Service Manual
EAS00001
XVZ13TF (L)
SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
First edition, January 1999
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd
is expressly prohibited.
EAS00003
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.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all 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:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
CAUTION:
NOTE:
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 inspection 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” on the following page.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear.
(In Chapter 3, “Periodic Inspection and Adjustments”, the sub-section title appears at the top of each
page, instead of the section title.)
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 (see “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.
2
1
4
3
5
8
6
7
EAS00008
1
SYMBOLS
2
GEN
INFO
SPEC
3
4
CHK
ADJ
ENG
5
6
COOL
CARB
7
8
CHAS
General information
Specifications
Periodic inspections and adjustments
Engine
Cooling system
Carburetor(-s)
Chassis
Electrical system
Troubleshooting
Symbols 10 to 17 indicate the following.
10
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
24
1
2
3
4
5
6
7
8
9
ELEC
9
21
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
22
23
25
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following:
24 Apply locking agent (LOCTITER)
25 Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTIONS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETORS
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
CARB
6
CHAS
7
ELEC
8
TRBL
SHTG
9
GEN
INFO
1
GEN
INFO
CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIGITAL SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-4
1-5
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1-13
1-13
1-13
1-14
1-14
1-14
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
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.
EAS00018
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-1
FEATURES
GEN
INFO
EAS00019
FEATURES
CRUISE CONTROL
This motorcycle is equipped with cruise control which designed to maintain a set speed.
CAUTION:
Giving a severe load like using as a trailer/tractor or driving on a steep slope could remove the
cruise control.
Do not set the cruise control while idling the rear tires for the preparation.
Do not disassemble the vacuum pump.
Never remove the cruise control actuator rubber cover. When putting it back, bolts or other
parts will be caught and the cruise control wire can be locked.
Do not remove the air cleaner cover of the vacuum pump in order not to cause a malfunction in
cancellation of the cruise control by dirt, trash etc.
Do not drive without holding the steering wheel whether the cruise control is ON or OFF.
3 “SET” indicator light
5 Cruise control switch
1 “CRUISE” switch
6 “CANCEL” switch
2 “ON” indicator light 4 “RES” indicator light
Cruise control switch functions
1 “CRUISE” switch
Push this switch to “ON” when the cruise control system is preset. The “ON” indicator light will come on.
Once the switch is released it will return to the center (Hold) position.
To cancel the cruise control system, push the switch to “OFF” or main switch to the “OFF” position.
2 “ON” indicator light
This indicator light comes on when the cruise control systems preset (when “ON” is selected by the
“CRUISE” switch).
3 “SET” indicator light
This indicator light comes on when the motorcycle is operating at a set speed.
4 “RES” indicator light
This light comes on when the set speed, which is cancelled by any steps, is memorized and when the
operating speed is in the range of approx. 50-130 km/h.
If the resume system is operated while this light is on, it continues flashing until the speed returns to that
memorized.
5 Cruise control switch
This switch is capable of the following controls.
Refer to the “Operation chart” for details.
Set speed ride
Minute adjustment of set speed
Consecutive adjustment of set speed
“RESUME” system
6 “CANCEL” switch
Push this switch to cancel the set speed ride in the cruise control system.
1-2
FEATURES
GEN
INFO
Operation chart
Operation
Mannual
acceleration
Cruise SW
ON
CRUISE
SET
Rear brake
cancel
Resume
Clutch
SET
Front brake
Out of range
Speed
Out of range
SET
IndicaRES
tor
ON
SET
SET
RES
RES
ON
ON
Flash
(After1.4sec)
Cruise control function
1) The cruise control can only be activated when riding in 4th, 5th gear and traveling between the
speed of 50 and 130 km/h.
2) To operate the system, the “CRUISE” switch should be turned “ON”.
3) When push the cruise control switch to “SET”, the cruise control system will be set the set speed.
4) By pushing (in shorter than 0.5 seconds), the control switch in the direction of either “ACC” or “DEC”,
the set speed can be changed in increments or decrements of approximately 1.6 km/h.
5) If the control switch is held in the “ACC” or “DEC” position (longer than 0.5 seconds), the speed can
be successively increased or decreased slowly.
6) The cruise control will be deactivated if the front or rear brake is applied or if the clutch is disengaged
or if the “CANCEL” switch is pushed.
7) After canceling, the speed is returned to the one set before the cancellation by pushing the control
switch once in the “RES” direction.
8) Auto cruise function is canceled;
a. In case of current speed drops 8 km/h less than the originally set speed.
b. In case of gear position is moved to gears other than of 4th, 5th.
c. In case of systems fines any faulty signal in the following systems.
Control unit
Actuator cable
Logical error in cut off signal
Error signal in speed sensor signal
Error signal in engine revolution
Cruise control switch lead (“SET”/“RES”)
9) When main switch is cut off once, “resume” is canceled.
1-3
FEATURES
GEN
INFO
DIGITAL SPEEDOMETER
This speedometer is equipped with:
An odometer
Two trip odometers
A fuel reserve trip meter
A clock
Odometer and trip meter modes
1) Selecting a mode
Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer
modes “TRIP 1” and “TRIP 2” in the following order.
“ODO” “TRIP 1” “TRIP 2” “ODO”
If the fuel level indicator light comes on, the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point.
Push the “SELECT” button to change between the fuel reserve tripmeter, trip odometer and odometer
modes in the following order:
“TRIP F” “TRIP 1” “TRIP 2” “ODO” “TRIP F”
2) Resetting a meter
To reset a trip odometer to 0.0, select it by pushing the “SELECT” button and push the “RESET” button.
To reset the fuel reserve trip meter, select it by pushing the “SELECT” button and push the “RESET”
button. The display will return to prior mode (“ODO”, “TRIP 1” or “TRIP 2”).
If you do not reset the fuel reserve trip meter manually, it will automatically reset and retum to “TRIP 1”
after refueling and the motorcycle has traveled both 5km.
NOTE:
If the fuel reserve trip meter appears, and a different mode was NOT selected prior to resetting the fuel
reserve trip meter, the display always returns to the “TRIP 1” mode.
If the fuel reserve trip meter appears, and a different mode was selected prior to resetting the fuel
reserve trip meter, the display automatically returns to the prior mode.
1-4
FEATURES
GEN
INFO
Clock mode
To change the display to the clock mode, push both the “SELECT” and “RESET” buttons.
To change the display back to odometer mode, push the “RESET” button.
1) To set the clock
a. Push both the “SELECT” and “RESET” buttons for at least two seconds.
b. When the hour digits start flashing, push the “RESET” button to set the hours.
c. Push the “SELECT” button and the minute digits will start flashing.
d. Push the “RESET” button to set the minutes.
e. Push the “SELECT” button to start the clock.
NOTE:
After setting the clock, be sure to push the “SELECT” button before turning the main switch to “OFF”,
otherwise the clock will not be set.
AUDIO SYSTEM
1. POWERING ON/OFF THE AUDIO SYSTEM
Turning on/off the audio system
Turn the main switch to the “ACC” or “ON” position.
To turn on the power for the audio system,
push the audio button “AUDIO”.
To turn off the audio system, push the audio
button “AUDIO” continuously for 1 second or
more.
1-5
FEATURES
GEN
INFO
2. CASSETTE DESK OPERATION
The cassette tape deck has the following functions.
Song search
Change tape play direction
Dolby noise reduction
Blank tape skip
a. Turn the main switch to the “ACC” or “ON”
position and push the “AUDIO”button to turn
on the power.
b. Insert a cassette tape into the cassette deck.
c. If a tape is aleady loaded in the cassette
deck, push the “AUDIO” button until “PLAY”
appears.
The tape will start playing.
d. Turn the volume control knob to set the volume level. The volume level can be set from
0 to 30.
Track searching
To search for a song on the tape, push the updown switch 1 for less than one second. The
“APC” (auto program control) indicator will appear in the display.
Push the witch once for each song to be skipped.
Pushing the switch in direction “n” will search in
the forward direction.
Pushing the switch in direction “o” will search in
the reserve direction.
When searching in the forward direction, the number of song that are being skipped will appear.
(i.e., “1”, meaning one track is being skipped)
When searching the reverse direction, the number of song that are being skipped will appear
along with a minus sign before the number. (i.e.,
“-1”, meaning one song is being skipped)
The maxmum number of songs that can be
skipped in either direction is 9.
To stop a searching operation, push the updown button in the opposite direction that it was
originally pushed.
1-6
FEATURES
GEN
INFO
Reserving tape play direction
Push the up-down button 1 in either direction
for more than one second to reverse tape play.
When the tape is playing the forward direction,
the “F” indicator will appear.
When the tape is playing in the reverse direction, the “R” indicator will appear.
Dolby noise reduction
The Dolby noise reduction can be turned on or
off by pushing the “EJECT” button for at least
two seconds.
When the noise reduction is on, the “BNR” indicator appears in the display.
Ejecting the cassette tape
Push the “EJECT” button to eject the tape from
the cassette dack.
Blank skipping
When there is a blank portion on the cassette
tape the “BLS” indicator light will come on and
the cassette deck automatically fast forwards
the tape to the next track.
1-7
FEATURES
GEN
INFO
3. RADIO OPERATION
The radio has the following functions.
Switching the receiving band
Switching the receiving station
Automatic tuning (Seek)
Manual tuning
Programing preset stations in memory
Automatic writing of stations in memory (Auto
store operation)
Switching the receiving bands
This radio system has 3 bands for FM and 1
band for AM. Select a band by pushing the “AUDIO” button for less than 1 second.
The display will change as follows.
TAPE FM1 FM2 FM3
AUX. CD(option) AM Automatic tuning (Seek operation)
Push the up-down switch 1 in either direction
and hold it for as least 1 second.
The tuner will automatically stop at the first station that has a strong enough radio wave.
Manually turning
When a radio wave is too weak to be picked up
automatically, it can be selected manually as
follows.
Push the “SELECT” button until “RADIO” station appears.
Push the up-down switch 1 for less than 1 second in either direction and the ferequency will
change in 0.1 MHz steps for FM and in 9 kHz for
AM.
Presetting station in memory
Station can be preset either automatically or
manually. 6 stations can be set for each band.
Preset station either manually or automatically
by the following procedure.
a. Select the station desired to be preset.
b. Push the “SELECT” button for as least 2 seconds unitl the radio frequency and the channel “Ch” start flashing.
1-8
FEATURES
GEN
INFO
c. Push the up-down switch 1 in either direction to select the channel number to be set for
the current station. (Ch1, Ch2, Ch3, Ch4,
Ch5 and Ch6)
d. Press the “SELECT” button to programing
the channel in memory.
Repeat this procedure for the remaining stations desired to be preset in the memory.
Stations can be also be automatically preset by
the following procedure.
a. Push the “SELECT” button until the radio frequency and the channel “Ch” start flashing.
b. Push the up-down button in either direction
for at least 1 second to automatically tune in
a station.
c. When the desired station is found, push the
up-down switch for less than one second to
select the channel number to be set for that
station.
d. Push the “SELECT” button to programing the
channels in memory.
e. Repeat this procedure for the remaining stations desived to be preset in memory.
Programing preset stations in memory automatically
Setting up to 6 channels can be made by the following procedure.
NOTE:
Stations will be starting from the station preset
at chanel 6.
It is recommended to use this function only in
areas with strong radio frequencies.
a. Push the “SELECT” button until the radio frequency and the channel “Ch” start flashing.
b. Push the up-down switch 1 in either direction to select channel “A”.
c. Press the “SELECT” button to start the random channel selection and the tuner will automatically write the channels in memory.
1-9
FEATURES
GEN
INFO
“AUX” (Auxiliary) operation
Auxiliary audio equipment can be used to play
through the audio system.
a. Insert the output plug of the auxiliary equipment into the jack located at the right side of
the dassette deck.
b. Push the “AUDIO” button until “AUX” appears and the auxiliary equipment can be
used to play through the audio system.
TAPE FM1 FM2 FM3
AUX. CD(option) AM 5. BASIC SETTINGS
AUDIO system
The following settings can be made in the audio
system.
Selecting output between speakers and a headset assembly
Controlling bass level
Controlling treble level
Controlling fader (balance between the front
and the rear speakers)
Controlling intercom volume level
Changing auto volume level
Setting procedure
The following setting procedures apply to the
audio system, auxiliary mode and CD Changer.
a. Select the desired setting mode by pushing
the “SELECT” button. On each press of the
button, the mode changes as follows.
Audio system
OUTPUT BASS TREB FADE
RADIO station AVC INT.VOL
b. Push the up-down switch 1 in either direction to change the setting for any mode.
1-10
FEATURES
GEN
INFO
Selecting the output for speaker or headset
(optional)
To select the output for speaker or headset,
push the “SELECT” button and the “SP” (speaker) or “HS” (headset) indicator will appear. To
change between speaker and headset, push
the up-down switch 1 in either direction.
NOTE:
The speaker and headset cannot be used the
same time.
Controlling the bass level
a. To control the bass level, push the “SELECT”
button until the “BASS” indicator appears.
b. Push the up-down switch 1 in either direction to change the level.
Controllingthe treble level
a. To control the treble level, push the “SELECT” button until the “TREB” indicator appears.
b. Push the up-down switch 1 in either direction to change the level.
The treble level can be set from –6 to +6.
Controlling the fader (balance between front
and rear speakers)
a. To control the fader, push the “SELECT” button until the “FAD” indicator appears.
b. Push the up-down switch 1 in either direction to change the balance.
The fader level can be adjusted from F9 to
R9.
Controlling the intercom volume level
a. To control the intercom volume level, push
the “SELECT” button until the “IC:” indicator
appears.
b. Push the up-down switch 1 in either direction to change the volume level.
The intercom volume level can be set from 0
to 20.
1-11
FEATURES
GEN
INFO
Changing the level for auto volume control
system
a. To control the level for the auto volume control system, push the “SELECT” button untill
the “AV:” indicator appears.
b. Push the up-down switch 1 in either direction to change the volume level.
The auto volume control rate of compensation can be adjusted from 0 to 5.
1-12
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” section.
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
1. 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 apply grease onto
the oil seal lips.
1-13
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
1. 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
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible. When installing oil seals, apply a light
coat of lithium soap base grease onto the oil
seal lips. 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
1. 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 that
the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.
4 Shaft
1-14
CHECKING THE CONNECTIONS
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 that all connections are tight.
5. Check:
continuity
(with a pocket tester)
Pocket tester
YU-03112,90890-03112
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.
1-15
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 umbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
P/N.YM-, YUFOr US, CDN
YS-, YK- ACCP/N.90890Except for US, CDN
Tool No.
Tool name/Usage
Tappet adjusting tool
YM-33961
90890-04105
This tool is needed to rotate the
camshaft for access to the valve lifter and valve pad
Vacuum gauge
YU-08030-A
90890-03094
This gauge is needed for carburetor
synchronization.
Engine tachometer
YU-08036-A
90890-03113
This tool is needed for observing engine rpm.
Timing light
YU-33277-A
90890-03141
This tool is necessary for checking
ignition timing.
Compression gauge/Set
YU-33223
90890-03081
These tools are needed to measure
engine compression.
Oil filter wrench
YU-38411
90890-01426
Gauge
90890-03153
Adapter
90890-03124
This tool is needed to remove and
install the oil filter.
Pressure gauge/adapter
These tools are needed to measure
engine oil pressure.
1-16
Illustration
SPECIAL TOOLS
Tool No.
YU-01268
90890-01268
YU-33975
90890-01403
Tool name/Usage
Ring nut wrench
This tool is needed to loosen and
tighten the steering stem ring nut.
Pocket tester
YU-03112
90890-03112
Compressor
YM-04019
90890-04019
Adapter
YM-01253-1
90890-04114
This instrument is needed for checking the electrical system.
Valve spring compressor/adapter
These tools are needed to remove
and install the valve assemblies.
Valve guide remover (6.0 mm)
YM-4064-A
90890-04064
This tool is needed to remove and
install the valve guide.
Vale guide installer (6.0 mm)
YM-04065-A
90890-04065
This tool is needed to install the
valve guide.
Valve guide reamer (6.0 mm)
YM-04066
90890-04066
This tool is needed to rebore the
new valve guide.
Universal clutch holder
YM-91042
90890-04085
This tool is needed to hold the clutch
when removing or installing the
clutch boss nut.
Sheave holder
YS-01880
90890-01701
Puller
YU-33270
90890-01362
Adapter
YM-33282
90890-04089
This tool is needed to hold the rotor
when removing or installing the rotor
bolt.
Flywheel puller/adapter
These tools are needed to remove
the rotor.
1-17
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
ACC-1100-15-01
90890-85505
Tool name/Usage
Quick gasket
Yamaha Bond No.1215
This sealant (bond) is used on
crankcase mating surfaces, etc.
Piston pin puller
YU-01304
90890-01304
This tool is used to remove the piston pin.
Piston ring compressor
YM-8037
90890-05158
This tool is used to compress the
piston rings when installing the piston into the cylinder.
Damper spring compressor
YM-33286
90890-04090
YM-33222
This tool is needed when removing
or installing the damper spring.
Middle drive gear holder
This tool is needed to remove and
install the middle drive pinion gear.
This tool is also used for the gear
backlash adjustment.
Middle drive gear holder
90890-04080
This tool is needed for the gear
backlash adjustment.
Offset wrench (55 mm)
YM-04054
90890-04054
This tool is needed when removing
or installing the middle drive gear
nut.
Universal joint holder
YM-04062
90890-04062
This tool is needed when removing
or installing the driven pinion gear
nut.
Dial gauge
YU-03097
90890-03097
This tool is used to measure the
middle gear backlash.
1-18
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tester
YU-24460-01
90890-01325
Adapter
YU-33984
Tool name/Usage
Radiator cap tester/adapter
This tester and its adapter are needed for checking the cooling system.
Fuel level gauge
YM-01312-A
90890-01312
This gauge is used to measure the
fuel level in the float chamber.
Rod holder
YM-01300-1
90890-01294
T-handle
YM-01326
90890-01326
Damper rod holder/T-handle
Weight
YM-33963
90890-01367
Adapter
YM-8020
90890-01374
Fork seal driver weight/adapter
These tools are needed to loosen
and tighten the damper rod holding
bolt.
These tools are needed when installing the slide metal, oil seal and dust
seal into the fork.
Final gear backlash band
YM-01230
90890-01230
This tool is needed when measuring
final gear backlash.
Coupling gear/middle shaft tool
YM-01229
90890-01229
This tool is needed when removing
or installing the coupling gear nut.
Bearing retainer wrench
YM-04050
90890-04050
YM-34487
90890-06754
This tool is needed when removing
or installing the final drive shaft
bearing.
Dynamic spark tester
Ignition checker
1-19
GEN
INFO
Illustration
GEN
INFO
SPEC
2
SPEC
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUDIO SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2-4
2-14
2-18
2-21
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code:
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning redius
Standard
XVZ13TF: 5JC1 (for GB. N. S. SF. D. NL. B. F.
G. E. P. I. A. GR)
XVZ13TFL: 5JL1 (for OCE)
2,705 mm
900 mm
1,565 mm (except for G)
1,380 mm (for G)
750 mm
1,705 mm
155 mm
3,500 mm
Basic weight:
Dri weight
With oil and a full fuel tank
366 kg
394 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Liquid cooled 4-stroke, DOHC
V-type 4-cylinder
1,294 cm3
79 66 mm
10 : 1
1,520 kPa (15.2 kg/cm2, 15.2 bar) at 175 r/min
Electric starter
Lubrication system:
Wet sump
Oil type or grade:
Engine oil
Yamalube 4 (20W40) or SAE20W40 type SE
motor oil
Yamalube 4 (10W30) or SAE10W30 type SE
motor oil
Final gear oil:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Final gear case oil
Total amount
SAE80API “GL-4” Hypoid Gear Oil
3.5 L
3.7 L
4.3 L
0.2 L
Radiator capacity (including all routes):
3.5 L
Air filter:
Dry type element
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
22.5 L
3.5 L
2-1
GENERAL SPECIFICATIONS
Item
Standard
Carburetor:
Type/quantity
Manufacturer
BDS32/4
MIKUNI
Spark plug:
Type
Manufacturer
Spark plug gap
DPR8EA-9/X24EPR-U9
NGK/DENSO
0.8 X 0.9 mm
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction radio
Transmission type
Operation
Gear ratio
1st
2nd
3rd
4th
5th
Spur gear
87/49 (1,776)
Shaft drive
21/27
33/10 (2.567)
Constant mesh 5-speed
Left foot operation
43/17 (2.529)
31/19 (1.632)
30/25 (1.200)
24/25 (0.960)
22/28 (0.786)
Chassis:
Frame type
Caster angle
Trail
Double cradle
29.10
152 mm
Tire:
Type
Size
Manufacturer
Type
front
rear
Tubeless
150/80B16 71H
150/90B15M/C 74H
front
rear
front
rear
BRIDGESTONE/DUNLOP
BRIDGESTONE/DUNLOP
G705/D404F
G702/D404
front
rear
250 kPa (2.50 kg/cm2, 2.50 bar)
250 kPa (2.50 kg/cm2, 2.50 bar)
front
rear
250 kPa (2.50 kg/cm2, 2.50 bar)
280 kPa (2.80 kg/cm2, 2.80 bar)
* Load is the total weight of the cargo, rider,
passenger and accessories.
type
operation
type
operation
Dual disc brake
Right hand operation
Single disc brake
Right foot operation
Tire pressure (cold tire):
0 X 90 kg load*
90 X 190 kg load*
Brake:
Front brake
Rear brake
Suspension:
Front suspension
Rear suspension
SPEC
Telescopic fork
Swingarm (link suspension)
2-2
GENERAL SPECIFICATIONS
Item
Standard
Shock absorber:
Front shock absorber
Rear shock absorber
Coil-air spring/Oil damper
Coil-air spring/Oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
140 mm
105 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capaity
T.C.I. (Digital)
A.C. magneto
YTX20L-BS
12 V 18 AH
Headlight type:
Halogen bulb
Bulb wattage quantity:
Headlight
Auxiliary light
Tail/brake light
Front flasher light
Rear flasher light
License light
Indicator light
Neutral indicator light
Turn indicator light
High beam indicator light
Fuel level indicator light
Oil level indicator light
Engine overheat indicator light
Engine trouble indicator light
Over drive indicator light
“SET” indicator light
“RES” indicator light
“ON” indicator light
12 V 60 W /55 W 1
12 V 4 W 1
12 V 21 W/5 W 1
12 V 21 W 2
12 V 21 W 2
12 V 5 W 2
12 V 1.7 W 1
12 V 1.7 W 2
12 V 1.7 W 1
14 V 3.0 W 1
12 V 1.7 W 1
12 V 1.7 W 1
12 V 1.7 W 1
12V1.7W x 1
12V1.7W x 1
12V1.7W x 1
12V1.7W x 1
2-3
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Limit
Cylinder head:
Warp limit
SSS
0.03 mm
Cylinder:
Bore size
Measuring point*
78.967 X 79.016 mm
40 mm
SSS
SSS
SSS
0.05 mm
Chain drive (Center)
25.000 X 25.021 mm
24.967 X 24.980 mm
0.020 X 0.054 mm
SSS
SSS
SSS
SSS
35.75 X 35.85 mm
27.95 X 28.05 mm
35.75 X 35.85 mm
27.95 X 28.05 mm
35.65 mm
27.85 mm
35.65 mm
27.85 mm
*
Out of round limit
Camshaft:
Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions
Intake
Exhaust
“A”
“B“
“A”
“B”
2-4
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
SSS
Camshaft runout limit
Cam chain:
Cam chain type/No. of links
Cam chain adjustment method
Valve, valve seat, valve guide:
Valve clearance (cold)
Limit
0.03 mm
BF05M/118
Automatic
IN
EX
0.11 X 0.15 mm
0.16 X 0.20 mm
Face Width
Seat Width
Valve dimensions:
Head Dia
“A” head diameter
“B” face width
“C” seat width
“D” margin thickness
Stem outside diameter
Guide inside diameter
Stem-to-guide clearance
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
IN
EX
28.9 X 29.1 mm
23.9 X 24.1 mm
1.3 X 3.2 mm
1.6 X 2.9 mm
0.9 X 1.1 mm
0.9 X 1.1 mm
0.8 X 1.2 mm
0.8 X 1.2 mm
5.975 X 5.990 mm
5.960 X 5.975 mm
6.000 X 6.012 mm
6.000 X 6.012 mm
0.010 X 0.037 mm
0.025 X 0.052 mm
2-5
Margin Thickness
1.4 mm
1.4 mm
0.7 mm
0.7 mm
5.945 mm
5.92 mm
6.05 mm
6.05 mm
0.08 mm
0.1 mm
MAINTENANCE SPECIFICATIONS
Item
Standard
Set length (valve closed)
Compressed pressure
(installed)
Tilt limit*
Direction of winding
(top view)
Valve spring:
Outer:
Free length
Set length (valve closed)
Compressed pressure
(installed)
Tilt limit*
Direction of winding
(top view)
Limit
SSS
0.01 mm
IN
EX
IN
EX
IN
EX
IN
EX
37.3 mm
37.3 mm
31.8 mm
31.8 mm
4.57 X 5.37 kg
4.57 X 5.37 kg
SSS
SSS
35.3 mm
35.3 mm
SSS
SSS
SSS
SSS
2.5_/1.6 mm
2.5_/1.6 mm
IN
EX
Counter clockwise
Counter clockwise
SSS
SSS
IN
EX
IN
EX
IN
EX
IN
EX
39.45 mm
39.45 mm
33.8 mm
33.8 mm
10.1 X 11.9 kg
10.1 X 11.9 kg
SSS
SSS
37.25 mm
37.25 mm
SSS
SSS
SSS
SSS
2.5_/1.7 mm
2.5_/1.7 mm
IN
EX
Clockwise
Clockwise
SSS
SSS
Stem runout limit
Valve spring:
Inner:
Free length
SPEC
2-6
MAINTENANCE SPECIFICATIONS
Item
Piston:
Piston to cylinder clearance
Piston size “D”
Measuring point “H”
Piston off-set
Piston pin bore inside diameter
Piston pin outside diameter
SPEC
Standard
Limit
0.055 X 0.069 mm
78.926 X 78.933 mm
0.15 mm
SSS
4 mm
0 mm
19.004 X 19.015 mm
18.991 X 19.000 mm
SSS
SSS
19.045 mm
18.975 mm
Barrel
3.1
1,0 mm
0.20 X 0.35 mm
0.03 X 0.07 mm
SSS
SSS
0.55 mm
0.12 mm
Taper
3.1
1.2 mm
0.35 X 0.50 mm
0.02 X 0.06 mm
SSS
SSS
0.8 mm
0.12 mm
3.1
2.5 mm
0.3 X 0.9 mm
SSS
SSS
Piston rings:
Top ring:
Type
Dimensions (B
T)
End gap (installed)
Side clearance (installed)
2nd ring:
Type
Dimensions (B
T)
End gap (installed)
Side clearance
Oil ring:
Dimensions (B
T)
End gap (installed)
2-7
MAINTENANCE SPECIFICATION
Item
Connecting rod:
Oil clearance
Color code (corresponding size)
Standard
SPEC
Limit
0.021 X 0.039 mm
1 Blue 2 Black 3 Brown 4 Green
5 Yellow 6 Pink
0.09 mm
SSS
83.92 X 83.97 mm
242.72 X 243.17 mm
SSS
0.160 X 0.264 mm
0.021 X 0.039 mm
0.020 X 0.038 mm
1 Blue 2 Black 3 Brown 4 Green
5 Yellow 6 Pink 7 Red
SSS
SSS
0.03 mm
SSS
SSS
0.1 mm
SSS
Crankshaft:
Crank width “A”
Assembly width “B”
Runout limit “C”
Big end side clearance “D”
Big end radial clearance
Journal oil clearance
Color code (corresponding size)
Ballancer:
Ballancer drive method
Gear
Clutch:
Friction plate thickness
Quantity
Friction plate wear limit
Clutch plate thickness
Quantity
Warp limit
Clutch spring free length
Quantity
Minimum length
Clutch housing thrust clearance
Clutch housing radial clearance
Clutch release method
Push rod bending limit
2.9 X 3.1 mm
8
SSS
2.2 X 2.4 mm
7
SSS
7 mm
1
SSS
0.10 X 0.37 mm
0.017 X 0.053 mm
Hydraulic inner push
SSS
2-8
SSS
SSS
2.8 mm
SSS
SSS
0.2 mm
SSS
SSS
6.5 mm
SSS
SSS
SSS
0.5 mm
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Transmission:
Main axle runout limit
Drive axle runout limit
SSS
SSS
0.08 mm
0.08 mm
Shifter:
Shifter type
Guide bar bending limit
Guide bar
SSS
SSS
0.025 mm
5JC1 00
#1, 2 : #122.5 #3 : #117.5 #4 : #120
#110
5DL41-54
P-0
#85
1.1
#15
0.8
0.8
0.8
1.5
#35
0.5
#110
17 mm
950 X 1,050 r/min
36 kPa (270 mmHg)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Electrical type
4NK/MITSUBISHI
1A
15 X 20 kPa (0.2 kg/cm2, 0.2 bar)
SSS
SSS
SSS
SSS
Paper type
Trochoid type
0 X 0.12 mm
0.03 X 0.08 mm
SSS
SSS
0.17 mm
0.08 mm
80 X 120 kPa (0.8 X 1.2 kg/cm2,
0.8 X 1.2 bar)
440 X 560 kPa (4.4 X 5.6 kg/cm2,
4.4 X 5.6 bar)
58 kPa (0.58 kg/cm2) at 1,000 r/min
SSS
Carburetor:
I.D.mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Valve seat size
Starter jet
Starter jet
Throttle valve size
Fuel level
Engine idle speed
Intake vacuum
Fuel pump:
Type
Model/manufacturer
Consumption amperage
Output pressure
(M.J)
(M.A.J)
(J.N)
(N.J)
(P.A.J.1)
(P.O)
(P.J)
(B.P.1)
(B.P.2)
(B.P.3)
(V.S)
(G.S.1)
(G.S.2)
(Th. V)
(F.L)
<max>
Lubrication system:
Oil filter type
Oil pump type
Inner rotor to outer rotor clearance
Outer rotor to oil pump housing
clearance
Bypass valve setting pressure
Relief valve operating pressure
Oil pressure (hot)
2-9
SSS
SSS
MAINTENANCE SPECIFICATIONS
Item
Cooling system:
Radiator core size
Width
Height
Thickness
Radiator cap opening pressure
Reservoir tank capacity
<From low to full level>
Water pump
Type
Reduction ratio
Shaft drive:
Middle gear backlash
Final gear backlash
SPEC
Standard
Limit
257.4 mm
360 mm
27 mm
95 X 125 kPa (0.95 X 1.25 kg/cm2,
0.95 X 1.25 bar)
0.84 L
<0.25 L>
SSS
SSS
SSS
SSS
Single suction centrifugal pump
31/21 (1.476)
SSS
SSS
0.05 X 0.12 mm
0.1 X 0.2 mm
SSS
SSS
2-10
SSS
SSS
MAINTENANCE SPECIFICATIONS
Item
Standard
Crankcase tightening sequence:
2-11
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Part to be tightened
g
Camshaft cap
Blind plug
Exhaust pipe
Spark plug
Cylinder head
Cylinder head cover
Chrome cover
Connecting rod
AC magneto
Camshaft sprocket
Timing chain damper bracket
Timing chain tensioner
Cap bolt (tensioner)
Water pump drain plug
Radiator
Radiator side cover
Radiator cap pipe
Oil filter mounting bolt
Oil gallery pipe
Oil drain plug
Oil baffle plate
Oil gallery bolt
Oil delivery pipe (head)
Oil delivery pipe (cover)
Oil pipe
Stay 1
Oil filter
Clamp bolt (clutch hose)
Carburetor joint
Air filter joint
Air filter assembly
Air filter case cover
Clamp bolt (exhaust pipe)
Clamp bolt (muffer)
Exhaust pipe
Cylinder
Main gallery blind plug
Crankcase
Middle gear bearing retainer
Main axle bearing retainer
Crankcase cover plate
Part name
Bolt
Plug
Stand bolt
Nut
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Plug
Bolt
Bolt
Bolt
Union bolt
Bolt
Plug
Bolt
Screw
Union bolt
Union bolt
Union bolt
Bolt
Bolt
Screw
Screw
Screw
Screw
Bolt
Bolt
Nut
Stud bolt
Plug
Bolt
Screw
Screw
Screw
2-12
Thread size
M6 1.0
M18 1.5
M8 1.25
M12 1.25
M10 1.25
M6 1.0
M6 1.0
M8 0.75
M12 1.25
M7 1.0
M8 1.25
M6 1.0
M16
M14
M6 1.0
M6 1,0
M6 1.0
M20 1.5
M6 1.0
M14
M6 1.0
M5 0.8
M8 1.25
M10 1.25
M8 1.25
M6 1.0
M20 1.5
M5 0.8
M4 0.8
M4 0.8
M5 x 0.8
M5
M8 1.25
M8 1.25
M8 1.25
M10 1.25
M20
M10 1.25
M8 1.25
M6 1.0
M6 1.0
Q’ty
y
32
6
8
4
16
16
16
8
1
8
1
4
2
1
2
4
2
1
2
1
2
1
2
1
1
1
1
1
4
4
2
14
2
2
8
16
1
8
4
3
2
Tightening
torque
Nm
mSkg
10
55
15
18
43
10
10
36
130
20
24
12
20
43
7
10
10
50
12
43
12
5
18
20
18
12
17
4
3
3
3
3
25
20
20
9
12
40
25
7
7
1.0
5.5
1.5
1.8
4.3
1.0
1.0
3.6
13.0
2.0
2.4
1.2
2.0
4.3
0.7
1.0
1.0
5.0
1.2
4.3
1.2
0.5
1.8
2.0
1.8
1.2
1.7
0.4
0.3
0.3
0.3
0.3
2.5
2.0
2.0
0.9
1.2
4.0
2.5
0.7
0.7
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
torque
Nm mSkg
Part to be tightened
g
Part name
Thread size
Q’ty
y
Oil drain plug (crankcase)
Starter clutch
Clutch spring plate
Clutch boss
Clutch release cylinder
Air bleed screw
Clutch pipe
Middle drive pinion gear
Middle driven pinion gear
Middle driven gear housing
Shift cam segment
Shift cam plate
Shift cam retainer
Shift shaft spring stopper
Stopper lever
Shift pedal bracket
Shift arm
Shift rod
Shift rod
Bolt
Bolt
Bolt
Nut
Bolt
Screw
Union bolt
Nut
Nut
Bolt
Torx
Screw
Screw
Bolt
Bolt
Screw
Bolt
Nut
Nut
M12 1.25
M8 1.25
M6 1.0
M20 1.0
M6 1.0
M8 1.25
M10 1.25
M44 1.5
M16 1.5
M8 1.25
M6 1.0
M5 0.8
M6 1.0
M8 1.25
M6 1.0
M6 1.0
M6 1.0
M6 1.0
M6 1.0
1
6
6
1
2
1
1
1
1
3
1
1
3
1
1
1
1
1
1
38
24
8
70
12
6
25
110
90
30
12
4
7
22
10
7
10
10
10
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
0.7
1.0
1.0
1.0
Shift pedal link
Shift lever assembly
Final gear case (rear arm)
Final gear case (bearing
housing)
Coupling gear
Bearing housing
Bolt
Bolt
Stud bolt
Stud bolt
M6 1.0
M6 1.0
M10 1.25
M8 1.25
1
1
4
6
10
18
18
9
1.0
1.8
1.8
0.9
Nut
Nut
Bolt
Plug
Plug
Screw
Bolt
Screw
Bolt
M16 1.25
M8 1.25
M10 1.25
M14 1.25
M14 1.25
M6 1.0
M6 1.0
M5 0.8
M6 1.0
M10 1.25
M18 1.5
M5 0.8
M6 1.0
1
6
2
1
1
3
2
3
2
1
1
8
2
110
23
40
23
23
7
10
4
10
8
23
4
7
11.0
2.3
4.0
2.3
2.3
0.7
1.0
0.4
1.0
0.8
2.3
0.4
0.7
Drain plug (final gear case)
Filler plug (final gear case)
Stator coil
Starter motor
Neutral switch
Oil level switch
Thermo unit
Thermo switch
Ignition coil assembly
Ignitor unit assembly
Bolt
Nut
2-13
Remarks
Left hand
thread
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item
Standard
Steering system:
Steering bearing type
Taper roller bearing
SSS
140 mm
573 mm
50 mm
8.83 N/mm (0.9 kg/mm)
0 X 140 mm
No
0.553 L
117 mm
Yamaha fork oil 5WT
0 kPa (0 kgf/cm2, 0 bar)
0 X 50 kPa (0 X 0.5 kgf/cm2,
0 X 0.5 bar)
SSS
568 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
45 mm
186.5 mm
165.5 mm
147 N/mm (14.7 kg/mm)
0 X 45 mm
No
0 kPa (0 kgf/cm2, 0 bar)
0 X 400 kPa (0 X 4.0 kgf/cm2,
0 X 4.0 bar)
SSS
181.5 mm
SSS
SSS
SSS
SSS
SSS
SSS
end
side
SSS
SSS
0 mm
0 mm
radial
lateral
Cast wheel
16
MT3.50
Aluminum
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
radial
lateral
Cast wheel
15M/C
MT4.00
Aluminum
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Front suspension:
Front fork travel
Fork spring free length
Collar length
Spring rate
(K1)
Stroke
(K1)
Optional spring
Oil capacity
Oil level
Oil grade
Endosed gas/air pressure
(STD)
(Min X Max)
Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring rate
(K1)
Stroke
(K1)
Optional spring
Enclosed gas/air pressure
(STD)
(Min X Max)
Swingarm:
Free play limit
Front wheel:
Type
Rim size
Rim material
Rim runout limit
Rear wheel:
Type
Rim size
Rim material
Rim runout
Limit
2-14
GENERAL SPECIFICATIONS
Item
Front disc brake:
Type
Disc outside diameter
Pad thickness
Pad thickness
Standard
thickness
inner
outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake:
Type
Disc outside diameter
Pad thickness
Pad thickness
thickness
inner
outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever & brake pedal:
Brake lever free play (at lever end)
Brake pedal position
Brake pedal free play
SPEC
Limit
Dual
298
5 mm
6 mm
6 mm
SSS
SSS
0.5 mm
0.5 mm
15.87 mm
30.1 mm
33.3 mm
DOT 4
SSS
SSS
SSS
SSS
Single
320
7 mm
7.5 mm
7.5 mm
SSS
SSS
0.5 mm
0.5 mm
12.7 mm
33.9 mm
30.2 mm
DOT 4
SSS
SSS
SSS
SSS
2 X 5 mm
100 mm
SSS
SSS
0 mm
SSS
2-15
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Thread size
Part to be tightened
g
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)
Frame and down tube
Cylinder head stay and frame
Frame and rear fender stay (rear frame)
Muffler stay and muffler
Ignitor unit
Ignition coil
Ignition bracket
Swingarm pivot shaft (left)
Swingarm pivot shaft (right)
Swingarm pivot shaft locknut (right)
Relay arm and frame
Relay arm and connecting rod
Connecting rod and swingarm
Rear shock absorber and frame
Rear shock absorber and connecting rod
Fuel petcock and fuel tank
Fuel sender and fuel tank
Fuel tank (front) and frame
Fuel tank (rear) and frame
Fuel pump bracket and bridge plate
Cover and fuel tank
Rider seat and frame
Passenger seat and frame
Starter relay and battery positive lead
Starter relay and starter motor lead
2-16
Tightening
torque
Nm
mSkg
M6
M22
M8
10
130
28
1.0
13.0
2.8
M25
M6
M4
M12
M6
M10
M10
3
7
2
32
10
30
19
0.3
0.7
0.2
3.2
1.0
3.0
1.9
M10
M12
M10
M10
M10
M10
M6
M5
M6
M25
M25
M25
M10
M12
M12
M12
M12
M6
M5
M6
M8
M6
M6
M6
M6
M6
M6
40
78
45
64
48
30
7
4
7
100
7
100
48
50
50
59
59
7
4
7
16
7
7
7
7
7
7
4.0
7.8
4.5
6.4
4.8
3.0
0.7
0.4
0.7
10.0
0.7
10.0
4.8
5.0
5.0
5.9
5.9
0.7
0.4
0.7
1.6
0.7
0.7
0.7
0.7
0.7
0.7
Remarks
See NOTE
MAINTENANCE SPECIFICATIONS
Thread size
Part to be tightened
g
Rear fender side mold and rear fender stay
Main switch and frame
Sidestand bolt and nut
Footrest bracket and frame
Rear footrest and frame
Rear master cylinder and rear brake bracket
Rear master cylinder and brake hose joint
Brake hose joint and brake hose
Rear brake reservoir tank
Union bolt (rear brake hose)
Footrest bracket and rear brake bracket
Footrest bracket and shift rod bracket
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
M8
M8
M12
M10
M8
M8
M10
M10
M6
M10
M8
M8
M18
M8
M18
M10
M10
M8
M8
SPEC
Tightening
toque
Nm
mSkg
23
30
122
52
23
23
30
26
4
30
23
23
78
19
150
40
40
23
6
2.3
3.0
12.2
5.2
2.3
2.3
3.0
2.6
0.4
3.0
2.3
2.3
7.8
1.9
15.0
4.0
4.0
2.3
0.6
Remarks
NOTE:
1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then loosen
the ring nut completely.
2. Retighten the ring nut to specification.
2-17
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Standard
Limit
Voltage:
12 V
SSS
Ignition system:
Ignition timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
5_ at 1,000 r/min
45_ at 5,000 r/min
SSS
SSS
T.C.I.:
Pickup coil resistance/color
T.C.I. unit model/manufacturer
189 X 231 Ω at 20_C/Gray/Black
JT112/MITSUBISHI
SSS
SSS
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
F6T541 /MITSUBISHI
6 mm
3.57 X 4.83 Ω at 20_C
10.71 X 14.49 kΩ at 20_C
SSS
SSS
SSS
SSS
Spark plug cap:
Type
Resistance
Resin type
10 kΩ
SSS
SSS
Charging system:
Type
Model/manufacturer
Nominal output
Stator coil resistance/color
A.C. magneto generator
F4T655 /MITSUBISHI
14 V 29 A at 5,000 r/min
0.279 X 0.341 Ω at 20_C/White – White
SSS
SSS
SSS
SSS
Rectifier/regulator:
Type
Model/manufacturer
No load regulated voltage
Capacity
Withstand voltage
Semi-conductor, short-circuit type
SH678-11/SHINDENGEN
14.1 X 14.9
22 A
200 V
SSS
SSS
SSS
SSS
SSS
2-18
MAINTENANCE SPECIFICATIONS
Item
Battery:
Specific gravity
SPEC
Standard
Limit
1.320
SSS
Constant mesh type
SSS
SM-13/MITSUBA
SM-13
0.8 kW
10 mm
28 mm
0.7 mm
SSS
SSS
SSS
5 mm
27 mm
SSS
MS5F-441 /JIDECO
180 A
4.18 X 4.62 Ω at 20_C
SSS
SSS
SSS
Plane type (for EUR)
Eddy type (for OCE)
YF-12/ NIKKO (for EUR)
YFM-12 / NIKKO (for OCE)
3 A (for EUR)
4 A (for OCE)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Flasher relay:
Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage
Full transistor type
FE246BH/DENSO
No
75 X 95 cycle/min
21 W
2 + 3.4
SSS
SSS
SSS
SSS
SSS
Oil level switch:
Model/manufacturer
4XY/DENSO
SSS
Fuel sensor:
Model/manufacturer
4XY/NIPPON SEIKI
SSS
Sidestand relay:
Model/manufacturer
Coil winding resistance
Diode
G8R-30Y-B/OMRON
202.5 X 247.5 Ω
Yes
SSS
SSS
SSS
Fuel pump relay:
Model/manufacturer
G8R-30Y-J/OMRON
SSS
Electric fan:
Model/manufacturer
4XY/DENSO
SSS
Electric starter system:
Type
Starter motor:
Model/manufacturer
I.D. number
Output
Brush overall length
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
Horn:
Type
Quantity
Model/manufacturer
Maximum amperage
2
2-19
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
Thermo switch:
Model/manufacturer
5EB/NIPPON THERMOSTAT
SSS
Thermo unit:
Model/manufacturer
3YX/NIPPON SEIKI
SSS
Vacume actuator:
4XY/MITSUBISHI
SSS
Vacume pump:
4XY/MITSUBISHI
SSS
Fuse
SSS
30 A 1
15 A 1
15 A 1
10 A 1
10 A 1
10 A 1
10 A 1
10 A 1
10 A 1
5A2
10 A 2
15 A 1
30 A 1
5A1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Circuit breaker:
Type
Amperage for individual circuit
MAIN
HEAD
SIGNAL
IGNITION
FAN
Back up (odometer)
Cruse control
Carburetor
Audio
DC outlet
Reserve
Reserve
Reserve
Reserve
2-20
MAINTENANCE SPECIFICATIONS
SPEC
AUDIO SYSTEM SPECIFICATIONS
Item
AM/FM Radio:
Tuning Range: AM
FM
Intermediate Frequency: AM
FM
Bass
Treb
Standard
531 X 1,602 KHz
87.5 X 108 MHz
450 KHz
10.7 MHz
"10dB/100 HZ
"10dB/10KHz
Amplifier:
Output Power
Auto-Vol. Range
Output Impedance: Speaker
Headset
14W x 4 (SP)/1W x 2 (HS)
5 steps
4Ω
8 Ω X 16 Ω
Deck:
Circuit System
Tape Speed
Taper
4-track. 2-channel, Stereo for reproduction
4.75 cm/sec.
Normal and Metal
2-21
SPEC
GENERAL TIGHTENING TORQUE SPECIFICATIONS
EAS00030
GENERAL TIGHTENING TORQUE SPECIFICATIONS
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: Distance between flats
B: Outside thread diameter
2-22
A
(nut)
B
(bolt)
10 mm
General torque
specifications
Nm
mkg
ftlb
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point
Symbol
Oil seal lips
O-ring
Bearing
Connecting rod bolt/nut
Connecting rod small end and big end
Crankshaft pin
Crankshaft journal/big end
Piston surface
Piston pin
Camshaft cam lobe/journal
Timing chain tensioner
Valve stem (IN, EX)
Valve stem end (IN, EX)
Valve lifter
Water pump impeller shaft
Oil pump rotor (inner/outer), housing
Oil strainer assembly
Idle gear surface
Starter idle gear
Starter idle gear shaft
Starter clutch (outer/roller)
Push rod ball
Pressure plate bearing
Transmission gear (wheel/pinion)
Shift cam
Shift fork/guide bar
Shift shaft assembly
Shift pedal
Shift lever joint
Middle drive shaft (drive damper cam/driven damper cam)
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS
Lubrication Point
Symbol
Steering bearing (upper/lower)
Steering bearing cover
Steering lock
Steering head pipe lower oil seal
Front wheel oil seal (right/left)
Rear wheel oil seal
Clutch hub fitting area
Rear brake pedal shaft
Shift pedal
Front footrest pivot
Rear footrest pivot
Sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever pivot bolt, contact surface
Clutch lever bolt, contact surface
Swingarm pivot shaft
Swingarm pivot bearing
Swingarm pivot oil seal
Relay arm bearing (inner)
Rear shock absorber bearing (inner)
Connecting rod bearing (inner)
2-24
COOLING SYSTEM DIAGRAMS
EAS00033
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
Radiator cap
Thermostatic valve housing
Radiator hose
Radiator
Water pump
A To coolant reservoir tank.
2-25
SPEC
LUBRICATION DIAGRAMS
EAS00034
LUBRICATION DIAGRAMS
1
2
3
4
5
6
7
8
9
Camshaft (intake)
Camshaft (exhaust)
Water pump impeller shaft
Water pump drive gear
Main gallery
Oil filter
Crankshaft
Oil strainer
Oil pump
10 Main axle
11 Drive axle
2-26
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Camshaft
Main gallery
Crankshaft
Oil level switch
2-27
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Main axle
Drive axle
Middle driven pinion gear
Middle drive pinion gear
2-28
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
5
6
Crankshaft
Oil pipe
Oil filter
Water pump drive gear
Oil strainer
Oil pump
2-29
SPEC
CABLE ROUTING
SPEC
EAS00035
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
Under cover (right)
Cruise control unit
Wire harness
Radiator assembly
Cruise control cable
Vacuum actuator
Sidestand switch lead
Fan motor lead
Noise filter lead
Frame complete
A
B
C
D
E
F
Fasten the wire harness with a plastic clamp.
To rear brake switch
Position the vacuum hose as shown.
To regulator
Fasten the wire harness with a plastic clamp.
Fasten the side stand switch lead, fan motor lead and noise filter lead
with a plastic clamp.
G Align the projection downward.
H Fasten teh side stand switch lead, fan motor lead and noise filter lead
with a plastic clamp.
2-30
CABLE ROUTING
I Fasten the regulator lead with a steel clamp.
J Route the rear brake switch lead between the
wire harness and cover.
K Fasten the side stand switch lead, fan motor lead
and noise filter lead with a plastic clamp.
L Route the side stand switch lead, fan motor
lead and noise filter lead inside the pipe.
Make sure that the leads are not come out of the
pipe.
M Fasten the cruise control cable and wire harness
with a plastic clamp.
N Route the cruise control cable and wire harness outside of the steel clamp.
SPEC
O Align the white mark on the rear brake switch
lead with the metal clamp.
2-31
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
Antenna lead (with cover)
Auxiliary terminal
CD code
Meter lead
Hazard relay
DC outlet lead
Speaker lead
Hazard relay lead
Antenna lead
Handlebar switch lead (right)
Front brake switch lead
Handlebar switch lead (left)
Plastic clamp
14
15
16
17
18
19
20
21
22
23
24
25
26
Headlight harness
Antenna lead
Front head set lead
Handlebar switch lead (left)
Handlebar switch lead (right)
Front brake switch lead
Wire harness sub lead (right)
Ground lead
Headlight harness
Meter lead
Antenna lead (with cover)
Handlebar switch lead (right)
Front brake switch lead
2-32
27
28
29
30
31
32
33
34
35
36
37
SPEC
Flasher relay
Ground lead
“CRUISE” switch lead
Front brake switch lead
Handlebar switch lead (left)
CD cord 13P (green)
CD cord (option)
Auxiliary terminal lead
Front remote controller 13P (blue)
EXT lead 5P (white)
Head set lead 5P (red)
CABLE ROUTING
A To the “CRUISE” switch.
B Connect the couplers with same color.
C Fasten the headlight harness and handlebar
switch (left and right) lead with a plastic clamp.
D Fasten the turn signal lead with a plastic clamp.
E To the turn signal light.
F To headlight.
G Fasten the audio coupler and headlight harness
with a plastic clamp.
H Fasten the meter lead and antenna harness with
a plastic clamp.
I Fasten the handlebar switch lead (right) and
front brake switch lead with a plastic clamp.
SPEC
J Fasten the headlight harness to the pipe with
plastic clamp.
K To the speedometer.
L Fasten the headlight harness to the pipe with a
plastic clamp.
M To the headlight (harness).
N Connect the handlebar switch lead (right) with
the headlight harness.
O Fasten the handlebar switch lead (left and right)
and front brake switch lead with a plastic clamp.
P To the headlight harness.
Q Put the plug for CD cord under the cassette deck.
2-33
CABLE ROUTING
R Align the ground lead paint mark and main harness sub lead with a plastic clamp.
S Clamp the head light harness (right). Route the
head light harness so that DIN cable set comes
upper side.
T For installing the stay, do not catch the throttle
cable.
U Put it under the cassette deck sideways.
Not clamped.
V At the white tape on the antenna lead attach a
plastic clamp.
2-34
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
Brake hose
Clutch hose
Handlebar switch lead (left)
Remote controller lead
Throttle cable
Handlebar switch lead (right)
Wire harness assembly
A
B
C
D
E
F
G
H
I
SPEC
Pass the clutch hose through the guide.
To the upper cowling.
To the engine stop switch.
To the ignition coil #2.
To the thermo switch.
To the left under cowling.
To the fan motor.
To the right under cowling.
Fasten the ignition coil lead with a plastic clamp (with the end towards
the under side of the motorcycle).
2-35
CABLE ROUTING
1
2
3
4
5
Wire harness
Starter lead
Brake hose
Battery negative lead
Wire harness
A
B
C
D
E
F
G
H
SPEC
To the rear fender.
From the radiator (breather hose).
From the fuel tank.
To the air cleaner.
From the fuel tank (breather hose).
To the carburetor.
To the wire harness.
Fasten the starter lead with a plastic clamp (with the end towards the
front side of the motorcycle).
I Align the white mark on the wire harness with the plastic clamp (with the
end towards the front side of the motor cycle).
2-36
CABLE ROUTING
J
K
L
M
N
O
Same rute with air cleaner drain hose.
Front the air cleaner.
From the coolant reservoir tank.
From the engine.
To the horn.
Fasten the wire harness with a plastic clamp
(with the end towards the front side of the motorcycle).
P To the relay.
2-37
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
Plastic clamp
Emergency stop switch
Bolt (ground)
Platic clamp
Bolt (ground)
Carburetor heater relay
Flasher relay
Thermo switch
High tension code
AIS hose
Coolant reservoir hose
A
B
C
D
E
F
G
H
I
J
K
L
SPEC
Route the high tension cord throgh the guide on the air induction box.
Clamp the coolant hose inside of the motorcycle with hose clamp.
Fasten the audio lead and CD lead (option) with a plastic clamp.
Route the audio lead tensely.
To the fuel tank.
Fasten the wire harness sub lead with a plastic clamp.
To the upper cowling.
Fasten the audio lead, CD lead (option) and ground lead with a plastic
clamp.
Fasten the ground lead and engine stop switch lead.
To the under cowling.
Insert the hose through the metal clilp.
To the AIS.
2-38
CABLE ROUTING
M Position the end of clamp to the rear side of the
motorcycle.
N Position the end of clamp to the rear side of the
motorcycle.
O To the engine.
P Clamp the horn lead white mark and ground lead.
Q Route the battery negative lead between the wire
harness and pipe.
R To the AIS.
S Fasten the wire harness, flasher relay and thermo switch lead with a plastic clamp.
T Fasten the wire harness with a plastic clamp.
U To the rear fender.
SPEC
V To the coolant reservoir tank cap.
W Fasten the high tension cord #1 and #3 with a
plastic clamp.
X Align the cover on the high tension cord with the
clamp.
Y Clamp the AIS hose as far as possible from the
frame.
2-39
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Front remote controller
TPS lead
Carburetor heater lead
Speed sensor lead
Main harness
Fuel tank breather hose
Audio lead
Coolant reservoir hose
Fuel hose (from fuel tank)
Fuel hose (from fuel pump)
AIS hose
Breather hose
Air cleaner case drain hose
Wire harness
Support stay
SPEC
A Connect the fuel sender lead on the fuel tank.
B Route the head set lead to the switch cover on the fuel tank.
C Fasten the wire harness sub lead, antenna lead and head set lead with
a plastic clamp. Align the wire harness sub lead and mark on the head
set lead with the clamp. At the cover on the antenna lead attach a
clamp.
D Fasten the throttle cable with a plastic clamp.
E Position the throttle cable (return side) at inside of the cable holder.
F Position the throttle cable (pull side) at outside of the cable holder.
G Route the wire harness with the frame guide (T-bar).
H Fasten the speed sensor lead and wire harness.
I Align the marking tape on the head set lead, CD cord (option), antenna
lead and CB cord and fasten them, tail lead and DC outlet lead with a
plastic clamp.
J Position the lead wires on the rear fender as shown.
K Clamp the speed sensor lead in the clip on the rear arms.
2-40
CABLE ROUTING
L Fasten the speed sensor lead, fuel pump lead and fuse box lead with a
plastic clamp.
M Fasten the speed sensor lead with a plastic clamp.
N Turn the lead wire to clamp on the rear arm section.
O Route the wire harness behind the igniter unit.
P From coolant reservoir tank.
Q From air cleaner case.
R From engine.
S Route the hoses on the left side of the engine leads.
T Fasten the starter lead, pick up lead, AC magneto lead, neutral switch
lead, ignition coil sub lead and oil level gauge lead with a plastic clamp.
U From fuel tank
V Make sure that the sidestand switch lead has no loosening.
2-41
SPEC
CABLE ROUTING
W Fasten the side stand switch lead with a plastic
clamp.
X Fasten the side stand switch lead with a plastic
clamp.
Y To under cowling.
Z Fasten the sidestand switch lead with a metal
band.
A’ Fasten the clutch pipe with a plastic clamp.
B’ To under cowling
C’ Insert the hose through the metal clip.
D’ Through the brake hose in the guide wire.
E’ To upper cowling.
F’ Fasten the wire harness sub lead, throttle cable,
head set lead and clutch hose with a plastic clamp.
SPEC
G’ Insert the wire harness into the air induction box
guide and hold it with clamp.
H’ Fasten the fuel hose on the carburetor with a
plastic clamp.
I’ Position the throttle cables do not outside of the
carburetors.
J’ To plastic clamp on the cross pipe.
K’ To wire harness assembly.
L’ Fasten the clutch hose and support stay with a
plastic clamp (with the end towards the in side of
the motorcycle).
M’ So that the white painted mark is exposed to
view.
2-42
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fuel tank breather hose
Bracket
Head set lead
CD code (option)
Antenna lead
Ground lead
Wire harness
Plastic clamp
CD cord (option)
DC outlet
Screw
Fuel sender lead
Plastic clamp
Wire harness
Ground lead
DC outlet
17
18
19
20
21
Tail/ brake light lead
Head set lead
CD cord (option)
Antenna lead
Plastic clamp
2-43
SPEC
A Fasten the handlebar switch
lead (right) and clutch hose with
a plastic clamp.
B Fasten the handlebar switch
lead (right) with a plastic clamp.
C Fasten the wirek harness, main
switch lead and fuel sender lead
with a plastic clamp.
D Fasten the wire harness, main
switch lead and ignition coil #4
lead with a plastic clamp.
E Be sure not to squeeze each
leads.
CABLE ROUTING
F Positon the clip end at upper.
G Route the AIS hose through the clip.
H Route the tail / brake light lead through the hole in
the cover at the back of the frame.
I After routing the leads, fasten them with clamp.
J Fix the connector with a clamp as shwon.
K Route the wireharness between bracket and rear
fender.
L Route the CD cord (option) outside the rear
frame into the hole on the cover.
M Make sure if the lead wires go to the left or right
side.
N
O
P
Q
R
S
T
SPEC
Route the wire harness with the guide (T-bar).
Route the AIS hose between the carburetor joints.
The protector section must be exposed.
Route the antenna lead at the left side.
To the fuel cock.
Fasten the wire harness with a plastic clamp.
Fasten the handlebar switch lead and remote
controller lead with a plastic clamp.
U Route the ignition coil lead downward the main
harness.
V Fasten the handlebar switch lead (left), clutch
hose and remote controler lead with a plastic
clamp.
2-44
CHK
ADJ
3
CHK
ADJ
CONTENTS
PERIODIC CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 3-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . 3-1
FRONT COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
REMOVING THE FRONT COWLING COVER . . . . . . . . . . . . . . . . . . 3-4
INSTALLING THE FRONT COWLING COVER . . . . . . . . . . . . . . . . . 3-4
RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SADDLEBAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . .
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE HYDRAULIC CLUTCH SYSTEM . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR JOINTS AND INTAKE
MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . .
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FINAL DRIVE OIL LEVEL . . . . . . . . . . . . . . . . . . . .
CHECKING THE FINAL DRIVE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
3-8
3-13
3-15
3-15
3-17
3-18
3-19
3-21
3-22
3-24
3-26
3-27
3-28
3-29
3-30
3-31
3-31
3-31
3-32
3-33
3-37
3-38
3-38
3-39
3-40
3-40
3-41
3-42
3-42
3-43
3-45
CHK
ADJ
ADJUSTING THE FRONT AND REAR SHOCK ABSORBER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . .
3-45
3-46
3-48
3-49
3-49
3-49
3-49
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . .
3-50
3-50
3-55
3-57
3-58
INTRODUCTION/PERIODICK
MAINTENANCE AND LUBRICATION INTERVALS
CHK
ADJ
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.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
EVERY
NO.
ITEM
CHECKS AND MAINTENANCE JOBS
1
*
Fuel line
Check fuel hoses for cracks or damage.
Replace if necessary.
2
*
Fuel filter
Check condition.
Replace if necessary.
Spark plugs
Check condition.
Clean, regap or replace if necessary.
Valves
Check vlave clearance.
Adjust if necessary.
Air filter
Clean or replace if necessary.
3
4
*
5
INITIAL
(1,000 km)
6,000 km
or
6 months
(whichever
comes first)
12,000 km
or
12 months
(whichever
comes first)
√
√
√
√
√
√
Every 42,000 km or 42 months
(whichever comes first)
√
√
√
√
√
6
*
Clutch
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
Correct accordingly.
7
*
Front brake
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
Correct accordingly.
Replace brake pads if necessary.
√
√
√
8
*
Rear brake
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
Correct accordingly.
Replace brake pads if necessary.
√
√
√
9
*
Wheels
Check balance, runout and for damage.
Rebalance or replace if necessary.
√
√
10 *
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
11 *
Wheel bearings
Check bearing for looseness or damage.
Replace if necessary.
√
√
12 *
Swingarm
Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
√
√
13 *
Steering bearings
Check bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
√
√
14 *
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
√
√
15
Sidestand
Check operation.
Lubricate and repair if necessary.
√
√
16 *
Sidestand switch
Check operation.
Replace if necessary.
√
√
17 *
Front fork
Check operation and for oil leakage.
Correct accordingly.
√
√
18 *
Rear shock absorber
assembly
Check operation and shock absorber for oil leakage.
Replace shock absorber assembly if necessary.
√
√
19 *
Rear suspension relay
arm and connecting arm
pivoting points
Check operation.
Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
√
√
√
3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EVERY
NO.
ITEM
CHECKS AND MAINTENANCE JOBS
INITIAL
(1,000 km)
6,000 km
or
6 months
(whichever
comes first)
12,000 km
or
12 months
(whichever
comes first)
20 *
Carburetors
S Check engine idling speed, synchronization and starter operation.
S Adjust if necessary.
√
√
√
21
Engien oil
S Check oil level and vehicle for oil leakage.
S Correct if necessary.
S Change. (Warm engine before draining.)
√
√
√
22
Engine oil filter cartridge
S Replace.
√
23 *
Cooling system
S Check coolant level and vehicle for coolant leakage.
S Correct if necessary.
S Change coolant every 24,000 km or 24 months (whichever comes first).
24
Final gear oil
S Check oil level and vehicle for oil leakage.
S Change oil at initial 1,000 km and thereafter every 24,000 km or
24 months (whichever comes first).
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake and clutch systems
S After disassembling the master cylinder, caliper cylinder or clutch relase cylinder, always replace the
brake fluid.
Check the brake fluid level of the master cylinder and clutch release cylinder regularly and fill as
required.
S Replace the oil seals on the inner parts of the master cylinder, caliper cylinder and clutch release
cylinder every two years.
S Replace the brake and clutch hoses every four yeras or if cracked or damaged.
3-2
FRONT COWLING
CHK
ADJ
FRONT COWLING
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
1
Remove the parts in the order listed.
Refer to “REMOVING/INSTALLING THE
FRONT COWLING COVER.”
Removing the front cowling
Front cowling chrome cover
Wind shield
Front cowling
Headlight unit
MCU lead/speedometer lead/
headlight lead
Front pannel
1
1
1
1/1/1 Disconnect
1
For installation, reverse the removal
procedure.
3-3
FRONT COWLING
CHK
ADJ
REMOVING THE FRONT COWLING COVER
1. Remove
front cowling cover
a. Loosen the bolt 1
b. First, lift up each side of the cowling cover 2 .
c. Then, push the center portion of the cover 3
inward and lift the entire cover upward.
INSTALLING THE FRONT COWLING COVER
1. Install
front cowling cover
a. First, insert each side of the cowling cover 1
into the cowling.
b. While pushing the center portion of the cowling cover 2 inward, push downward to
install.
c. Tighten the bolts 3 .
3-4
RIDER AND PASSENGER SEATS
CHK
ADJ
EB302001
RIDER AND PASSENGER SEATS
Order
1
2
Job/Part
Q’ty
Removing the rider and passenger
seats
Rider seat
Passenger seat
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-5
FUEL TANK
CHK
ADJ
EB302002
FUEL TANK
7 Nm (0.7mkg)
16 Nm (1.6mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “RIDER AND PASSENGER
SEATS”.
Removing the fuel tank
Rider seat
1
2
3
4
5
Remarks
1
1
1
1
1
Top cover
Fuel tank breather hose
Fuel sender lead coupler
Fuel hose
Fuel tank
Disconnect
Disconnect
NOTE:
Before disconnecting the hose, turn the
fuel cock “OFF”.
For installation, reverse the removal
procedure.
3-6
SADDLEBAGS
CHK
ADJ
SADDLEBAGS
7.5 Nm (0.75 mkg)
6.5 Nm (0.65 mkg)
6.5 Nm (0.65 mkg)
2.5 Nm (0.25 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the trunk and saddlebags
1
Antenna
1/1/1 Disconnect
Antenna/trunk/wire harness lead
1
Trunk
2
Saddlebags
For installation, reverse the removal
procedure.
3-7
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:
rider seat
fuel tank
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK”.
air induction box
carburetor assembly
Refer to “CARBURETOR” in CHAPTER 6.
cylinder head stay
under cowling
2. Drain:
coolant
Refer to “CHANGING THE COOLANT”.
3. Disconnect:
spark plug leads
coolant hose 1
4. Remove:
chrome cylinder head covers 2
5. Remove:
spark plugs
cylinder head cover 1
6. Measure:
valve clearance
Out of specification Adjust.
Valve clearance (cold):
Intake valve:
0.11 0.15 mm
Exhaust valve:
0.16 0.20 mm
3-8
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
generator rotor with the mark b on the
crankcase cover.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thickness gauge 1 .
NOTE:
S If the valve clearance is incorrect, record the
measured reading.
S Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 #3 #2 #4
A Front
d. For each cylinder, starting with cylinder #1 at
TDC, turn the crankshaft counterclockwise
as specified in the following table.
B Degrees that the crankshaft is turned counterclockwise
C Cylinder
D Combustion cycle
#3 Cylinder
#2 Cylinder
180_
430_
#4 Cylinder
610_
7. Adjust:
S valve clearance
a. Align he intake and exhaust valve lifter slots
with each other.
b. Position the tappet adjusting tool 1 between
the camshaft and the valve lifter.
Tappet adjusting tool:
YM-33961, 90890-04105
3-9
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
Make sure that 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 range
No.200 2.00 320
3.20 mm
Available
valve pads
25 thickness in
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.
3-10
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
VALVE CLEARANCE (cold):
270 275 280 285 290 295 300 305 310 315 320
0.11 0.15 mm
275 280 285 290 295 300 305 310 315 320
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
Pad No. 250 = 2.50 mm
305 310 315 320
Pad No. 260 = 2.60 mm
310 315 320
Always
install pad with number down.
315 320
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 0.86
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
200 205 210 215
200
200 205
200 205 210
220
205
210
215
225
210
215
220
230
215
220
225
235
220
225
230
205
210
215
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
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
INSTALLED PAD NUMBER
240 245 250 255 260 265 270 275 280 285 290 295 300 305
225 230 235 240 245 250 255 260 265 270 275 280 285 290
230 235 240 245 250 255 260 265 270 275 280 285 290 295
235 240 245 250 255 260 265 270 275 280 285 290 295 300
STANDARD CLEARANCE
245 250 255 260 265 270 275 280 285 290 295 300 305 310
250 255 260 265 270 275 280 285 290 295 300 305 310 315
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
275 280 285 290 295 300 305 310 315 320
280 285 290 295 300 305 310 315 320
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
VALVE CLEARANCE (cold):
310 315 320
0.16 0.20 mm
315 320
Example: Installed is pad 250
320
310
295
300
305
315 320
300 305
305 310
310 315
315 320
320
Measured clearance is 0.32 mm
Replace pad 250 with pad 265
Pad number: (example)
Pad No. 250 = 2.50 mm
Pad No. 265 = 2.65 mm
Always install pad with number down.
3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
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.
8. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.
9. Install:
cylinder head cover
10 Nm (1.0 mkg)
spark plugs
18 Nm (1.8 mkg)
chrome cylinder head cover
10 Nm (1.0 mkg)
cylinder head stay
64 Nm (6.4 mkg)
carburetor assembly
air induction box
under cowling
fuel tank
rider seat
3-12
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:
vacuum plugs
3. Install:
adapters
vacuum gauge 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Vacuum gauge
YU-08030-A, 90890-03094
Engine tachometer
YU-08036-A, 90890-03113
4. Start the engine and let it warm up for several
minutes.
5. Check:
engine idling speed
Out of specification Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
950 1,050 r/min
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.
3-13
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
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
37 kPa (280 mmHg)
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa
(10.0 mmHg).
7. Check:
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)
4 6 mm
10. Install:
vacuum plugs
3-14
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
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 should be clean, and the
engine should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:
engine tachometer
(to the spark plug lead of cyl. #1)
Engine tachometer
YU-08036-A,90890-03113
3. Check:
engine idling speed
Out of specification !I! Adjust.
4. Adjust:
engine idling speed
Engine idling speed
950 1,050 r/min
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)
4 6 mm
EAS00055
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.
3-15
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
1. Check:
throttle cable free play a
Out of specification Adjust.
Throttle cable free play (at the
flange of the throttle grip)
4 6 mm
2. Remove:
rider seat
fuel tank
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK”.
3. Adjust:
throttle cable free play
a. Loosen the lock nut 1 on the throttle cable.
b. Loosen the lock nut 2 on the cruise control
cable.
c. Turn the adjusting nut 3 in direction a or b
to take up any slack on the throttle cable.
Direction a Throttle cable free play is
increased.
Direction b Throttle cable free play is
decreased.
d. Tighten the lock nut 1 .
e. Turn the adjusting nut 4 in direction c or d
to take up any slack on the cruise control
cable.
Direction c Cruise control cable free
play is increased.
Direction d Cruise control cable free
play is decreased.
Cruise control cable free play
1 2mm
f. Tighten the lock nut 2 .
WARNING
Adjusting only on the carburetor side cannot obtain the specified throttle cable free.
So the adjustment on the handlebar side
also has to be done.
Handlebar side
a. Loosen the locknut 7 .
b. Turn the adjuster 8 in direction a or b until
the specified throttle cable free play is obtained.
3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
CHK
ADJ
Direction a Throttle cable free play is
increased.
Direction b Throttle cable free play is
decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the engine idling speed to change.
WARNING
Pay attention to the mark on throttle cable
(1) and throttle rotor (2), when installing.
Refer to ”HANDLEBAR” in chapter 7.
4. Check:
throttle grip movement
Stroke the cruise control wire, when throttle grip
movement.
5. Install:
fuel tank
rider seat
Refer to “FUEL TANK” and “RIDER AND
PASSENGER SEATS”.
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:
electrode 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is a medium-to-light tan color.
3-17
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
CHK
ADJ
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
7. Install:
spark plug
18 Nm (1.8 mkg)
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 that all connections are tight and free
of corrosion.
1. Remove:
timing plug 1
2. Install:
timing light 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Timing light
YU-33277-A, 90890-03141
Engine tachometer
YU-08036-A, 90890-03113
3-18
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
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
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. Remove:
timing light
engine tachometer
5. Install:
timing plug 1
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. Check:
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
3-19
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
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
YU-33223, 90890-03081
6. Measure:
compression pressure
Above the maximum pressure Inspect the
cylinder head, valve surfaces, and piston
crown for carbon deposits.
Below the minimum pressure Squirt a few
drops of oil into the affected cylinder and
measure again.
Refer to the following table.
Compression pressure
(with oil applied in 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.
Compression pressure (at sea
level)
Standard:
1,520 kPa (15,2 kg/cm2,
15.2 bar)
Minimum:
1,300 kPa (13,0 kg/cm2,
13.0 bar)
Maximum:
1,700 kPa (17,0 kg/cm2,
17.0 bar)
3-20
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
a. Turn 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
7. Install:
spark plug
18 Nm (1,8 mkg)
8. Connect:
spark plug cap
EAS00071
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
engine oil level
The engine oil level should be between the
minimum level marks a and maximum level
marks b .
Below the minimum level mark Add the
recommended engine oil to the proper level.
Recommended oil:
Yamalube 4 (10W–30) or SAE
10W–30 type SE motor oil
Yamalube 4 (20W–40) or SAE
20W–40 type SE motor oil
3-21
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
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.
Do not allow foreign materials to enter the
crankcase.
NOTE:
API Service “SE”, “SF” and “SG” type or equivalent (e.g., “SF-SE”, “SF-SE-CC”, “SF-SE-SD”)
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS00073
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
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 rectifier/regulator 1
3-22
CHANGING THE ENGINE OIL
CHK
ADJ
a. Remove the oil filter cartridge 1 with an oil
filter wrench 2 .
Oil filter wrench
YU-38411, 90890-01426
b. Apply a thin coat of engine oil onto the O-ring
3 of the new oil filter cartridge.
CAUTION:
Make sure that the O-ring 3 is positioned
correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge 1 to specification with an oil filter wrench 2 .
Oil filter cartridge
17 Nm (1.7 mkg)
6. Check:
engine oil drain bolt gasket
Damage Replace.
7. Install:
engine oil drain bolt
43 Nm (4.3 mkg)
8. Fill:
crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
4.3 L
Without oil filter cartridge replacement
3.5 L
With oil filter cartridge replacement
3.7 L
9. Install:
engine oil filler cap
3-23
CHANGING THE ENGINE OIL/
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
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”.
13. Check:
engine oil pressure
a. Slightly loosen the oil gallery bolt 1 .
b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
If no engine oil comes out after one minute,
turn the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “CHECKING THE OIL
PUMP” in chapter 4.
d. Start the engine after solving the problem(-s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
Oil gallery bolt
5 Nm (0.5 mkg)
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.
3-24
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
3. Remove:
S main gallery bolt 1
WARNING
The engine, muffler and engine oil are extremely hot.
4. Install:
S oil pressure gauge 1
S adapter 2
Oil pressure gauge
90890-03153
Adapter
90890-03124
5. Measure:
S engine oil pressure
(at the following conditions)
Engine oil pressure
250 350 kPa
(2.5 3.5 kg/cm2,
2.5 3.5 bar)
Engine speed
Approx. 5,000 r/min
Engine oil temperature
100_C
Out of specification Adjust.
Engine oil pressure
Possible causes
Faulty oil pump
Clogged oil filter
Below specification Leaking oil passage
Broken or damaged
oil seal
Leaking oil passage
Faulty oil filter
Above specification
Oil viscosity too
high
6. Install:
S main gallery bolt
12 Nm (1.2 mSkg)
3-25
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 a 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 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 that the top of the reservoir is horizontal.
3-26
BLEEDING THE HYDRAULIC CLUTCH SYSTEM
CHK
ADJ
EAS00084
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 master cylinder reservoir to overflow.
When bleeding the hydraulic clutch system,
make sure that 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. Remove:
left rear cylinder side cover 1
2. Bleed:
hydraulic clutch system
a. Add the recommended clutch fluid to the
proper level.
b. Install the clutch master cylinder 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.
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.
Bleed screw
6 Nm (0.6 mkg)
k. Add the recommended clutch fluid to the
proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL”.
3-27
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
WARNING
After bleeding the hydraulic clutch system,
check the clutch operation.
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
under cover 1
2. Remove:
air filter case 1
3. Remove:
air filter case cover
4. Remove:
air filter element
5. Clean:
air filter element
Apply compressed air to the inner surface of
the air filter element.
6. Check:
air filter element
Damage Replace.
3-28
CLEANING THE AIR FILTER ELEMENT/CHECKING
THE CARBURETOR JOINTS AND INTAKE MANIFOLDS
CHK
ADJ
7. 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.
NOTE:
Make sure that the air filter element is properly
installed in the air filter case.
Make sure that the air filter is installed with its
mesh side facing towards the rear of the motorcycle.
8. Install:
air filter case
9. Connect:
breather hoses
EAS00095
CHECKING THE CARBURETOR JOINTS
AND INTAKE MANIFOLDS
The following procedure applies to all of the carburetor joints and intake manifolds.
1. Check:
carburetor joint 1
intake manifold 2
Cracks/damage Replace.
Refer to “CARBURETOR” in CHAPTER 6.
3-29
CHECKING THE FUEL HOSES AND FUEL FILTER
CHK
ADJ
EAS090097
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of the fuel
hoses.
1.Remove:
rider seat
fuel tank
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK”.
2. Remove:
left side cover
right side cover
3. Remove:
rear inner cover
4. Check:
fuel hose 1
Cracks/damage Replace.
fuel filter 2
Damage/dirt Replace.
NOTE:
Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
The arrow mark a on the fuel filter should face
to the side of the fuel pump 3 .
5. Install:
rear inner cover
6. Install:
left side cover
right side cover
3-30
CHECKING THE FUEL HOSE AND FUEL FILTER/ CHECKING THE
CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST
SYSTEM / CHECKING THE COOLANT LEVEL
CHK
ADJ
7. Install:
fuel tank
rider seat
Refer to “FUEL TANK” and “RIDER AND
PASSENGER SEAT”.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Check:
crankcase breather hose 1
Cracks/damage Replace.
Loose connection Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
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
Exhaust pipe nut 4
20 Nm (2.0 mkg)
Exhaust pipe bolt 5
25 Nm (2.5 mkg)
Muffler and muffler bracket bolt 6
30 Nm (3.0 mkg)
Muffler bolt 7
20 Nm (2.0 mkg)
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Remove:
side cover right 1
3-31
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
CHK
ADJ
3. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks 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 correct
the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
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:
side cover right
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
under cowling.
2. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
Cracks/damage Replace.
Refer to “COOLING SYSTEM” in CHAPTER
5.
3. Install:
under cowling
fuel tank
rider seat
Refer to “FUEL TANK” and “RIDER AND
PASSENGER SEATS”.
3-32
CHANGING THE COOLANT
CHK
ADJ
EAS00105
CHANGING THE COOLANT
1. Remove:
rider seat
fuel tank
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK”.
2. Remove:
left side cover
right side cover
rear inner cover
3. Remove:
reservoir tank 1
Drain the reservoir tank of its coolant.
4. Remove:
cylinder side covers
5. Remove:
radiator cap 1
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:
Place a thick rag or a towel over the radiator
cap and slowly rotate 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, while still pressing down turn it
counterclockwise, and then remove it.
The following procedure applies to all of the
coolant drain bolts and copper washers.
3-33
CHANGING THE COOLANT
CHK
ADJ
6. Remove:
coolant drain bolt (radiator) 1
(along with the copper washer)
coolant drain bolt (water pump) 2
(along with the copper washer)
7. Remove:
drain plugs (cylinders) 1
Drain the coolant.
NOTE:
To remove the drain plug (cylinder) screw a
spark plug into the threaded hole and pull on the
spark plug.
8. Drain:
coolant
(from the engine and radiator)
9. Check:
rubber washer 1 (coolant drain bolt-radiator
2)
copper washer 3 (coolant drain bolt-water
pump 4 )
Damage Replace.
10. Install:
drain plugs (cylinders)
coolant drain bolt (radiator)
25 Nm (0.25mkg)
coolant drain bolt (water pump)
43 Nm (4.3 mkg)
11. Fill:
cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mix ratio
50 % antifreeze/50 % water
3-34
CHANGING THE COOLANT
CHK
ADJ
Quantity
Total amount
3.5 L
Coolant reservoir capacity
0.84 L
From minimum to maximum
level mark
0.25 L
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. Soft water may be
used if distilled water is not available.
If coolant comes into contact with painted
surfaces, immediately wash them with water.
Do not mix different types of antifreeze.
12. Install:
radiator cap
3-35
CHANGING THE COOLANT
CHK
ADJ
13. Fill:
coolant reservoir
(with the recommended coolant to the maximum level mark a )
14. Install:
coolant reservoir cap
15. Start the engine, warm it up for several minutes, and then turn it off.
16. Check:
coolant level
Refer to “CHECKING THE COOLANT LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
17. Install:
rear inner cover
right side cover
left side cover
18. Install:
fuel tank
rider seat
Refer to “FUEL TANK” and “RIDER AND
PASSENGER SEATS”.
19. Start the engine and let it warm up for several minutes.
20. Turn off the engine and inspect the coolant
level.
Refer to “CHECKING THE COOLANT LEVEL”.
NOTE:
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.
3-36
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00111
CHASSIS
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)
100 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 height,
check that the adjuster end b is in the center of the projections a .
c. Tighten the locknut 1 to specification.
Locknut
26 Nm (2.6 mkg)
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, inspect and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
3. Adjust:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
3-37
CHECKING THE BRAKE FLUID LEVEL/
CHECKING THE BRAKE PADS
CHK
ADJ
EAS00115
A
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
B
Recommended brake fluid
DOT 4
A Front brake
B 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 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 that the top of the reservoir is horizontal.
EAS00118
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
3-38
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
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 “FRONT AND REAR BRAKES” in
CHAPTER 7.
A Front brake
B Rear brake
A
B
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by movement of the brake pedal.
Adjustment is correct when the brake light
comes on by depressing the brake pedal less
than 3 8 mm.
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.
CAUTION:
When on adjustment of the brake light
switch is wrong, the cruise control is not
operated correctly.
When the brake light comes on too early,
the period of time to cancel the cruise control is shortened
When the brake light comes on too late, the
cruise control cannot be canceled.
3-39
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 clamps.
1. Check:
brake hose
Cracks/damage/wear Replace.
2. Check:
brake hose clamp
Loose connection Tighten.
3. Hold the motorcycle upright and apply the
brake.
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 was disassembled,
a brake hose was loosened or removed,
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 that 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.
3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SHIFT PEDAL
CHK
ADJ
3-41
2. Bleed:
hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
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 .
A Front
B 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.
This will release the tension 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.
Bleed screw
6 Nm (0.6 mkg)
k. Fill the reservoir to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Check:
shift pedal position
Check the shift pedal rod length a .
If the position is incorrect Adjust.
Shift pedal rod length:
26.8 mm
3-41
ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL
DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL
CHK
ADJ
2. Adjust:
shift pedal position
a. Loosen both locknuts 1 .
b. Turn the shift rod 2 in direction a or b to
obtain the correct shift pedal position.
Direction a ! Shift pedal is raised.
Direction b ! Shift pedal is lowered.
Tighten both locknuts.
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 that the motorcycle is upright.
2. Remove:
final drive housing oil filler bolt 1
3. Check:
final drive oil level
The final drive oil level should be to the bottom brim 2 of the filler hole.
Below the bottom brim ! Add the recommended final drive oil to the proper level.
Recommended final drive oil
SAE 80 hypoid gear oil graded
“GL-4”, “GL-5” or “GL-6”
or
multi-purpose SAE 80W 90
hypoid gear oil
4. Install:
final drive housing oil filler bolt
23 Nm (2.3 mkg)
EAS00145
CHANGING THE FINAL DRIVE OIL
1. Place a container under the final drive housing.
2. Remove:
final drive housing oil filler bolt 1
final drive housing oil drain bolt 2
Completely drain the final drive housing of its
oil.
3. Check:
final drive housing oil drain bolt gasket
Damage ! Replace.
3-42
CHANGING THE FINAL DRIVE OIL/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
4. Install:
final drive housing oil drain bolt
23 Nm (2.3 mkg)
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”.
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.
Looseness or binding Adjust the steering
head.
3. Remove:
front cowling
Refer to “FRONT COWLING”.
4. Remove:
handlebar 1
5. Loosen
upper bracket pinch bolts 1
6. Remove
steering stem nut 2
upper bracket 3
3-43
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
7. 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.
Ring nut wrench
YU-33975, 90890-01403
Lower ring nut (initial tightening
torque)
52 Nm (5.2 mkg)
c. Loosen the lower ring nut 4 completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
3 Nm (0.3 mkg)
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 inspect the upper and
lower bearings.
Refer to “STEERING HEAD AND HANDLEBAR” in CHAPTER 7.
e. Install the rubber washer 6 .
f. Install the upper ring nut 7 .
g. Finger tighten the upper ring nut, 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 8 .
NOTE:
Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
8. Install:
upper bracket
steering stem nut
130 Nm (13.0 mkg)
3-44
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORK / ADJUSTING THE
FRONT AND REAR SHOCK ABSORBER ASSEMBRY
CHK
ADJ
9. Install:
front cowling
EAS00149
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:
operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation Repair.
Refer to “FRONT FORK” in CHAPTER 7.
EAS00156
ADJUSTING THE FRONT AND
SHOCK ABSORBER ASSEMBLY
REAR
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
A
B
1. Check:
shock absorber air pressure
A Front
B Rear
Out of specification → Adjust
Air pressure
Front
0 50 kPa
(0 0.5 kgf/cm2, 0 0.5 bar)
Rear
0 400 kPa
(0 4.0 kgf/cm2, 0 4,0 bar)
3-45
CHECKING THE TIRES /
CHECKING THE FRONT FORK /ADJUSTING THE FRONT AND
REAR SHOCK ABSORBER ASSEMBRY
CHK
ADJ
EAS00166
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 394 kg
full fuel tank)
Maximum
load*
190 kg
Cold tire
pressure
Front tire
Up to 90 kg
load*
250 kPa
250 kPa
(2.50 kgf/
(2.50 kgf/
2
cm , 2.50 bar) cm2, 2.50 bar)
90 kg maximum
load*
250 kPa
280 kPa
(2.50 kgf/
(2.80 kgf/
cm2, 2.50 bar) cm2, 2.80 bar)
High speed
riding
250 kPa
280 kPa
(2.50 kgf/
(2.80 kgf/
cm2, 2.50 bar) cm2, 2.80 bar)
Rear tire
*: 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.
3-46
CHECKING THE TIRES
CHK
ADJ
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth
1.0 mm
1
2
3
Tire tread depth
Side wall
Wear indicator
WARNING
A
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 that
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.
A Tire
B Wheel
B
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.
FRONT TIRE:
Manufacturer
Size
Type
BRIDGESTONE
150/80-16 71H
G705
DUNLOP
150/80-16 71H
D404F
Size
Type
BRIDGESTONE
150/90B15M/C
74H
G702
DUNLOP
150/90B15M/C
74H
D404
REAR TIRE:
Manufacturer
3-47
CHECKING THE TIRES/CHECKING THE WHEELS
CHK
ADJ
WARNING
After mounting a new tire, ride conservatively for a while to become accustomed to
the “feel” of the new tire and to allow the
tire to seat itself properly in the rim. Failure
to do so could lead to an accident with possible injury to the rider or damage to the
motorcycle.
After a tire has been repaired or replaced,
be sure to tighten the tire valve stem locknut 1 to specification.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
Tire valve stem locknut
1.6 Nm (0.16 mkg)
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.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
3-48
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATINGTHE SIDESTAND/ LUBRICATING THE REAR SUSPENSION
CHK
ADJ
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
Unsmooth operation 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 lubing device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Engine oil
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Engine oil
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 AND CHARGING THE BATTERY
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING 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.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery performance will deteriorate.
Charging time, charging amperage and
charging voltage for a MF battery are different from those of conventional batteries.
The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
3-50
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
rider seat
Refer to “RIDER SEATS”.
2. Disconnect:
battery leads
(fron the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
battery
4. Check:
battery charge
a. Connect a pocket tester to the battery terminals.
Tester positive lead battery positive terminal
Tester negative lead battery negative terminal
NOTE:
The charge state of a MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is
disconnected).
No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
b. Check he charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 30 %
3-51
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
5. Charge:
battery
(refer to the appropriate charging method illustration)
WARNING
Do not quick charge a battery.
CAUTION:
Make sure that the battery breather hose
and battery vent are free of obstructions.
Never remove the MF battery sealing caps.
Do not use a high-rate battery charger.
They force a high-amperage current 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.)
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 that the battery charger lead
clips are in full contact with the battery terminal and that they are not shorted. A corrected 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!
As shown in the following illustration, the
open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
3-52
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) type charger
Measure the open-circuit
voltage prior to charging.
Connect a charger and
AMP meter to the battery
and start charging.
YES
Make sure that current is
higher than the standard
charging current written on
the battery.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
NO
By turning the charging voltage adjust dial, set the charging voltage at 20 25 V.
Adjust the voltage so that current is at standard charging
level.
YES
Monitor the amperage for 3 5 minutes to check if the standard charging current is
reached.
NO
Set the timer according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.
If the current does not exceeds standard charging
current after 5 minutes, replace the battery.
In case that charging requires more than 5 hours, it is advisable to
check he charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.
Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12,8 V or more – Charging is complete.
12.7 V or less – Recharging is required.
Under 12.0 V – Replace the battery.
3-53
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant-voltage type charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and
AMP meter to the battery
and start charging.
YES
Make sure the current is
higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.
NO
This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
NOTE:
Set the charging time at 20 hours
(maximum).
Measure the battery open-circuit
voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more – Charging is complete.
12.7 V or less – Recharging is required.
Under 12.0 V – Replace the battery.
Charging method using a constant-current type charger
This type of battery charger cannot charge the MF battery.
3-54
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Check:
battery.
Damage Replace.
7. Install:
battery
8. Connect:
battery leads
(to he battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
9. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
10. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
11. Install:
rider seat
Refer to “RIDER AND PASSENGER SEAT”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
side cover left
2. Check:
fuse
3-55
CHECKING THE FUSES
CHK
ADJ
a. Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the pocket tester selector to “Ω
1”.
Pocket tester
YU-03112, 90890-03112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:
blown fuse
a. Turn off the ignition.
b. Install a new fuse of the correct amperage
rating.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Amperage
rating
Quantity
Main fuse
30 A
1
Headlight
fuse
15 A
1
Signaling
system fuse
15 A
1
Ignition fuse
10 A
1
Digital clock
fuse
10 A
1
Radiator fan
fuse
10 A
1
30 A
15 A
10A
5A
1
1
2
1
Fuses
Reserve fuse
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.
3-56
REPLACING THE HEADLIGHT BULB
CHK
ADJ
4. Install:
side cover left
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
headlight unit
2. Disconnect:
headlight leads 1
3. Remove:
bulb cover 2
4. Remove:
headlight bulb holder 1
5. 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 (New)
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.
3-57
REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM
CHK
ADJ
7. Install:
headlight bulb holder
8. Install:
bulb cover
9. Connect:
headlight leads
10. Install:
headlight unit
EAS00184
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
headlight beam (vertically)
a. Turn the adjusting knob 1 in direction a or
b.
Direction a Headlight beam is raised.
Direction b Headlight beam is lowered.
3-58
ENG
4
ENG
CONTENTS
ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS, CABLES AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR AND AIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MUFFLERS AND EXHAUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN AND BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-3
4-4
4-5
4-6
4-8
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAINS, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONERS . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
4-9
4-11
4-12
4-14
4-16
4-16
4-17
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
INSTALLING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-27
4-28
4-30
4-32
4-32
4-33
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . .
ASSEMBLYNG THE CLUTCH MASTER CYLINDER . . . . . . . . . . . .
INSTALLING THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . .
DISASSEMBLING THE CLUTCH RELEASE CYLINDER . . . . . . . . .
CHECKING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . .
ASSEMBLING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . .
INSTALLING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . .
CLUCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRING PLATE . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-35
4-35
4-37
4-38
4-38
4-43
4-43
4-44
4-44
4-46
4-47
4-49
4-49
4-50
4-50
4-50
4-50
ENG
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . 4-51
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-54
4-54
4-56
4-56
4-56
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-57
4-57
4-59
4-60
4-60
4-61
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL GALLERY PIPES . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL GALLERY PIPES . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-62
4-65
4-65
4-66
4-66
4-66
4-66
4-67
4-67
4-68
4-68
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-69
4-72
4-73
4-74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
4-77
4-78
4-78
4-82
4-86
4-86
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . .
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . .
INSTALLING THE PISTON AND CONNECTING RODS . . . . . . . . . .
4-87
4-88
4-89
4-90
4-92
4-93
4-95
ENG
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-98
4-101
4-101
4-102
4-102
4-103
4-103
MIDDLE GEAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . .
DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . .
CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . . . . . . . .
CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . . . . . . . .
ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . . . . .
ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . . . . . .
ALIGNING THE MIDDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE MIDDLE GEAR BACKLASH . . . . . . . . . . . . . . . . .
4-104
4-106
4-107
4-107
4-108
4-108
4-109
4-111
4-113
ENG
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
LEADS, CABLES AND HOSES
64 Nm (6.4 mkg)
Order
Job/Part
Q’ty
Disconnecting the leads, cables
and hoses
Remarks
Disconnecting 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
Drain
Refer to “CHARGING THE ENGINE OIL”
in CHAPTER 3.
Drain
Refer to “CHARGING THE COOLANT”
in CHAPTER 3.
Drain
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK” in CHAPTER 3.
Coolant
Clutch fluid
Rider seat, fuel tank
4-1
ENGINE REMOVAL
ENG
64 Nm (6.4 mkg)
Order
Job/Part
Q’ty
Remarks
1
Battery leads
2
Disconnect
NOTE:
First, disconnect the negative lead, then
the positive lead.
2
3
4
5
6
7
8
9
10
Battery
Cylinder head stays
Spark plug leads
Hoses (coolant)
Side covers (left and right)
Rear inner cover
Plastic shroud
Under covers
Air cleaner box
1
2
4
2
2
1
1
2
2
Disconnect
Disconnect
Disconnect
For connecting, reverse the disconnection
procedure.
4-2
ENGINE REMOVAL
ENG
RADIATOR AND AIS
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Removing the radiator and AIS
Radiator
Engine guards and horn (left and right)
Starter lead
AIS pipe
Reed valve
Air cutoff valve
Air cleaner
1
2
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “RADIATOR” in CHAPTER 5.
For EUR.
For installation, reverse the removal
procedure.
4-3
ENGINE REMOVAL
ENG
MUFFLERS AND EXHAUSTS
30 Nm (3.0 mkg)
20 Nm (2.0 mkg)
10 Nm (1.0 mkg)
25 Nm (2.5 mkg)
30 Nm (3.0 mkg)
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the mufflers and exhausts
Carburetors
Air induction box
Cylinder side covers
Muffler assemblies
Exhaust pipes
Copper gaskets
Shift pedal link
Clutch release cylinder
4
2
4
4
1
1
7
AIS pipe
2
Remarks
Remove the parts in the order listed.
Refer to “CARBURETORS” in
CHAPTER 6.
Disconnect
Refer to “CLUTCH RELEASE
CYLINDER”.
For installation, reverse the removal
procedure.
4-4
ENGINE REMOVAL
ENG
HORN AND BRAKE PEDAL
52 Nm (5.2 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the Horn and brake pedal
Horn leads
Horn
Ground lead
Spring (rear brake switch)
Reservoir tank (rear brake)
Brake pedal assembly
4-5
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect For OCE.
For OCE.
Disconnect
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 7.
For installation, reverse the removal
procedure.
ENGINE REMOVAL
ENG
ENGINE
78 Nm (7.8 mkg)
M12 75
45 Nm (4.5 mkg)
M10 30 (4)
40 Nm (4.0 mkg)
M10 70 (6)
40 Nm (4.0 mkg)
M10 70 (4)
Order
Job/Part
Q’ty
Removing the engine
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
7
8
Rear brake switch leads
Rear brake switch
Rectifier/regulator coupler
Rear brake hose protector
Bolts (engine bracket)
Bolts (front-lower/upper)
Bolts (down tube)
Down tube (right side)
2
1
1
1
6
4
4
1
4-6
Disconnect
Disconnect
Refer to “INSTALLING THE ENGINE”.
ENGINE REMOVAL
ENG
78 Nm (7.8 mkg)
M12 75
45 Nm (4.5 mkg)
M10 30 (4)
40 Nm (4.0 mkg)
M10 70 (6)
40 Nm (4.0 mkg)
M10 70 (4)
Order
9
10
11
Job/Part
Q’ty
Remarks
1
2
1
Refer to “INSTALLING THE ENGINE”.
Engine bracket
Bolts (rear)
Engine assembly
NOTE:
Remove the engine assembly from the
right side of the motorcycle.
For installation, reverse the removal
procedure.
4-7
ENGINE REMOVAL
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
engine assembly
(from the right side of the motorcycle)
2. Install:
bolts (rear) 1
down tube (right) 2
engine bracket 3
rear brake switch
bolts (front-lower) 4
bolts (front-upper) 5
cylinder head stay 6
NOTE:
Do not fully tighten the bolts
3. Tighten the bolts in the following order.
1. Bolts (rear) 1
78 Nm (7.8 mkg)
2. Down tube (right) 2
45 Nm (4.5 mkg)
3. Engine bracket 3
40 Nm (4.0 mkg)
4. Bolts (front-lower) 4
40 Nm (4.0 mkg)
5. Bolts (front-upper) 5
40 Nm (4.0 mkg)
6. Bolts (cylinder head stay) 6
64 Nm (6.4 mkg)
4. Install:
shift arm 1
10 Nm (1.0 mkg)
NOTE:
Align the punch mark a in the shift shaft with
the slot b in the shift arm.
Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.
4-8
CAMSHAFTS
ENG
CAMSHAFTS
CYLINDER HEAD COVERS
18 Nm (1.8 mkg)
10 Nm (1.0 mkg)
M6 30 (4)
10 Nm (1.0 mkg)
M6 14 (12)
10 Nm (1.0 mkg)
M6 23 (16)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Removing the cylinder head covers
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK” in CHAPTER 3.
Refer to “CLEANING THE AIR FILTER” in
CHAPTER 3.
Refer to “CARBURETORS” in CHATER 6.
Rider seat and fuel tank
Air filter case
Carburetors
Cylinder head stay
Coolant
Drain
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
4-9
CAMSHAFTS
ENG
18 Nm (1.8 mkg)
10 Nm (1.0 mkg)
M6 30 (4)
10 Nm (1.0 mkg)
M6 14 (12)
10 Nm (1.0 mkg)
M6 23 (16)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
4
2
8
4
16
2
2
Spark plug caps
Coolant hoses (to cylinder head)
Chrome cylinder head covers
Spark plugs
Bolts (cylinder head covers)
Cylinder head covers
Gaskets (cylinder head covers)
Remarks
Disconnect
Disconnect
For installation, reverse the removal
procedure.
4-10
ENG
CAMSHAFTS
CAMSHAFTS
20 Nm (2.0 mkg)
M6 28
10 Nm (1.0 mkg)
M6 40 (32)
12 Nm (1.2 mkg)
M6 20 (4)
20 Nm (2.0 mkg)
M7 12 (8)
7 Nm (0.7 mkg)
M6 12 (2)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the camshafts
Cylinder head covers
Crankcase cover plate
Timing plug
Cap bolts (tensioners)
Timing chain tensioners
Gaskets
Timing chain guides (metal and rubber)
Bolts (camshaft sprockets)
Camshaft caps
Camshafts (intake and exhaust)
Camshaft sprockets
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD COVERS”.
1
1
2
2
2
4
8
16
4
4
Refer to “REMOVING/INSTALLING
THE CAMSHAFTS”.
For installation, reverse the removal
procedure.
4-11
CAMSHAFTS
ENG
EAS00201
REMOVING THE CAMSHAFTS
Rear cylinder head
1. Remove:
spark plugs
cylinder head cover
gasket (cylinder head cover)
NOTE:
Loosen each bolt 1/4 of a turn in a crisscross
pattern. After all the bolts are loosened, remove
them.
2. Remove:
crankcase cover plate 1
timing plug 2
3. Align:
“–” and “I” marks on the generator rotor
(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 “–” and “I” marks 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.
4. Loosen:
cap bolt 1
5. Remove:
timing chain tensioner 2
gasket
6. Remove:
timing chain guide (exhaust side) 1
camshaft caps (#2) 2
4-12
CAMSHAFTS
ENG
7. Remove:
camshaft sprocket bolts
Hold the camshaft with a 22 mm wrench.
8. Remove:
camshaft caps
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.
NOTE:
When loosening the camshaft cap bolts, make
sure that the camshaft lobes do not touch the
valve lifters.
9. Remove:
intake camshaft
exhaust camshaft
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire to it.
10. Remove:
camshaft sprockets
4-13
CAMSHAFTS
ENG
Front cylinder head
NOTE:
When removing the front cylinder camshafts,
repeat the rear cylinder camshaft removal procedure. However, note the following points.
1. Turn:
S crankshaft
NOTE:
From the “–” and “I” marks, turn the crankshaft
counterclockwise 430_ (i.e., 360_ plus an additional 70_).
2. Align:
S “–” mark
(with the stationary pointer)
EB401401
CHECKING THE CAMSHAFTS
1. Check:
S camshaft lobes
Blue discoloration/pitting/scratches Replace the camshaft.
2. Measure:
S camshaft lobe dimensions a and b
Out of specification Replace the camshaft.
Camshaft lobe dimension limit
Intake
a 35.65 mm
b 27.85 mm
Exhaust
a 35.65 mm
b 27.85 mm
3. Measure:
S camshaft runout
Out of specification Replace.
Camshaft runout
Less than 0.03 mm
4-14
CAMSHAFTS
ENG
4. Measure:
camshaft-journal-to-camshaft-cap
clearance
Out of specification Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.020 X 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.
Camshaft cap bolt
10 Nm (1.0 mkg)
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 X 24.980 mm
4-15
CAMSHAFTS
ENG
EAS00209
CHECKING THE TIMING CHAINS, CAMSHAFT SPROCKETS, AND TIMING CHAIN
GUIDES
The following procedure applies to all of the timing chains, camshaft sprockets, and timing
chain guides.
1. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and its respective camshaft sprockets
as a set.
2. Check:
camshaft sprocket
Damage/wear Replace the respective
camshaft sprockets and the respective timing chain as a set.
3. Check:
timing chain guide (exhaust side)
timing chain guide (intake side)
timing chain guide (top side)
Damage/wear Replace the defective
part(-s).
EAS00211
CHECKING THE TIMING CHAIN TENSIONERS
The following procedure applies to both of the
timing chain tensioners.
1. Check:
timing chain tensioner
Cracks/damage Replace.
2. Check:
one-way cam operation
Rough movement Replace the timing
chain tensioner housing.
3. Check:
cap bolt
copper washer
spring
one-way cam
gasket
timing chain tensioner rod
Damage/wear Replace the defective
part(-s).
4-16
CAMSHAFTS
ENG
EAS00218
INSTALLING THE CAMSHAFTS
1. Align:
“–” and “I” marks on the generator rotor
(with the crankcase edge)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the “–” and “I” marks 1 on
the generator rotor with the crankcase edge
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 that the “REAR” marks a on the
camshaft sprockets face away from the “IN” b
and “EX” marks c on the camshafts.
b. First, install the exhaust camshaft, then the
intake camshaft.
NOTE:
Be sure to install the camshafts in the correct
place as sown.
“IN” mark = intake camshaft
“EX” mark = exhaust camshaft.
Make sure that the timing marks a (o: small
hole) in the camshaft face up.
4-17
CAMSHAFTS
ENG
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. Apply engine oil onto the threads of the camshaft cap bolts.
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.
CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
Camshaft cap bolt
10 Nm (1.0 mkg)
g. Apply engine oil onto the camshaft bearing
surfaces, camshaft lobes, and camshaft
journals.
2. Install:
intake camshaft sprocket
exhaust camshaft sprocket
(onto the camshafts)
4-18
CAMSHAFTS
ENG
CAUTION:
Do not turn the crankshaft when installing
the camshaft sprockets to avoid damage or
improper valve.
a. Place the timing chain onto the intake
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 a hole in the intake camshaft sprocket with the thread hole in the camshaft.
c. Turn the intake camshaft so that the camshaft timing mark 1 (o: small hole) is aligned
with the camshaft cap mark 2 .
d. To remove the timing chain slack, force the
intake camshaft counterclockwise.
e. Place 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.
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 that 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.
4-19
CAMSHAFTS
ENG
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 5 and gasket 6 onto the cylinder block.
WARNING
Always use a new gasket.
Timing chain tensioner bolt
12 Nm (1.2 mkg)
d. Install the spring 3 , washer 2 , and cap bolt
1.
Cap bolt
20 Nm (2.0 mkg)
4. Turn:
crankshaft
(several turns counterclockwise)
5. Check:
TDC mark a
Make sure that the TDC mark on the generator rotor is aligned with the crankcase edge
b.
camshaft timing punch mark c (o: small
hole)
Make sure hat 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.
4-20
CAMSHAFTS
ENG
6. Tighten:
S camshaft sprocket bolts
20 Nm (2.0 mSkg)
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:
S camshaft caps “I-2” 1
S camshaft caps “E-2” 2
S timing chain guide (top side) 3
10 Nm (1.0 mSkg)
S timing chain guide (exhaust side) 4
10 Nm (1.0 mSkg)
8. Lubricate:
S timing chain
S camshaft sprockets
S camshafts
S 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.
1. Install:
S exhaust camshaft
S intake camshaft
a. From the “–” and “I” 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 “–” mark a with the
crankcase edge b .
4-21
CAMSHAFTS
ENG
c. Install the camshaft sprockets onto the camshafts.
Refer to the camshaft sprocket installation
steps below.
NOTE:
Make sure that 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 “–” mark a on the generator rotor
with the crankcase edge b .
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 c (o: big
hole) with the camshaft cap marks d .
3. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” in CHAPTER 3.
4. Install:
timing mark accessing screw 1
crankshaft end cover 2
7 Nm (0.7 mkg)
4-22
CYLINDER HEADS
ENG
CYLINDER HEADS
30 Nm (3.0 mkg)
M10 28
30 Nm (3.0 mkg)
30 Nm (3.0 mkg)
M8 22 (2)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Removing the cylinder heads
Engine assembly
Cylinder head covers
Camshafts
Lock pins
Water jacket joints
Oil delivery pipes
Cylinder heads
Timing chain dampers
Gaskets (cylinder heads)
Dowel pins
Refer to “CAMSHAFTS”.
2
2
2
2
2
2
4
Refer to “INSTALLING THE CYLINDER
HEADS”.
For installation, reverse the removal
procedure.
4-23
CYLINDER HEADS
ENG
EAS00230
CHECKING THE CYLINDER HEADS
The following procedure applies to all of the cylinder heads.
1. Eliminate:
carbon deposits
(from the combustion chambers with a
rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
spark plug threads
valve seats
2. Check:
cylinder head
Damage/scratches Replace.
cylinder head water jacket 1
Mineral deposits/rust Eliminate.
timing chain damper
Damage/wear Replace.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylinder head.
Cylinder head warpage
Less than 0.03 mm
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited is exceeded, resurface the cylinder head as follows.
d. Place a 400 X 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.
EAS00235
INSTALLING THE CYLINDER HEADS
Rear cylinder
1. Install:
dowel pins 1
gasket (New) 2
timing chain guide (exhaust side) 3
4-24
CYLINDER HEADS
ENG
2. Install:
cylinder head 1
43 Nm (4.3 mkg)
washers
NOTE:
To prevent the timing chain 2 from falling into
the crankcase, fasten it with a wire.
Tighten the cylinder head nuts and bolts in two
stages and in a crisscross pattern.
Install the timing chain guide (intake side) into
the timing chain guide slot in the cylinder head.
Front cylinder
NOTE:
When installing the front cylinder head, repeat
the rear cylinder head installation procedure.
However, note the following points.
1. Install:
cylinders nuts
4-25
VALVES AND VALVE SPRINGS
ENG
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the valves and valve
springs
Engine assembly
Camshafts
Cylinder heads
Valve pads
Valve lifters
Valve cotters
Valve spring retainers
Valve springs (inner/outer)
Valves (intake/exhaust)
Valve spring seats
Oil seals
Valve guides
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
Refer to “REMOVING/INSTALLING
THE VALVES”.
For installation, reverse the removal
procedure.
4-26
VALVES AND VALVE SPRINGS
ENG
EAS00237
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 that the valves properly seal.
1. Remove:
valve pad 1
valve lifter 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
valve sealing
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 spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor
YM-04019, 90890-04019
Attachment
YM-01253-1, 90890-04114
4-27
VALVES AND VALVE SPRINGS
ENG
4. Remove:
S upper spring seat 1
S valve springs 2
S oil seal 3
S lower spring seat 4
S valve 5
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:
S valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a X
Valve stem diameter b
Out of specification Replace the valve guide.
Valve-stem-to-valve-guide
clearance
Intake
0.010 X 0.037 mm
Limit: 0.08 mm
Exhaust
0.025 X 0.052 mm
Limit: 0.1 mm
2. Replace:
S 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.
4-28
VALVES AND VALVE SPRINGS
ENG
a. Remove the valve guide with a valve guide
remover 1 .
b. Install the new valve guide with a valve guide
installer 2 and valve guide remover 1 .
c. After installing the valve guide, bore the
valve guide with a valve guide reamer 3 to
obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (6.0 mm):
YM-4064-A, 90890-04064
Valve guide installer (6.0 mm):
YM-04065-A, 90890-04065
Valve guide reamer (6.0 mm):
YM-04066, 90890-04066
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.
4-29
VALVES AND VALVE SPRINGS
ENG
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
1.15 X 1.45 mm
<Limit>: 0.7 mm
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
<Limit>: 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 X 1.1 mm
<Limit>: 1.4 mm
Exhaust: 0.9 X 1.1 mm
<Limit>: 1.4 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 pattern.
d. Measure the valve seat width. Where the
valve seat and valve face contacted one
another, the blueing will have been removed.
4-30
VALVES AND VALVE SPRINGS
ENG
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 unit 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 hand.
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.
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.
4-31
VALVES AND VALVE SPRING
ENG
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
inner (IN, EX) 37.3 mm
<Limit>: 35.3 mm
outer (IN, EX) 39.45 mm
<Limit>: 37.25 mm
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
Compressed spring force
(installed)
inner (IN, EX) 4.57 5.37 kg
outer (IN, EX) 10.1 11.9 kg
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
Spring tilt limit
inner (IN, EX) 2.5/1.6 mm
outer (IN, EX) 2.5/1.7 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.
4-32
VALVES AND VALVE SPRING
ENG
EAS00245
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 1
oil seal 2 New
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
valve 1
lower spring seat 2
oil seal 3 New
valve spring 4
upper spring seat 5
(into the cylinder head)
NOTE:
Install the valve spring with the larger pitch a
facing up.
b Smaller pitch
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor
YM-04019, 90890-04019
Attachment
YM-01253-1, 90890-04114
4-33
VALVES AND VALVE SPRINGS
ENG
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. Install:
valve lifter 1
valve pad 2
NOTE:
Apply molybdenum disulfide oil onto the valve
lifter and valve pad.
The valve lifter must move smoothly when rotated with a finger.
Each valve lifter and valve pad must be reinstalled in its original position.
4-34
CLUTCH
ENG
CLUTCH
CLUTCH MASTER CYLINDER
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Before removing the master cylinder,
drain the clutch fluid from the entire clutch
system.
Removing the clutch master cylinder
1
2
3
4
5
6
7
8
9
10
1
1
1
1
1
1
2
1
1
1
Rear view mirror
Front remote controller
Coupler (clutch switch)
Clutch lever
Holder (push rod)
Union bolt
Copper washers
Clutch hose
Master cylinder
Clutch switch
Remarks
Disconnect
Refer to “INSTALLING THE CLUTCH
MASTER CYLINDER”.
For installation, reverse the removal
procedure.
4-35
CLUTCH
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
Disassembling the clutch master
cylinder
Master cylinder cap
Holder (diaphragm)
Diaphragm
Push rod
Dust boot
Circlip
Washer
Master cylinder kit
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-36
CLUTCH
ENG
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 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.
EAS00308
CHECKING THE CLUTCH MASTER CYLINDER
Recommended clutch component
replacement schedule
Piston seals
Every two years
Clutch hose
Every four years
Clutch fluid
Every two years and
whenever the clutch
is disassembled
1. Check:
clutch master cylinder body 1
Cracks/damage Replace the clutch master cylinder.
clutch fluid delivery passage 2
(clutch master cylinder body)
Obstruction Blow out with compressed air.
WARNING
Whenever a clutch master cylinder is disassembled, replace the piston seals.
4-37
CLUTCH
ENG
2. Check:
clutch master cylinder 1
clutch master cylinder kit 2
Rust/scratches/wear Replace the clutch
master cylinder and clutch master cylinder kit
as a set.
clutch hose
Cracks/damage/wear Replace.
EAS00309
ASSEMBLING THE CLUTCH MASTER CYLINDER
WARNING
Before installation, all internal clutch components must be cleaned and lubricated
with clean or new clutch fluid.
Never use solvents on internal clutch components as they will cause the piston seals
to swell and distort.
Whenever a clutch master cylinder is disassembled, replace the piston seals.
Recommended clutch fluid
Brake fluid DOT 4
EAS00310
INSTALLING THE CLUTCH MASTER CYLINDER
1. Install:
clutch master cylinder 1
WARNING
Install the clutch lever holder with the “UP”
mark facing up.
Align the end of the clutch lever holder with
the punch mark a in the handlebar.
First, tighten the upper bolt, then the lower
bolt.
4-38
CLUTCH
2. Install:
copper washers (New)
clutch hose 1
union bolt 2
ENG
30 Nm (3.0 mkg)
WARNING
Proper clutch hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the clutch hose, tighten the union
bolt.
3. Install:
clutch push rod holder 1
clutch lever 2
NOTE:
Lubricate the clutch lever pivot bolt 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 hat water does
not enter the reservoir. Water will significantly lower the boiling point of the clutch
fluid and could cause vapor lock.
4-39
CLUTCH
ENG
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 that the top of the reservoir is horizontal.
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 spongy feeling Bleed the clutch system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in CHAPTER 3.
4-40
CLUTCH
ENG
CLUTCH RELEASE CYLINDER
12 Nm (1.2 mkg)
25 Nm (2.5 mkg)
Order
1
2
3
4
5
Job/Part
Q’ty
Remarks
Removing the clutch release cylinder
Remove the parts in the order listed.
NOTE:
Before removing the clutch release
cylinder or the master cylinder, drain the
clutch fluid from the entire clutch system.
Engine oil
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Middle gear case cover, shift pedal
assembly, crankcase cover (left side)
Rubber cover
Clutch pipe clamps
Union bolt
Copper washers
Clutch release cylinder
1
2
1
2
1
Refer to “INSTALLING THE CLUTCH
RELEASE CYLINDER”.
For installation, reverse the removal
procedure.
4-41
CLUTCH
ENG
6 Nm (0.6 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the clutch rlease
cylinder
Oil seal
Piston (release cylinder)
Spring
Piston seal
1
1
1
1
Refer to “DISASSEMBLING THE
CLUTCH RELEASE CYLINDER”.
CAUTION:
Never attempt to pry out the piston.
5
Air bleed screw
1
For assembly, reverse the disassembly
procedure.
4-42
CLUTCH
ENG
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
oil seal 1
clutch release cylinder piston 2
spring 3
piston seal 4
a. Blow compressed air into the clutch hose
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
seals.
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.
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.
4-43
CLUTCH
ENG
3. Check:
spring 1
Wear/rust Replace the clutch release cylinder assembly.
ASSEMBLING THE CLUTCH RELEASE CYLINDER
WARNING
All internal parts shoud be cleaned in new
fluid only.
During installation internal parts should be
lubricated with new fluid.
Recommended brake fluid:
DOT #4
Replace the piston seal and oil seal whenever the clutch release and master cylinder
are disassembled.
1. Install:
piston seal 1 New
spring 2
piston (release cylinder) 3
oil seal 4 New
EAS00315
INSTALLING THE CLUTCH RELEASE CYLINDER
1. Install:
copper washers (New)
clutch hose 1
union bolt 2
25 Nm (2.5 mkg)
WARNING
Proper clutch hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the clutch hose onto the
clutch release cylinder, make sure that the
pipe touches the projection a .
4-44
CLUTCH
ENG
2. 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 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 that the top of the reservoir is horizontal.
3. Bleed:
clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in CHAPTER 3.
4. 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.
5. Check:
clutch lever operation
Soft or spongy feeling Bleed the clutch
system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in CHAPTER 3.
4-45
CLUTCH
ENG
CLUTCH COVER
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface
Removing the clutch cover
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “ENGINE REMOVAL”.
Engine oil
1
2
3
4
5
Muffler assembly (right side), exhaust
pipe (#4 cylinder)
Horn leads
Horn
Crankcase cover (right side)
Gasket
Dowel pins
2
1
1
1
2
Disconnect for OCE.
For OCE.
Refer to “INSTALLING THE CLUTCH”.
For installation, reverse the removal
procedure.
4-46
CLUCH
ENG
CLUTCH
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
M6
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
25 (6)
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the clutch
Clutch spring plate
Clutch spring
Clutch spring seat
Pressure plate
Push rod #2
O-ring
Ball
Friction plates
Clutch plates
Nut
Lock washer
Clutch boss
Retaining wire
Clutch plate
1
1
1
1
1
1
1
7
6
1
1
1
1
1
4-47
Refer to “INSTALLING THE CLUTCH”.
Refer to “REMOVING/INSTALLING
THE CLUTCH”.
Refer to “INSTALLING THE CLUTCH”.
CLUTCH
ENG
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
M6
Order
15
16
17
18
19
20
21
22
25 (6)
Job/Part
Q’ty
1
1
1
1
1
1
1
2
Friction plate
Spring plate
Washer
Clutch housing
Push rod #1
Circlip
Oil pump drive gear
Dowel pins
Remarks
Refer to “INSTALLING THE CLUTCH”.
For installation, reverse the removal
procedure.
4-48
CLUTCH
ENG
EAS00275
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.
Universal clutch holder
YM-91042, 90890-04086
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.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.9 3.1 mm
<Limit>: 2.8 mm
4-49
CLUTCH
ENG
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
Less than 0.2 mm
EAS00283
CHECKING THE CLUTCH SPRING PLATE
1. Check:
clutch spring plate 1 .
Damage Replace.
clutch spring 2 .
clutch spring plate seat 3
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.
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.
4-50
CLUTCH
ENG
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
pressure plate 1
Cracks/damage Replace.
bearing 2
Damage/wear Replace.
EAS00288
CHECKING THE CLUTCH PUSH RODS
1. Check:
short clutch push rod 1
O-ring 2
ball 3
long clutch push rod 4
Cracks/damage/wear Replace the defective part(-s).
EAS00300
INSTALLING THE CLUTCH
1. Install:
clutch spring plate 1
friction plate 2
clutch plate 3
wire circlip (New) 4
NOTE:
Install the clutch spring plate with the “OUTSIDE” mark facing towards the clutch cover.
2. Tighten:
clutch boss nut 1
70 Nm (7.0 mkg)
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3 , tighten the clutch boss nut.
Universal clutch holder
YM-91042, 90890-04086
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
friction plates
clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
4-51
CLUTCH
ENG
5. 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 slots a in the friction plates with
the two punch marks b in the clutch housing.
6. Lubricate:
long clutch push rod 1
ball 2
short clutch push rod 3
(with the recommended lubricant)
Recommended lubricant
Lithium soap base grease
7. Install:
long clutch push rod 1
ball 2
short clutch push rod 3
(along with a new O-ring 4 )
8. Install:
pressure plate 1
NOTE:
Align the punch mark a in the clutch boss with
the punch mark b in the pressure plate.
4-52
CLUTCH
ENG
9. Install:
clutch spring plate seat 1
clutch spring plate 2
clutch spring plate retainer 3
clutch spring plate bolts 4
8 Nm (0.8 mkg)
NOTE:
Tighten the clutch spring plate bolts in stages
and in a crisscross pattern.
10. Install:
clutch cover 1
10 Nm (1.0 mkg)
NOTE:
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
4-53
SHIFT SHAFT
ENG
SHIFT SHAFT
SHIFT ARM
10 Nm (1.0 mkg)
M6
20
10 Nm (1.0 mkg)
M6
M6
Order
Job/Part
Q’ty
35 (3)
45 (3)
Remarks
Remove the parts in the order listed.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “ENGINE REMOVAL”.
Removing the shift arm
Engine oil
1
Muffler assembly (left side), exhaust
pipe (#2 cylinder)
Middle gear case cover
1
2
3
4
Gasket
Dowel pins
Shift pedal link
1
2
1
4-54
NOTE:
Loosen the bolts in a crisscross pattern.
Disconnect
For installation, reverse the removal
procedure.
SHIFT SHAFT
ENG
SHIFT SHAFT AND STOPPER LEVER
10 Nm (1.0 mkg)
M6
18
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the shift shaft and stopper
lever (B)
Shift shaft assembly
Circlip
Washer
Torsion spring
Stopper lever
Return spring
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
Refer to “INSTALLING THE SHIFT
SHAFT”.
For installation, reverse the removal
procedure.
4-55
SHIFT SHAFT
ENG
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.
EAS00333
INSTALLING THE SHIFT SHAFT
1. Install:
stopper lever spring 1
stopper lever 2
2. Install:
shift shaft
NOTE:
Install the stopper lever spring and stopper lever as shown.
Hook the end of the shift lever spring onto the
shift lever spring stopper 1 .
4-56
STARTER CLUTCH AND GENERATOR
ENG
STARTER CLUTCH AND GENERATOR
STARTOR COIL
7 Nm (0.7 mkg)
M6 30 (3)
10 Nm (1.0 mkg)
52 Nm (5.2 mkg)
M6 45 (7)
M6 60 (4)
M10 32 (2)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “ENGINE REMOVAL”.
Removing the stator coil
Engine oil
1
2
Muffler assembly (left side), exhaust
pipe (#2 cylinder)
Middle gear case cover, shift pedal link
Shift pedal assembly
Crankcase cover (left side)
3
4
5
6
7
Gasket
Dowel pins
Pickup coil lead, stator coil lead
Cable holder
Pickup coil
Remarks
Refer to “SHIFT SHAFT”.
1
1
1
2
1/1
1
1
4-57
Refer to “CRANKCASE COVER (LEFT
SIDE)”.
Remove from the cable clamp.
STARTER CLUTCH AND GENERATOR
ENG
7 Nm (0.7 mkg)
M6 30 (3)
10 Nm (1.0 mkg)
52 Nm (5.2 mkg)
M6 45 (7)
M6 60 (4)
M10 32 (2)
Order
8
9
Job/Part
Q’ty
Plate (stater coil)
Stater coil
Remarks
1
1
For installation, reverse the removal
procedure.
4-58
ENG
STARTER CLUTCH AND GENERATOR
STARTER CLUTCH AND GENERATOR
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
M6 25
M6 55
M8 25 (6)
130 Nm (13.0 mkg)
M12 48
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
1
2
3
Removing the stater clutch and
generator rotor
Shafts
Starter idler gears
Rotor
2
3
1
4
5
6
7
8
Woodruff key
Starter wheel gear
Starter clutch assembly
Starter motor lead
Starter motor
1
1
1
1
1
Refer to “REMOVING/INSTALLING THE
GENERATOR”.
Refer to “INSTALLING THE
GENERATOR”.
Disconnect
For installation, reverse the removal
procedure.
4-59
STARTER CLUTCH AND GENERATOR
ENG
EAS00346
REMOVING THE GENERATOR
1. Remove:
generator rotor bolt 1
washer
NOTE:
While holding the generator rotor with the
sheave holder 2 , loosen the generator rotor
bolt.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
YS-01880, 90890-01701
2. Remove:
generator rotor 1
(with the flywheel puller set 2 )
woodruff key
Flywheel puller set
YU-33270, 90890-01362
Adopter
YM-33282, 90890-04089
EAS00350
CHECKING THE STARTER CLUTCH
1. Check:
starter clutch rollers 1
Damage/wear Replace.
2. Check:
starter clutch idler gear 1
starter clutch drive gear 2
starter clutch gear
Burrs/chips/roughness/wear
the defective part(-s).
Replace
3. Check:
starter clutch gear’s contacting surfaces
Damage/pitting/wear Replace the starter
clutch gear.
4-60
STARTER CLUTCH AND GENERATOR
ENG
4. Check:
starter clutch operation
a. Install the starter clutch 1 onto the generator rotor 2 and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the starter clutch drive gear should engage.
If the starter clutch drive gear and starter
clutch do not engage, the starter clutch is
faulty and must be replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely. If
the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.
EAS00354
INSTALLING THE GENERATOR
1. Install:
starter wheel gear 1
woodruff key 2
generator rotor 3
washer 4
pin 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 key
way of the crankshaft.
2. Tighten:
generator rotor bolt 1
130 Nm (13.0 mkg)
NOTE:
While holding the generator rotor with the
sheave holder 2 , tighten the generator rotor
bolt.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
YS-01880, 90890-01701
4-61
OIL PAN AND OIL PUMP
ENG
OIL PAN AND OIL PUMP
17 Nm (1.7 mkg)
24 Nm (2.4 mkg)
M8 95
10 Nm (1.0 mkg)
M6 25 (3)
12 Nm (1.2 mkg)
M6 12
10 Nm (1.0 mkg)
M6 30 (12)
Order
10 Nm (1.0 mkg)
M6 16
Job/Part
Q’ty
1
2
3
Removing the oil pan and oil pump
Engine assembly
Clutch assembly
Circlip
Idler gear (oil pump)
Oil pan
1
1
1
4
5
6
7
8
9
10
11
12
13
Dowel pins
Gasket
Oil level switch
Oil pump assembly
Dowel pins
Oil pump pipe
Bracket tabs
Oil pipe
Oil gallery pipe
Oil filter
2
1
1
1
2
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CLUTCH”.
Refer to “REMOVING/INSTALLING THE
OIL PAN”.
Refer to “INSTALLING THE OIL PUMP”.
Straighten
For installation, reverse the removal
procedure.
4-62
OIL PAN AND OIL PUMP
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
Disassembling the oil pump
Oil strainer
Oil strainer housing
Gasket
Circlip
Driven gear (oil pump)
Gear housing
Spring
Relief valve
Inner rotor
Shaft
Pin
Outer rotor
1
1
1
1
1
1
1
1
1
1
1
1
4-63
Refer to “ASSEMBLING THE OIL
PUMP”.
OIL PAN AND OIL PUMP
Order
13
14
Job/Part
Q’ty
Dowel pins
Oil pump housing
2
1
4-64
ENG
Remarks
Refer to “ASSEMBLING THE OIL
PUMP”.
For assembly, reverse the disassembly
procedure.
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
oil lever 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 driver gear 1
oil pump driven gear 2
oil pump housing 3
oil pump housing cover
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
oil-pump-housing-to-inner-rotor-and-outerrotor clearance C
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 X 0.12 mm
<Limit>: 0.17 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 X 0.08 mm
<Limit>: 0.08 mm
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.03 X 0.08 mm
3. Check:
oil pump operation
Unsmooth Repeat steps (1) and (2) or replace the defective part(-s).
4-65
OIL PAN AND OIL PUMP
ENG
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
relief valve body
relief valve 1
spring 2
Damage/wear Replace the defective
part(-s).
EAS00367
CHECKING THE OIL GALLERY PIPES
The following procedure applies to all of the oil
gallery pipes.
1. Check:
oil gallery pipe 1
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.
INSTALLING THE OIL GALLERY PIPES
1. Install:
oil gallery pipe 1
oil pipe 2
WARNING
Always use new O-rings.
2. Bend:
bracket tabs 1
4-66
OIL PAN AND OIL PUMP
ENG
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor
outer rotor
oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
oil pump shaft 1
(to the oil pump cover 2 )
pin 3
inner rotor 4
outer rotor 5
pin 6
oil pump housing
screw
NOTE:
When installing the inner rotor, align the pin 3 in
the oil pump shaft with the groove a on the inner rotor 4 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
oil pump 1
10 Nm (1.0 mkg)
CAUTION:
After tightening the bolts, make sure that the
oil pump turns smoothly.
4-67
OIL PAN AND OIL PUMP
ENG
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
oil strainer housing 1
2. Install:
oil strainer cover 2
relief valve
NOTE:
The arrow a on the oil strainer cover must point
towards the rear of the engine.
EAS00380
INSTALLING THE OIL PAN
1. Install:
dowel pins
gasket (New)
oil pan 1
10 Nm (1.0 mkg)
oil level switch 2
10 Nm (1.0 mkg)
engine oil drain bolt
WARNING
Always use new copper washers.
NOTE:
Tighten the oil pan bolts in stages and in a
crisscross pattern.
Lubricate the oil level switch’s O-ring with engine oil.
4-68
CRANKCASE
ENG
CRANKCASE
25 Nm (2.5 mkg)
M8 21 (4)
30 Nm (3.0 mkg)
M8 30 (3)
7 Nm (0.7 mkg)
M6 13 (3)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEADS”.
Refer to “WATER PUMP” in CHAPTER 5.
Refer to “CLUTCH”.
Refer to “SHIFT SHAFT AND STOPPER
LEVER”.
Refer to “CLUTCH RELEASE
CYLINDER”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “OIL PAN AND OIL PUMP”.
Crankcase separation
Engine assembly
Cylinder head
Water pump
Clutch assembly
Shift shaft, stopper lever
Clutch release cylinder
AC Magneto
Oil pan and oil pump assembly
4-69
CRANKCASE
ENG
25 Nm (2.5 mkg)
M8 21 (4)
30 Nm (3.0 mkg)
M8 30 (3)
7 Nm (0.7 mkg)
M6 13 (3)
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
4-70
Remarks
Refer to “ASSEMBLING THE
CRANKCASE”.
Refer to “DISASSEMBLING/
ASSEMBLING THE CRANKCASE”.
For installation, reverse the removal
procedure.
CRANKCASE
ENG
10 Nm (1.0 mkg)
M6 40 (6)
10 Nm (1.0 mkg)
M6 16 (4)
18 Nm (1.8 mkg)
M8 22
24 Nm (2.4 mkg)
M8 25
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the crankcase
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)
1
1
2
1
4
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-71
CRANKCASE
ENG
EAS00384
A
DISASSEMBLING THE CRANKCASE
1. Remove:
crankcase bolts
A Upper crankcase
B Lower crankcase
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.
B
2. Remove:
upper crankcase
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
3. Remove:
dowel pins
O-ring
4. 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.
4-72
CRANKCASE
ENG
EAS00399
CHECKING THE CRANKCASE
1. Throughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
crankcase
Cracks/damage ! Replace.
oil delivery passages
Obstruction ! Blow out with compressed air.
4. Check:
crankcase breather cover 1
crankcase breather spacer 2
Cracks damage ! Replace.
oil pipe (crankcase breather) 3
Blockage ! Blow out the passages with
compressed air.
5. Check:
drain plugs (cylinders) 1
Cracks/wear/damage ! Replace.
6. Check:
oil pipe 1
Blockage ! Blow out the passages with
compressed air.
union bolt 2
Blockage ! Blow out the passages with
compressed air.
7. Check:
idler gear (oil pump) 1
shaft 2
Bends/wear/damage ! Replace.
4-73
CRANKCASE
ENG
EAS00417
ASSEMBLING THE CRANKCASE
1. Install:
S shaft 1
S Idler gear (oil pump) 2
S circlip 3 New
2. Install:
S bracket (timing chain damper) 1
24 Nm (2.4 mSkg)
S oil pipe 2
18 Nm (1.8 mSkg)
NOTE:
Apply LOCTITER to the bracket bolt.
3. Install:
S drain plugs (cylinders) 2
4. Install:
S oil pipe 1
S rubber gaskets 2 New
S crankcase breather spacer 3
S crankcase breather cover 4
WARNING
Always use new O-rings.
5. Install:
S crankcase breather assembly 4
10 Nm (1.0 mSkg)
4-74
CRANKCASE
ENG
6. Lubricate:
crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Apply:
sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
Quick Gasket
ACC-11001-15-01
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 X 3 mm of
the crankshaft journal bearings.
8. Install:
upper crankcase 1
(onto the lower crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift correctly when the shift drum assembly is
turned by hand.
9. Install:
final drive assembly
Refer to “MIDDLE GEAR”.
NOTE:
The arrow on the final drive assembly must
point towards the upper crankcase.
10. Install:
middle driven shaft bearing housing bolts
NOTE:
The bolt with the washer goes in the lower right
hole a of the middle driven shaft bearing housing.
Middle driven shaft bearing
housing bolt
30 Nm (3.0 mkg)
4-75
CRANKCASE
ENG
11. Tighten:
S upper crankcase bolts
S lower crankcase bolts
A
WARNING
Always use new copper washers.
NOTE:
S Tighten the bolts in the tightening sequence
cast on the crankcase.
S Install copper washers on bolts 28 and 30 .
S Install the cable holder on bolts 22 and 32 .
S Install the washers on bolts 2 and 4 X 8 .
A Upper crankcase
B
B Lower crankcase
M10 bolt
40 Nm (4.0 mSkg)
M8 bolt
24 Nm (2.4 mSkg)
M6 bolt
12 Nm (1.2 mSkg)
12. Install:
S middle driven shaft bearing housing retainers 1
25 Nm (2.5 mSkg)
S main axle bearing retainer 2
7 Nm (0.7 mSkg)
WARNING
Always use new screws.
CAUTION:
S Apply LOCTITER on to the retainer screws.
S After tightening the middle driven shaft
bearing housing retainer screws, be sure
to stake them with a center punch.
4-76
CRANKSHAFT
ENG
CRANKSHAFT
Order
Job/Part
Q’ty
1
2
3
4
5
Removing the crankshaft assembly
Crankcase separation
Balancer shaft
Balancer shaft bearings
Crankshaft
Timing chains
Main journal bearings
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE”.
1
4
1
2
8
Refer to “REMOVING/INSTALLING
THE CRANKSHAFT”.
For installation, reverse the removal
procedure.
4-77
CRANKSHAFT
ENG
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
balancer shaft 1
crankshaft assembly 2
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.
EAS00395
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
0.020 X 0.038 mm
<Limit>: 0.1 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.
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
1 and the crankshaft into the upper crankcase.
4-78
CRANKSHAFT
ENG
NOTE:
Align the projections a of the crakshaft journal
upper bearings with the notches b in the crankcase.
d. Put a piece of Plastigauge 2 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
3 into the lower crankcase and assemble
the crankcase halves.
NOTE:
Align the projections a of the crankshaft journal lower bearings with the notches b in the
crankcase.
Do not move the crankshaft until the clearance
measurement has been completed.
4-79
CRANKSHAFT
ENG
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
A
NOTE:
Install copper washers on bolts 28 and 30 .
Install the coble holder on bolts 22 and 32 .
Install the washers on bolts 2 and 4 X 8 .
A Upper crankcase
B Lower crankcase
M 10 bolt
40 Nm (4.0 mkg)
M 8 bolt
24 Nm (2.4 mkg)
M 6 bolt
12 Nm (1.2 mkg)
B
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge
width c on each crankshaft journal.
If the clearance is out of specification, select
replacement crankshaft journal bearings.
4-80
CRANKSHAFT
ENG
4. Select:
crankshaft journal bearings (J1 X J4)
NOTE:
The numbers A 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 X J4” refer to the bearings shown in the
crankshaft illustration.
If “J1 X J4” are the same, use the same size for
all of the bearings.
For example, if the crankcase “J” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
Bearing size for J1:
J1 (crankcase) – J1 (crankshaft web) =
6 – 2 = 4 (green)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
4-81
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
7
red
CRANKSHAFT
ENG
CHECKING THE BALANCER SHAFT
1. Measure
balancer shaft runout
out of specification Replace the balancer
shaft
Balancer shaft runout
Less than 0.03 mm
2. Check:
balancer shaft journal surfaces
bearing surface
balancer shaft driven gear 1
water pump drive gear 2
Scratches/wear Replace the balancer
shaft
3. Measure
balancer shaft journal-to-balancer shaft journal bearing clearance
Out of specification Replace the balancer
shaft journal bearings.
Balancer shaft journal-to-balancer shaft bearing clearance
0.020 X 0.048 mm
CAUTION:
Do not interchange the balancer shaft bearings
To obtain the correct balancer shaft journal-to-balancer shaft journal bearing clearance and prevent engine damage, the balancer shaft journal bearings mst be
installed in their original positions.
4-82
CRANKSHAFT
ENG
a. Clean the balancer shaft journal bearings,
balancer shaft journals, and bearing portions
of the crankcas.
b. Place the upper crankcase upside down on a
bench.
c. Install the balancer shaft journal upper bearings 1 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 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 1 into the lower crankcase and assemble the crankcase halves.
NOTE:
Align the projections a of the balancer shaft
journal lower bearings with the notches b in
the crankcase.
Do not move the balancer shaft until the clearance measurement has been completed.
4-83
CRANKSHAFT
ENG
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
A
NOTE:
Install copper washers on bolts 28 and 30 .
Install the coble holder on bolts 22 and 32 .
Install the washers on bolts 2 and 4 8 .
A Upper crankcase
B Lower crankcase
M 10 bolt
40 Nm (4.0 mkg)
M 8 bolt
24 Nm (2.4 mkg)
M 6 bolt
12 Nm (1.2 mkg)
B
g. Remove the lower crankcase and the balancer shaft journal lower bearings.
h. Measure the compressed Plastigauge
width c on each balancer shaft journal. If the
clearance is out of specification, select replacement balancer shaft journal bearings.
4-84
CRANKSHAFT
ENG
4. Select:
Balancer shaft journal bearings (P1 P2)
NOTE:
The numgers A stamped into the balancer
weight and the numbers 1 stamped into the
lower creankcase are used to determine the replacement balancer shaft journal bearing sizes.
“P1 P2” refer to the bearings shown in the balancer shaft illustration.
If “P1 P2” are the same, use the same size for all
of the bearings.
For example, if the crankcase “P1” and balancer
weight “P1” numbers are “6” and “2” respectively, then the bearing size for “P1” is:
Bearing size for P1:
P1 (crankcase) – P1 (balancer weight) =
6 – 2 = 4 (green)
BALANCER SHAFT JOURNAL BEARING
COLOR CODE
4-85
1
blue
2
black
3
brown
4
green
5
yellow
6
pink
7
red
CRANKSHAFT
ENG
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
crankshaft journal upper bearings 1
(into the upper crankcase)
NOTE:
Align the projections a on the crankshaft journal upper bearings with the notches b in the
crankcase.
Be sure to install each crankshaft journal upper bearing in its original place.
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.
4-86
CONNECTING RODS AND PISTONS
ENG
CONNECTING RODS AND PISTONS
36 Nm (3.6 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Connecting rod and piston removal
Crankcase separation
Nuts (connecting rod caps)
Connecting rod caps/plain bearings
Connecting rods/pistons
Piston pin clips
Piston pins
Pistons
Piston rings
8
4/8
4/4
8
4
4
12
Remarks
Remove th parts in the order listed.
Refer to “CRANKCASE”.
Refer to “INSTALLING THE PISTONS
AND CONNECTING RODS”.
Refer to “REMOVING/INSTALLING THE
CONNECTING RODS AND PISTONS”.
For installation, reverse the removal
procedure.
4-87
ONNECTING RODS AND PISTONS
ENG
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
1. Remove:
connecting rod bearings
NOTE:
Identify the position of each bearing very carefully so that it can be reinstalled in its original
place.
The following procedure applies to all of the cylinders and pistons.
2. Remove:
piston pin clip 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
For reference during installation, put an identification mark on each 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
YU-01304, 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.
4-88
CONNECTING RODS AND PISTONS
ENG
EAS00260
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of 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.
Standard
Wear
limit
Cylinder
78.967 79.016 mm 79.1 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.
4-89
CONNECTING RODS AND PISTONS
ENG
c. Measure piston skirt diameter “P” with the
micrometer.
4
b mm from the bottom edge of the piston.
Piston size P
Standard
78.926 78.933 mm
Oversize 2
79.25 mm
Oversize 4
79.50 mm
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 0.069 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.
4-90
CONNECTING RODS AND PISTONS
ENG
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 as shown.
a 40 mm
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
0.20 0.35 mm
<Limit>: 0.55 mm
2nd ring
0.35 0.50 mm
<Limit>: 0.8 mm
Oil ring
0.3 0.9 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.
4-91
Oversize 2
0.25 mm
Oversize 4
0.50 mm
CONNECTING RODS AND PISTONS
ENG
Oil ring
The expander spacer of the oil ring is colorcoded for size identificaton.
Size
Color
Oversize 2
Blue
Oversize 4
Red
EAS00266
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
1. Check:
pison pin
Blue discoloration/grooves Replace the
piston pin and then check the lubrication system.
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 0.0024 mm
<Limit>: 0.007 mm
4-92
CONNECTING RODS AND PISTONS
ENG
EAS00395
CHECKING THE CRANKSHAFT AND CONNECTING RODS
1. Measure:
crankshaft-pin-to-big-end-bearing
clearance
Out of specification Replace the big end
bearings.
Crankshaft-pin-to-big-endbearing 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 bearing portions of the connecting rods.
b. Install the big end upper bearing into the connecting rod and the big end lower bearing
into the connecting rod cap.
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.
Apply molybdenum disulfide grease onto the
bolts, threads, and nut seats.
Make sure that the “Y” mark 1 on the connecting rod faces towards the left side of the crankshaft at #1, #3 cylinder.
Make sure that the “Y” mark 1 on the connecting rod faces towards the right side of the
crankshaft at #2, #4 cylinder.
Make sure that the characters 2 on both the
connecting rod and connecting rod cap are
aligned.
4-93
CONNECTING RODS AND PISTONS
ENG
e. Tighten the connecting rod nuts.
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 mkg.
Once you reach 3.0 mkg, DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted between 3.0 and 3.6 mkg, loosen the connecting rod nut to less than 3.0 mkg and
start again.
Refer to “INSTALLING THE CONNECTING
RODS”.
Connecting rod nut
36 Nm (3.6 mkg)
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS”.
g. Measure the compressed Plastigauge
width 1 on the crankshaft pin.
If the clearance is out of specification, select
replacement big end bearings.
2. Select:
big end bearings (P1 P2)
NOTE:
The numbers A 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 for “P1”:
“P1” (connecting rod) – “P1”
(crankshaft)=
4 – 1 = 3 (brown)
4-94
CONNECTING RODS AND PISTONS
ENG
BIG END BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
EAS00267
INSTALLING THE PISTONS AND CONNECTING RODS
1. Install:
top ring 1
2nd ring 2
lower oil ring rail 3
upper oil ring rail 4
oil ring expander 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers a face up.
2. Install:
piston 1
piston pin 2
piston pin clip (New) 3
NOTE:
Apply engine oil onto the piston pin.
4 “Y” mark
5 “EX” exhaust side
6 “IN” intake side
7 Projection
3. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4-95
CONNECTING RODS AND PISTONS
ENG
4. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
5. Install:
plain bearings 1
NOTE:
Align the projection a of the bearings with the
notches b in the connecting rod cap.
Install each bearing in its original place.
6. Install:
Piston ring compressor 1
Piston ring compressor:
YM-8037, 90890-05158
7. Install:
connecting rod and piston assembly
NOTE:
The stamped “Y” mark 1 on the No.2 and
No.4 connecting rods should face towards the
right side of the crankcase.
The stamped “Y” mark 1 on the No.1 and
No.3 connecting rods should face towards the
left side of the crankcase.
A Top view
A
2 Front
3 “Y” mark facing direction
4 Piston exhaust mark
5 Piston intake mark
4-96
CONNECTING RODS AND PISTONS
ENG
8. Install:
connecting rod cap
NOTE:
Be sure that the characters on the side of the
cap and connecting rod are aligned.
9. Tighten:
nuts (connecting rod cap)
36 Nm (3.6 mkg)
NOTE:
Apply Molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.
The projection 1 on the connecting rod cap
should face toward the crankshaft web.
CAUTION:
When tightening the nuts be sure to use an
F-type torque wrench.
Without pausing tighten to full torque
specification. Apply continuous torque between 3.0 and 3.6 mkg. Once you reach 3.0
mkg DO NOT STOP TIGHTENING until final torque is reached. If the tightening is interrupted between 3.0 and 3.6 mkg, loosen
the nut to less than 3.0 mkg and start
again.
4-97
TRANSMISSION
ENG
TRANSMISSION
7 Nm (0.7 mkg)
M6
13 (3)
4 Nm (0.4 mkg)
M5
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Removing the transmission
Crankcase separation
Drive axle assembly
Main axle assembly
Push rod support bearing
Oil seal
Bearing circlips
Guide bars
Shift forks
Neutral switch
Shift cam retainer
Shift cam
1
1
1
1
2
2
3
1
1
1
9 (3)
Remarks
Remove the parts in the order listed.
Refer to “CRANKCASE”.
Refer to “INSTALLING THE
TRANSMISSION”.
Refer to “INSTALLING THE SHIFT
FORKS”,
For installation, reverse the removal
procedure.
4-98
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Q’ty
ENG
Remarks
Remove the parts in the order listed.
Refer to “MIDDLE GEAR”.
Disassembling the transmission
Middle drive pinion gear assembly
Circlip
Bearing
1st wheel gear
4th wheel gear
Circlip
Washer
3rd wheel gear
Drive axle
Plug
2nd wheel gear
Washer
Circlip
1
1
1
1
1
1
1
1
1
1
1
1
4-99
TRANSMISSION
Order
13
14
15
16
17
18
19
20
21
22
23
24
25
Job/Part
Q’ty
ENG
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
5th wheel gear
Bearing
Circlip
Bearing
Main axle
4th pinion gear
Washer
Circlip
2nd, 3rd pinion gear
5th pinion gear
Washer
Circlip
Bearing
For installation, reverse the disassembly
procedure.
4-100
TRANSMISSION
ENG
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
bearings 1
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals 2
Damage/wear Replace.
circlips 3
Bends/damage/looseness Replace.
EAS00402
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks and related components.
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
(on the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
4-101
TRANSMISSION
ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum.
shift drum bearing 1
Damage/pitting Replace.
shift drum segment 2
Damage/wear Replace.
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
Damage/bends/looseness Replace.
4-102
TRANSMISSION
ENG
EAS00426
INSTALLING THE SHIFT FORKS
1. Install:
S shift forks 1
S shift fork guide bars 2
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”.
2. Install:
S shift cam 1
S shift cam retainer 2
7 Nm (0.7 mSkg)
NOTE:
S Apply LOCTITER #648 to the shift cam retainer screws.
S Rotate the shift cam to the neutral position.
3. Install:
S neutral switch 1
4 Nm (0.4 mSkg)
NOTE:
Apply grease to the neutral switch.
WARNING
Always use a new O-ring.
EAS00428
INSTALLING THE TRANSMISSION
1. Install:
S main axle assembly 1
S drive axle assembly 2
NOTE:
S Make sure that the bearing circlips 3 are inserted into the grooves in the lower crankcase.
S The bearing pin 4 are inserted into the
grooves in the lower crankcase.
2. Check:
S transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing throughly.
4-103
MIDDLE GEAE
ENG
MIDDLE GEAE
90 Nm (9.0 mkg)
30 Nm (3.0 mkg)
110 Nm (11.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Q’ty
Removing the middle gear
Crankcase separation
Drive axle assembly
Nut
Washer
Universal joint (yoke)
Dust seal
Middle driven gear housing
Shims
O-ring
Bearing
Collapsible collar
Spacer
Bearing
Middle drive shaft
Retainer
1
1
1
1
1
2
1
1
1
1
1
1
1
4-104
Remarks
Remove the parts in the ordr listed.
Refer to “CRANKCASE”.
Refer to “TRANSMISSION”.
Refer to “DISASSEMBLING/
ASSEMBLING THE MIDDLE DRIVEN
SHAFT ASSEMBLY”.
Refer to “DISASSEMBLING/
ASSEMBLING THE MIDDLE DRIVE
SHAFT ASSEMBLY”.
MIDDLE GEAR
ENG
90 Nm (9.0 mkg)
30 Nm (3.0 mkg)
110 Nm (11.0 mkg)
Order
14
15
16
17
18
19
20
21
Job/Part
Q’ty
1
1
1
1
1
1
1
1
Thrust washer
Middle drive pinion gear
Damper cam
Damper spring
Spring seat
Bearing
Nut
Bearing
4-105
Remarks
Refer to “DISASSEMBLING/
ASSEMBLING THE MDDLE DRIVE
SHAFT ASSEMBLY”.
For installation, reverse the removal
procedure.
MIDDLE GEAR
ENG
EAS00434
DISASSEMBLING THE
SHAFT ASSEMBLY
1. Remove:
spring retainers 1
MIDDLE
DRIVE
NOTE:
While compressing the spring with a damper
spring compressor 2 , remove the spring retainers.
Damper spring compressor
YM-33286, 90890-04090
2. Straighten the stake.
3. Remove:
middle drive shaft nut 1
bearing 2
middle drive shaft 3
a .Secure the middle drive shaft holder in a
vice.
b. Loosen the middle drive shaft nut with the
middle drive shaft nut wrench 4 .
Middle drive shaft nut wrench
YM-04054, 90890-04054
c. Remove the middle drive shaft nut and bearing.
4-106
MIDDLE GEAR
ENG
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.
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
deneath 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
YM-04062, 90890-04062
EB414400
CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY
1. Check:
damper cam surface
Scratches/wear Replace the damper
cam.
2. Check:
spring
Cracks/damage Replace.
4-107
MIDDLE GEAR
ENG
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
110 Nm (11 mkg)
NOTE:
Lock the threads on the middle drive shaft nut by
staking them with a center punch 1 .
4-108
MIDDLE GEAR
ENG
2. Install:
S spring retainers 1
NOTE:
While compressing the spring with a damper
spring compressor 2 , and then install the
spring retainers.
Damper spring compressor
YM-33286, 90890-04090
EAS00443
ASSEMBLING THE MIDDLE DRIVEN SHAFT
ASSEMBLY
NOTE:
The following points are critical when assembling the middle gears:
S The collapsible collar must be replaced whenever the middle driven shaft assembly is removed from the middle driven shaft bearing
housing.
S When performing this procedure for the first
time, be sure to have at least one extra collapsible collar on hand.
S 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:
S 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.
2. Tighten:
S middle driven shaft nut
90 Nm (9.0 mSkg)
CAUTION:
Apply LOCTITER on to the middle driven
shaft nut.
While holding the universal joint driven yoke with
the univesal joint holder 1 , tighten the middle
driven shaft nut.
4-109
MIDDLE GEAR
ENG
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.
Universal joint holder
YM-04062, 90890-04062
3. Measure:
middle driven gear spinning torque
(with the beam-type torque wrench)
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).
Middle driven gear spinning
torque
0.40.5 Nm (0.040.05 mkg)
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.
4-110
MIDDLE GEAR
ENG
5. Install:
bearings
(onto the universal joint driven yoke/cross
joint)
CAUTION:
Then needles can easily fall out of their
races, so check each bearing carefully. Slide
the universal joint driven yok 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.
ALIGNING THE MIDDLE GEAR
1. Select:
middle drive gear shim(-s)
NOTE:
Select the proper middle drive gear shim(-s)
whenever the crankcase or the middle gears
are replaced.
4-111
MIDDLE GEAR
ENG
Example
Shim thickness =
Distance “A” – Distance “B”
A = 43 + a
B = 42 + b
a. If the middle drive gear is stamped “06” ( a
positive number (+ 06) is implied since only
the negative (–) designations are stamped
alongside the numbers), then:
“A” = 43 + 0.06
= 43.06
NOTE:
All stamped numbers are in hundredths of a
millimeter.
b. If the left crankcase is stamped “45”, then:
“B” = 42 + 0.45
= 42.45
Therefore:
T=A–B
= 43.06 – 42.45
= 0.61 mm
c. Then calculated shim thickness is 0.61 mm.
Shims can only be selected in 0.05 mm increments, therefore round off to the hundredths
digit of the calculated thickness and select
the appropriate shim(-s) with the following
chart.
Hundredths digit
Rounded value
0, 1, 2
0
3, 4, 5, 6
5
7, 8, 9
10
d. Using the above example, the calculated
shim thickness of 0.61 mm is rounded off to
0.60 mm. Therefore, you may choose either
four 0.15 mm shims, two 0.30 mm shims or
one 0.30 mm and two 0.15 mm shims as selected from the shim thickness chart below.
Shim sizes are supplied in the following
thicknesses:
Middle drive pinion shim
Thickness (mm)
4-112
0.15 0.30 0.50
MIDDLE GEAR
ENG
EAS00450
ADJUSTING THE MIDDLE GEAR BACKLASH
1. Install:
middle gear backlash tool
Middle gear backlash tool
90890-04080
2. Loosen:
middle driven shaft bearing housing bolts
3. Remove:
shim(-s)
4. 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. If the bolts are overtightened,
loosen them until the crankcase-to-middledriven-shaft-bearing-housing clearance is
within specification, as stated below. Then,
repeat all of the previous steps.
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 (0.08 in), when measured
with a thickness gauge 1 .
5. 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.
6. Measure:
crankcase-to-middle-driven-shaft-bearinghousing clearance
(with a thickness gauge)
4-113
MIDDLE GEAR
ENG
7. Select:
S shim(-s) 1
a. Shims can only be selected in 0.05 mm increments, therefore round off to the hundredths
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 0.42 mm. Therefore, the chart
instructs you to round off the 2 to 0. Thus, you
should use one 0.40 mm shim.
Hundredths
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle drive gear shim
Thickness (mm)
0.10, 0.15, 0.20,
0.30, 0.40, 0.50
8. Loosen:
S middle driven shaft bearing housing bolts
9. Install:
S shim(-s)R
10. Tighten:
S middle driven shaft bearing housing bolts
30 Nm (3 mSkg)
11. Measure:
S middle gear backlash
Out of specification Refer to “MEASURING THE MIDDLE GEAR BACKLASH”.
12. Install:
S bearing retainers 1
25 Nm (2.5 mSkg)
WARNING
Always use new screws.
CAUTION:
S Apply LOCTITER on to the retainer screws.
S After tightening the bearing retainer
screws, stake them with a center punch.
4-114
COOL
5
COOL
CONTENTS
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
5-6
5-7
5-7
5-8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9
5-11
5-11
5-13
5-14
COOL
RADIATOR
COOL
COOLING SYSTEM
RADIATOR
2 Nm (0.2 mkg)
M6 12 (3)
7 Nm (0.7 mkg)
M6 40 (2)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK” in
CHAPTER 3.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
Removing the radiator
Rider seat, fuel tank
Coolant
1
2
3
4
5
6
7
Remarks
Steering head side covers
Lower radiator bolts
Radiator hose clamps (upper and lower)
Thermo unit lead
Fan lead
Radiator
Fan motor
2
2
2
1
1
1
1
Loosen
Disconnect
Disconnect
For installation, reverse the removal
procedure.
5-1
RADIATOR
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. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Radiator cap opening pressure
95 X 125 kPa
(0.95 X 1.25kgf/cm2,
0.95 X 1.25 bar)
a. Install the radiator cap tester 1 to the radiator cap.
Radiator cap tester
YU-24460-01,
90890-01325
b. Apply the specified pressure for ten seconds
and make sure that there is no drop in pressure.
4. Check
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
5-2
RADIATOR
COOL
EAS00456
INSTALLING THE RADIATOR
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”.
5-3
COOL
THERMOSTAT
THERMOSTAT
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Removing the thermostat
Rider seat, fuel tank
Coolant
Air filter case
1
2
3
4
5
6
Steering head side covers
Overflow hose
Bolts (radiator cap assembly)
Coolant pipe (right)
Thermostatic hose clamp (lower)
Thermo switch lead
Thermostat
1
2
1
2
1
1
5-4
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
CHAPTER 3.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
Refer to “CLEANING THE AIR FILTER” in
CHAPTER 3.
Refer to “REMOVING THE RADIATOR”.
Disconnect
Loosen
Disconnect
COOL
THERMOSTAT
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
7
Job/Part
Q’ty
Radiator cap pipe
Remarks
1
For installation, reverse the removal
procedure.
5-5
THERMOSTAT
COOL
THERMOSTAT HOUSING
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the thermostat
Thermostat stay
Thermostat housing cover
O-ring (housing cover)
Thermostatic valve
Thermo switch
Thermostat housing
1
1
1
1
1
1
Refer to “ASSEMBLING THE
THERMOSTAT”.
For assembly, reverse the disassembly
procedure.
5-6
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
S thermostat 1
Does not open at 80.5 X 83.5_C Replace.
Thermostat full opening range
8 mm at 95 _C
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 thermometer’s indicated temperature.
e. Check the opening range of the thermostat
valve after keep the water around 95 _C in
5 X 6 minuts.
1 Thermometer
2 Water
3 Thermostat
4 Container
A Closes
B Opens
NOTE:
S Do not put the thermostat directly to the bottom
of the container 4 .
S If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
2. Check
S thermostat housing cover 1
S thermostat housing 2
Cracks/damage Replace.
EAS500464
ASSEMBLING THE THERMOSTAT
1. Install:
S thermostat housing 1
S thermostat 2
S O-ring (New) 3
S thermostat housing cover 4
NOTE:
Install the thermostat with its breather hole a
facing up.
5-7
THERMOSTAT
COOL
2. Install:
thermo switch 1
75Nm (0.75 mkg)
CAUTION:
Use extreme care when handing the thermo
switch and temperature sender. Replace
any part that was dropped or subjected to a
strong impact.
EAS00466
INSTALLING THE THERMOSTAT
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”.
5-8
WATER PUMP
COOL
WATER PUMP
10 Nm (1.0 mkg)
M6 25 (4)
10 Nm (1.0 mkg)
M6 14
10 Nm (1.0 mkg)
M6 30 (2)
M6 80 (3)
Order
Job/Part
Q’ty
Removing the water pump
Coolant
1
2
3
4
5
6
7
8
9
1
2
1
1
1
1
1
1
2
Radiator hose clamp (lower)
Bolts (water pump inlet pipe)
Water pump cover
O-ring
Water pump inlet pipe
O-ring
Water pump housing
Gasket
Dowel pins
Remarks
Remove the parts in the order listed.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
Loosen
Refer to “INSTALLING THE WATER
PUMP”.
For installation, reverse the removal
procedure.
5-9
WATER PUMP
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
COOL
Remarks
Disassemble the parts in the order listed.
Disassembling the water pump
Circlip
Driven gear
Gear stopper pin
Circlip
Impeller
Bearing
Oil seal
Water pump seal
Damper rubber
Slip ring
1
1
1
1
1
1
1
1
1
1
Refer to “ASSEMLING THE WATER
PUMP”.
Refer to “DISASSEMBLING/
ASSEMBLING THE WATER PUMP”.
For assembly, reverse the disassembly
procedure.
5-10
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
2. Check
impeller 1
rubber damper 2
rubber damper holder 3
Cracks/damage/wear Replace.
5-11
WATER PUMP
COOL
3. Check:
water pump seal 1
oil seal 2
Cracks/damage/wear Replace.
4. Check:
bearing
Roughness Replace.
5. Check:
water pump driven gear
Pitting/wear Replace.
7. Check:
water pump inlet pipe
radiator outlet hose
Cracks/damage/wear Replace.
5-12
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:
tilt
Out of specification Repeat step 1.
CAUTION:
Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Tilt limit
0.15 mm
1 Straightedge
2 Impeller
3. Install:
water pump seal 1 New
CAUTION:
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
Install the water pump seal from the special
tools.
Before installing the water pump seal, apply
Yamaha bond No. 1215 to the water pump
housing 2 .
Mechanical seal installer 3
90890-04078
Middle driven shaft bearing
driver 4
90890-04058
Yamaha bond No. 1215
90890-85505
A push down.
5-13
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 that 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
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
EAS00478
INSTALLING THE WATER PUMP
1. Install:
water pump housing 1
WARNING
Always use a new gascket.
5-14
WATER PUMP
COOL
2. Install:
O-ring (New)
water pump housing cover 1
10 Nm (1.0 mkg)
O-ring (New)
water pump inlet hose 2
WARNING
Always use a new O-ring.
NOTE:
Before installing the water pump inlet pipe 2 ,
apply a thin coat of lithium soap base grease
onto the O-rings.
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”.
5-15
COOL
CARB
6
CARB
CONTENTS
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL COCK OPERATION . . . . . . . . . . . . . . . . . . .
6-1
6-6
6-8
6-10
6-10
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . .
6-16
6-16
6-16
6-17
6-18
6-11
6-14
6-15
6-15
CARB
CARBURETORS
CARB
CARBURETORS
CARBURETORS
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK” in CHAPTER 3.
Removing the carburetors
Rider seat, fuel tank
1
2
3
4
5
6
7
8
9
Remarks
1
1
2
1
1
2
2
4
1
Air induction box
Fuel hose
Drain hose
Throttle position sensor lead
Carburetour heater lead
Throttle cables
Air vent hoses
Clamps (carburetor joints)
Carburetor assembly
Disconnect
Disconnect
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
Q’ty
CARB
Remarks
Remove the parts in the order listed.
Separating the carburetors
Choke knob
Choke knob bracket
Choke lever
TPS
Throttle stop screw
Bracket
Connecting bolt
Bracket
Carburetor heater
Bracket
Fuel feed pipe
Breather hose
Synchronization rod
Bracket
1
2
2
1
1
1
4
1
4
1
2
1
1
1
6-2
CARBURETORS
Order
15
16
Job/Part
Q’ty
Bracket
Carburetors
CARB
Remarks
1
4
For assembly, reverse the disassembly
procedure.
6-3
CARBURETORS
Order
Job/Part
Q’ty
10
11
12
Remarks
Disassemble the parts in the order listed.
NOTE:
The remaining steps should be followed for
all four of the carburetors.
Disassembling the carburetor
1
2
3
4
5
6
7
8
9
CARB
1
1
1
1
1
1
1
1
1
1
1
1
Starter plunger holder
O-ring
Starter plunger assembly
Coasting enrichment cover
Spring
Diaphragm
Vacuum chamber cover
Spring
Vacuum piston
Plastic screw
Spring
Plastic bushing
6-4
Refer to “ASSEMBLING THE
CARBURETORS”.
CARBURETORS
Order
13
14
15
16
17
18
19
20
21
22
23
24
Job/Part
Q’ty
CARB
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
Jet needle
Float chamber cover
Gasket
Float pin
Float
Needle valve
Holding screw (valve seat)
Valve seat
Main jet
Main jet holder
Pilot jet
Needle jet
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 petroleumbased
solvent. Do not use any caustic-carburetorcleaning 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
needle valve seat 2
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:
O-ring 3
Damage/wear replace the needle valve,
needle valve seat and O-ring as a set.
6-6
CARBURETORS
CARB
8. Check:
piston valve 1
Damage/scratches/wear Replace.
rubber diaphragm 2
Cracks/tears Replace.
9. Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder
Cracks/damage Replace.
10. Check:
jet needle kit 1
needle jet 2
main jet 3
pilot jet 4
pilot screw 5
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
11. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
12. Check:
fuel feed pipes
hose joint
Cracks/damage Replace.
Obstruction Clean.
Blow out the pipes with compressed air.
6-7
CARBURETORS
CARB
13. Check:
fuel feed hoses
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
EAS00489
ASSEMBLING THE CARBURETORS
The following procedure applies to both 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:
piston valve holder
2. Install:
needle jet 1
pilot jet
main jet
NOTE:
Align the slot a on the needle jet with the projection b on the carburetor body.
3. Measure:
float height a
Out of specification Adjust.
Float height
8.0 9.0 mm
6-8
CARBURETORS
CARB
a. Hold the carburetor upside down.
b. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float.
NOTE:
The float arm should rest on the needle valve
without depressing it.
c. If the float height is not within specification,
inspect the needle valve seat and needle
valve.
d. If either the needle valve seat or needle valve
is worn, replace them both.
e. If both the needle valve seat and needle
valve are fine, adjust the float height by bending the float tang 1 .
f. Check the float height again.
4. Install:
coasting enricher diaphragm 1
coasting enricher spring 2
coasting enricher cover 3
NOTE:
Align the tab a on the coasting enricher diaphragm with the recess b in the carburetor
body.
5. Install:
piston valve
piston valve spring
vacuum chamber cover 1
NOTE:
Align the tab a on the vacuum chamber cover
with the recess in the carburetor body.
6. Install:
connecting bracket
NOTE:
After installing the connecting bracket check
that the throttle cable lever and starter plunger
link operate smoothly.
6-9
CARBURETORS
CARB
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 ENGINE IDLING
SPEED” in CHAPTER 3.
3. Adjust:
throttle cable free play
Throttle cable free play (at
the flange of the throttle grip)
4 6 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in CHAPTER 3.
EAS00495
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
fuel level a
Out of specification Adjust.
Fuel level (above the edge of
body b )
13.0 14.0 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 to the fuel drain
pipe 2 .
Fuel level gauge
YM-01312-A, 90890-01312
d. Loosen the fuel drain screw 3 .
6-10
CARBURETORS
CARB
e. Hold the fuel level gauge vertically next to the
edge of body 4 .
f. Measure the fuel level on both sides of the
carburetor assembly.
NOTE:
The fuel level readings should be equal on both
sides.
2. Adjust:
S 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.
EAS00502
CHECKING
AND
ADJUSTING
THROTTLE POSITION SENSOR
THE
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly adjusted.
1. Check:
S throttle position sensor
(with it installed on the carburetor)
a. Disconnect the throttle position sensor coupler.
b. Connect the pocket tester (Ω
1 k) to the
throttle position sensor.
Tester positive lead Blue 1
Tester negative lead Black 2
c. Check the throttle position sensor maximum
resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor
maximum resistance
4 X 6 kΩ at 20_C
(Blue X Black)
6-11
CARBURETORS
CARB
d. Connect the pocket tester (Ω
throttle position sensor.
1 k) to the
Tester positive lead Yellow 3
Tester negative lead Black 2
e. While slowly opening the throttle, check that
the throttle position sensor resistance is within the specified range.
NOTE:
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified.
Out of specification or the resistance changes
abruptly Go to step 2.
Throttle position sensor
resistance
0.6 X 5.7 kΩ at 20_C
(Yellow X Black)
2. Check:
S throttle position sensor
(with it removed from the carburetor)
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω
1 k) to the
throttle position sensor.
Tester positive lead Blue 1
Tester negative lead Black 2
d. Check the throttle position sensor maximum
resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor
maximum resistance
4 X 6 kΩ at 20_C
(Blue X Black)
e. Connect the pocket tester (Ω
1 k) to the
throttle position sensor’s coupler.
Tester positive lead Yellow 3
Tester negative lead Blue 1
f. While slowly opening the throttle, check that
the throttle position sensor resistance is within the specified range.
The resistance does not change or it
changes abruptly Replace the throttle
position sensor.
The slot is worn or broken 4 Replace the
throttle position sensor.
6-12
CARBURETORS
CARB
NOTE:
Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide -open throttle) may differ slightly from those specified.
Throttle position sensor
resistance
0.6 X 5.7 kΩ at 20_C
(Yellow X Blue)
3. Adjust:
S throttle position sensor angle
a. Disconnect the throttle position sensor coupler.
b. Connect the pocket tester (Ω
1 k) to the
throttle position sensor.
Tester positive lead Blue 1
Tester negative lead Black 2
c. Measure the throttle position sensor maximum resistance.
d. Calculate the throttle position sensor maximum resistance when the throttle is fully
closed.
Throttle position sensor maximum
resistance (throttle is fully closed) =
Maximum resistance
(0.13 – 0.15)
Example
If the maximum resistance = 5 kΩ, then the
throttle position sensor’s maximum resistance
when the throttle is fully closed should be:
5 kΩ
(0.13 – 0.15) = 650 – 750 Ω
e. Lift the carburetor assembly slightly out of
the intake manifolds.
f. Loosen the throttle position sensor screws
4
g. Connect the pocket tester (Ω
100) to the
throttle position sensor.
Tester positive lead Yellow 3
Tester negative lead Blue 1
h. Adjust the throttle position sensor angle so
that the measured resistance is within the
specified range.
Throttle position sensor
resistance
583 X 875 Ω
(Yellow X Blue)
i. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
6-13
CARBURETORS
CARB
EAS00504
CHECKING THE FUEL PUMP
1. Check:
fuel pump
a. Place a container under the end of the fuel
hose.
b. Start the engine and check if fuel flows from
the fuel hose 1 .
Fuel flows Fuel pump is OK
Fuel does not flow Replace the fuel pump
c. 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 the fuel pump
WARNING
Gasoline and its vapors are highly flammable and explosive. Therefore, keep gasoline away from fire, sparks or open flames
(e.g., welding equipment, lighted cigarettes).
Failure to check for gasoline leaks may result in fire or explosion.
6-14
CARBURETORS
CARB
EAS00505
CHECKING THE FUEL COCK
1. Check:
fuel lock
Cracks/damage/wear Replace.
EAS00506
CHECKING THE FUEL COCK OPERATION
NOTE:
After installing the fuel cock, check its operation.
1. Check that the fuel cock lever is positioned to
“ON” or “RES”.
2. Place a container under the end of the fuel
hose.
3. Check:
fuel cock operation
a. Suck on the end of the vacuum hose.
Fuel flows Fuel cock is OK
Fuel does not flow Replace the fuel cock
6-15
AIR INDUCTION SYSTEM
CARB
EB601000
AIR INDUCTION SYSTEM(AIS)
AIR INJECTION
This system burns the unburned exhaust gases
by injecting fresh air (secondary air) at the exhaust port. This is to reduce the output of the hydrocarbons.
When there is negative pressure around the exhaust port, the reed valve opens and the secondary air flows into the exhaust port.
The required temperature for burning the unburned exhaust gases is approximately 600_ to
700_C.
AIR CUT-OFF VALVE
The air cut-off valve is operated by intake gas
pressure through the diaphragm. Normally, this
valve is opened in order to allow fresh air to flow
into the exhaust port.
When the throttle is rapidly closed, negative
pressure is generated and the valve closes in
order to prevent after-burning.
VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the
valve will close.
VIEW 1. (NO FLOW)
VIEW 2. (FLOW)
During normal operation the valve is open.
A From the air filter
B To the reed valve
C To the carburetor joint
VIEW 2. (FLOW)
6-16
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1
2
3
4
5
Reed valve
Air cleaner
Air cutoff valve
Carburetor joint (cylinder #2)
Carburetor joint (cylinder #4)
A
B
C
D
E
F
6-17
To cylinder #1
To cylinder #2
To cylinder #3
To cylinder #4
To carburetor joint (#2)
To carburetor joint (#4)
CARB
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
hoses
Loose connection Connect properly.
Cracks/damage Replace.
pipes
Cracks/damage Replace.
2. Check:
air cutoff valve
Cracks/damage Replace.
6-18
CHAS
7
CHAS
CONTENTS
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . .
7-1
7-3
7-4
7-4
7-6
7-7
7-8
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . .
7-10
7-10
7-11
7-14
7-14
7-15
7-15
7-15
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . .
REMOVING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . .
INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . .
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . .
INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . .
INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . .
7-16
7-16
7-17
7-18
7-20
7-23
7-25
7-28
7-28
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
7-46
7-50
7-50
7-51
7-52
7-29
7-30
7-32
7-34
7-36
7-38
7-38
7-40
7-41
7-43
CHAS
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 7-55
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-56
7-56
7-58
7-58
7-59
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
7-61
7-61
7-63
7-63
7-64
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
7-66
7-66
7-68
7-68
7-69
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-70
7-70
7-72
7-72
7-73
SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION
AND INSPECTING THE SHAFT DRIVE FOR LEAKS . . . . . . . .
7-74
7-74
7-74
7-77
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT . . . . . . . . . . . . . . . . . . .
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT . . . . . . . . . . . . . . . . .
MEASURING THE RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . .
ADJUSTING THE RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . .
MEASURING THE RING-GEAR-TO-STOPPER-BOLT
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-78
7-78
7-79
7-80
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . .
REMOVING AND INSTALLING THE RING GEAR BEARINGS . . . .
ALIGNING THE FINAL DRIVE PINION GEAR AND RING
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-83
7-83
7-85
7-86
7-81
7-81
7-87
CHAS
CHECKING THE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
INSTALLING THE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
CHAS
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
25 Nm (2.5 mkg)
78 Nm (7.8 mkg)
23 Nm (2.3 mkg)
M8 25 (6)
19 Nm (1.9 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
M8 25 (6)
Order
Job/Part
Q’ty
Removing the front wheel and brake
discs
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.
2/2 NOTE:
Do not depress the brake lever when the
wheel is off of the motorcycle as the brake
pads will be forced shut.
1
Front brake calipers/brackets (left and
right)
2
3
Pinch bolt(front wheel axle)
Front wheel axle
1
1
4
Front wheel
1
7-1
Loosen
Elevate the front wheel. Place a suitable
stand under the engine.
FRONT WHEEL AND BRAKE DISCS
CHAS
“
25 Nm (2.5 mkg)
78 Nm (7.8 mkg)
23 Nm (2.3 mkg)
M8 25 (6)
19 Nm (1.9 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
M8 25 (6)
Order
5
6
7
8
Job/Part
Q’ty
Collars
Brake disc cover (left)
Brake discs
Brake disc cover (right-with weight)
2
1
2
1
Remarks
Refer to “INSTALLING THE FRONT
WHEEL”.
For installation, reverse the removal
procedure.
7-2
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00518
FRONT WHEEL
Order
Job/Part
Q’ty
Disassemble the parts in the order
listed.
Disassembling the front wheel
1
2
3
Remarks
Oil seals
Bearings
Spacer
2
2
1
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. Loosen
front wheel axle 1 .
3. Remove:
brake caliper
brake caliper bracket
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.
4. Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
EAS00525
CHECKING THE FRONT WHEEL
1. Check:
wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
tire
front wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-4
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits Replace.
Front wheel radial runout limit
1.0 mm
Front wheel lateral runout limit
0.5 mm
4. Check:
wheel bearings
Front wheel turns roughly or is loose Replace the wheel bearings.
oil seals
Damage/wear Replace.
5. Replace:
wheel bearings (New)
oil seals (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 with a general
bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
NOTE:
Use a socket 1 that matches the diameter of
the wheel bearing outer race and oil seal.
CAUTION:
Do not contact the wheel bearing center race
2 or balls 3 . Contact should be made only
with the outer race 4 .
7-5
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00531
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.
Brake disc deflection limit
(maximum)
Front: 0.15 mm
Rear: 0.15 mm
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 1 at a right angle
against the brake disc surface.
e. Measure the deflection 2 X 3 mm b below
the edge of the brake disc.
3. Measure:
brake disc thickness a
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Brake disc thickness limit
(minimum)
Front: 4.5 mm
Rear: 6.5 mm
4. Adjust:
brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
7-6
FRONT WHEEL AND BRAKE DISCS
CHAS
Brake disc bolt
23 Nm (2.3 mkg)
LOCTITE
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00544
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:
wheel axle
oil seal lips
Recommended lubricant
Lithium soap base grease
2. Install:
brake disc 1
brake disc cover 2
NOTE:
Apply LOCTITE 648 to the threads of the
brake disc bolts.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
3. Tighten:
wheel axle 1
wheel axle pinch bolt 2
78 Nm (7.8 mkg)
19 Nm (1.9 mkg)
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds smoothly.
4. Install:
brake caliper bracket 1
40 Nm (4.0 mkg)
brake caliper 2
25 Nm (2.5 mkg)
WARNING
Make sure that the brake hose is routed
properly.
7-7
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
S After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
S Adjust the front wheel static balance with the
brake discs installed.
1. Remove:
S balancing weight (-s)
NOTE:
Place the front wheel on a suitable balancing
stand.
2. Find:
S front wheel’s heavy spot
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 “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (b) through (d) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
3. adjust:
S 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.
7-8
FRONT WHEEL AND BRAKE DISCS
CHAS
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.
4. Check:
S front wheel static balance
a. Turn the front wheel and make sure that it
stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
7-9
REAR WHEEL AND BRAKE DISC
CHAS
EAS00551
REAR WHEEL AND BRAKE DISC
REAR FENDER
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Removing the rear fender
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.
Ride seat
1
2
3
4
5
Refer to ”RIDER AND PASSENGER
SEATS” in CHAPTER 3.
Refer to ”SADDLEBAGS” in CHAPTER3.
Antenna, trunk and saddlebags
Antenna lead
Tail/brake and flasher lights lead
coupler
Passenger footrests (left and right)
Side covers (left and right)
Rear fender assembly
1
1
2
2
1
Disconnect
For installation, reverse the removal
procedure.
7-10
REAR WHEEL AND BRAKE DISC
CHAS
EAS00560
REAR WHEEL AND BRAKE DISC
40 Nm (4.0 mkg)
150 Nm (1.5 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
Removing the rear wheel and brake
disc
Muffler (right)
Saddlebag guide bar (left and right)
Side cover (right)
Exhaust pipe
Rear brake caliper
1
1
1
1
1
6
7
8
Pinch bolt
Rear wheel axle nut
Washer
1
1
1
7-11
Remarks
Remove the parts in the order listed.
NOTE:
Do not depress the brake pedal when
removing the rear brake caliper.
Loosen
REAR WHEEL AND BRAKE DISC
CHAS
40Nm (4.0mkg)
150 Nm (1.5 mkg)
40Nm (4.0mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Remarks
NOTE:
Elevate the rear wheel. Place a suitable
stand under the engine.
Move the wheel to the right to separate it
from the final gear case.
9
Rear wheel axle
1
10
11
12
13
14
Washer
Rear brake caliper bracket
Rear wheel
Collar
Brake disc
1
1
1
1
1
For installation, reverse the removal
procedure.
7-12
REAR WHEEL AND BRAKE DISC
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
CHAS
Remarks
Disassemble the parts in the order listed.
Disassembling the rear wheel
Oil seal
Bearing
Collar
Oil seal
Bearing
Circlip
Clutch hub
Hub dust seal
Damper
O-ring
1
1
1
1
1
1
1
1
6
1
For assembly, reverse the disassembly
procedure.
7-13
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:
pinch bolt 1
4. Remove:
wheel axle nut 2
washer
wheel axle 3
Move the rear wheel to the right to separate it
from the final drive housing.
5. Remove:
rear wheel
EAS00565
CHECKING THE REAR WHEEL
1. Check:
wheel axle
rear wheel
wheel bearings
oil seals
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
2. Check:
tire
rear wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in CHAPTER 3.
3. Measure:
rear wheel radial runout
rear wheel lateral runout
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
7-14
REAR WHEEL AND BRAKE DISC
CHAS
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
2. Tighten:
wheel axle nut
pinch bolt
brake caliper bolts
150 Nm (15.0 mkg)
23 Nm (2.3 mkg)
40 Nm (4.0 mkg)
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
DISCS”.
7-15
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
25 Nm (2.5 mkg)
Order
1
2
3
Job/Part
Q’ty
Removing the front brake pads
Brake caliper retaining bolts
Brake caliper
Brake pads
Remarks
Remove the parts in the order listed
2
1
2
Refer to “REPLACING THE FRONT
BRAKE PADS”.
For installation, reverse the removal
procedure.
7-16
FRONT AND REAR BRAKES
CHAS
REAR BRAKE PADS
40 Nm (4.0 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
Removing the rear brake pad
Brake pad cover
Retaining clips
Retaining pins
Brake pad spring
Brake pads
1
2
2
1
2
6
Brake caliper
1
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE REAR
BRAKE PADS”.
NOTE:
When the brake pads have to be
replaced install a new brake pad spring.
Replace the brake pads as a set if either
is found to be worn to the wear limit.
For installation, reverse the removal
procedure.
7-17
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 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. Remove:
brake hose holder 1
brake caliper 2
7-18
FRONT AND REAR BRAKES
CHAS
2. Remove:
brake pads 1
(along with the brake pad shims)
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.6 mm
4. Install:
brake pad shims
(onto the brake pads)
brake pads
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.
Bleed screw
6 Nm (0.6 mkg)
d. Install new brake pad shims onto the new
brake pads.
e. Install new brake pads.
7-19
FRONT AND REAR BRAKES
CHAS
5. Install:
brake caliper retaining bolt
25 Nm (2.5 mkg)
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 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 pad cover 1
brake caliper 2
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
7-20
FRONT AND REAR BRAKES
CHAS
3. Remove:
brake pads 1
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 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.
Bleed screw
6 Nm (0.6 mkg)
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow mark a of the brake pad spring must
point in the direction of disc rotation.
7-21
FRONT AND REAR BRAKES
CHAS
6. Install:
brake pad pins
brake pad clips
brake pad cover
brake caliper
Brake caliper bolt
40 Nm (4.0 mkg)
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.
7-22
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
New
Order
Job/Part
Q’ty
Remove the parts in the order below.
NOTE:
Before removing the master cylinder,
drain the brake fluid from the entire
brake system.
Removing the front brake master
cylinder
1
2
3
4
5
6
7
8
Remarks
1
1
1
1
2
1
1
1
Rear view mirror
Brake lever
Union bolt
Brake hose
Copper washers
Master cylinder bracket
Master cylinder
Front brake switch
Refer to “REMOVING/INSTALLING THE
FRONT BRAKE MASTER CYLINDER”.
For installation, reverse the removal
procedure.
7-23
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the front brake
master cylinder
Master cylinder cap
Holder (diaphragm)
Master cylinder diaphragm
Dust boot
Circlip
Master cylinder kit
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-24
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
30 Nm (3.0 mkg)
New
52 Nm (5.2 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Before removing the master cylinder,
drain the brake fluid from the entire
brake system.
Removing the rear brake master
cylinder
1
2
3
4
5
6
7
Remarks
1
1
1
1
1
1
1
Rear brake switch
Brake hose
Copper washer
Brake pedal assembly
Master cylinder
Cotter pin
Washer
7-25
Disconnect
Disconnect
Refer to “REMOVING/INSTALLING THE
REAR BRAKE MASTER CYLINDER”.
FRONT AND REAR BRAKES
CHAS
30 Nm (3.0 mkg)
New
52 Nm (5.2 mkg)
23 Nm (2.3 mkg)
Order
8
9
10
11
Job/Part
Q’ty
Clevis pin
Reservoir hose
Reservoir tank cover
Reservoir tank
1
1
1
1
Remarks
Unhook from the clamps.
For installation, reverse the removal
procedure.
7-26
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Disassembling the rear brake master
cylinder
Dust boot
Circlip
Brake pedal push rod
Master cylinder kit
Cap (reservoir tank)
Diaphragm
Reservoir tank
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
7-27
FRONT AND REAR BRAKES
CHAS
EAS00588
REMOVING THE FRONT BRAKE MASTER
CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
brake switch 1
2. Remove:
union bolt 1
copper washers 2
brake hoses 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
REMOVING THE REAR BRAKE MASTER
CYLINDER
1. Remove:
brake pedal assembly 1
2. Remove:
joint 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.
7-28
FRONT AND REAR BRAKES
EAS00592
A
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 2
(brake master cylinder body)
Obstruction Blow out with compressed air.
A Front
B Rear
A
A
CHAS
2. Check:
brake master cylinder kit 1
Damage/scratches/wear Replace.
A Front
B Rear
B
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.
7-29
FRONT AND REAR BRAKES
CHAS
5. Check:
brake reservoir hose 1
Cracks/damage/wear Replace.
EAS00598
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
10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
copper washers 1 (New)
brake hose 2
union bolt 3
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
7-30
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 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.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
7-31
FRONT AND REAR BRAKES
CHAS
EAS00610
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
copper washers 1 (New)
brake hose 2
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2. Fill:
brake fluid reservoir
(to the maximum level mark a )
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 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.
7-32
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)
100 mm
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in CHAPTER 3.
7-33
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPERS
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
25 Nm (2.5 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Before removing the brake caliper, drain
the brake fluid from the entire brake
system.
Removing the front brake calipers
1
2
3
4
Brake hose holders
Union bolts
Copper washers
Brake hoses
2
2
4
2
5
6
Front brake calipers
Brake caliper brackets
2
2
Refer to “INSTALLING THE FRONT
BRAKE CALIPERS”.
NOTE:
Put the brake hose end into a container
and pump out the brake fluid carefully.
For installation, reverse the removal
procedure.
7-34
FRONT AND REAR BRAKES
CHAS
6 Nm (0.6 mkg)
Order
1
2
3
Job/Part
Q’ty
Remarks
Disassemble the parts in the order listed.
Disassembling the front brake
caliper
Air bleed screw
Caliper pistons
Caliper piston seals
1
8
4
7-35
Refer to “DISASSEMBLING THE FRONT
BRAKE CALIPERS
For assembly, reverse the disassembly
procedure.
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
NOTE:
Before removing the master cylinder, drain
the brake fluid from the entire brake
system.
Removing the rear brake caliper
1
2
3
Union bolt
Copper washers
Brake hose
1
2
1
4
Rear brake caliper
1
Refer to ”INSTALLING THE REAR
BRAKE CALIPER”.
NOTE:
Put the brake hose end into a container
and pump out the brake fluid carefully.
For installation, reverse the removal
procedure.
7-36
FRONT AND REAR BRAKES
CHAS
EAS00617
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
Disassembling the rear brake caliper
Brake pads cover
Brake pads
Air bleed screw
Caliper pistons
Caliper piston seals
7-37
Remarks
Disassemble the parts in the order listed.
1
2
1
4
8
Refer to “REAR BRAKE PADS”.
Refer to “DISASSEMBLING THE REAR
BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
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 one brake caliper piston with a
piece of wood a
b. Blow compressed air into the brake hose
joint opening b to force out the left side pistons from the brake caliper.
WARNING
Never try to pry out the brake caliper pistons.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
other side pistons from the brake caliper.
EAS00629
DISASSEMBLING THE REAR BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
7-38
FRONT AND REAR BRAKES
CHAS
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.
7-39
FRONT AND REAR BRAKES
CHAS
EAS00632
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
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.
A
B
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
brake caliper brackets 1
Cracks/damage Replace.
7-40
FRONT AND REAR BRAKES
CHAS
EAS00638
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
1. Install:
brake caliper bracket
40 Nm (40 mkg)
brake caliper 1
(temporarily)
copper washers (New)
brake hose 2
union bolt 3
30 Nm (30 mkg)
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 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
2. Remove:
brake caliper
7-41
FRONT AND REAR BRAKES
CHAS
3. Install:
brake pads
brake pad shim
25 Nm (2.5 mkg)
brake caliper
Refer to “REPLACING THE BRAKE PADS”.
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 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.
7-42
FRONT AND REAR BRAKES
CHAS
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
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
1. Install:
brake caliper 1
(temporarily)
copper washers (New)
brake hose 2
union bolt 3
30 Nm (3.0 mkg)
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 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
2. Remove:
brake caliper
7-43
FRONT AND REAR BRAKES
CHAS
3. Install:
brake pads
brake pad springs
brake pins
retaining clips
40 Nm (4.0 mkg)
brake caliper
Refer to “REPLACING THE BRAKE PADS”.
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 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.
7-44
FRONT AND REAR BRAKES
CHAS
7. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
7-45
FRONT FORK
CHAS
EAS00647
FRONT FORK
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Removing the front fork
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Refer to “FRONT AND REAR BRAKES”.
Refer to “FRONT WHEEL”.
Refer to “FRONT COWLING” in
CHAPTER 3.
Refer to “HANDLEBAR”.
Front brake calipers (left and right)
Front wheel
Front cowling
Handlebar
7-46
FRONT FORK
CHAS
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
1
Upper bracket
1
2
3
4
5
6
7
8
Upper fork covers
Upper fork cover spacers
Upper fork cover washers
Front fork pinch bolts (lower)
Front fork legs
Brake hose guides
Lower fork covers
2
2
2
4
2
2
2
Remarks
Refer to “CHECKING THE STEERING
HEAD” in CHAPTER 3.
Refer to “REMOVING/INSTALLING THE
FRONT FORK LEGS”.
Loosen.
For installation, reverse the removal
procedure.
7-47
FRONT FORK
CHAS
EAS00648
23 Nm (2.3 mkg)
20 Nm (2.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Disassemble the parts in the order listed.
Disassembling the front fork
Cap bolt
O-ring
Fork spring
Dust seal
Retaining clip
Bolt/gasket
Damper rod/rebound spring
Inner tube
Oil seal
Seal spacer
Remarks
1
1
1
1
1
1/1
1/1
1
1
1
7-48
Drain the fork oil.
Pump the fork tube several times to
remove the fork oil.
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
FRONT FORK
CHAS
23 Nm (2.3 mkg)
20 Nm (2.0 mkg)
Order
11
12
13
14
Job/Part
Q’ty
Outer tube bushing
Inner tube bushing
Oil flow stopper
Outer tube
1
1
1
1
Remarks
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT FORK
LEGS”.
For assembly, reverse the disassembly
procedure.
7-49
FRONT FORK
CHAS
EAS00649
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 motocycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
upper bracket
Refer to “STEERING HEAD”
3. Loosen:
lower bracket pinch bolt 1
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
4. Remove:
front fork leg
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
dust seal 1
oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
2. Remove:
damper rod bolt
NOTE:
While holding the damper rod with the damper
rod holder 1 and T-handle 2 , loosen the
damper rod bolt.
Damper rod holder
YM-01300-1, 90890-01294
T-Handle
YM-01326, 90890-01326
7-50
FRONT FORK
CHAS
3. 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.
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:
spring free length a
Over the specified limit Replace.
Spring free length limit
573 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.
7-51
FRONT FORK
CHAS
CAUTION:
The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
4. Check:
cap bolt O-ring
Damage/wear Replace.
EAS00658
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
Make sure that 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 that 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.
7-52
FRONT FORK
CHAS
2. Lubricate:
inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil 5W
or equivalent
3. Tighten:
damper rod bolt
LOCTITE 204
20 Nm (2.0 mkg)
NOTE:
While holding the damper rod with the damper
rod holder and T-handle, tighten the damper rod
bolt.
Damper rod holder
YM-01300-1, 90890-01294
T-handle
YM-01326, 90890-01326
4. Install:
outer tube bushing 1
(with the fork seal driver weight 2 and adapter 3 )
Fork seal driver weight
YM-33963, 90890-01367
Adapter
YM-8020, 90890-01374
5. Install:
washer
oil seal 1
(with the fork seal driver weight and adapter)
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, apply lithium soap
base grease onto its lips.
Apply fork oil onto the outer surface of the inner
tube.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag a to protect
the oil seal during installation.
7-53
FRONT FORK
CHAS
6. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube groove.
7. Install:
dust seal 1
(with the fork seal driver weight)
8. Fill:
front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.553 L
Front fork leg oil level (from the
top of the inner tube, with the
inner tube fully compressed, and
without the fork spring)
117 mm
Recommended oil
Yamaha fork and shock oil 5W
or equivalent
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.
9. Install:
spring 1
cap bolt 2
NOTE:
Install the spring with the smaller pitch facing
down.
Before installing the cap bolt, apply grease
onto the O-ring.
Temporarily tighten the cap bolt.
7-54
FRONT FORK
CHAS
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
front fork leg
Temporarily tighten the lower bracket pinch
bolts.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar holder.
2. Install:
upper bracket
Temporarily tighten the steering stem nut.
3. Tighten
lower bracket pich bolt
20 Nm (2.0 mkg)
4. remove
upper bracket
5. Install
upper fork cover 1
upper bracket 2
10 Nm (1.0 mkg)
6. Tighten
cap bolt 3
23 Nm (2.3 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
7. Adjust:
spring preload
Refer “ADJUSTING THE FRONT FORK” in
CHAPTER 3.
7-55
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
28 Nm (2.8 mkg)
M8 25 (4)
10 Nm (1.0 mkg)
M6 25
32 Nm (3.2 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed .
Stand the motorcycle on a level surface.
Removing the handlebar
WARNING
Securely support the motorcycle so
that there is no danger of it falling over.
1
2
Plastic locking ties
Front brake master cylinder
4
1
3
4
Handlebar switch (right)
Throttle grip
1
1
7-56
Refer to “FRONT AND REAR BRAKES”.
Refer to ”INSTALLING THE HANDLEBAR”.
HANDLEBAR
CHAS
23 Nm (2.3 mkg)
M8 25 (4)
10 Nm (1.0 mkg)
M6 25
35 Nm (3.5 mkg)
Order
5
6
7
8
9
10
11
Job/Part
Q’ty
1
1
1
1
2
1
2
Clutch master cylinder
Clutch switch coupler
Handlebar switches (left)
Grip (left)
Handlebar bracket (upper)
Handlebar
Handlebar bracket (lower)
Remarks
Refer to “CLUTCH” in CHAPTER 4.
Disconnect
Refer to “INSTALLING THE HANDLEBAR”.
For installation, reverse the removal
procedure.
7-57
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is not danger of it falling over.
2. Remove:
throttle cable housing 1
throttle grip 2
3. Remove:
left 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. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
handlebar 1
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
3. Install:
handlebar grip
a. Apply a light coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
7-58
HANDLEBAR
CHAS
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.
EAS00672
INSTALLING 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. Install:
handlebar 1
upper handlebar holders 2
28 Nm (2.8 mkg)
CAUTION:
First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
Align the match marks a on the handlebar with
the upper surface of the lower handlebar holders.
3. Install:
throttle grip 1
throttle cables
7-59
HANDLEBAR
CHAS
a. Installing the throttle cable 1 on cruise control rotor No.4
b. Installing the throttle cable 2 on cruise control rotor No.3
c. Installing the throttle 3 on cruise control rotor No.2
d. Installing the throttle cable 4 on cruise control rotor No.1
WARNING
Pay attention to the mark on throttle cable 1
X 4 and throttle rotor 5 , when installing.
6 Throttle grip
7 Carburetor
8 Cruise control actuator
4. Install:
right handlebar switch
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.
5. Install:
left handlebar switch
NOTE:
Align the mating surfaces of the left handlebar
switch with the punch mark a on the handlebar.
6. Install:
brake master cylinder
Refer to “FRONT AND REAR BRAKES”.
7. Adjust:
throttle cable free play
cruise control 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)
4 X 6 mm
Cruise control cable free play
1 X 2 mm
7-60
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
130 Nm (13.0 mkg)
1st.
2nd.
Order
52 Nm (5.2 mkg)
3 Nm (0.3 mkg)
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Removing the steering head
WARNING
Securely support the motorcycle so
that there is no danger of it falling over.
Refer to “RIDER AND PASSENGER
SEATS” and “FUEL TANK” in
CHAPTER 3.
Refer to “HANDLEBAR”.
Refer “FRONT COWLING” in CHAPTER 3.
Refer to“FRONT FORK”.
Disconnect
Rider seat, fuel tank
1
2
Handlebar
Front cowling
Front wheel, front forks
Leads (to the front cowling body)
Chrome flasher bracket cover
1
7-61
STEERING HEAD
CHAS
130 Nm (13.0 mkg)
1st.
2nd.
Order
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
52 Nm (5.2 mkg)
3 Nm (0.3 mkg)
Job/Part
Q’ty
Remarks
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
Refer to “REMOVING THE LOWER
BRAKET/INSTALLING THE STEERING
HAND”.
Flasher light bracket assembly
Brake hose joint
Brake hose guide
Steering stem nut
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Bearing cover
Bearing (upper)
Bearing races
Lower bracket
Bearing (lower)
Rubber seal
For installation, reverse the removal
procedure.
7-62
STEERING HEAD
CHAS
EAS00679
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:
upper ring nut 1
lower ring nut 2
NOTE:
Hold the lower ring nut with the exhaust and
steering nut wrench, then remove the upper ring
nut with the ring nut wrench.
Exhaust and steering nut wrench
90890-01268
Ring nut wrench
YU-33975, 90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
bearing
Recommended cleaning solvent
Kerosine
2. Check:
bearing 1
bearing races
Damage/pitting Replace.
7-63
STEERING HEAD
CHAS
3. Replace:
bearing balls
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 dust seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damage.
NOTE:
Always replace the bearing balls and bearing
races as a set.
Whenever the steering head is disassembled,
replace the dust 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. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “INSPECTING THE STEERING
HEAD” in chapter 3.
7-64
STEERING HEAD
CHAS
3. Install:
upper bracket
steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
7-65
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
59 Nm (5.9 mkg)
48 Nm (4.8 mkg)
50 Nm (5.0 mkg)
50 Nm (5.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Removing the rear shock absorber
assembly
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “ENGIEN REMOVAL” in
CHAPTER 4.
Rear fender and rear wheel
Muffler
1
2
3
Bolt (shock absorber-frame)
Bolt (shock absorber-relay arm)
Rear shock absorber
4
5
Bolt (connecting arm-relay arm)
Bolt (connecting arm-swingarm)
1
1
1
1
1
1
7-66
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
REAR SHOCK ABSORBER ASSEMBLY
CHAS
59 Nm (5.9 mkg)
48 Nm (4.8 mkg)
50 Nm (5.0 mkg)
50 Nm (5.0 mkg)
Order
6
7
8
Job/Part
Q’ty
Connecting arms
Bolt (relay arm -frame)
Relay arm
Remarks
2
1
1
For installation, reverse the removal
procedure.
7-67
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
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:
rear shock absorber assembly
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND RELAY ARM
1. Check:
rear shock absorber
Gas leaks/oil leaks ! Replace the rear
shock absorber assembly.
bushings
Damage/wear ! Replace.
bolts
Bends/damage/wear ! Replace.
2. Check:
relay arm
Cracks/damage ! Replace.
3. Check:
connecting arms
Cracks/damage ! Replace.
7-68
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00698
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
1. Lubricate:
spacers
bearings
Recommended lubricant
Molybdenum disulfide grease
2. Install:
rear shock absorber assembly
Rear shock absorber assembly
upper nut 1
59 Nm (5.9 mkg)
Rear shock absorber assembly
lower nut 2
50 Nm (5.0 mkg)
Relay-arm-to-frame-nut 3
50 Nm (5.0 mkg)
NOTE:
When installing the rear shock absorber assembly, lift up the swingarm.
Install the connecting arm front bolt from the
right.
7-69
SWINGARM
CHAS
EAS00701
SWINGARM
SWINGARM
100 Nm (10.0 mkg)
42 Nm (4.2 mkg)
(4)
16 Nm (1.6 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Stand the motorcycle on a level surface.
Removing the swingarm
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Rear fender and rear wheel
Rear shock absorber
1
2
3
4
5
1
1
1
3
1
Speedometer sensor
Final gear case
Drive shaft
Brake hose holder
Speedometer sensor leads
7-70
Unhook from the cable guide.
SWINGARM
CHAS
100 Nm (10.0 mkg)
42 Nm (4.2 mkg)
(4)
16 Nm (1.6 mkg)
Order
6
7
Job/Part
Q’ty
Remarks
2
1
Refer to “REMOVING THE SWINGARM”.
Pivot shafts (right and left)
Swingarm
For installation, reverse the removal
procedure.
7-71
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. Check:
swingarm side play A
swingarm vertical movement B
a. Check the tightening torque of the swingarm
pivot bolts and locknut.
Locknut
100 Nm (10.0 mkg)
Left pivot bolt
100 Nm (10.0 mkg)
Right pivot bolt
7 Nm (0.7 mkg)
b. Check the swingarm side play A 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 B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers and
bearings.
EAS00708
CHECKING THE SWINGARM
1. Check:
swingarm
Bends/cracks/damage Replace.
7-72
SWINGARM
CHAS
2. Check:
left pivot bolt
right pivot bolt
Damage/wear Replace.
3. Check:
spacers 1
oil seals 2
bearings 3
universal joint boot 4
Damage/wear Replace.
EAS00712
INSTALLING THE SWINGARM
1. Lubricate:
drive shaft splines
Recommended lubricant
Lithium soap base grease
2. Lubricate:
bearings
spacers
oil seals
Recommended lubricant
Molybdenum disulfide grease
7-73
SHAFT DRIVE
CHAS
SHAFT DRIVE
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
A
Symptoms
B
1.A Pronounced hesitation of jerky movement
during acceleration, deceleration, or sustained
speeds (This must not 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 area
3.A locked-up condition of the shaft drive mechanism or no power transmitted from the engine
to the rear wheel
Possible Causes
A. Bearing damage
B. Improper gear lash
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 these components are damaged, remove them for individual inspection.
7-74
SHAFT DRIVE
CHAS
Inspection notes
1. Investigate any unusual noises.
The following noises may indicate a mechanical defect:
a. A rolling “rumble” during coasting, acceleration, or deceleration. The noise increases
with 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,
too little gear lash
CAUTION:
Insufficient gear lash is extremely destructive to the gear teeth. If a test ride following
reassembly indicates this condition, stop
riding immediately to minimize gear damage.
c. A slight “clunk” evident at low speed operation. This noise must be distinguished from
normal motorcycle operation.
Diagnosis: Possible broken gear teeth
WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result
in a locking of the shaft drive assembly,
causing loss of control of the motorcycle
and possible injury to the rider.
2. Check:
drained oil
Drained oil contains a large amount of metal
particles Check the bearing for seizure.
NOTE:
A small amount of metal particles in the oil is
normal.
7-75
SHAFT DRIVE
CHAS
EAS00716
Troubleshooting chart
When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section
exist, check following points.
YES
Place the motorcycle on a suitable stand so
that the front wheel is elevated and then spin
the front wheel. Is the wheel bearing damaged?
Replace the wheel bearing.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
NO
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?
Rear wheel bearings and shaft drive bearings
are probably not damaged.
Repeat the test or remove and check the
components.
YES
YES
Remove the rear wheel. Is the wheel bearing
damaged?
Replace the rear wheel bearing.
Refer to “REAR WHEEL AND BRAKE
DISCS”.
NO
Remove and check the drive shaft components.
7-76
SHAFT DRIVE
CHAS
EAS00717
CHECKING THE FINAL DRIVE OIL FOR
CONTAMINATION AND INSPECTING 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.
7-77
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
CHAS
EAS00718
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
42 Nm (4.2 mkg)
Order
Job/Part
Q’ty
Removing the final drive assembly
and drive shaft
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.
Rear fender and rear wheel
1
2
3
Refer to “REAR WHEEL AND BRAKE
DISC”.
Speedometer sensor
Final gear assembly
Drive shaft
1
1
1
For installation, reverse the removal
procedure.
7-78
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
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 X 0.2 mm
a. Install a bolt 1 of the specified size, into the
final drive oil filler hole.
b. Finger tighten the bolt until it stops the ring
gear from moving.
1.5 mm
14 mm
NOTE:
Do not overtighten the bolt.
100 mm
c. Install the special tool 2 and dial gauge 3 .
Final gear backlash band
YM-01230, 90890-01230
3 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, special tool, and
bolt.
7-79
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
CHAS
g. Rotate the final drive pinion gear 90_.
h. Reinstall the bolt, special tool, and dial
gauge.
i. Repeat steps (d) to (h) three more times
(for a total of four measurements).
j. If any of the readings are over specification,
adjust the ring gear backlash.
EAS00720
ADJUSTING THE RING GEAR BACKLASH
1. Remove:
S ring gear bearing housing nuts
S 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. Remove
S ring gear bearing housing 1
Remove the ring gear bearing housing off the
final gear case by using a flat head screw
driver at grooves a .
CAUTION:
S Do not use a driver at any other part than .
S Do not damage the joint surface of the final
gear case.
3. Remove:
S final gear housing rim 1
S ring gear 2
S ring gear shim(-s) 3
S thrust washer 4
3. Adjust:
S ring gear backlash
a. Use the following chart to select the suitable
shim(-s) and thrust washer.
Thinner shim Ring gear backlash is increased.
Thicker shim Ring gear backlash is decreased.
7-80
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
CHAS
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)
0.30, 0.40, 0.50
Thrust washers
Thickness (mm)
1.2, 1.4, 1.6, 1.8, 2.0
EAS00721
MEASURING THE RING-GEAR-TO-STOPPER-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
0.3 X 0.6 mm
1 Ring gear
2 Stopper bolt
3. Install:
ring gear bearing housing
(along with the ring gear)
EAS00722
ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE
1 Remove:
ring gear 1
stopper bolt 2
stopper bolt shim(-s) 3
4 ring gear bearing housing
7-81
FINAL DRIVE ASSEMBLY AND DRIVE SHAFT
CHAS
Select:
stopper bolt shim(-s)
Stopper bolt shims
thickness (mm) 0.10, 0.15, 0.20, 0.30,
0.40, 0.50
2. Install:
stopper bolt shim(-s) 1
stopper bolt 2
9 Nm ( 0.9 mkg)
ring gear 3
4 Ring gear bearing housing
CAUTION:
Apply LOCTITE onto the stopper bolt.
3. Measure:
ring-gear-to-stopper-bolt clearance
NOTE:
If the ring-gear-to-stopper-bolt clearance is out
of specification, repeat the above procedure.
7-82
FINAL DRIVE
CHAS
EAS00723
FINAL DRIVE ASSEMBLY
23 Nm (2.3 mkg)
9 Nm (0.9 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
110 Nm (11.0 mkg)
110 Nm (11.0 mkg)
42 Nm (4.2 mkg)
Order
Job/Part
1
2
Disassembling the final drive
assembly
Nuts (bearing housing)
Bolts (bearing housing)
3
4
5
6
7
8
9
Bearing housing
Dust cover
Shim(s)
Thrust washer
Self-locking nut (gear coupling)
Gear coupling
Bearing retainer (final drive shaft)
Q’ty
Remarks
Disassemble the parts in the order listed
NOTE:
Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the bolts
are loosened, remove them.
1
1
1
1
1
1
7-83
Refer to “DISASSEMBLING THE FINAL
DRIVE ASSEMBLY/ALIGHING THE FINAL
DRIVE PINION GEAR AND RING GEAR”.
FINAL DRIVE
CHAS
23 Nm (2.3 mkg)
9 Nm (0.9 mkg)
40 Nm (4.0 mkg)
23 Nm (2.3 mkg)
110 Nm (11.0 mkg)
110 Nm (11.0 mkg)
42 Nm (4.2 mkg)
Order
Job/Part
10
11
12
Shim(s)
Final drive shaft assembly
Final drive shaft roller bearing
13
14
Ring gear stopper
Shim(s)
Q’ty
1
1
Remarks
Refer to “REMOVING AND INSTALLING
THE RING GEAR BEARINGS”.
1
For assembly, reverse the disassembly
procedure.
7-84
FINAL 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. Remove:
self-locking nut
gear coupling
(with the special tool 1 )
Final drive shaft holder
YM-01229, 90890-01229
3. Remove:
bearing retainer
(with the special tool 1 )
Final drive shaft bearing
retainer wrench
YM-04050, 90890-04050
CAUTION:
The bearing retainer has left-hand threads.
To loosen the bearing retainer, turn it clockwise.
4. Remove:
final drive pinion gear
WARNING
Always use new bearings.
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.
7-85
FINAL DRIVE
CHAS
EAS00725
REMOVING AND INSTALLING THE RING
GEAR BEARINGS
1. Remove:
S collar 1
S oil seal 2
S bearing 3
(With an appropriate press tool 4 and an appropriate support for the final drive housing)
2. Check:
S bearing
Damage Replace.
3. Remove:
S bearing 1
a. Heat the final gear case 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.
4. Install:
S bearing (New) 1
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.
7-86
FINAL DRIVE
CHAS
5. Install:
collar 1
oil seal 2 (New)
bearing 3
(with an appropriate press tool 4 and press)
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
any bearing
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 = (87 + a /100) - (86 + b /100)
7-87
FINAL DRIVE
CHAS
Where:
a = a numeral (positive or negative) on the ring
gear, to be divided by 100 and added to “87”
b = a numeral on the final drive housing, to be
divided by 100 and added to “86”
Example:
If the final drive pinion gear is marked “+01” and
the final drive housing is marked “50”:
A = (87 + 1/100) - (86 + 50/100)
= (87 + 0.01) - (86 + 0.05)
= 87.01 - 86.50
= 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)
0.30, 0.40 0.50
Since the final drive pinion gear shims are only
available in 0.10-mm increments, round off to
the hundredths digit.
Hundredths
Rounded value
0, 1, 2, 3, 4
0
5, 6, 7, 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
7-88
FINAL DRIVE
CHAS
Ring gear bearing thickness “f”
13 mm
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)
0.30, 0.40, 0.50
Since the ring gear shims are only available in
0.10-mm increments, round off the hundredths
digit.
Hundredths
Rounded value
0, 1, 2, 3, 4
0
5, 6, 7, 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.
2. Install:
shims (as calculated)
final drive pinion gear
bearing retainer
110 Nm (11.0 mkg)
(with the bearing retainer wrench)
CAUTION:
The bearing retainer has left-hand threads.
To tighten the bearing retainer, turn it counterclockwise.
Bearing retainer wrench
YM-04050, 90890-04050
7-89
FINAL DRIVE
CHAS
3. Install:
gear coupling
110 Nm (11.0 mkg)
self-locking nut
(with the special tool 1 )
Coupling gear/middle shaft tool
YM-01229, 90890-01229
CAUTION:
Apply LOCTITE to the self-locking nut.
4. Install:
ring gear bearing housing
(along with the ring gear, but without the
thrust washer)
5. Adjust:
ring gear backlash
Refer to “MEASURING THE RING GEAR
BACKLASH” and “ADJUSTING THE RING
GEAR BACKLASH”.
6. Measure:
ring-gear-to-thrust-washer clearance
a. Remove the ring gear bearing housing
(along with the ring gear).
b. Place four pieces of Plastigauge between
the original thrust washer and the ring gear.
c. Install the ring gear bearing housing and
tighten the bolts and nuts to specification.
Ring gear housing bolt
40 Nm (4.0 mkg)
Ring gear bearing housing nut
23 Nm (2.3 mkg)
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
0.1 X 0.2 mm
f. If the ring-gear-to-thrust-washer clearance is
within specification, install the ring gear bearing housing (along with the ring gear).
7-90
FINAL DRIVE
CHAS
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, 20
Repeat the measurement steps until the ringgear-to-thrust-washer clearance is within the
specified limits.
Ring-gear-to-thrust-washer
clearance
0.1 X 0.2 mm
EAS00727
CHECKING THE DRIVE SHAFT
1. Check:
drive shaft splines
Damage/wear Replace the drive shaft.
EAS00728
INSTALLING THE DRIVE SHAFT
1. Lubricate:
drive shaft splines
Recommended lubricant
Molybdenum disulfide grease
2. Apply:
sealant
(onto both final drive housing mating surfaces)
Quickgasket
ACC-11001-15-01
Yamaha bond No.1215
90890-85505
3. Install:
drive shaft
(to the final drive pinion gear)
7-91
FINAL DRIVE
CHAS
4. Install:
drive shaft
NOTE:
Align the drive shaft splines with the driven yoke
to the universal joint.
5. Tighten:
final bearing housing nuts
42 Nm (4.2 mkg)
6. Install:
rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
7-92
–
ELEC
+
8
ELEC
CONTENTS
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . .
TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . .
8-5
8-5
8-5
8-7
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13
8-13
8-14
8-15
8-18
8-20
8-21
8-22
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
8-26
8-26
8-27
8-28
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-43
8-43
8-44
8-45
8-47
ELEC
CARBURETOR HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
AUDIO SYSTEM CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8-53
CRUISE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-62
8-62
8-64
8-65
8-66
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“SET”/“RES” INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-75
8-77
8-80
8-82
8-84
8-86
8-72
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Front brake switch
Clutch switch
Thermo unit
Fuel sender
TPS (throttle position sensor)
Ignition coil
Spark plug
Ignitor unit
9
10
11
12
13
14
15
16
Battery
Fuse (main)
Starter relay
Speed sensor
Neutral switch
Oil level switch
Pickup coil
Sidestand switch
for EUR
for OCE
8-1
17
18
19
20
21
22
23
24
25
26
Rear brake switch
Flasher relay
Starting circuit cut-off relay
Rectifier/ regulator
Horn 2
Fan motor
Thermo switch
Main switch
Brake light relay (blue)
Cruise control relay (white)
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:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity, between brown/blue and
red, and between blue/yellow and blue/black
when the switch is set to “ON”.
8-2
SWITCH INSPECTION
ELEC
EAS00731
SWITCH CONTINUITY INSPECTION
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 the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
for EUR
1
2
3
4
5
6
Dimmer switch
Horn switch
Turn signal switch
Pass switch
Clutch switch
Main switch
7
8
9
10
11
12
Front brake switch
Gruise control switch
“CANCEL” switch
Engine stop switch
Start switch
Light switch
8-3
13
14
15
16
17
Emargency stop switch
Side stand switch
Neutral switch
Rear brake switch
Oil level switch
SWITCH INSPECTION
ELEC
for OCE
1
2
3
4
5
6
Dimmer switch
Horn switch
Turn signal switch
Pass switch
Clutch switch
Main switch
7
8
9
10
11
12
Front brake switch
Gruise control switch
“CANCEL” switch
Engine stop switch
Start switch
Emargency stop switch
8-4
13
14
15
16
Side stand switch
Neutral switch
Rear brake switch
Oil level switch
CHECKING THE BULBS AND BULB SOCKETS
ELEC
EAS00732
CHECKING THE
BULB SOCKETS
BULBS
AND
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.
Incorrect continuity reading 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 headlights and
usually use a bulb holder which must be detached before removing the bulb. The majority
of these bulbs can be removed from their respective socket by turning them counterclockwise.
Bulb 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
8-5
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:
bult (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 tester positive probe to terminal
1 and the tester negative probe to terminal
2 , and check the continuity.
b. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
8-6
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.
8-7
IGNITION SYSTEM
ELEC
DAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
4
5
6
13
14
15
23
25
28
65
8-8
Main switch
Battery
Fuse (main)
Ignitor
Ignition coil
Spark plug
Engine stop switch
Fuse (ignition)
Pick up coil
Neutral switch
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S 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. Starting circuit cut-off relay (diode)
12. Wiring connections
(of the entire ignition system)
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
S Clean the battery
terminals.
S Recharge or replace
the battery.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Rider and passenger seats
2) Side cover (left and right)
3) Front cowling
S Troubleshoot with the following special
tool(-s).
EAS00741
3. Spark plugs
S The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in CHAPTER 3.
Dynamic spark tester
YM-34487
Ignition checker
90890-60754
Pocket tester
YU-03112, 90890-03112
Standard spark plug
DPR8EA-9 (NGK)
X24EPR-U9 (DENSO)
Spark plug gap
0.8 X 0.9 mm
EAS00738
S Is the spark plug in good condition, it is of the
correct type, and its gap within specification?
1. Main and ignition fuses
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main and ignition fuses OK?
YES
NO
YES
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(-s).
8-9
ELEC
IGNITION SYSTEM
EAS00743
Spark plug cap resistance
10 kΩ at 20_C
4. Ignition spark gap
S The following procedure applies to all of the
spark plugs.
S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker/dynamic
spark tester 1 as shown.
2 Spark plug cap
S Set the main switch to “ON”.
S Measure the ignition spark gap a .
S Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
S Is the spark plug cap OK?
YES
NO
Replace the spark
plug cap.
EAS00747
6. Ignition coil resistance
S The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil leads from the
wire harness.
S Connect the pocket tester (Ω
1) to the
ignition coil as shown.
Tester positive probe red/black
Tester negative probe orange (gray)
Minimum ignition spark gap
0.8 mm
S Is there a spark and is the spark gap within
specification?
NO
S Measure the primary coil resistance.
YES
Primary coil resistance
3.57 X 4.83 Ω at 20_C
The ignition system
is OK.
S Connect the pocket tester (Ω
1k) to the
ignition coil as shown.
S Measure the secondary coil for the specified
resistance.
EAS00745
5. Spark plug cap resistance
Tester posltlve probe red/black
Tester negative probe spark plug lead
S The following procedure applies to all of the
spark plug caps.
S Remove the spark plug cap.
S Connect the pocket tester (Ω 1k range) to
the spark plug cap as shown.
S Measure the spark plug cap resistance.
8-10
IGNITION SYSTEM
ELEC
EAS00750
Secondary coil resistance
10.71 X 14.49 kΩ at 20_C
9. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
S Is the ignition coil OK?
YES
NO
YES
Replace the ignition
coil.
NO
Replace the right
handlebar switch.
EAS00748
7. Pickup coil resistance
EAS00751
S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester (Ω
100) to the
pickup coil terminal as shown.
10. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
Tester positive probe – green/yellow 1
Tester negative probe – black 2
YES
NO
Replace the neutral
switch.
EAS00753
12. Starting circuit cut-off relay (diode)
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.
S Check the starting circuit cut-off relay for
continuity.
S Measure the pickup coil resistance.
Pickup coil resistance
189 X 231 Ω at 20_C
(between gray and black)
S Is the pickup coil OK?
YES
NO
Replace the pickup
coil.
EAS00749
8. Main switch
No
continuity
Tester positive probe light green 1
Tester negative probe blue/yellow 2
Continuity
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
Tester positive probe blue/yellow 1
Tester negative probe light green 2
S Are the tester readings correct?
NO
YES
Replace the main
switch.
NO
Replace the starting
circuit cut-off relay.
8-11
IGNITION SYSTEM
EAS00754
13. Wiring
Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the ignition system’s wiring properly connected and without defects?
NO
Properly connect or
repair the ignition
system’s wiring.
YES
Replace the ignitor
unit.
8-12
ELEC
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
4
5
6
7
8
10
11
23
24
25
26
49
65
8-13
Main switch
Battery
Fuse (main)
Starter relay
Starter motor
Starting circuit cutoff relay
Diode
Engine stop switch
Start switch
Fuse (ignition)
Side stand switch
Clutch switch
Neutral switch
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 neutral relay prevents the starter motor
from operating when neither of these conditions
has been met. In this instance, the neutral relay
is open so current cannot reach the starter motor. When at least one of the above conditions
has been met the neutral relay is closed and the
engine can be started by pressing the start
switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1 Battery
2 Fuse (main)
3 Main switch
4 Fuse (ignition)
5 Engine stop switch
6 Starting circuit cutoff relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
8-14
ELECTRIC STARTING SYSTEM
ELEC
EAS00739
EAS00757
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
The starter motor fails to turn.
Check:
1. Main and ignition fuses
2. Battery
3. Starter motor
4. Starting circuit cut-off relay
5. Starter relay
6. Main switch
7. Engine stop switch
8. Neutral switch
9. Sidestand switch
10. Clutch switch
11. Start switch
12. Wiring connections
(of the entire starting system)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00758
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Rider and passenger seats
2) Fuel tank
3) Front cowling
S Troubleshoot with the following special tool(-s).
3. Starter motor
S Connect the battery positive terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
YU-03112, 90890-03112
EAS00738
1. Main and ignition fuses
WARNING
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S A wire that is used as a jumper lead must
have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
S This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
S Are the main and ignition fuses OK?
YES
NO
S Does the starter motor turn?
Replace the fuse (-s).
YES
NO
Repair or replace the
starter motor.
8-15
ELEC
ELECTRIC STARTING SYSTEM
EAS00759
Does the starter relay have continuity between red and black?
4. Starting circuit cut-off relay
Disconnect the starting circuit cut-off relay
coupler from the wire harness.
Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay
coupler as shown.
YES
NO
Replace the starter
relay.
Battery positive terminal red/black 1
Battery negative terminal black/yellow 2
EAS00749
6. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Tester positive probe blue 3
Tester negative probe black 4
Is the main switch OK?
YES
NO
Replace the main
switch.
EAS00750
7. Engine stop switch
Does the starting circuit cut-off relay have
continuity between blue and black?
YES
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
NO
Is the engine stop switch OK?
Replace the starting
circuit cut-off relay.
YES
NO
Replace the right
handlebar switch.
EAS00761
5. Starter relay
Disconnect the starter relay coupler from the
wire harness.
Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as
shown.
EAS00751
8. Neutral switch
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
Battery positive terminal blue 1
Battery negative terminal red/white 2
YES
Tester positive probe red 3
Tester negative probe black 4
NO
Replace the neutral
switch.
8-16
ELECTRIC STARTING SYSTEM
EAS00752
9. Sidestand switch
Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES
NO
Replace the sidestand switch.
EAS00763
10. Clutch switch
Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the clutch switch OK?
YES
NO
Replace the clutch
switch.
EAS00764
11. Start switch
Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
12. Wiring
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly connected and without defects?
YES
The starting system
circuit is OK?
NO
Properly connect or
repair the starting
system’s wiring.
8-17
ELEC
ELECTRIC STARTING SYSTEM
ELEC
STARTER MOTOR
7 Nm (0.7 mkg)
M5 110 (2)
10 Nm (1.0 mkg)
M6 25 (1)
M6 55 (1)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “REMOVING THE ENGINE” in
CHAPTER 4.
Removing the starter motor
Exhaust pipe assembly
1
2
Starter motor lead
Starter motor/O-ring
Remarks
1
1/1
For installation, reverse the removal
procedure.
8-18
ELECTRIC STARTING SYSTEM
ELEC
7 Nm (0.7 mkg)
M5 110 (2)
10 Nm (1.0 mkg)
M6 25 (1)
M6 55 (1)
Order
Job/Part
1
2
3
4
5
Disassembling the starter motor
Front bracket
Washer kit
Rear bracket
Washer kit
Brush seat/Brush #1
6
Armature coil
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
2
1
1/1
Refer to “ASSEMBLING THE STARTER
MOTOR”.
NOTE:
Be sure to remove the installation nut on
brush #1 first.
1
For assembly reverse the disassembly
procedure.
8-19
ELECTRIC STARTING SYSTEM
ELEC
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Commutator wear limit
27 mm
3. Measure:
S mica (insulation) undercut a
Out of specification Scrape the mica (insulation) to the proper measurement with a
hacksaw blade which has been grounded to
fit the commutator.
Mica (insulation) undercut
0.7 mm
NOTE:
The mica (insulation) of the commutator must
be undercut to ensure proper operation of the
commutator.
4. Measure:
S armature coil resistances (continuity and insulation)
Out of specification Replace the starter
motor.
a. Check the continuity resistance 1 and mica
(insulation) resistances 2 with a pocket tester.
Pocket tester
YU-03112, 90890-03112
b. Measure the armature coil resistances.
Armature coil continuity resistance
0.015 X 0.025 Ω at 20_C
Armature coil insulation resistance
Above 1MΩ at 20_C
c. If any resistance is out of specification, replace the starter motor.
8-20
ELECTRIC STARTING SYSTEM
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
Fatigue/out of specification Replace the
brush springs as a set.
Brush spring force
570 X 920 N
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing 1
oil seal 2
bushing 3
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 rear cover.
2. Install:
washers 1
armature coil 2
o-ring 3
rear bracket 4
NOTE:
To prevent damaging the brushes during installation push down on the brush springs.
8-21
ELECTRIC STARTING SYSTEM
ELEC
3. Install:
o-ring 1 New
washers 2
front bracket 3
o-ring 4 New
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.
4. Install:
bolts 1
7 Nm (0.7 mkg)
INSTALLATION
1. Install:
10 Nm (1.0 mkg)
starter motor
Refer to “AC MAGNETO AND STARTER
CLUTCH” in CHAPTER 4.
8-22
CHARGING SYSTEM
ELEC
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
1
3
5
6
8-23
AC magneto
Rectifire/ reguretor
Battery
Fuse (main)
ELEC
CHARGING SYSTEM
EAS00774
EAS00775
TROUBLESHOOTING
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead of cylinder #1.
S Connect the pocket tester (20 V DC) to the
battery as shown.
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:
S Before troubleshooting, remove the following
part(-s):
1) Rider and passenger seats
2) Side cover (left)
S Troubleshoot with the following special
tool(-s).
Tester positive probe battery positive terminal
Tester negative probe battery negative terminal
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
Engine tachometer
YU-08036-A, 90890-03113
Pocket tester
YU-03112, 90890-03112
Charging voltage
14 V at 5,000 r/min
EAS00738
1. Main fuses
NOTE:
Make sure that the battery is fully charged.
S Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Is the charging voltage within specification?
NO
S Are the fuses OK?
YES
NO
YES
The charging circuit
is OK.
Replace the fuse (-s).
EAS00776
4. Stator coil resistance
EAS00739
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the stator coils as shown.
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Tester positive probe white 1
Tester negative probe white 2
Open-circuit voltage
12.8 V or more at 20_C
Tester positive probe white 3
Tester negative probe white 1
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
8-24
CHARGING SYSTEM
S Measure the stator coil resistances.
Stator coil resistance
0.279 X 0.341 Ω at 20_C
S Is the stator coil OK?
YES
NO
Replace the stator
coil assembly.
EAS00779
5. Wiring
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly
connected and without defects?
YES
Replace the rectifier/regulator.
NO
Properly connect or
repair the charging
system’s wiring.
8-25
ELEC
LIGHTING SYSTEM
ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4
5
6
20
34
45
8-26
Main switch
Battery
Fuse (main)
Light switch
Fuse (headlight)
Dimmer switch
58
61
75
77
78
79
High beam indicator light
Ilumination light
Tail/ brake light
Headlight
Front turn signallight (left)
Front turn signallight (right)
ELEC
LIGHTING SYSTEM
EAS00782
EAS00739
TROUBLESHOOTING
3. Main switch
Any of the following fail to come on: headlight, high beam indicator light, taillight,
and meter light.
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
Check:
1. Main and headlight fuses
2. Battery
3. Main switch
4. Light/dimmer switch
5. Wiring connections
(of the entire charging system)
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Rider and passenger seats
2) Side cover (left and right)
3) Front cowling
S Troubleshoot with the following special
tool(-s).
YES
NO
Replace the main
switch.
EAS00785
4. Light/dimmer switch
S Check the light/dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the light/dimmer switch OK?
YES
NO
The
light/dimmer
switch is faulty. Replace the left handlebar switch.
Pocket tester
YU-03112, 90890-03112
EAS00738
1. Main and headlight fuses
S Check the main and headlight fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
EAS00787
5. Wiring
S Check entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the lighting system’s wiring properly connected and without defects?
S Are the main and headlight fuses OK?
NO
YES
YES
NO
Replace the fuse (-s).
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
WAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
8-27
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
EAS00788
Set the main switch to “ON”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) of green 2 (yellow 1 ) on the headlight coupler (headlight
side).
Is the voltage within specification?
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
1. Headlight buld and scocket
Check the headlight bulb and socket for
continuity.
Are the headlight bulb and socket OK?
YES
YES
NO
This circuit is OK.
Replace the headlight
bulb, socket or both
2. Voltage
Connect the pocket tester (20 V DC) to the
headlight and high beam indicator light couplers as shown.
A When the dimmer switch is set to “
B When the dimmer switch is seto to “
ELEC
NO
The wiring circuit
from the main switch
to the headlight coupler (wire harness
side) is faulty and
must be repaired.
EAS00789
2. The meter light fails to come on.
1. Meter light bulb and socket
”.
”.
Check the meter light bulb and socket for
continuity.
Are the meter light bulb and socket OK?
Headlight
Tester positive probe yellow 1 or green 2
Tester negative probe black 3
High beam indicator light
Tester positive probe yellow 4
Tester negative probe black 5
NO
YES
Replace the meter
light bulb, socket of
both.
Headlight coupler (headlight side)
2. Vollage
Connect the pocket tester (20 V) to the meter
light coupler (wire harness side) as shown.
Tester positive probe blue 1
Tester negative probe black 2
Meter light coupler (wire harness side)
8-28
LIGHTING SYSTEM
Set the main switch to “ON”.
Measure the voltage (12 V) of blue 1 on the
meter light coupler (wire harness side).
Is the voltage within specification?
YES
Set the main switch to “ON”.
Measure the voltage (12 V) of blue/red 1 ,
yellow 3 on the tail/brake light coupler
(tail/brake light side).
Is the voltage within specification?
NO
YES
This circuit is OK.
The wiring circuit from
the main switch to the
meter light coupler
(wire harness side) is
faulty and must be repaired.
This circuit is OK.
EAS00790
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
Chek the tail/brake light bulb and socket for
continuity.
Are the tail/brake light bulb and socket OK?
YES
ELEC
NO
Replace the tail/brake
light bulb, socket or
both.
2. Voltage
Connect the pocket tester (20 V DC) to the
tail/brake light coupler (wire harness side)
as shown.
Tester positive probe blue/red 1 ,
yellow 3
Tester negative probe black 2
for EUR
for OCE
8-29
NO
The wiring circuit from
the main switch to the
tail/brake light coupler
(tail/brake light side)
is faulty and must be
repaired.
SIGNAL SYSTEM
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-30
ELEC
SIGNAL SYSTEM
4
5
6
9
10
18
23
25
35
38
40
41
42
43
46
47
52
54
55
56
59
60
65
68
75
77
78
Main switch
Battery
Fuse (main)
Oil level switch
Starting circuit cutoff relay
Front brake switch
Engine stop switch
Fuse (ignition)
Fuse (signal)
Brake light relay
Rear brake switch
Horn 2
Horn 1
Flasher relay
Horn switch
Turn signal switch
Oil level indicator light
Over drive indicator light
Neutral indicater light
Fuel level indicator light
Turn indicator light (left)
Turn indicator light (right)
Neutral switch
Fuel sender unit
Tail/ brake light
Front turn signal light (left)
Front turn signal light (right)
8-31
ELEC
ELEC
SIGNAL SYSTEM
EAS00794
EAS00749
TROUBLESHOOTING
3. Main switch
S Any of the following fail to come on: turn
signal light, brake light or indicator light.
S The horn fails to sound.
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
Check:
1. Main, signal and ignition fuses
2. Battery
3. Main switch
4. Wiring connections
(of the entire signal system)
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Rider seat
2) Side covers (left and right)
3) Fuel tank
4) Front upper cowling
S Troubleshoot with the following special tool(-s).
YES
Replace the main
switch.
EAS00795
4. Wiring
S Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the signaling system’s wiring properly
connected and without defects?
NO
YES
Pocket tester
YU-03112, 90890-03112
Check the condition
of each of the signal
system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
EAS00738
1. Main, signal and ignition fuses
S Check the main, signal and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
Properly connect or
repair the signal system’s wiring.
EAS00796
CHECKING THE SIGNAL SYSTEM
1. The horn fails to sound.
S Are the main, signal and ignition fuses OK?
YES
NO
1. Horn switch
NO
Refer to “CHECKING THE SWITCHES”.
Replace the fuse (-s).
YES
NO
EAS00739
Replace the left handlebar switch.
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
2. Voltage
S Connect the pocket tester (20 V DC) to the
horn lead (at the horn terminal) as shown.
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
8-32
SIGNAL SYSTEM
Tester positive probe black/white 1
Tester negative probe ground
Tester positive probe pink 1
Tester negative probe ground
Set the main switch to “ON”.
Measure the voltage (12 V) of the black/
white connector at the horn terminal.
Is the voltage within specification?
YES
ELEC
Set the main switch to “ON”.
Measure the voltage (12 V) of pink 1 at the
horn terminal.
Is the voltage within specification?
NO
YES
The wiring circuit
from the main switch
to the horn terminal is
faulty and must be
repaired.
Repair or adjust the
horn.
NO
Replace the horn.
EAS00797
2. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket.
3. Horn
Check the tail/brake light bulb and socket for
continuity.
Are the tail/brake light bulb and socket OK?
Disconnect the black/red 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?
YES
NO
Replace the tail/brake
light bulb, socket or
both.
2. Brake switch
Check the brake switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake switch OK?
YES
YES
NO
NO
Replace the brake
switch.
Replace the horn.
4. Voltage
3. Voltage
Connect the pocket tester (20 V DC) to the
horn at the black terminal as shown.
Connect the pocket tester (20 V DC) to the
tail/brake light coupler (wire harness side)
as shown.
8-33
SIGNAL SYSTEM
Tester positive probe yellow 1
Tester negative probe black 2
ELEC
3. Voltage
Connect the pocket tester (20 V DC) to the
flasher relay coupler (flasher relay side) as
shown.
Tester positive probe brown 1
Tester negative probe ground
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 coupler (wire harness side).
Is the voltage within specification?
YES
This circuit is OK.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 at
the flasher relay coupler (wire harness
side).
Is the voltage within specification?
NO
YES
The wiring circuit from
the main switch to the
tail/brake light coupler
(wire harness side) is
faulty and must be repaired.
The wiring circuit
from the main switch
to the flasher relay
coupler (wire harness side) is faulty
and must be repaired.
EAS00799
3. The turn signal light, turn indicator light or
both fail to blink.
4. Voltage
1. Turn indicator light bulb and socket
Connect the pocket tester (20 V DC) to the
flasher relay coupler (wire harness side) as
shown.
Check the turn signal light bulb and socket
for continuity.
Are the turn signal light bulbs and socket OK?
YES
Tester positive probe brown/white 1
Tester negative probe ground
NO
Replace the turn signal light bulb, socket
or both.
2. Turn signal switch
Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the turn signal switch OK?
YES
NO
NO
Replace the left handlebar switch.
8-34
SIGNAL SYSTEM
EAS00800
Set the main switch to “ON”.
Measure the voltage (12 V) on brown/white
1 at the flasher relay coupler (wire harness
side).
Is the voltage within specification?
YES
ELEC
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.
Are the neutral indicator light bulb and socket OK?
NO
The flasher relay is
faulty and must be
replaced.
YES
NO
Replace the neutral
indicator light bulb,
socket or both.
5. Voltage (rear)
Connect the pocket tester (20 V DC) to the
turn signal light connector (wire harness
side) as shown.
2. Neutral switch
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
A Rear turn signal light
B Turn signal indicator light
Left turn signal light
Tester positive probe chocolate 1
Tester negative probe ground
Right turn signal light
Tester positive probe dark green 2
Tester negative probe ground
B
A
YES
NO
Replace the neutral
switch.
3. Voltage
Connect the pocket tester (20 V DC) to the
meter light bulb coupler (wire harness side)
as shown.
Tester positive probe brown 1
Tester negative probe ground
Set the main switch to “ON”.
Set the turn switch to “
” or “
”.
Measure the voltage (12 V) of the chocolate
1 or dark green 2 on the turn signal light
connector (wire harness side).
Is the voltage within specification?
YES
This circuit is OK.
NO
Set the main switch to “ON”.
Measure the voltage (12 V).
Is the voltage within specification?
The wiring circuit
from the turn signal
switch to the turn signal light connector
(wire harness side) is
faulty and must be
repaired.
YES
NO
The wiring circuit
from the main switch
to the meter light bulb
coupler (wire harness
side) is faulty and
must be repaired.
8-35
ELEC
SIGNAL SYSTEM
4. Voltage
2. Starting circuit cut-off relay
S Connect the pocket tester (20 V DC) to the
neutral switch coupler (wire harness side) as
shown.
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω 1) to the
starting circuit cut-off relay coupler (wire harness side) as shown.
S Measure the resistor for the specified resistance.
Tester positive probe light green 1
Tester negative probe ground
Tester positive terminal black/red 1
Tester negative terminal brack/white 2
S Set the main switch to “ON”.
S Set the transmission within neutral.
S Measure the voltage (12 V).
S Is the voltage within specification?
YES
6.4 – 9.6 Ω at 20_C
S Is the resistor resistance within specification?
NO
YES
This circuit is OK.
The wiring circuit
from the neutral
switch to neutral
switch coupler (wire
harness side) is
faulty and must be
repaired.
Replace the starting
circuit cut-off relay.
3. Engine oil level switch
S Drain the engine oil and remove the engine
oil level switch from the oil pan.
S Check the engine oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine oil level switch OK?
EAS00802
5. The oil level indicator light fails to come on.
1. Oil level indicator light bulb and socket
S Check the oil level indicator light bulb and
socket for continuity.
S Are the oil level indicator light bulb and socket OK?
YES
NO
YES
NO
Replace the engine
oil level switch.
NO
EAS00750
4. Engine stop switch
Replace the oil level
indicator light bulb,
socket or both.
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
YES
NO
Replace the right
handlebar switch.
8-36
SIGNAL SYSTEM
ELEC
Tester positive probe green/red 1
Tester negative probe black 2
5. Voltage
Connect the pocket tester (20 V DC) to the
meter light coupler (wire harness side) as
shown.
Tester positive probe red/brack 1
Tester negative probe ground
Check: Does the fuel sender have continuity?
YES
Set the main switch to “ON”.
Measure the voltage (12 V).
Is the voltage within specification?
YES
NO
Replace
sender.
the
fuel
NO
3. Voltage
This circuit is OK.
Connect the pocket tester (20 V DC) to the
fuel sender coupler (wire harness side) as
shown.
The wiring circuit
from the main switch
to the meter light
coupler (wire harness side) is faulty
and must be repaired.
Tester positive probe green/white 1
Tester negative probe ground
EAS00803
6. The fuel level indicator light fails to come
on.
1. Fuel level indicator light bulb and socket
Check: Do the fuel level indicator light bulb
and socket have continuity?
YES
Set the main switch to “ON”.
Measure the voltage (12 V).
Is the voltage within specification?
NO
Replace the fuel level indicator light bulb,
socket of both.
YES
This circuit is OK.
2. 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 as shown.
8-37
NO
The wiring circuit
from the main switch
to the fuel sender
coupler (wire harness side) is faulty
and must be repaired.
SIGNAL SYSTEM
7. The over drive indicator light fails to come on.
Set the main switch to “ON”.
Set the transmission 5th gear.
Measure the voltage (12 V).
1. Over drive indicator light bulb and socket
Check the over drive indicator light bulb and
socket for continuity.
Is the voltage within specification?
Are the over drive indicator light bulb and
socket OK?
YES
YES
NO
This circuit is OK.
Replace the over
drive 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
ELEC
NO
Replace the neutral
switch.
3. Voltage
Connect the pocket tester (20 V DC) to the
meter light bulb coupler (wire harness side)
as shown.
Tester positive probe brown 1
Tester negative probe white/green 2
8-38
NO
The wiring circuit
from the main switch
to the meter light coupler (wire harness
side) and meter light
coupler to over drive
switch are faulty and
must be repaired.
COOLING SYSTEM
ELEC
COOLING SYSTEM
CIRCUIT DIAGRAM
Main switch
Battery
Fuse (main)
Thermo switch
Noise filter
Fan motor
Fues (fan motor)
Fuse (signal)
Engine overheat indica
tor light
67 Thermo unit
4
5
6
30
31
32
33
35
53
8-39
ELEC
COOLING SYSTEM
EAS00808
S Is the battery OK?
TROUBLESHOOTING
S The radiator fan motor fails to turn.
S The engine overheat indicator light fails
to come on when the engine is hot.
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
Check:
1. Main, turn signal, and rediator fan motor
fuses
2. Battery
3. Main switch
4. Radiator fan motor
5. Thermo switch
6. Thermo unit
7. Water temperature warning light bulb and
socket
8. Wiring connections
(the entire cooling system)
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NO
YES
NOTE:
S Before troubleshooting, remove the following
part(-s).
1) Rider and passenger seats
2) Side covers (left and right)
3) Fuel tank
S Troubleshoot with the following special
tool(-s).
Replace the main
switch.
EAS00809
4. Radiator fan motor
S Disconnect the rediator fan motor coupler
(wire harness side).
S Connect the battery (12 V) as shown.
Battery positive lead blue 1
Battery negative lead black 2
Pocket tester
YU-03112, 90890-03112
EAS00738
1. Main, signal, and radiator fan motor fuses
S Check the main, signal, and radiator fan motor fuses for continuity.
Refert to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main, turn signal, and radiator fan
motor fuses OK?
S Does the rediator fan motor turn?
YES
NO
YES
NO
The radiator fan motor is faulty and must
be replaced.
Replace the fuse (-s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
8-40
COOLING SYSTEM
ELEC
EAS00811
WARNING
5. Thermo switch
S Handle the thermo switch with special care.
S Never subject the thermo switch to strong
shocks.
If the thermo switch is dropped, replace it.
S Remove the thermo switch from the thermostat housing.
S Connect the pocket tester (Ω 1) to the
thermo switch 1 as shown.
Thermo switch
8 Nm (0.8 mSkg)
Three bond sealock 10
S Thermo switch circuit open, radiator fan off
S Thermo switch circuit closed, radiator fan on
S Does the thermo switch operate properly as
described above?
S Does the rediator fan motor turn?
YES
S Immerse the thermo switch in a container
filled with coolant 2 .
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant, then let it cool down
to the specified temperature.
S Check the thermo switch for continuity at
the temperaures indicated below.
Test step
1
Coolant temperature
Thermo switch
0 – 98_C
Replace the thermo
switch.
6. Engine overheat indicator light bulb and
socket
S Check the engine overheat indicator light
bulb and socket for continuity.
Continuity
S Are the engine overheat indicator light bulb
and socket OK?
NO
YES
2
More than
105 ± 3_C
YES
3*
105 to 98_C
YES
4*
Less than 98_C
NO
NO
NO
Replace the engine
overheat
indicator
light bulb, socket or
both.
Steps 1 & 2: Heating phase
Steps 3* & 4*: Cooling phase
8-41
COOLING SYSTEM
EAS00812
ELEC
EAS00813
7. Thermo unit
8. Wiring
S Remove the thermo unit sender from the radiator.
S Connect the pocket tester (Ω 10) to the
thermo unit 1 as shown.
S Immerse the temperature sender in a container filled with coolant 2 .
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant. Check the thermo
unit sender for continuity at the temperaures indicated below.
S Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the cooling system’s wiring properly connected and without defects?
YES
This circuit is OK.
Temperature sender resistance
80_C: 47 – 53 Ω
100_C: 26 – 30 Ω
WARNING
S Handle the temperature sender with special
care.
S Never subject the temperature sender to
strong shocks. If the temperature sender is
dropped, replace it.
Temperature sender
23 Nm (2.3 mSkg)
Three bond sealock 10
S Does the thetmo unit operate properly?
YES
NO
Replace the thermo
unit sender.
8-42
NO
Properly connect or
repair the cooling
system’s wiring.
FUEL PUMP SYSTEM
ELEC
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
4
5
6
10
12
13
23
25
8-43
Main switch
Battery
Fuse (main)
Starting circuit cutoff relay
Fuel pump
Ignitor
Engine stop switch
Fuse (ignition)
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The fuel pump circuit consists of the fuel pump
relay, fuel pump, engine stop switch and ignitor
unit.
The ignitor unit includes the control unit for the
fuel pump.
1
2
3
4
5
6
7
8
8-44
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Ignitor unit
Fuel pump relay
Fuel pump
ELEC
ELEC
FUEL PUMP SYSTEM
EAS00816
EAS00749
TROUBLESHOOTING
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
If the fuel pump fails to operate:
Check:
1. Main and ignition fuses
2. Battery
3. Main switch
4. Engine stop switch
5. Starting circuit cut-off relay
(the fuel pump relay)
6. Fuel pump
7. Wiring connections
(the entire fuel system)
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Rider seat
2) Side cover (left)
3) Fuel tank
Troubleshoot with the following special tool(-s).
S Is the main switch OK?
NO
YES
Replace
switch.
the
main
EAS00750
4. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
NO
YES
Replace the right
handlebar switch.
Pocket tester
YU-03112, 90890-03112
EAS00759
EAS00738
1. Main, and ignition fuses
5. Starting circuit cut-off relay
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay
coupler as shown.
S Are the main and ignition fuses OK?
Battery positive terminal red/black 1
Battery negative terminal blue/red 2
NO
YES
Tester positive probe red/black 3
Tester negative probe blue/black 4
Replace the fuse (-s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
S Does the starting circuit cut-off relay have continuity between red/black and blue/black?
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
NO
Replace the starting
circuit cut-off relay.
8-45
FUEL PUMP SYSTEM
EAS00817
6. Fuel pump resistance
S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler as shown.
Tester positive probe blue/black 1
Tester negative probe black 2
S Measure the fuel pump resistance.
Fuel pump resistance
4 – 30 Ω at 20_C
S Is the fuel pump OK?
NO
YES
Replace
pump.
the
fuel
EAS00818
7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S 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.
8-46
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 refuelling.
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
not, a fire may occur. Therefore, make sure
that 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.
Battery positive lead blue/black 1
Battery negative 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.
8-47
CARBURETOR HEATING SYSTEM
ELEC
CABURETOR HEATING SYSTEM
4
5
6
36
37
Main switch
Battery
Fuse (main)
Fuse (carburetor heater)
Carburetor heater relay
8-48
39
65
70
71
72
73
Thermo switch
Neutral switch
Carburetor heater #1
Carburetor heater #2
Carburetor heater #3
Carburetor heater #4
ELEC
CARBURETOR HEATING SYSTEM
EAS00821
EAS00749
TROUBLESHOOTING
3. Main switch
The carburetor heating system fails to
operate.
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Check:
1. Main and carburetor heater fuses
2. Battery
3. Main switch
4. Neutral switch
5. Carburetor heater relay
6. Thermo switch
7. Carburetor heater
8. Wiring connections
(of the entire carburetor heating system)
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Rider and passenger seats
2) Fuel tank
Troubleshoot with the following special tool(-s).
S Is the main switch OK?
NO
YES
Replace
switch.
the
main
EAS00751
4. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
NO
YES
Replace the neutral
switch.
Pocket tester
YU-03112, 90890-03112
EAS00822
EAS00738
1. Main, and carbretor heater fuses
5. Carburetor heater relay
S Check the main and carbretor heater fuses
for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Disconnect the carburetor heater relay coupler from the wire harness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the carburetor heater relay
coupler as shown.
S Are the main and carbretor heater fuses
OK?
Battery positive terminal brown 1
Battery negative terminal light green 2
Tester positive probe brown 3
Tester negative probe black/white 4
NO
YES
Replace the fuse (-s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
S Check the carburetor heater relay for no
continuity.
S Is the carburetor heater relay OK?
S Is the battery OK?
YES
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
NO
Replace the carburetor heater relay.
8-49
CARBURETOR HEATING SYSTEM
ELEC
EAS00825
6. Thermo switch
The following procedure applies to all of the
carburetor heating elements.
S Remove the thermo switch from the thermo
switch plate.
S Connect the pocket tester to the (Ω
1) to
the thermo switch as shown.
7. Carburetor heater
S Remove the carburetor heating element
from the carburetor.
S Connect the pocket tester to the carburetor
heating element as shown.
Tester positive probe black/white 1
Tester negative probe black/yellow 2
Tester positive probe heating element 1
Tester negative probe heating element body 2
B/W
B/Y
S Check the thermo switch for continuity at the
temperatures indicated below.
S Measure the carburetor heater resistance.
20_C
Carburetor heating element
resistance
6 X 12 Ω at 20_C
S Is the carburetor heating element OK?
26_C
YES
NO
A COOL DOWN
B HEAT UP
Replace the carburetor heating element.
S Does the thermo switch operated properly?
YES
NO
EAS00826
8. Wiring
S Check the entire carburetor heating system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the carburetor heating system’s wiring
properly connected and without defects?
Replace the thermo
switch.
NO
Properly connect or
repair the carburetor
heating system’s wiring.
8-50
AUDIO SYSTEM
ELEC
AUDIO SYSTEM
4
5
6
17
8-51
Main switch
Battery
Fuse (main)
Fuse (back up)
AUDIO SYSTEM
80
81
82
83
84
85
86
87
88
89
8-52
ELEC
Fuse (audio)
MCU
Speaker (front)
Speaker (front)
Speaker (rear)
Rear remoto controller
Fuse (front DC outlet)
Fuse (rear DC outlet)
DC outlet (front)
DC outlet (rear)
AUDIO SYSTEM
ELEC
AUDIO SYSTEM CIRCUIT OPERATION
The audio system circuit consists of the front/rear remote
controllers, front/rear speakers,
tape deck, and main control unit
(MCU).
1
2
3
4
5
6
7
8
9
10
Battery
Fuse (main)
Main switch
Fuse (back up)
Fuse (audio)
Main control unit
Front remoto controller
Rear remoto controller
Front speakers
Rear speakers
8-53
11
12
13
14
15
16
17
18
19
FM / AM antenna
Tape deck
Fuse (front DC outlet)
Fuse (rear DC outlet)
DC outlet (front)
DC outlet (rear)
Front headset (option)
Rear headset (option)
CD changer (option)
AUDIO SYSTEM
ELEC
REMOVAL
1. Disconnect:
Front remote control coupler (from the main
control unit)
Tape deck coupler (from the main control
unit)
CAUTION:
When disconnect a coupler, be sure to push
on the coupler as shown, and pull it out
straight.
If the coupler is twisted when disconnecting, the inner pins may be damaged.
INSTALL
1. Connect:
Front remote control coupler (to the main
control unit)
Tape deck coupler (to the main control unit)
CAUTION:
When connecting a coupler, be sure to align
projection 1 with indent 2 and push inward straightly.
If the coupler is twisted when connecting,
the inner pins may be damaged.
8-54
AUDIO SYSTEM
ELEC
3. MCU coupler
AUDIO SYSTEM does not operation
Check the connection of MCU 18P connector.
Refer to “checking the connection”.
Check:
1. Fuses
2. Ground
3. MCU
4. Wiring connections
(of the entire audio system)
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Front cowlling
2) Trunk
Troubleshoot with the following special
tool(-s).
Is the MCU connector OK?
YES
NO
Correct the
connector.
MCU
4. MCU back up
Disconnect the MCU 18P connector from
the wire harness.
Connect the pocket tester (20 V DC) to the
MCU 18P connector as shown.
Pocket tester
YU-03112, 90890-03112
Back up
Tester positive probe red/green 1
Tester negative probe ground
1. All AUDIO system does not operation.
1. Fuse
Audio
Tester positive probe brown/white 2
Tester negative probe ground
Check the main back up and audio fuse for
continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
Is the main back up and audio fuse OK?
YES
NO
Replace the fuses.
Measure the voltage (12 V) on the MCU
18P connector.
Is the voltage within specification?
2. Ground lead
Check the ground lead 1 .
Check the wiring.
Check the ground.
YES
NO
Correct the wiring.
5. Wiring connections
Check the wiring (blue/green) of MCU front remote controller.
Front remote
Controller / Display
Is the ground lead OK?
YES
NO
Correct the ground
lead.
8-55
AUDIO SYSTEM
Is the MCU front remote controller wiring
properly connected and without defects?
YES
Replace the MCU.
Is the MCU cassette deck 13P wiring
properly connected and without defected?
NO
YES
Correct the MCU front remote controller wiring.
Replace the MCU.
2. Radio does not sound.
1. Wiring connections
Check the wiring of MCU antenna.
Is the MCU antenna wiring properly connected and without defected?
YES
Replace the MCU.
NO
Correct the MCU antenna wiring.
3. Casset deck does not sound.
1. Casset deck
Check the cassette deck operation.
Is the cassette deck moved?
YES
ELEC
NO
Replace the cassette
deck.
2. Wiring connections
Check the wiring (gray) of MCU cassette
deck 13P DIN wiring.
8-56
NO
Correct the MCU cassette deck 13P
wiring.
AUDIO SYSTEM
ELEC
3. Does not sound of the speaker.
Speaker does not sound
1. Speaker
Check:
1. Out put mode
2. Speaker
3. Wiring connections
(of the entire audio system)
S Remove the speaker.
S Connect the pocket tester (Ω
speaker as shown.
1) to the
Front left
Tester positive prove red/white 1
Tester negative prove gray 2
NOTE:
S Before troubleshooting, remove the following
part(-s).
1) Front cowling
2) Trunk
S Troubleshoot with the following special
tool(-s).
Front right
Tester positive prove red/black 1
Tester negative prove blue/black 2
Rear left
Tester positive prove blue/green 1
Tester negative prove pink/black 2
Pocket tester
YU-03112, 90890-03112
Rear right
Tester positive prove red/yellow 1
Tester negative prove brown/black 2
1. Out put mode.
S Change the out put mode “HS” “SP”.
S Measure the speaker resistance.
Speaker resistance
3.4 X 4.6 Ω at 20_C
2. Front or rear speaker does not sound.
S Is the speaker resistance within specification?
1. “FADE” switch
S “FADE” switch set up near front or rear.
YES
NO
Replace the speaker.
S “FADE” switch set up OK?
YES
Replace the MCU.
NO
Set up the “FADE”
switch.
8-57
AUDIO SYSTEM
Headset does not sound
2. Wiring connections
Check the wiring of MCU wire harness speaker wiring.
Check:
1. Out put mode
2. Front head set
3. Rear head set
4. Wiring connections
(of the entire audio system)
NOTE:
Before troubleshooting, remove the following
part(-s).
1) Front cowling
2) Trunk
Troubleshoot with the following special tool(-s).
Is the MCU wire harness speaker wiring properly connected and without defected?
YES
Replace the MCU.
ELEC
Pocket tester
YU-03112, 90890-03112
NO
1. Out put mode.
Correct the MCU wire harness speaker wiring.
Change the out put mode “SP” “HS”.
4. All speaker does not sound
1. MCU 18P connector
Check the MCU 18P connector.
Refer to “CHECKING THE CONNECTION”.
2. Front head set does not sound
1. Wiring connections
Check the wining of head set.
Check the pocket tester (Ω 1) to the head
set wiring as shown.
Is the MCU 18P connector OK?
YES
Replace the MCU.
Left
Tester positive prove 3
Tester negative prove 2
NO
Right
Tester positive prove 5
Tester negative prove 2
Correct the MCU
18P connector.
8-58
AUDIO SYSTEM
Check the head set wiring for continuity.
Is the head set wiring OK?
YES
ELEC
Is the rear remote controller volume out put
level OK?
NO
YES
Correct the head set
wiring.
NO
Adjust the rear remote controller volume out put level.
2. Wiring connections
2. Wiring connections
Check the wiring of MCU X 5P DIN cable X
head set (red).
Check the wiring of head set.
Connect the pocket tester (Ω
head set as shown.
1) to the
Left
Tester positive prove 3
Tester negative prove 2
Right
Tester positive prove 5
Tester negative prove 2
Is the MCU X 5P DIN cable X head set wiring properly connected and without defected OK?
YES
Replace the MCU.
NO
Correct the MCU X
5P DIN cable X
head set wiring.
Check the head set wiring for continuity.
Is the head set wiring OK?
3. Rear head set does not sound
1. Rear remote controller volume
YES
Check the rear remote controller volume 1
out put level.
NO
Correct the head set
wiring.
8-59
AUDIO SYSTEM
Mike
Tester positive prove 1
Tester negative prove 4
2. Wiring connections
Check the wiring of MCU X 5P DIN cable X
head set (white).
Check the head set wiring for continuity.
Is the head set wiring OK?
Is the MCU X 5P DIN cable X head set wiring properly connected and without defected?
YES
YES
NO
NO
Replace the MCU.
Replace the MCU.
ELEC
Correct the MCU X
5P DIN cable X
head set wiring.
4. Intercom does not used
1. Intercom volume out put level
YES
NO
Adjust the Intercom
volume out put level.
2. Wiring connections
Check the head set wiring.
Connect the pocket tester (Ω
head set wiring as shown.
1) to the
Left
Tester positive prove 3
Tester negative prove 2
Right
Tester positive prove 5
Tester negative prove 2
8-60
Correct the head set
wiring.
AUDIO SYSTEM
Front remote controller does not operation
ELEC
Rear remote controller does not operation
Check:
1. Wiring connections
(of the entire audio system)
Check:
1. Wiring connections
(of the entire audio system)
NOTE:
Before troubleshooting, remove the following part(-s):
1) Front cowling
2) Trunk
Troubleshoot with the following special
tool(-s).
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Front cowling
2) Trunk
Troubleshoot with the following special
tool(-s).
Pocket tester
YU-03112, 90890-03112
Pocket tester
YU-03112, 90890-03112
1. Wiring connections
1. Wiring connections
Check the MCU front remote controller
13P wiring (blue).
Check the wire harness rear remote controller wiring.
Is the MCU front remote controller 13P
wiring properly connected and without defected?
Is the wire hamess rear remote controller
wiring properly connected and without defected?
YES
Repalce MCU or
front remoto controller
YES
NO
Replace MCU or rear
remoto controller.
Correct the MCU front remote controller 13P wiring.
8-61
NO
Correct the Wire harness rear remote
controller wiring.
CRUISE CONTROL SYSTEM
CRUISE CONTROL SYSTEM
CIRCUIT DIAGRAM
8-62
ELEC
CRUISE CONTROL SYSTEM
(4
(5
(6
( 14
( 18
( 21
( 22
( 35
( 38
( 40
( 49
( 57
( 62
( 63
( 64
( 66
( 75
( 90
( 91
( 92
( 93
( 94
Main switch
Battery
Fuse (main)
Ignition coil
Front brake switch
Cruise control switch
“CANCEL” switch
Fuse (signal)
Brake light relay
Rear brake switch
Clutch switch
Speedometer/ Fuel meter
Cruise control light (MAIN)
Cruise control light (SET)
Cruise control light (RES)
Speed sensor
Tail/ brake light
Cruise control unit
Vacuum pump
Fuse (cruise control)
“CRUISE” switch
Cruise control relay
8-63
ELEC
CRUISE CONTROL SYSTEM
ELEC
CRUISE CONTROL CIRCUIT OPERATION
1
2
3
4
5
6
7
8
9
10
Battery
Main fuse
Main switch
Signal fuse
Cruise control fuse
“CRUISE” switch
Cruise contrl relay
“ON” indicator light
“SET” indicator light
“RES” indicator light
11
12
13
14
15
16
17
18
19
20
Cruise contrl unit
Vacuum pump
Cruise contrl switch
Rear brake switch
Cancel switch
Clutch switch
Front brake switch
Rear brake light switch
Front brake light switch
Brake lamp relay
8-64
21
22
23
24
Brake light
To ignition coil
Speed sensor
Speedometer
CRUISE CONTROL SYSTEM
ELEC
CRUISE CONTROL SYSTEM COMPONENTS
1
2
3
4
5
6
Speed sensor
Battery
Fuse
Main switch
Fuse
Indicators
7 Front brake switch
8 Cruise control switch /cancel
9
10
11
12
13
14
switch
Clutch switch
Cruise control unit
Rear brake switch
Vacuum pump
Vacuum autuator
Throttle cable joint
8-65
15
16
17
18
19
20
Air
Carburetor (s)
Throttle valve
Air/ Fuel mixture
“CRUISE” switch
Ignition coil
CRUISE CONTROL SYSTEM
EAS00781
ELEC
EAS00739
TROUBLESHOOTING
Check:
1. main, signal and cruise control
2. battery
3. main switch
4. “CRUISE” switch
5. cruise control relay
6. wiring
(of the entire charging system)
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
NOTE:
S Before troubleshooting, remove the folling part
(-s):
1) seat
2) under cowl (left and right)
3) upper cowl
S Troubleshoot with the following special tool
(-s).
YES
NO
S Clean the battery
terminals
S Recharge or replace the battery.
EAS00749
3. Main switch
Pocket tester
90890-03112
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
EAS00738
YES
1. Main, signal, and cruise control fuses
S Check the control fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the control fuses OK?
YES
Replace the main
switch.
4. “CRUISE” switch
S Disconnect the “CRUISE” switch connector.
S Check the “CRUISE” switch for continuity.
NO
Replace
(-s).
the
NO
Tester positive prove red/blue 1
Tester negative prove brown/red 2 or
yellow/black 3
fuse
S Is the “CRUISE” switch OK?
YES
NO
Replace the
“CRUISE” switch.
8-66
CRUISE CONTROL SYSTEM
CHECKING THE CRUISE CONTROL SYSTEM
Detecting an abnormality with the motorcycle stopped
1. The cruise control indicator light fail to come
on.
5. Cruise control relay.
Disconnect the relay from the coupler.
Connect the pocket tester (Ω
1) and battery (12 V) to the relay unit terminal as
shown.
Battery positive terminal yellow/red
Battery negative terminal black 3
1. Cruise control indicator light bulb and
socket
1
Check the cruise control indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the cruise control indicator light bulb
and socket OK?
Tester positive prove brown/red 2
Tester negative prove yellow/red 4
YES
NO
Replace the cruise
control indicator light
bulb, socket or both.
Does the cruise control relay have continuity between brown/red and yellow/red?
YES
ELEC
2. Voltage
NO
Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as
shown.
Replace the relay
unit.
Tester positive probe yellow/black 1
Tester negative probe black 2
6. Wiring
Check the entire cruise control system’s
wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the cruise control system’s wiring properly connected and without defects?
YES
Check the condition
of each of the cruise
control system’s circuits.
Refer to “CHECKING
THE CRUISE CONTROL SYSTEM”.
NO
Set the main switch to “ON”.
Set the cruise switch to “ON”.
Measure the voltage (12V) of blue 1 on the
meter assembly coupler (wire harness
side).
Is the voltage within specification?
Properly connect or
repair the cruise control system’s wiring.
YES
This circuit is OK.
8-67
NO
The wiring circuit
from the cruise control relay to the meter
assembly coupler is
faulty and must be
repaired.
CRUISE CONTROL SYSTEM
2. The “SET”/“RES” indicator light will show any
an abnormality of the cruise control system.
3. Check
Set the main switch to “ON” and the
“CRUISE” switch to “ON”.
The cruise control, “SET” and “RES” indicator lights come on.
The “SET”,“RES” and “ON” indicator lights
go out after approximaterly 1.4 second (to
check for a burned bulb). The ”ON” indicator light stays on.
Is it correct?
1. “SET”/“RES” indicator light bulb and socket
Check the “SET”/“RES” indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the “SET”/“RES” indicator light bulb
and socket OK?
YES
ELEC
NO
YES
Replace the “SET”/
“RES” indicator light
bulb, socket or both.
This circuit is OK.
2. Voltage
Connect the pocket tester (DC 20 V) to the
“SET”/“RES” indicator light couplers (wire
harness side) as shown.
NO
The
“SET”
and
“RES”
indicator
light(s) flashes.
Refer to “SELFDIAGNOSIS”.
Detecting and abnormality during operation
1. The cruise control system can not be set.
(The “SET” indicator light does not come on)
“SET” indicator light
Tester positive probe ! yellow/black 1
Tester negative probe ! green/blue 2
1. Cruise control switch
Disconnect the right handlebar switch coupler from the wire harness.
Connect the pocket tester (Ω x 1) to the coupler.
“RES” indicator light
Tester positive probe ! yellow/black 1
Tester negative probe ! orang/blue 3
Tester positive prove !
pink/white or pink/black 1
Tester negative prove ! black 2
Set the main switch to “ON”.
Set the “CRUISE” switch to “ON”.
Measure the voltage (12 V) of yellow/black
1 on the meter assembly couplers (wire
harness side).
Is the voltage within specification?
YES
When set the cruise control switch to “SET.
DEC”, the resistance reading 0 Ω to ∞ Ω.
Is the resistance with specification?
NO
YES
The wiring circuit from
the cruise control
relay to the meter light
coupler is faulty and
must be repaired.
NO
The cruise control
switch is faulty. Replace the right handlebar switch.
8-68
ELEC
CRUISE CONTROL SYSTEM
2. Speed sensor
3. Cruise control unit
Check the following items.
1) Speedometer is faulty operation
a. Engine warning light is flashing (Fault code 4)
Refer to “SELF-DIAGNOSIS”.
b. “SET” and/or “RES” indicator light is flashing (Fault code 4)
Refer to “SELF-DIAGNOSIS”.
Is the speed sensor OK?
Disconnect the coupler from the cruise
control unit.
Connect the pocket tester (DC20V) to the
coupler.
NO (Faulty)
Tester positive prove yellow/black 1
or green/white 2
Tester negative prove black 3
YES
(Normal)
Replace the speed Replace the cruise
control unit.
sensor.
2. Set speed can not be cancelled by cansel
switches (“CANCEL”, front brake, rear brake
and/or clutch switches)
Set the main switch to “ON” and the
“CRUISE” switch to “ON”.
When operating the cancel switches
(“CANCEL,” front brake, rear brake or clutch
switches), the voltage reading is 12 V to 0 V.
Is the voltage with specification?
1. “CANCEL” switch
Disconnect the right handlebar switch coupler from the wire harness.
Check the “CANCEL” switch for continuity.
Tester positive prove yellow/green 1
Tester negative prove yellow/blue 2
YES
NO
The wiring circuit is
faulty and must be
repaired.
4. Vacuum hose
Check the vacuum hose for clogging and/
or damage.
Is the “CANCEL” switch OK?
YES
NO
The “CANCEL” switch
is faulty. Replace the
right handlebar switch.
2. Front brake, rear brake and clutch switch.
Is the vacuum hose OK?
Check the switches for continuity.
Refer to “CHECKING THE SWITCHES”.
Are the switches OK?
YES
YES
NO
NO
Repair or replace the
vacuum hose.
Replace the faulty
switch(es).
8-69
CRUISE CONTROL SYSTEM
ELEC
5. Throttle cables
2. Throttle cable joint
Checke the throttle cables and throttle
housing condition.
Check the throttle cable joint operation by
operating the actuator manualy, and check
if the throttle valve opens.
Is the throttle cables OK?
Is the throttle cable joint OK?
NO
YES
NO
YES
Replace the cruise Repair or replace the
throttle cables.
control unit.
Repaire or replace the
throttle cable joint.
3. Cruise control system can not be set (“SET”
indicator light come on)
3. Vacuum actuator
1. Throttle cable free play
Disconnect the vacuum hose at the vacuum
pump and operate the actuator manualy
and play the open end of the hose by a finger.
Check the throttle cable free play a .
Free Play a :
1 2 mm
Is the actuator diaphram staying?
Is the throttle cable free play OK?
YES
YES
NO
NO
Actuator diaphram
and/or vacuum hose
are faulty. Replace
as required.
Adjust the free play.
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY
in CHAPTER 3.
8-70
CRUISE CONTROL SYSTEM
ELEC
4. Vacuum pump 1
4. Vehicle speed fluctuate during the cruising
Reconnect the vacuum hose and disconnect the vacuum pump connector.
Connect the battery (12 V) as shown.
1. Speed sensor
Check the following items.
1) Speedometer is faulty operation.
a. Engine warning light is flashing (Fault
code 4)
Refer to “SELF-DIAGNOSIS”.
b. “SET” and/or “RES” indicator light is
flashing (Fault code 4)
Refer to “SELF-DIAGNOSIS”.
Is the speed sensor OK?
Battery positive terminal red 1
Battery negative terminal blue/black 2
blue/white 3
blue/red 4
YES
(Normal)
Replace the speed
sensor.
Replace the cruise
control unit.
5. Cruising speed can not be increased or resume can not be operated by cruise control
switch.
Is the actuator operating?
NO
YES
NO
(Faulty)
1. Cruise control switch
Disconnect the right handlebar switch connector from the wire harness.
Connect the pocket tester (Ω x 1) to the connector.
Replace the vacuum
pump.
5. Vacuum pump 2
Tester positive prove pink/black 1
Tester negative prove black 2
After operating the actuator, stop the vacuum pump by disconnecting the battery lead
from the 4 terminals. In this condition, leave
it approximetely 5 seconds and check if the
actuator diaphragm stays or returns.
When set the cruise control switch to “RES.
ACC”, the resistance reading 0 Ω to ∞ Ω.
Is the resistance with specification?
Is the actuator diagram stying?
YES
Replace the cruise
control unit.
YES
NO
NO
Replace the cruise
control unit.
Replace the vacuum
pump.
8-71
The cruise control
switch is faulty. Replace the right handlebar switch.
CRUISE CONTROL SYSTEM
ELEC
SELF DIAGNOSIS FUNCTION OF THE
CRUISE CONTROL SYSTEM
The cruise control system has a self diagnosis function.
Use of the function allows the self diagnosis
about the following:
1. Trouble diagnosis of the cancel switch signal.
2. Trouble diagnosis of the brake light signal.
3. Trouble diagnosis of the throttle drive system.
Operating procedure for the self diagnosis
mode
1) Turn on the main switch.
2) Set the “CRUISE” switch to the “ON” position.
3) Start the engine.
4) Use the engine stop switch and stop the engine.
5) Wait for 10 seconds.
6) Push the cruise control switch to the “SET”
and “RES” alternatively three times (total of 6
times) within 2 seconds while pressing the
cancel switch.
Then the indicator light will be lit and the
cruise control system will enter the self
diagnosis mode.
1) The “SET” and “RES” indicator lights will
then blink alternatively three times.
NOTE:
When the cruise control system is not failure,
the “SET” and “RES” indicator lights will be remained on.
Exiting the self diagnosis mode
Perform any one of the four steps shown below.
The system will then exit the self diagnosis
mode.
1) Start the engine.
2) Turn the rear wheels.
3) Turn off the main switch.
4) Push the “CRUISE” switch to “OFF”.
8-72
CRUISE CONTROL SYSTEM
14
15
16
17
18
19
Rear brake switch
Concel switch
Clutch switch
Front brake light switch
Rear brake light switch
Front brake light switch
ELEC
1. Trouble diagnosis of the cancel switch
signal
1) The “SET” indicator light is lit.
2) Operate the cancel, front brake, rear brake,
and clutch switches.
If the “SET” indicator light is not extinguished
after any one of these switches is operated, it
mean that the relevant switch is in failure.
Example:
If the cancel switch is operated and the “SET”
indicator light is not extinguished, it means
that the cancel switch is in failure.
8-73
CRUISE CONTROL SYSTEM
ELEC
2. Trouble diagnosis of the brake light signal
1) The “RES” indicator light is lit.
2) Operate the following front brake and rear
switches.
If the RES indicator light is not extinguished
after either of these switches is operated, it
means that the relevant switch is in failure.
Example:
If the front brake switch is operated and the
“RES” indicator light is not extinguished, it
means that the front brake switch is infailure.
3. Trouble diagnosis of the throttle drive
1) Push the cruise control switch to ”RES”.
The throttle will be then opened fully in
approx. 2.5 seconds and kept fully open for 3
seconds.
The throttle will be fully closed approx. 2.5
seconds later.
Check the closing throttle for noises and operation.
If noise is heard from the vacuum pump but
the throttle is not operating, it means that the
throttle cable is in failure.
If no noises are heard from the vacuum
pump, it means that the vacuum pump is in
failure.
12 Vacuum pump
13 Vacuum actuator
14 Throttle cable joint
17 Throttle valve
8-74
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The XVZ13TF features a self-diagnosing system for following displays.
1. Engine warning light
2. Fuel meter
3. “SET”/“RES” indicator light
1. ENGINE TROUBLE INDICATOR LIGHT
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine trouble indicator light (irrespective of whether the engine is running or not).
NOTE:
The XVZ13TF features a self-diagnosing system.
In the XVZ13TF, when the main switch is turned on the “Engine trouble indicator light” in the speedometer comes on tor 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds, goes off and then begins flashing. (However, it is on while the engine is running.)
Display condition code
Item
Condition
Response
When
When engine
engine is
is stationary
running
Throttle position
sensor (TPS)
Disconnected
Short-circuit
Locked
Enables the motorcycle to
run so that the ignition timing
is fixed when the throttle is
Blinks in
fully opened.
Light on
Fault code [3]
Displays the condition
code on the engine indicator
light.
Speed sensor
Illegality pulse
Disconnected
Short-circuit
Operate the speed limiter Blinks in
Light on
(5,000 r/min)
Fault code [4]
Emergency stop
switch
Disconnected
–
8-75
Blinks in
Light on
Fault code [9]
SELF-DIAGNOSIS
ELEC
Display order on the engine warning light
When one item being monitored
1
2
3
4
Light on (seconds) . . . . . . .
Light off (seconds) . . . . . . .
Number of blinks . . . . . . . .
Light off (seconds) . . . . . . .
0.5 seconds
0.5 seconds
Fault code
3 seconds
Light on
Light off
Repetition
When more than one item is being monitored
1
2
3
4
5
Light on (seconds) . . . . . . .
Light off (seconds) . . . . . . .
Number of blinks . . . . . . . .
Light off (seconds) . . . . . . .
Number of blinks . . . . . . . .
0.5 seconds
0.5 seconds
Fault code [4]
3 seconds
Fault code [3]
Light on
Light off
Repetition
8-76
ELEC
SELF-DIAGNOSIS
EAS00835
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
The tachometer starts to display the selfdiagnosis sequence.
Check:
1. throttle position sensor
2. speed sensor
3. emergency stop switch
YES
NO
Repair or replace the
wire harness.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) rider seat
2) fuel tank
3) air filter case
Troubleshoot with the following special
tool(-s).
EB812401
2. Throttle position sensor
Check the throttle position sensor for continuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
Is the throttle position sensor OK?
Pocket tester
90890-03112
YES
NO
EAS00836
1. Throttle position sensor
CIRCUIT DIAGRAM
Replace the ignitor
unit.
13 Ignitor unit
29 Throttle position sensor
8-77
Replace the throttle
position sensor.
SELF-DIAGNOSIS
ELEC
EB812401
2. Speed sensor
CIRCUIT DIAGRAM
2. Speedometer
Check the speedometer operation.
Is the speedometer OK?
YES
Replace the ignitor
unit.
NO
Replace the speed
sensor.
3. Emergency stop switch
CIRCUIT DIAGRAM
13 Ignitor unit
27 Emergency stop switch
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
13 Ignitor unit
66 Speed sensor
1. Wire harness
YES
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
NO
Repair or replace the
wire harness.
8-78
SELF-DIAGNOSIS
EB812401
2. Emergency stop switch
S Remove the emergency stop switch.
S Connect the pocket tester (Ω
1) to the
emergency stop switch coupler as shown.
Tester positive prove black/white 1
Tester negative prove black 2
50_
S When turn the emergency stop switch approx.
50_, the resistance reading is 0 Ω to ∞ Ω.
S Is the emergency stop switch OK?
YES
Replace the ignitor
unit.
NO
Replace the emergency stop switch.
8-79
ELEC
SELF-DIAGNOSIS
ELEC
2. FUEL METER
The fuel meter is indicated the fault displays as follows
Fuel sender
Fuel thermistor
Fuel meter display sequence
Fuel sender
1
2
3
4
5
Light on . . . . . . . . . . . 0.5 seconds
Light off . . . . . . . . . . . 0.5 seconds
Number of blinks . . . 8 times
Light off . . . . . . . . . . . 3 seconds
1 cycle
3 times repetition
Light on
Light off
Repetition
1 Light on . . . . . . . . . . . 0.5 seconds
2 Light off . . . . . . . . . . . 0.5 seconds
Light on
Light off
Repetition
8-80
SELF-DIAGNOSIS
ELEC
Fuel thermistor
1
2
3
4
5
Light on . . . . . . . . . . . 0.5 seconds
Light off . . . . . . . . . . . 0.5 seconds
Number of blinks . . . 8 times
Light off . . . . . . . . . . . 3 seconds
1 cycle
3 times repetition
Light on
Light off
Repetition
1 Light on . . . . . . . . . . . 0.5 seconds
2 Light off . . . . . . . . . . . 0.5 seconds
Light on
Light off
Repetition
8-81
SELF-DIAGNOSIS
ELEC
EAS00835
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
The tuel meter starts to display the selfdiagnosis sequence.
Check:
1. fuel sender
2. fuel thermistor
YES
NO
Repair or replace the
wire harness.
NOTE:
Before troubleshooting, remove the following
part (-s):
1) rider seat
2) fuel tank
3) air filter case
Troubleshoot with the following special tool
(-s).
EB812401
2. Fuel sender
Check the fuel sender for continuity.
Refer to “SIGNAL SYSTEM”.
Is the fuel sender OK?
Pocket tester
90890-03112
YES
Replace the fuel meter.
EAS00836
1. Fuel sender
CIRCUIT DIAGRAM
NO
Replace the
sender unit.
2. Fuel thermistor
CIRCUIT DIAGRAM
57 Fuel meter
68 Fuel sender unit (thermistor)
57 Fuel meter
68 Fuel sender unit
8-82
fuel
SELF-DIAGNOSIS
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
EB812401
2. Fuel thermistor
Check the fuel thermistor operation.
When set the main switch to on, the fuel level
indicator light comes on.
After 1.4 second, the fuel level indicator light
goes off.
Is the fuel thermistor OK?
YES
Replace the fuel meter.
NO
The fuel thermistor is
faulty. Replace the
fuel sender unit.
8-83
ELEC
ELEC
SELF-DIAGNOSIS
3. “SET”/“RES” INDICATOR LIGHT
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the “SET”/“RES” indicator light at same time (irrespective of whether the engine is running or not).
Display condition
Item
Condition
When
engines is
stationary
When
engine is
running
Fault code
Cruise control unit
Disconnected
Short-circuit
Blinks in
Blinks in
1
Vacuum pump
Disconnected
Shart-circuit
Blinks in
Blinks in
2
Concel switch,
Front brake switch,
Rear brake switch or
Clutch switch
Disconnected
Short-circuit
Blinks in
Blinks in
3
Speed sensor
Illegality palse
Blinks in
Blinks in
4
Ignition coil
Illegality pulse
Disconnected
Short-circuit
Blinks in
Blinks in
5
Cruise control switch
Disconnected
Blinks in
Blinks in
6
Display order on the “SET/“RES” indicator light
1
2
3
4
Light on (seconds) . . . .
Light off (seconds) . . . .
Number of blinks . . . . .
Light off (seconds) . . . .
0.5 seconds
0.5 seconds
Fault code
3 seconds
Light on
Light off
Repetition
8-84
ELEC
Fault code
A
1
B
A
2
B
A
3
B
A
4
B
A
5
B
A
6
B
1
2
3
4
0.5 seconds
0.5 seconds
Number of blinks . . . . . Fault code
3 seconds
A Light on
B Light off
8-85
SELF-DIAGNOSIS
ELEC
EAS00835
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
The “SET”/“RES” indicator light starts to
display the self-diagnosis sequence.
Check:
1. cruise control unit
2. vacuum pump
3. cancel switch, front brake switch, rear
brake switch or clutch switch
4. speed sensor
5. ignition coil
6. cruise control switch
YES
NO
Repair or replace the
wire harness.
EB812401
2. Vacuum pump
NOTE:
Before troubleshooting, remove the following
part (-s):
1) rider seat
2) fuel tank
3) air filter case
Troubleshoot with the following special tool
(-s):
Check the vacuum pump for continuity.
Refer to “CRUISE COUTROL SYSTEM”.
Is the vacuum pump OK?
YES
Replace the cruise
control.
Pocket tester
90890-03112
NO
Replace the vacuum
pump.
3. Cancel switch, front brake switch, rear
brake switch or clutch switch
1. Cruise control unit
Replace the cruise control unit.
1. Wire harness
2. Vacuum pump
CIRCUIT DIAGRAM
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
2. Cancel switch, front brake switch, rear
brake switch and clutch switch
Check the switches for continuity.
Refer to “CRUISE CONTROL SYSTEM”.
Are the switches OK?
YES
Replace the cruise
control unit.
90 Cruise control unit
91 Vacuum pump
8-86
NO
Repair or replace the
faulty switch (es).
SELF-DIAGNOSIS
ELEC
CIRCUIT DIAGRAM
18 Front brake switch
22 “CANCEL” switch
40 Rear brake switch
49 Clutch switch
90 Cruise control unit
8-87
SELF-DIAGNOSIS
4. Speed sensor
CIRCUIT DIAGRAM
5. Ignition coil
CIRCUIT DIAGRAM
66 Speed sensor
90 Cruise control unit
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
EB812401
2. Speed sensor
Check the speed sensor operation.
Refer to “CRUISE CONTROL SYSTEM”.
Is the speed sensor OK?
YES
NO
14 Ignition coil
Replace the cruise
control unit.
90 Cruise control unit
Replace the speed
sensor.
8-88
ELEC
ELEC
SELF-DIAGNOSIS
6. Cruise control switch
1. Wire harness
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
NO
YES
Repair or replace the
wire harness.
NO
Repair or replace the
wire harness.
2. Engine condition
2. Cruise control switch
Start the engine and check the engine condition from the idling to full opening the throttle.
Is the engine condition OK?
YES
Replace the cruise
control unit.
Disconnect the rihgt handlebar switch coupler from the wire harness.
Connect the pocket tester (Ω
1) to the
coupler.
NO
Tester positive prove pink/white 1
pink/black 2
Tester negative prove black 3
Replace the ignition
coil.
Check the cruise control switch for continuity.
Is the cruise control switch OK?
YES
Replace the cruise
control unit.
8-89
NO
The cruise control
switch is faulty.
Replace the right
handlebar switch.
SELF-DIAGNOSIS
CIRCUIT DIAGRAM
8-90
ELEC
TRBL
SHTG
9
TRBL
SHTG
CONTENTS
TROUBLESHOOTING
STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-2
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-2
9-2
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 9-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4
9-4
9-4
9-4
9-4
9-4
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
LEAKAGE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
UNSTABLE HANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TRBL
SHTG
FAULTY SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
TROUBLESHOOTING
TRBL
SHTG
EAS00844
TROUBLESHOOTING
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
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
Crankcase and crankshaft
Improperly assembled crankcase
Seized crankshaft
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
Fuel cock
Clogged or damaged fuel hose
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
9-1
TROUBLESHOOTING
ELECTRICAL SYSTEMS
Battery
Improperly charged 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
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cut-off relay
Faulty starter clutch
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
Ignition coil(-s)
Cracked or broken ignition coil
Broken or shorted primary or secondary coils
Faulty spark plug lead
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 (at the flange
of the throttle grip)
Flooded carburetor
Faulty air induction system
ELECTRICAL SYSTEMS
Battery
Improperly charged 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
TROUBLESHOOTING
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
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 fork(-s)
Foreign object in the shift drum groove
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Foreign object between transmission gears
Improperly assembled transmission
JUMPS OUT OF GEAR
Shift shaft
Incorrect shift pedal position
Improperly returned stopper lever
Shift fork(-s)
Worn shift fork
Shift drum
Incorrect axial play
Worn shift drum groove
Transmission
Worn gear dog
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 viscosity (high)
Deteriorated oil
CLUTCH SLIPS
Clutch
Improperly assembled clutch
Improperly assembled clutch master cyinder
Improperly assembled clutch release cylinder
Incorrect clutch fluid level
Damage clutch hose
Loose or fatigued clutch spring
Loose union bolt
Worn friction plate
Worn clutch plate
Damage clutch release cylinder
Engine oil
Incorrect oil level
Incorrect viscosity (low)
Deteriorated oil
9-3
TROUBLESHOOTING
TRBL
SHTG
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages Cylinder head(-s)
and piston(-s)
Heavy carbon buildup
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
FUEL SYSTEM
Carburetor(-s)
Incorrect main jet setting
Incorrect fuel level
Air leak at carburetor joint
Air filter
Clogged air filter element
ELECTRICAL SYSTEMS
Spark plug(-s)
Incorrect spark plug gap
Incorrect spark plug heat range
Ignition system
Faulty ignitor unit
COOLING SYSTEM
Coolant
Low coolant level
Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fins
Water pump
Damaged or defective water pump
Thermostat
Thermostat stays closed
CHASSIS
Brake(-s)
Dragging brake
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
Disc brake
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper kit
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
9-4
TROUBLESHOOTING
TRBL
SHTG
EAS00861
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 bolt
Damaged damper rod bolt copper washer
Cracked or damaged cap bolt O-ring
MALFUNCTION
Bent, deformed or damaged inner tube
Bent, deformed 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
Front fork leg(-s)
Uneven oil levels (both front fork legs)
Uneven fork spring tension (both front fork
legs)
Broken fork spring
Bent or damaged inner tube
Bent or damaged outer tube
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
Handleber
Bent or improperly installed handlebar
Steering
Improperly installed upper bracket
Improperly installed lower bracket (improperly tightened ring nut)
Bent steering stem
Damaged ball bearing or bearing race
Tire(-s)
Uneven tire pressures (front and rear)
Incorrect tire pressure
Uneven tire wear
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
Rear shock absorber assembly
Faulty rear shock absorber spring
Leaking oil or gas
9-5
TROUBLESHOOTING
TRBL
SHTG
EAS00866
FAULTY SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Incorrect ground
Poor contacts (main or light switch)
Burnt-out headlight bulb
TURN SIGNAL DOES NOT LIGHT
Faulty turn signal switch
Faulty flasher relay
Bumt-out turn signal bulb
Incorrect connection
Damaged or defective wire harness
Incorrect ground
Discharged battery
Blown, damaged or incorrect fuse
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 BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier/regulator
Incorrect ground
Faulty main switch
Faulty light switch
Headlight bulb life expired
TURN SIGNAL BLINKS SLOWLY
Faulty flasher relay
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty flasher relay
Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty flasher relay
Burnt-out turn signal bulb
9-6
XVZ13TF (for EUR) WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
AC magneto
Condenser
Rectifire/ regurator
Main switch
Battery
Fuse (main)
Starter relay
Starter motor
Oil level switch
Starting circuit cutoff relay
Diode
Fuel pump
Ignitor
Ignition coil
Spark pulg
CYCLELOCK (option)
Fuse (back up)
Front brake switch
Handlebar switch (right)
Light switch
Cruise control switch
“CANCEL” switch
Engine stop switch
Start switch
Fuse (ignition)
Side stand switcn
Emargency stop switch
Pick up coil
Throttle position sensor
Thermo switch
Noise filter
Fan motor
Fuse (fan motor)
Fuse (head light)
Fuse (signal)
Fuse (caburetor heater)
Carburetor heater relay
Brake light relay
Thermo switch
Rear brake switch
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
Horn 2
Horn 1
Flasher relay
Handlebar switch (left)
Dimmer switch
Horn switch
Turn signal switch
“PASS” switch
Clutch switch
Meter assembly
Engine trouble indicator light
Oil level indicator light
Engine overheat indicator light
Over drive indicator light
Neutral indicater light
Fuel level indicator light
Speedometer/ Fuel meter
High beam indicator light
Turn indicator light (left)
Turn indicator light (right)
Ilumination light
“ON” indicator light (MAIN)
“SET” indicator light (SET)
“RES” indicator light (RES)
Neutral switch
Speed sensor
Thermo unit
Fuel sender unit
Carburetor heater ground
Carburetor heater #1
Carburetor heater #2
Carburetor heater #3
Carburetor heater #4
License light
Tail/ brake light
Auxiliary light
Headlight
Front turn signal light (left)
Front turn signal light (right)
MCU
CUISE CONTROL UNIT
“CRUISE” SWITCH
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
Fuse (audio)
MCU
Speaker (front)
Speaker (front)
Speaker (rear)
Rear remote controller
Fuse (front DC outlet)
Fuse (rear DC outlet)
DC outlet (front)
DC outlet (rear)
Cruise control unit
Vacuum pump
Fuse (cruise control)
“CRUISE” switch
Cruise control relay
D.C OUTLET
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
L .....
Lg . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
O ....
P .....
R.....
Sb . . . .
W ....
Y .....
B/ L . . .
B/ R . . .
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
B/ W . .
B/ Y . . .
Br/ B . .
Br/ L . .
Br/ R . .
Br/ W .
Br/ Y . .
G/B . .
Black/ White
Black/ Yellow
Brown/ Black
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
G/L . . .
G/R . .
G/W . .
G/Y . .
L/B . . .
L/G . . .
L/R . . .
L/W . .
Green / Blue
Green / Red
Green / White
Green / Yellow
Blue/ Black
Blue/ Green
Blue/ Red
Blue/ White
L/Y . . .
O/L . . .
P/ B . . .
P/ L . . .
P/ W . .
R/ B . . .
R/ G . .
R/ L . . .
Blue/ Yellow
Orange / Blue
Pink/ Black
Pink/ Blue
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
R/ W . .
R/ Y . . .
W/ G . .
W/ R . .
W/ Y . .
Y/ B . . .
Y/ G . .
Y/ L . . .
Red/ White
Red/ Yellow
White/ Green
White/ Red
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Y/ R . . . Yellow/ Red
Y/ W . . Yellow/ White
XVZ13TFL (for OCE) WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
AC magneto
Condenser
Rectifire/ regurator
Fuse (back up)
Main switch
Fuse (main)
Battery
Starter relay
Starter motor
Oil level switch
Starting circuit cutoff relay
Diode
Fuel pump
Ignitor
Ignition coil
Spark plug
Front brake switch
Handlebar switch (right)
Cruise control switch
“CANCEL” switch
Engine stop switch
Start switch
Fuse (ignition)
Side stand switch
Emargency stop switch
Pick up coil
Throttle position sensor
Thermo switch
Noise filter
Fan motor
Fuse (fan motor)
Fuse (head light)
Fuse (signal)
Fuse (carburetor heater)
Carburetor heater relay
Brake light relay
Thermo switch
Rear brake switch
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Horn 2
Horn 1
Flasher relay
Handlebar switch (left)
Dimmer switch
Horn switch
Turn signal switch
“PASS” switch
Clutch switch
Meter assembly
Engine trouble indicator light
Oil level indicator light
Engine overheat indicator light
Over drive indicator light
Neutral indicator light
Fuel level indicator light
Speedometer/ Fuel meter
High beam indicator light
Turn indicator light (left)
Turn indicator light (right)
Ilumination light
“ON” indicator light (MAIN)
“SET” indicator light (SET)
“RES” indicator light (RES)
Neutral switch
Speed sensor
Thermo unit
Fuel sender unit
Carburetor heater ground
Carburetor heater #1
Carburetor heater #2
Carburetor heater #3
Carburetor heater #4
License light
Tail/ brake light
Headlight
Front turn signal light (left)
Front turn signal light (right)
MCU
CUISE CONTROL UNIT
“CRUISE” SWITCH
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
Fuse (audio)
MCU
Speaker (front)
Speaker (front)
Speaker (rear)
Rear remote controller
Fuse (front DC outlet)
Fuse (rear DC outlet)
DC outlet (front)
DC outlet (rear)
Cruise control unit
Vacuum pump
Fuse (cruise control)
“CRUISE” switch
Cruise control relay
D.C OUTLET
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
L .....
Lg . . . .
O ....
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
P .....
R.....
Sb . . . .
W ....
Y .....
B/ L . . .
B/ R . . .
B/ W . .
B/ Y . . .
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Br/ B . .
Br/ L . .
Br/ R . .
Br/ W .
Br/ Y . .
G/B . .
G/L . . .
G/R . .
G/W . .
Brown/ Black
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
Green / Blue
Green / Red
Green / White
G/Y . .
L/B . . .
L/G . . .
L/R . . .
L/W . .
L/Y . . .
O/L . . .
P/ B . . .
P/ L . . .
Green / Yellow
Blue/ Black
Blue/ Green
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Blue
Pink/ Black
Pink/ Blue
P/ W . .
R/ B . . .
R/ G . .
R/ L . . .
R/ W . .
R/ Y . . .
W/ G . .
W/ L . .
W/ R . .
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red/ White
Red/ Yellow
White/ Green
White/ Blue
White/ Red
W/ Y . .
Y/ B . . .
Y/ G . .
Y/ L . . .
Y/ R . . .
Y/ W . .
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Yellow/ Red
Yellow/ White
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