring
final gear backlash.
Piston pin puller set
90890-01304
This tool is used to remove the piston
pin.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
Tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
This tester and its adapter are needed
for checking the cooling system.
1-5
Illustration
SPECIAL TOOLS
Tool No.
Puller
90890-01362
Attachment
90890-04089
Weight
90890-01367
Attachment
90890-01373
Rod holder
90890-01375
T-handle
90890-01326
Tool name/Function
Flywheel puller
Attachment
These tools are needed to remove the
rotor.
Fork seal driver weight
Attachment (f40)
These tools are needed when installing
the slide metal, oil seal and dust seal
into the fork.
Damper rod holder (29 mm)
T-handle
These tools are needed to loosen and
tighten the damper rod holding bolt.
Steering nut wrench
90890-01403
This tool is needed to loosen and
tighten the steering stem ring nut.
Oil filter wrench
90890-01426
This tool is needed to remove and
install the oil filter.
Sheave holder
90890-01701
This tool is needed to hold the rotor
when removing or installing the rotor
bolt.
Cylinder bore gauge (50 ~ 100 mm)
90890-03017
This tool is used to measure the cylinder bore.
Compression gauge
90890-03081
These tools are needed to measure
engine compression.
1-6
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Vacuum gauge
90890-03094
This gauge is needed for carburetor
synchronization.
Dial gauge
90890-03097
This tool is used to measure the middle
gear backlash.
Pocket tester
90890-03112
This instrument is needed for checking
the electrical system.
Engine tachometer
90890-03113
This tool is needed for observing engine
rpm.
Timing light
90890-03141
This tool is necessary for checking ignition timing.
Gauge
90890-03153
Oil pressure adaptor B
90890-03124
Pressure gauge
Oil pressure adaptor B
These tools are needed to measure
engine oil pressure.
Valve guide installer (5.5 mm)
90890-04015
This tool is needed to install the valve
guide.
Valve spring compressor/attachment
Compressor
90890-04019
Attachment
90890-04114
These tools are needed to remove and
install the valve assemblies.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Bearing retainer wrench
90890-04050
This tool is needed when removing or
installing the final drive shaft bearing.
Middle drive shaft nut wrench (55 mm)
90890-04054
This tool is needed when removing or
installing the middle drive shaft nut.
Middle drive gear holder
YM-33222
This tool is needed to remove and
install the middle drive pinion gear.
This tool is also used for the gear backlash adjustment.
Universal joint holder
90890-04062
This tool is needed when removing or
installing the driven pinion gear nut.
Middle gear backlash tool
90890-04080
This tool is needed for the gear backlash adjustment.
Clutch holding tool
90890-04086
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.
Damper spring compressor
90890-04090
This tool is needed when removing or
installing the damper spring.
Tappet adjusting tool
90890-04105
This tool is needed to rotate the camshaft for access to the valve lifter and
valve pad.
1-8
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
GEN
INFO
Illustration
Piston ring compressor
90890-05158
This tool is used to compress the piston
rings when installing the piston into the
cylinder.
Ignition checker
90890-06754
Yamaha Bond No. 1215
90890-85505
This sealant (bond) is used on crankcase mating surfaces, etc.
Ring gear fix bolt (M14)
90890-01524
This tool is used to measure the gear
lash.
1-9
M14×P1.5
SPEC
2
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
ENGINE SPECIFICATIONS ..........................................................................2-2
CHASSIS SPECIFICATIONS ....................................................................... 2-11
ELECTRICAL SPECIFICATIONS ................................................................2-14
CONVERSION TABLE ................................................................................. 2-17
GENERAL TIGHTENING TORQUE SPECIFICATION .................................2-17
TIGHTENING TORQUES ............................................................................. 2-18
ENGINE TIGHTENING TORQUES ........................................................ 2-18
CHASSIS TIGHTENING TORQUES ......................................................2-21
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-23
ENGINE .................................................................................................. 2-23
CHASSIS ...............................................................................................2-24
COOLING SYSTEM DIAGRAMS .................................................................2-25
OIL FLOW DIAGRAMS ................................................................................ 2-27
CABLE ROUTING ........................................................................................ 2-31
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
2,300 mm
795 mm
1,160 mm
765 mm
1,590 mm
145 mm
2,900 mm
----------------------
281 kg
262 kg
209 kg
----------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Final gear oil
Recommended oil
Final gear case oil
Total amount
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
1,198 cm3
V-type 4-cylinder
76 × 66 mm
10.5 : 1
950 ~ 1,050 r/min
26.7 kPa (200 mm Hg)
----------------------
1,450 kPa (14.5 kgf/cm2) at 350 r/min
----
Regular unleaded gasoline
----
15 L
3L
-------
Wet sump
-------
SAE 20W40SE or SAE 10W30SE
----
4L
3.2 L
-------
3.4 L
25 kPa at 1,000 r/min
(0.25 kgf/cm2 at 1,000 r/min)
440 ~ 560 kPa (4.4 ~ 5.6 kgf/cm2)
-------
SAE 80 API “GL-4” Hypoid Gear Oil
----
0.2 L
----
2-2
----
ENGINE SPECIFICATIONS
Item
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
<From low to full level>
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
Starting system type
Spark plugs
Model (manufacturer) × quantity
Spark plug gap
Cylinder head
Max. warpage
SPEC
Standard
Cartridge (paper)
170 ~ 240 kPa (1.7 ~ 2.4 kgf/cm2)
Trochoid
0 ~ 0.12 mm
0.03 ~ 0.08 mm
Limit
---------0.17 mm
0.08 mm
3.05 L
75 ~ 105 kPa (0.75 ~ 1.05 kgf/cm2)
-------
363.8 mm
240 mm
16 mm
----------
0.3 L
0.2 L
-------
Single-suction centrifugal pump
31/21 (1.476)
---Electric starter
DPR8EA-9/X24EPR-U9 (NGK/DENSO) × 4
0.8 ~ 0.9 mm
----
------0.15 mm
---------0.03 mm
2-3
ENGINE SPECIFICATIONS
Item
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap
clearance
Intake camshaft lobe dimensions
Standard
Chain drive (center)
25.000 ~ 25.021 mm
24.967 ~ 24.980 mm
0.020 ~ 0.054 mm
SPEC
Limit
-------------
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
36.25 ~ 36.35 mm
28.02 ~ 28.12 mm
36.15 mm
27.92 mm
Measurement A
Measurement B
Max. camshaft runout
36.25 ~ 36.35 mm
28.02 ~ 28.12 mm
----
36.15 mm
27.92 mm
0.03 mm
2-4
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
SPEC
Limit
219FTS/117
Automatic
-------
0.11 ~ 0.15 mm
0.26 ~ 0.30 mm
-------
B
C
D
A
Head Diameter
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
Seat Width
Face Width
Margin Thickness
30.4 ~ 30.6 mm
24.9 ~ 25.1 mm
-------
1.6 ~ 3.1 mm
1.3 ~ 2.4 mm
-------
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
1.4 mm
1.4 mm
1.1 ~ 1.5 mm
1.1 ~ 1.5 mm
0.7 mm
0.7 mm
5.475 ~ 5.490 mm
5.460 ~ 5.475 mm
5.445 mm
5.42 mm
5.500 ~ 5.512 mm
5.500 ~ 5.512 mm
5.55 mm
5.55 mm
0.010 ~ 0.037 mm
0.025 ~ 0.052 mm
----
0.08 mm
0.1 mm
0.01 mm
0.9 ~ 1.1 mm
0.9 ~ 1.1 mm
1.4 mm
1.4 mm
2-5
ENGINE SPECIFICATIONS
Item
Valve springs
Inner springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
Outer springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
Standard
39.65 mm
39.65 mm
SPEC
Limit
37.45 mm
37.45 mm
31.8 mm
31.8 mm
-------
61.7 ~ 72.5 N (6.29 ~ 7.39 kgf)
61.7 ~ 72.5 N (6.29 ~ 7.39 kgf)
-------
-------
2.5° /1.7 mm
2.5° /1.7 mm
Counterclockwise
Counterclockwise
41.1 mm
41.1 mm
-------
38.9 mm
38.9 mm
33.8 mm
33.8 mm
-------
130.4 ~ 154.0 N (13.3 ~ 15.7 kgf)
130.4 ~ 154.0 N (13.3 ~ 15.7 kgf)
-------
2-6
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
-------
2.5° /1.8 mm
2.5° /1.8 mm
Clockwise
Clockwise
Cylinders
Cylinder arrangement
Bore × stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
Pistons
Piston-to-cylinder clearance
Diameter D
-------
V-type 4-cylinder
76 × 66 mm
10.5 : 1
75.967 ~ 76.016 mm
-------
------------0.05 mm
0.05 mm
0.055 ~ 0.075 mm
75.905 ~ 75.955 mm
0.15 mm
----
H
D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore clearance
6.2 mm
----
19.004 ~ 19.015 mm
0 mm
-------
18.991 ~ 19.000 mm
0.004 ~ 0.024 mm
2-7
---0.072 mm
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Piston rings
Top ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
2nd ring
Barrel
1.0 × 3.1 mm
0.35 ~ 0.50 mm
0.03 ~ 0.07 mm
------0.75 mm
0.12 mm
Taper
1.2 × 3.1 mm
0.35 ~ 0.50 mm
0.02 ~ 0.06 mm
------0.75 mm
0.12 mm
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
2.5 × 3.1 mm
0.2 ~ 0.8 mm
-------
0.021 ~ 0.039 mm
----
1 = Blue 2 = Black 3 = Brown 4 = Green
5 = Yellow 6 = Pink
----
Crankshaft
C
D
A
B
Width A
Width B
Max. runout C
Big end side clearance D
Big end radial clearance
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
83.92 ~ 83.97 mm
242.72 ~ 243.17 mm
---0.320 ~ 0.924 mm
0.021 ~ 0.045 mm
0.040 ~ 0.058 mm
1 = Blue 2 = Black 3 = Brown 4 = Green
5 = Yellow 6 = Pink 7 = Red
2-8
------0.03 mm
------0.1 mm
----
ENGINE SPECIFICATIONS
Item
Clutch
Clutch type
Clutch release method
Operation
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Minimum length
Clutch housing thrust clearance
Clutch housing radial clearance
Push rod bending limit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Max. main axle runout
Max. drive axle runout
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Installed shift rod length
Air filter type
Fuel pump
Pump type
Model (manufacturer)
Consumption amperage
<max>
Output pressure
Standard
Wet, multiple disc
Hydraulic inner push
Left-hand operation
SPEC
Limit
----------
2.9 ~ 3.1 mm
8
2.8 mm
----
2.2 ~ 2.4 mm
7
----
------0.2 mm
7 mm
1 PCS
---0.10 ~ 0.27 mm
0.017 ~ 0.053 mm
----
------6.5 mm
------0.5 mm
Constant mesh, 5-speed
Spur gear
87/49 (1.776)
Shaft drive
21/27 × 33/10 (2.567)
Left-foot operation
-------------------
43/17 (2.529)
39/22 (1.773)
31/23 (1.348)
28/26 (1.077)
26/28 (0.929)
-------
---------------0.08 mm
0.08 mm
Guide bar
---367.8 mm
Dry element
---0.025 mm
-------
Electrical
UCV5A (MITSUBISHI)
1A
18 kPa (0.18 kgf/cm2)
2-9
-------------
ENGINE SPECIFICATIONS
Item
Carburetors
Model (manufacturer) × quantity
Throttle cable free play (at the flange
of the throttle grip)
ID 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 turns out
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Fuel level (below the line on the vacuum chamber)
Shaft drive
Middle gear backlash
Final gear backlash
Standard
SPEC
Limit
BDS35 (MIKUNI) × 4
3 ~ 5 mm
-------
3LRC 10
#150
2.0
5DZ19-3
Y-0
#95
#170
0.9
#42.5
0.8
0.8
0.9
2-1/2
1.5
#45
0.8
#125
15 ~ 17 mm
-------------------------------------------------------
0.05 ~ 0.12 mm
0.1 ~ 0.2 mm
2 - 10
0.3 mm
0.3 mm
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 209 kg
High-speed riding
Min. tire tread depth
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 197 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Double cradle
29°
119 mm
----------
Cast wheel
----
18 × MT2.15
Aluminum
140 mm
----------
-------
1 mm
0.5 mm
Cast wheel
----
15M/C × MT3.50
Aluminum
100 mm
----------
-------
1 mm
0.5 mm
Tubeless
110/90V18 (61V)
ME33 (METZELER)
225 kPa (2.25 kg/cm2, 2.25 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
---Tubeless
150/90B-15M/C (74V)
ML2 (METZELER)
225 kPa (2.25 kg/cm2, 2.25 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
----
2 - 11
------------------1.6 mm
------------------1.6 mm
CHASSIS SPECIFICATIONS
Item
Front brakes
Brake type
Operation
Brake lever free play (at lever end)
Recommended fluid
Brake discs
Diameter × thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position
Recommended fluid
Brake discs
Diameter × thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Spring rate (K2)
Spring stroke (K2)
Optional spring available
Standard enclosed gas/air pressure
Standard
Dual-disc brake
Right-hand operation
2 ~ 5 mm
DOT 4
298 × 5 mm
------5 mm
15.87 mm
33.96 mm and 30.23 mm
Single-disc brake
Right-foot operation
20 mm
DOT 4
282 × 7.5 mm
------5.1 mm
12.7 mm
42.85 mm
Telescopic fork
Coil air spring/oil damper
140 mm
386.5 mm
245 mm
242.4 mm
3.7 N/mm (0.38 kgf/mm)
0 ~ 78 mm
4.9 N/mm (0.5 kgf/mm)
78 ~ 140 mm
No
40 kPa
2 - 12
SPEC
Limit
---------------4.5 mm
0.3 mm
0.5 mm
---------------------7.0 mm
0.3 mm
0.5 mm
---------------381.5 mm
-------------------------
CHASSIS SPECIFICATIONS
Item
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully compressed, and without the fork
spring)
Steering
Steering bearing type
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Spring rate (K2)
Spring stroke (K2)
Optional spring available
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
Standard
SPEC
Limit
Yamaha fork oil 10 WT
Fork oil 10 W or equivalent
621 cm3
123 mm
-------------
Taper roller bearing
----
Swingarm
Coil spring/oil damper
85 mm
----------
245.5 mm
217.4 mm
19.1 N/mm (1.95 kgf/mm)
0 ~ 50 mm
26.5 N/mm (2.7 kgf/mm)
50 ~ 85 mm
No
240.5 mm
-------------------
-------
0 mm
0 mm
2 - 13
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
System voltage
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug caps
Material
Resistance
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance
Voltage regulator
Regulator type
Model
No-load regulated voltage
Rectifier
Model
Rectifier capacity
Withstand voltage
Battery
Battery type
Battery voltage/capacity
Specific gravity
Headlight type
Indicator light type × quantity
Bulbs (voltage/wattage × quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
License plate light
Meter light
Standard
Limit
12 V
----
Transistorized coil ignition (digital)
3° BTDC at 1,000 r/min
31° BTDC at 9,000 r/min
Vacuum and electrical
80.8 ~ 121.2 Ω/O–B
BB7224 (HITACHI)
-------------------
CM11-61 (HITACHI)
6 mm
2.43 ~ 2.97 Ω
10.56 ~ 15.84 kΩ
-------------
Resin
10 kΩ
-------
AC magneto
GP9415 (KOKUSAN)
14 V/22.5 A at 5,000 r/min
0.33 ~ 0.45 Ω
-------------
Semiconductor, short circuit
SH662-12
14.1 ~ 14.9 V
----------
SH662-12
18 A
200 V
----------
YB16AL-A2
12 V/16 AH
1.280
Halogen bulb
Bulb type × 3
----------------
12 V 60 W/55 W × 1
12 V 3.4 W × 1 (for GB)
12 V 4 W × 1 (for B, F, P, I)
12 V 21 W/5 W × 2
12 V 21 W × 4
12 V 5 W × 2
14 V 3 W × 2
----------------------
2 - 14
ELECTRICAL SPECIFICATIONS
Item
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Horn
Horn type
Model (manufacturer) × quantity
Max. amperage
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Oil level switch model (manufacturer)
Fuel sender
Model (manufacturer)
Resistance
Sidestand relay
Model
Coil resistance
Fuel pump maximum amperage
Fuel pump relay model (manufacturer)
Radiator fan model (manufacturer)
Thermo switch model (manufacturer)
Temperature sender
Model (manufacturer)
Resistance
Standard
SPEC
Limit
Constant mesh
----
SM-13 (MITSUBA)
0.65 kW
-------
10 mm
8.82 N (899 gf)
0.025 ~ 0.035 Ω
28 mm
0.7 mm
5 mm
------27 mm
----
MS5D-341 (HITACHI)
100 A
3.87 ~ 4.73 Ω
----------
Plane
YF-12 (NIKKO) × 1
3A
----------
Semi-transistor
FB257H (DENSO)
Yes
75 ~ 95 cycles/min.
21 W × 2 + 3.4 W
1FK (DENSO)
-------------------
1FK (NIPPON SEIKI)
700 ~ 1,100 Ω at 25 °C
-------
1RL-92
72 ~ 88 Ω
1.2 A
G8D-04Y (OMRON)
-------------
4XV (TOYO RADIATOR)
3LN (NIPPON THERMOSTAT)
-------
11H (NIPPON SEIKI)
153.9 Ω at 50 °C
47.5 ~ 56.8 Ω at 80 °C
26.2 ~ 29.3 Ω at 100 °C
-------------
2 - 15
ELECTRICAL SPECIFICATIONS
Item
Fuses (amperage × quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Reserve fuse
Standard
30 A × 1
15 A × 1
10 A × 1
10 A × 1
10 A × 1
30 A, 15 A, 10 A × 1
2 - 16
SPEC
Limit
-------------------
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATION
SPEC
EB201000
EAS00029
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATION
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
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m·kg
Tightening torque m·kg
cm·kg
cm·kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
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)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP lip.)
cu-in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (°F)
Misc.
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A: Width across flats
B: Thread diameter
A
(nut)
2 - 17
B
(bolt)
General tightening
torques
Nm
m•kg
10 mm
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
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Part to be tightened
Camshaft caps
Blind plug
Cylinder head (exhaust pipe)
Spark plugs
Cylinder head
Cylinder head cover
Connecting rod caps
AC magneto
Camshaft sprocket
Timing chain damper bracket
Timing chain tensioner
Cap bolt (tensioner)
Water pump cover
Water pump drain plug
Water pump housing
Thermostat assembly
Thermostat housing cover
Crankcase breather assembly
Crankcase breather cover
Radiator
Radiator side cover
Coolant drain cock
Radiator cap pipe
Conduit
Oil strainer housing
Oil pump gear housing
Oil gallery pipe
Engine oil drain bolt
Oil pan
Oil baffle plate
Oil delivery pipe (head)
Oil delivery pipe (cover)
Oil pipe
Oil pump housing cover 1
Oil pump housing cover 1
Stay 1
Oil filter
Carburetor joint
Fuel pump
Exhaust pipe joint clamp (#1 and #3)
Part name Thread size Q’ty
Bolt
Plug
Stud bolt
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Plug
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Screw
Screw
Screw
Screw
Bolt
Plug
Bolt
Bolt
Union bolt
Union bolt
Union bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
2 - 18
M6
M20
M8
M12
M10
M6
M8
M12
M7
M8
M6
M16
M6
M14
M6
M6
M6
M6
M6
M6
M6
M4
M6
M6
M6
M6
M6
M14
M6
M6
M8
M10
M8
M6
M6
M6
M20
M6
M6
M6
32
6
8
4
16
16
8
1
8
1
4
2
5
1
4
2
2
6
4
4
4
1
3
3
3
4
2
1
12
2
2
1
1
2
1
1
1
8
2
2
Tightening
torque
Nm
m·kgf
10
43
15
18
43
10
36
130
24
24
12
20
10
43
10
10
7
10
10
7
4
3
7
7
7
7
12
43
10
12
18
20
18
7
10
12
17
10
12
7
1.0
4.3
1.5
1.8
4.3
1.0
3.6
13.0
2.4
2.4
1.2
2.0
1.0
4.3
1.0
1.0
0.7
1.0
1.0
0.7
0.4
0.3
0.7
0.7
0.7
0.7
1.2
4.3
1.0
1.2
1.8
2.0
1.8
0.7
1.0
1.2
1.7
1.0
1.2
0.7
Remarks
LT
M
LT
TIGHTENING TORQUES
Part to be tightened
Part name Thread size Q’ty
Exhaust pipe joint clamp (#2 and #4)
Bolt
Exhaust pipe clamp bolt (exhaust
Bolt
chamber)
Exhaust pipes
Nut
Exhaust pipe cover
Bolt
Exhaust pipe cover
Bolt
Muffler bracket
Bolt
Muffler
Bolt
Cylinder (cylinder head)
Stud bolt
Main gallery blind plug
Plug
Crankcase
Bolt
Crankcase
Bolt
Crankcase
Bolt
Middle gear bearing retainer
Screw
Main axle bearing retainer
Screw
Wire lead clamp
Screw
Generator cover
Bolt
Crankcase cover plate
Screw
Middle gear case cover
Bolt
Clutch cover
Bolt
Oil baffle plate
Screw
Oil drain plug (crankcase)
Bolt
Starter clutch
Bolt
Clutch spring plate
Bolt
Clutch boss
Nut
Clutch release cylinder
Bolt
Air bleed screw
Screw
Clutch pipe
Union bolt
Middle drive pinion gear
Nut
Middle driven pinion gear
Nut
Middle driven gear housing
Bolt
Shift cam segment
Screw
Shift cam plate
Screw
Shift cam retainer
Screw
Shift shaft spring stopper
Bolt
Stopper lever
Bolt
Shift arm
Bolt
Shift rod locknut
Nut
Shift rod locknut
Final gear case (rear arm)
Final gear case (bearing housing)
Coupling gear
SPEC
Tightening
torque
Nm
m·kgf
M8
1
20
2.0
M8
4
20
2.0
M8
M6
M5
M6
M10
M10
M20
M6
M8
M10
M8
M6
M6
M6
M6
M6
M6
M6
M8
M8
M6
M20
M6
M8
M10
M44
M16
M8
M6
M5
M6
M8
M6
M6
M6
8
3
6
2
3
16
1
10
18
8
4
3
2
11
2
6
9
4
1
3
6
1
2
1
1
1
1
3
1
1
3
1
1
1
1
20
7
6
10
25
9
12
12
24
40
25
7
7
10
7
10
10
7
38
24
8
70
12
6
25
110
90
30
12
4
7
22
10
10
10
2.0
0.7
0.6
1.0
2.5
0.9
1.2
1.2
2.4
4.0
2.5
0.7
0.7
1.0
0.7
1.0
1.0
0.7
3.8
2.4
0.8
7.0
1.2
0.6
2.5
11.0
9.0
3.0
1.2
0.4
0.7
2.2
1.0
1.0
1.0
Nut
M6
1
10
1.0
Stud bolt
Stud bolt
Nut
M10
M8
M16
4
6
1
18
9
130
1.8
0.9
13.0
2 - 19
Remarks
LT
LT
LT
LT
LT
LT
LT
LT
LT
Left hand
thread
TIGHTENING TORQUES
Part to be tightened
Bearing housing
Drain plug (final gear case)
Filler plug (final gear case)
Stator coil
Pickup coil
Starter motor
Neutral switch
Oil level switch
Thermo unit
Thermo switch
Part name Thread size Q’ty
Nut
Bolt
Plug
Plug
Screw
Screw
Bolt
Screw
Bolt
M8
M10
M14
M14
M6
M6
M6
M5
M6
M10
M16
6
2
1
1
3
4
2
3
2
1
1
Tightening
torque
Nm
m·kgf
23
40
23
23
7
7
10
4
10
15
15
2.3
4.0
2.3
2.3
0.7
0.7
1.0
0.4
1.0
1.5
1.5
Crankcase tightening sequence:
Lower case
Upper case
* : With washer
2 - 20
SPEC
Remarks
LT
LT
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Part to be tightened
Thread size
Upper bracket and inner tube
Upper bracket and steering shaft
Handlebar holder (lower) and handlebar holder
(upper)
Ring nut (steering shaft)
Brake hose joint and lower bracket
Front master cylinder cap (brake and clutch)
Handlebar holder (lower)
Front master cylinder (brake and clutch)
Union bolt (brake hose)
Clutch hose and clutch pipe
Engine mounting:
Mounting bolt (engine and front frame)
Mounting bolt (engine and rear frame)
Engine bracket and frame
Frame and down tube
Frame and rear cross bar
Swingarm pivot shaft (left)
Swingarm pivot shaft (right)
Swingarm pivot shaft locknut (right)
Rear shock absorber and frame
Rear shock absorber and swingarm
Rear shock absorber and final gear case
Swingarm and final gear case
Fuel sender and fuel tank
Side cover and frame
Sidestand bolt and nut
Left footrest bracket and frame
Left footrest bracket and rear frame pipe
Rear frame pipe and frame
Right footrest bracket and frame
Union bolt (rear brake hose)
Front fender brace
Front wheel axle
Front wheel axle pinch bolt
Rear wheel axle nut
Front brake caliper
Rear brake caliper
Brake disc and wheel
Caliper bleed screw
2 - 21
Tightening
torque
Nm
m·kgf
M8
M22
23
110
2.3
11.0
M8
20
2.0
M25
M6
M4
M10
M6
M10
M10
3
7
2
40
9
30
19
0.3
0.7
0.2
4.0
0.9
3.0
1.9
M10
M12
M8
M10
M8
M25
M25
M25
M8
M10
M10
M10
M6
M6
M10
M8
M8
M8
M8
M10
M6
M14
M8
M18
M10
M10
M8
M8
42
70
16
45
23
100
7
100
20
35
30
42
7
7
40
26
26
30
23
30
9
58
20
150
40
40
23
6
4.2
7.0
1.6
4.5
2.3
10.0
0.7
10.0
2.0
3.5
3.0
4.2
0.7
0.7
4.0
2.6
2.6
3.0
2.3
3.0
0.9
5.8
2.0
15.0
4.0
4.0
2.3
0.6
Remarks
See NOTE
LT
TIGHTENING TORQUES
SPEC
NOTE:
1.First, tighten the ring nut approximately 52 Nm (5.2 m • kg) by using the torque wrench, then
loosen the ring nut completely.
2.Retighten the ring nut to specification.
2 - 22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point
Symbol
Oil seal lips
LS
O-ring
LS
Bearing
E
Connecting rod bolt/nut
M
Connecting rod small end and big end
E
Crankshaft pin
E
Crankshaft journal/big end
E
Balancer shaft journal
E
Piston surface
E
Piston pin
E
Camshaft cam lobe/journal
E
Timing chain tensioner
E
Valve stem (IN, EX)
M
Valve stem end (IN, EX)
E
Valve lifter
E
Water pump impeller shaft
E
Oil pump rotor (inner/outer), housing
E
Oil strainer assembly
E
Idle gear surface
E
Starter idle gear
E
Starter idle gear shaft
E
Starter clutch (outer/roller)
E
Push rod ball
LS
Pressure plate bearing
E
Transmission gear (wheel/pinion)
M
Shift cam
E
Shift fork/guide bar
E
Shift shaft assembly
LS
Shift pedal
LS
Shift lever joint
LS
Middle drive shaft (drive damper cam/driven damper cam)
2 - 23
E
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
CHASSIS
Lubrication Point
Symbol
Steering bearing (upper/lower)
LS
Steering bearing cover
LS
Steering lock
LS
Steering head pipe lower oil seal
LS
Front wheel oil seal (right/left)
LS
Rear wheel oil seal
LS
Clutch hub fitting area
LS
Rear brake pedal shaft
LS
Shift pedal
LS
Sidestand sliding surface
LS
Centerstand sliding surface
LS
Tube guide (throttle grip) inner surface
LS
Brake lever pivot bolt, contact surface
LS
Clutch lever pivot bolt, contact surface
LS
Swingarm pivot shaft
LS
Swingarm pivot bearing
M
Swingarm pivot oil seal
M
Rear shock absorber bearing (inner)
M
2 - 24
COOLING SYSTEM DIAGRAMS
COOLING SYSTEM DIAGRAMS
1 Radiator cap
2 Conduit
3 Radiator hose
4 Radiator
5 Thermostatic valve
6 Coolant drain cock
7 Water pump
È To coolant reservoir tank
É To thermostatic valve
Ê To coolant drain cock
2 - 25
SPEC
COOLING SYSTEM DIAGRAMS
1 Radiator cap
2 Conduit
3 Radiator hose
4 Radiator
5 Coolant drain cock
6 Thermostatic valve housing
7 Water pump
È To thermostatic valve
É To coolant drain cock
2 - 26
SPEC
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1 Camshaft (intake)
2 Camshaft (exhaust)
3 Water pump impeller shaft
4 Water pump drive gear
5 Oil filter
6 Main gallery
7 Crankshaft
8 Oil strainer
9 Oil pump
0 Main axle
A Drive axle
2 - 27
SPEC
OIL FLOW DIAGRAMS
1 Camshaft
2 Main gallery
3 Crankshaft
4 Oil level switch
2 - 28
SPEC
OIL FLOW DIAGRAMS
1 Oil pump
2 Oil strainer
3 Main axle
4 Drive axle
5 Middle driven pinion gear
6 Middle drive pinion gear
2 - 29
SPEC
OIL FLOW DIAGRAMS
1 Crankshaft
2 Oil pipe
3 Oil filter
2 - 30
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1 Front brake hose
2 Clutch hose
3 Front flasher light lead (left)
4 Speedometer cable
5 Wire harness
6 Speedometer light lead
7 Front flasher light lead (right)
È Insert the wire harness, speedometer light lead
and front flasher light leads (left and right)
through the hole in the housing at the back of the
headlight.
É Pass the clutch hose through the guide.
2 - 31
CABLE ROUTING
1 Main switch coupler
2 Handlebar switch coupler
3 Fuel switch coupler
4 Ignition coil lead
5 Ground lead
6 Rear brake switch lead
7 Coolant reservoir tank breather hose
8 Battery breather hose
9 Fuel sender lead
0 Fuel sender coupler
A Battery negative lead
B Coolant breather hose
C Conduit
D Rear brake reservoir tank
E Battery
F Wire harness
2 - 32
SPEC
CABLE ROUTING
È Fasten the wire harness with a plastic locking
tie.
É To the conduit.
Ê Pass the ground lead outside the coolant reservoir tank breather hose.
Ë Pass the battery breather hose and coolant reservoir tank breather hose through the guide.
SPEC
Ì Pass the battery breather hose through the
clamp.
Í Fasten the rear brake switch lead with a plastic
locking tie.
Î Pass the wire harness through the clamp.
2 - 33
CABLE ROUTING
1 Clutch hose
2 Handlebar switch lead (left)
3 Clutch hose clump
4 Throttle cable holder
5 Throttle cables
6 Fuse box
7 Ignitor unit
8 Ignition coil
9 Radiator fan lead coupler
0 Horn lead
A Speedometer cable
B Front brake hose
C Fuel pump control unit
D Relay unit
2 - 34
SPEC
CABLE ROUTING
È Pass the handlebar switch lead inside the clutch
hose.
É Pass the meter lead outside the clutch hose.
Ê Pass the clutch hose outside the throttle cable.
Ë Fasten the clutch hose with a plastic locking tie.
Ì Pass the horn lead through the clamp.
Í Pass the speedometer cable through the guide.
Î Pass the front brake hose through the clamp.
Ï Pass the front brake hose outside the speedometer cable.
SPEC
Ð Pass the clutch hose under the throttle cable
guide.
Ñ Pass the throttle cables through the guide.
2 - 35
CABLE ROUTING
1 Starter relay
2 Main fuse
3 Ignition coil
4 Oil level switch lead
5 Neutral switch lead
6 Rectifier/regulator lead coupler
7 Ground lead coupler
8 Sidestand switch lead coupler
9 AC generator lead coupler
0 Clutch hose
È Fasten the oil level switch lead, neutral switch
lead, ground lead, sidestand switch lead, overflow
hose and AC generator lead with a plastic band to
the frame guide.
SPEC
É Fasten the oil level switch lead, neutral switch
lead, ground lead, sidestand switch lead, overflow
hose and AC generator lead with plastic band.
Ê Pass the oil level switch lead, neutral switch lead,
ground lead, and AC generator lead through the
clamp.
Ë Pass the clutch hose and overflow hose through
the guide.
Ì Fasten the oil level switch lead, neutral switch
lead, ground lead, sidestand switch lead and AC
generator lead with a plastic locking tie.
Í Pass the clutch hose through the guide.
2 - 36
CABLE ROUTING
1 Coolant reservoir tank
2 Spring
3 Filler cover
4 Drain hose
5 Overflow hose
6 Overflow valve
7 Fuel sender
8 Battery breather hose
SPEC
É Fasten the oil level switch lead, neutral switch
lead, ground lead, sidestand switch lead, overflow hose and AC generator lead with a plastic
band.
Ê Pass the clutch hose and overflow hose through
the guide.
Ë Fasten the overflow hose with a plastic clamp.
Ì Pass the overflow hose through the guide.
È Fasten the oil level switch lead, neutral switch
lead, ground lead, sidestand switch lead, overflow hose and AC generator lead with a plastic
band.
2 - 37
CABLE ROUTING
1 Fuel pump
2 Fuel pipe
3 Fuel filter bracket
4 Fuel filter
5 Over flow hose
6 Filler cover
7 Filler cap
8 Battery band
SPEC
È Pass the fuel pipe and overflow hose through
the hose holder.
2 - 38
CABLE ROUTING
1 Diode
2 Ignitor unit
3 Ignition coil lead coupler
4 Starter relay
5 Battery negative lead
6 Ignition coil
7 Ignition coil lead coupler
8 Starter relay lead coupler
9 Fuel filter
0 Rubber boot
A Rear flasher light lead (left)
SPEC
B Pick up coil lead coupler
C Ground lead coupler
D Side stand switch lead coupler
E Rectifier/regulator lead coupler
F Oil level switch lead
G Neutral switch lead
H Battery positive lead
I Main fuse
J Starter motor lead
K Fuel pump
2 - 39
CABLE ROUTING
L Fuse box
M Meter lead coupler
N Handlebar switch lead coupler
SPEC
È To the conduit.
É Fasten the wire harness with a plastic locking
tie.
Ê Clamp the taillight lead and rear flasher light
lead (right).
Ë Clamp the rear flasher light lead (left).
2 - 40
CHK
ADJ
3
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ................... 3-1
SEATS AND SIDE COVERS ..........................................................................3-3
TOP COVER AND COVERS ..........................................................................3-4
AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD ................ 3-5
ENGINE ..........................................................................................................3-6
ADJUSTING THE VALVE CLEARANCE ................................................. 3-6
SYNCHRONIZING THE CARBURETORS ............................................. 3-11
ADJUSTING THE ENGINE IDLING SPEED ..........................................3-13
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................. 3-14
CHECKING THE SPARK PLUGS .......................................................... 3-15
CHECKING THE IGNITION TIMING ......................................................3-16
MEASURING THE COMPRESSION PRESSURE .................................3-17
CHECKING THE ENGINE OIL LEVEL ...................................................3-19
CHANGING THE ENGINE OIL ..............................................................3-20
MEASURING THE ENGINE OIL PRESSURE ....................................... 3-21
CHECKING THE CLUTCH FLUID LEVEL ............................................. 3-23
BLEEDING THE HYDRAULIC CLUTCH SYSTEM ................................3-24
CLEANING THE AIR FILTER ELEMENT ............................................... 3-25
CHECKING THE CARBURETOR JOINTS ............................................3-26
CHECKING THE VACUUM HOSES ......................................................3-26
CHECKING THE FUEL HOSES AND FUEL FILTER ............................ 3-27
CHECKING THE CRANKCASE BREATHER HOSE ............................. 3-27
CHECKING THE EXHAUST SYSTEM ...................................................3-28
CHECKING THE COOLANT LEVEL ......................................................3-28
CHECKING THE COOLING SYSTEM ...................................................3-29
CHANGING THE COOLANT .................................................................. 3-29
CHK
ADJ
CHASSIS ...................................................................................................... 3-32
ADJUSTING THE FRONT BRAKE ........................................................ 3-32
ADJUSTING THE REAR BRAKE ........................................................... 3-33
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-34
CHECKING THE BRAKE PADS ............................................................ 3-35
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................3-35
CHECKING THE BRAKE HOSES .......................................................... 3-36
BLEEDING THE HYDRAULIC BRAKE SYSTEM ..................................3-36
ADJUSTING THE SHIFT PEDAL ........................................................... 3-38
CHECKING THE FINAL DRIVE OIL LEVEL ..........................................3-38
CHANGING THE FINAL DRIVE OIL ......................................................3-39
CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-40
CHECKING THE FRONT FORK ............................................................ 3-42
ADJUSTING THE FRONT FORK LEGS ................................................ 3-42
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES ............. 3-43
CHECKING THE TIRES .........................................................................3-45
CHECKING THE WHEELS .................................................................... 3-47
CHECKING AND LUBRICATING THE CABLES ................................... 3-48
LUBRICATING THE LEVERS AND PEDALS ........................................ 3-48
LUBRICATING THE SIDESTAND .......................................................... 3-49
LUBRICATING THE CENTERSTAND ...................................................3-49
LUBRICATING THE REAR SUSPENSION ............................................3-49
ELECTRICAL SYSTEM ................................................................................ 3-50
CHECKING THE BATTERY ................................................................... 3-50
CHECKING THE FUSES ....................................................................... 3-54
REPLACING THE HEADLIGHT BULB ...................................................3-55
ADJUSTING THE HEADLIGHT BEAM .................................................. 3-57
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No.
ITEM
1 * Fuel line
CHECK OR MAINTENANCE JOB
1
• Check fuel hoses for cracks or damage.
2 * Fuel filter
• Check condition.
3
• Check condition.
• Clean and regap.
Spark plugs
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
√
5
Air filter element
√
• Check valve clearance.
• Adjust.
√
√
• Clean.
√
√
• Replace.
6 * Battery
• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.
7 * Clutch
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
8 * Front brake
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
9 * Rear brake
• Check operation, fluid level and vehicle for fluid
leakage. (See NOTE on page 3-2.)
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Replace brake pads.
√
√
√
√
√
√
• Check for cracks or damage.
• Replace.
√
√
√
Every 4 years
• Check runout and for damage.
√
√
√
√
12 * Tires
•
•
•
•
√
√
√
√
13 * Wheel bearings
• Check bearings for looseness or damage.
√
√
√
√
• Check swingarm pivoting point for play.
√
√
√
√
15 * Steering bearings
√
√
Whenever necessary
11 * Wheels
14 * Swingarm
√
Whenever necessary
• Replace brake pads.
10 * Brake hoses
√
√
• Replace.
4 * Valves
√
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
• Lubricate with molybdenum disulfide grease.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
3-1
Every 50,000 km
√
√
√
√
Every 50,000 km
√
√
PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
CHK
ADJ
ODOMETER READING (× 1,000 km)
10
20
30
40
ANNUAL
CHECK
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
√
√
Sidestand/centerstand
• Check operation.
• Lubricate.
√
√
√
√
√
18 * Sidestand switch
• Check operation.
√
√
√
√
√
19 * Front fork
• Check operation and for oil leakage.
√
√
√
√
√
√
√
√
No.
ITEM
16 * Chassis fasteners
17
20 *
CHECK OR MAINTENANCE JOB
1
√
• Check operation and shock absorbers for oil leakRear shock
absorber assembly age.
21 * Carburetors
• Check engine idling speed, synchronization and
starter operation.
√
√
√
√
√
√
22
Engine oil
• Change.
√
√
√
√
√
√
23
Engine oil filter
cartridge
• Replace.
√
24 * Cooling system
25
Final gear oil
Front and rear
26 *
brake switches
√
√
• Check coolant level and vehicle for coolant leakage.
• Change coolant.
√
√
√
• Check operation.
28 *
Lights, signals and • Check operation.
• Adjust headlight beam.
switches
√
√
√
√
• Change.
Moving parts and
cables
√
Every 3 years
• Check oil level and vehicle for oil leakage.
27
√
√
• Lubricate.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake and clutch service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper as
well as clutch master and release cylinders, and change the brake and clutch fluids.
3-2
SEATS AND SIDE COVERS
CHK
ADJ
SEATS AND SIDE COVERS
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Removing the seats and side covers
Remove the parts in the order listed.
Rider seat
1
Tool cover
1
Tool band
1
Tool kit
1
Passenger seat
1
Side covers (left and right)
2
For installation, reverse the removal procedure.
3-3
TOP COVER AND COVERS
CHK
ADJ
TOP COVER AND COVERS
Order
1
2
Job/Part
Removing the top cover and covers
Top cover
Covers (left and right)
Q’ty
Remarks
Remove the parts in the order listed.
1
2
For installation, reverse the removal procedure.
3-4
AIR FILTER CASE AND ELECTRICAL COMPONENTS
BOARD
CHK
ADJ
AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Removing the air filter case and
Remove the parts in the order listed.
electrical components board
Top cover and covers
Refer to “TOP COVER AND COVERS”.
Fuel pump control unit
1
Disconnect.
Relay unit
1
Disconnect.
Electrical components board
1
Air vent hose holder
2
Air filter case cover
1
Air filter
1
Air filter case
1
For installation, reverse the removal procedure.
3-5
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00044
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
@
@
1. Remove:
• top cover
• covers (left and right)
Refer to “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD”.
2.
•
3.
•
4.
•
•
Remove:
electrical components board 1
Disconnect:
all electrical component leads
Remove:
radiator side covers
radiator bolt
Refer to “COOLING SYSTEM” in chapter 5.
NOTE:
It is not necessary to remove the radiator completely from the motorcycle.
5.
•
6.
•
Disconnect:
spark plug caps
Remove:
air baffle plate (rear)
Refer to “ENGINE REMOVAL” in chapter 4.
7. Remove:
• cylinder head covers
NOTE:
Be sure you do not lose the oil plugs 1 on the
camshaft caps.
3-6
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
8. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.11 ~ 0.15 mm
Exhaust valve
0.26 ~ 0.30 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a with the
stationary pointer b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
@
@
1 TDC for No. 1 cylinder
2 TDC for No. 2 cylinder
c. Measure the valve clearance with a thickness gauge 3.
NOTE:
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
@
@
Valve clearance measuring sequence
Cylinder #1 → #3 → #2 → #4
È Front
d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
TDC, turn the crankshaft counterclockwise
as specified in the following table.
É Degrees that the crankshaft is turned counterclockwise
Ê Cylinder
Ë Combustion cycle
Cylinder #3
180°
Cylinder #2
430°
Cylinder #4
610°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-7
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
9. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Align the intake and exhaust valve lifter
slots with each other.
b. Install the tappet adjusting tool 1 between
the camshaft and the valve lifter.
Tappet adjusting tool
90890-04105
NOTE:
Make sure the tappet adjusting tool touches
only the valve lifter 2, not the valve pad 3.
@
@
c. Slowly turn the tappet adjusting tool so that
the valve pad can be removed.
d. Remove the valve pad from the valve lifter
with a small screwdriver and a pair of tweezers. Make a note of the position of each
valve pad and valve pad number so they
can be installed in the correct place.
e. Select the proper valve pad from the following table.
Valve pad thickness
Available valve pads
range
Nos.
2.00 ~
25 thicknesses in
200 ~ 320 3.20 mm 0.05 mm increments
NOTE:
• The thickness of each valve pad is marked in
hundredths of millimeters on the side that
touches the valve lifter (not the camshaft).
• Since valve pads of various sizes are originally installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
@
@
3-8
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
INTAKE
MEASURED
CLEARANCE
0.00 ~ 0.05
0.06 ~ 0.10
0.11 ~ 0.15
0.16 ~ 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
INSTALLED PAD NUMBER
200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310
200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315
STANDARD CLEARANCE
205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
255 260 265 270 275 280 285 290 295 300 305 310 315 320
260 265 270 275 280 285 290 295 300 305 310 315 320
265 270 275 280 285 290 295 300 305 310 315 320
270 275 280 285 290 295 300 305 310 315 320
VALVE CLEARANCE (cold):
275 280 285 290 295 300 305 310 315 320
0.11 ~ 0.15 mm
280 285 290 295 300 305 310 315 320
Example: Installed is pad 250
285 290 295 300 305 310 315 320
Measured clearance is 0.23 mm
290 295 300 305 310 315 320
Replace
pad 250 with pad 260
295 300 305 310 315 320
Pad
number:
(example)
300 305 310 315 320
305 310 315 320
Pad No. 250 = 2.50 mm
310 315 320
Pad No. 260 = 2.60 mm
315 320
Always install pad with number down.
320
EXHAUST
MEASURED
CLEARANCE
0.00 ~ 0.05
0.06 ~ 0.10
0.11 ~ 0.15
0.16 ~ 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
1.41 ~ 1.45
1.46 ~ 1.50
200 205 210 215 220 225
200
200 205
200 205 210
200 205 210 215
200 205 210 215 220
230
205
210
215
220
225
235
210
215
220
225
230
240
215
220
225
230
235
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
INSTALLED PAD NUMBER
245 250 255 260 265 270 275 280
220 225 230 235 240 245 250 255
225 230 235 240 245 250 255 260
230 235 240 245 250 255 260 265
235 240 245 250 255 260 265 270
240 245 250 255 260 265 270 275
STANDARD CLEARANCE
250 255 260 265 270 275 280 285
255 260 265 270 275 280 285 290
260 265 270 275 280 285 290 295
265 270 275 280 285 290 295 300
270 275 280 285 290 295 300 305
275 280 285 290 295 300 305 310
280 285 290 295 300 305 310 315
285 290 295 300 305 310 315 320
290 295 300 305 310 315 320
295 300 305 310 315 320
300 305 310 315 320
305 310 315 320
310 315 320
315 320
VALVE
320
0.26
285
260
265
270
275
280
290
265
270
275
280
285
295
270
275
280
285
290
300
275
280
285
290
295
305
280
285
290
295
300
310
285
290
295
300
305
315
290
295
300
305
310
290
295
300
305
310
315
320
295
300
305
310
315
320
300
305
310
315
320
305 310 315 320
310 315 320
315 320
320
320
295
300
305
310
315
CLEARANCE (cold):
~ 0.30 mm
Example: Installed is pad 250
Measured clearance is 0.32 mm
Replace pad 250 with pad 255
Pad number: (example)
Pad No. 250 = 2.50 mm
Pad No. 255 = 2.55 mm
Always install pad with number down.
3-9
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
f. Round off the original valve pad number
according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 248 (thickness =
2.48 mm)
Rounded value = 250
g. Locate the rounded number of the original
valve pad and the measured valve clearance in the valve pad selection table. The
point where the column and row intersect is
the new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be
repeated if the measurement is still incorrect.
@
@
h. Install the new valve pad with the numbered
side facing down.
i. Remove the tappet adjusting tool.
j. Measure the valve clearance again.
k. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10.Install:
• all removed parts
NOTE:
For installation, reverse the removal procedure. Note the following points.
@
@
11.Install:
• cylinder head covers
T.
R.
R.
3 - 10
T.
• spark plugs
10 Nm (1.0 m · kg)
18 Nm (1.8 m · kg)
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
EAS00050
SYNCHRONIZING THE CARBURETORS
NOTE:
Prior to synchronizing the carburetors, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition
timing should be checked.
@
@
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
@
@
2.
•
•
•
Remove:
carburetor joint covers (left and right)
vacuum plugs (left and right)
vacuum hose
Refer to “CARBURETORS” in chapter 6.
3. Install:
• vacuum gauge attachment
(into the bolt holes)
• vacuum gauge 1
(onto the vacuum gauge attachments)
• engine tachometer 2
(onto the spark plug lead of cylinder #1)
Vacuum gauge
90890-03094
Engine tachometer
90890-03113
4. Start the engine and let it warm up for several minutes.
5. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
950 ~ 1,050 r/min
3 - 11
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
6. Adjust:
• carburetor synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Synchronize carburetor #1 to carburetor #2
by turning the synchronizing screw 1 in
either direction until both gauges read the
same.
NOTE:
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
@
@
b. Synchronize carburetor #4 to carburetor #3
by turning the synchronizing screw 2 in
either direction until both gauges read the
same.
c. Synchronize carburetor #2 to carburetor #3
by turning the synchronizing screw 3 in
either direction until both gauges read the
same.
Vacuum pressure at engine idling
speed
26.7 kPa (200 mm Hg)
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa
(10 mm Hg).
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Measure:
• engine idling speed
Out of specification → Adjust.
8. Stop the engine and remove the measuring
equipment.
9. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
10.Install:
• vacuum hose
• vacuum plugs (left and right)
• carburetor joint covers (left and right)
Refer to “CARBURETORS” in chapter 6.
3 - 12
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
EAS00053
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter element should be clean,
and the engine should have adequate compression.
@
@
1. Start the engine and let it warm up for several minutes.
2. Attach:
• engine tachometer
(onto the spark plug lead of cylinder #1)
Engine tachometer
90890-03113
3. Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
950 ~ 1,050 r/min
4. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the throttle stop screw 1 in direction
a or b until the specified engine idling
speed is obtained.
Direction a
Engine idling speed is
increased.
Direction b
Engine idling speed is
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
3 - 13
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
EAS00057
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed and carburetor synchronization should be adjusted properly.
@
@
1. Check:
• throttle cable free play a
Out of specification → Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
2. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Carburetor side
a. Loosen the locknut 1.
b. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Throttle cable free play
is increased.
Direction b
Throttle cable free play
is decreased.
c. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot
be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.
@
@
Handlebar side
a. Loosen the locknut 3.
b. Turn the adjusting nut 4 in direction c or
d until the specified throttle cable free play
is obtained.
3 - 14
Direction c
Throttle cable free play
is increased.
Direction d
Throttle cable free play
is decreased.
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
CHK
ADJ
c. Tighten the locknut.
WARNING
@
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Disconnect:
• spark plug cap
2. Remove:
• spark plug
CAUTION:
@
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to prevent it
from falling into the cylinders.
@
3. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
DPR8EA-9 (NGK)
X24EPR-U9 (DENSO)
4. Check:
• electrodes 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• spark plug gap a
(with a wire gauge)
Out of specification → Regap.
Spark plug gap
0.8 ~ 0.9 mm
3 - 15
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
T.
R.
7. Install:
• spark plug
CHK
ADJ
18 Nm (1.8 m · kg)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
@
@
8. Connect:
• spark plug cap
EAS00064
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system. Make sure all connections are tight and
free of corrosion.
@
@
1. Remove:
• timing plug 1
2. Attach:
• timing light 1
• engine tachometer 2
(onto the spark plug lead of cylinder #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several minutes, and then let it run at the specified
engine idling speed.
Engine idling speed
950 ~ 1,050 r/min
3 - 16
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
b. Check that the stationary pointer a is within
the firing range b on the generator rotor.
Incorrect firing range → Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• timing plug
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
@
@
1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
CAUTION:
@
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
@
5. Install:
• compression gauge 1
Compression gauge
90890-03081
6. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
3 - 17
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
Compression pressure (at sea
level)
Minimum
1,200 kPa (12 kg/cm2, 12 bar)
Standard
1,400 kPa (14 kg/cm2, 14 bar)
Maximum
1,600 kPa (16 kg/cm2, 16 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
@
To prevent sparking, ground all spark plug
leads before cranking the engine.
@
NOTE:
The difference in compression pressure
between cylinders should not exceed 100 kPa
(1 kg/cm2, 1 bar).
@
@
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than without oil
Piston wear or
damage → Repair.
Same as without oil
Piston ring(s),
valves, cylinder
head gasket or piston possibly defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
3 - 18
Install:
spark plug
Connect:
spark plug cap
T.
7.
•
8.
•
18 Nm (1.8 m · kg)
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
@
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Check:
• engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
Recommended oil
Refer to the chart for the engine
oil grade which is best suited for
certain atmospheric temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
CAUTION:
@
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CONSERVING II” d or higher.
• Do not allow foreign materials to enter the
crankcase.
@
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
@
@
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
@
@
3 - 19
CHK
ADJ
CHANGING THE ENGINE OIL
EAS00074
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the gasket)
4. Drain:
• engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be
replaced, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge 1 with an oil
filter wrench 2.
Oil filter wrench
90890-01426
b. Lubricate the O-ring 3 of the new oil filter
cartridge with a thin coat of engine oil.
CAUTION:
@
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
@
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
Oil filter cartridge
17 Nm (1.7 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Check:
• engine oil drain bolt gasket
Damage → Replace.
7. Install:
• engine oil drain bolt
T.
R.
3 - 20
43 Nm (4.3 m · kg)
CHANGING THE ENGINE OIL/
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
8. Fill:
• crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
4.0 L
Without oil filter cartridge
replacement
3.2 L
With oil filter cartridge replacement
3.4 L
9. Install:
• engine oil filler cap
10.Start the engine, warm it up for several minutes, and then turn it off.
11.Check:
• engine
(for engine oil leaks)
12.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
• engine oil level
Below the minimum level mark → Add the
recommended engine oil to the proper level.
2. Start the engine, warm it up for several minutes, and then turn it off.
CAUTION:
@
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
@
3 - 21
CHK
ADJ
MEASURING THE ENGINE OIL PRESSURE
3. Remove:
• main gallery bolt
WARNING
@
The engine, muffler and engine oil are
extremely hot.
@
4. Install:
• pressure gauge 1
• oil pressure adapter B 2
Pressure gauge
90890-03153
Oil pressure adapter B
90890-03124
5. Measure:
• engine oil pressure
(at the following conditions)
Engine oil pressure
25 kPa (0.25 kg/cm2, 0.25 bar)
Engine speed
Approx. 1,000 r/min
Engine oil temperature
60 ~ 70 °C
Out of specification → Adjust.
Engine oil pressure
Below specification
• Faulty oil pump
• Clogged oil filter
• Leaking oil passage
• Broken or damaged oil seal
Above specification
• Leaking oil passage
• Faulty oil filter
• Oil viscosity too
high
T.
R.
6. Install:
• main gallery bolt
3 - 22
Possible causes
12 Nm (1.2 m · kg)
CHECKING THE CLUTCH FLUID LEVEL
CHK
ADJ
EAS00083
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
@
@
2. Check:
• clutch fluid level
Below the minimum level mark 1 → Add
the recommended clutch fluid to the proper
level.
Recommended clutch fluid
Brake fluid DOT 4
WARNING
@
• Use only the designated clutch fluid.
Other clutch fluids may cause the rubber
seals to deteriorate, causing leakage and
poor clutch performance.
• Refill with the same type of clutch fluid
that is already in the system. Mixing
clutch fluids may result in a harmful
chemical reaction, leading to poor clutch
performance.
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor
lock.
@
CAUTION:
@
Clutch fluid may damage painted surfaces
or plastic parts. Therefore, always clean up
any spilt clutch fluid immediately.
@
NOTE:
In order to ensure a correct reading of the
clutch fluid level, make sure the top of the reservoir is horizontal.
@
@
3 - 23
BLEEDING THE HYDRAULIC CLUTCH SYSTEM
CHK
ADJ
EAS00085
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
WARNING
@
Bleed the hydraulic clutch system whenever:
• the system was disassembled,
• a clutch hose was loosened or removed,
• the clutch fluid level is very low,
• clutch operation is faulty.
@
NOTE:
• Be careful not to spill any clutch fluid or allow
the clutch fluid reservoir to overflow.
• When bleeding the hydraulic clutch system,
make sure there is always enough clutch
fluid before applying the clutch lever. Ignoring this precaution could allow air to enter the
hydraulic clutch system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the clutch fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
@
@
1. Bleed:
• hydraulic clutch system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Add the recommended clutch fluid to the
proper level.
b. Install the clutch fluid reservoir diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
d. Place the other end of the hose into a container.
e. Slowly squeeze the clutch lever several
times.
f. Fully squeeze the clutch lever without
releasing it.
g. Loosen the bleed screw. This will release
the tension and cause the clutch lever to
contact the handlebar grip.
h. Tighten the bleed screw and then release
the clutch lever.
3 - 24
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the clutch
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T.
Bleed screw
6 Nm (0.6 m • kg)
R.
k. Add the recommended clutch fluid to the
proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL”.
WARNING
@
After bleeding the hydraulic clutch system,
check the clutch operation.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• top cover
2. Remove:
• air filter case cover 1
• air filter element
3. Clean:
• air filter element
Apply compressed air to the outer surface
of the air filter element.
4. Check:
• air filter element
Damage → Replace.
5. Install:
• air filter element
• air filter case cover
CAUTION:
@
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheating.
3 - 25
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE CARBURETOR JOINTS/
CHECKING THE VACUUM HOSES
CHK
ADJ
NOTE:
When installing the air filter element into the air
filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.
@
@
6. Install:
• top cover
EAS00095
CHECKING THE CARBURETOR JOINTS
The following procedure applies to all of the
carburetor joints and intake manifolds.
1. Remove:
• carburetor joint covers
2. Check:
• carburetor joint 1
Cracks/damage → Replace.
Refer to “CARBURETORS” in chapter 6.
3. Install:
• carburetor joint covers
CHECKING THE VACUUM HOSES
The following procedure applies to all of the
fuel and vacuum hoses.
1. Remove:
• covers (left and right)
Refer to “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD”.
2. Check:
• vacuum hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• covers (left and right)
Refer to “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD”.
3 - 26
CHECKING THE FUEL HOSES AND FUEL FILTER/
CHECKING THE CRANKCASE BREATHER HOSE
CHK
ADJ
EAS00097
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of the
fuel hoses.
1. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
2. Check:
• fuel hose 1
Cracks/damage → Replace.
• fuel filter 2
Contaminants/damage → Replace.
NOTE:
• Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
• The arrow mark on the fuel filter must point
towards the fuel pump 3 as shown.
@
@
3. Install:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Check:
• crankcase breather hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
@
Make sure the crankcase breather hose is
routed correctly.
@@
3 - 27
CHECKING THE EXHAUST SYSTEM/
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00100
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes, mufflers and gaskets.
1. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
• gasket 3
Exhaust gas leaks → Replace.
2. Check:
• tightening torque
T.
R.
Exhaust pipe nut 4
20 Nm (2.0 m • kg)
Muffler bolt 5
25 Nm (2.5 m • kg)
Muffler and muffler bracket bolt 6
10 Nm (1.0 m • kg)
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
@
2. Remove:
• top cover
3. Check:
• coolant level
The coolant level should be between the
maximum level mark a and minimum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
CAUTION:
@
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available soft water may
be used.
@
3 - 28
CHECKING THE COOLANT LEVEL/CHECKING THE
COOLING SYSTEM/CHANGING THE COOLANT
CHK
ADJ
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
@
@
6. Install:
• top cover
EAS00104
CHECKING THE COOLING SYSTEM
1. Check:
• radiator 1
• radiator inlet hose 2
• radiator outlet hose 3
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 5.
2. Install:
• top cover
EAS00105
CHANGING THE COOLANT
1. Turn the coolant drain cock 1 to the “ON”
position 2.
2.
•
3.
•
4.
•
Disconnect:
coolant reservoir hose 1
Drain:
coolant (from the coolant reservoir)
Remove:
radiator cap 2
WARNING
@
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
3 - 29
CHK
ADJ
CHANGING THE COOLANT
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
@
The following procedure applies to all of the
coolant drain bolts and copper washers.
5. Remove:
• cover
• coolant drain plug (engine) 1
• coolant drain bolt (water pump) 2
6. Drain:
• coolant (from the engine and radiator)
7. Install:
• coolant drain plug (engine)
• cover
• coolant drain bolt (water pump)
T.
R.
43 Nm (4.3 m · kg)
8. Connect:
• coolant reservoir hose
9. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
3.05 L
Coolant reservoir capacity
0.3 L
From minimum to maximum
level mark
0.2 L
3 - 30
CHANGING THE COOLANT
CHK
ADJ
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
@
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
@
CAUTION:
@
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water
may be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
@
10.Turn the coolant drain cock 1 to the “OFF”
position 2.
11.Install:
• radiator cap
12.Fill:
• coolant reservoir
(with the recommended coolant to the maximum level mark a)
13.Install:
• coolant reservoir cap
14.Start the engine, warm it up for several minutes, and then stop it.
15.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
@
3 - 31
ADJUSTING THE FRONT BRAKE
CHK
ADJ
EAS00108
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
• brake lever free play a
Out of specification → Adjust.
Brake lever free play (at the end
of the brake lever)
2 ~ 5 mm
2. Adjust:
• brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction a or
b until the specified brake lever free play is
obtained.
Direction a
Brake lever free play is
increased.
Direction b
Brake lever free play is
decreased.
c. Tighten the locknut.
WARNING
@
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
@
CAUTION:
@
After adjusting the brake lever free play,
make sure there is no brake drag.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 32
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00110
ADJUSTING THE REAR BRAKE
1. Check:
• brake pedal position
(distance a from the top of the rider footrest to the top of the brake pedal)
Out of specification → Adjust.
Brake pedal position (below the
top of the rider footrest)
20 mm
2. Adjust:
• brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction a or
b until the specified brake pedal position is
obtained.
Direction a
Brake pedal is raised.
Direction b
Brake pedal is lowered.
WARNING
@
After adjusting the brake pedal position,
check that the end c of the adjusting bolt
is visible through the hole d.
@
c. Tighten the locknut 1 to specification.
Locknut
16 Nm (1.6 m • kg)
WARNING
@
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
@
CAUTION:
@
After adjusting the brake pedal position,
make sure there is no brake drag.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 33
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
È
@
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
É
È Front brake
É Rear brake
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
@
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
@
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
@
@
3 - 34
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
EAS00119
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REPLACING THE FRONT
BRAKE PADS” and “REPLACING THE
REAR BRAKE PADS” in chapter 7.
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal. The rear brake
light switch is properly adjusted when the
brake light comes on just before the braking
effect starts.
@
@
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper
time.
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 35
CHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00131
CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
• brake hose
Activate the brake several times.
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
EAS00134
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
@
Bleed the hydraulic brake system whenever:
• the system is disassembled,
• a brake hose is loosened, disconnected
or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
@
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
• 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 hose have disappeared.
@
@
3 - 36
BLEEDING THE HYDRAULIC BRAKE SYSTEM
È
CHK
ADJ
1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
É
È Front
É Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
@
@
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T.
Bleed screw
6 Nm (0.6 m • kg)
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
@
After bleeding the hydraulic brake system,
check the brake operation.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 37
ADJUSTING THE SHIFT PEDAL/
CHECKING THE FINAL DRIVE OIL LEVEL
CHK
ADJ
EAS00137
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined by the
installed shift rod length a.
@
@
1. Check:
• installed shift rod length a
Incorrect → Adjust.
Installed shift rod length
30 ~ 34 mm
2. Adjust:
• installed shift rod length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 1.
b. Turn the adjusting bolt 2 in direction b or
c to obtain the correct shift pedal position.
Direction b
Installed shift rod length
increases.
Direction c
Installed shift rod length
decreases.
c. Tighten both locknuts.
d. Make sure the installed shift rod length is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00144
CHECKING THE FINAL DRIVE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
@
@
3 - 38
CHECKING THE FINAL DRIVE OIL LEVEL/
CHANGING THE FINAL DRIVE OIL
2.
•
3.
•
CHK
ADJ
Remove:
final drive housing oil filler bolt 1
Check:
final drive oil level
The final drive oil level should be to the bottom brim 2 of the filler hole.
Below the top brim → Add the recommended final drive oil to the proper level.
Recommended oil
SAE 80 hypoid gear oil graded
“GL-4”
multi-purpose SAE 80W90 hypoid
gear oil
4. Install:
• final drive housing oil filler bolt
T.
R.
23 Nm (2.3 m · kg)
EAS00145
CHANGING THE FINAL DRIVE OIL
1. Place a container under the final drive
housing.
2. Remove:
• final drive housing oil filler bolt
• final drive housing oil drain bolt 1
Completely drain the final drive housing of
its oil.
3. Check:
• final drive housing oil drain bolt gasket
Damage → Replace.
4. Install:
• final drive housing oil drain bolt
T.
R.
23 Nm (2.3 m · kg)
5. Fill:
• final drive housing
(with the specified amount of the recommended final drive oil)
Quantity
0.2 L
Refer to “CHECKING THE FINAL DRIVE
OIL LEVEL”.
3 - 39
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00146
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
@
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• headlight body bracket bolt
• flasher light bracket
• handlebar holder assembly
4. Loosen:
• upper bracket pinch bolts 1
5. Remove:
• steering stem nut 2
• washer
• upper bracket 3
6. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer 1, the upper ring
nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring nut
wrench 5.
NOTE:
Set the torque wrench at a right angle to the
ring nut wrench.
@
@
Steering nut wrench
90890-01403
T.
R.
3 - 40
Lower ring nut (initial tightening
torque)
50 Nm (5.0 m • kg)
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
c. Loosen the lower ring nut completely, then
tighten it to specification.
WARNING
@
Do not overtighten the lower ring nut.
@
T.
R.
Lower ring nut (final tightening
torque)
3.0 Nm (0.3 m • kg)
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” and “HANDLEBAR” in chapter 7.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2, then
align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the
upper ring nut until their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure the lock washer tabs sit correctly in
the ring nut slots.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Install:
upper bracket
washer
steering stem nut
110 Nm (11.0 m · kg)
Tighten:
upper bracket pinch bolt
9.
•
•
•
Install:
handlebar holder assembly
flasher light bracket
headlight body bracket bolt
T.
7.
•
•
•
8.
•
R.
T.
R.
T.
R.
3 - 41
20 Nm (2.0 m · kg)
40 Nm (4.0 m · kg)
CHECKING THE FRONT FORK/
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 7.
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
@
• Always adjust both front fork legs evenly.
Uneven adjustment can result in poor
handling and loss of stability.
• Securely support the motorcycle so that
there is no danger of it falling over.
@
Spring preload
1. Place the motorcycle on a suitable stand so
that the front wheel is elevated.
NOTE:
When checking and adjusting the air pressure,
there should be no weight on the front end of
the motorcycle.
@
@
2. Remove:
• front fork air valve cap
3 - 42
ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE
REAR SHOCK ABSORBER ASSEMBLIES
CHK
ADJ
3. Regulate:
• air pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front fork leg air pressure with an
air pressure gauge 1.
Supplying air
Spring
preload
is
increased (suspension
is harder).
Releasing air
Spring
preload
is
decreased (suspension
is softer).
Air pressure
Standard
40 kPa (0.4 kg/cm2, 0.4 bar)
Maximum
100 kPa (1.0 kg/cm2, 1.0 bar)
WARNING
@
The difference in air pressure between the
left and right front fork legs should not
exceed 10 kPa (0.1 kg/cm2, 0.1 bar).
@
CAUTION:
@
Exceeding the maximum air pressure may
damage the oil seal.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• front fork air valve cap
EAS00161
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
WARNING
@
• Securely support the motorcycle so that
there is no danger of it falling over.
• Always adjust both rear shock absorber
assemblies evenly. Uneven adjustment
can result in poor handling and loss of
stability.
@
3 - 43
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLIES
CHK
ADJ
Spring preload
CAUTION:
@
Never go beyond the maximum or minimum adjustment positions.
@
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert a screwdriver into the hole 1 in the
spring seat.
b. Turn the spring seat 2 in direction a or b.
Direction a
Spring
preload
is
increased (suspension
is harder).
Direction b
Spring
preload
is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 1
Maximum: 5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rebound damping
CAUTION:
@
Never go beyond the maximum or minimum adjustment positions.
@
1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob 1 in direction a or
b.
Direction a
Rebound
damping
is
increased (suspension is
harder).
Direction b
Rebound
damping
is
decreased (suspension is
softer).
Adjusting positions
Minimum: 1
Standard: 1
Maximum: 4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 44
CHECKING THE TIRES
CHK
ADJ
EAS00164
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:
• tire pressure
Out of specification → Regulate.
WARNING
@
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
@
Basic weight
(with oil and
281 kg
a full fuel
tank)
Maximum
load*
209 kg
Cold tire
pressure
Front
Rear
225 kPa
225 kPa
Up to 90 kg
(2.25 kgf/cm2, (2.25 kgf/cm2,
load*
2.25 bar)
2.25 bar)
225 kPa
250 kPa
90 kg – maxi2
(2.25 kgf/cm , (2.5 kgf/cm2,
mum load*
2.25 bar)
2.5 bar)
High-speed
riding
225 kPa
250 kPa
2
(2.25 kgf/cm , (2.5 kgf/cm2,
2.25 bar)
2.5 bar)
* total of cargo, rider, passenger and accessories
WARNING
@
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
@
3 - 45
CHECKING THE TIRES
CHK
ADJ
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Sidewall
WARNING
@
È
É
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recommended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.
È Tire
É Wheel
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning handling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
@
3 - 46
CHECKING THE TIRES/
CHECKING THE WHEELS
CHK
ADJ
Front tire
Manufacturer
Model
Size
METZELER
ME33
110/90
V18 (61V)
Manufacturer
Model
Size
METZELER
ML2
150/90B15MC
(74V)
Rear tire
WARNING
@
• New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed
before any high-speed riding is done.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
nut 1 and locknut 2 to specification.
@
NOTE:
For tires with a direction of rotation mark 3:
• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 4 with the valve installation
point.
@
@
T.
R.
Tire air valve stem
Vlave stem nut
1.6 Nm (0.16 m • kg)
Valve stem locknut
1.6 Nm (0.16 m • kg)
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
• wheel
Damage/out-of-round → Replace.
WARNING
@
Never attempt to make any repairs to the
wheel.
@
3 - 47
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS
CHK
ADJ
NOTE:
After a tire or wheel has been changed or
replaced, always balance the wheel.
@
@
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the
cable sheaths and cables.
WARNING
@
Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement.
Replace
damaged
cable
sheaths and cables as soon as possible.
@
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
@
@
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium soap base grease
3 - 48
LUBRICATING THE SIDESTAND/
LUBRICATING THE CENTERSTAND/
LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium soap base grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Lithium soap base grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum disulfide grease
3 - 49
CHECKING THE BATTERY
CHK
ADJ
EAS00176
ELECTRICAL SYSTEM
CHECKING THE BATTERY
WARNING
@
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
@
1. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
@
First, disconnect the negative battery lead
1, and then the positive lead 2.
@
3. Remove:
• battery
3 - 50
CHECKING THE BATTERY
CHK
ADJ
4. Check:
• electrolyte level
The electrolyte level should be between the
minimum level mark 1 and the maximum
level mark 2.
Below the minimum level mark → Add distilled water to the proper level.
CAUTION:
@
Add only distilled water. Tap water contains minerals which are harmful to the battery.
@
5. Check:
• specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20 °C
6. Charge:
• battery
Battery charging amperage and
time
1.4 amps/10 hrs
WARNING
@
Do not quick charge a battery.
@
CAUTION:
@
• Loosen the battery sealing caps.
• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charging has to be done with the battery
mounted on the motorcycle, disconnect
the negative lead from the battery terminal.)
3 - 51
CHECKING THE BATTERY
CHK
ADJ
• To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
@
NOTE:
Replace the battery whenever:
• battery voltage does not rise to specification
or bubbles fail to rise during charging,
• sulphation of one or more battery cells
occurs (as indicated by the battery plates
turning white or material accumulating in the
bottom of the battery cell),
• specific gravity readings after a long, slow
charge indicate that one battery cell’s charge
is lower than the rest,
• warpage or buckling of the battery plates or
insulators is evident.
@
@
7. Check:
• battery breather hose and battery vent
Obstruction → Clean.
Damage → Replace.
8. Connect:
• battery breather hose 1
9. Install:
• battery
10.Connect:
• battery breather hose 1
3 - 52
CHECKING THE BATTERY
CHK
ADJ
CAUTION:
@
• When checking the battery, make sure the
battery breather hose is properly installed
and routed correctly. If the battery
breather hose is positioned so as to allow
electrolyte or hydrogen gas from the battery to contact the frame, the motorcycle
and its finish may be damaged.
• Make sure the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.
@
11.Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
12.Connect:
• battery leads
(to the battery terminals)
CAUTION:
@
First, connect the positive battery lead 1,
and then the negative lead 2.
@
13.Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
14.Install:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
3 - 53
CHECKING THE FUSES
CHK
ADJ
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
@
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
@
1. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
2. Check:
• continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
@
@
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
3 - 54
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULB
CHK
ADJ
Items
Amperage
rating
Q’ty
Main fuse
30 A
1
Headlight fuse
15 A
1
Signaling system
fuse
10 A
1
Ignition fuse
10 A
1
Radiator fan motor
fuse
10 A
1
Reserve fuse
30 A
1
Reserve fuse
15 A
1
Reserve fuse
10 A
1
WARNING
@
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
• screw 1
• headlight lens unit 2
3 - 55
REPLACING THE HEADLIGHT BULB
CHK
ADJ
2.
•
3.
•
Disconnect:
headlight coupler 1
Remove:
headlight bulb holder cover 2
4.
•
5.
•
Detach:
headlight bulb holder 1
Remove:
headlight bulb 2
WARNING
@
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
@
6. Install:
• headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
@
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
@
7. Attach:
• headlight bulb holder
8. Install:
• headlight bulb holder cover
9. Connect:
• headlight coupler
10.Install:
• headlight lens unit
• screws
3 - 56
ADJUSTING THE HEADLIGHT BEAM
CHK
ADJ
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Headlight
raised.
beam
is
Direction b
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Headlight beam moves
to the right.
Direction b
Headlight beam moves
to the left.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 57
ENG
4
ENG
CHAPTER 4
ENGINE
ENGINE REMOVAL .......................................................................................4-1
EXHAUST PIPE, MUFFLER AND AIR BAFFLE PLATES .......................4-1
BRAKE PEDAL, FOOTLEST (RIGHT), MASTER CYLINDER
AND GROUND LEAD ..............................................................................4-2
LEADS, CABLES AND HOSES ............................................................... 4-3
ENGINE MOUNTING BOLTS ..................................................................4-4
INSTALLING THE ENGINE ...................................................................... 4-6
CAMSHAFT .................................................................................................... 4-7
CYLINDER HEAD COVERS .................................................................... 4-7
CAMSHAFTS ........................................................................................... 4-9
REMOVING THE CAMSHAFTS ............................................................. 4-10
CHECKING THE CAMSHAFTS ............................................................. 4-11
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES ..............................................................4-13
CHECKING THE TIMING CHAIN TENSIONER ..................................... 4-13
INSTALLING THE CAMSHAFTS ........................................................... 4-14
CYLINDER HEADS ......................................................................................4-21
REMOVING THE CYLINDER HEADS ...................................................4-22
CHECKING THE CYLINDER HEADS ....................................................4-22
INSTALLING THE CYLINDER HEAD ....................................................4-23
VALVES AND VALVE SPRINGS .................................................................4-24
REMOVING THE VALVES ..................................................................... 4-25
CHECKING THE VALVES AND VALVE GUIDES .................................4-26
CHECKING THE VALVE SEATS ........................................................... 4-28
CHECKING THE VALVE SPRINGS .......................................................4-30
CHECKING THE VALVE LIFTERS ........................................................ 4-31
INSTALLING THE VALVES ................................................................... 4-31
CLUTCH ....................................................................................................... 4-33
CRANKCASE COVER (RIGHT SIDE) ...................................................4-33
CLUTCH ASSEMBLY ............................................................................. 4-34
REMOVING THE CLUTCH .................................................................... 4-36
CHECKING THE FRICTION PLATES ....................................................4-36
CHECKING THE CLUTCH PLATES ......................................................4-37
CHECKING THE CLUTCH SPRING PLATE...........................................4-37
CHECKING THE CLUTCH HOUSING ...................................................4-38
CHECKING THE CLUTCH BOSS .......................................................... 4-38
CHECKING THE PRESSURE PLATE ...................................................4-38
CHECKING THE CLUTCH PUSH RODS .............................................. 4-39
CHECKING THE PRIMARY DRIVE .......................................................4-39
INSTALLING THE CLUTCH ................................................................... 4-39
ENG
SHIFT SHAFT ...............................................................................................4-42
GENERATOR ROTOR COVER ............................................................. 4-42
SHIFT SHAFT AND STOPPER LEVER ................................................. 4-43
CHECKING THE SHIFT SHAFT ............................................................ 4-44
CHECKING THE STOPPER LEVER .....................................................4-44
INSTALLING THE SHIFT SHAFT .......................................................... 4-44
GENERATOR ...............................................................................................4-46
STATOR COIL ASSEMBLY ................................................................... 4-46
GENERATOR ......................................................................................... 4-48
REMOVING THE GENERATOR ............................................................ 4-49
CHECKING THE STARTER CLUTCH ...................................................4-50
INSTALLING THE GENERATOR ........................................................... 4-51
OIL PAN AND OIL PUMP ............................................................................4-52
OIL PUMP ..............................................................................................4-54
REMOVING THE OIL PAN ..................................................................... 4-56
CHECKING THE OIL PUMP .................................................................. 4-56
CHECKING THE RELIEF VALVE .......................................................... 4-57
CHECKING THE OIL DELIVERY PIPE .................................................. 4-57
CHECKING THE OIL STRAINER .......................................................... 4-57
ASSEMBLING THE OIL PUMP ..............................................................4-58
INSTALLING THE OIL STRAINER ........................................................ 4-59
INSTALLING THE OIL PAN ................................................................... 4-59
CRANKCASE ...............................................................................................4-60
SEPARATING THE CRANKCASE ......................................................... 4-63
ASSEMBLING THE CRANKCASE ......................................................... 4-64
CRANKSHAFT ............................................................................................. 4-67
REMOVING THE CRANKSHAFT ASSEMBLY ...................................... 4-68
CHECKING THE CRANKSHAFT ........................................................... 4-68
CHECKING THE BALANCER SHAFT ...................................................4-71
INSTALLING THE CRANKSHAFT ......................................................... 4-73
INSTALLING THE BALANCER SHAFT .................................................. 4-74
CONNECTING RODS AND PISTONS ......................................................... 4-75
REMOVING THE CONNECTING RODS AND PISTONS ......................4-76
CHECKING THE CYLINDERS AND PISTONS ..................................... 4-77
CHECKING THE PISTON RINGS .......................................................... 4-78
CHECKING THE PISTON PINS ............................................................. 4-79
INSTALLING THE PISTONS AND CYLINDERS ................................... 4-82
TRANSMISSION ........................................................................................... 4-85
CHECKING THE SHIFT FORKS ............................................................ 4-88
CHECKING THE SHIFT DRUM ASSEMBLY .........................................4-88
CHECKING THE TRANSMISSION ........................................................ 4-89
INSTALLING THE TRANSMISSION ......................................................4-90
ENG
MIDDLE GEAR ............................................................................................. 4-92
DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY .............. 4-94
DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY ............4-94
CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY ......................... 4-95
CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY ......................4-96
ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....................4-96
ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY .................. 4-97
INSTALLING THE MIDDLE GEAR ......................................................... 4-99
ADJUSTING THE MIDDLE GEAR BACKLASH ................................... 4-100
ALIGNING THE MIDDLE GEAR .......................................................... 4-103
ENG
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
EXHAUST PIPES, MUFFLER AND AIR BAFFLE PLATES
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Removing the exhaust pipes, mufRemove the parts in the order listed.
fler and air baffle plates
Carburetors
Refer to “REMOVING THE CARBURETOR” in chapter 6.
Radiator
Refer to “REMOVING THE RADIATOR”
in chapter 5.
Middle gear case cover
Refer to “SHIFT SHAFT”.
Air baffle plate (front)
1
Plate cover
2
Air baffle plate (rear)
1
Front exhaust pipes
2
Muffler
1
Rear exhaust pipes
2
Gaskets
11
For installation, reverse the removal procedure.
4-1
ENGINE REMOVAL
ENG
BRAKE PEDAL, FOOTREST (RIGHT), MASTER CYLINDER AND GROUND LEAD
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Removing the brake pedal, footrest
Remove the parts in the order listed.
(right), master cylinder and ground
lead
Brake pedal
1
Footrest (right)
1
Rear brake hose
1
Disconnect.
Brake fluid reservoir hose
1
Disconnect.
Brake master cylinder
1
Rear brake switch
1
Ground lead
1
For installation, reverse the removal procedure.
4-2
ENGINE REMOVAL
ENG
LEADS, CABLES AND HOSES
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Remarks
Removing the leads, cables and
Remove the parts in the order listed.
hoses
Spark plug leads
4
Disconnect.
Vacuum hose
1
Disconnect.
Horn lead
2
Disconnect.
Starter lead (starter motor)
1
Disconnect.
Plastic locking tie
1
Plastic band
2
Starter lead (starter relay)
1
Disconnect.
Pickup coil coupler
1
Disconnect.
Neutral switch lead
1
Disconnect.
Oil level switch lead
1
Disconnect.
Rectifier/regulator coupler
1
Disconnect.
For installation, reverse the removal procedure.
4-3
ENGINE REMOVAL
ENG
ENGINE MOUNTING BOLTS
Order
Job/Part
Removing the engine
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
1
2
3
4
5
6
Bolts (front-lower)
Bolts (engine bracket)
Engine bracket
Nuts (front-upper)
Bolts (rear)
Bolts (down tube)
2
4
1
2
2
4
4-4
ENGINE REMOVAL
Order
7
8
9
10
Job/Part
Down tube (right side)
Bolts (engine stay)
Engine stay
Engine assembly
ENG
Q’ty
Remarks
1
2
1
1 NOTE:
Remove the engine assembly from the
right side of the motorcycle.
For installation, reverse the removal procedure.
4-5
ENG
ENGINE REMOVAL
EAS00192
INSTALLING THE ENGINE
1. Install:
• engine stay 1
• bolt (engine stay) 2
T.
R.
R.
T.
R.
down tube (right) 3
bolt (down tube) 4
bolt (rear) 5
nut (front-upper) 6
T.
•
•
•
•
16 Nm (1.6 m · kg)
45 Nm (4.5 m · kg)
70 Nm (7.0 m · kg)
T.
R.
42 Nm (4.2 m · kg)
• engine bracket 7
• bolt (engine bracket) 8
T.
R.
T.
R.
• bolt (front-lower) 9
16 Nm (1.6 m · kg)
42 Nm (4.2 m · kg)
NOTE:
Do not fully tighten the bolts.
@
@
T.
R.
2. Install:
• shift pedal link 1
10 Nm (1.0 m · kg)
NOTE:
• Align the punch mark a in the shift shaft with
the slot b in the shift pedal link.
• Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.
@
@
4-6
CAMSHAFTS
ENG
CAMSHAFTS
CYLINDER HEAD COVERS
Order
Job/Part
Removing the cylinder head covers
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Top cover and covers
Air filter case and electrical components board
Carburetors
Coolant
4-7
Refer to “TOP COVER AND COVERS” in
chapter 3.
Refer to “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD” in
chapter 3.
Refer to “REMOVING THE CARBURETOR” in chapter 6.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
CAMSHAFTS
Order
1
2
3
4
5
6
Job/Part
Spark plug cap
Coolant hoses (to cylinder head)
Spark plugs
Cylinder head covers bolts
Cylinder head covers
Cylinder head covers gaskets
ENG
Q’ty
Remarks
4
Disconnect.
2
Disconnect.
4
16
2
2
For installation, reverse the removal procedure.
4-8
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the camshafts
Cylinder head covers
Crankcase cover plate
Timing plug
Tensioners cap bolts
Timing chain tensioners
Gaskets
Timing chain guides
Camshaft sprockets bolts
Camshaft caps
Camshafts
Camshaft sprockets
Q’ty
1
1
2
2
2
4
8
16
4
4
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD COVERS”.
Refer to “Rear cylinder”.
For installation, reverse the removal procedure.
4-9
CAMSHAFTS
ENG
EAS00199
REMOVING THE CAMSHAFTS
1. Remove:
• timing mark accessing screw 1
• crankshaft end cover 2
2. Align:
• “T1” mark on the flywheel
(with the stationary pointer on the crankcase cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T1” mark a with the
stationary pointer b.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• timing chain guide (top side)
4. Loosen:
• camshaft sprocket bolts 1
5.
•
6.
•
•
4 - 10
Loosen:
cap bolt 1
Remove:
timing chain tensioner 2
gasket
CAMSHAFTS
7.
•
•
•
ENG
Remove:
timing chain guide (exhaust side)
camshaft caps 1
dowel pins
NOTE:
For reference during installation, put identification marks on each camshaft cap.
@
@
CAUTION:
@
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
@
8. Remove:
• camshafts
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 1.
@
@
9. Remove:
• camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Camshaft lobe dimension limit
Intake camshaft
a 36.15 mm
b 27.92 mm
Exhaust camshaft
a 36.15 mm
b 27.92 mm
4 - 11
CAMSHAFTS
ENG
3. Measure:
• camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.03 mm
4. Measure:
• camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.020 ~ 0.054 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of Plastigauge® 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the
inner caps out.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap clearance with the Plastigauge®.
@
@
T.
Camshaft cap bolt
10 Nm (1.0 m • kg)
R.
d. Remove the camshaft caps and then measure the width of the Plastigauge® 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• camshaft journal diameter a
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
24.967 ~ 24.980 mm
4 - 12
CAMSHAFTS
ENG
EAS00208
CHECKING THE TIMING CHAIN,
CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a → Replace the
camshaft sprockets and the timing chain as
a set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
• timing chain guide (exhaust side)
• timing chain guide (top side)
Damage/wear → Replace the defective
part(s).
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage → Replace.
• one-way cam operation
Rough movement → Replace the timing
chain tensioner housing.
2. Check:
• cap bolt
• copper washer
• spring
• one-way cam
• gasket
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
4 - 13
CAMSHAFTS
ENG
EAS00218
INSTALLING THE CAMSHAFTS
1. Align:
• “T1” marks on the flywheel
(with the stationary pointer on the crankcase cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T1” marks 1 on the
generator rotor with the stationary pointer
2.
CAUTION:
@
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
@
NOTE:
First, install the rear cylinder camshafts, camshaft sprockets, timing chain, and timing chain
tensioner. Then, install the front cylinder camshafts and related parts.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rear cylinder
1. Install:
• intake camshaft
• exhaust camshaft
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
@
Do not turn the crankshaft when installing
the camshafts to avoid damage or improper
valve timing.
@
a. Install the camshaft sprockets onto the
camshafts.
Refer to the camshaft sprocket installation
steps below.
NOTE:
Make sure the “REAR” marks 3 on the camshaft sprockets face away from the “IN” 4 and
“EX” marks 5 on the camshafts.
@
@
4 - 14
CAMSHAFTS
ENG
b. First, install the exhaust camshaft, and then
the intake camshaft.
NOTE:
• Be sure to install the camshafts in the correct
place as shown.
“IN” mark = intake camshaft
“EX” mark = exhaust camshaft
• Make sure the timing marks 6 (o: small
hole) in the camshaft face up.
• Be sure to keep the timing chain as tight as
possible on the exhaust side.
• Remove the wire from the timing chain.
@
@
CAUTION:
@
Do not turn the camshaft, as damage could
occur to the pistons and valves.
@
c. Install intake and exhaust camshaft caps
#1, #3, and finally #4.
NOTE:
At this point, do not install intake camshaft cap
#2, exhaust camshaft cap #2, and the timing
chain guide (top side).
@
@
d. Align the mark a on the camshaft with the
mark b camshaft cap.
NOTE:
Cylinder #1 is at TDC when the small hole in
the camshaft is aligned with the camshaft cap
mark.
@
@
e. Lubricate the camshaft cap bolts with
engine oil.
f. Tighten the camshaft cap bolts.
NOTE:
• The camshaft caps are numbered from right
to left.
• First, tighten intake and exhaust camshaft
cap bolts #3, #1, and finally #4.
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the
inner caps out.
@
@
4 - 15
CAMSHAFTS
ENG
CAUTION:
@
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
@
T.
Camshaft cap bolt
10 Nm (1.0 m • kg)
R.
g. Lubricate the camshaft bearing surfaces,
camshaft lobes, and camshaft journals with
engine oil.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• intake camshaft sprocket
• exhaust camshaft sprocket
(onto the camshafts)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
@
Do not turn the crankshaft when installing
the camshaft sprockets to avoid damage or
improper valve.
@
a. Install the timing chain onto the intake camshaft sprocket.
b. Install the intake camshaft sprocket with the
“REAR” mark facing out, and then finger
tighten the camshaft sprocket bolts.
NOTE:
Align the “IN” mark 1 hole in the intake camshaft sprocket with the thread hole in the camshaft.
@
@
c. Turn the intake camshaft so that the camshaft timing mark 2 (o: small hole) is
aligned with the camshaft cap mark 3.
d. To remove the timing chain slack, force the
intake camshaft counterclockwise.
e. Install the timing chain onto the exhaust
camshaft sprocket.
f. Install the exhaust camshaft sprocket with
the “REAR” mark facing out, and then finger
tighten the camshaft sprocket bolts.
NOTE:
Align the “EX” mark hole in the exhaust camshaft sprocket with the thread hole in the camshaft.
@
@
4 - 16
CAMSHAFTS
ENG
g. Turn the exhaust camshaft so that the mark
(o: small hole) on the camshaft is aligned
with the mark on the camshaft cap.
h. To remove the timing chain slack, force the
exhaust camshaft clockwise.
i. Insert your finger into the timing chain tensioner hole and push the timing chain guide
(intake side) in.
j. When pushing the timing chain guide
(intake side), make sure the camshaft cap
marks and camshaft timing marks stay
aligned.
k. If the camshaft cap marks and camshaft
timing marks are not aligned, change the
meshing position of the camshaft sprockets
and timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cap bolt 1, washer 2 and
spring 3.
b. Release the timing chain tensioner one-way
cam 4.
c. Install the timing chain tensioner and gasket
5 onto the cylinder block.
WARNING
@
Always use a new gasket.
@
T.
Timing chain tensioner bolt
12 Nm (1.2 m • kg)
R.
d. Install the spring 3, washer 2, and cap
bolt 1.
T.
Cap bolt
20 Nm (2.0 m • kg)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Turn:
• crankshaft
(several turns counterclockwise)
4 - 17
ENG
CAMSHAFTS
5. Check:
• TDC mark a
Make sure the TDC mark on the generator
rotor is aligned with the stationary pointer
b.
• camshaft timing punch mark c (o: small
hole)
Make sure the punch marks in the camshafts are aligned with the marks d on the
camshaft caps.
Out of alignment → Adjust.
Refer to the camshaft installation steps
above.
6. Tighten:
• camshaft sprocket bolts
T.
R.
24 Nm (2.4 m · kg)
CAUTION:
@
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
@
7.
•
•
•
Install:
camshaft caps “I-2” 1
camshaft caps “E-2” 2
timing chain guide (top side) 3
T.
R.
•
8.
•
•
•
•
10 Nm (1.0 m · kg)
timing chain guide (exhaust side) 4
Lubricate:
timing chain
camshaft sprockets
camshafts
valve pads
Recommended lubricant
Engine oil
Front cylinder
NOTE:
When installing the front cylinder camshafts,
repeat the rear cylinder camshaft installation
procedure. However, note the following points.
@
@
4 - 18
CAMSHAFTS
ENG
1. Install:
• exhaust camshaft
• intake camshaft
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. From the “T1” marks, turn the crankshaft
counterclockwise 430° (i.e., 360° plus an
additional 70°).
b. When piston #2 is at TDC on the compression stroke, align the “T2” mark a with the
stationary pointer b.
c. Install the camshaft sprockets onto the
camshafts.
Refer to the camshaft sprocket installation
steps below.
NOTE:
Make sure the “FRONT” marks 1 on the camshaft sprockets face away from the “IN” 2 and
“EX” marks 3 on the camshafts.
@
@
d. Turn the camshafts by hand so that the
camshaft timing marks (o: big hole) face up.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• intake camshaft sprocket
• exhaust camshaft sprocket
(onto the camshafts)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Align the “T2” mark on the generator rotor
with the stationary pointer.
b. Install the camshaft sprocket with the
“FRONT” mark facing out, and then finger
tighten the camshaft sprocket bolts.
c. Turn the intake and exhaust camshafts and
align the camshaft timing marks (o: big
hole) with the camshaft cap marks.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE
CLEARANCE” in chapter 3.
4 - 19
VALVE
ENG
CAMSHAFTS
4. Install:
• timing mark accessing screw 1
• crankshaft end cover 2
T.
R.
4 - 20
7 Nm (0.7 m · kg)
CYLINDER HEADS
ENG
CYLINDER HEADS
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the cylinder head
Engine assembly
Cylinder head covers
Camshafts
Intake manifold
Lock pins
Water jacket joints
Oil delivery pipes
Cylinder heads
Timing chain dampers
Gaskets (cylinder heads)
Dowel pins
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD COVERS”.
Refer to “CAMSHAFTS”.
2
2
2
2
2
2
2
4
For installation, reverse the removal procedure.
4 - 21
CYLINDER HEADS
ENG
EAS00223
REMOVING THE CYLINDER HEADS
1. Remove:
• cylinder head nuts
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After
all of the nuts are fully loosened, remove
them.
@
@
EAS00230
CHECKING THE CYLINDER HEADS
The following procedure applies to all of the
cylinder heads.
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
@
@
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket 1
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
4 - 22
ENG
CYLINDER HEADS
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00233
INSTALLING THE CYLINDER HEAD
1. Install:
• timing chain dampers 1
2. Install:
• dowel pins 2
• gasket 3 New
NOTE:
The “HEAD” mark a on the gasket must face
up.
@
@
3. Install:
• cylinder head 1
NOTE:
Pass the timing chain 2 through the timing
chain cavity.
@
@
T.
R.
4. Tighten:
• cylinder head nuts
43 Nm (4.3 m · kg)
NOTE:
• Lubricate the cylinder head nuts with engine
oil.
• Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
@
@
5. Install:
• exhaust camshaft
• intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
4 - 23
VALVES AND VALVE SPRINGS
ENG
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the valves and valve
springs
Engine assembly
Camshafts
Cylinder heads
Valve pads
Valve lifters
Valve cotters
Spring retainer
Outer valve springs
Inner valve springs
Valves (intake/exhaust)
Spring seat
Oil seal
Valve guide
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CAMSHAFTS”.
Refer to “CYLINDER HEADS”.
16
16
32
16
16
16
8/8
16
16
16
For installation, reverse the removal procedure.
4 - 24
VALVES AND VALVE SPRINGS
ENG
EAS00238
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
@
@
1. Remove:
• valve pad 1
• valve lifter 2
NOTE:
Make a note of the position of each valve lifter
2 and valve pad 1 so that they can be reinstalled in their original place.
@
@
2. Check:
• valve (for leakage)
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal. There
should be no leakage at the valve seat 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3.
@
@
Valve spring compressor
90890-04019
Attachment
90890-04114
4 - 25
VALVES AND VALVE SPRINGS
4.
•
•
•
•
•
•
ENG
Remove:
spring retainer 1
inner valve springs 2
outer valve springs 3
valve 4
spring seat 5
oil seal 6
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
@
@
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clearance
Intake
0.010 ~ 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 ~ 0.052 mm
<Limit>: 0.1 mm
4 - 26
VALVES AND VALVE SPRINGS
ENG
2. Replace:
• valve guide
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C in an oven.
@
@
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valveguide clearance.
NOTE:
After replacing the valve guide, reface the
valve seat.
@
@
Valve guide remover (5.5 mm)
90890-01122
Valve guide installer (5.5 mm)
90890-04015
Valve guide reamer (5.5 mm)
90890-01196
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness
1.1 ~ 1.5 mm
<Limit>: 0.7 mm
4 - 27
VALVES AND VALVE SPRINGS
ENG
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
@
@
Valve stem runout
0.01 mm
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width
Intake
0.9 ~ 1.1 mm
Exhaust
0.9 ~ 1.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
4 - 28
VALVES AND VALVE SPRINGS
ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
@
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
@
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
@
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
@
@
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
4 - 29
VALVES AND VALVE SPRINGS
ENG
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width c again. If
the valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• valve spring free length a
Out of specification → Replace the valve
spring.
Valve spring free length limit
(intake and exhaust)
Inner valve spring
37.45 mm
Outer valve spring
38.90 mm
2. Measure:
• compressed valve spring force
Out of specification → Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
Intake and exhaust inner valve
spring
6.29 ~ 7.39 kg at 31.8 mm
Intake and exhaust outer valve
spring
13.3 ~ 15.7 kg at 33.8 mm
4 - 30
VALVES AND VALVE SPRINGS
ENG
3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
Spring tilt limit
Intake and exhaust inner valve
spring
1.7 mm
Intake and exhaust outer valve
spring
1.8 mm
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
• valve lifter
Damage/scratches → Replace the valve lifters and cylinder head.
EAS00250
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem
• oil seal
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
• valve 1
• spring seat 2
• oil seal 3
• outer valve springs 4
• inner valve springs 5
• spring retainer 6
(into the cylinder head)
NOTE:
Install the valve springs with the larger pitch a
facing up.
@
@
b Smaller pitch
4 - 31
VALVES AND VALVE SPRINGS
ENG
4. Install:
• valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3.
@
@
Valve spring compressor
90890-04019
Attachment
90890-04114
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
@
Hitting the valve tip with excessive force
could damage the valve.
@
6. Lubricate:
• valve lifter 1
(with the recommended lubricant)
• valve pad 2
Recommended lubricant
Molybdenum disulfide oil
7. Install:
• valve lifter
• valve pad
NOTE:
• The valve lifter must move smoothly when
rotated with a finger.
• Each valve lifter and valve pad must be reinstalled in its original position.
@
@
4 - 32
CLUTCH
ENG
CLUTCH
CRANKCASE COVER (RIGHT SIDE)
Order
Job/Part
Q’ty
Remarks
Removing the crankcase (right side)
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Engine oil
1
2
3
Brake pedal and footrest (right)
Crankcase cover (right side)
Gasket
Dowel pins
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “ENGINE REMOVAL”.
1
1
2
For installation, reverse the removal procedure.
4 - 33
CLUTCH
ENG
CLUTCH ASSEMBLY
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the clutch
Clutch spring plate retainer
Clutch spring plate
Clutch spring plate seat
Pressure plate
Short clutch push rod
O-ring
Ball
Friction plates
Clutch plates
Lock washer
Clutch boss
Wire circlip
Q’ty
1
1
1
1
1
1
1
7
6
1
1
1
4 - 34
Remarks
Remove the parts in the order listed.
CLUTCH
Order
13
14
15
16
17
18
19
20
21
22
Job/Part
Clutch plate
Friction plate
Clutch damper spring
Clutch damper spring seat
Thrust washer
Clutch housing
Long clutch push rod
Circlip
Oil pump drive gear
Dowel pins
Q’ty
1
1
1
1
1
1
1
1
1
2
ENG
Remarks
For installation, reverse the removal procedure.
4 - 35
CLUTCH
ENG
EAS00277
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss
nut.
@
@
Clutch holding tool
90890-04086
3.
•
•
•
•
•
Remove:
clutch boss nut 1
lock washer 2
clutch boss assembly 3
thrust washer 4
clutch housing 5
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip and disassemble the
built-in damper unless there is serious clutch
chattering.
@
@
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
1. Check:
• friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the friction
plates as a set.
4 - 36
CLUTCH
ENG
NOTE:
Measure the friction plate at four places.
@
@
Friction plate thickness
2.9 ~ 3.1 mm
<Limit>: 2.8 mm
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.
Clutch plate warpage limit
0.2 mm
EAS00283
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate 1
Damage → Replace.
2. Measure:
• clutch spring free height a
Out of specification → Replace the clutch
spring plate.
Clutch spring free height
7 mm
<Limit>: 6.5 mm
3. Check:
• clutch spring plate seat 2
Damage → Replace.
4 - 37
CLUTCH
ENG
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.
@
@
2. Check:
• bearing
Damage/wear → Replace the bearing and
clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
@
@
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.
4 - 38
CLUTCH
ENG
EAS00288
CHECKING THE CLUTCH PUSH RODS
1. Check:
• O-ring 1
• short clutch push rod 2
• long clutch push rod 3
• ball 4
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• long clutch push rod bending limit
Out of specification → Replace the long
clutch push rod.
Long clutch push rod bending
limit
0.5 mm
EAS00292
CHECKING THE PRIMARY DRIVE
1. Check:
• primary drive gear
• primary driven gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation →
Replace the primary drive and primary
driven gears as a set.
2. Check:
• primary-drive-gear-to-primary-driven-gear
free play
Free play exists → Replace the primary
drive and primary driven gears as a set.
EAS00296
INSTALLING THE CLUTCH
1. Install:
• clutch housing 1
• thrust washer 2
4 - 39
ENG
CLUTCH
2. Install:
• clutch boss assembly 1
NOTE:
• If the wire circlip 2 has been removed, carefully install a new one as shown.
• Install the clutch spring plate 3 with the
“OUTSIDE” mark facing out.
@
@
R.
Install:
clutch boss 1
lock washer New
clutch boss nut 2
T.
3.
•
•
•
70 Nm (7.0 m · kg)
NOTE:
While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss
nut.
@
@
Clutch holding tool
90890-04086
4. Bend the lock washer tab along a flat side of
the nut.
5.
•
•
•
Lubricate:
long clutch push rod 1
ball 2
short clutch push rod 3
(with the recommended lubricant)
Recommended lubricant
Lithium soap base grease
6.
•
•
•
Install:
long clutch push rod
ball
short clutch push rod
(along with the O-ring 4)
NOTE:
Insert the rounded end of the long clutch push
rod into the clutch boss first.
@
@
4 - 40
ENG
CLUTCH
7. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
8. Install:
• friction plates
• clutch plates
NOTE:
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Align the two embossed mark a on the
clutch housing with the two semicircular slots
b in the friction plates.
@
@
9. Install:
• pressure plate 1
NOTE:
Align the punch mark a on the pressure plate
with the punch mark b on the clutch boss.
10.Install:
• clutch spring plate seat 1
• clutch spring plate 2
• clutch spring plate retainer 3
• clutch spring bolts 4
T.
R.
8 Nm (0.8 m · kg)
NOTE:
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
@
T.
R.
11.Install:
• clutch cover 1
10 Nm (1.0 m · kg)
NOTE:
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
@
@
4 - 41
SHIFT SHAFT
ENG
SHIFT SHAFT
GENERATOR ROTOR COVER
Order
1
2
Job/Part
Removing the generator rotor cover
Engine oil
Shift pedal
Middle gear case cover
Q’ty
1
1
Remarks
Remove the parts in the order listed.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
NOTE:
Loosen the bolts in stages and in a crisscross pattern.
@
@ For installation, reverse the removal procedure.
3
4
Gasket
Dowel pins
1
2
For installation, reverse the removal procedure.
4 - 42
SHIFT SHAFT
ENG
SHIFT SHAFT AND STOPPER LEVER
Order
1
2
3
4
5
6
Job/Part
Removing the shift shaft and stopper lever
Clutch assembly
Shift shaft assembly
Circlip
Washer
Torsion spring
Stopper lever
Return spring
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CLUTCH”.
1
1
1
1
1
1
For installation, reverse the removal procedure.
4 - 43
ENG
SHIFT SHAFT
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
• shift lever 2
Bends/damage/wear → Replace.
• shift lever spring 3
Damage/wear → Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
EAS00336
T.
INSTALLING THE SHIFT SHAFT
1. Install:
• stopper lever spring 1
• stopper lever 2
10 Nm (1.0 m · kg)
R.
NOTE:
• Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss.
• Mesh the stopper lever with the shift drum
segment assembly.
@
@
2.
•
•
•
4 - 44
Install:
shift lever spring 1
washer 2
circlip 3 New
SHIFT SHAFT
ENG
3. Install:
• shift shaft 1
NOTE:
• Lubricate the oil seal lips with lithium soap
base grease.
• Hook the end of the shift shaft spring onto
the shift shaft spring stopper 2.
@
@
4. Install:
• clutch
• clutch cover
Refer to “INSTALLING THE CLUTCH”.
5.
•
•
•
•
Install:
dowel pins
gasket New
middle gear cover 1
shift pedal 2
WARNING
@
Always use a new copper washer on the
lower bolt.
@
NOTE:
Tighten the middle gear cover bolts in stages
and in a crisscross pattern.
@
@
4 - 45
GENERATOR
ENG
GENERATOR
STATOR COIL ASSEMBLY
Order
Job/Part
Removing the stator coil assembly
Engine oil
Q’ty
Muffler and exhaust pipes
Thermostat assembly
1
2
3
4
5
6
Middle gear case cover
Generator cover
Gasket
Dowel pins
Pickup coil lead and stator coil lead
Cable holder
Pickup coil
1
1
2
1/1
1
1
4 - 46
Remarks
Remove the parts in the order listed.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “ENGINE REMOVAL”.
Refer to “THERMOSTAT ASSEMBLY
AND CONDUIT” in chapter 5.
Refer to “SHIFT SHAFT”.
Remove from the cable clamp.
GENERATOR
Order
7
8
Job/Part
Plate (stator coil)
Stator coil assembly
Q’ty
1
1
ENG
Remarks
For installation, reverse the removal procedure.
4 - 47
GENERATOR
ENG
GENERATOR
Order
1
2
3
4
5
6
7
Job/Part
Removing the generator rotor
Starter clutch idle gear shaft
Starter clutch idle gear
Generator rotor
Woodruff key
Starter clutch gear
Starter motor lead
Starter motor
Q’ty
2
3
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
For installation, reverse the removal procedure.
4 - 48
GENERATOR
ENG
EAS00347
REMOVING THE GENERATOR
1. Remove:
• generator rotor bolt 1
• washer
NOTE:
• While holding the generator rotor 2 with the
sheave holder 3, loosen the generator rotor
bolt.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
@
@
Sheave holder
90890-01701
2. Remove:
• generator rotor 1
(with the flywheel puller set 2 and adapter
3)
• woodruff key
CAUTION:
@
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set’s center bolt and the
crankshaft.
@
NOTE:
Make sure the flywheel puller is centered over
the generator rotor.
@
@
Flywheel puller
90890-01362
Attachment
90890-04089
4 - 49
GENERATOR
ENG
EAS00350
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
Damage/wear → Replace.
• starter clutch spring cap 2
• starter clutch spring 3
2. Check:
• starter clutch idle gear 1
• starter clutch gear 2
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter clutch gear clockwise, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch drive gear
counterclockwise, it should turn freely, otherwise the starter clutch is faulty and must
be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
• starter clutch shafts
Bends/damage/wear → Replace.
4 - 50
ENG
GENERATOR
EAS00354
INSTALLING THE GENERATOR
1. Install:
• starter clutch gear 1
• woodruff key 2
• generator rotor 3
• pin 4
• washer 5
• generator rotor bolt 6
NOTE:
• Clean the tapered portion of the crankshaft
and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
@
@
2. Tighten:
• generator rotor bolt 1
T.
R.
130 Nm (13.0 m · kg)
NOTE:
• While holding the generator rotor 2 with the
sheave holder 3, tighten the generator rotor
bolt.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
@
@
Sheave holder
90890-01701
4 - 51
OIL PAN AND OIL PUMP
ENG
OIL PAN AND OIL PUMP
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the oil pan and oil pump
Engine oil
Muffler and exhaust pipes
Clutch assembly
Circlip
Oil pump drive gear
Oil pan
Dowel pins
Gasket
Oil level switch
Oil pump assembly
Dowel pins
Oil pump pipe
Q’ty
1
1
1
2
1
1
1
2
1
4 - 52
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “ENGINE REMOVAL”.
Refer to “CLUTCH”.
OIL PAN AND OIL PUMP
Order
10
11
12
13
Job/Part
Bracket tabs
Oil pipe
Oil gallery pipe
Oil filter
ENG
Q’ty
Remarks
2
Straighten.
1
1
1
For installation, reverse the removal procedure.
4 - 53
OIL PAN AND OIL PUMP
ENG
OIL PUMP
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the oil pump
Engine oil
Oil pan and oil pump assembly
Oil strainer
Oil strainer housing
Gasket
Circlip
Oil pump driven gear
Oil pump gear housing
Spring
Relief valve
Inner rotor 1
Outer rotor 1
Q’ty
1
1
1
1
1
1
1
1
1
1
4 - 54
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL PAN AND OIL PUMP”.
OIL PAN AND OIL PUMP
Order
A
B
C
D
E
F
G
H
I
J
Job/Part
Pin
Dowel pins
Oil pump housing cover 1
Inner rotor 2
Outer rotor 2
Pin
Oil pump shaft
Oil pump housing cover 2
Dowel pin
Oil pump housing
Q’ty
1
2
1
1
1
1
1
1
1
1
ENG
Remarks
For assembly, reverse the disassembly
procedure.
4 - 55
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• gasket
• dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
@
@
EAS00364
CHECKING THE OIL PUMP
1. Check:
• oil pump drive gear 1
• oil pump driven gear 2
• oil pump gear housing 3
• oil pump housing cover 1 4
• oil pump housing cover 2 5
Cracks/damage/wear → Replace the defective part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance b
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0 ~ 0.12 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 ~ 0.08 mm
4 - 56
OIL PAN AND OIL PUMP
ENG
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
• relief valve 1
• spring 2
Damage/wear → Replace the defective
part(s).
EAS00366
CHECKING THE OIL DELIVERY PIPE
1. Check:
• oil gallery pipe 1
• oil pipe 2
• oil pump pipe 3
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
• oil strainer housing 2
Damage → Replace.
Contaminants → Clean with engine oil.
4 - 57
ENG
OIL PAN AND OIL PUMP
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor 1
• outer rotor 1
• inner rotor 2
• outer rotor 2
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2.
•
•
•
•
•
•
•
•
•
Install:
oil pump housing 1
dowel pin 2
oil pump housing cover 2 3
oil pump shaft 4
pin 5
outer rotor 2 6
inner rotor 2 7
oil pump housing cover 1 8
oil pump housing cover 1 screw 9
T.
R.
7 Nm (0.7 m · kg)
• oil pump housing cover 1 bolt 0
T.
R.
•
•
•
•
•
•
•
T.
R.
• oil pump driven gear H
• circlip I
4 - 58
10 Nm (1.0 m · kg)
dowel pins A
pin B
outer rotor 2 C
inner rotor 2 D
relief valve E
spring F
oil pump gear housing G
7 Nm (0.7 m · kg)
ENG
OIL PAN AND OIL PUMP
NOTE:
• When installing the inner rotor, align the pin
in the oil pump shaft with the groove in the
inner rotor.
• The arrow a on the gear housing faces
toward the front of the engine.
@
@
3. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer housing 1
T.
R.
7 Nm (0.7 m · kg)
• oil strainer cover 2
NOTE:
The arrow a on the oil strainer cover must
point towards the rear of the engine.
@
@
EAS00380
T.
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• gasket New
• oil pan 1
10 Nm (1.0 m · kg)
• oil level switch 2
10 Nm (1.0 m · kg)
• engine oil drain bolt
R.
T.
R.
T.
R.
43 Nm (4.3 m · kg)
NOTE:
• Tighten the oil pan bolts in stages and in a
crisscross pattern.
• Lubricate the oil level switch O-ring with
engine oil.
@
@
4 - 59
CRANKCASE
ENG
CRANKCASE
Order
Job/Part
Separating the crankcase
Engine assembly
Cylinder head
Water pump
Clutch assembly
Shift shaft, stopper lever
Q’ty
Clutch release cylinder
Generator
Oil pan and oil pump assembly
Connecting rods and pistons
4 - 60
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD COVERS”.
Refer to “WATER PUMP” in chapter 5.
Refer to “CLUTCH ASSEMBLY”.
Refer to “SHIFT SHAFT AND STOPPER
LEVER”.
Refer
to
“DISASSEMBLING
THE
CLUTCH RELEASE CYLINDER” in chapter 7.
Refer to “GENERATOR”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “CONNECTING RODS AND
PISTONS”.
CRANKCASE
Order
1
2
3
4
5
6
Job/Part
Retainer (main axle bearing)
Retainers (middle gear bearing)
Middle driven gear assembly
Shims
Crankcase (upper)
Crankcase (lower)
Q’ty
1
2
1
2/4
1
1
4 - 61
ENG
Remarks
Refer to “SEPARATING THE CRANKCASE”.
For installation, reverse the removal procedure.
CRANKCASE
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the crankcase
Engine assembly
Crankcase separation
Crankshaft
Transmission
Crankcase breather cover
Crankcase breather spacer
Rubber gaskets
Oil pipe
Drain plugs (cylinders)
Oil pipe
Bracket (timing chain damper)
Circlip
Oil pump drive shaft
Idler gear (oil pump)
Q’ty
ENG
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CRANKCASE”.
Refer to “CRANKSHAFT”.
Refer to “TRANSMISSION”.
1
1
2
1
4
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 62
CRANKCASE
È
ENG
SEPARATING THE CRANKCASE
1. Remove:
• crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
@
@
* With a washer
É
2. Place the engine upside down.
3. Separate:
È Upper crankcase
É Lower crankcase
NOTE:
While pulling up on the timing chains separate
the upper crankcase from the lower crankcase.
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
@
4.
•
•
5.
•
Remove:
dowel pins
O-ring
Remove:
crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
@
@
4 - 63
CRANKCASE
ENG
EAS00417
ASSEMBLING THE CRANKCASE
1. Lubricate:
• crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
• sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm
of the crankshaft journal bearings.
@
@
3. Install:
• upper crankcase 1
(onto the lower crankcase 2)
CAUTION:
@
Before tightening the crankcase bolts,
make sure the transmission gears shift correctly when the shift drum assembly is
turned by hand.
@
4. Install:
• final drive assembly
Refer to “MIDDLE GEAR”.
NOTE:
The arrow on the final drive assembly must
point towards the upper crankcase.
@
@
4 - 64
ENG
CRANKCASE
5. Install:
• middle driven shaft bearing housing bolts
T.
R.
30 Nm (3.0 m · kg)
NOTE:
The bolt with the washer goes in the lower
right hole a of the middle driven shaft bearing
housing.
@
@
È
6. Tighten:
• upper crankcase bolts
• lower crankcase bolts
WARNING
@
Always use new copper washers.
@
NOTE:
• Tighten the bolts in the tightening sequence
cast on the crankcase.
• Install copper washers on bolts R and T.
• Install the cable holder on bolts L and V.
• Install the washers on bolts 2 and 4 ~ 8.
@
@
É
È Lower crankcase
É Upper crankcase
R.
T.
R.
T.
R.
4 - 65
T.
(M10 bolt)
(M8 bolt)
(M6 bolt)
40 Nm (4.0 m · kg)
24 Nm (2.4 m · kg)
12 Nm (1.2 m · kg)
ENG
CRANKCASE
T.
7. Install:
• middle driven shaft bearing housing retainers 1
25 Nm (2.5 m · kg)
• main axle bearing retainer 2
R.
T.
R.
7 Nm (0.7 m · kg)
WARNING
@
Always use new screws.
@
NOTE:
Apply LOCTITE® to the middle gear and main
bearing retainer screws.
CAUTION:
@
After tightening the middle driven shaft
bearing housing retainer screws, be sure to
stake them with a center punch.
@
4 - 66
CRANKSHAFT
ENG
CRANKSHAFT
Order
1
2
3
4
5
Job/Part
Removing the crankshaft
Engine assembly
Crankcase separation
Crankshaft
Timing chains
Main journal bearings
Balancer shaft
Main journal bearings
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CRANKCASE”.
1
2
8
1
4
For installation, reverse the removal procedure.
4 - 67
CRANKSHAFT
ENG
EAS00387
REMOVING THE CRANKSHAFT
ASSEMBLY
1. Remove:
• crankshaft assembly
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
@
@
EAS00396
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
Out of specification → Replace the crankshaft.
Crankshaft runout
Less than 0.03 mm
2.
•
•
•
Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
• crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification → Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.040 ~ 0.058 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
@
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
@
4 - 68
CRANKSHAFT
ENG
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on
a bench.
c. Install the crankshaft journal upper bearings
and the crankshaft into the upper crankcase.
NOTE:
Align the projections a of the crankshaft journal upper bearings with the notches b in the
upper crankcase.
@
@
d. Put a piece of Plastigauge® 1 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
@
@
e. Install the crankshaft journal lower bearings
into the lower crankcase and assemble the
crankcase halves.
NOTE:
• Align the projections of the crankshaft journal
lower bearings with the notches in the lower
crankcase.
• Do not move the crankshaft until the clearance measurement has been completed.
@
@
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
T.
Crankcase bolt
40 Nm (4.0 m • kg)
R.
* With a washer
NOTE:
Lubricate the bolt threads with engine oil.
@
@
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge®
width 2 on each crankshaft journal. If the
crankshaft-journal-to-crankshaft-journalbearing clearance is out of specification,
select replacement crankshaft journal bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 69
CRANKSHAFT
ENG
4. Select:
• crankshaft journal bearings (J1 ~ J4)
NOTE:
• The numbers È stamped into the crankshaft
web and the numbers 1 stamped into the
lower crankcase are used to determine the
replacement crankshaft journal bearing sizes.
• “J1 ~ J4” refer to the bearings shown in the
crankshaft illustration.
• If “J1 ~ J4” are the same, use the same size
for all of the bearings.
@
@
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
Bearing size of J1:
“J1” (crankcase) – “J1” (crankshaft web)
6 – 2 = 4 (green)
BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
7
red
NOTE:
If the size is the same for all “J1 to J4”, one digit
for that size is indicated. (crankcase side only)
4 - 70
CRANKSHAFT
ENG
CHECKING THE BALANCER SHAFT
1. Measure:
• balancer shaft-journal-to-balancer shaftjournal-bearing clearance
Out of specification → Replace the balancer
shaft journal bearings.
balancer shaft-journal-to-balancer shaft-journal-bearing clearance
0.020 ~ 0.048 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
@
Do not interchange the balancer shaft journal bearings. To obtain the correct balancer
shaft-journal-to-balancer
shaft-journalbearing clearance and prevent engine damage, the balancer shaft journal bearings
must be installed in their original positions.
@
a. Clean the balancer shaft journal bearings,
balancer shaft journals, and bearing portions of the crankcase.
b. Place the upper crankcase upside down on
a bench.
c. Install the balancer shaft journal upper
bearings and the balancer shaft into the
upper crankcase.
NOTE:
Align the projections a of the balancer shaft
journal upper bearings with the notches b in
the upper crankcase.
@
@
d. Put a piece of Plastigauge® 1 on each balancer shaft journal.
NOTE:
Do not put the Plastigauge® over the oil hole in
the balancer shaft journal.
@
@
e. Install the balancer shaft journal lower bearings into the lower crankcase and assemble
the crankcase halves.
4 - 71
CRANKSHAFT
ENG
NOTE:
• Align the projections of the balancer shaft
journal lower bearings with the notches in the
lower crankcase.
• Do not move the crankshaft until the clearance measurement has been completed.
@
@
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
T.
Crankcase bolt
24 Nm (2.4 m • kg)
R.
NOTE:
Lubricate the bolt threads with engine oil.
@
@
g. Remove the lower crankcase and the balancer shaft journal lower bearings.
h. Measure the compressed Plastigauge®
width 2 on each balancer shaft journal. If
the balancer shaft-journal-to-balancer shaftjournal-bearing clearance is out of specification, select replacement balancer shaft
journal bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• balancer shaft journal bearings (J5 ~ J6)
NOTE:
• The numbers È stamped into the balancer
shaft web and the numbers 1 stamped into
the lower crankcase are used to determine
the replacement balancer shaft journal bearing sizes.
• “J5 ~ J6” refer to the bearings shown in the
balancer shaft illustration.
• If “J5 ~ J6” are the same, use the same size
for all of the bearings.
@
@
For example, if the crankcase “J5” and balancer shaft web “J5” numbers are “6” and “2”
respectively, then the bearing size for “J5” is:
4 - 72
CRANKSHAFT
ENG
Bearing size of J1:
“J5” (crankcase) – “J5” (balancer shaft
web)
6 – 2 = 4 (green)
BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
7
red
NOTE:
If the size is the same for all “J5 and J6”, one
digit for that size is indicated. (crankcase side
only)
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft journal upper bearings
(into the upper crankcase)
NOTE:
• Align the projections a on the crankshaft
journal upper bearings with the notches b in
the upper crankcase.
• Be sure to install each crankshaft journal
upper bearing in its original place.
@
@
4 - 73
CRANKSHAFT
ENG
2. Install:
• timing chain 1
(onto the crankshaft sprocket)
• crankshaft assembly 2
NOTE:
• Pass the timing chain through the timing
chain cavity.
• To prevent the timing chain from falling into
the crankcase, fasten it with a wire.
@
@
EAS00410
INSTALLING THE BALANCER SHAFT
1. Install:
• balancer shaft
NOTE:
Align the punch mark a in the balancer shaft
drive gear with the punch mark b in the balancer shaft driven gear.
NOTE:
4 - 74
CONNECTING RODS AND PISTONS
ENG
CONNECTING RODS AND PISTONS
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Removing the connecting rod and
Remove the parts in the order listed.
piston
Engine assembly
Refer to “ENGINE REMOVAL”.
Cylinder heads
Refer to “CYLINDER HEAD COVERS”.
Oil pan and oil pump assembly
Refer to “OIL PAN AND OIL PUMP”.
Nuts (connecting rod caps)
8
Connecting rod caps and plain bear- 4/8
ings
Connecting rods with pistons
4
Piston pin clips
8
Piston pins
4
Pistons
4
Piston rings
12
For installation, reverse the removal procedure.
4 - 75
CONNECTING RODS AND PISTONS
ENG
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
• connecting rod
• big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
@
@
2.
•
•
•
Remove:
piston pin clips 1
piston pin 2
piston 3
CAUTION:
@
Do not use a hammer to drive the piston
pin out.
@
NOTE:
• For reference during installation, put identification marks on the piston crown.
• Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller 4.
@
@
Piston pin puller set
90890-01304
3.
•
•
•
Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
@
@
4 - 76
ENG
CONNECTING RODS AND PISTONS
EAS00255
CHECKING THE CYLINDERS AND PISTONS
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
a 40 mm from the top of the cylinder
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
@
@
Cylinder bore gauge
(50 ~ 100 mm)
90890-03017
Standard
Wear
limit
Cylinder
75.967 ~ 76.016 mm 76.1 mm
bore “C”
C= X+Y
2
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
b 6.2 mm from the bottom edge of the piston
Piston size “P”
4 - 77
Standard
75.905 ~ 75.955 mm
Oversize 1
76.25 mm
Oversize 2
76.50 mm
CONNECTING RODS AND PISTONS
ENG
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.055 ~ 0.075 mm
<Limit>: 0.15 mm
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00264
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
@
@
Piston ring side clearance
Top ring
0.03 ~ 0.07 mm
<Limit>: 0.12 mm
2nd ring
0.02 ~ 0.06 mm
<Limit>: 0.12 mm
2. Install:
• piston ring (into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
@
@
a 20 mm
4 - 78
CONNECTING RODS AND PISTONS
ENG
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
@
@
Piston ring end gap
Top ring
0.35 ~ 0.50 mm
<Limit>: 0.75 mm
2nd ring
0.35 ~ 0.50 mm
<Limit>: 0.75 mm
Oil ring
0.2 ~ 0.8 mm
Piston ring oversize
• Top and 2nd piston rings
The size of the top and 2nd oversize piston
rings is stamped on the top of each ring.
Oversize 1
0.25 mm
Oversize 2
0.50 mm
• Oil ring
The expander spacer of the oil ring is colorcoded for size identification.
Size
Mark
Oversize 1
25
Oversize 2
50
EAS00266
CHECKING THE PISTON PINS
The following procedure applies to all of the
piston pins.
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
4 - 79
CONNECTING RODS AND PISTONS
ENG
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
Piston pin outside diameter
18.991 ~ 19.000 mm
3. Calculate:
• piston-pin-to-piston clearance
Out of specification → Replace the piston
pin.
Piston-pin-to-piston clearance =
Piston pin bore size b –
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.004 ~ 0.024 mm
<Limit>: 0.072 mm
4. Measure:
• crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing clearance
0.021 ~ 0.039 mm
The following procedure applies to all of the
connecting rods.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
@
Do not interchange the big end bearings
and connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage, the big
end bearings must be installed in their original positions.
@
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower bearing into the connecting rod cap.
4 - 80
CONNECTING RODS AND PISTONS
ENG
NOTE:
Align the projections a on the big end bearings with the notches b in the connecting rod
and connecting rod cap.
@
@
c. Put a piece of Plastigauge® on the crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or crankshaft until the clearance measurement has
been completed.
• Lubricate the bolts threads and nut seats
with molybdenum disulfide grease.
• Make sure the “Y” mark 1 on the connecting
rod faces towards the left side of the crankshaft.
• Make sure the characters 2 on both the connecting rod and connecting rod cap are
aligned.
@
@
e. Tighten the connecting rod nuts.
Refer to “INSTALLING THE PISTONS AND
CYLINDERS”.
T.
Connecting rod nut
36 Nm (3.6 m • kg)
R.
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS AND PISTONS”.
g. Measure the compressed Plastigauge®
width 1 on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is
out of specification, select replacement big
end bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 81
CONNECTING RODS AND PISTONS
ENG
5. Select:
• big end bearings (P1 ~ P2)
NOTE:
• The numbers È stamped into the crankshaft
web and the numbers 1 on the connecting
rods are used to determine the replacement
big end bearing sizes.
• “P1” ~ “P2” refer to the bearings shown in the
crankshaft illustration.
@
@
For example, if the connecting rod “P1” and the
crankshaft web “P1” numbers are “4” and “1”
respectively, then the bearing size for “P1” is:
Bearing size of P1:
“P1” (connecting rod) – “P1” (crankshaft web)
4 – 1 = 3 (brown)
BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00270
INSTALLING THE PISTONS AND
CYLINDERS
The following procedure applies to all of the
pistons and cylinders.
1. Install:
• top ring
• 2nd ring
• oil ring
NOTE:
• Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
• Lubricate the piston and piston rings liberally
with engine oil.
@
@
4 - 82
CONNECTING RODS AND PISTONS
2.
•
•
•
ENG
Position:
top ring
2nd ring
oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Lower oil ring end
c Upper oil ring end
d 2nd ring end
3.
•
•
•
Install:
piston 1
piston pin 2
piston pin clip 3
New
NOTE:
• Apply engine oil onto the piston pin.
• Be sure that the piston is positioned correctly, as shown in the illustration.
@
@
4 “Y” mark
5 “EX” exhaust side
6 “IN” exhaust side
7 Projection
4. Install:
• big end bearings 1
NOTE:
• Align the projections a on the big end bearings with the notches b in the connecting
rods and connecting rod caps.
• Be sure to reinstall each big end bearing in
its original place.
5.
•
•
•
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4 - 83
ENG
CONNECTING RODS AND PISTONS
6. Attach:
• piston ring compressors 1
Piston ring compressor
90890-05158
7. Install:
• connecting rod and piston assembly
È
NOTE:
• The stamped “Y” mark 2 on the No. 2 and
No. 4 connecting rods should face towards
the right side of the crankcase.
• The stamped “Y” mark 2 on the No. 1 and
No. 3 connecting rods should face towards
the left side of the crankcase.
È Top view
3 Front
4 “Y” mark facing direction
5 Piston exhaust mark
6 Piston intake mark
8. Align:
• bolt heads 1
(with the connecting rod caps)
9. Tighten:
• connecting rod nuts
T.
R.
36 Nm (3.6 m · kg)
CAUTION:
@
• When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
• Without pausing, tighten the connecting
rod nuts to the specified torque. Apply continuous torque between 3.0 and 3.6 m • kg.
Once you reach 3.0 m • kg DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted
between 3.0 and 3.6 m • kg, loosen the
connecting rod nut to less than 3.0 m • kg
and start again.
@
4 - 84
TRANSMISSION
ENG
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the transmission
Crankcase separation
Drive axle assembly
Main axle assembly
Push rod bearing
Oil seal
Bearing stoppers
Shift fork guide bars
Shift forks
Neutral switch
Shift drum retainer
Shift drum
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE”.
1
1
1
1
2
2
3
1
1
1
For installation, reverse the removal procedure.
4 - 85
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the transmission
Middle drive pinion gear assembly
Bearing
Shim
1st wheel gear
4th wheel gear
Circlip
Washer
3rd wheel gear
Drive axle
Plug
2nd wheel gear
Washer
Circlip
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
4 - 86
ENG
Remarks
Remove the parts in the order listed.
Refer to “MIDDLE GEAR”.
TRANSMISSION
Order
C
D
E
F
G
H
I
J
K
L
M
N
O
Job/Part
5th wheel gear
Bearing
Circlip
Bearing
Main axle
4th pinion gear
Washer
Circlip
2nd, 3rd pinion gear
5th pinion gear
Washer
Circlip
Bearing
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
ENG
Remarks
For assembly, reverse the disassembly
procedure.
4 - 87
TRANSMISSION
ENG
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the
shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear → Replace
the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
@
Do not attempt to straighten a bent shift
fork guide bar.
@
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift drum
assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift drum
assembly.
4 - 88
TRANSMISSION
ENG
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the main
axle.
Main axle runout limit
0.08 mm
2. Measure:
• drive axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the drive
axle.
Drive axle runout limit
0.08 mm
3. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
4. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
4 - 89
ENG
TRANSMISSION
EAS00430
INSTALLING THE TRANSMISSION
1. Install:
• shift drum assembly 1
• shift drum retainer 2
T.
R.
7 Nm (0.7 m · kg)
NOTE:
• Apply LOCTITE® #648 to the shift drum
retainer screws.
• Turn the shift drum assembly to the neutral
position.
@
@
2. Lubricate:
• neutral switch
(with the recommended lubricant)
Recommended lubricant
Lithium soap base grease
T.
R.
3. Install:
• neutral switch 1
3.5 Nm (0.35 m · kg)
WARNING
@
Always use a new O-ring.
@
4.
•
•
•
•
Install:
shift fork “C” 1
shift fork “L” 2
shift fork “R” 3
shift fork guide bars 4
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.
@
4 - 90
TRANSMISSION
ENG
5. Install:
• bearing stoppers 1
NOTE:
Insert the bearing stoppers completely into the
grooves in the lower crankcase.
@
@
6. Lubricate:
• oil seal lips
(with a thin coat of the recommended lubricant)
Recommended lubricant
Lithium soap base grease
7. Install:
• push rod bearing 1
• oil seal 2
WARNING
@
Always use a new O-ring.
@
NOTE:
• Insert the bearing pin into the hole in the
crankcase.
• Position the oil seal against the push rod
bearing.
@
@
8. Install:
• main axle assembly 1
• drive axle assembly 2
WARNING
@
Always use new circlips.
@
NOTE:
Position the bearing pins 3 as shown.
@
@
9. Check:
• transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
@
@
4 - 91
MIDDLE GEAR
ENG
MIDDLE GEAR
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the middle gear
Crankcase separation
Drive axle assembly
Nut
Washer
Universal joint (yoke)
Dust seal
Middle driven shaft bearing housing
Shims
O-ring
Bearing
Collapsible collar
Spacer
Bearing
Q’ty
1
1
1
1
1
2
1
1
1
1
1
4 - 92
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE”.
Refer to “TRANSMISSION”.
MIDDLE GEAR
Order
12
13
14
15
16
17
18
19
20
21
Job/Part
Middle driven shaft
Retainer
Thrust washer
Middle drive pinion gear
Damper cam
Damper spring
Spring seat
Bearing
Nut
Bearing
Q’ty
1
1
1
1
1
1
1
1
1
1
ENG
Remarks
For installation, reverse the removal procedure.
4 - 93
MIDDLE GEAR
ENG
EAS00435
DISASSEMBLING THE MIDDLE DRIVE
SHAFT ASSEMBLY
1. Remove:
• spring retainers
NOTE:
While holding the spring with the middle drive
gear holder 1, compress the spring with the
damper spring compressor 2, and then
remove the spring retainers.
@
@
Middle gear backlash tool
90890-04080
Damper spring compressor
90890-04090
2.
•
•
•
Remove:
middle drive shaft nut
bearing
shim(s)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the end of the middle drive shaft in a
folded rag 1.
b. Secure the middle drive shaft in a vice.
c. Attach the middle drive shaft nut wrench as
shown.
Middle drive shaft nut wrench
(55 mm)
90890-04054
d. Remove the middle drive shaft nut, bearing,
and shim(s).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00437
DISASSEMBLING THE MIDDLE DRIVEN
SHAFT ASSEMBLY
NOTE:
The following procedure should only be performed if the middle drive gear or middle
driven shaft bearing(s) has to be replaced.
@
@
4 - 94
MIDDLE GEAR
ENG
1. Remove:
• universal joint
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the circlips 1.
b. Place the universal joint in a press.
c. With a pipe of the proper diameter positioned beneath the universal joint driven
yoke as shown, press the bearing into the
pipe.
NOTE:
It may be necessary to lightly tap the universal
joint driven yoke with a center punch.
@
@
d. Repeat the above steps to remove the
opposite side’s bearing.
e. Separate the universal joint yokes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Loosen:
• middle driven shaft nut
NOTE:
While holding the universal joint driven yoke
with the universal joint holder 1, loosen the
middle driven shaft nut.
@
@
Universal joint holder
90890-04062
EAS00438
CHECKING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Check:
• damper cam surface
Scratches/wear → Replace the damper
cam.
2. Check:
• spring
Cracks/damage → Replace.
4 - 95
ENG
MIDDLE GEAR
EAS00439
CHECKING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
1. Check:
• middle driven gear
Galling/pitting/wear → Replace the middle
driven shaft assembly.
2. Check:
• bearings
Damage/pitting → Replace the middle drive
shaft bearing housing assembly.
3. Check:
• O-ring
• oil seal
Damage → Replace the defective part(s).
4. Check:
• universal joint movement
Rough movement → Replace the universal
joint.
EAS00441
ASSEMBLING THE MIDDLE DRIVE SHAFT
ASSEMBLY
1. Tighten:
• middle drive shaft nut
T.
R.
110 Nm (11.0 m · kg)
NOTE:
• Apply LOCTITE® #620 or #201 to the middle
drive pinion gear nut.
• Lock the threads on the middle drive shaft
nut by staking them with a center punch 1.
@
@
2. Install:
• spring retainers
NOTE:
While holding the spring with the middle drive
gear holder 2, compress the spring with the
damper spring compressor 1, and then install
the spring retainers.
@
@
Middle gear backlash tool
90890-04080
Damper spring compressor
90890-04090
4 - 96
MIDDLE GEAR
ENG
3. Measure:
• drive axle assembly length a
Out of specification → Add shim 1.
Drive axle assembly length
253.81 ~ 254.37 mm
Length a
Shim thickness
252.66 ~ 253.00 mm
1.3 mm
253.01 ~ 253.40 mm
0.9 mm
253.41 ~ 253.80 mm
0.5 mm
EAS00443
ASSEMBLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
NOTE:
The following points are critical when assembling the middle gears:
• The collapsible collar must be replaced
whenever the middle driven shaft assembly
is removed from the middle driven shaft
bearing housing.
• When performing this procedure for the first
time, be sure to have at least one extra collapsible collar on hand.
• If there is insufficient preload on the bearings, the middle driven shaft can move
slightly, allowing oil to leak past the seal. In
addition to torquing the middle driven shaft
nut to specification, you must also check the
spinning torque (bearing preload).
@
@
1. Install:
• bearing outer race
(into the middle driven shaft bearing housing)
WARNING
@
Do not press the bearing outer race. During
installation, always press the bearing inner
race carefully.
@
4 - 97
ENG
MIDDLE GEAR
2. Tighten:
• middle driven shaft nut
T.
R.
90 Nm (9.0 m · kg)
While holding the universal joint driven yoke
with the universal joint holder, tighten the
middle driven shaft nut.
Universal joint holder
90890-04062
CAUTION:
@
Tighten the middle driven shaft nut in small
increments, checking the torque it takes to
keep the middle driven gear turning in the
middle driven shaft bearing housing - not
the torque it takes to start it turning.
@
3. Measure:
• middle driven gear spinning torque
(with the beam-type torque wrench)
T.
R.
Middle driven gear spinning
torque
0.4 ~ 0.5 Nm (0.04 ~ 0.05 m • kg)
Under specification → Repeat steps (2) and
(3).
CAUTION:
@
• Never exceed the standard spinning
torque.
• If the spinning torque is not high enough,
tighten the middle driven shaft nut
slightly and check the spinning torque
again. Repeat these steps until the proper
spinning torque is obtained.
• If the spinning torque specification is
exceeded, remove the middle driven shaft
assembly, install a new collapsible collar,
and repeat steps (1) ~ (3).
@
4 - 98
MIDDLE GEAR
ENG
4. Install:
• universal joint driven yoke/cross joint
(into the universal joint drive yoke)
CAUTION:
@
Do not hammer the universal joint drive
yoke or the collapsible collar may be distorted. This will result in a change in the
standard
spinning
torque,
requiring
replacement of the collapsible collar and
reassembly of the middle driven shaft
assembly.
@
5. Install:
• bearings
(onto the universal joint driven yoke/cross joint)
CAUTION:
@
The needles can easily fall out of their
races, so check each bearing carefully.
Slide the universal joint driven yoke assembly back and forth on the bearings. If a needle is out of place, the yoke will not go all
the way onto the bearings.
@
6. Press each bearing into the universal joint
driven yoke assembly with a socket of the
proper size.
NOTE:
The bearings must be inserted far enough into
the universal joint driven yoke assembly so
that circlips can be installed.
@
@
EAS00446
INSTALLING THE MIDDLE GEAR
1. Install:
• shim(s) 1
• middle driven shaft housing 2
NOTE:
Finger tighten the middle driven shaft housing
bolts.
@
@
4 - 99
ENG
MIDDLE GEAR
T.
2. Tighten:
• crankcase bolts
24 Nm (2.4 m · kg)
• middle driven shaft housing bolts
R.
T.
R.
30 Nm (3.0 m · kg)
NOTE:
Before tightening the bolts:
1. Adjust the middle gear backlash.
Refer to “ADJUSTING THE MIDDLE GEAR
BACKLASH”.
2. Check that the middle driven gear turns
smoothly.
3. Make sure the arrow on the middle driven
shaft bearing housing points towards the
upper crankcase.
@
3. Install:
• bearing retainers 1
T.
R.
25 Nm (2.5 m · kg)
NOTE:
Apply LOCTITE® to the middle gear bearing
retainer screws.
WARNING
@
Always use new screws.
@
CAUTION:
@
After tightening the bearing retainer
screws, stake them with a center punch.
@
EAS00451
ADJUSTING THE MIDDLE GEAR
BACKLASH
1. Install:
• middle gear backlash tool 1
Middle gear backlash tool
90890-04080
4 - 100
MIDDLE GEAR
2.
•
3.
•
4.
•
ENG
Loosen:
middle driven shaft bearing housing bolts
Remove:
shim(s)
Tighten:
middle driven shaft bearing housing bolts
CAUTION:
@
Do not overtighten the middle driven shaft
bearing housing bolts or you may obtain
too little middle gear backlash, and damage
the middle gears and collapsible collar. If
the bolts are overtightened, replace the collapsible collar. Then, repeat all of the previous steps until the crankcase-to-middledriven-shaft-bearing-housing clearance is
within specification.
@
NOTE:
• Tighten the middle driven shaft bearing
housing bolts carefully, one thread turn at a
time only. Push in the middle driven shaft
bearing housing and then tighten the bolts to
specification.
• Clearance between the crankcase and the
middle driven shaft bearing housing should
be approximately 2 mm, when measured
with a thickness gauge 2.
@
@
5. Position:
• dial gauge 3
(onto the outside edge of the universal joint)
Dial gauge
90890-03097
NOTE:
Be sure that the gauge is positioned over the
centerline of the yoke bearing hole.
4 - 101
MIDDLE GEAR
ENG
6. Turn:
• universal joint drive yoke
NOTE:
While carefully tightening the middle driven
shaft bearing housing bolts in stages and in a
crisscross pattern, turn the universal joint drive
yoke back and forth until the dial gauge reads
0.05 ~ 0.12 mm.
@
@
7. Measure:
• crankcase-to-middle-driven-shaft-bearinghousing clearance (with a thickness gauge)
8. Select:
• shim(s) 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Shims can only be selected in 0.05 mm
increments, therefore round off to the hundredth’s digit of the calculated thickness
and select the appropriate shim(s) with the
following chart.
b. For example, the clearance between the
crankcase and the middle driven shaft bearing housing is 0.46 mm. Therefore, the
chart instructs you to round off the 6 to 5.
Thus, you should use one 0.15 mm and one
0.30 shim.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6
5
7, 8, 9
10
Shims are supplied in the following thicknesses.
Middle driven pinion gear shim
Thickness (mm)
0.10 0.15 0.30
0.40 0.50 0.60
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 102
ENG
MIDDLE GEAR
9. Loosen:
• middle driven shaft bearing housing bolts
10.Install:
• shim(s)
11.Tighten:
• middle driven shaft bearing housing bolts
T.
R.
30 Nm (3.0 m · kg)
NOTE:
Before tightening the middle driven shaft bearing housing bolts, make sure the arrow on the
middle driven shaft bearing housing points
towards the upper crankcase.
@
@
12.Measure:
• middle gear backlash
EAS00453
ALIGNING THE MIDDLE GEAR
NOTE:
Aligning the middle gear is necessary when
any of the following parts are replaced:
• Crankcase
• Middle driven shaft
• Middle driven shaft bearing housing
@
1 Drive pinion gear
2 Driven pinion gear
3 Drive pinion gear shim
4 Driven pinion gear shim
1. Select:
• drive pinion gear shim
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the drive pinion gear with the
appropriate shim(s) 3. Calculate the
respective thicknesses from the information
marked on the crankcase.
4 - 103
MIDDLE GEAR
ENG
b. To find drive pinion gear shim thickness “T”,
use the following formula:
Drive pinion gear shim thickness
T=A–B
Where:
A = 54.5 + (constant number)
B = 53 + (a/100)
a = a numeral stamped on the left-side of the
upper crankcase, divided by 100.
If the left-side of the upper crankcase is
stamped “96”:
B = 53 + (96/100)
= 53 + 0.96
= 53.96
Therefore:
T =A–B
= 54.5 – 53.96
= 0.54
Therefore, the calculate drive pinion gear shim
thickness is 0.54.
4 - 104
MIDDLE GEAR
ENG
Since the shims are only available in 0.10- or
0.15-mm increments, round off the hundredths’ digit.
Hundredth’s digit
Rounded value
0, 1, 2
0
3, 4, 5, 6
5
7, 8, 9
10
In the example above, the calculated drive pinion gear shim thickness is 0.54 mm. The chart
instructs you to round off to 0.55 mm. Thus,
0.15 mm and 0.4 mm should be used as indicated in the following chart.
Drive pinion gear shim
Thickness (mm)
0.15 0.30 0.40 0.50
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 105
COOL
5
COOL
CHAPTER 5
COOLING SYSTEM
RADIATOR AND RADIATOR HOSES ........................................................... 5-1
CHECKING THE RADIATOR ...................................................................5-3
INSTALLING THE RADIATOR .................................................................5-3
THERMOSTAT ASSEMBLY AND CONDUIT ................................................ 5-4
CHECKING THE THERMOSTAT ............................................................. 5-8
CHECKING THE RADIATOR CAP .......................................................... 5-9
ASSEMBLING THE THERMOSTAT ASSEMBLY ....................................5-9
INSTALLING THE THERMOSTAT ASSEMBLY .................................... 5-10
WATER PUMP ..............................................................................................5-11
DISASSEMBLING THE WATER PUMP ................................................. 5-14
CHECKING THE WATER PUMP ........................................................... 5-14
ASSEMBLING THE WATER PUMP .......................................................5-16
INSTALLING THE WATER PUMP ......................................................... 5-17
COOL
RADIATOR AND RADIATOR HOSES
COOL
EAS00454
COOLING SYSTEM
RADIATOR AND RADIATOR HOSES
Order
Job/Part
Removing the radiator
Top cover and covers
Q’ty
Coolant
1
2
3
4
5
Radiator fan motor coupler
Radiator hose clamps
Radiator side panels
Radiator
Fan motor
1
3
2
1
1
Remarks
Remove the parts in the order listed.
Refer to “TOP COVER AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Loosen.
For installation, reverse the removal procedure.
5-1
RADIATOR AND RADIATOR HOSES
Order
1
2
3
4
5
6
7
Job/Part
Removing the radiator hoses
Radiator inlet hose
Coolant drain cock assembly hose
Radiator outlet hose
Thermostat assembly breather hose
Conduit breather hose
Conduit inlet hoses
Coolant breather hose
Q’ty
COOL
Remarks
Remove the parts in the order listed.
1
1
1
1
1
2
1
For installation, reverse the removal procedure.
5-2
RADIATOR AND RADIATOR HOSES
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
@
@
2. Check:
• radiator hoses
• radiator pipes
Cracks/damage → Replace.
3. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
EAS00456
INSTALLING THE RADIATOR
1. Install:
• radiator hoses
NOTE:
Align the hose match marks 1 with the match
marks 2 on the conduit.
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR
CAP”.
5-3
THERMOSTAT ASSEMBLY AND CONDUIT
COOL
EAS00460
THERMOSTAT ASSEMBLY AND CONDUIT
Order
Job/Part
Removing the thermostat assembly
Top cover and covers
Q’ty
Coolant
Radiator assembly and hoses
1
2
3
4
5
6
7
Coolant drain cock assembly
O-ring
Thermostat assembly
Water pump inlet pipe
O-ring
Coolant drain cock
Stopper ball
1
1
1
1
2
1
1
5-4
Remarks
Remove the parts in the order listed.
Refer to “TOP COVER AND COVERS” in
chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “RADIATOR AND RADIATOR
HOSES”.
THERMOSTAT ASSEMBLY AND CONDUIT
Order
8
9
Job/Part
Spring
O-ring
Q’ty
1
1
COOL
Remarks
For installation, reverse the removal procedure.
5-5
THERMOSTAT ASSEMBLY AND CONDUIT
Order
1
2
3
4
Job/Part
Disassembling the thermostat
assembly
Thermostat housing cover
O-ring
Thermostat
Thermostat housing
Q’ty
COOL
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-6
THERMOSTAT ASSEMBLY AND CONDUIT
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the conduit assembly
Thermo switch coupler
Temperature sender lead
Ground lead
Conduit
Temperature sender
Thermo switch
O-ring
Conduit board
Q’ty
1
1
1
1
1
1
1
1
COOL
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
5-7
THERMOSTAT ASSEMBLY AND CONDUIT
COOL
EAS00463
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 80 ~ 84°C → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermometer
2 Water
3 Thermostat
4 Container
È Fully closed
É Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
@
@
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage → Replace.
3. Check:
• thermostat housing cover O-ring
• thermostat housing inlet pipe O-ring
• water pump inlet pipe
Damage → Replace.
5-8
COOL
THERMOSTAT ASSEMBLY AND CONDUIT
CHECKING THE RADIATOR CAP
1. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
75 ~ 105 kPa
(0.75 ~ 1.05 kg/cm2, 0.75 ~ 1.05 bar)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and adapter
2 to the radiator cap 3.
Radiator cap tester
90890-01325
Adapter
90890-01352
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00464
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing 1
• thermostat 2
• O-ring 3 New
• thermostat housing cover 4
NOTE:
• Install the thermostat with its breather hole
a facing up.
• Align the projection b on the thermostat with
the slot c on the thermostat housing.
@
@
T.
2. Install:
• thermo switch 1
15 Nm (1.5 m · kg)
• temperature sender 2
R.
T.
R.
15 Nm (1.5 m · kg)
CAUTION:
Use extreme care when handling the
thermo switch and temperature sender.
Replace any part that was dropped or subjected to a strong impact.
5-9
THERMOSTAT ASSEMBLY AND CONDUIT
COOL
EAS00467
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR
CAP”.
5 - 10
WATER PUMP
COOL
EAS00468
WATER PUMP
Order
Job/Part
Removing the water pump
Q’ty
Coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Engine oil
1
2
3
4
Water pump cover
O-ring
Water pump housing
Water pump inlet pipe
Remarks
Remove the parts in the order listed.
NOTE:
It is not necessary to remove the water
pump unless the coolant level is
extremely low or the coolant contains
engine oil.
1
1
1
1
5 - 11
WATER PUMP
Order
5
6
7
Job/Part
O-ring
Gasket
Dowel pins
Q’ty
1
1
2
COOL
Remarks
For installation, reverse the removal procedure.
5 - 12
WATER PUMP
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the water pump
Circlip
Driven gear
Gear stopper pin
Circlip
Impeller
Bearing
Oil seal
Water pump seal
Rubber damper
Rubber damper holder
Q’ty
1
1
1
1
1
1
1
1
1
1
COOL
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE
WATER PUMP”.
For assembly, reverse the disassembly
procedure.
5 - 13
WATER PUMP
COOL
EAS00470
DISASSEMBLING THE WATER PUMP
1. Remove:
• bearing 1
• oil seal 2
NOTE:
Tap out the bearing and oil seal from the outside of the water pump housing.
@
2. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
@
@
3. Remove:
• rubber damper holder 1
• rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
@
@
EAS00474
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover 1
• water pump housing 2
• impeller 3
• rubber damper 4
• rubber damper holder 5
Cracks/damage/wear → Replace.
5 - 14
WATER PUMP
COOL
2. Check:
• water pump seal 1
• oil seal 2
Cracks/damage/wear → Replace.
3. Check:
• bearing
Rough movement → Replace.
4. Check:
• water pump driven gear
Pitting/wear → Replace.
5. Check:
• water pump inlet pipe
Cracks/damage/wear → Replace.
5 - 15
WATER PUMP
COOL
EAS00476
ASSEMBLING THE WATER PUMP
1. Install:
• rubber damper 1
• rubber damper holder 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
@
@
2. Measure:
• impeller shaft tilt
Out of specification → Repeat step 1.
CAUTION:
@
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
@
Impeller shaft tilt limit
0.15 mm
1 Straightedge
2 Impeller
3. Install:
• water pump seal 1
CAUTION:
@
Never lubricate the water pump seal surface with oil or grease.
@
NOTE:
• Install the water pump seal from the outside
of the water pump housing.
• Install the water pump seal with a socket 2
that matches its outside diameter.
@
@
5 - 16
WATER PUMP
COOL
4. Install:
• oil seal
• bearing 1
NOTE:
• Install the oil seal and bearing from the inside
of the water pump housing.
• Make sure the side of the bearing with the
number faces up.
• Gently tap the bearing into place until it is
flush with the water pump housing.
@
@
5. Install:
• impeller 1
• circlip 2 New
6. Install:
• key
• water pump driven gear
NOTE:
Align the slot a in the water pump driven gear
with the pin b.
@
@
7. Install:
• circlip 1
New
INSTALLING THE WATER PUMP
1. Install:
• water pump housing 1
WARNING
@
Always use a new gasket.
@
5 - 17
WATER PUMP
2.
•
•
•
•
COOL
Install:
O-ring New
water pump housing cover 1
O-rings New
water pump inlet pipe 2
NOTE:
Before installing the water pump outlet pipe 2,
lubricate the O-rings with a thin coat of lithium
soap base grease.
@
@
T.
Water pump housing cover bolt
10 Nm (1.0 m • kg)
R.
3. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:
• cooling system
Leaks → Repair or replace the faulty part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR
CAP”.
5 - 18
CARB
6
CARB
CHAPTER 6
CARBURETION
CARBURETORS ............................................................................................ 6-1
CHECKING THE CARBURETORS .......................................................... 6-6
ASSEMBLING THE CARBURETORS .....................................................6-8
INSTALLING THE CARBURETORS ........................................................6-9
MEASURING AND ADJUSTING THE FUEL LEVEL ............................. 6-10
CHECKING THE FUEL PUMP ...............................................................6-11
CARB
CARBURETORS
CARB
CARBURETION
CARBURETORS
Order
Job/Part
Removing the carburetor
Top cover and covers
Q’ty
Air filter case and electrical components board
1
2
3
4
5
6
7
8
Fuel hose
Throttle cable holder cover
Throttle cable holder
Throttle cable joint
Throttle cables
Carburetor joint covers (left and right)
Clamps (carburetor joints)
Carburetor assembly
1
2
1
2
2
2
8
1
Remarks
Remove the parts in the order listed.
Refer to “TOP COVER AND COVERS” in
chapter 3.
Refer to “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD” in
chapter 3.
Disconnect.
Disconnect.
Loosen.
For installation, reverse the removal procedure.
6-1
CARBURETORS
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Separating the carburetors
Fuel overflow hose
Fuel feed joint
Upper bracket (left)
Upper bracket (right)
Throttle stop screw bracket
Throttle stop screw
Throttle stop screw spring
Lower bracket
Side bracket (front)
Side bracket (rear)
Starter lever shaft
Starter lever shaft bracket
Plastic bushings
Plastic washer
Q’ty
2
2
1
1
1
1
1
1
1
1
1
4
4
1
6-2
CARB
Remarks
Remove the parts in the order listed.
CARBURETORS
Order
15
16
17
18
19
Job/Part
Synchronization screw
Synchronization screw spring
Synchronization rod
Throttle cable
Carburetor
Q’ty
1
1
1
2
4
CARB
Remarks
For installation, reverse the removal procedure.
6-3
CARBURETORS
Order
Job/Part
Disassembling the carburetor
Q’ty
CARB
Remarks
Remove the parts in the order listed.
NOTE:
The remaining steps should be followed
for all four of the carburetors.
1
2
3
4
5
6
7
8
9
0
A
Pilot air jet No. 1
Starter plunger assembly
Starter body
Gasket
Coasting enricher cover
Coasting enricher spring
Coasting enricher
Float chamber
Float chamber rubber gasket
Float
Needle valve
1
1
1
1
1
1
1
1
1
1
1
6-4
CARBURETORS
Order
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Job/Part
Needle jet screw
Main jet
Jet block
Gasket
Main bleed pipe
Pilot jet
Vacuum chamber cover
Piston valve spring
Pilot screw assembly
Pilot air jet No. 2
Plastic screw
Jet needle kit
Piston valve
Needle jet
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
CARB
Remarks
For assembly, reverse the disassembly
procedure.
6-5
CARBURETORS
CARB
EAS00486
CHECKING THE CARBURETORS
The following procedure applies to all of the
carburetors.
1. Check:
• carburetor body
• float chamber
• jet housing
Cracks/damage → Replace.
2. Check:
• fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• float chamber body
Dirt → Clean.
4. Check:
• float chamber rubber gasket 1
Cracks/damage/wear → Replace.
5. Check:
• float
Damage → Replace.
6. Check:
• needle valve 1
Damage/obstruction/wear → Replace the
needle valve.
7. Check:
• piston valve 1
Damage/scratches/wear→ Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.
6-6
CARBURETORS
CARB
8.
•
•
•
•
Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
jet needle spring 4
Cracks/damage → Replace.
9.
•
•
•
•
•
•
•
•
Check:
jet needle kit 1
needle jet 2
main jet 3
pilot jet 4
pilot screw assembly 5
pilot air jet No. 1 6
pilot air jet No. 2 7
starter plunger assembly 8
Bends/damage/wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
10.Check:
• piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness → Replace the piston valve.
11.Check:
• fuel feed hoses
• fuel hoses
Cracks/damage/wear → Replace.
Obstruction → Clean.
Blow out the hoses with compressed air.
6-7
CARBURETORS
CARB
EAS00488
ASSEMBLING THE CARBURETORS
The following procedure applies to all of the
carburetors.
CAUTION:
@
• Before assembling the carburetors, wash
all of the parts in a petroleum-based solvent.
• Always use a new gasket.
@
1.
•
•
•
•
Install:
O-ring New
washer
pilot screw spring
pilot screw 1
Pilot screw setting
2-1/2 turns out
2.
•
•
•
•
Install:
gasket 1
O-ring 2
needle jet 3
jet block 4
NOTE:
Align the slot a on the needle jet with the projection b on the jet block.
3.
•
•
•
•
•
Install:
piston valve 1
jet needle kit
jet needle holder
piston valve spring
vacuum chamber cover 2
NOTE:
• Install the end of the piston valve spring onto
the spring guide on the vacuum chamber
cover.
• Align the tab a on the piston valve diaphragm with the recess b in the carburetor
body.
@
@
6-8
CARBURETORS
4.
•
•
•
CARB
Install:
coasting enricher 1
coasting enricher spring
coasting enricher cover 2
NOTE:
Align the tab a on the coasting enricher with
the recess b in the carburetor body.
EAS00493
INSTALLING THE CARBURETORS
1. Adjust:
• carburetor synchronization
Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3.
2. Adjust:
• engine idling speed
Engine idling speed
950 ~ 1,050 r/min
Refer to “ADJUSTING THE
IDLING SPEED” in chapter 3.
3. Adjust:
• throttle cable free play
ENGINE
Throttle cable free play
(at the flange of the throttle grip)
3 ~ 5 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
6-9
CARBURETORS
CARB
EAS00495
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel level a
Out of specification → Adjust.
Fuel level
(below the line on the vacuum
chamber)
15 ~ 17 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 onto the fuel
drain pipe 2.
Fuel level gauge
90890-01312
d. Loosen the fuel drain screw 3.
e. Hold the fuel level gauge vertically next to
the line on the vacuum chamber 4.
f. Measure the fuel level a on both sides of
the carburetor assembly.
NOTE:
The fuel level readings should be equal on
both sides.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor assembly.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by
slightly bending the float tang 1.
e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 10
CARBURETORS
CARB
EAS00504
CHECKING THE FUEL PUMP
1. Check:
• fuel pump
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the top cover and air filter case.
Refer to “TOP COVER AND COVERS” and
“AIR FILTER CASE AND ELECTRICAL
COMPONENTS BOARD” in chapter 3.
b. Disconnect the fuel hose (fuel pump to carburetor) 1 from the carburetor.
c. Place a container under the end of the fuel
hose.
d. Install the top cover and air filter case.
Refer to “TOP COVER AND COVERS” and
“AIR FILTER CASE AND ELECTRICAL
COMPONENTS BOARD” in chapter 3.
e. Start the engine and check if fuel flows from
the fuel hose 1.
Fuel flows.
Fuel pump is OK.
Fuel does not flow.
Replace
pump.
the
fuel
f. Stop the engine and check if the fuel stops
flowing from the fuel hose 1.
Fuel stops flowing.
Fuel pump is OK.
Fuel flows.
Replace
pump.
the
fuel
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 11
CHAS
7
CHAS
CHAPTER 7
CHASSIS
FRONT WHEEL AND BRAKE DISCS ........................................................... 7-1
REMOVING THE FRONT WHEEL ........................................................... 7-4
DISASSEMBLING THE FRONT WHEEL ................................................. 7-4
CHECKING THE FRONT WHEEL ........................................................... 7-5
CHECKING THE BRAKE DISCS ............................................................. 7-6
CHECKING THE SPEEDOMETER GEAR UNIT ..................................... 7-8
ASSEMBLING THE FRONT WHEEL .......................................................7-8
INSTALLING THE FRONT WHEEL .........................................................7-8
ADJUSTING THE FRONT WHEEL STATIC BALANCE .......................... 7-9
REAR WHEEL AND BRAKE DISC ..............................................................7-12
REMOVING THE REAR WHEEL ........................................................... 7-15
CHECKING THE REAR WHEEL ............................................................ 7-16
CHECKING THE REAR WHEEL DRIVE HUB ....................................... 7-16
INSTALLING THE REAR WHEEL .......................................................... 7-16
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 7-17
FRONT AND REAR BRAKES ...................................................................... 7-18
REPLACING THE FRONT BRAKE PADS ............................................. 7-20
REPLACING THE REAR BRAKE PADS ................................................ 7-22
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............7-31
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER ............... 7-31
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS ..........................................................................7-32
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ............................................................................7-33
ASSEMBLING AND INSTALLING THE REAR BRAKE
MASTER CYLINDER ............................................................................7-35
DISASSEMBLING THE FRONT BRAKE CALIPERS ............................. 7-42
DISASSEMBLING THE REAR BRAKE CALIPER .................................7-43
CHECKING THE FRONT AND REAR BRAKE CALIPERS ................... 7-44
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS .... 7-45
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER .........7-47
HYDRAULIC CLUTCH ................................................................................. 7-50
DISASSEMBLING THE CLUTCH MASTER CYLINDER .......................7-53
CHECKING THE CLUTCH MASTER CYLINDER ..................................7-54
ASSEMBLING AND INSTALLING THE CLUTCH
MASTER CYLINDER ............................................................................7-55
DISASSEMBLING THE CLUTCH RELEASE CYLINDER ......................7-61
CHECKING THE CLUTCH RELEASE CYLINDER ................................7-62
ASSEMBLING AND INSTALLING THE CLUTCH
RELEASE CYLINDER ...........................................................................7-63
CHAS
FRONT FORK ...............................................................................................7-65
REMOVING THE FRONT FORK LEGS ................................................. 7-68
DISASSEMBLING THE FRONT FORK LEGS ....................................... 7-69
CHECKING THE FRONT FORK LEGS ................................................. 7-70
ASSEMBLING THE FRONT FORK LEGS ............................................. 7-71
INSTALLING THE FRONT FORK LEGS ............................................... 7-74
HANDLEBAR ...............................................................................................7-75
REMOVING THE HANDLEBAR ............................................................. 7-78
CHECKING THE HANDLEBAR ............................................................. 7-78
INSTALLING THE HANDLEBAR ........................................................... 7-79
STEERING HEAD ......................................................................................... 7-81
REMOVING THE LOWER BRACKET ....................................................7-83
CHECKING THE STEERING HEAD ......................................................7-83
INSTALLING THE STEERING HEAD ....................................................7-84
REAR SHOCK ABSORBER ........................................................................7-86
HANDLING THE REAR SHOCK ABSORBER ....................................... 7-87
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES .............. 7-87
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 7-88
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES ............. 7-88
SWINGARM .................................................................................................. 7-89
REMOVING THE SWINGARM ...............................................................7-91
CHECKING THE SWINGARM ...............................................................7-92
INSTALLING THE SWINGARM ............................................................. 7-92
SHAFT DRIVE ..............................................................................................7-94
TROUBLESHOOTING ...........................................................................7-94
CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND
CHECKING THE SHAFT DRIVE FOR LEAKS ...................................... 7-97
MEASURING THE RING GEAR BACKLASH ........................................ 7-98
ADJUSTING THE RING GEAR BACKLASH ..........................................7-99
MEASURING THE RING-GEAR-TO-STOPPER-BOLT
CLEARANCE ....................................................................................... 7-100
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT
CLEARANCE ....................................................................................... 7-100
DISASSEMBLING THE FINAL DRIVE ASSEMBLY ............................7-105
REMOVING AND INSTALLING THE RING GEAR BEARINGS ..........7-106
ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR .......7-107
CHECKING THE DRIVE SHAFT .......................................................... 7-113
INSTALLING THE FINAL DRIVE ASSEMBLY ..................................... 7-113
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
D
FW
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the front wheel and brake
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
1
2
3
4
5
6
Speedometer cable
Brake hose holder (left and right)
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
1
2
2
1
1
1
7-1
Loosen.
Refer to “REMOVING THE
FRONT WHEEL” and
“INSTALLING THE
FRONT WHEEL”.
FRONT WHEEL AND BRAKE DISCS
CHAS
D
FW
Order
7
8
9
Job/Part
Speedometer gear unit
Collar
Brake disc (left and right)
Q’ty
1
1
2
Remarks
Refer to “INSTALLING THE FRONT
WHEEL”.
For installation, reverse the removal procedure.
7-2
FRONT WHEEL AND BRAKE DISCS
CHAS
D
FW
Order
1
Job/Part
Disassembling the front wheel
Oil seal (left and right)
Q’ty
2
3
4
Speedometer clutch retainer
Speedometer clutch
Wheel bearing (left and right)
1
1
2
5
6
Spacer flange
Spacer
1
1
2
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE FRONT
WHEEL” and “ASSEMBLING THE
FRONT WHEEL”.
Refer to “DISASSEMBLING THE FRONT
WHEEL” and “ASSEMBLING THE
FRONT WHEEL”.
For assembly, reverse the disassembly
procedure.
7-3
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
@
2. Remove:
• left brake caliper
• right brake caliper
NOTE:
Do not squeeze the brake lever when removing the brake calipers.
@
@
3. Elevate:
• front wheel
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
@
EAS00523
DISASSEMBLING THE FRONT WHEEL
1. Remove:
• oil seals
• wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
@
@
c. Remove the wheel bearings 3 with a general bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-4
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
• front wheel axle
Roll the front wheel axle on a flat surface.
Bends → Replace.
WARNING
@
Do not attempt to straighten a bent front
wheel axle.
@
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Radial wheel runout limit
1 mm
Lateral wheel runout limit
0.5 mm
4. Check:
• collar
Damage/wear → Replace.
5. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.
7-5
FRONT WHEEL AND BRAKE DISCS
6. Replace:
• wheel bearings
• oil seals New
CHAS
New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
@
@
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
@
Do not contact the wheel bearing inner race
4 or balls 5. Contact should be made only
with the outer race 6.
@
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00531
È
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
É
Brake disc deflection limit (maximum)
Front: 0.3 mm
Rear: 0.15 mm
È Front
É Rear
a 1.5 mm from the edge of the brake discs.
7-6
FRONT WHEEL AND BRAKE DISCS
CHAS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 ~ 3 mm below the
edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
Front: 4.5 mm
Rear: 7.0 mm
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
@
@
T.
R.
Brake disc bolt
23 Nm (2.3 m • kg)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-7
CHAS
FRONT WHEEL AND BRAKE DISCS
EAS00535
CHECKING THE SPEEDOMETER GEAR
UNIT
1. Check:
• speedometer clutch
Bends/damage/wear → Replace.
2. Check:
• speedometer gear unit
Damage/wear → Replace.
EAS00539
ASSEMBLING THE FRONT WHEEL
1. Install:
• wheel bearings New
• oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
@
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race 3.
@
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
• speedometer gear unit
Recommended lubricant
Lithium soap base grease
T.
R.
2. Install:
• brake discs 1
23 Nm (2.3 m · kg)
NOTE:
• Apply the locking agent (LOCTITE®) to the
threads of the brake disc bolts.
• Tighten the brake disc bolts in stages and in
a crisscross pattern.
7-8
CHAS
FRONT WHEEL AND BRAKE DISCS
3. Install:
• speedometer gear unit
NOTE:
Make sure the speedometer gear unit and the
wheel hub are installed with the two projections 1 meshed into the two slots 2 respectively.
@
@
4.
•
5.
•
Install:
collar
Install:
front wheel
NOTE:
Make sure the slot in the speedometer gear
unit fits over the stopper on the outer tube.
@
@
T.
6. Tighten:
• front wheel axle 1
58 Nm (5.8 m · kg)
• wheel axle pinch bolt 2
R.
T.
R.
20 Nm (2.0 m · kg)
• brake caliper bolts 3
T.
R.
40 Nm (4.0 m · kg)
WARNING
@
Make sure the brake cable is routed properly.
@
CAUTION:
@
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
@
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
• Adjust the front wheel static balance with the
brake discs installed.
@
@
7-9
FRONT WHEEL AND BRAKE DISCS
1.
•
2.
•
CHAS
Remove:
balancing weight(s)
Find:
front wheel’s heavy spot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Place the front wheel on a suitable balancing
stand.
@
@
a. Spin the front wheel.
b. When the front wheel stops, put an “X” mark
at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X”
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
@
@
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 10
FRONT WHEEL AND BRAKE DISCS
CHAS
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 11
REAR WHEEL AND BRAKE DISC
CHAS
EAS00551
REAR WHEEL AND BRAKE DISC
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the rear wheel and brake
disc
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
1
2
3
4
5
6
7
8
Brake caliper
Wheel axle nut
Pinch bolt
Rear wheel axle
Brake caliper bracket
Rear wheel
Collar
Brake disc
1
1
1
1
1
1
1
1
Loosen.
Refer to “REMOVING THE
REAR WHEEL” and
“INSTALLING THE REAR
WHEEL”.
For installation, reverse the removal procedure.
7 - 12
REAR WHEEL AND BRAKE DISC
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the rear wheel
Dust cover
Hub dust seal
Circuit
Clutch hub
O-ring
Damper
Oil seal
Circlip
Bearing
Flange spacer
Q’ty
1
1
1
1
1
6
1
1
1
1
7 - 13
CHAS
Remarks
Remove the parts in the order listed.
REAR WHEEL AND BRAKE DISC
Order
A
B
C
D
Job/Part
Spacer
Collar
Oil seal
Bearing
Q’ty
1
1
1
1
CHAS
Remarks
For assembly, reverse the disassembly
procedure.
7 - 14
REAR WHEEL AND BRAKE DISC
CHAS
EAS00562
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
@
2. Remove:
• brake caliper 1
NOTE:
Do not depress the brake pedal when removing the brake caliper.
@
@
3. Loosen:
• wheel axle nut 1
• pinch bolt 2
4.
•
•
•
•
Remove:
wheel axle nut
washer
wheel axle 1
washer
5. Remove:
• rear wheel
Move the rear wheel to the right to separate
it from the final drive housing.
7 - 15
CHAS
REAR WHEEL AND BRAKE DISC
EAS00565
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
Refer to “FRONT WHEEL AND BRAKE
DISC”.
2. Check:
• tire
• rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL AND BRAKE
DISC”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub
Cracks/damage → Replace.
• rear wheel drive hub dampers
Damage/wear → Replace.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
Recommended lubricant
Lithium soap base grease
R.
T.
R.
T.
R.
Tighten:
wheel axle nut
pinch bolt
brake caliper bolts
brake torque rod nut
T.
2.
•
•
•
•
T.
R.
7 - 16
150 Nm (15.0 m · kg)
20 Nm (2.0 m · kg)
40 Nm (4.0 m · kg)
22 Nm (2.2 m · kg)
REAR WHEEL AND BRAKE DISC
CHAS
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub
installed.
@
@
1. Adjust:
• rear wheel static balance
Refer to “FRONT WHEEL AND BRAKE
DISC”.
7 - 17
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FW
D
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the front brake pads
Brake caliper bolt
Brake hose holder bolt
Brake pad cover
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim (left and right)
Q’ty
2
1
1
2
2
1
2
2
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal procedure.
7 - 18
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
Job/Part
Removing the rear brake pads
Brake caliper bolt
Brake pad cover
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim (left and right)
Q’ty
2
1
2
2
1
2
2
CHAS
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE REAR
BRAKE PADS”.
For installation, reverse the removal procedure.
7 - 19
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
@
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
@
EAS00582
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
@
@
1.
•
•
•
•
7 - 20
Remove:
brake caliper bolt 1
brake hose holder bolt 2
brake caliper 3
brake pad cover 4
FRONT AND REAR BRAKES
2.
•
•
•
CHAS
Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
3. Remove:
• brake pads 1
(along with the brake pad shims)
4. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
5. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
@
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
R.
7 - 21
Bleed screw
6 Nm (0.6 m • kg)
CHAS
FRONT AND REAR BRAKES
d. Install a new brake pad shim onto the new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
Install:
brake pad pins
brake pad clips
brake pad cover
brake caliper
T.
6.
•
•
•
•
40 Nm (4.0 m · kg)
7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
@
@
1. Remove:
• brake caliper 1
• brake pad cover 2
7 - 22
FRONT AND REAR BRAKES
2.
•
•
•
CHAS
Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
3. Remove:
• brake pads 1
(along with the brake pad shims)
4. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
5. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
@
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
T.
R.
7 - 23
Bleed screw
6 Nm (0.6 m • kg)
CHAS
FRONT AND REAR BRAKES
d. Install a new brake pad shim 3 onto each
new brake pad 4.
NOTE:
The arrow a on the brake pad shim must point
in the direction of disc rotation.
@
@
e. Install new brake pads and a new brake pad
spring 5.
NOTE:
The longer tangs b of the brake pad spring
must point in the direction of disc rotation.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
Install:
brake pad pins
brake pad clips
brake pad cover
brake caliper
T.
6.
•
•
•
•
40 Nm (4.0 m · kg)
7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 24
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
9
CHAS
Job/Part
Q’ty
Remarks
Removing the front brake master
Remove the parts in the order listed.
cylinder
Brake fluid
Drain.
Rear view mirror
1
Brake master cylinder reservoir cap
1
Brake master cylinder reservoir dia1
phragm
Brake lever
1
Brake lever spring
1
Front brake light switch connector
2
Disconnect.
Union bolt
1
Refer to “DISASSEMBrake hose
1
Disconnect. BLING THE FRONT
BRAKE MASTER CYLINCopper washer
2
DER” and “ ASSEMBLING
AND INSTALLING THE
FRONT BRAKE MASTER
CYLINDER”.
7 - 25
FRONT AND REAR BRAKES
Order
10
11
12
Job/Part
Brake master cylinder holder
Brake master cylinder
Front brake light switch
Q’ty
1
1
1
7 - 26
CHAS
Remarks
Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER”.
For installation, reverse the removal procedure.
FRONT AND REAR BRAKES
Order
1
2
3
4
CHAS
Job/Part
Q’ty
Remarks
Disassembling the front brake masRemove the parts in the order listed.
ter cylinder
Dust boot
1
Circlip
1
Brake master cylinder kit
1
Brake master cylinder
1
For assembly, reverse the disassembly
procedure.
7 - 27
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
9
CHAS
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Right side cover
Refer to “SEATS AND SIDE COVERS” in
chapter 3.
Right rider footrest
Refer to “ENGINE” in chapter 4.
Brake fluid
Drain.
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Union bolt
1
Refer to “DISASSEMBLING
THE REAR BRAKE MASTER
Copper washer
2
Brake hose
1
Disconnect. CYLINDER” and “ASSEMBLING AND INSTALLING
Brake master cylinder bolt
2
THE REAR BRAKE CALICotter pin
1
PER”.
7 - 28
FRONT AND REAR BRAKES
Order
10
11
Job/Part
Pin
Brake master cylinder
Q’ty
1
1
CHAS
Remarks
For installation, reverse the removal procedure.
7 - 29
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
CHAS
Job/Part
Q’ty
Remarks
Disassembling the rear brake masRemove the parts in the order listed.
ter cylinder
Hose joint
1
Dust boot
1
Circlip
1
Brake master cylinder push rod
1
Brake master cylinder kit
1
Brake master cylinder
1
For assembly, reverse the disassembly
procedure.
7 - 30
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
@
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
@
@
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
@
@
7 - 31
FRONT AND REAR BRAKES
È
CHAS
EAS00592
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
É
È Front
É Rear
È
É
2. Check:
• brake master cylinder kit 1
Damage/scratches/wear → Replace.
È Front
É Rear
3. Check:
• rear brake fluid reservoir 1
Cracks/damage → Replace.
• rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
4. Check:
• front brake master cylinder reservoir 1
Cracks/damage → Replace.
• front brake master cylinder reservoir diaphragm 2
Damage/wear → Replace.
5. Check:
• brake hoses
Cracks/damage/wear → Replace.
7 - 32
CHAS
FRONT AND REAR BRAKES
EAS00598
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
@
Recommended brake fluid
DOT 4
1. Install:
• brake master cylinder 1
• brake master cylinder holder 2
T.
R.
9 Nm (0.9 m · kg)
NOTE:
• Adjust the brake master cylinder to the
proper angle, as shown.
• First, tighten the upper bolt, then the lower
bolt.
@
@
New
R.
Install:
copper washers
brake hose 1
union bolt 2
T.
2.
•
•
•
30 Nm (3.0 m · kg)
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
@
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and to the right
to make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
@
@
7 - 33
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
@
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
@
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7 - 34
CHAS
FRONT AND REAR BRAKES
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components.
@
Recommended brake fluid
DOT 4
New
R.
Install:
copper washers 1
brake hose 2
union bolt 3
T.
1.
•
•
•
30 Nm (3.0 m · kg)
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
@
CAUTION:
@
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
@
2. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
7 - 35
FRONT AND REAR BRAKES
CHAS
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
@
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
@
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7 - 36
FRONT AND REAR BRAKES
CHAS
5. Adjust:
• brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position (below the
top of the rider footrest)
20 mm
6. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
7 - 37
FRONT AND REAR BRAKES
CHAS
EAS00615
Order
1
2
3
4
5
6
Job/Part
Removing the front brake calipers
Brake fluid
Brake hose holder bolt
Union bolt
Brake hose
Copper washer
Brake caliper bolt
Brake caliper
Q’ty
1
1
1
2
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Drain.
Disconnect.
Refer to “DISASSEMBLING THE FRONT
BRAKE CALIPERS” and
“ASSEMBLING AND
INSTALLING THE FRONT
BRAKE CALIPERS”.
For installation, reverse the removal procedure.
7 - 38
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
9
CHAS
Job/Part
Q’ty
Remarks
Disassembling the front brake caliRemove the parts in the order listed.
pers
The following procedure applies to both
of the front brake calipers.
Brake pad cover
1
Brake pad clip
2
Brake pad pin
2
Brake pad spring
1
Brake pad
2
Brake pad shim (left and right)
2
Brake caliper piston
4
Refer to “DISASSEMBLING THE
FRONT BRAKE CALIPERS”.
Brake caliper piston seal
8
Bleed screw
1
For assembly, reverse the disassembly
procedure.
7 - 39
FRONT AND REAR BRAKES
Order
1
2
3
4
5
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bolt
Brake caliper
Q’ty
1
2
1
2
1
7 - 40
CHAS
Remarks
Remove the parts in the order listed.
Drain.
Refer to “DISASSEMBLING THE REAR BRAKE
Disconnect. CALIPER” and “ASSEMBLING AND INSTALLING
THE REAR BRAKE CALIPER”.
For installation, reverse the removal procedure.
FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
9
CHAS
Job/Part
Q’ty
Remarks
Disassembling the rear brake caliRemove the parts in the order listed.
per
Brake pad cover
1
Brake pad clip
2
Brake pad pin
2
Brake pad spring
1
Brake pad
2
Brake pad shim (left and right)
2
Brake caliper piston
2
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER”.
Brake caliper piston seal
4
Bleed screw
2
For assembly, reverse the disassembly
procedure.
7 - 41
FRONT AND REAR BRAKES
CHAS
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the entire brake system.
@
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
@
@
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper pistons
with a piece of wood 3.
b. Blow compressed air into the brake hose
joint opening a to force out the left side pistons from the brake caliper.
WARNING
@
• Never try to pry out the brake caliper pistons.
• Do not loosen the bolts 4.
@
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 42
FRONT AND REAR BRAKES
CHAS
EAS00629
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
@
@
1.
•
•
•
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
@
@
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper piston
with a piece of wood 3.
b. Blow compressed air into the brake hose
joint opening a to force out the left side piston from the brake caliper.
WARNING
@
• Never try to pry out the brake caliper pistons.
• Do not loosen the bolts 4.
@
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 43
FRONT AND REAR BRAKES
CHAS
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
È
É
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every two years
Brake fluid
Every two years
and whenever the
brake is disassembled
1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper.
• brake caliper cylinders 2
Scratches/wear → Replace the brake caliper.
• brake calipers 3
Cracks/damage → Replace.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
@
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
@
È Front
É Rear
2. Check:
• rear brake caliper bracket 1
Cracks/damage → Replace.
7 - 44
CHAS
FRONT AND REAR BRAKES
EAS00638
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
@
Recommended brake fluid
DOT 4
Install:
brake caliper 1 (temporarily)
copper washers New
brake hose 2
union bolt 3
30 Nm (3.0 m · kg)
T.
R.
1.
•
•
•
•
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
@
CAUTION:
@
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection a on the brake caliper.
@
R.
7 - 45
Remove:
brake caliper
Install:
brake pads
brake pad spring
brake pad pins
brake pad clips
brake caliper
40 Nm (4.0 m · kg)
brake hose holder
Refer to “REPLACING THE FRONT
BRAKE PADS”.
T.
2.
•
3.
•
•
•
•
•
•
FRONT AND REAR BRAKES
CHAS
4. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
@
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
@
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7 - 46
CHAS
FRONT AND REAR BRAKES
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00642
ASSEMBLING AND INSTALLING THE
REAR BRAKE CALIPER
WARNING
@
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
@
Recommended brake fluid
DOT 4
Install:
brake caliper 1 (temporarily)
copper washers New
brake hose 2
union bolt 3
30 Nm (3.0 m · kg)
T.
R.
1.
•
•
•
•
WARNING
@
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
@
CAUTION:
@
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection a on the brake caliper.
@
7 - 47
CHAS
FRONT AND REAR BRAKES
Remove:
brake caliper
Install:
brake pads
brake pad spring
brake caliper
40 Nm (4.0 m · kg)
Refer to “REPLACING THE REAR BRAKE
PADS”.
T.
R.
2.
•
3.
•
•
•
4. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
@
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
@
CAUTION:
@
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
@
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 48
FRONT AND REAR BRAKES
CHAS
6. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7 - 49
HYDRAULIC CLUTCH
CHAS
EAS00305
HYDRAULIC CLUTCH
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Remarks
Removing the clutch master cylinder
Remove the parts in the order listed.
Clutch fluid
Drain.
Rear view mirror
1
Clutch master cylinder reservoir cap
1
Clutch master cylinder reservoir dia1
phragm
Clutch lever
1
Refer to “ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”.
Clutch push rod holder
1
Clutch switch connector
2
Disconnect.
Union bolt
1
Refer to “DISASSEMClutch hose
1
Disconnect. BLING THE CLUTCH
MASTER CYLINDER” and
Copper washer
2
“ASSEMBLING AND
INSTALLING THE
CLUTCH MASTER CYLINDER”.
7 - 50
HYDRAULIC CLUTCH
Order
10
11
12
Job/Part
Clutch master cylinder holder
Clutch master cylinder
Clutch switch
Q’ty
1
1
1
CHAS
Remarks
Refer to “ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”.
For installation, reverse the removal procedure.
7 - 51
HYDRAULIC CLUTCH
Order
1
2
3
4
5
6
7
CHAS
Job/Part
Q’ty
Remarks
Disassembling the clutch master
Remove the parts in the order listed.
cylinder
Clutch master cylinder push rod
1
Dust boot
1
Spring
1
Circlip
1
Washer
1
Clutch master cylinder kit
1
Clutch master cylinder
1
For assembly, reverse the disassembly
procedure.
7 - 52
HYDRAULIC CLUTCH
CHAS
EAS00307
CAUTION:
@
Clutch components rarely require disassembly.
Therefore, always follow these preventive
measures:
• Never disassemble clutch components
unless absolutely necessary.
• If any connection on the hydraulic clutch
system is disconnected, the entire clutch
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal clutch
components.
• Use only clean or new clutch fluid for
cleaning clutch components.
• Clutch fluid may damage painted surfaces and plastic parts. Therefore, always
clean up any spilt clutch fluid immediately.
• Avoid clutch fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR CLUTCH FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
@
DISASSEMBLING THE CLUTCH MASTER
CYLINDER
NOTE:
Before disassembling the clutch master cylinder, drain the clutch fluid from the entire clutch
system.
1.
•
•
•
Remove:
union bolt 1
copper washers 2
clutch hose 3
NOTE:
To collect any remaining clutch fluid, place a
container under the master cylinder and the
end of the clutch hose.
7 - 53
HYDRAULIC CLUTCH
CHAS
EAS00308
CHECKING THE CLUTCH MASTER
CYLINDER
Recommended clutch component
replacement schedule
Piston seals
Every two years
Clutch hose
Every two years
Clutch fluid
Every two years
and whenever the
clutch is disassembled
1. Check:
• clutch master cylinder 1
Damage/scratches/wear → Replace.
• clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed
air.
2. Check:
• clutch master cylinder kit 1
Damage/scratches/wear → Replace.
• clutch hose
Cracks/damage/wear → Replace.
3. Check:
• clutch master cylinder reservoir 1
Cranks/damage → Replace.
• clutch master cylinder reservoir diaphragm 2
Damage/wear → Replace.
4. Check:
• clutch hose
Cracks/damage/wear → Replace.
7 - 54
CHAS
HYDRAULIC CLUTCH
EAS00309
ASSEMBLING AND INSTALLING THE
CLUTCH MASTER CYLINDER
WARNING
@
• Before installation, all internal clutch
components should be cleaned and lubricated with clean or new clutch fluid.
• Never use solvents on internal clutch
components.
@
Recommended clutch fluid
Brake fluid DOT 4
1. Install:
• clutch master cylinder 1
• clutch master cylinder holder 2
T.
R.
9 Nm (0.9 m · kg)
NOTE:
• Install the clutch master cylinder holder with
the “UP” mark facing up.
• Adjust the clutch master cylinder to the
proper angle, as shown.
• First, tighten the upper bolt, then the lower
bolt.
@
@
New
T.
R.
2. Install:
• copper washers
• clutch hose 1
• union bolt 2
30 Nm (3.0 m · kg)
WARNING
Proper clutch hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
@
7 - 55
HYDRAULIC CLUTCH
CHAS
NOTE:
• While holding the clutch hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and to the right
to make sure the clutch hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3. Install:
• clutch push rod holder 1
• clutch lever 2
NOTE:
Lubricate the clutch lever pivot with lithium
soap base grease.
@
@
4. Fill:
• clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
WARNING
@
• Use only the designated clutch fluid.
Other clutch fluids may cause the rubber
seals to deteriorate, causing leakage and
poor clutch performance.
• Refill with the same type of clutch fluid
that is already in the system. Mixing
clutch fluids may result in a harmful
chemical reaction, leading to poor clutch
performance.
• When refilling, be careful that water does
not enter the clutch master cylinder reservoir. Water will significantly lower the
boiling point of the clutch fluid and could
cause vapor lock.
@
7 - 56
HYDRAULIC CLUTCH
CHAS
CAUTION:
@
Clutch fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt clutch fluid immediately.
@@
5. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
6. Check:
• clutch fluid level
Below the minimum level mark a → Add
the recommended clutch fluid to the proper
level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” in chapter 3.
7. Check:
• clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
7 - 57
HYDRAULIC CLUTCH
CHAS
EAS00311
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the clutch release cylinder
Engine oil
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Middle gear case cover, shift pedal
Refer to “SHIFT SHAFT” in chapter 4.
assembly
Clutch fluid
Drain.
Rubber cover
1
Union bolt
1
Refer to “DISASSEMClutch hose
1
Disconnect. BLING THE CLUTCH
RELEASE CYLINDER” and
Copper washer
2
“ASSEMBLING AND
INSTALLING THE
CLUTCH RELEASE CYLINDER”.
7 - 58
HYDRAULIC CLUTCH
Order
5
6
7
Job/Part
Joint
Copper washer
Clutch release cylinder
Q’ty
1
1
1
7 - 59
CHAS
Remarks
Refer to “ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER”.
For installation, reverse the removal procedure.
HYDRAULIC CLUTCH
Order
1
2
3
4
5
CHAS
Job/Part
Q’ty
Remarks
Disassembling the clutch release
Remove the parts in the order listed.
cylinder
Oil seal
1
Clutch release cylinder piston
1
Refer to “DISASSEMBLING THE
CLUTCH RELEASE CYLINDER”.
Spring
1
Clutch release cylinder piston seal
1
Bleed screw
1
For assembly, reverse the disassembly
procedure.
7 - 60
HYDRAULIC CLUTCH
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
NOTE:
Before disassembling the clutch release cylinder, drain the clutch fluid from the entire clutch
system.
1.
•
•
•
Remove:
union bolt 1
copper washers
clutch hose 2
NOTE:
Put the end of the clutch hose into a container
and pump out the clutch fluid carefully.
2.
•
•
•
•
Remove:
oil seal
clutch release cylinder piston
spring
clutch release cylinder piston seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the joint opening
a to force out the piston from the clutch
release cylinder.
WARNING
@
• Cover the clutch release cylinder with a
rag. Be careful not to get injured when the
piston is expelled from the clutch release
cylinder.
• Never try to pry out the clutch release cylinder piston.
@
b. Remove the clutch release cylinder piston
seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 61
HYDRAULIC CLUTCH
CHAS
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
Recommended clutch component
replacement schedule
Piston seals
Every two years
Clutch hose
Every two years
Clutch fluid
Every two years
and whenever the
clutch is disassembled
1. Check:
• clutch release cylinder body 1
Cracks/damage → Replace the clutch
release cylinder.
2. Check:
• clutch release cylinder 1
• clutch release cylinder piston 2
Rust/scratches/wear → Replace the clutch
release cylinder and clutch release cylinder
piston as a set.
7 - 62
CHAS
HYDRAULIC CLUTCH
ASSEMBLING AND INSTALLING THE
CLUTCH RELEASE CYLINDER
WARNING
• Before installation, all internal clutch
components should be cleaned and lubricated with clean or new clutch fluid.
• Never use solvents on internal clutch
components as they will cause the piston
seal to swell and distort.
• Whenever a clutch master cylinder is disassembled, replace the piston seal.
Recommended clutch fluid
Brake fluid DOT 4
1. Install:
• clutch release cylinder 1
T.
R.
25 Nm (2.5 m · kg)
New
T.
R.
Install:
copper washers
clutch hose 1
union bolt 2
R.
3.
•
•
•
New
T.
2. Install:
• copper washer
• joint 1
12 Nm (1.2 m · kg)
25 Nm (2.5 m · kg)
WARNING
@
Proper clutch hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
@
7 - 63
HYDRAULIC CLUTCH
CHAS
4. Fill:
• clutch master cylinder reservoir
(with the specified amount of the recommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
WARNING
@
• Use only the designated clutch fluid.
Other clutch fluids may cause the rubber
seals to deteriorate, causing leakage and
poor clutch performance.
• Refill with the same type of clutch fluid
that is already in the system. Mixing
clutch fluids may result in a harmful
chemical reaction, leading to poor clutch
performance.
• When refilling, be careful that water does
not enter the clutch release cylinder reservoir. Water will significantly lower the
boiling point of the clutch fluid and could
cause vapor lock.
@
CAUTION:
@
Clutch fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt clutch fluid immediately.
@@
5. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
6. Check:
• clutch fluid level
Below the minimum level mark a → Add
the recommended clutch fluid to the proper
level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” in chapter 3.
7. Check:
• clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
7 - 64
FRONT FORK
CHAS
EAS00647
FRONT FORK
Order
Job/Part
Removing the front fork legs
Q’ty
Front wheel
1
2
3
4
5
6
7
Front fender
Front fender brace
Front fork air valve cap
Cap bolt
Upper bracket pinch bolt
Lower bracket pinch bolt
Front fork leg
1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Loosen.
Loosen.
Loosen.
Refer to “REMOVING THE
FRONT FORK LEGS” and
“INSTALLING THE FRONT
FORK LEGS”.
For installation, reverse the removal procedure.
7 - 65
FRONT FORK
Order
1
2
3
4
5
6
7
8
9
Job/Part
Disassembling the front fork legs
Cap bolt
O-ring
Collar
Spring seat
Fork spring
Dust seal
Oil seal clip
Damper rod bolt
Copper washer
Q’ty
1
1
1
1
1
1
1
1
1
7 - 66
CHAS
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to “ASSEMBLING THE FRONT
FORK LEGS”.
Refer to “DISASSEMBLING THE FRONT
FORK LEGS” and “ASSEMBLING THE
FRONT FORK LEGS”.
FRONT FORK
Order
0
A
B
C
D
E
F
G
H
Job/Part
Damper rod
Damper rod spring
Inner tube
Oil seal
Seal spacer
Outer tube bushing
Inner tube bushing
Oil flow stopper
Outer tube
Q’ty
1
1
1
1
1
1
1
1
1
CHAS
Remarks
Refer to “DISASSEMBLING THE FRONT
FORK LEGS” and “ASSEMBLING THE
FRONT FORK LEGS”.
Refer to “ASSEMBLING THE FRONT
FORK LEGS”.
For assembly, reverse the disassembly
procedure.
7 - 67
FRONT FORK
CHAS
EAS00650
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
@
@
2. Loosen:
• cap bolt 1
NOTE:
Release the air pressure the front fork leg by
pressing down on the front fork air valve 2.
@
@
3. Loosen:
• upper bracket pinch bolt 1
• lower bracket pinch bolts 2
WARNING
@
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
@
4. Remove:
• front fork leg
7 - 68
FRONT FORK
CHAS
EAS00653
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Drain:
• fork oil
NOTE:
Stroke the outer tube several times while
draining the fork oil.
2. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
@
Do not scratch the inner tube.
@
3. Remove:
• damper rod bolt
• damper rod
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2, loosen the
damper rod assembly bolt.
@
@
Damper rod holder (29 mm)
90890-01375
T-handle
90890-01326
4. Remove:
• inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube by
pulling the inner tube forcefully but carefully.
CAUTION:
@
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
• Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 69
FRONT FORK
CHAS
EAS00657
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
@
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
@
2. Measure:
• fork spring free length a
Out of specification → Replace.
Spring free length limit
381.5 mm
3. Check:
• damper rod 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• oil flow stopper 2
Damage → Replace.
4. Check:
• cap bolt O-ring
Damage/wear → Replace.
7 - 70
FRONT FORK
CHAS
EAS00659
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
@
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
@
NOTE:
• When assembling the front fork leg, be sure
to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
@
@
1. Install:
• damper rod 1
CAUTION:
@
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
@
2.
•
•
3.
•
Install:
inner tube bushing 1 New
oil flow stopper 2
Lubricate:
inner tube’s outer surface
Recommended lubricant
Fork oil 10W or equivalent
4. Install:
• outer tube
(on to inner tube)
• copper washer New
• damper rod bolt
7 - 71
CHAS
FRONT FORK
T.
R.
5. Tighten:
• damper rod bolt
30 Nm (3.0 m · kg)
NOTE:
• Apply the locking agent (LOCTITE®) to the
threads of the damper rod bolt.
• While holding the damper rod assembly with
the damper rod holder 1 and T-handle 2,
tighten the damper rod assembly bolt.
@
@
Damper rod holder (29 mm)
90890-01375
T-handle
90890-01326
6. Install:
• outer tube bushing 1 New
• seal spacer 2
(with the fork seal driver weight 3 and fork
seal driver attachment 4)
Fork seal driver weight
90890-01367
Attachment (f40)
90890-01373
7. Install:
• washer
• oil seal 1 New
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
CAUTION:
@
Make sure the numbered side of the oil seal
faces up.
@
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium soap base grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to protect the oil seal during installation.
@
@
7 - 72
FRONT FORK
CHAS
8. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
@
@
9. Install:
• dust seal 1 New
(with the fork seal driver weight 2)
10.Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
621 cm3
Recommended oil
Yamaha fork oil 10W or equivalent
Front fork leg oil level a
(from the top of the inner tube,
with the inner tube fully compressed and without the fork
spring)
123 mm
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
@
@
7 - 73
CHAS
FRONT FORK
11.Install:
• fork spring
• spring seat
• collar
• cap bolt
NOTE:
• Install the spring with the smaller pitch a facing
up È.
• Before installing the cap bolt, lubricate its O-ring
with grease.
• Temporarily tighten the cap bolt.
@
@
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
NOTE:
• Make sure the inner tube is flush with the top
of the upper bracket.
• Temporarily tighten the upper and lower
bracket pinch bolts.
@
@
2. Tighten:
• lower bracket pinch bolts 1
T.
R.
23 Nm (2.3 m · kg)
T.
• cap bolt 2
23 Nm (2.3 m · kg)
• upper bracket pinch bolt 3
R.
T.
R.
23 Nm (2.3 m · kg)
WARNING
Make sure the brake hoses and clutch hose
are routed properly.
3.
•
•
4.
•
7 - 74
Install:
front fender brace
front fender
Adjust:
compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the master cylinders,
handlebar switches and handlebar
grips
Rear view mirror (left and right)
2
Plastic band
2
Front brake light switch connector
2
Disconnect.
Brake master cylinder holder
1
Brake master cylinder
1
Refer to “INSTALLING THE HANDLEBAR”.
Right handlebar switch
1
Throttle cable holder
1
Throttle cable
2
Disconnect.
Throttle grip
1
Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”.
Clutch switch connector
2
Disconnect.
7 - 75
HANDLEBAR
Order
11
12
13
14
Job/Part
Clutch master cylinder holder
Clutch master cylinder
Left handlebar switch
Handlebar grip
CHAS
Q’ty
Remarks
1
1
Refer to “INSTALLING THE HANDLEBAR”.
1
1
Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”.
For installation, reverse the removal procedure.
7 - 76
HANDLEBAR
Order
1
2
3
4
5
Job/Part
Removing the handlebar
Upper handlebar holder
Handlebar
Turn signal light bracket assembly
Speedometer assembly
Lower handlebar holder
Q’ty
1
1
1
1
1
CHAS
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE HANDLEBAR”.
For installation, reverse the removal procedure.
7 - 77
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
2. Remove:
• handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
@
@
EAS00668
CHECKING THE HANDLEBAR
1. Check:
• handlebar 1
Bends/cracks/damage → Replace.
WARNING
@
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
@
2. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
@
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 78
CHAS
HANDLEBAR
EAS00670
INSTALLING THE HANDLEBAR
1. Install:
• lower handlebar holder 1
T.
R.
40 Nm (4.0 m · kg)
• turn signal light bracket assembly 2
• speedometer assembly 3
2. Install:
• handlebar 1
• upper handlebar holder 2
T.
R.
20 Nm (2.0 m · kg)
CAUTION:
@
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
top cover, adjust the handlebar position.
@
NOTE:
• Install upper handlebar holder as shown.
• Align the match marks a on the handlebar
with the upper surface of the lower handlebar
holder.
@
@
3. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe of any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 79
HANDLEBAR
CHAS
4. Install:
• left handlebar switch
NOTE:
Install the left handlebar switch as shown.
5. Install:
• clutch master cylinder
Refer to “HYDRAULIC CLUTCH”.
6. Install:
• right handlebar switch
NOTE:
Install the right handlebar switch as shown.
7. Install:
• front brake master cylinder
Refer to “FRONT AND REAR BRAKES”.
8. Adjust:
• brake lever free play
Refer to “ADJUSTING
BRAKE” in chapter 3.
THE
FRONT
Brake lever free play (at the end
of the brake lever)
2 ~ 5 mm
9. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm
7 - 80
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the lower bracket
Handlebar/handlebar holders
Front fork legs
Headlight lens unit
Lead (in the headlight body)
Turn signal light bracket assembly
Speedometer assembly
Headlight body
Hose joint cover
Brake hose joint
Steering stem nut
Q’ty
1
1
1
1
1
1
1
1
7 - 81
Remarks
Remove the parts in the order listed.
Refer to “HANDLEBAR”.
Refer to “FRONT FORK”.
Disconnect.
Refer to “INSTALLING THE STEERING
HEAD”.
STEERING HEAD
Order
9
10
11
12
13
14
15
16
17
18
19
Job/Part
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Bearing cover
Upper bearing
Lower bearing
Bearing outer race
Rubber seal
Q’ty
1
1
1
1
1
1
CHAS
Remarks
Refer to “INSTALLING THE STEERING
HEAD”.
Refer to “REMOVING THE LOWER
BRACKET” and “INSTALLING THE
STEERING HEAD”.
1
1
1
2
1
For installation, reverse the removal procedure.
7 - 82
STEERING HEAD
CHAS
EAS00677
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
2. Remove:
• lower ring nut 1
(with the steering nut wrench 2)
• lower bracket
Steering nut wrench
90890-01403
WARNING
@
Securely support the lower bracket so that
there is no danger of it falling.
@
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• bearings 1
• bearing races 2
Damage/pitting → Replace.
7 - 83
STEERING HEAD
CHAS
3. Replace:
• bearings
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
@
If the bearing race is not installed properly,
the steering head pipe could be damaged.
@
NOTE:
• Always replace the bearings and bearing
races as a set.
• Whenever the steering head is disassembled, replace the rubber seal.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium soap base grease
2.
•
•
•
•
•
7 - 84
Install:
lower bracket
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
CHAS
STEERING HEAD
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
@
@
4. Install:
• front fork legs
NOTE:
Temporarily tighten the lower bracket pinch
bolts.
5. Tighten:
• steering stem nut 1
T.
R.
6 Nm (0.6 m · kg)
Install:
hose joint cover 1
6 Nm (0.6 m · kg)
Install:
front fork legs
Refer to “FRONT FORK”.
T.
R.
7 - 85
R.
7.
•
8.
•
T.
6. Install:
• brake hose joint 1
110 Nm (11.0 m · kg)
REAR SHOCK ABSORBER
CHAS
REAR SHOCK ABSORBER
Order
1
2
3
4
5
Job/Part
Removing the rear shock absorbers
Nut (left and right)
Washer (left and right)
Bolt (left and right)
Spacer (left and right)
Rear shock absorber (left and right)
Q’ty
2
2
2
2
2
Remarks
Remove the parts in the order listed.
Refer to “REMOVING THE REAR
SHOCK ABSORBER ASSEMBLIES”
and “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES”.
For installation, reverse the removal procedure.
7 - 86
REAR SHOCK ABSORBER
CHAS
EAS00686
HANDLING THE REAR SHOCK ABSORBER
WARNING
@
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure you understand the following information. The manufacturer cannot be held
responsible for property damage or personal injury that may result from improper
handling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock
absorber damage will result in poor
damping performance.
@
EAS00691
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
@
2.
•
•
3.
Remove:
rear shock absorber upper bolt
rear shock absorber lower nut
Pull out the rear shock absorber top, and
turn the rear shock absorber backward.
4. Remove:
• rear shock absorber
7 - 87
CHAS
REAR SHOCK ABSORBER
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Gas leaks/oil leaks → Replace the rear
shock absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bolt
Bends/damage/wear → Replace.
EAS00699
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES
1. Lubricate:
• rear shock absorber mounting pivot
Recommended lubricant
Molybdenum disulfide grease
2. Install:
• rear shock absorber
NOTE:
The rear shock absorber should be installed so
that mark a on the rear shock absorber faces
outward.
3. Tighten:
• rear shock absorber upper bolt
T.
R.
20 Nm (2.0 m · kg)
• rear shock absorber lower nut
T.
R.
7 - 88
30 Nm (3.0 m · kg)
SWINGARM
CHAS
EAS00701
SWINGARM
Order
1
2
3
4
5
6
7
Job/Part
Removing the swingarm
Muffler
Rear shock absorbers
Final drive assembly
Pinch bolt
Brake torque rod
Pivot bolt cover (left and right)
Locknut
Right pivot bolt
Left pivot bolt/lock washer
Swingarm
Q’ty
1
1
2
1
1
1/1
1
7 - 89
Remarks
Remove the parts in the order listed.
Refer to “ENGINE” in chapter 4.
Refer to “REAR SHOCK ABSORBER”.
Refer to “SHAFT DRIVE”.
Refer to “INSTALLING THE SWINGARM”.
Refer to “REMOVING THE SWINGARM”
and “INSTALLING THE SWINGARM”.
SWINGARM
Order
8
9
10
11
Job/Part
Rubber boot/spring
Spacer (left and right)
Oil seal (left and right)
Bearing (left and right)/
bearing race (left and right)
CHAS
Q’ty
Remarks
1/1 Refer to “INSTALLING THE SWINGARM”.
2
2
2/2
For installation, reverse the removal procedure.
7 - 90
SWINGARM
CHAS
EAS00702
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
WARNING
@
Securely support the motorcycle so that
there is no danger of it falling over.
@
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
@
@
2. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the swingarm pivot bolts and locknut.
T.
R.
Left pivot bolt
100 Nm (10.0 m • kg)
Locknut
100 Nm (10.0 m • kg)
Right pivot bolt
6 Nm (0.6 m • kg)
b. Measure the swingarm side play by moving
the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers and bearings.
Swingarm side play (at the end of
the swingarm)
0 mm
d. Check the swingarm vertical movement by
moving the swingarm up and down. If swingarm vertical movement is not smooth or if
there is binding, check the spacers and
bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 91
SWINGARM
CHAS
EAS00708
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
2. Check:
• left pivot bolt
• right pivot bolt
Damage/wear → Replace.
3. Check:
• spacers
• oil seals
• bearings
• pivot bolt covers
Damage/wear → Replace.
EAS00712
INSTALLING THE SWINGARM
1. Lubricate:
• bearings
• spacers
• oil seals
Recommended lubricant
Lithium soap base grease
2. Install:
• rubber boot 1
NOTE:
Make sure the hole 2 on the rubber boot is
facing downward.
7 - 92
CHAS
SWINGARM
3.
•
•
•
Tighten:
left pivot bolt 1
right pivot bolt 2
locknut 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the left pivot bolt 1 to specification.
T.
Left pivot bolt
100 Nm (10.0 m • kg)
R.
b. Tighten the right pivot bolt 2 to specification.
T.
Right pivot bolt
6 Nm (0.6 m • kg)
R.
c. Tighten the locknut 3 to specification.
T.
Locknut
100 Nm (10.0 m • kg)
R.
d. Bend the lock washer tab 4 along a flat
side of the locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• brake torque rod 1
T.
R.
22 Nm (2.2 m · kg)
WARNING
@
Always use a new cotter pin.
@
5. Install:
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
7 - 93
SHAFT DRIVE
CHAS
EAS00715
SHAFT DRIVE
TROUBLESHOOTING
A
Symptom
B
1. A pronounced hesitation or jerky movement
during acceleration, deceleration or sustained
speeds. (not to be confused with engine surging or transmission-related movements.)
2. A rolling “rumble” noticeable at low speeds, a
high-pitched whine or a “clunk” from a shaft
drive component, or from the vicinity of the
shaft drive.
3. The shaft drive is locked up or no power is
transmitted from the engine to the rear wheel.
Possible cause
A. Bearing damage
B. Improper gear backlash
C. Damaged gear teeth
D. Broken drive shaft
E. Broken gear teeth
F. Seizure due to lack of lubrication
G. Small foreign objects lodged between moving
parts
NOTE:
Causes A, B, and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal operating noises. If there is reason to believe that these components are damaged, remove them and check them individual.
@
@
7 - 94
SHAFT DRIVE
CHAS
Inspection notes
1. Inves tigate any unusual noises.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The following noises may indicate a
mechanical defect:
a. A rolling “rumble” during coasting, acceleration or deceleration (increases with the rear
wheel speed, but does not increase with
higher engine or transmission speeds).
Diagnosis: Possible wheel bearing damage
b. A whining noise that varies with acceleration and deceleration.
Diagnosis: Possible incorrect reassembly or
too little gear backlash
WARNING
@
Insufficient gear backlash is extremely
destructive to the gear teeth. If a test ride,
following reassembly, indicates these
symptoms, stop riding immediately to minimize gear damage.
@
c. A slight “clunk” evident at low speed operation (not to be confused with normal motorcycle operation).
Diagnosis: Possible broken gear teeth
WARNING
@
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing a loss of control and possible
injury to the rider.
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 95
SHAFT DRIVE
CHAS
EAS00716
Troubleshooting chart
When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section
exist, check the following points.
Place the motorcycle on a suitable stand so YES Replace the wheel bearing.
Refer to “FRONT WHEEL AND BRAKE
that the front wheel is elevated and then
DISCS”.
spin the front wheel. Is the wheel bearing
damaged?
NO
Place the motorcycle on a suitable stand so
that the rear wheel is elevated and then spin
the rear wheel. Is the wheel bearing damaged?
NO
Rear wheel bearings and shaft drive bearings are probably not damaged. Repeat the
test or remove and check the components.
YES
Remove the rear wheel. Is the wheel bear- YES Replace the rear wheel bearing.
Refer to “REAR WHEEL AND BRAKE
ing damaged?
DISCS”.
NO
Remove and check the drive shaft components.
7 - 96
SHAFT DRIVE
CHAS
EAS00717
CHECKING THE FINAL DRIVE OIL FOR
CONTAMINATION AND CHECKING THE
SHAFT DRIVE FOR LEAKS
1. Drain:
• final drive oil
(from the final drive housing)
Refer to “CHANGING THE FINAL DRIVE
OIL” in chapter 3.
2. Check:
• final drive oil
Large amount of metal particles → Check
for bearing seizure.
NOTE:
A small amount of metal particles in the final
drive oil is normal.
@
@
3. Check:
• shaft drive housing
(for oil leaks)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Thoroughly clean the entire motorcycle and
then completely dry it.
b. Apply a leak-locating compound or dry powder spray to the shaft drive.
c. Test ride the motorcycle long enough to
locate a leak.
Oil leak → Repair or replace the faulty
part(s).
1 Oil seal
2 O-ring
3 Forward
NOTE:
• What may appear to be an oil leak on a new
or fairly new motorcycle, may result from the
application of a rust preventive coating or
excessive seal lubrication.
• Always clean the motorcycle and recheck the
area where the leak is thought to originate
from.
@
@ STPEL
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 97
SHAFT DRIVE
CHAS
EAS00719
MEASURING THE RING GEAR BACKLASH
1. Secure the final drive assembly in a vise.
2. Remove:
• final drive oil drain bolt
3. Drain:
• final drive oil
(from the final drive assembly)
4. Measure:
• ring gear backlash
Out of specification → Adjust.
Ring gear backlash
0.1 ~ 0.2 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the ring gear fix bolt 1, into the final
gear oil drain hole.
Ring gear fix bolt (M14)
90890-01524
b. Finger tighten the bolt until it stops the ring
gear from moving.
NOTE:
Do not overtighten the bolt.
@
@
c. Install the final gear backlash band 2 and
dial gauge 3.
Final gear backlash band
90890-01230
a Dial-gauge-plunger contact point
d. Gently rotate the gear coupling from
engagement to engagement.
e. Record the reading on the dial gauge.
f. Remove the dial gauge, final gear backlash
band, and bolt.
g. Rotate the final drive pinion gear 90°.
h. Reinstall the bolt, special tool, and dial
gauge.
i. Repeat steps (d) to (h) three more times (for
a total of four measurements).
j. If any of the readings are over specification,
adjust the ring gear backlash.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 98
CHAS
SHAFT DRIVE
EAS00720
ADJUSTING THE RING GEAR BACKLASH
1. Remove:
• ring gear bearing housing nuts
• ring gear bearing housing bolts
NOTE:
Working in a crisscross pattern, loosen each
nut 1/4 of a turn. After all of the nuts are fully
loosened, remove them and the bolts.
@
@
2.
•
•
•
•
•
3.
•
Remove:
ring gear bearing housing 1
dust cover 2
ring gear 3
ring gear shim(s) 4
thrust washer 5
Adjust:
ring gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shim(s) and thrust
washer with the following chart.
Thinner shim
Ring gear backlash is
increased.
Thicker shim
Ring gear backlash is
decreased.
b. If it is necessary to increase the ring gear
backlash by more than 0.2 mm, reduce the
thrust washer thickness by 0.2 mm for every
0.2 mm increase of ring gear shim thickness.
c. If it is necessary to reduce the ring gear
backlash by more than 0.2 mm, increase
the thrust washer thickness by 0.2 mm for
every 0.2 mm decrease of ring gear shim
thickness.
Ring gear shims
Thickness (mm)
0.25 0.30 0.40 0.50
Thrust washers
Thickness (mm)
1.2 1.4 1.6 1.8 2.0
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 99
SHAFT DRIVE
CHAS
EAS00721
MEASURING THE RING-GEAR-TOSTOPPER-BOLT CLEARANCE
1. Remove:
• ring gear bearing housing
(along with the ring gear)
Refer to “ADJUSTING THE RING GEAR
BACKLASH”.
2. Measure:
• ring-gear-to-stopper-bolt clearance a
Out of specification → Adjust.
Ring-gear-to-stopper-bolt clearance
0.30 ~ 0.60 mm
1 Stopper bolt
2 Ring gear
3. Install:
• ring gear bearing housing
(along with the ring gear)
EAS00722
ADJUSTING THE RING-GEAR-TOSTOPPER-BOLT CLEARANCE
1. Remove:
• ring gear 1
• stopper bolt 2
• stopper bolt shim(s) 3
• ring gear bearing housing
2. Select:
• stopper bolt shim(s)
Stopper bolt shims
Thickness (mm)
7 - 100
0.15 0.20
CHAS
SHAFT DRIVE
Install:
stopper bolt shim(s) 1
9 Nm (0.9 m · kg)
stopper bolt 2
ring gear 3
ring gear bearing housing
T.
R.
3.
•
•
•
•
CAUTION:
@
• The stopper bolt has left-hand threads. To
tighten the stopper bolt, turn it counterclockwise.
• Apply LOCTITE® onto the stopper bolt.
@
4. Measure:
• ring-gear-to-stopper-bolt clearance
NOTE:
If the ring-gear-to-stopper-bolt clearance is out
of specification, repeat the above procedure.
@
@
7 - 101
SHAFT DRIVE
Order
1
Job/Part
Removing the final drive assembly
Final gear oil
Rear wheel
Rear shock absorber (left)
Final drive assembly
Q’ty
1
7 - 102
CHAS
Remarks
Remove the parts in the order listed.
Drain.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER”.
Refer to “INSTALLING THE FINAL
DRIVE ASSEMBLY”.
For installation, reverse the removal procedure.
SHAFT DRIVE
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the final drive
assembly
Circlip
Oil seal
Drive shaft
Spring
Ring gear bearing housing/oil seal
Dust cover
Ring gear/bearing
Ring gear shim(s)
Thrust washer
Stopper bolt
Stopper bolt shim(s)
Q’ty
2
1
1
1
1/1
1
1/1
1
1
7 - 103
CHAS
Remarks
Remove the parts in the order listed.
Refer to “ALIGNING THE FINAL DRIVE
PINION GEAR AND RING GEAR”.
SHAFT DRIVE
Order
B
C
D
E
F
G
H
I
J
K
Job/Part
Nut
Gear coupling
Bearing retainer/oil seal
Final drive pinion gear/bearing
Final drive pinion gear shim(s)
Bearing
Bearing
Oil seal
Collar
Final drive housing
CHAS
Q’ty
Remarks
1
Left-hand threads.
Refer to “DISAS1
SEMBLING THE
1/1 Left-hand threads.
FINAL DRIVE
1/1
ASSEMBLY” and
“ALIGNING THE
FINAL DRIVE PIN1
ION GEAR AND
1
RING GEAR”.
1
1
1
For assembly, reverse the disassembly
procedure.
7 - 104
SHAFT DRIVE
CHAS
EAS00724
DISASSEMBLING THE FINAL DRIVE
ASSEMBLY
1. Remove:
• ring gear bearing housing nuts
• ring gear bearing housing bolts
NOTE:
Working in a crisscross pattern, loosen each
nut 1/4 of a turn. After all of the nuts are fully
loosened, remove them and the bolts.
@
@
2. Straighten:
• punched portion of the nut
3. Remove:
• nut
• gear coupling 1
(with the coupling gear/middle shaft tool 2)
Coupling gear/middle shaft tool
90890-01229
4. Remove:
• bearing retainer
(with the bearing retainer wrench 1)
Bearing retainer wrench
90890-04050
CAUTION:
@
The bearing retainer has left-hand threads.
To loosen the bearing retainer, turn it
clockwise.
@
5. Remove:
• final drive pinion gear
WARNING
@
Always use new bearings.
@
7 - 105
SHAFT DRIVE
CHAS
CAUTION:
@
The final drive pinion gear should only be
removed if ring gear replacement is necessary.
@
NOTE:
Lightly tap on the end of the final drive pinion
gear with a soft hammer.
@
@
EAS00725
REMOVING AND INSTALLING THE RING
GEAR BEARINGS
1. Remove:
• collar 1
• oil seal 2
• bearing 3
(with an suitable press tool 4 and an
appropriate support for the final drive housing)
2. Check:
• bearing
Damage → Replace.
3. Remove:
• bearing 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the final drive housing to approximately 150°C.
b. Remove the bearing outer races with an
appropriately shaped punch 2.
c. Remove the inner race from the final drive
pinion gear.
NOTE:
The removal of the final drive pinion gear bearing is a difficult procedure and is rarely necessary.
@
@
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 106
SHAFT DRIVE
4. Install:
• bearing
CHAS
New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the final gear case to approximately
150°C.
b. Install the bearing outer races with a socket
or appropriate tool that matches the diameter of the races.
c. Install the inner race onto the final drive pinion gear.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.
•
•
•
Install:
collar 1
oil seal 2 New
bearing 3
(with a suitable press tool 4 and an appropriate support for the final drive housing)
NOTE:
The bearing can be reused, but Yamaha recommends installing a new one.
@
@
EAS00726
ALIGNING THE FINAL DRIVE PINION GEAR
AND RING GEAR
NOTE:
Aligning the final drive pinion gear and ring
gear is necessary when any of the following
parts are replaced:
• Final drive housing
• Ring gear bearing housing
• Any bearing
@
7 - 107
SHAFT DRIVE
CHAS
1. Select:
• final drive pinion gear shim(s) 1
• ring gear shim(s) 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the final drive pinion gear and the
ring gear with shims 1 and 2. Calculate
the respective thicknesses from information
marked on the final drive housing and the
drive pinion gear.
1 Final drive pinion gear shim
2 Ring gear shim
3 Thrust washer
b. To find final drive pinion gear shim thickness
“A”, use the following formula:
Final drive pinion gear shim thickness
A = (84 + a/100) – (83 + b/100)
Where:
a = a numeral (positive or negative) on the
ring gear, to be divided by 100 and added to
“84”.
b = a numeral on the final drive housing, to be
divided by 100 and added to “83”.
Example:
If the final drive pinion gear is marked “+01”
and the final drive housing is marked “50”:
A = (84 + 1/100) – (83 + 50/100)
= (84 + 0.01) – (83 + 0.50)
= 84.01 – 83.50
= 0.51
Therefore, the calculated final drive pinion
gear shim thickness is 0.51 mm. Shim sizes
are supplied in the following thicknesses.
Final drive pinion gear shims
Thickness (mm)
7 - 108
0.30 0.40 0.50
SHAFT DRIVE
CHAS
Since the final drive pinion gear shims are only
available in 0.10 mm increments, round off to
the hundredths digit.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
In the example above, the calculated final
drive pinion gear shim thickness is 0.51 mm.
The chart instructs you to round off the 1 to 0.
Thus, you should use a 0.50 mm final drive
pinion gear shim.
c. To find ring gear shim thickness “B”, use the
following formula:
Ring gear shim thickness
B = (45 + c/100) + (3 + d/100) –
[(35.40 – e/100) + f]
Where:
c = a numeral on the final drive housing, to be
divided by 100 and added to “45”.
d = a numeral usually on the outside of the
ring gear bearing housing, to be divided by 100
and added to “3”.
e = a numeral (positive or negative) on the
inside of the ring gear, to be divided by 100
and added to “35.40”.
f = the ring gear bearing thickness constant.
Ring gear bearing thickness “f”
13.00 mm
7 - 109
SHAFT DRIVE
CHAS
Example:
If the final drive housing is marked “51”, the
ring gear bearing housing is marked “35”, the
ring gear is marked “– 05”, and “f” is 13.00:
B = (45 + 51/100) + (3 + 35/100) –
[(35.40 – 5/100) + 13]
= (45 + 0.51) + (3 + 0.35) –
[(35.40 – 0.05) + 13]
= 45.51 + 3.35 – [(35.40 – 0.05) + 13]
= 48.86 – [35.35 + 13]
= 48.86 – 48.35
= 0.51
Therefore, the calculated ring gear shim thickness is 0.51 mm.
Shim sizes are supplied in the following thicknesses.
Ring gear shims
Thickness (mm)
0.25 0.30 0.40 0.50
Since the ring gear shims are only available in
0.10 mm increments, round off the hundredths
digit.
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
In the example above, the calculated ring gear
shim thickness is 0.51 mm. The chart instructs
you to round off the 1 to 0. Thus, you should
use a 0.50 mm ring gear shim.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 110
CHAS
SHAFT DRIVE
Install:
shims (as calculated)
final drive pinion gear
110 Nm (11.0 m · kg)
bearing retainer
(with the bearing retainer wrench 1)
T.
R.
2.
•
•
•
CAUTION:
@
The bearing retainer has left-hand threads.
To tighten the bearing retainer, turn it
counterclockwise.
@
Bearing retainer wrench
90890-04050
T.
3. Install:
• gear coupling 1
130 Nm (13.0 m · kg)
• nut 2
(with the coupling gear/middle shaft tool 3)
R.
Coupling gear/middle shaft tool
90890-01229
CAUTION:
@
Apply LOCTITE® to the nut.
@
4. Lock the threads with a drift punch.
5. Install:
• ring gear bearing housing
(along with the ring gear, but without the
thrust washer)
6. Adjust:
• ring gear backlash
Refer to “MEASURING THE RING GEAR
BACKLASH” and “ADJUSTING THE RING
GEAR BACKLASH”.
7 - 111
CHAS
SHAFT DRIVE
7. Measure:
• ring-gear-to-thrust-washer clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the ring gear bearing housing
(along with the ring gear).
b. Place four pieces of Plastigauge® between
the original thrust washer and the ring gear.
c. Install the ring gear bearing housing and
tighten the bolts and nuts to specification.
T.
R.
Ring gear bearing housing bolt
40 Nm (4.0 m • kg)
Ring gear bearing housing nut
23 Nm (2.3 m • kg)
NOTE:
Do not turn the final drive pinion gear and ring
gear while measuring the ring-gear-to-thrustwasher clearance with Plastigauge®.
@
@
d. Remove the ring gear bearing housing.
e. Measure the width of the flattened Plastigauge® 1.
Ring-gear-to-thrust-washer clearance
0.10 ~ 0.20 mm
f. If the ring-gear-to-thrust-washer clearance
is within specification, install the ring gear
bearing housing (along with the ring gear).
g. If the ring-gear-to-thrust-washer clearance
is out of specification, select the correct
thrust washer as follows.
h. Select the suitable thrust washer from the
following chart.
Thrust washers
Thickness (mm)
1.2 1.4 1.6 1.8 2.0
i. Repeat the measurement steps until the
ring-gear-to-thrust-washer clearance is
within the specified limits.
Ring-gear-to-thrust-washer clearance
0.10 ~ 0.20 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 112
CHAS
SHAFT DRIVE
EAS00727
CHECKING THE DRIVE SHAFT
1. Check:
• drive shaft splines
Damage/wear → Replace the drive shaft.
EAS00728
INSTALLING THE FINAL DRIVE ASSEMBLY
1. Lubricate:
• drive shaft splines
Recommended lubricant
Molybdenum disulfide grease
2. Install:
• final drive assembly
NOTE:
Align the drive shaft splines with the driven
yoke of the universal joint.
@
@
3. Tighten:
• final drive assembly nuts
T.
R.
42 Nm (4.2 m · kg)
NOTE:
Apply locking agent (LOCTITE®) to the threads
of the final gear assembly nuts.
4. Install:
• rear shock absorber (left)
Refer to “REAR SHOCK ABSORBER”.
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
5. Fill:
• final drive assembly
Refer to “CHECKING THE FINAL DRIVE
OIL LEVEL” in chapter 3.
7 - 113
–
ELEC
+
8
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ....................................................................... 8-1
SWITCHES ..................................................................................................... 8-3
CHECKING SWITCH CONTINUITY ........................................................8-3
CHECKING THE SWITCHES ......................................................................... 8-5
CHECKING THE BULBS AND BULB SOCKETS ......................................... 8-7
TYPES OF BULBS ................................................................................... 8-7
CHECKING THE CONDITION OF THE BULBS ...................................... 8-7
CHECKING THE CONDITION OF THE BULB SOCKETS ......................8-9
IGNITION SYSTEM ......................................................................................8-10
CIRCUIT DIAGRAM ............................................................................... 8-10
TROUBLESHOOTING ...........................................................................8-11
ELECTRIC STARTING SYSTEM .................................................................8-15
CIRCUIT DIAGRAM ............................................................................... 8-15
STARTING CIRCUIT CUTOFF SYSTEM OPERATION ........................ 8-16
TROUBLESHOOTING ...........................................................................8-17
STARTER MOTOR ....................................................................................... 8-21
CHECKING THE STARTER MOTOR ....................................................8-23
ASSEMBLING THE STARTER MOTOR ................................................ 8-24
CHARGING SYSTEM ...................................................................................8-26
CIRCUIT DIAGRAM ............................................................................... 8-26
TROUBLESHOOTING ...........................................................................8-27
LIGHTING SYSTEM .....................................................................................8-29
CIRCUIT DIAGRAM ............................................................................... 8-29
TROUBLESHOOTING ...........................................................................8-30
CHECKING THE LIGHTING SYSTEM ...................................................8-31
SIGNALING SYSTEM .................................................................................. 8-34
CIRCUIT DIAGRAM ............................................................................... 8-34
TROUBLESHOOTING ...........................................................................8-36
CHECKING THE SIGNALING SYSTEM ................................................ 8-37
–
+
ELEC
COOLING SYSTEM ......................................................................................8-43
CIRCUIT DIAGRAM ............................................................................... 8-43
TROUBLESHOOTING ...........................................................................8-44
FUEL PUMP SYSTEM .................................................................................. 8-47
CIRCUIT DIAGRAM ............................................................................... 8-47
FUEL PUMP CIRCUIT OPERATION .....................................................8-48
TROUBLESHOOTING ...........................................................................8-49
CHECKING THE FUEL PUMP ...............................................................8-52
–
+
ELECTRICAL COMPONENTS
tEAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Ignitor unit
2 Pressure sensor
3 Ignition coil (#1 & #3)
4 Neutral switch
5 Oil level gauge
6 Ignition coil (#2 & #4)
7 Fuel pump relay
8 Thermo switch
9 Temperature sender
D
FW
8-1
ELEC
–
+
ELECTRICAL COMPONENTS
1 Starter relay
2 Main fuse
3 Battery
4 Rectifier/regulator
5 Sidestand switch
6 Rear brake light switch
7 Horn
8 Turn signal relay
9 Starting circuit cutoff relay
0 Diode assembly
A Main switch
B Wire harness
D
FW
8-2
ELEC
–
+
SWITCHES
ELEC
–
+
EAS00730
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
@
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
@
Pocket tester
90890-03112
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
and forth between the switch positions a few
times.
@
@
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
“
” terminals (i.e., a closed circuit at the
respective switch position).
@
@
The example illustration on the left shows
that:
There is no continuity between all terminals
when the switch is set to “OFF”.
There is continuity between red and brown
when the switch is set to “ON”.
8-3
SWITCHES
8-4
ELEC
–
+
CHECKING THE SWITCHES
ELEC
–
+
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
8-5
CHECKING THE SWITCHES
1 Dimmer switch
2 Pass switch
3 Horn switch
4 Turn signal switch
5 Clutch switch
6 Light switch
7 Engine stop switch
8 Start switch
9 Fuel reserve switch
0 Front brake light switch
A Main switch
B Fuse
C Rear brake light switch
D Sidestand switch
E Neutral switch
F Oil level switch
8-6
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for continuity between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs c is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs d and e are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
8-7
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
WARNING
@
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
@
CAUTION:
@
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
@
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
@
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
@
@
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-9
Br
L
8 - 10
L
Br
Br
Br
B
Br
Br
p
B
L
Br
R/Y
B
2
2
R/W
R/G
L
B
Y
Y
B
B
Br
k
G/Y
j
=
Br
W
W
R/Y
L
A
3
W W
W W
R
R
L
L/B
B
B
B
Dg
(R)
OFF
(L)
h
Ch
Ch
W/G
L/W
R/W
B
Dg
Dg
Y/R
Br
B
B
Sb
B/Y R/W
Sb R/B
c
B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
_
Br
Br/W
7
6
R
b
i
Ch
a
R/Y
5
R
8
R/B
P
Br
d
R/Y
]
Y
G
R/W
C
B
L/W
R/B
R/W
B
e
B
g
Y
Y
ON
RES
D
L/B
B
G
G
R/W
R/B
R/G
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
\
[
W/G
G
B
B
J
G
G
L/B
B
B
G
B
X
F
R/B
B
G
G Y
R/B
Z
B/R B O
B
B/Y
B/Y
B/R
W
W
Sb
Sb
Y
Y
B
I
W
B/L
G
Sb
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
O
B
Ch
Dg
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
O
O
O
O
B
O
R/W
O
R/W
Gy
R/W
Y
R/W
W
R/W
Q
R
O
N
R/B
L
B
G/R
K
K
K
K
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
P
J
J
J
J
B
V
(RED)
(RED)
Y
L
Sb G
Dg Ch
B/R R/B
G Sb
Ch Dg
R/B B/R
Br Gy
L G/R
B Y
1 Main switch S
4 Main fuse
5 Battery
B Engine stop switch
E Sidestand switch
T
H Vacuum pressure sensor
I Ignitor unit U
J Ignition coils
K Spark plugs
L Pickup coil
W Diode assembly
Z Neutral switch
r Ignition fuse
Y B/R L/W
W
B/R Sb G W/G
G
B/R
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
W
R/B B/R
B/Y
R/B
ELEC
B
B
L/R
L/R
B
R
R
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
R/W
B
R/B
R/G
l
(BLACK) (BLACK)
B
L
r
L/R L
Br R
R
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
q
L L/R
L L/R
R Br
n
o
m
P
OFF
ON
1
R
R
4
R R
IGNITION SYSTEM
–
+
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00737
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. engine stop switch
10.neutral switch
11.sidestand switch
12.diode assembly
13.vacuum pressure sensor
14.wiring connections (of the entire ignition
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) electrical components board
3) left side cover
4) rider seat
5) main switch cover
• Troubleshoot with the following special
tool(s).
@
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
DPR8EA-9 (NGK)
X24EPR-U9 (DENSO)
Spark plug gap
0.8 ~ 0.9 mm
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
@
Ignition checker
90890-06754
Pocket tester
90890-03112
YES
NO
EAS00738
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
Replace the fuse(s).
8 - 11
Re-gap or replace
the spark plug.
–
ELEC
IGNITION SYSTEM
+
EAS00743
4. Ignition spark gap
The following procedure applies to all of the
spark plugs.
• Disconnect the spark plug cap from the
spark plug.
• Connect the ignition checker 1 as shown.
2 Spark plug cap
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
Spark plug cap resistance
10 kΩ at 20 °C
• Is the spark plug cap OK?
NO
YES
Replace the
plug cap.
spark
EAS00747
6. Ignition coil resistance
Minimum ignition spark gap
6 mm
• Is there a spark and is the spark gap within
specification?
NO
The following procedure applies to all of the
ignition coils.
• Disconnect the ignition coil leads from the
wire harness.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe → red/white 1
Negative tester probe → orange 2
YES
The ignition system
is OK.
EAS00745
5. Spark plug cap resistance
The following procedure applies to all of the
spark plug caps.
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.
• Measure the primary coil resistance.
Primary coil resistance
2.43 ~ 2.97 Ω at 20 °C
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Negative tester probe → red/white 1
Positive tester probe → spark plug lead 2
8 - 12
IGNITION SYSTEM
–
ELEC
+
EAS00749
8. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
• Measure the secondary coil resistance.
main
EAS00750
Secondary coil resistance
10.56 ~ 15.84 kΩ at 20 °C
9. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Is the ignition coil OK?
NO
YES
the
YES
Replace the ignition
coil.
NO
Replace the right
handlebar switch.
EAS00748
7. Pickup coil resistance
EAS00751
• Disconnect the pickup coil coupler from the
wire harness.
• Connect the pocket tester (Ω × 100) to the
pickup coil terminal as shown.
Positive tester probe → orange 1
Negative tester probe → black 2
10.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EAS00752
11.Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
• Measure the pickup coil resistance.
YES
Pickup coil resistance
80.8 ~ 121.2 Ω at 20 °C
(between orange and black)
Replace the
stand switch.
• Is the pickup coil OK?
YES
NO
NO
Replace the pickup
coil.
8 - 13
side-
IGNITION SYSTEM
ELEC
–
+
12.Diode assembly
13.Vacuum pressure sensor
• Disconnect the diode assembly coupler
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
diode assembly coupler as shown.
• Check the diode assembly for continuity.
• Disconnect the vacuum pressure sensor
coupler from the wire harness.
• Connect the pocket tester (DC 20 V) and
battery (12 V) to the vacuum pressure sensor terminals as shown.
Positive tester probe →
sky blue 1 ContinuNegative tester probe →
ity
yellow 2
Battery positive terminal → red/black 1
Battery negative terminal → black/yellow 2
Positive tester probe →
yellow 2 No continuity
Negative tester probe →
sky blue 1
Tester positive probe → black/red 3
Tester negative probe → black/yellow 2
• Measure the vacuum pressure sensor output voltage.
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
Vacuum pressure sensor out put
voltage
2.0 V at 0 Pa (0 bar)
@
• Is the vacuum pressure sensor OK?
YES
NO
@
• Are the tester readings correct?
YES
Replace the vacuum
pressure sensor.
NO
EAS00754
Replace the diode
assembly.
14.Wiring connections
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly connected and without defects?
YES
Replace the ignitor
unit.
8 - 14
NO
Properly connect or
repair the ignition
system’s wiring.
Br
L
8 - 15
L
Br
Br
Br
B
Br
Br
B
L
p
q
B
L
Br
R/Y
B
2
2
R/W
R/G
L
B
Y
Y
B
B
Br
j
k
G/Y
Br
W
W
R
R/Y
L
A
3
W W
W W
=
R
R
L
R/Y
B
Dg
(R)
OFF
(L)
b
B
Dg
Dg
hB
Ch
Ch
W/G
Y/R
_
Br
Br
B
B
Sb
B/Y R/W
Sb R/B
c
B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
L/W
R/W
8
Br/W
7
6
R
iB
Ch
a
L/B
5
R
R/B
P
Br
d
R/Y
]
Y
G
R/W
C
B
L/W
R/B
R/W
B
e
B
g
Y
Y
ON
RES
D
L/B
B
G
G
R/W
R/B
R/G
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
G
B
\
[
W/G
B
J
G
G
L/B
B
B
G
B
X
F
R/B
B
G
G Y
B/R B O
B
B/Y
B/Y
B/R
W
W
Sb
Sb
Y
Y
B
I
W
B/L
G
Sb
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
O
B
Ch
Dg
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
O
O
O
O
B
O
R/W
O
R/W
Gy
R/W
Y
R/W
W
R/W
Q
O
N
R
R/B
L
B
V
G/R
K
K
K
K
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
P
J
J
J
J
Y
L
(RED)
G Sb
Ch Dg
R/B B/R
(RED)
Sb G
Dg Ch
B/R R/B
Br Gy
L G/R
B Y
B
1 Main switch S
4 Main fuse
5 Battery
6 Starter relay
7 Starter motor
T
8 Starting circuit cutoff relay
U
B Engine stop switch
C Start switch
E Sidestand switch
W Diode assembly
Z Neutral switch
f Clutch switch
r Ignition fuse
Y B/R L/W
W
B/R Sb G W/G
G
B/R
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
R/B
Z
W
R/B B/R
B/Y
R/B
ELEC
B
B
L/R
L/R
B
R
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
R/W
B
R/B
R/G
l
(BLACK) (BLACK)
n
r
L/R L
Br R
R
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
L L/R
R Br
L L/R
o
m
P
OFF
ON
1
R
R
4
R R
ELECTRIC STARTING SYSTEM
–
+
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
+
EAS00756
STARTING CIRCUIT CUTOFF SYSTEM
OPERATION
If the engine stop switch is set to “
” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
• The transmission is in neutral (the neutral
switch is closed).
• 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 cutoff relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cutoff relay is open
so current cannot reach the starter motor.
When at least one of the above conditions has
been met the starting circuit cutoff 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 TO THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cutoff relay
7 Diode assembly
8 Clutch switch
9 Sidestand switch
0 Neutral switch
A Start switch
B Starter relay
C Starter motor
8 - 16
ELECTRIC STARTING SYSTEM
EAS00757
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. starting circuit cutoff relay
5. starter relay
6. main switch
7. engine stop switch
8. neutral switch
9. sidestand switch
10.clutch switch
11.start switch
12.diode assembly
13.wiring connections (of the entire starting
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) electrical components board
3) left side cover
4) rider seat
5) main switch cover
• Troubleshoot with the following special
tool(s).
@
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00758
3. Starter motor
• Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3.
@
Pocket tester
90890-03112
WARNING
@
EAS00738
1. Main and ignition fuses
• Check the main and ignition fuses for continuity. Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
• A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
@
YES
NO
• Does the starter motor turn?
YES
NO
Replace the fuse(s).
Repair or replace the
starter motor.
8 - 17
ELECTRIC STARTING SYSTEM
EAS00759
–
ELEC
+
EAS00761
4. Starting circuit cutoff relay
5. Starter relay
• Disconnect the starting circuit cutoff relay
coupler from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cutoff relay
coupler as shown.
• Disconnect the starter relay coupler from
the coupler.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as
shown.
Positive battery terminal → red/black 1
Negative battery terminal →
black/yellow 2
Positive battery terminal → red/white 1
Negative battery terminal → blue/white 2
Positive tester probe → red/black 1
Negative tester probe → red/white 3
• Does the starting circuit cutoff relay have
continuity between red/black and red/
white?
YES
Positive tester probe → red 3
Negative tester probe → black 4
• Does the starter relay have continuity
between red and black?
NO
YES
NO
Replace the starter
relay.
Replace the starting
circuit cutoff relay.
EAS00749
6. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
8 - 18
the
main
ELECTRIC STARTING SYSTEM
EAS00750
ELEC
–
+
EAS00764
7. Engine stop switch
11.Start switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
NO
YES
Replace the right
handlebar switch.
Replace the right
handlebar switch.
EAS00751
8. Neutral switch
12.Diode assembly
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
• Disconnect the diode assembly coupler
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
diode assembly coupler as shown.
• Check the diode assembly for continuity.
YES
NO
Replace the neutral
switch.
EAS00752
Positive tester probe →
yellow 2 No contiNegative tester probe →
nuity
sky blue 1
9. Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
YES
Positive tester probe →
sky blue 1 ContinuNegative tester probe →
ity
yellow 2
NO
Replace the
stand switch.
side-
EAS00763
10.Clutch switch
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
@
NO
@
Replace the clutch
switch.
• Are the tester readings correct?
YES
NO
Replace the diode
assembly.
8 - 19
ELECTRIC STARTING SYSTEM
13.Wiring connections
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly connected and without defects?
YES
This circuit is OK.
NO
Properly connect or
repair the starting
system’s wiring.
8 - 20
ELEC
–
+
STARTER MOTOR
ELEC
–
+
EAS00767
STARTER MOTOR
Order
1
2
Job/Part
Removing the starter motor
Coolant drain cock assembly
Starter motor lead
Starter motor assembly
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “THERMOSTAT ASSEMBLY
AND CONDUIT” in chapter 5.
1
1
For installation, reverse the removal procedure.
8 - 21
STARTER MOTOR
ELEC
–
+
EAS00768
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the starter motor
Starter motor front cover
Washer kit
Starter motor rear cover
Washer kit
Armature coil
Brush seat
Brush holder
Starter motor yoke
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
8 - 22
STARTER MOTOR
ELEC
–
+
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit
27 mm
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
0.7 mm
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
@
@
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.025 ~ 0.035 Ω at 20 °C
Insulation resistance 2
Above 1 MΩ at 20 °C
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 23
STARTER MOTOR
ELEC
–
+
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit
5 mm
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
8.82 N (899 gf)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush seat 1
NOTE:
Align the tab a on the brush seat with the slot
b in the starter motor yoke.
@
@
2.
•
•
•
Install:
starter motor yoke 1
starter motor front cover 2
starter motor rear cover 3
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear cover.
@
@
8 - 24
ELEC
STARTER MOTOR
R.
8 - 25
New
T.
3. Install:
• O-rings 1
• bolts 2
–
5 Nm (0.5 m · kg)
+
CHARGING SYSTEM
ELEC
–
+
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
R R
4
8
R
R
R
R
R
R
R
L/R
Br
B/Y
R/W
R
W W
W W
W
W
L/W
R/W
5
3
2
L/R L
Br R
6
B
R/W
B
B
B
7
B
L/R
r
R/W
R/W
9
Br L R/W
B G/Y R/B
B L/B R/Y
R/B
R/G
R/W L Br
R/W G/Y B
R/Y L/B L/W
A
=
R/W
R/G
G/Y
R/Y
Br
L
L
R/Y
R/Y
q
8 - 26
L/B
2 Rectifier/regulator
3 Generator
4 Main fuse
5 Battery
CHARGING SYSTEM
EAS00774
ELEC
–
+
EAS00739
TROUBLESHOOTING
2. Battery
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections (of the entire charging
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) left side cover
2) rider seat
• Troubleshoot with the following special
tool(s).
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
@
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00775
3. Charging voltage
@
• Connect the engine tachometer to the spark
plug lead of cylinder #1.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
YES
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
NO
Replace the fuse.
• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
Charging voltage
14 V at 5,000 r/min
8 - 27
CHARGING SYSTEM
ELEC
–
+
EAS00779
NOTE:
Make sure the battery is fully charged.
5. Wiring connections
@
• Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
@
• Is the charging voltage within specification?
NO
YES
The charging circuit
is OK.
YES
NO
EAS00776
4. Stator coil resistance
• Disconnect the stator coils coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the stator coils coupler as shown.
Replace the rectifier/
regulator.
Positive tester probe → white 1
Negative tester probe → white 2
Positive tester probe → white 1
Negative tester probe → white 3
• Measure the stator coil resistances.
Stator coil resistance
0.33 ~ 0.45 Ω at 20 °C
• Is the stator coil OK?
YES
NO
Replace the stator
coil assembly.
8 - 28
Properly connect or
repair the charging
system’s wiring.
Br
L
8 - 29
L
Br
Br
Br
B
Br
Br
B
L
p
q
B
L
Br
R/Y
R/W
B
B
2
2
R/W
R/G
L
B
Y
Y
B
B
Br
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
B
R
k
j
G/Y
Br
W
W
R
R/Y
L
A
3
W W
W W
=
R
R
L
L/B
B
Dg
(R)
OFF
(L)
b
B
Dg
Dg
hB
Ch
Ch
W/G
Y/R
Br
R/B
B
B
Sb
B/Y R/W
Sb R/B
c
B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
L/W
R/W
_
Br
Br/W
7
6
R
iB
Ch
a
R/Y
5
R
8
P
Br
d
R/Y
]
Y
G
L/W
R/W
C
B
R/B
R/W
B
e
B
g
Y
Y
ON
RES
D
L/B
B
G
G
R/W
R/B
R/G
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
\
[
W/G
G
B
B
J
G
G
L/B
B
G
B
X
B
F
R/B
B
G
G Y
B/R B O
B
B/Y
B/Y
B/R
R/B
W
W
Sb
Sb
Y
Y
B
G
Y B/R L/W
W
B/R Sb G W/G
B/R
W
B/L
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
R/B
Z
W
R/B B/R
B/Y
G
Sb
O
B
(RED)
(RED)
Y
L
Sb G
Dg Ch
B/R R/B
Br Gy
L G/R
B Y
Ch
Dg
O
O
O
O
G Sb
Ch Dg
R/B B/R
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
B
O
R/W
Gy
R/W
Y
R/W
W
R/W
S
R
O
N
U
T
Q
P
R/B
L
B
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
V
G/R
B
1 Main switch
4 Main fuse
5 Battery J
K
A Light switch
T Meter light
J
U High beam indicator
light
K
! Meter light
J
d Pass switch
I
e Dimmer switch K
g HeadlightJ
k Tail/brake light K
l Auxiliary light
q Headlight fuse
ELEC
B
B
L/R
L/R
R/B
R/G
l
(BLACK) (BLACK)
n
r
L/R L
Br R
R
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
L L/R
R Br
L L/R
o
m
P
OFF
ON
1
R
R
4
R R
LIGHTING SYSTEM
–
+
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00781
–
ELEC
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
Any of the following fail to light: headlight, high beam indicator light, taillight,
auxiliary light or meter light.
Check:
1. main and headlight fuses
2. battery
3. main switch
4. light switch
5. dimmer switch
6. pass switch
7. wiring connections (of the entire lighting
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) electrical components board
3) rider seat
4) main switch cover
5) headlight lens unit
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
@
Replace
switch.
Pocket tester
90890-03112
the
main
EAS00783
4. Light switch
EAS00738
1. Main and headlight fuses
• Check the main and headlight fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and headlight fuses OK?
YES
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the light switch OK?
YES
NO
• The light switch is
faulty.
• Replace the right
handlebar switch.
NO
Replace the fuse(s).
8 - 30
LIGHTING SYSTEM
EAS00784
ELEC
–
+
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
5. Dimmer switch
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
YES
1. Headlight bulb and socket
NO
• The dimmer switch
is faulty.
• Replace the left
handlebar switch.
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the headlight bulb and socket OK?
NO
YES
EAS00786
6. Pass switch
Replace the headlight bulb, socket or
both.
• Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the pass switch OK?
YES
2. High beam indicator light bulb and socket
NO
• The pass switch is
faulty.
• Replace the left
handlebar switch.
• Check the high beam indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the high beam indicator light bulb and
socket OK?
EAS00787
7. Wiring connections
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly connected and without defects?
YES
NO
YES
Replace the high
beam indicator light
bulb, socket or both.
NO
3. Voltage
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
Properly connect or
repair the lighting
system’s wiring.
• Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light couplers as shown.
È When the dimmer switch is set to “
É When the dimmer switch is set to “
Headlight coupler (wire harness side)
8 - 31
”
”
LIGHTING SYSTEM
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
High beam indicator light
Positive tester probe → yellow 4
Negative tester probe → black 5
2. Voltage
Meter light coupler (wire harness side)
Tachometer coupler
•
•
•
•
Speedometer coupler
Set the main switch to “ON”.
Set the light switch to “
”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) of yellow 1 or
green 2 on the headlight coupler and yellow 4 on the meter light coupler (wire harness side).
• Is the voltage within specification?
NO
YES
This circuit is OK.
The wiring circuit
from the main switch
to the headlight coupler and meter light
coupler is faulty and
must be repaired.
–
+
• Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
Positive tester probe → blue 1
Negative tester probe → black 2
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue 1 on
the meter light coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
EAS00789
2. The meter light fails to come on.
1. Meter light bulb and socket
• Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the meter light bulb and socket OK?
YES
ELEC
NO
Replace the meter
light bulb, socket or
both.
8 - 32
NO
The wiring circuit
from the main switch
to the meter light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
ELEC
–
+
EAS00790
EAS00791
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
4. The auxiliary light fails to come on.
1. Auxiliary light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket OK?
• Check the auxiliary light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the auxiliary light bulb and socket OK?
NO
YES
NO
YES
Replace the auxiliary
light bulb, socket or
both.
Replace the tail/
brake
light
bulb,
socket or both.
2. Voltage
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
• Connect the pocket tester (DC 20 V) to the
auxiliary light connectors (auxiliary light
side) as shown.
Positive tester probe → blue 1
Negative tester probe → black 2
Positive tester probe → blue/red 1
Negative tester probe → black 2
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue 1 on
the tail/brake light connectors (wire harness
side).
• Is the voltage within specification?
• Set the main switch to “ON”.
• Set the light switch to “
” or “
”.
• Measure the voltage (12 V) of blue/red 1
on the auxiliary light connectors (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
YES
The wiring circuit
from the main switch
to the tail/brake light
connectors is faulty
and
must
be
repaired.
This circuit is OK.
8 - 33
NO
The wiring circuit
from the main switch
to the auxiliary light
connectors is faulty
and
must
be
repaired.
Br
L
8 - 34
L
Br
Br
Br
B
Br
Br
p
q
B
L
Br
R/Y
B
B
L/R
L/R
B
R
B
2
2
R/W
R/G
L
B
Y
Y
B
B
Br
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
R/W
B
R/B
R/G
l
(BLACK) (BLACK)
B
L
r
L/R L
Br R
R
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
L L/R
R Br
L L/R
n
o
m
P
OFF
ON
1
R
R
j
k
G/Y
Br
W
W
R
R/Y
L
A
3
W W
W W
=
R
4
R R
R
L
L/B
B
B
iB
Dg
(R)
OFF
(L)
Dg
Dg
hB
Ch
Ch
Br/W
Y/R
_
W/G
Br
B
c
B
B
Sb
B/Y R/W
Sb R/B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
L/W
R/W
8
Br
7
6
R
b
Ch
a
R/Y
5
R
R/B
P
Br
d
R/Y
]
Y
G
B
B
g
Y
Y
ON
RES
D
e
R/W
C
B
L/W
R/B
R/W
L/B
B
G
G
R/W
R/B
R/G
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
\
[
W/G
G
B
B
J
G
G
L/B
B
B
G
B
X
F
R/B
B
G
G Y
R/B
Z
B/R B O
B
B/Y
B/Y
B/R
W
W
Sb
Sb
Y
Y
B
I
Y B/R L/W
W
B/R Sb G W/G
G
B/R
W
B/L
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
W
R/B B/R
B/Y
R/B
G
Sb
O
B
(RED)
(RED)
Y
L
Sb G
Dg Ch
B/R R/B
Br Gy
L G/R
B Y
Ch
Dg
O
O
O
O
G Sb
Ch Dg
R/B B/R
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
B
O
R/W
O
R/W
Gy
R/W
Y
R/W
W
R/W
S
R
U
T
Q
O
N
R/B
L
B
V
G/R
K
K
K
K
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
P
J
J
J
J
B
SIGNALING SYSTEM
ELEC
–
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
+
SIGNALING SYSTEM
1 Main switch
4 Main fuse
5 Battery
0 Front brake light switch
B Engine stop switch
N Fuel level indicator light
O Oil level warning light
R Neutral indicator light
S Turn signal indicator light
W Diode assembly
X Fuel sender
Y Engine oil level switch
Z Neutral switch
] Horn
_ Turn signal relay
b Turn signal switch
c Horn switch
h Front turn signal light
i Rear turn signal light
j Rear brake light switch
k Tail/brake light
p Signaling system fuse
r Ignition fuse
8 - 35
ELEC
–
+
SIGNALING SYSTEM
EAS00794
–
ELEC
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
• Any of the following fail to light: flasher
light, brake light or an indicator light.
• The horn fails to sound.
Check:
1. main, ignition, and signaling system fuses
2. battery
3. main switch
4. wiring connections (of the entire signaling
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) electrical components board
3) rider seat
4) main switch cover
5) left side cover
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
@
NO
YES
Pocket tester
90890-03112
Replace
switch.
EAS00738
1. Main, ignition, and signaling system fuses
the
main
EAS00795
• Check the main, ignition, and signaling system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and signaling system
fuses OK?
YES
4. Wiring connections
• Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
YES
NO
Replace the fuse(s).
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
8 - 36
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
ELEC
–
+
EAS00796
3. Horn
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
• Disconnect the pink connector at the horn
terminal.
• Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
NO
YES
Replace the left handlebar switch.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
NO
Positive tester probe → brown 1
Negative tester probe → ground
YES
The horn is OK.
4. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the pink terminal as
shown.
Positive tester probe → pink 1
Negative tester probe → ground
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown at the
horn terminal.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
• Set the main switch to “ON”.
• Measure the voltage (12 V) of pink 1 at the
horn terminal.
• Is the voltage within specification?
YES
Repair or replace the
horn.
8 - 37
NO
Replace the horn.
SIGNALING SYSTEM
ELEC
–
+
EAS00797
2. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket OK?
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (12 V) of yellow 1 on
the tail/brake light connectors (wire harness
side).
• Is the voltage within specification?
YES
NO
NO
YES
This circuit is OK.
Replace the tail/
brake
light
bulb,
socket or both.
The wiring circuit
from the main switch
to the meter light
coupler is faulty and
must be repaired.
EAS00799
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
NO
YES
Replace the brake
light switch.
3. The turn signal light, turn signal indicator
light or both fail to blink.
1. Turn signal indicator light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
OK?
YES
NO
3. Voltage
Replace the turn signal light bulb, socket
or both.
• Connect the pocket tester (DC 20 V) to the
tail/brake light connectors (wire harness
side) as shown.
Positive tester probe → yellow 1
Negative tester probe → black 2
2. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
YES
NO
Replace the left handlebar switch.
8 - 38
ELEC
SIGNALING SYSTEM
3. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe → brown 1
Negative tester probe → ground
–
+
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12 V) on brown/white
1 at the turn signal relay coupler (wire harness side).
• Is the voltage within specification?
NO
YES
The turn signal relay
is faulty and must be
replaced.
5. Voltage
• Set the main switch to “ON”.
• Measure the voltage (12 V) on brown 1 at
the turn signal relay coupler (wire harness
side).
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and
must
be
repaired.
• Connect the pocket tester (DC 20 V) to the
turn signal light connector or tachometer
coupler (wire harness side) as shown.
È Turn signal light
É Turn signal indicator light
Left turn signal light
Positive tester probe → chocolate 1
Negative tester probe → ground
Right turn signal light
Positive tester probe → dark green 2
Negative tester probe → ground
È
4. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe → brown/white 1
Negative tester probe → ground
É
8 - 39
SIGNALING SYSTEM
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12 V) of the chocolate
1 or dark green 2 at the turn signal light
connector (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
ELEC
–
+
3. Voltage
• Connect the pocket tester (DC 20 V) to the
tachometer coupler (wire harness side) as
shown.
Positive tester probe → brown 1
Negative tester probe → ground
NO
The wiring circuit
from the main switch
to the tachometer
coupler is faulty and
must be repaired.
EAS00800
4. The neutral indicator light fails to come on.
1. Neutral indicator light bulb and socket
• Check the neutral indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the neutral indicator light bulb and
socket OK?
YES
YES
This circuit is OK.
NO
Replace the neutral
indicator light bulb,
socket or both.
2. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
• Set the main switch to “ON”.
• Measure the voltage (12 V).
• Is the voltage within specification?
NO
The wiring circuit
from the main switch
to the tachometer
coupler is faulty and
must be repaired.
EAS00802
5. The oil level warning light fails to come on.
1. Oil level warning light bulb and socket
• Check the oil level warning light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the oil level warning light bulb and
socket OK?
NO
YES
Replace the neutral
switch.
8 - 40
NO
Replace the oil level
warning light bulb,
socket or both.
ELEC
SIGNALING SYSTEM
–
+
2. Engine stop switch
4. Voltage
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
• Connect the pocket tester (DC 20 V) to the
tachometer coupler (wire harness side) as
shown.
Positive tester probe → red/black 1
Negative tester probe → ground
NO
YES
Replace the right
handlebar switch.
3. Diode assembly
• Disconnect the diode assembly coupler
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
diode assembly coupler as shown.
• Measure the resistor resistance.
Positive tester probe → green 1
Negative tester probe → black/red 2
• Set the main switch to “ON”.
• Set the engine stop switch to “
”.
• Measure the voltage (12 V) of brown 1 at
the tachometer coupler.
• Is the voltage within specification?
NO
YES
The wiring circuit
from the main switch
to the tachometer
coupler is faulty and
must be repaired.
Resistor resistance
8.2 Ω at 20 °C
• Is the resistor resistance within specification?
NO
YES
Replace the
assembly.
diode
5. Engine oil level switch
• Check the oil level warning light bulb and
socket for continuity.
• Are the oil level warning light bulb and
socket OK?
• Drain the engine oil and remove the engine
oil level switch from the oil pan.
• Check the engine oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine oil level switch OK?
YES
This circuit is OK.
8 - 41
NO
Replace the engine
oil level switch.
ELEC
SIGNALING SYSTEM
–
+
EAS00803
6. The fuel level indicator light fails to come
on.
• Measure the fuel sender resistances.
Fuel sender resistance
(Ω × 100)
700 ~ 1,100 Ω at 25 °C
1. Fuel level indicator light bulb and socket
• Check the fuel level indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the fuel level indicator light bulb and
socket OK?
• Is the fuel sender OK?
NO
YES
Replace
sender.
the
fuel
NO
YES
4. Voltage
Replace the fuel level
indicator light bulb,
socket or both.
• Connect the pocket tester (DC 20 V) to the
tachometer coupler (wire harness side) as
shown.
Positive tester probe → red/black 1
Negative tester probe → ground
2. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
NO
YES
Replace the right
handlebar switch.
3. Fuel sender
• Drain the fuel from the fuel tank and remove
the fuel sender from the fuel tank.
• Disconnect the fuel sender coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the fuel
sender coupler as shown.
Positive tester probe → green 1
Negative tester probe → black 2
• Set the main switch to “ON”.
• Set the engine stop switch to “
”.
• Measure the voltage (12 V) of red/black 1
at the tachometer coupler.
• Is the voltage within specification?
YES
This circuit is OK.
8 - 42
NO
The wiring circuit
from the main switch
to the tachometer
coupler is faulty and
must be repaired.
Br
L
8 - 43
L
Br
Br
Br
B
Br
Br
n
p
q
B
L
Br
R/Y
B
2
2
R/W
R/G
L
B
Y
Y
B
B
Br
j
k
G/Y
Br
W
W
R
R/Y
L
A
3
W W
W W
=
R
R
L
R/Y
B
Dg
(R)
OFF
(L)
b
B
Dg
Dg
hB
Ch
Ch
W/G
Y/R
_
Br
Br
B
B
Sb
B/Y R/W
Sb R/B
c
B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
L/W
R/W
8
Br/W
7
6
R
iB
Ch
a
L/B
5
R
R/B
P
Br
d
R/Y
]
Y
G
R/W
C
B
L/W
R/B
R/W
B
e
B
g
Y
Y
ON
RES
D
L/B
B
G
G
R/W
R/B
R/G
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
\
[
W/G
G
B
B
J
G
G
L/B
B
B
G
B
X
F
R/B
B
G
G Y
B/R B O
B
B/Y
B/Y
B/R
W
W
Sb
Sb
Y
Y
B
Y B/R L/W
W
B/R Sb G W/G
G
B/R
W
B/L
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
R/B
Z
W
R/B B/R
B/Y
R/B
G
Sb
O
B
(RED)
(RED)
Y
L
Sb G
Dg Ch
B/R R/B
Br Gy
L G/R
B Y
Ch
Dg
O
O
O
O
G Sb
Ch Dg
R/B B/R
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
B
O
R/W
Gy
R/W
Y
R/W
W
R/W
S
R
U
T
Q
O
N
R/B
L
B
V
G/R
K
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
P
J
O
R/W
(YELLOW) (YELLOW)
O
R/W
B
1 Main switch
4 Main fuse J
5 Battery
K
Q Coolant temperature gauge
J sender
V Temperature
m Radiator fan motor K
n Thermo switch
J
oIRadiator fan motor K
fuse
p Signaling system fuse
ELEC
B
B
L/R
L/R
B
R
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
R/W
B
R/B
R/G
l
(BLACK) (BLACK)
B
L
r
L/R L
Br R
R
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
L L/R
R Br
L L/R
o
m
P
OFF
ON
1
R
R
4
R R
COOLING SYSTEM
–
+
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EAS00808
–
ELEC
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
• The radiator fan motor fails to turn.
• The water temperature gauge needle
fails to move when the engine is warm.
Check:
1. main, signaling system, and radiator fan
motor fuses
2. battery
3. main switch
4. radiator fan motor
5. thermo switch
6. temperature sender
7. wiring connections (the entire cooling system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) electrical components board
3) rider seat
4) main switch cover
• Troubleshoot with the following special
tool(s).
@
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
@
Pocket tester
90890-03112
the
main
EAS00809
4. Radiator fan motor
EAS00738
1. Main, signaling system, and radiator fan
motor fuses
• Check the main, signaling system, and radiator fan motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, signaling system, and radiator fan motor fuses OK?
YES
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (12 V) as shown.
Positive battery lead → blue 1
Negative battery lead → black 2
NO
Replace the fuse(s).
8 - 44
COOLING SYSTEM
ELEC
–
+
• Does the radiator fan motor turn?
NO
YES
The
radiator
fan
motor is faulty and
must be replaced.
EAS00811
5. Thermo switch
• Remove the thermo switch from the conduit.
• Connect the pocket tester (Ω × 1) to the
thermo switch 1 as shown.
• Immerse the thermo switch in a container
filled with coolant 2.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool
down to the specified temperature.
• Check the thermo switch for continuity at
the temperatures indicated below.
Test step
Coolant temperature Continuity
Thermo switch
1
0 ~ 105 ± 3 °C
NO
2
More than
102 ~ 108 °C
YES
3*
108 to 98 °C
YES
4*
Less than 98 °C
NO
È The thermo switch circuit is open and the radiator fan is off.
É The thermo switch circuit is closed and the
radiator fan is on.
Steps 1 & 2: Heating phase
Steps 3* & 4*: Cooling phase
• Does the thermo switch operate properly as
described above?
WARNING
@
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
T.
R.
Thermo switch
15 Nm (1.5 m • kg)
Three bond sealock®10
8 - 45
YES
NO
Replace the thermo
switch.
COOLING SYSTEM
ELEC
–
+
EAS00812
6. Temperature sender
WARNING
@
• Remove the temperature sender from the
radiator.
• Connect the pocket tester (Ω × 10) to the
temperature sender 1 as shown.
• Immerse the temperature sender in a container filled with coolant 2.
• Handle the temperature sender with special care.
• Never subject the temperature sender to
strong shocks. If the temperature sender
is dropped, replace it.
@
NOTE:
Make sure the temperature sender terminals
do not get wet.
@
Temperature sender resistance
50 °C: 153.9 Ω
80 °C: 47.5 ~ 56.8 Ω
100 °C: 26.2 ~ 29.3 Ω
R.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in the
table.
• Check the temperature sender for resistance at the temperatures indicated below.
T.
@
Temperature sender
15 Nm (1.5 m • kg)
Three bond sealock®10
• Does the temperature sender operate properly?
YES
NO
Replace the temperature sender.
EAS00813
7. Wiring connections
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly connected and without defects?
YES
This circuit is OK.
8 - 46
NO
Properly connect or
repair the cooling
system’s wiring.
8 - 47
Br
L
Br
Br
Br
o
Br
Br
B
L
r
L/R L
Br R
p
B
L
Br
R/Y
L/R
R/B
R/G
B
R
B
2
2
R/W
R/G
L
Y
B
B
Br
R/W L Br
R/W G/Y B
R/Y L/B L/W
9
R/W
B
Br L R/W
B G/Y R/B
B L/B R/Y
R/W
q
L L/R
L L/R
R Br
R
R
j
=
G/Y
Br
W
W
B
L
(BLACK) (BLACK)
B
R/Y
L
A
R
L
R/Y
B
Dg
(R)
OFF
(L)
b
B
Dg
Dg
hB
Ch
Ch
W/G
Y/R
Br
B
B
Sb
B/Y R/W
Sb R/B
c
B
Br/W
Br
W/G Y/R B
B
R/W
B/Y
R/W
L/W
R/W
_
Br
Br/W
7
6
R
iB
Ch
a
L/B
5
R
8
R/B
P
Br
d
R/Y
]
Y
G
R/W
C
B
L/W
R/B
R/W
B
e
B
g
Y
Y
ON
RES
D
L/B
B
G
G
R/W
R/G
R/B
f
B/Y
L/Y
R/B
R/W
B
B
B
B
L/Y
B/Y
R/Y
E
Ch Br/W G
Y/R B P
L/B Dg Y
L/Y
B/Y
R/Y
(BLUE) (BLUE)
G Br/W Ch
P B Y/R
Y Dg L/B
B
B
W/G
L
B
L
L/B
B
L/B
B
W/G
L
B
R/G
R/G R/B Y
G B L/B
\
[
W/G
G
B
B
J
G
G
L/B
B
B
G
B
X
F
R/B
B
G
G Y
B/R B O
B
B/Y
B/Y
B/R
W
W
Sb
Sb
Y
Y
B
I
Y B/R L/W
W
B/R Sb G W/G
G
B/R
W
B/L
Sb L/W L/W B/L
Sb
Y W/G
G
B
O Gy R/B
Y W B
L/Y
H
R/B
Z
W
R/B B/R
B/Y
R/B
G
Sb
O
B
(RED)
(RED)
Y
L
Sb G
Dg Ch
B/R R/B
Br Gy
L G/R
B Y
Ch
Dg
O
O
O
O
G Sb
Ch Dg
R/B B/R
Gy Br
G/R L
Y B
L/W B/L L/Y
L/W
G B/R Sb
Br
B/R
B
M
O
B
R/W
R/W
R/W
O
W
Y
Gy
O
R/W
O
B
O
R/W
O
R/W
Gy
R/W
Y
R/W
W
R/W
T
S
U
Q
O
N
R
R/B
L
B
V
G/R
K
K
K
K
Gy
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
O
R/W
(YELLOW) (YELLOW)
P
J
J
J
J
B
ELEC
B
B
L/R
Y
R
3
W W
W W
1 Main
n switch
4 Main fuse
5 Battery
B Engine stop switch
D Fuel reserve switch
m
F Fuel pump relay
G Fuel pump
l
k
I Ignitor unit
N Fuel level indicator light
X Fuel sender
r Ignition fuse
P
OFF
ON
1
R
R
4
R R
FUEL PUMP SYSTEM
–
+
EAS00814
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
FUEL PUMP SYSTEM
EAS00815
FUEL PUMP CIRCUIT OPERATION
The ignitor unit includes the control unit for the fuel pump.
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Fuel level indicator light
7 Fuel sender
8 Fuel reserve switch
9 Fuel pump relay
0 Fuel pump
A Ignitor unit
8 - 48
ELEC
–
+
FUEL PUMP SYSTEM
EAS00816
–
ELEC
+
EAS00739
TROUBLESHOOTING
2. Battery
• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
If the fuel pump fails to operate.
Check:
1. main and ignition fuses
2. battery
3. main switch
4. engine stop switch
5. fuel reserve switch
6. fuel level indicator light bulb and socket
7. fuel sender
8. fuel pump relay
9. fuel pump resistance
10.wiring connections (the entire fuel system)
Minimum open-circuit voltage
12.8 V or more at 20 °C
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1) top cover
2) rider seat
3) main switch cover
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
@
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
@
Pocket tester
90890-03112
Replace
switch.
the
main
EAS00738
EAS00750
1. Main and ignition fuses
4. Engine stop switch
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
NO
Replace the right
handlebar switch.
Replace the fuse(s).
8 - 49
ELEC
FUEL PUMP SYSTEM
5. Fuel reserve switch
• Is the fuel sender OK?
NO
Replace the
reserve switch.
+
Fuel sender resistance
(Ω × 100)
700 ~ 1,100 Ω at 25 °C
• Check the fuel reserve switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the fuel reserve switch OK?
YES
–
NO
YES
fuel
Replace
sender.
the
fuel
6. Fuel level indicator light bulb and socket
8. Fuel pump relay
• Check the fuel level indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the fuel level indicator light bulb and
socket OK?
• Connect the pocket tester (DC 20 V) to the
fuel pump relay as shown.
Positive tester probe → blue/black 1
Negative tester probe → black 2
NO
YES
Replace the fuel level
indicator light bulb,
socket or both.
7. Fuel sender
• Drain the fuel from the fuel tank and remove
the fuel sender from the fuel tank.
• Disconnect the fuel sender coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the fuel
sender coupler as shown.
• Start the engine.
• Measure the fuel pump relay output voltage.
Fuel pump relay output voltage
12 V
• Is the fuel pump control unit OK?
Positive tester probe → green 1
Negative tester probe → black 2
YES
NO
Replace the
pump relay.
• Measure the fuel sender resistances.
8 - 50
fuel
FUEL PUMP SYSTEM
EAS00817
9. Fuel pump resistance
• Disconnect the fuel pump coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the fuel
pump coupler as shown.
Positive tester probe → blue/black 1
Negative tester probe → black 2
• Measure the fuel pump resistance.
Fuel pump resistance
1 ~ 10 Ω at 20 °C
• Is the fuel pump OK?
NO
YES
Replace
pump.
the
fuel
EAS00818
10.Wiring connections
• Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the fuel system’s wiring properly connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the fuel system’s wiring.
8 - 51
ELEC
–
+
FUEL PUMP SYSTEM
ELEC
–
+
EAS00819
CHECKING THE FUEL PUMP
WARNING
@
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
• Stop the engine before refueling.
• Do not smoke, and keep away from open
flames, sparks, or any other source of
fire.
• If you do accidentally spill gasoline, wipe
it up immediately with dry rags.
• If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make
sure the engine is completely cool before
performing the following test.
@
1. Check:
• Fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose into an open
container.
c. Connect the battery (12 V) to the fuel pump
coupler as shown.
Positive battery lead → blue/black 1
Negative battery lead → black 2
d. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace
the fuel pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 52
TRBL
SHTG
9
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING PROBLEMS ................................................................................ 9-1
ENGINE .................................................................................................... 9-1
FUEL SYSTEM ......................................................................................... 9-1
ELECTRICAL SYSTEMS ......................................................................... 9-2
INCORRECT ENGINE IDLING SPEED .......................................................... 9-2
ENGINE .................................................................................................... 9-2
FUEL SYSTEM ......................................................................................... 9-2
ELECTRICAL SYSTEMS ......................................................................... 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................9-3
ENGINE .................................................................................................... 9-3
FUEL SYSTEM ......................................................................................... 9-3
FAULTY GEAR SHIFTING .............................................................................9-3
SHIFTING IS DIFFICULT ......................................................................... 9-3
SHIFT PEDAL DOES NOT MOVE ........................................................... 9-3
JUMPS OUT OF GEAR ............................................................................9-3
FAULTY CLUTCH .......................................................................................... 9-3
CLUTCH SLIPS ........................................................................................9-3
CLUTCH DRAGS .....................................................................................9-3
OVERHEATING .............................................................................................. 9-4
ENGINE .................................................................................................... 9-4
COOLING SYSTEM ................................................................................. 9-4
FUEL SYSTEM ......................................................................................... 9-4
CHASSIS ..................................................................................................9-4
ELECTRICAL SYSTEMS ......................................................................... 9-4
OVERCOOLING ............................................................................................. 9-4
COOLING SYSTEM ................................................................................. 9-4
POOR BRAKING PERFORMANCE ............................................................... 9-4
TRBL
SHTG
FAULTY FRONT FORK LEGS ....................................................................... 9-5
LEAKING OIL ........................................................................................... 9-5
MALFUNCTION ........................................................................................9-5
UNSTABLE HANDLING ................................................................................. 9-5
FAULTY LIGHTING OR SIGNALING SYSTEM .............................................9-6
HEADLIGHT DOES NOT LIGHT .............................................................. 9-6
HEADLIGHT BULB BURNT OUT ............................................................. 9-6
TAIL/BRAKE LIGHT DOES NOT LIGHT .................................................. 9-6
TAIL/BRAKE LIGHT BULB BURNT OUT ................................................. 9-6
TURN SIGNAL DOES NOT LIGHT .......................................................... 9-6
TURN SIGNAL BLINKS SLOWLY ............................................................ 9-6
TURN SIGNAL REMAINS LIT ..................................................................9-6
TURN SIGNAL BLINKS QUICKLY ........................................................... 9-6
HORN DOES NOT SOUND ..................................................................... 9-6
STARTING PROBLEMS
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
@
@
STARTING PROBLEMS
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel filter
• Clogged fuel strainer
• Clogged fuel tank drain hose
• Clogged rollover valve
• Clogged rollover valve hose
• Deteriorated or contaminated fuel
Fuel pump
• Faulty fuel pump
• Faulty fuel pump relay
Carburetor(s)
• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Damaged float
• Worn needle valve
• Improperly installed needle valve seat
• Incorrect fuel level
• Improperly installed pilot jet
• Clogged starter jet
• Faulty starter plunger
• Improperly adjusted starter cable
ENGINE
Cylinder(s) and cylinder head(s)
• Loose spark plug
• Loose cylinder head
• Damaged cylinder head gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
Piston(s) and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Improperly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
9-1
STARTING PROBLEMS/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil(s)
• Cracked or broken ignition coil
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
TRBL
SHTG
Ignition system
• Faulty ignitor unit
• Faulty pickup coil
• Broken generator rotor woodruff key
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
• Improperly grounded circuit
• Loose connections
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cutoff relay
• Faulty starter clutch
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder(s) and cylinder head(s)
• Incorrect valve clearance
• Damaged valve train components
Air filter
• Clogged air filter element
FUEL SYSTEM
Carburetor(s)
• Faulty starter plunger
• Loose or clogged pilot jet
• Loose or clogged pilot air jet
• Damaged or loose carburetor joint
• Improperly synchronized carburetors
• Improperly adjusted engine idling speed
(throttle stop screw)
• Improper throttle cable free play
• Flooded carburetor
ELECTRICAL SYSTEMS
Battery
• Discharged battery
• Faulty battery
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil(s)
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Cracked or broken ignition coil
Ignition system
• Faulty ignitor unit
• Faulty pickup coil
• Broken generator rotor woodruff key
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY GEAR SHIFTING/FAULTY CLUTCH
TRBL
SHTG
EAS00849
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
• Clogged air filter element
Air intake system
• Bent, clogged or disconnected carburetor
air vent hose
• Clogged or leaking air duct
FUEL SYSTEM
Carburetor(s)
• Faulty diaphragm
• Incorrect fuel level
• Loose or clogged main jet
Fuel pump
• Faulty fuel pump
EAS00850
FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS00852
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
• Air in hydraulic clutch system
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
• Damaged clutch release cylinder
• Match marks not aligned
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
CLUTCH SLIPS
Clutch
• Improperly assembled clutch
• Improperly assembled clutch master cylinder
• Improperly assembled clutch release cylinder
• Incorrect clutch fluid level
• Damaged clutch hose
• Loose or fatigued clutch spring
• Loose union bolt
• Worn friction plate
• Worn clutch plate
• Damaged clutch release cylinder
Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
9-3
OVERHEATING/OVERCOOLING/
POOR BRAKING PERFORMANCE
TRBL
SHTG
EAS00855
OVERHEATING
FUEL SYSTEM
Carburetor(s)
• Incorrect main jet setting
• Incorrect fuel level
• Damaged or loose carburetor joint
Air filter
• Clogged air filter element
CHASSIS
Brake(s)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty ignitor unit
ENGINE
Clogged coolant passages
• Cylinder head(s) and piston(s)
• Heavy carbon buildup
Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
Water pump
• Damaged or faulty water pump
Thermostat
• Thermostat stays closed
Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
•
•
•
•
•
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper seal
•
•
•
•
•
9-4
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
FAULTY FRONT FORK LEGS/
UNSTABLE HANDLING
TRBL
SHTG
EAS00860
FAULTY FRONT FORK LEGS
LEAKING OIL
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
• Loose drain bolt
• Damaged drain bolt gasket
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS00862
UNSTABLE HANDLING
Rear shock absorber assemblies
• Faulty rear shock absorber spring
• Leaking oil or gas
Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
Handlebar
• Bent or improperly installed handlebar
Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket (improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
9-5
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
TURN SIGNAL DOES NOT LIGHT
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal relay
• Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal bulb
HORN DOES NOT SOUND
• Improperly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
HEADLIGHT DOES NOT LIGHT
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT LIGHT
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
9-6
VMX12 WIRING DIAGRAM
R/W
R R
4
R
R
R
8
R
R
B/Y R/W
Sb R/B
L L/R
R Br
1
R
W W
W W
W
W
L/W
R/W
5
B
R/W
L/B
B
7
L/B
B
J
G
G
r
R/W
J
R/B
R/W
R/B
R/G
W
O
=
R/W
R/G
B
A
B
R/B
L/W
R/W
B
B
D
C
B
B
O
BB
B
E
Y
M
R/Y
Br
L
R/Y
B/R
Br
Br
Br
_
B
Br/W
Y
P
Y/R
R/Y
L/B
B/Y
c
d
e
f
(R)
OFF
(L)
n
G
B/R
G
Y W/G
Sb
W
W
Y B/R L/W
W
B/R Sb G W/G
L/W B/L L/Y
L/W
G B/R Sb
Sb L/W L/W B/L
L/Y
R
Sb
L/Y
B/Y
R/Y
G Br/W Ch
P B Y/R
Y Dg L/B
L/R
Y
Ch Br/W G
Y/R B P
L/B Dg Y
B
L
Ch
Y
Dg
Sb
L/Y
B/Y
R/Y
L
W/G
L
B
Sb
W/G
L
B
Z
\
W
Y
Gy Br
G/R L
Y B
Br Gy
L G/R
B Y
G Sb
Ch Dg
R/B B/R
Sb G
Dg Ch
B/R R/B
(RED)
(RED)
B
G
L
Y
B
L
(BLACK) (BLACK)
B
Ch
Dg
Ch
Dg
Y
G
G
L/R
l
Y
k
B
g
B
B
B
B
iB
hB
COLOR CODE
B ............black
Br ...........brown
Ch ..........chocolate
Dg ..........dark green
G ............green
Gy ..........gray
L ............ blue
O ........... orange
P............ pink
R ........... red
Sb.......... sky blue
W........... white
Y............ yellow
B/L......... black/blue
B/R ........ black/red
B/Y ........ black/yellow
Br/W ...... brown/white
G/R........ green/red
G/Y ........ green/yellow
L/B ......... blue/black
L/R......... blue/red
L/W ........ blue/white
L/Y ......... blue/yellow
R/B ........ red/black
R/G ........ red/green
R/W ....... red/white
R/Y ........ red/yellow
W/G ....... white/green
Y/R ........ yellow/red
V
S
Ch
Dg
B/L
[
G/R
Q
W/G
b
Br
L
W
G
B
B
a
B
G
B
B
j
o
X
]
Br/W
Br
W/G Y/R B
L/Y
Gy
P
Br
G
Br
W/G
Br
N
O
G
R/Y
Br
p
R/B
L/B
LL
q
O
B
B
G/Y
B
L
K
L
O
B
B
(BLUE) (BLUE)
ON
RES
O
B
m
W
R/W
(YELLOW) (YELLOW)
B
R/G
R/W
R/W L Br
R/W G/Y B
R/Y L/B L/W
Br L R/W
B G/Y R/B
B L/B R/Y
Br
L
O
R/W
K
B
R/W
9
Br
Y
R/W
O
R/W
O Gy R/B
Y W B
K
B
L L/R
Br
O
R/W
(YELLOW) (YELLOW)
Y
B/R B O
B
B/Y
G Y
B
Br
I
B
R/W
K
Gy
R/W
(YELLOW) (YELLOW)
J
B
B
O
R/W
O
F
R/G
B
B
R/W
Gy
L/B
P
OFF
ON
B/Y
R/G R/B Y
G B L/B
6
3
2
2
L/R L
Br R
J
B/R
H
O
R/W
O
O
R/B
Sb
O
R/W
(YELLOW) (YELLOW)
R/B
R/B B/R
B/Y
B/Y
R/W
R
J
R/B
R/W
R
R
R/B
R/B
B
T
U
B
1 Main switch
2 Rectifier/regulator
3 Generator
4 Main fuse
5 Battery
6 Starter relay
7 Starter motor
8 Starting circuit cutoff relay
9 Right handlebar switch
0 Front brake light switch
A Light switch
B Engine stop switch
C Start switch
D Fuel reserve switch
E Sidestand switch
F Fuel pump relay
G Fuel pump
H Vacuum pressure sensor
I Ignitor unit
J Ignition coil
K Spark plug
L Pickup coil
M Meter assembly
N Fuel level indicator light
O Oil level warning light
P Tachometer
Q Water temperature gauge
R Neutral indicator light
S Turn signal indicator light
T Meter light
U High beam indicator light
V Temperature sender
W Diode assembly
X Fuel sender
Y Oil level switch
Z Neutral switch
[ Speedometer
! Meter light
] Horn
_ Turn signal relay
a Left handlebar switch
b Turn signal switch
c Horn switch
d Pass switch
e Dimmer switch
f Clutch switch
g Headlight
h Front turn signal light
i Rear turn signal light
j Rear brake light switch
k Tail/brake light
l Auxiliary light
m Radiator fan motor
n Thermo switch
o Radiator fan motor fuse
p Signaling system fuse
q Headlight fuse
r Ignition fuse
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement