GEN INFO SPEC ENG CARB ELEC COOL CHK ADJ

GEN INFO SPEC ENG CARB ELEC COOL CHK ADJ
EAS00000
FZS1000 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, December 2000
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.
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 checking 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 check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to “SYMBOLS” 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 Checks and Adjustments”), where the sub-section title(-s) appears.
(In Chapter 3, “Periodic Checks 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.
6
1
2
3
4
5
8
7
EAS00008
1
SYMBOLS
2
GEN
INFO
SPEC
3
4
CHK
ADJ
CHAS
5
6
COOL
ENG
7
8
CARB
ELEC
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Carburetor(-s)
8 Electrical system
9 Troubleshooting
Symbols 10 to 17 indicate the following.
10
9
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
18
21
16
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
17
19
20
22
23
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
25
24 Apply locking agent (LOCTITER)
25 Replace the part
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
CARBURETORS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
CARB
7
ELEC
8
TRBL
SHTG
9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-2
1-3
1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
GEN
INFO
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the right side of the steering head.
EAS00018
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS” 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
lip
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 with greace.
lip
spring
oil
grease
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.
1-2
IMPORTANT INFORMATION
GEN
INFO
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
1-3
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead 1
coupler 2
connector 3
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
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps 1 to 3.
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
SPECIAL TOOLS
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/Function
Rotor puller
90890-01080
This tool is used to remove the generator
rotor.
Rotor holding tool
90890-01235
This tool is used to hold the generator rotor
when removing or installing the generator
rotor bolt or pickup coil rotor bolt.
Piston pin puller set
90890-01304
This tool is used to remove the piston pins.
Fuel level gauge
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Radiator cap
tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Damper rod holder
90890-01447
This tool is used to hold the damper rod assembly when loosening or tightening the
damper rod assembly bolt.
1-5
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Oil filter wrench
90890-01426
This tool is needed to loosen or tighten the
oil filter cartridge.
Rod holder
90890-01434
This tool is used to support the damper adjusting rod.
Rod puller
90890-01437
Rod puller
attachment
90890-01436
Rod puller
Rod puller attachment
Fork seal driver
weight
90890-01367
Fork seal driver
attachment (ø43)
90890-01374
Fork seal driver weight
Fork seal driver attachment (ø43)
These tools are used to pull up the front
fork damper rod.
This tool is used to install the front fork’s oil
seal and dust seal.
Micrometer (50 75 mm)
90890-03008
This tool is used to measure the piston skirt
diameter.
Vacuum gauge
90890-03094
Vacuum gauge
attachment
90890-03060
Compression
gauge
90890-03081
Compression
gauge adapter
90890-04136
Vacuum gauge
Vacuum gauge attachment
This guide is used to synchronize the carburetors.
Compression gauge
Compression gauge adapter
These tools are used to measure engine
compression.
Pocket tester
90890-03112
This tool is used to check the electrical system.
Engine tachometer
90890-03113
This tool is used to check engine speed.
1-6
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Timing light
90890-03141
This tool is used to check the ignition timing.
Carburetor angle driver 2
90890-03173
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring compressor
90890-04019
Attachmenht
90890-04108
90890-04114
Valve spring compressor
Valve spring compressor attachment
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to remove or install
the valve assemblies.
These tools are used to install the water
pump seal.
Universal clutch holder
90890-04086
90890-04111
90890-04116
90890-04112
90890-04117
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
Valve guide remover (ø4)
Valve guide remover (ø4.5)
This tool is used to remove or install the
valve guides.
Valve guide installer (ø4)
Valve guide installer (ø4.5)
This tool is used to install the valve guides.
90890-04113
90890-04118
Valve guide reamer (ø4)
Valve guide reamer (ø4.5)
This tool is used to rebore the new valve
guides.
Ignition checker
90890-06754
This tool is used to check the ignition system components.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
1-8
GEN
INFO
Illustration
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18
2-18
2-19
2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
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 radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I)
(N) (NL) (S) (SF) (CH) (P)
5LV2 (F)
5LV3 (D)
5LV4 (AUS)
2,125 mm
765 mm
1,190 mm
820 mm
1,450 mm
140 mm
2,900 mm
231 kg
208 kg
189 kg
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
998 cm3
Forward-inclined parallel 4-cylinder
74 58 mm
11.4 : 1
1,050 1,150 r/min
30 kPa (225 mm Hg)
1,450 kPa (14.5 kg/cm2) at 400 r/min
Regular unleaded gasoline
21 L
4.0 L
Wet sump
SAE20W40SE or SAE10W30SE
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
3.7 L
2.8 L
3.0 L
45 kPa at 1,100 r/min
(0.45 kg/cm2 at 1,100 r/min)
490 570 kPa (4.9 5.7 kg/cm2)
2-2
ENGINE SPECIFICATIONS
Item
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
SPEC
Standard
Limit
Cartridge (paper)
180 220 kPa (1.8 2.2 kg/cm2)
Trochoid
0.09 0.15 mm
0.03 0.08 mm
2.4 L
95 125 kPa (0.95 1.25 kg/cm2)
340 mm
238 mm
24 mm
0.3 L
Single-suction centrifugal pump
68/43 28/28 (1.581)
0.15 mm
Starting system type
Electric starter
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR9E/U27ESR-N (NGK/DENSO) 4
0.7 0.8 mm
Cylinder head
Max. warpage
0.1 mm
2-3
ENGINE SPECIFICATIONS
Item
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Intake camshaft lobe dimensions
SPEC
Standard
Limit
Chain drive (right)
24.500 24.521 mm
24.459 24.472 mm
0.028 0.062 mm
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
32.5 32.6 mm
24.95 25.05 mm
7.45 7.65 mm
32.4 mm
24.85 mm
Measurement A
Measurement B
Measurement C
Max. camshaft runout
32.95 33.05 mm
24.95 25.05 mm
7.75 7.95 mm
32.85 mm
24.85 mm
0.03 mm
2-4
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Head Diameter
Limit
RH2015/130
Automatic
0.11 0.20 mm
0.21 0.25 mm
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
SPEC
Seat Width
Margin Thickness
22.9 23.1 mm
24.4 24.6 mm
1.76 2.90 mm
1.76 2.90 mm
0.9 1.1 mm
0.9 1.1 mm
0.5 0.9 mm
0.5 0.9 mm
3.975 3.990 mm
4.465 4.480 mm
3.945 mm
4.43 mm
4.000 4.012 mm
4.500 4.512 mm
4.05 mm
4.55 mm
0.010 0.037 mm
0.020 0.047 mm
0.08 mm
0.10 mm
0.01 mm
0.9 1.1 mm
0.9 1.1 mm
2-5
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
SPEC
Standard
Limit
38.9 mm
40.67 mm
SSS
SSS
34.5 mm
35 mm
SSS
SSS
82 96 N (8.36 9.79 kg)
110 126 N (11.22 12.85 kg)
SSS
SSS
Intake
SSS
Exhaust
SSS
2.5_/
1.7 mm
2.5_/
1.8 mm
Winding direction (top view)
Intake
Exhaust
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
Clockwise
Clockwise
SSS
SSS
Forward-inclined, parallel 4-cylinder
74 58 mm
11.4 : 1
74.00 74.01 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.05 mm
0.05 mm
2-6
ENGINE SPECIFICATIONS
Item
Piston
Piston-to-cylinder clearance
Diameter D
SPEC
Standard
Limit
0.030 0.055 mm
73.955 73.970 mm
0.12 mm
5 mm
17.002 17.013 mm
Intake side
17.043
16.991 17.000 mm
0.002 0.022 mm
16.971
0.072 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Barrel
0.90 2.75 mm
0.32 0.44 mm
0.030 0.065 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Taper
0.8 2.8
0.43 0.58 mm
0.020 0.055 mm
1.5 2.6 mm
0.10 0.35
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Dimensions (B T)
End gap (installed)
2-7
ENGINE SPECIFICATIONS
Item
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
SPEC
Standard
Limit
0.031 0.055 mm
–1 = Violet 0 = White 1 = Blue 2 = Black
52.40 57.25 mm
300.75 302.65 mm
0.160 0.262 mm
0.029 0.053 mm
0.03 mm
–1 = Pink/violet 0 = Pink/white
1 = Pink/blue 2 = Pink/black
3 = Pink/brown
Wet, multiple disc
Cam (pull rod type)
Cable operation
Left-hand operation
10 15 mm
2.92 3.08 mm
8
3.42 3.58 mm
1
2.82 mm
3.32 mm
1.9 2.1 mm
8
0.1 mm
50 mm
6
Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Thickness
Plate quantity
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
2-8
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
SPEC
Standard
Limit
Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
44/16 (2.750)
Left-foot operation
35/14 (2.500)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)
0.08 mm
0.08 mm
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Installed shift rod length
Guide bar
260 mm
0.1 mm
Air filter type
Dry element
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
4SV (MITSUBISHI)
20 kPa (0.2 kg/cm2)
2-9
ENGINE SPECIFICATIONS
Item
Carburetors
Model (manufacturer) quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Fuel level (above the line on the
float chamber)
Max. EXUP cable free play (at the
EXUP valve pulley)
SPEC
Standard
Limit
BSR37 (MIKUNI) 4
3 5 mm
5LV1 00
Carburetors 1 and 4: #132.5
Carburetors 2 and 3: #130
#80
Carburetor 1 and 4: 5D129-3/5
Carburetor 2 and 3: 5D130-3/5
P-OM
#85
1.0
#15
0.9
0.9
0.9
2.0
1.5
#42.5
0.8
#115
3.0 4.0 mm
1.5 mm
2-10
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 201 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Double cradle
26_
104 mm
SSS
SSS
SSS
Cast wheel
SSS
17 MT3.50
Aluminum
140 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Cast wheel
SSS
17 MT5.50
Aluminum
135 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Tubeless
120/70 ZR17 (58W)
MEZ4Y FRONT (METZELER)
BT020F U (BRIDGESTONE)
SSS
SSS
SSS
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
SSS
SSS
SSS
SSS
1.6 mm
2-11
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 201 kg
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position (from the top
of the brake pedal to the top of the
rider footrest)
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
SPEC
Standard
Limit
Tubeless
180/55 ZR17 (73W)
MEZ4Y (METZELER)
BT020R U (BRIDGESTONE)
270 kPa (2.7 kgf/cm2, 2.7 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
1.6 mm
Dual-disc brake
Right-hand-operation
DOT 4
298 5 mm
5.5 mm
4.5 mm
0.1 mm
0.5 mm
14 mm
30.2 mm and 27 mm
Single-disc brake
Right-foot operation
35 40 mm
DOT 4
267 5 mm
5.5 mm
4.5 mm
0.1 mm
0.5 mm
12.7 mm
42.9 mm
2-12
CHASSIS SPECIFICATIONS
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
140 mm
344.0 mm
78.5 mm
320.0 mm
8.1 N/mm (0.83 kg/mm)
11.8 N/mm (1.2 kg/mm)
0 55 mm
55 140 mm
No
Suspension oil “01” or equivalent
440 cm3
140 mm
8
4
1
17
7
1
21
6
1
2-13
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
SPEC
Standard
Limit
Angular ball bearings
Swingarm (link suspension)
Coil spring/gas-oil damper
65 mm
182.5 mm
163 mm
73.6 N/mm (7.5 kgf/mm)
0 65 mm
No
1,200 kPa (12 kgf/cm2)
1
6
11
20
10
3
1
7
12
Swingarm
Free play (at the end of the
swingarm)
Radial
Axial
1 mm
1 mm
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
50ZVM (DAIDO)
116
40 50 mm
150.1 mm
152.5 mm
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
2-14
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
System voltage
12 V
SSS
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit
model (manufacturer)
Transistorized coil ignition
5_ BTDC at 1,100 r/min
55_ BTDC at 5,000 r/min
Throttle position sensor and electrical
248 372 Ω/Gy-B
TNDF66 (DENSO)
SSS
SSS
SSS
SSS
SSS
SSS
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
J0313 (DENSO)
6 mm
1.87 2.53 Ω
12 18 kΩ
SSS
SSS
SSS
SSS
Spark plug caps
Material
Resistance
Rubber
10 kΩ
SSS
SSS
Throttle position sensor standard
resistance
4 6 kΩ
SSS
Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance/color
AC magneto
F4T361 (MITSUBISHI)
14 V/365 W at 5,000 r/min
0.27 0.33 Ω at 20_C/W-W
SSS
SSS
SSS
SSS
Rectifier/regulator
Regulator type
Model ((manufacture))
No-load regulated voltage
Rectifier capacity
Withstand voltage
Semiconductor short circuit
SH650C-11 ((SHINDENGEN))
14.1 14.9 V
18 A
200 V
SSS
SSS
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity
GT14B-4
12 V/12AH
SSS
SSS
Headlight type
Halogen bulb
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Meter light
12 V 60 W/55 W 2
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W 4
12 V 2 W 3
2-15
SSS
SSS
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item
Indicator light
(voltage /wattage quantity)
Neutral indicator light
High beam indicator light
Oil level indicator light
Turn signal indicator light
Fuel indicator light
Water temperature indicator light
SPEC
Standard
Limit
14 V 1.4 W 1
14 V 1.4 W 1
14 V 1.4 W 1
14 V 1.4 W 2
12 V 2 W 1
LED
SSS
SSS
SSS
SSS
SSS
SSS
Constant mesh
SSS
SM-13 (MITSUBA)
0.8 kW
SSS
SSS
12.5 mm
7.65 10.01 N (780 1,021 gf)
0.025 0.035 Ω
28 mm
0.7 mm
4 mm
SSS
SSS
27 mm
SSS
Starter relay
Model (manufacturer)
Amperage
Coil resistance
MS5F-631 (JIDECO)
180 A
4.18 4.62 Ω
SSS
SSS
SSS
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Plain
YF-12 (NIKKO) 1
3A
SSS
SSS
SSS
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full-transistor
FE246BH (DENSO)
No
75 95 cycles/min.
21 W 2 + 3.4 W
SSS
SSS
SSS
SSS
SSS
Oil level switch
Model (manufacturer)
5LV (DENSO)
SSS
Fuel sender
Model (manufacturer)
Resistance
5LV (NIPPON SEIKI)
4 100 Ω at 25_C
SSS
SSS
Sidestand /fuel pump relay
Model (manufacturer)
Coil resistance
5EB-20 (OMRON)
180 Ω
SSS
SSS
Fuel pump maximum amperage
1.2 A
SSS
Radiator fan
Model (manufacturer)
4XV (TOYO RADIATOR)
SSS
Thermo switch
Model (manufacturer)
5JJ (NIPPON THERMOSTAT)
SSS
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
2-16
ELECTRICAL SPECIFICATIONS
Item
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Turn signal relay fuse
Backup fuse (odometer)
Reserve fuse
SPEC
Standard
30 A 1
20 A 1
20 A 1
20 A 1
10 A 1
10 A 1
10 A 1
30 A 1
20 A 1
10 A 1
2-17
Limit
TIGHTENING TORQUES
EAS00029
TIGHTENING TORQUE
GENERAL TIGHTENING TORQUES
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
A
(Nut)
B
(Bolt)
10 mm
General tightening
torques
Nm
mkg
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
2-18
SPEC
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Thread
size
Q’ty
y
Spark plugs
–
Cylinder head
Nut
Cylinder head
Cap nut
Cylinder head
Bolt
Camshaft caps
Bolt
Cylinder head cover
Bolt
Cylinder head (exhaust pipe)
Stud bolt
Connecting rod caps
Nut
Generator rotor
Bolt
Crankshaft sprocket
Bolt
Cap bolt (timing chain tensioner)
Bolt
Camshaft sprocket
Bolt
Water pump inlet pipe
Bolt
Water pump outlet pipe
Bolt
Oil/water pump assembly driven
Bolt
sprocket
Oil pump
Bolt
Oil cooler
Bolt
Engine oil drain bolt
–
Oil strainer housing
Bolt
Oil/water pump assembly driven
Bolt
sprocket cover
Oil delivery pipe
Bolt
Oil filter bolt
Bolt
Oil filter cartridge
–
Oil pipe
Bolt
Air cleaner cap and air cleaner
Screw
Frame and air cleaner
Bolt
Air cleaner cover and air cleaner Screw
Ring nut and cylinder head
Nut
Exhaust pipe and muffler
Bolt
Emission check bolt
Bolt
EXUP pulley cover
Bolt
EXUP cable bracket
Bolt
EXUP pulley and shaft arm
Bolt
Exhaust joint
Bolt
Exhaust pipe assembly
Bolt
Air induction system pipe
Band
Crankcase (cylinder head)
Stud bolt
M10
M10
M10
M6
M6
M6
M8
M8
M10
M10
M6
M7
M6
M6
Crankcase
Crankcase
Crankcase
Crankcase
Item
Fastener
Tightening
torque
Nm
mSkgf
4
8
2
2
28
6
8
8
1
1
1
4
1
1
13
50
50
12
10
12
15
36
65 + 60_
60
6.4
24
10
10
1.3
5.0
5.0
1.2
1.0
1.2
1.5
3.6
6.5 + 60_
6.0
0.64
2.4
1.0
1.0
M6
1
15
1.5
M6
M20
M14
M6
1
1
1
2
12
35
43
10
1.2
3.5
4.3
1.0
M6
1
12
1.2
M6
M20
M20
M6
M6
M6
M6
M8
M8
M8
M6
M6
M5
M4
M8
–
M10
1
1
1
2
4
3
6
8
3
4
3
3
1
2
1
4
10
10
70
17
10
6
7
2
20
20
10
10
10
10
3
20
3.5
10
1.0
7.0
1.7
1.0
0.6
0.7
0.2
2.0
2.0
1.0
1.0
1.0
1.0
0.3
2.0
0.35
1.0
Bolt
M9
10
Bolt
Bolt
Bolt
M6
M6
M8
2
14
2
2-19
See note
14
12
24
1.4
1.2
2.4
Remarks
TIGHTENING TORQUES
Item
Fastener
Thread
size
Q’ty
y
SPEC
Tightening
torque
Nm
mSkgf
Remarks
AC magneto cover
Drive sprocker cover
Plate
Clutch cover
Timing chain cap bolt
Shift shaft cover
Breather plate
Timing mark accessing screw
Starter clutch idle gear shaft
Starter one-way clutch
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M6
M6
M6
M6
M6
M8
M6
M6
9
4
2
8
8
5
5
1
1
3
12
10
10
12
12
12
10
15
10
12
1.2
1.0
1.0
1.2
1.2
1.2
1.0
1.5
1.0
1.2
Clutch boss
Nut
M20
1
90
9.0
Clutch spring
Bolt
M6
6
8
0.8
Drive sprocket
Nut
M22
1
85
8.5
Screw
Bolt
Screw
Nut
Nut
Bolt
Bolt
Screw
Screw
–
Bolt
–
M6
M6
M8
M6
M6
M6
M6
M6
M5
M10
M6
–
3
2
1
1
2
1
1
3
2
1
2
1
12
10
22
6.5
6.5
10
10
14
7
20
10
15
1.2
1.0
2.2
0.65 Left thread
0.65
1.0
1.0
1.4
0.7
2.0
1.0
1.5
Main axle bearing housing
Shift lever stopper
Stopper screw
Shift rod
Shift rod
Shift rod joint
Shift arm
AC magneto stator coil
Ignitor unit
Neutral switch
Pick up coil
Thermo unit
NOTE:
1. First, tighten the bolt to approximately 14.7 Nm (1.5 mSkg) with a torque wrench.
2. Retighten the bolt to 14.7 Nm (1.5 mSkg), and tighten another 45 50_.
2-20
Use a lock
washer.
Use a lock
washer.
TIGHTENING TORQUES
Crankcase tightening sequence:
2-21
SPEC
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Item
Thread size
Upper bracket pinch bolt
Upper bracket cap nut
Upper bracket and handlebar holder
Handlebar holder
Lower bracket pinch bolt
Lower bracket ring nut
Front brake master cylinder
Front brake hose union bolt
Engine mounting
Engine mounting bolt/nut
Engine mounting bolt/nut
Frame and down tube
Clutch cable lock nut
Ignition coil and stay
Pivot shaft
Rear shock absorber (upper)
Rear shock absorber and relay arm
Relay arm and frame
Relay arm and connecting arm
Connecting arm and swing arm
Drive chain guard
Drive chain case
Fuel cock
Fuel sender
Side cover
Coolant reservoir tank
Front wheel axle
Front wheel axle pinch bolt
Front brake caliper
Front brake disk
Front brake bleed screw
Rear brake torque rod
Rear wheel sprocket
Drive chain adjusting nut
Rear brake caliper
Rear wheel axle
Rear brake hose union bolt
Rear brake bleed screw
Rear brake disk
Rider footrest bracket and frame
Rear brake reservoir tank
Rear brake master cylinder
Rider footrest and bracket
Passenger footrest bracket and frame
Passenger footrest bracket and muffler
Tightening
Nm
mkgf
M8
M22
M10
M8
–
M25
M6
M10
30
110
32
23
23
18
10
30
3.0
11
3.2
2.3
2.3
1.8
10
3.0
M10
M8
M10
M8
M6
M18
M10
M10
M10
M12
M12
M6
M6
M6
M5
M6
M6
M16
M8
M10
M6
M8
M8
M10
M8
M10
M24
M10
M8
M8
M8
M6
M8
M10
M8
M10
55
33
89
7
7
125
40
40
40
48
48
7
7
7
4
4
4
72
23
40
18
6
23
69
16
40
150
30
6
23
30
4
23
55
28
48
5.5
3.3
8.9
0.7
0.7
12.5
4.0
4.0
4.0
4.8
4.8
0.7
0.7
0.7
0.4
0.4
0.4
7.2
2.3
4.0
1.8
0.6
2.3
6.9
1.6
4.0
15
3.0
0.6
2.3
3.0
0.4
2.3
5.5
2.8
4.8
Remarks
See note
NOTE:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubricant
Lubrication point
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Connecting rod bolts and nuts
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil strainer
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surface
Yamaha bond
No.1215
Crankcase mating surface
Yamaha bond
No.1215
Clutch cover (crankcase mating surface)
Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)
Yamaha bond
No.1215
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings, steering seal lips and ball race cover lips
Pivot shaft
Swing arm pivoting points and connecting arm bearings
Connecting arm oil seal lips
Swing arm oil seal lips
Relay arm bearings
Relay arm oil seal lips
Rear shock absorber upper bolt
Front wheel oil seal lips
Rear wheel oil seal lips
Clutch hub oil seal lips
Throttle cable end
Starter cable end and starter lever
Rear brake pedal moving point
Shift pedal moving point
Side stand moving point
Passenger footrest ball joint and moving point
Engine mounting bracket collar and oil seal lips
Mainstand moving point
2-24
COOLING SYSTEM DIAGRAMS
EAS00033
COOLING SYSTEM DIAGRAMS
1
2
3
4
Radiator cap
Thermostat housing
Radiator
Water pump
2-25
SPEC
COOLING SYSTEM DIAGRAMS
1
2
3
4
5
Radiator cap
Thermostat housing
Radiator
Oil cooler
Water jacket joint
2-26
SPEC
COOLING SYSTEM DIAGRAMS
1 Radiator cap
2 Thermostat
3 Thermo unit
2-27
SPEC
COOLING SYSTEM DIAGRAMS
1 Radiator
2-28
SPEC
ENGINE OIL LUBRICATION CHART
SPEC
ENGINE OIL LUBRICATION CHART
Exhaust
camshaft
Intake
camshaft
Main gallery
Oil filter
Main axle
Oil
cooler
Strainer
Relief
valve
Drive axle
2-29
LUBRICATION DIAGRAMS
EAS00034
LUBRICATION DIAGRAMS
1
2
3
4
5
6
Oil cooler
Oil filter cartridge
Drain bolt
Oil level switch
Oil strainer
Oil pump
2-30
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
5
Intake camshaft
Exhaust camshaft
Oil cooler
Oil strainer
Oil pump
2-31
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Intake camshaft
Exhaust camsahft
Oil filter cartridge
Oil level switch
2-32
SPEC
LUBRICATION DIAGRAMS
1 Cylinder head
2 Crankshaft
2-33
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Oil delivery pipe
3 Drive axle
2-34
SPEC
CABLE ROUTING
SPEC
EAS00035
CABLE ROUTING
A Fasten the handlebar switch lead (right) and handlebar with a plastic band.
B Route the handlebar switch lead (right) backward
the throttle cable and right side the brake hose
guide.
C Fasten the handlebar switch lead (left) and handlebar with a plastic band.
D Fasten the handlebar switch lead (left), main switch
lead, clutch cable and starter cable with a plastic
band. Clamp beneath the horn lead branching position. Do not fasten the horn lead.
E Route the main switch lead front and left side the
another leads.
F Route the horn lead outside the motorcycle body,
and fasten with the under bracket. Do not loose between the horn and under bracket.
G Route the brake hose through the brake hose
guide.
H Route the throttle cable 1 and 2 backward the brake
hose, and left side the brake hose guide.
2-35
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fuel pump lead
Fuel pump
EXUP cable
Handlebar switch lead (right)
Throttle cable 1
Throttle cable 2
Water-carburetor hose
Fan motor lead
Coolant reservoir tank over flow
hose
Fuel tank drain hose
Fuel tank breather hose
White paint mark
Rear brake light switch lead
Neutral switch lead
Speedo sensor lead
Pickup coil lead
SPEC
17 Handle crown
18 Handlebar switch lead
19 Brake hose guide
A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed
sensor lead, rear brake light switch lead and fuel pump with a plastic
clamp.
B Fasten the fuel hose, pickup coil lead, neutral switch lead and speed
sensor lead with a plastic clamp under the fuel hose.
C Put the EXUP cable into the air box cover.
D Route the T.P.S. lead inward the EXUP cable.
E Fasten the water-carburetor hose with a plastic band.
F Route the coolant hose over the frame.
G Fasten the handlebar switch lead and frame with a plastic guide.
H Align the white tape mark of the handlebar switch lead (right) with the
tank rail welding bead and clamp down throttle cables 1 and 2.
2-36
CABLE ROUTING
I Route the water-carburetor hose between the
frame cross pipe and fan motor lead.
J To the carburetor
K Fasten the T.P.S. lead with a steel clamp.
L Fasten the coolant hose with a plastic band.
M Fasten the pickup coil lead with a steel clamp.
N Pass the coolant reservoir tank overflow hose, fuel
tank drain hose and fuel tank breather hose through
the frame hose holder from the inside of the vehicle
to the outside. At this time, pull the fuel tank drain
hose and fuel tank breather hose so that the white
paint marks are within a 20 mm range.
O Route the EXUP cable forward the another hoses,
and upward the engine mounting bracket.
P Fasten the rear brake light switch lead with a plastic
guide.
SPEC
Q Insert the all couplers into the rubber cover.
R Route the rear brake light switch lead inside the
another leads.
S Route the neutral switch lead and speed sensor
lead left side the coolant reservoir hose.
T Route the coolant reservoir hose left side the engine mounting bracket.
U Route the coolant reservoir hose forward the neutral switch lead and speed sensor lead.
V Route the coolant reservoir hose backward the
another hoses.
W Route the EXUP cable forward the another hoses.
X Route the EXUP cable forward the frame cross
pipe.
Y Route the fuel tank drain hose and fuel tank breather hose forward the neutral switch lead and speed
sensor lead.
2-37
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Starter cable
Clutch cable
Handlebar switch lead (left)
Main switch lead
EXUP servo motor
Starting circuit cutoff relay
Starter motor lead
Fan motor relay
Air cleaner case drain hose
Sidestand switch lead
oil level switch lead
ACgenerator lead
Water-head pipe
Water-carburetor hose
Throttle cable 2
Throttle cable 1
EXUP cable
SPEC
A Fasten the main switch lead and handlebar switch lead with a plastic
guide.
B Fasten the water-head hose and water-carburetor hose with a plastic
band.
C Fasten the clutch cable with a plastic band.
D Fasten the clutch cable with a steel clamp.
E Fasten the wire harness with a plastic band.
F To the fuel sender.
G Route the fuel sender lead inside the seat rail.
H Route the battery negative lead forward the frame stay.
I Route the main harness inside the rear fender groove.
J Fasten the wire harness, sidestand switch lead, oil level switch and
flame with a plastic band. Do not fasten the Acgenerator lead (white).
K Route the starter motor lead and battery negative lead inside the plastic
band.
L Route the all hoses outside the fuel hose.
M Route the fuel hose through the steel guide.
2-38
CABLE ROUTING
N Fasten the sidestand switch lead, oil level switch lead,
ACgenerator lead, starter motor lead, battery negative
lead and air cleaner case drain hose with a plastic clamp.
O Fasten the sidestand switch lead, oil level switch lead,
ACgenerator lead and air filter case drain hose with a
plastic clamp.
P Fasten the sidestand switch lead and frame with a plastic
clamp.
Q Route the air cleaner box drain hose inside the sidestand
switch lead, and put the end of the hose backward.
R Fasten the sidestand switch lead and frame with a plastic
clamp.
S Fasten the sidestand switch lead, oil level switch lead and
air filter case drain hose with a plastic clamp. Do not crush
the air filter case drain hose.
T Route the high tension cable (#1) outside the starter cable
and water-carburetor hose, and under the clutch cable
SPEC
and rectifier regulator lead.
U Route the water carburetor hose outside the coolant
hose.
V Route the starter cable outside the coolant hose, and upper the water-carburetor hose.
W Route the high tension cable (#2, 3) forward the EXUP
cable and high tension cable (#4).
X Route the throttle cable between the water-head hose,
and upper the EXUP cable.
Y Route the high tension cable (#4) between the waterhead hose.
Z Taillight lead and flasher light lead (right) should not be
stick out from the gap between the rear fender and taillight.
AA Route the flasher light lead through the hole on the rear
fender.
AB Route the wire harness in the groove.
2-39
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Clutch cable
Handlebar switch lead
Main switch lead
Starter cable
Thermo unit lead
Throttle cable 1
Throttle cable 2
Handlebar switch lead (right)
Coolant reservoir hose
Ignition coil
Fuel hose
Fan motor lead
EXUP servo motor lead
Rectifier/ regulator lead
White paint mark
Main harness
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Ignition coil lead
Battery
Emergency engine stop switch
Flasher relay
Fuse box
Igniter unit
Flasher light lead
Taillight lead
Alarm coupler (free)
Starter relay
Battery positive lead
Fan motor lead
Battery negative lead
Starting circuit cutoff relay
2-40
SPEC
CABLE ROUTING
A Fasten the flasher light lead and headlight lead with
a plastic clamp.
B Route the rectifier / regulator lead upper the fan motor lead and EXUP servomotor lead.
C Route the throttle cable right side the fan motor
lead, EXUP servo motor lead and thermo unit lead.
D Fasten the flasher light lead with a plastic clamp.
E Route the all leads between the frame cross pipe
and bracket.
F Do not excessively bend the throttle cable.
G Route the coolant reservoir hose under the frame
cross pipe.
H Fasten the ignition coil and ignition coil lead with a
plastic clamp.
I Route the T.P.S. lead under the air vent hose.
J Fasten the EXUP cable with a plastic band.
SPEC
K Fasten the fuel hose and air induction system hose
with a plastic clamp.
L Route the coolant reservoir hose under the frame
cross pipe.
M Fasten the fuel hose and frame with a plastic band.
N Put the fuel tank drain hose into the frontward nipple
on the fuel tank.
O Put the fuel tank breather hose into the backward
nipple on the fuel tank.
P Route the coolant reservoir hose under the air vent
hose and air induction system hose.
Q Route the air vent hose upper the main harness.
R All coupler into the rubber cover.
S Fasten the Rectifier / regulator lead with a plastic
band in the main harness.
2-41
CABLE ROUTING
SPEC
T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear
with a plastic clamp. Do not fasten the red / black
fender.
lead and orange lead.
AB Fasten the battery positive lead with a plastic band.
U Fasten the handlebar switch lead (left / right), main
switch lead, EXUP servo motor lead, fan motor lead
and thermo unit lead with a plastic clamp.
V Fasten the rectifier / regulator stay and rectifier / regulator lead with a plastic clamp.
W Route the wire harness under the rectifier / regulator.
X Fasten the battery negative lead with a battery
band.
Y Insert the ground lead coupler in the battery band.
Z Fasten the taillight lead and flasher light lead, and
put in the groove on the taillight bracket.
2-42
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK . . . . . . . . . . . . . . 3-3
FRONT COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
SEAT, SIDE COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-5
3-10
3-12
3-13
3-15
3-16
3-17
3-19
3-20
3-22
3-23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-33
3-33
3-34
3-35
3-36
3-36
3-37
3-37
3-38
3-39
3-41
3-41
3-43
3-43
3-45
3-47
3-24
3-24
3-25
3-25
3-26
3-27
3-29
3-30
CHK
ADJ
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . .
3-50
3-50
3-50
3-50
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-51
3-51
3-56
3-58
3-59
3-59
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO
NO.
ITEM
CHECK OR MAINTENANCE JOB
1
*
Fuel line
(See page 3-24)
Check fuel hoses for cracks or damage.
2
*
Fuel filter
(See page 3-24)
Check condition.
Spark plugs
(See page 3
3-15)
15)
3
4
*
Valves
(See page 3-5)
5
Air filter element
(See page 3-23)
6
Clutch
(See page 3-22)
7
8
*
*
Front brake
(See page 3-35)
3 35)
(See page 3-36)
Rear brake
(See page 3-35)
3 35)
(See page 3-36)
ODOMETER READING ( 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
√
√
√
√
√
√
Check condition.
Clean and regap.
√
√
√
√
Replace.
Check valve clearance.
Adjust.
√
Every 40,000 km
√
Clean.
√
√
Replace.
√
Check operation.
Adjust.
√
√
√
√
√
Check operation, fluid level and vehicle
for fluid leakage. (See NOTE)
√
√
√
√
√
Replace brake pads.
Whenever worn to the limit
Check operation, fluid level and vehicle
for fluid leakage. (See NOTE)
√
√
Replace brake pads.
√
√
√
√
√
√
Brake hoses
(See page 3-37)
*
Wheels
(See page 4-4)
Check runout and for damage.
√
√
√
√
11
*
Tires
(See page 3-47)
√
√
√
√
12
*
Wheel bearings
(Seep age 4-4)
Check bearing for looseness or damage.
√
√
√
√
13
*
Swingarm
(See page 4
4-68)
68)
(See page 4-69)
Check operation and for excessive play.
√
√
√
√
10
Drive chain
(See page 3-39)
(See page 4-69)
14
15
*
Steering bearings
(See page 3-41)
3 41)
(See page 4-59)
√
Whenever worn to the limit
√
Check for cracks or damage.
*
9
√
Replace. (See NOTE)
Every 4 years
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Lubricate with lithium-soap-based grease.
Every 50,000 km
Check chain slack.
Make sure that the rear wheel is properly
aligned.
Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in the rain.
Check bearing play and steering for
roughness.
Lubricate with lithium-soap-based grease.
3-1
√
√
√
√
Every 20,000 km
√
√
CHK
ADJ
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NO
NO.
16
ITEM
*
17
CHECK OR MAINTENANCE JOB
ODOMETER READING ( 1,000 km)
1
10
20
30
40
ANNUAL
CHECK
Chassis fasteners
(See page 2-22)
Make sure that all nuts, bolts and
screws and properly tightened.
√
√
√
√
√
Sidestand /
centerstand
(Seep age 3-50)
Check operation.
Lubricate.
√
√
√
√
√
√
√
√
√
√
18
*
Sidestand switch
(See page 8-21)
Check operaiton.
19
*
Front fork
(See page 3-43)
Check operation and for oil leakage.
√
√
√
√
20
*
Rear shock
absorber
assembly
(See page 4-64)
Check operation and shock absorber for
oil leakage.
√
√
√
√
Check operation.
√
√
√
√
*
Rear suspension
relay arm and
connecting arm
pivoting points
(See page 4-69)
Carburetors
(See page 3-10)
(See page 3-12)
Check starter (choke) operation.
Adjust engine idling speed and
synchronization.
√
√
√
√
√
√
23
Engine oil
(See page 3-20)
Change.
√
√
√
√
√
√
24
Engine oil filter
cartridge
(See page 3-20)
Replace.
√
21
22
25
26
*
28
29
√
Lubricate with lithium-soap-based grease.
Check coolant level and vehicle. for
coolant leakage
*
Cooling system
(See page 3-29)
3 29)
(See page 3-30)
*
Front and rear
brake switches
(See page 3-36)
(See page 8-38)
Chck operation.
Moving parts and
cables
(See page 2-24)
(See page 3-50)
*
*
27
√
√
√
√
Change.
√
√
√
√
√
Every 3 years
√
√
√
√
√
√
Lubricate.
√
√
√
√
√
Air induction
system
(See page 7-16)
Check the air cut valve and reed valve for
damage.
Replace the entire air induction system if
necessary.
√
√
√
√
√
Lights, signals
and switches
(See page 3-59)
(See page 8-30)
(See page 8-35)
Check operation.
Adjust headlight beam.
√
√
√
√
√
√
*: It is recommended that these items be serviced by a Yamaha dealer.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
3-2
FRONT COWLING
CHK
ADJ
EAS00038
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK
FRONT COWLING
Order
1
2
3
4
5
6
Job/Part
Removing the fron cowling
Inner panel
Headlight/meter coupler
Front cowling assembly
Back view mirror
Meter unit
Headlight unit
Q’ty
Remarks
Remove the4 parts in the order listed.
2
1/1
1
2
1
1
Disconnect.
For installation, reverse the removal
procedure.
3-3
SEAT, SIDE COVER AND FUEL TANK
CHK
ADJ
EAS00040
SEAT, SIDE COVER AND FUEL TANK
19 Nm (1.9 mkg)
10 Nm (1.0 mkg)
4 Nm (0.4 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
1
2
3
4
5
6
7
Removing the seat, side cover and
fuel tank
Seat
Side cover (left and right)
Fuel sender coupler
Fuel tank
Fuel tank breather hose
Fuel tank drain hose
Fuel hose
1
2
1
1
1
1
1
8
9
Grab bar
Rear cowling
1
1
Disconnect.
NOTE:
Befor disconnecting the fuel hose, turn
the fuel cock off.
For installation, reverse the removal
procedure.
3-4
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00045
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:
cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.
2. Measure:
valve clearance
Out of specification Adjust.
Valve clearance (cold)
Intake valve
0.11 X 0.20 mm
Exhaust valve
0.21 X 0.25 mm
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
pickup rotor with the crankcase mating surface b .
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:
If the valve clearance is incorrect, record the
measured reading.
Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 #2 #4 #3
3-5
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
A Front
d. For each cylinder, starting with cylinder #1 at
TDC, turn the crankshaft clockwise as specified in the following table.
B Degrees that the crankshaft is turned clockwise
C Cylinder
D Combustion cycle
#2 Cylinder
180_
#4 Cylinder
360_
#3 Cylilnder
540_
3. Remove:
S intake camshaft
S exhaust camshaft
NOTE:
S Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chapter 5.
S When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.
4. Adjust:
S valve clearance
a. Remove the valve lifter 1 and the valve pad
2 with a valve lapper 3 .
Valve lapper
90890–04101
3-6
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
b. Select the proper valve pad from the following table.
Valve pad
thickness range
Available valve
pads
Nos.
1.20 X
120 X 240 2.40 mm
25 thicknesses
in 0.05 mm
increments
NOTE:
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
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.
c. 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 = 148 (thickness
=1.48 mm (0.058 in))
Rounded value = 150
d. 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.
3-7
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
VALVE PAD SELECTION TABLE
INTAKE
Measured
clearance
#
0.00 X 0.02
0.03 X 0.07
0.08 X 0.10
0.11 X 0.20
exa 0.21 X 0.22
0.23 X 0.27
!
0.28 X 0.32
0.33 X 0.37
0.38 X 0.42
0.43 X 0.47
0.48 X 0.52
0.53 X 0.57
0.58 X 0.62
0.63 X 0.67
0.68 X 0.72
0.73 X 0.77
0.78 X 0.82
0.83 X 0.87
0.88 X 0.92
0.93 X 0.97
0.98 X 1.02
1.03 X 1.07
1.08 X 1.12
1.13 X 1.17
1.18 X 1.22
1.23 X 1.27
1.28 X 1.32
1.33 X 1.37
INSTALLED PAD NUMBER
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145 150 155 160 165 170
120 125 130 135 140 145 150 155 160 165 170 175
120 125 130 135 140 145 150 155 160 165 170 175 180
Specification
130 135 140 145 150 155 160 165 170 175 180 185 190
135 140 145 150 155 160 165 170 175 180 185 190 195
140 145 150 155 160 165 170 175 180 185 190 195 200
145 150 155 160 165 170 175 180 185 190 195 200 205
150 155 160 165 170 175 180 185 190 195 200 205 210
155 160 165 170 175 180 185 190 195 200 205 210 215
160 165 170 175 180 185 190 195 200 205 210 215 220
165 170 175 180 185 190 195 200 205 210 215 220 225
170 175 180 185 190 195 200 205 210 215 220 225 230
175 180 185 190 195 200 205 210 215 220 225 230 235
180 185 190 195 200 205 210 215 220 225 230 235 240
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
240
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
195
200
205
210
215
220
225
230
235
240
200
205
210
215
220
225
230
235
240
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
EXAMPLE:
VALVE CLEARANCE: 0.11 X 0.20 mm
Installed is 150
Measured clearance is 0.25 mm
Replace 150 pad with 160 pad
EXHAUST
Measured
clearance
#
0.00 X 0.02
0.03 X 0.07
0.08 X 0.10
0.13 X 0.17
0.18 X 0.20
0.21 X 0.30
exa 0.31 X 0.32
0.33 X 0.37
!
0.38 X 0.42
0.43 X 0.47
0.48 X 0.52
0.53 X 0.57
0.58 X 0.62
0.63 X 0.67
0.68 X 0.72
0.73 X 0.77
0.78 X 0.82
0.83 X 0.87
0.88 X 0.92
0.93 X 0.97
0.98 X 1.02
1.30 X 1.07
1.08 X 1.12
1.13 X 1.17
1.18 X 1.22
1.23 X 1.27
1.28 X 1.32
1.33 X 1.37
1.38 X 1.42
1.43 X 1.47
INSTALLED PAD NUMBER
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
120
120 125
120 125 130
120 125 130 135
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120
125
130
135
140
125
130
135
140
145
130
135
140
145
150
135
140
145
150
155
140
145
150
155
160
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145 150 155 160
150 155 160 165
155 160 165 170
160 165 170 175
165 170 175 180
Specification
175 180 185 190
180 185 190 195
185 190 195 200
190 195 200 205
195 200 205 210
200 205 210 215
205 210 215 220
210 215 220 225
215 220 225 230
220 225 230 235
225 230 235 240
230 235 240
235 240
240
165
170
175
180
185
170
175
180
185
190
175
180
185
190
195
180
185
190
195
200
185
190
195
200
205
190
195
200
205
210
195
200
205
210
215
200
205
210
215
220
205
210
215
220
225
210
215
220
225
230
195
200
205
210
215
220
225
230
235
240
200
205
210
215
220
225
230
235
240
205
210
215
220
225
230
235
240
210
215
220
225
230
235
240
215
220
225
230
235
240
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
EXAMPLE:
VALVE CLEARANCE: 0.21 X 0.30 mm
Installed is 175
Measured clearance is 0.35 mm
Replace 175 pad with 185 pad
3-8
215
220
225
230
235
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
e. Install the new valve pad 1 and the valve lifter 2 .
NOTE:
Apply molybdenum disulfide to the valve pad.
Lubricate the valve lifter with molybdenum disulfide oil.
The valve lifter must turn smoothly when rotated by hand.
Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 mkg)
NOTE:
Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAMSHAFT” in chapter 4.
Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft
cap marks.
Rotate the crankshaft clockwise several turns
to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
5. Install:
cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.
6. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.
3-9
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 cap
3. Install:
vacuum gauge attachment
vacuum gauge 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
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
1,050 X 1,150 r/min
3-10
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
6. Adjust:
carburetor synchronization
a. Synchronize carburetor #1 to carburetor #2
by turning the synchronizing screw 1 in either direction until both gauges read the
same.
NOTE:
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
b. Synchronize carburetor #4 to carburetor #3
by turning the synchronizing screw 2 in either direction until both gauges read the
same.
c. Synchronize carburetor #2 to carburetor #3
by turning the synchronizing screw 3 in either direction until both gauges read the
same.
Vacuum pressure at engine idling
speed
30 kPa (225 mm Hg)
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa (10
mm Hg).
7. Measure:
engine idling speed
Out of specification Adjust.
8. Stop the engine and remove the measuring
equipment.
9. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 X 5 mm
10. Install:
vacuum cap
3-11
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
EAS00052
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
90890-03113
3. Measure:
engine idling speed
Out of specification Adjust.
Engine idling speed
1,050 X 1,150 r/min
4. Adjust:
engine idling speed
a. Turn the pilot screw 1 in or out until it is lightly seated.
b. Turn the pilot screw out the specified number
of turns.
Carburetor angle driver 2
908900-03173
Pilot screw
2 turns out
3-12
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
c. Turn the throttle stop screw 2 in direction a
or b until the specified engine idling speed is
obtained.
Direction a
Engine idling speed is increased.
Direction b
Engine idling speed is
decreased.
5. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 X 5 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.
1. Check:
throttle cable free play a
Out of specification Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3 X 5 mm
2. Remove:
seat
fuel tank
3-13
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
3. Adjust:
throttle cable free play
NOTE:
When the motorcycle is accelerating, the accelerator cable 1 is pulled.
Carburetor side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 4 on the accelerator
cable.
d. Turn the adjusting nut 5 in direction a or b
until the specified throttle cable free play is
obtained.
Direction a
Throttle cable free play is
increased.
Direction b
Throttle cable free play is
decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable, use
the adjusting nut on the handlebar side.
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.
Direction a
Throttle cable free play is
increased.
Direction b
Throttle cable free play is
decreased.
c. Tighten the 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.
3-14
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
CHK
ADJ
4. Install:
fuel tank
seat
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)
CR9E (NGK)
U27ESR-N (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.
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
0.7 0.8 mm
3-15
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
CHK
ADJ
7. Install:
spark plug
13 Nm (1.3 mkg)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Connect:
spark plug cap
EAS00063
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
90890-03141
Engine tachometer
90890-03113
3. Check:
ignition timing
a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed.
Engine idling speed
1,050 X 1,150 r/min
3-16
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
b. Check that the mark a is within the required
firing range b on the pickup coil 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
EAS00065
MEASURING THE COMPRESSION PRESSURE
The following procedure applies to all of the cylinders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Disconnect:
spark plug cap
4. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
compression gauge 1
Compression gauge
90890-03081
Compression gauge adapter
90890-04136
3-17
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
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 into cylinder)
Reading
Diagnosis
Higher than
without oil
Piston ring(-s) wear or
damage Repair.
Same as
without oil
Piston valves, cylinder
head gasket or piston
possibly defective Repair.
Compression pressure
(at sea level)
Compression pressure (at sea
level):
Standard:
1,450 kPa (14.5 kg/cm2)
Minimum:
1,260 kPa (12.6 kg/cm2)
Maximum:
1,620 kPa (16.2 kg/cm2)
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 (1
kg/cm2).
7. Install:
spark plug
8. Connect:
spark plug cap
3-18
13 Nm (1.3 mkg)
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Let the engine idle for a few minutes.
3. 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 engine oil
Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
CAUTION:
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD a or higher and do
not use oils labeled “ENERGY CONSERVING II” b or higher.
Do not allow foreign materials to enter the
crankcase.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
3-19
CHANGING THE ENGINE OIL
CHK
ADJ
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
(along with the gasket)
4. Drain:
engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.
a. Remove the oil filter cartridge 1 with an oil
filter wrench 2 .
Oil filter wrench
90890-01426
b. Apply a thin coat of engine oil onto the O-ring
1 of the new oil filter cartridge.
CAUTION:
Make sure that the O-ring 1 is positioned
correctly in the groove of the oil filter cartridge.
3-20
CHANGING THE ENGINE OIL
CHK
ADJ
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
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
3.7 L
Without oil filter cartridge
replacement
2.7 L
With oil filter cartridge replacement
3.0 L
9. Install:
engine oil filler cap
10. Start the engine, warm it up for several minutes, and then turn it off.
11. Check:
engine
(for engine oil leaks)
12. Check:
engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
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 “OIL PAN AND OIL PUMP”
in chapter 5.
d. Start the engine after solving the problem(-s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
3-21
CHANGING THE ENGINE OIL/
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
Oil gallery bolt
10 Nm (1.0 mkg)
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
clutch cable free play a
Out of specification Adjust.
Clutch cable free play (at the end
of the clutch lever)
10 X 15 mm
2. Adjust:
clutch cable free play
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is obtained.
Direction a
Clutch cable free play is
increased.
Direction b
Clutch cable free play is
decreased
c. Tighten the locknut.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Loosen the locknuts 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is obtained.
Direction a
Clutch cable free play is
increased.
Direction b
Clutch cable free play is
decreased
c. Tighten the locknuts.
3-22
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
seat
fuel tank
side cover
cover 1
2. Remove:
air filter case cover 1
air filter element
3. Clean:
air filter element
Apply compressed air to the outer surface of
the air filter element.
4. Check:
air filter element
Damage Replace.
5. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor engine performance and possible overheating.
3-23
CLEANING THE AIR FILTER ELEMENT /
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS /
CHECKING THE FUEL HOSES AND FUEL FILTER
CHK
ADJ
NOTE:
When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.
6. Install:
cover
side cover
fuel tank
seat
EAS00095
CHECKING THE CARBURETOR JOINTS
AND INTAKE MANIFOLDS
The following procedure applies to all of the carburetor joints and intake manifolds.
1. Remove:
seat
fuel tank
air filter case panel 1
2. Check:
carburetor joint 1
intake manifold 2
Cracks/damage Replace.
Refer to “CARBURETOR” in chapter 6.
3. Install:
air chamber cover
fuel tank
seat
EAS00097
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of the fuel
hoses.
1. Remove:
seat
fuel tank
side cover
2. Check:
fuel hose 1
Cracks/damage Replace.
fuel filter 2
Damage/dirt Replace.
3-24
CHECKING THE FUEL HOSES AND FUEL FILTER/
CHECKING THE CRANKCASE BREATHER HOSE /
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
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 1 .
3. Install:
side cover
fuel tank
seat
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
seat
fuel tank
2. Check:
crankcase breather hose 1
Cracks/damage Replace.
Loose connection Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
fuel tank
seat
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes 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 and muffler bolt 5
20 Nm (2.0 mkg)
Exhaust pipe and bracket bolt 6
20 Nm (2.0 mkg)
Muffler and muffler bracket bolt 7
48 Nm (4.8 mkg)
3-25
ADJUSTING THE EXUP CABLES
CHK
ADJ
EAS00101
ADJUSTING THE EXUP CABLES
1. Remove:
seat
fuel tank
2. Remove:
EXUP valve pulley cover 1
3. Check:
EXUP operation
a. Disconnect the EXUP servomotor connector
1.
b. Connect the battery to the EXUP servomotor
connector and check if the servomotor operates properly.
Battery positive lead black/yellow 2
Battery negative lead black/red 3
CAUTION:
To avoid damaging the servomotor, do not
leave the battery connected to it for more
than a few seconds.
c. Check that the EXUP valve operates properly.
d. Connect the EXUP servomotor connector.
3-26
ADJUSTING THE EXUP CABLES/
CHECKING THE COOLANT LEVEL
CHK
ADJ
4. Check:
EXUP cable free play a
EXUP cable free play
1.5 mm max.
5. Adjust:
EXUP cable free play
a. Loosen both locknuts 1 .
b. Insert a 4 mm long pin through the notch in
the EXUP valve pulley and into the hole in the
EXUP valve cover.
c. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable free play.
d. Turn both adjusting bolts 1/2 of a turn clockwise.
e. Tighten both locknuts and then remove the
pin.
6. Install:
EXUP valve pulley cover
10 Nm (1.0 mkg)
7. Install:
fuel tank
seat
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. 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.
3-27
CHECKING THE COOLANT LEVEL
CHK
ADJ
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.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
3-28
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
oil cooler inlet hose 4
oil cooler outlet hose 5
water jacket inlet joint 6
water pump outlet joint 7
Cracks/damage Replace.
Refer to “COOLING SYSTEM” in chapter 5.
3-29
CHANGING THE COOLANT
CHK
ADJ
EAS00105
CHANGING THE COOLANT
1. Remove
seat
fuel tank
front cowling
rear suspension
Refer to “REAR SHOCK ABSORBER ASSEMBLY” in chapter 4.
2. Disconnect:
coolant reservoir hose 1
3. Drain:
coolant
(from the coolant reservoir)
4. 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 turn the radiator cap counterclockwise toward the detent to allow any
residual pressure to escape. When the hissing sound has stopped, press down on the
radiator cap, 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.
5. Remove:
coolant drain bolt 1
(along with the copper washer)
6. Drain:
coolant
(from the engine and radiator)
3-30
CHANGING THE COOLANT
CHK
ADJ
7. Check:
copper washer 1
coolant drain bolt 2
Damage Replace.
8. Install:
coolant drain bolt
7 Nm (0.7 mkg)
9. Connect:
coolant reservoir hose
10. Fill:
cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol anti
freeze containing corrosion inhibi
tors for aluminum engines
Mix ratio
50% antifreeze/50% water
Quantity
Total amount
2.4 L
Coolant reservoir capacity
0.3 L
From minimum to maximum
level mark
0.2 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.
3-31
CHANGING THE COOLANT
CHK
ADJ
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.
11. Install:
radiator cap
12. Fill:
coolant reservoir
(with the recommended coolant to the maximum level mark a )
13. Install:
coolant reservoir cap
14. Start the engine, warm it up for several minutes, and then turn it off.
15. Check:
coolant level
Refer to “CHECKING THE COOLANT LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
16. Install:
rear suspension
Refer to “REAR SHOCK ABSORBER ASSEMBLY” in chapter 4.
fuel tank
seat
3-32
ADJUSTING THE FRONT BRAKE
CHK
ADJ
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
brake lever position
(distance a from the throttle grip to the brake
lever)
a. While pushing the brake lever forward, turn
the adjusting dial 1 until the brake lever is in
the desired position.
NOTE:
Be sure to align the setting on the adjusting dial
with the arrow mark 2 on the brake lever holder.
Position #1
Distance a is the largest.
Position #4
Distance a is the smallest.
WARNING
After adjusting the brake lever position,
make sure that the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system . Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake lever position,
make sure that there is no brake drag.
3-33
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00110
ADJUSTING THE REAR BRAKE
1. Check:
brake pedal position
(distance a from the top of the rider footrest
to the top of the brake pedal)
Out of specification Adjust.
Brake pedal position (below the
top of the rider footrest)
40 mm
2. Adjust:
brake pedal position
a. Loosen the locknut 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified brake pedal position is obtained.
Direction a
Brake pedal is raised.
Direction b
Brake pedal is lowered.
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt 2 is
visible through the hole c .
c. Tighten the locknut 1 to specification.
Locknut
18 Nm (1.8 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, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
3-34
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
3. Adjust:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
A
2. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
A Front brake
B Rear brake
B
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.
3-35
CHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
EAS00122
A
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
front brake pad
rear brake pad
Wear indicator groove 1 almost disappeared Replace the brake pads as a set.
Refer to “REPLACING THE FRONT BRAKE
PADS” and “REPLACING THE REAR
BRAKE PADS” in chapter 4.
A Front brake
B Rear brake
B
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
rear brake light operation timing
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.
3-36
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on later.
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 1
Cracks/damage/wear Replace.
2. Check:
brake hose clamp 2
Loose connection Tighten.
3. Hold the motorcycle upright and apply the
brake.
4. Check:
brake hose 1
Activate the brake several times.
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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.
1. Remove:
reservoir cap 1
diaphragm 2
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.
3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
ADJUSTING THE SHIFT PEDAL
CHK
ADJ
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.
EAS00110
ADJUSTING THE SHIFT PEDAL
1. Check:
shift pedal position
(distance a from the top of the rider footrest
to the top of the shift pedal)
Out of specification Adjust.
Shift pedal position (below the
top of the rider footrest)
40 mm
3-38
ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
2. Adjust:
adjusting bolt length
a. Loosen both locknuts 1 .
b. Turn the adjusting bolt 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.
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swingarm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
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. Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.
3. Check:
drive chain slack a
Out of specification Adjust.
Drive chain slack
40 50 mm
3-39
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
4. Adjust:
drive chain slack
a.
b.
c.
d.
Loosen the brake caliper bracket bolt.
Loosen the wheel axle nut 1 .
Loosen both locknuts 2 .
Turn both adjusting nuts 3 in direction a or
b until the specified drive chain slack is obtained.
Direction a
Drive chain is tightened.
Direction b
Drive chain is loosened.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
e. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 mkg)
f. Tighten the wheel axle nut to specification.
Wheel axle nut
150 Nm (15 mkg)
3-40
LUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00142
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable forO-ring chains
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 assembly
Refer to “FRONT COWLING”.
upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:
steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
3-41
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
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
90890-01403
Lower ring nut (initial tightening
torque)
52 Nm (5.2 mkg)
c. Loosen the lower ring nut 6 completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
18 Nm (1.8 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 4.
e. Install the rubber washer 7 .
f. Install the upper ring nut 8 .
g. Finger tighten the upper ring nut 8 , 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 9 .
NOTE:
Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
5. Install:
upper bracket
front cowling assembly
3-42
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
Steering stem nut
110 Nm (11 mkg)
Upper bracket pinch bolt
30 Nm (3.0 mkg)
Handlebar holder bolt
23 Nm (2.3 mkg)
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 4.
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Grooves are provided to indicate the adjustment position.
Never go beyond the maximum or minimum adjustment positions.
3-43
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
1. Adjust:
spring preload
a. Turn the adjusting bolt 1 in direction a or
b.
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension is
softer).
Adjusting positions
Standard: 4
Minimum: 8
Maximum: 1
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Rebound damping
p g is
increased (suspension is
harder).
Direction b
Rebound damping
p g is
decreased (suspension is
softer).
Adjusting positions
Standard: 7 clicks out*
Minimum: 17 clicks out*
Maximum: 1 clicks out*
*: from the fully turned-in position
3-44
ADJUSTING THE FRONT FORK LEGS/
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction
Compression damping is
increased (suspension is
harder).
Direction
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Standard: 6 clicks out*
Minimum: 21 clicks out*
Maximum: 1 clicks out*
*: from the fully turned-in position
EAS00158
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the owner’s tool kit.
3-45
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
a. Turn the adjusting ring 1 in direction a or
b.
b. Align the desired position on the adjusting
ring with the stopper 2 .
Direction a
Spring preload is
(s spension is
increased (suspension
harder).
Direction b
Spring preload is de(s spension is
creased (suspension
softer).
Adjusting positions
Standard: 6
Minimum: 1
Maximum: 11
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
a. Turn the adjusting knob 1 in direction a or
b.
Direction a
Rebound damping is
(s spension is
increased (suspension
harder).
Direction b
Rebound damping is
(s spension is
decreased (suspension
softer).
Adjusting positions
Standard: 20 clicks out*
Minimum: 10 clicks out*
Maximum: 3 clicks out*
*: from the fully turned-in position
3-46
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/
CHECKING THE TIRES
CHK
ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Standard: 7 clicks in
Minimum: 1 clicks in
Maximum: 12 clicks in
*: from the fully turned-out position
EAS00162
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.
3-47
CHECKING THE TIRES
CHK
ADJ
Basic weight
(with oil and a
full fuel tank)
231 kg
Maximum
load*
189 kg
Cold tire
pressure
Up to 90 kg
load*
Front tire
Rear tire
250 kPa
270 kPa
(2.5 kgf/cm2) (2.7 kgf/cm2)
90 kg 250 kPa
290 kPa
maximum load* (2.5 kgf/cm2) (2.9 kgf/cm2)
High
speed riding
250 kPa
290 kPa
(2.5 kgf/cm2) (2.9 kgf/cm2)
*: 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.
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
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 a tube tire, 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
3-48
CHK
ADJ
CHECKING THE TIRES
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
Type
Size
BRIDGESTONE
Tubeless
120/70
ZR17 (58 W)
METZELER
Tubeless
120/70
ZR17 (58 W)
Manufacturer
Type
Size
BRIDGESTONE
Tubeless
180/55
ZR17 (73 W)
METZELER
Tubeless
180/55
ZR17 (73 W)
Rear tire
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any highspeed riding is done.
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.
3-49
CHECKING AND LUBRICATING THE CABLES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE 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
lithium soap base grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
lithium soap base grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
lithium soap base grease
3-50
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.
3-51
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:
S seat
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
S battery
4. Check:
S battery charge
a. Connect a pocket tester to the battery terminals.
Open-circuit voltage (V)
Tester positive lead battery positive
Tester positive lead terminal
Tester negative lead battery negative
Tester negative lead terminal
13.0
NOTE:
S 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).
S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
Relationship between the open-circuit voltage
and the charging time at 20_C
12.5
12.0
11.5
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
b. Check the 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%
3-52
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
5. Charge:
S battery
(refer to the appropriate charging method illustration)
Charging
Open-circuit voltage (V)
Ambient temperature 20_C
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
S Make sure that the battery vent is free of obstructions.
S Never remove the MF battery sealing caps.
S 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.
S If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
S 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.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure that the battery charger lead
clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip
spring may cause sparks.
S 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!
S 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.
Open-circuit voltage (V)
Ambient
temperature
20_C
Charging condition of the battery (%)
3-53
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable voltage charger
Measure the open-circuit
voltage prior to charging.
Connect a charged and
AMP meter to the battery
and start charging.
YES
Make sure that the current
is higher than the standard
charging current written on
the battery.
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
NO
By turning the charging
voltage adjust dial, set the
charging voltage at 20 24 V.
Adjust the voltage so that the
current is at the standard
charging level.
YES
Monitor the amperage for
3 5 minutes to check if the
standard charging current is
reached.
NO
Set the time according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.
If the current does not
exceed the standard
charging current after 5
minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the
charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
3-54
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
Connect a charger and
AMP meter to the battery
and start charging.
YES
Make sure that the current
is higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V. Charge the
battery until the battery’s charging
voltage is 15 V.
NO
This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
NOTE:
Set the charging time at 20 hours
(maximum).
Measure the battery open-circuit
voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
3-55
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Check:
battery vent
Obstruction Clean.
Damage Replace.
7. Install:
battery
8. Connect:
battery leads
(to the 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:
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:
seat
2. Check:
fuse
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω
3-56
1”.
CHK
ADJ
CHECKING THE FUSES
Pocket tester
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.
Fuses
Amperage rating Quantity
Main fuse
30A
1
Headlight fuse
20A
1
Signaling
system fuse
20A
1
Ignition fuse
20A
1
Turn signal
relay fuse
10 A
1
Digital clock
fuse
10A
1
Radiator fan
fuse
10A
1
Reserve fuse
30A
1
Reserve fuse
20 A
1
Reserve fuse
10 A
1
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using a fuse with the wrong amperage rating
may cause extensive damage to the electrical system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
seat
3-57
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:
headlight coupler 1
bulb cover 2
2. Remove:
headlight bulb holder 1
3. 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.
4. 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.
5. Install:
headlight bulb holder
6. Install:
bulb cover
7. Connect:
headlight coupler
3-58
ADJUSTING THE HEADLIGHT BEAMS/
ADJUSTING THE DIGITAL CLOCK
CHK
ADJ
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Adjust:
headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Headlight beam is raised.
Direction b
Headlight beam is lowered.
2. Adjust:
headlight beam (horizontally)
a. Turn the adjusting knob 1 in direction a or
b.
Left headlight
Direction a
Headlight beam moves to
the right.
Direction b
Headlight beam moves to
the left.
Right headlight
Direction a
Headlight beam moves to
the left.
Direction b
Headlight beam moves to
the right.
EAS00187
ADJUSTING THE DIGITAL CLOCK
NOTE:
This digital clock constantly displays the time.
1. Adjust:
digital clock 1
a. Hold down the “RESET” button 2 and “SELECT” button 3 .
b. Push the “RESET” button 2 to set the hour.
And push the “SELECT” button.
c. Push the “RESET” button 2 to set the minutes. And push the “SELECT” button.
NOTE:
When setting the time (e.g., after reconnecting
the battery), first set the clock to 1:00 AM, then
set it to the correct time.
3-59
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . .
4-1
4-2
4-3
4-3
4-4
4-5
4-6
4-7
4-7
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .
CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . .
4-9
4-9
4-12
4-13
4-13
4-13
4-14
4-15
4-15
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . .
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . .
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16
4-16
4-18
4-20
4-23
4-25
4-27
4-27
4-28
4-29
4-31
4-33
4-35
4-37
4-38
4-39
4-40
4-42
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
4-44
4-46
4-46
4-48
4-49
4-53
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-54
4-55
4-55
4-56
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
4-58
4-59
4-59
4-60
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
4-61
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-65
4-67
4-68
4-68
4-69
4-71
4-71
4-62
4-62
4-63
4-64
4-64
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
72 Nm (7.2 mkg)
40 Nm (4.0 mkg)
18 Nm (1.8 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
Removing the front wheel and brake
discs
1
2
3
4
5
6
7
8
2
2
1
1
1
2
2
2
Brake hose holder (left and right)
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collar (left and right)
Oil seal cover (left and right)
brake disc (left and right)
Remarks
Loosen.
For installation, reverse the removal
procedure.
4-1
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00518
FRONT WHEEL
Order
1
2
3
Job/Part
Q’ty
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
Remarks
Disassemble the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISCS
CHAS
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
left brake caliper
right brake caliper
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.
3. Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
EAS00523
DISASSEMBLING THE FRONT WHEEL
1. Remove:
oil seals
wheel bearings
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings with a general
bearing puller.
4-3
FRONT WHEEL AND BRAKE DISCS
CHAS
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.
3. Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits Replace.
Front wheel radial runout limit
1 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.
4-4
FRONT WHEEL AND BRAKE DISCS
CHAS
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center race
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
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)
0.1 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 at a right angle against
the brake disc surface.
e. Measure the deflection 2 3 mm below the
edge of the brake disc.
4-5
FRONT WHEEL AND BRAKE DISCS
CHAS
3. Measure:
S brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Brake disc thickness limit
(minimum)
4.5 mm
4. Adjust:
S 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.
Brake disc bolt
18 Nm (1.8 mSkg)
LOCTITER
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.
EAS00539
ASSEMBLING THE FRONT WHEEL
1. Install:
S wheel bearings
S oil seals New
a. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a shocket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
4-6
FRONT WHEEL AND BRAKE DISCS
CHAS
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. Tighten:
wheel axle 1
wheel axle pinch bolt 2
72 Nm (7.2 mkg)
23 Nm (2.3 mkg)
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar several times and
check if the front fork rebounds smoothly.
3. Install:
brake caliper
40 Nm (4.0 mkg)
WARNING
Make sure that the brake hose is routed
properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
Adjust the front wheel static balance with the
brake discs installed.
1. Remove:
balancing weight(-s)
NOTE:
Place the front wheel on a suitable balancing
stand.
4-7
FRONT WHEEL AND BRAKE DISCS
CHAS
2. Find:
S front wheel’s heavy spot
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
c. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
f. Repeat steps (b) through (d) several times
until all the marks come to rest at the 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.
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.
4-8
REAR WHEEL AND BRAKE DISC
CHAS
EAS00551
REAR WHEEL AND BRAKE DISC
REAR WHEEL
150 Nm (15 mkg)
40 Nm (4.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Removing the rear wheel
1
2
3
4
5
6
Remarks
1
1
1
1
1
1
Brake caliper
Brake torque rod
Nut
Washer
Wheel axle
Rear wheel assembly
Loosen.
For installation, reverse the removal
procedure.
4-9
REAR WHEEL AND BRAKE DISC
CHAS
EAS00560
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear wheel
Spacer
Bearing
Spacer
Oil seal
Circlip
Bearing
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-10
REAR WHEEL AND BRAKE DISC
CHAS
18 Nm (1.8 mkg)
69 Nm (6.9 mkg)
Order
1
2
3
4
5
6
7
Job/Part
Removing the brake disc and rear
wheel sprocket
Brake disc
Rear wheel sprocket
Collar (left and right)
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Q’ty
Remarks
Remove the parts in the order listed.
1
1
2
1
1
1
6
For installation, reverse the removal
procedure.
4-11
REAR WHEEL AND BRAKE DISC
CHAS
EAS00561
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:
locknut 1
adjusting nut 2
4. Remove:
wheel axle nut 3
wheel axle
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
left collar 1
rear wheel drive hub 2
rear wheel drive hub damper
right collar
4-12
REAR WHEEL AND BRAKE DISC
CHAS
EAS00565
CHECKING THE REAR WHEEL
1. Check:
wheel axle
rear wheel
wheel bearings
oil seals
Refer to “FRONT WHEEL”.
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”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
rear wheel drive hub 1
Cracks/damage Replace.
rear wheel drive hub dampers 2
Damage/wear Replace.
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
rear wheel sprocket
More than 1/4 tooth a wear Replace the
rear wheel sprocket.
Bent teeth Replace the rear wheel sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
4-13
REAR WHEEL AND BRAKE DISC
CHAS
Rear wheel sprocket self-locking
nut
69 Nm (6.9 mkg)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00531
CHECKING THE BRAKE DISC
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)
0.1 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 at a right angle against
the brake disc surface.
e. Measure the deflection 2 3 mm below the
edge of the brake disc.
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Brake disc thickness limit
(minimum)
4.5 mm
4-14
REAR WHEEL AND BRAKE DISC
CHAS
4. Adjust:
S 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.
Brake disc bolt
18 Nm (1.8 mSkg)
LOCTITER
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.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips
Recommended lubricant
Lithium soap base grease
2. Tighten:
S wheel axle nut
S brake caliper bolts
150 Nm (15 mSkg)
40 Nm (4.0 mSkg)
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
S After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
S Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
S rear wheel static balance
Refer to “FRONT WHEEL”.
4-15
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Brake pad clip
Brake pad pin
Brake pad spring
brake pad
Brake pad shim
Bleed scrw
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
2
2
1
For installation, reverse the removal
procedure.
4-16
FRONT AND REAR BRAKES
CHAS
40 Nm (4.0 mkg)
6 Nm (0.6 mkg)
Order
1
2
3
4
5
6
Job/Part
Removing the rear brake pads
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake pad shim
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
4
2
1
2
2
2
For installation, reverse the removal
procedure.
4-17
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
4-18
FRONT AND REAR BRAKES
CHAS
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
3. Remove:
brake pads 1
(along with the brake pad shims)
4. Measure:
brake pad wear limit
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
5. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg)
4-19
FRONT AND REAR BRAKES
CHAS
d. Install new brake pad shims onto the new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must point
in the direction of disc rotation.
6. Install:
brake pad cover
brake pad pins
brake pad clips
brake caliper
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.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
brake caliper 1
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
brake pads
(along with the brake pad shims)
4-20
FRONT AND REAR BRAKES
CHAS
3. Measure:
brake pad wear limit
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm
4. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, brake pad pins, brake pad clips, 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 a new brake pad shim 3 onto each
new brake pad 4 .
e. Install new brake pads and a new brake pad
spring.
4-21
FRONT AND REAR BRAKES
5. Install:
brake pad cover
brake pad pins
brake pad clips
brake caliper
CHAS
40 Nm (4.0 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.
4-22
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
5
6
7
Job/Part
Removing the front brake master
cylinder
Brake fluid
Brake lever
Brake switch lead
Brake switch
Union bolt
Brake hose/copper washer
Master cylinder bracket
Master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
1/2
1
1
Refer to “REMOVING/ASSEMBLING
AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER” section.
For installation, reverse the removal
procedure.
4-23
FRONT AND REAR BRAKES
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake
master cylinder
Master cylinder boot
Circlip
Master cylinder kit
Spring
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-24
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
30 Nm (3.0 mkg)
4 Nm (0.4 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
1
2
3
Removing the rear brake master
cylinder
Side cover (right)
Brake fluid
Master cylinder bolt
Union bolt
Brake hose/copper washer
2
1
1/2
4
5
6
7
8
Clip/hose
Cotter pin
Pin
Washer
Master cylinder
2/1
1
1
1
1
Drain.
Refer to “REMOVING/ASSEMBLING
AND INSTALLING THE REAR BRAKE
MASTER CYLINDER” section.
For installation, reverse the removal
procedure.
4-25
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
Job/Part
Q’ty
1
2
3
4
Disassembling the rear brake master
cylinder
Master cylinder boot
Circlip
Master cylinder kit
Spring
Remarks
Disassemble the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-26
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:
brake switch coupler
(from the brake switch)
2. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER
1. Remove:
side cover (right)
2. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4-27
FRONT AND REAR BRAKES
A
B
C
D
CHAS
EAS00592
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
brake master cylinder
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
A Front
B Rear
2. Check:
brake master cylinder kit 1
Damage/scratches/wear Replace.
C Front
D Rear
3. Check:
rear brake fluid reservoir 1
Cracks/damage Replace.
rear brake fluid reservoir diaphragm 2
Cracks/damage Replace.
4. Check:
front brake master cylinder reservoir 1
Cracks/damage Replace.
front brake master cylinder reservoir diaphragm 2
Damage/wear Replace.
5. Check:
brake hoses
Cracks/damage/wear Replace.
4-28
FRONT AND REAR BRAKES
CHAS
EAS00598
ASSEMBLING AND INSTALLING
FRONT BRAKE MASTER CYLINDER
THE
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)
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a on the
brake master cylinder.
a
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
4-29
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.
4-30
FRONT AND REAR BRAKES
CHAS
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
copper washers 1 New
brake hose 2
union bolt 3
30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a as
shown.
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.
4-31
FRONT AND REAR BRAKES
CHAS
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.
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)
40 mm
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4-32
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPERS
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
30 Nm (3.0 mkg)
Order
1
2
3
4
Job/Part
Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-33
FRONT AND REAR BRAKES
CHAS
EAS00615
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
Disassemble the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
Disassembling the front brake calipers
1
2
3
4
5
6
7
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
Remarks
2
1
1
2
4
8
1
For assembly, reverse the disassembly
procedure.
4-34
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-35
FRONT AND REAR BRAKES
CHAS
EAS00617
6 Nm (0.6 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
Disassembling the rear brake caliper
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw
Remarks
Disassemble the parts in the order listed.
4
2
1
2
2
4
2
For assembly, reverse the disassembly
procedure.
4-36
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 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Secure the right side brake caliper pistons
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.
Do not loosen the bolts 3 .
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
4-37
FRONT AND REAR BRAKES
CHAS
EAS00628
DISASSEMBLING THE REAR BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
union bolt 1
copper washers 2
brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Secure the right side brake caliper piston
with a piece of wood a .
b. Blow compressed air into the brake hose
joint opening b to force out the left side piston from the brake caliper.
WARNING
Never try to pry out the brake caliper pistons.
Do not loosen the bolts 3 .
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side piston from the brake caliper.
4-38
FRONT AND REAR BRAKES
CHAS
EAS00633
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
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.
4-39
FRONT AND REAR BRAKES
CHAS
EAS00638
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
brake caliper
(temporarily)
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”.
CAUTION:
When installing the brake hose onto the
brake caliper, make sure that the brake pipe
a touches the projection b on the brake
caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad pins
brake pad clips
6 Nm (0.6 mkg)
brake hose holder
brake caliper
40 Nm (4.0 mkg)
Refer to “REPLACING THE BRAKE PADS”.
4-40
FRONT AND REAR BRAKES
CHAS
4. Fill:
brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the 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. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-41
FRONT AND REAR BRAKES
CHAS
EAS00644
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solevents 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, make sure that the brake pipe
a touches the projection b on the brake
caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad pin
brake pad 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
4-42
FRONT AND REAR BRAKES
CHAS
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
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. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-43
FRONT FORK
CHAS
EAS00647
FRONT FORK
30 Nm (3.0 mkg)
25 Nm (2.5 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Removing the front fork
Front wheel
1
2
3
4
5
Front fender
Bolt (upper bracket)
Cap bolt
Bolt (lower bracket)
Front fork assembly (left/right)
Remarks
1
2
2
4
1/1
Loosen.
Loosen.
Loosen.
Refer to “REMOVING/
INSTALLING THE FRONT
FORK LEGS” section.
For installation, reverse the removal
procedure.
4-44
FRONT FORK
CHAS
EAS00648
25 Nm (2.5 mkg)
35 Nm (3.5 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Job/Part
Disassembly the front fork
Cap bolt
O-ring
Spacer
Spring seat
Fork spring
Damper adjusting rod
Dust seal
Oil seal clip
Damper rod bolt
Copper washer
Damper rod
Inner tube
Oil seal
Washer
Slide metal
Oil flow stopper
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-45
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 motorcycle on a suitable stand so that
the front wheel is elevated.
2. Loosen:
upper bracket pinch bolt 1
cap bolt 2
lower bracket pinch bolt 3
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
3. Remove:
front fork leg
EAS00653
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
cap bolt 1
(from the damper adjusting rod)
nut 2
NOTE:
Remove the cap bolt with the piston rod holder
3.
Piston rod holder
90890-01434
4-46
FRONT FORK
CHAS
2. Remove:
spacer 1
spring seat 2
spring 3
damper adjusting rod 4
3. Drain:
fork oil
4. Remove:
oil seal clip 1
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
5. Remove:
damper rod bolt
damper rod 1
NOTE:
While holding the damper rod with the damper
rod holder 2 , loosen the damper rod bolt.
Damper rod holder
90890-01447
6. 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.
4-47
FRONT FORK
CHAS
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
347.0 mm
3. Check:
damper rod
Damage/wear Replace.
Obstruction Blow out all of the oil passages with compressed air.
oil flow stopper
Damage Replace.
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.
4-48
FRONT FORK
CHAS
EAS00660
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 2 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
NOTE:
Install the oil flow stopper with a flat surface part
a downward.
2. Lubricate:
inner tube’s outer surface
Recommended lubricant
Fork oil 5W or equivalent
3. Tighten:
damper rod bolt 1
35 Nm (3.5 mkg)
LOCTITE
NOTE:
While holding the damper rod with the damper
rod holder 2 , tighten the damper rod bolt.
Damper rod holder
90890-01447
4-49
FRONT FORK
CHAS
4. Install:
oil seal 1
(with the fork seal driver weight 2 and fork
seal driver attachemt 3 )
Fork seal driver weight
90890-01367
Fork seal driver attachment
90890-01374
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 to protect
the oil seal during installation.
5. Install:
oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
6. Fill:
front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.44 L (440 cm3)
Recommended oil
Yamaha suspension oil “01” or
equivalent
CAUTION:
Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
NOTE:
Be sure to bleed the front fork.
4-50
FRONT FORK
CHAS
7. Install:
rod puller 1
rod puller attachment 2
(onto the damper rod 3 )
Rod puller
90890-01437
Rod puller attachment
90890-01436
8. After filling the front fork leg, slowly stroke the
damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly because the fork oil may spurt out.
9. Slowly stroke the inner tube 2 up and down
to distribute the fork oil once more (1 stroke =
about 150 mm).
NOTE:
Be careful not to stroke the inner tube over 150
mm as this will cause air to enter. If the inner
tube is stroke more than 150 mm, repeat steps
(10) and (11).
10. Before checking the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
11. Measure:
front fork leg oil level a
Out of specification Correct.
Front fork leg oil level (from the
top of the inner tube and damper
rod, with the inner tube fully
compressed, and without the
spring)
140 mm
4-51
FRONT FORK
CHAS
12. Install:
spring 1
spring seats 2
spacer 3
nut 4
damper adjusting rod 5
cap bolt 6
a. Install the fork spring, spring seats, and
spacer.
NOTE:
Install the fork spring with the larger pitch a facing up.
b smaller pitch
b. Install the rod puller and the rod puller attachment onto the damper rod.
c. Pull up the rod puller and install the rod holder 1 between the rod puller attachment 2
and the spacer.
NOTE:
Use the side of the rod holder that is marked “B”.
Piston rod holder
90890-01434
d. Remove the rod puller and the rod puller attachment.
e. Install the damper adjusting rod locknut.
f. Tighten the damper adjusting rod locknut.
Damper adjusting rod locknut
25 Nm (2.5 mkg)
g. Install the damper adjusting rod and cap bolt,
and finger tighten it.
h. Remove the rod holder.
CAUTION:
The spring is compressed.
4-52
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 upper and lower
bracket pinch bolts.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar holder.
2. Tighten:
lower bracket pinch bolt 1
23 Nm (2.3 mkg)
cap bolt 2
25 Nm (2.5 mkg)
upper bracket pinch bolt 3
30 Nm (3.0 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
3. Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK”
in chapter 3.
4-53
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
23 Nm (2.3 mkg)
26 Nm (2.6 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Removing the handlebar
Front brake master cylinder
Right handlebar switch
Throotle cable
Grip end (right)
Throttle grip
Grip end (left)
Left grip
Left handlebar switch
Starter cable
Clutch cable
Clutch lever
Handlebar holder
Handlebar
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
2
1
For installation, reverse the removal
procedure.
4-54
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
throttle cable housing 1
throttle grip 2
3. Remove:
handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR
1. 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
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
4-55
HANDLEBAR
CHAS
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.
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
23 Nm (2.3 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 in the handlebar with
the upper surface of the lower handlebar holders.
3. Install:
throttle grip 1
throttle cables
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.
4-56
HANDLEBAR
CHAS
5. Install:
left handlebar switch
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.
6. Install:
clutch lever holder
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the left handlebar.
7. Install:
brake master cylinder
Refer to “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER”.
8. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 5 mm
4-57
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
110 Nm (11.0 mkg)
1st 52 Nm (5.2 mkg)
2nd 18 Nm (1.8 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Removing the steering head
Front wheel
Front fork
Handlebar
Front brake hose bracket
Horn/bracket
Brake hose joint
Upper bracket cap nut
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Dust cover
Steering bearing (upper)
Lower bracket
Steering bearing (lower)
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL”
Refer to “FRONT FORK”
Refer to “HANDLEBAR”
1
1/1
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
4-58
STEERING HEAD
CHAS
EAS00677
REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
lower ring nut 1
(with the special tool 2 )
Ring nut wrench
90890-01403
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
bearings
bearing races
Recommended cleaning solvent
Kerosine
2. Check:
bearings 1
bearing races 2
Damage/pitting Replace.
3. Replace:
bearings
bearing races
a. Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer.
4-59
STEERING HEAD
CHAS
b. Remove the bearing race 3 from the lower
bracket with a floor chisel 4 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
upper bearing
lower bearing
bearing races
Recommended lubricant
Lithium soap base grease
2. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “INSPECTING THE STEERING
HEAD” in chapter 3.
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.
4-60
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
40 Nm (4.0 mkg)
40 Nm (4.0 mkg)
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
40 Nm (4.0 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Removing the rear shock absorber
assembly
Rear wheel
Side cover (left/right)
Connecting arm
Relay arm
Rear shock absorber
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL”
1/1
1
1
1
For installation, reverse the removal
procedure.
4-61
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.
Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER
a. Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. To release the gas pressure, drill a 2 3 mm hole through the gas cylinder at a point
15 20 mm from its end as shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
4-62
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00694
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:
connecting arm bolt 1
relay arm bolt 2
rear shock absorber assembly lower bolt 3
NOTE:
While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
rear shock absorber assembly upper bolt 1
rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
4-63
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
spring
Damage/wear Replace the rear shock absorber assembly.
bushings
Damage/wear Replace.
dust seals
Damage/wear Replace.
bolts
Bends/damage/wear Replace.
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
40 Nm (4.0 mkg)
Rear shock absorber assembly
lower nut
40 Nm (4.0 mkg)
Relay-arm-to-frame-nut
40 Nm (4.0 mkg)
NOTE:
When installing the rear shock absorber assembly, lift up the swingarm.
Install the connecting arm front bolt from the
right.
4-64
SWINGARM AND DRIVE CHAIN
CHAS
EAS00700
SWINGARM AND DRIVE CHAIN
125 Nm (12.5 mkg)
85 Nm (8.5 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the swing arm and drive
chain
Rear wheel
Rear shock absorber assembly
1
2
3
Rear brake caliper
Brake hose holder
Side protector (left/right)
4
5
6
7
8
9
Pivot shaft
Swing arm
Drive chain case
Drive chain guard
Dust cover
Oil seal
Remarks
Refer to “REAR WHEEL”
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”
1
2
1/1 NOTE:
Remove the side protector assembly.
Do not remove the center cap.
1
1
1
1
2
2
4-65
SWINGARM AND DRIVE CHAIN
CHAS
125 Nm (12.5 mkg)
85 Nm (8.5 mkg)
23 Nm (2.3 mkg)
Order
10
11
12
13
14
15
16
Job/Part
Bearing
Spacer
Shoft pedal assembly
Drive sprocket cover
Drive chain guide
Drive sprocket
Drive chain
Q’ty
Remarks
2
1
1
1
1
1
1
For installation, reverse the removal
procedure.
4-66
SWINGARM AND DRIVE CHAIN
CHAS
EAS00703
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. Remove:
connecting arm bolt 1
relay arm bolt 2
rear shock absorber assembly lower bolt 3
NOTE:
When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it
does not drop down.
3. Check:
swingarm side play A
swingarm vertical movement B
a. Check the tightening torque of the pivot shaft
nut.
Pivot shaft nut
125 Nm (12.5 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, bearings, washers,
and dust covers.
Swingarm side play (at the end
of the swingarm)
1.0 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,
bearings, washers, and dust covers.
4-67
SWINGARM AND DRIVE CHAIN
CHAS
EAS00704
REMOVING THE DRIVE CHAIN
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:
foot rest (left)
drive sprocket cover
drive chain guide 1
drive sprocket 2
EAS00707
CHECKING THE SWINGARM
1. Check:
swingarm
Bends/cracks/damage Replace.
2. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
pivot shaft
dust covers
spacer
washers
bearings
Recommended cleaning solvent
Kerosine
4-68
SWINGARM AND DRIVE CHAIN
CHAS
4. Check:
dust covers 1
spacer 2
oil seals 3
Damage/wear Replace.
bearings 4
Damage/pitting Replace.
5. Check:
connecting arms 1
relay arm 2
Damage/wear Replace.
bearings 3
oil seals 4
Damage/pitting Replace.
spacers 5
Damage/scratches Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:
ten-link section a of the drive chain
Out of specification Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three different places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
4-69
SWINGARM AND DRIVE CHAIN
CHAS
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosine and remove
any remaining dirt.
c. Remove the drive chain from the kerosine
and completely dry it.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s internals, and solvents will deteriorate the Orings. A coarse brush can also damage the
O-rings. Therefore, use only kerosine to
clean the drive chain.
4. Check:
O-rings 1
Damage Replace the drive chain.
drive chain rollers 2
Damage/wear Replace the drive chain.
drive chain side plates 3
Damage/wear Replace the drive chain.
Cracks Replace the drive chain and make
sure that the battery breather hose is properly routed away from the drive chain and below the swingarm.
5. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
drive sprocket
rear wheel sprocket
More than 1/4 tooth a wear Replace the
drive chain sprockets as a set.
Bent teeth Replace the drive chain sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
4-70
SWINGARM AND DRIVE CHAIN
CHAS
EAS00713
INSTALLING THE DRIVE CHAIN
1. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
2. Install:
drive chain 1
drive sprocket 2
washer 3 New
drive sprocket nut 4
drive chain guide 5
85 Nm (8.5 mkg)
NOTE:
While applying the rear brake, tighten the drive
sprocket nut.
3. Bend the lock washer tab a along a flat side
of the nut.
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
bearings
spacers
dust covers
pivot shaft
Recommended lubricant
Molybdenum disulfide grease
2. Install:
relay arm
left connecting arm
right connecting arm
4-71
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
SWINGARM AND DRIVE CHAIN
CHAS
NOTE:
Install the connecting arm front bolt 1 from the
right.
3. Install:
rear shock absorber assembly
rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and ”REAR
WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
40 50 mm
CAUTION:
A drive chain that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swingarm
or cause an accident. Therefore, keep the
drive chain slack within the specified limits.
4-72
ENG
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-3
5-4
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
5-5
5-6
5-8
5-9
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16
5-17
5-17
5-18
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19
5-21
5-22
5-24
5-26
5-27
5-27
5-11
5-11
5-12
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
INSTATLLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
REMOVING THE PLCKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34
ENG
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER AND PULL ROD . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-36
5-36
5-38
5-40
5-40
5-42
5-42
5-43
5-43
5-43
5-43
5-44
5-45
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR ROTOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-48
5-48
5-49
5-49
5-49
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-50
5-53
5-53
5-54
5-54
5-54
5-54
5-55
5-55
5-56
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . .
CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-57
5-57
5-59
5-60
5-61
5-62
5-63
5-64
5-65
5-66
5-67
5-72
5-72
5-73
5-73
5-74
5-76
ENG
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-78
5-78
5-83
5-83
5-84
5-84
5-85
ENG
ENGINE
ENG
EAS00188
OVERHAULING THE ENGINE
ENGINE
DRIVE SPROCKET AND EXHAUST PIPE
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
85 Nm (8.5 mkg)
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the drive sprocket and
exhaust pipe
Carburetor
Plug code
Ignition coil
Radiator
Water hose
Air iduction system
1
2
3
4
5
6
7
Side cover (left)
Stator coil coupler/oil level switch
Shit rod
Drive sprocket cover
Drive sprocket
Water outlet hose
Exhaust pipe
Remarks
Refer to “CARBURETOR” in chapter 6.
Refer to “RADIATOR” in chapter 7.
Refer to “AIR INDUCTION SYSTEM” in
chapter 6.
1
1/1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-1
ENGINE
ENG
EAS00189
LEADS AND HOSES
Order
1
2
3
4
5
Job/Part
Removing the leads and hoses
Cover
Clutch cable
Nuetral switch/speed sensor/pickup
coil lead
Water head pipe
Coolant outlet hose
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1/1/1 Disconnect.
1
1
For installation, reverse the removal procedure.
5-2
ENGINE
ENG
EAS00191
ENGINE
55 Nm (5.5 mkg)
55 Nm (5.5 mkg)
24 Nm (2.4 mkg)
24 Nm (2.4 mkg)
33 Nm (3.3 mkg)
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the engine
Down tube
Engine mounting bolt (front)
Engine bracket
Engine mounting bolt (rear upper)
Engine mounting bolt (rear lower)
Engine
1
2
1
1
1
1
For installation, reverse the removal
procedure.
5-3
ENGINE
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
engine mount bolt 1
engine mount bolt 2
engine mount bolt 3
engine bracket 4
engine mount bolt 5
down tube 6
NOTE:
Do not fully tighten the bolts.
2. Tighten the bolts in the following order.
Engine mount bolt 1
55 Nm (5.5 mkg)
Engine mount bolt 2
55 Nm (5.5 mkg)
Engine mount bolt 3
33 Nm (3.3 mkg)
Engine mount bolt 5
55 Nm (5.5 mkg)
Down tube 6
24 Nm (2.4 mkg)
3. Install:
shift arm 1
10 Nm (10 mkg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.
5-4
CAMSHAFT
ENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVERS
13 Nm (1.3 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CARBURETORS” in chapter 6.
Refer to “RADIATOR” and
“THERMOSTAT ASSEMBLY” in chapter 7.
Removing the cylinder head cover
Carburetor assembly
Radiator assembly and thermostat
assembly
Spark plug
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
4
1
1
1
For installation, reverse the removal
procedure.
5-5
CAMSHAFT
ENG
EAS00196
CAMSHAFTS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “PICKUP COIL”.
Removing the camshafts
Pickup coil rotor cover
Float chamber air vent hose holder
Timing chain tensioner
Timing chain tensioner gasket
Timing chain guide (exhaust side)
Intake camshaft cap
Dowel pin
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
1
1
1
1
3
6
3
6
1
1
5-6
NOTE:
During removal, the dowel pins may still
be connected to the camshaft caps.
CAMSHAFT
ENG
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
10 Nm (1.0 mkg)
Order
11
12
13
14
Job/Part
Q’ty
Intake camshaft sprocket
Exhaust camshaft sprocket
Pin
Timing chain guide (intake side)
Remarks
1
1
1
1
For installation, reverse the removal
procedure.
5-7
CAMSHAFT
ENG
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:
pickup rotor coil cover
2. Align:
“T” mark on the pickup coil rotor a
(with the crankcase mating surface b )
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a with the
crankcase mating surface b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3. Loosen:
camshaft sprocket bolts 1
4. Loosen:
cap bolt 1
5. Remove:
timing chain tensioner 2
gasket
6. Remove:
camshaft sprocket 1
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 2 .
5-8
CAMSHAFT
ENG
7. Remove
timing chain guide (exhaust side) 1
camshaft caps
dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
8. Remove:
intake camshaft 1
exhaust camshaft 2
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
camshaft lobes
Blue discoloration/pitting/scratches Replace the camshaft.
2. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the camshaft.
Camshaft lobe dimension limit
Intake
a 32.4 mm
b 24.85 mm
Exhaust
a 32.85 mm
b 24.85 mm
5-9
CAMSHAFT
ENG
3. Measure:
S camshaft runout
Out of specification Replace.
Camshaft runout
Less than 0.03 mm
4. Measure:
S camshaft-journal-to-camshaft-cap
clearance
Out of specification ³ Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.028 X 0.062 mm
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of PlastigaugeR 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
S Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
S Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the PlastigaugeR.
Camshaft cap bolt
10 Nm (1.0 mSkg)
d. Remove the camshaft caps and then measure the width of the Plastigauge 1 .
5. Measure:
S 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
24.459 X 24.472 mm
5-10
CAMSHAFT
ENG
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and camshaft sprockets as a set.
2. Check:
camshaft sprocket
More than 1/4 tooth a wear Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
timing chain guide (exhaust side) 1
timing chain guide (intake side) 2
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
EAS00210
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
timing chain tensioner
Cracks/damage Replace.
5-11
CAMSHAFT
ENG
2. Check:
one-way cam operation
Rough movement Replace the timing
chain tensioner housing.
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
3. Check:
cap bolt
copper washer
spring
gasket
timing chain tensioner rod
Damage/wear Replace the defective
part(-s).
EAS00217
INSTALLING THE CAMSHAFTS
1. Install:
exhaust camshaft 1
intake camshaft 2
NOTE:
Install the camshafts with the punch mark a
facing up.
2. Install:
dowel pins
intake camshaft caps
exhaust camshaft caps
NOTE:
Make sure that the punch marks a on the camshafts are aligned with the arrow marks b on
the camshaft caps.
Out of alignment Reinstall.
5-12
CAMSHAFT
ENG
3. Install:
camshaft cap bolts
10 Nm (1.0 mkg)
NOTE:
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.
4. Install:
intake camshaft sprocket
exhaust camshaft sprocket
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the pickup coil rotor with the crankcase mating surface b .
c. Place the timing chain onto both camshaft
sprockets and then install the camshaft
sprockets onto the camshafts.
NOTE:
When installing the camshaft sprockets, start
with the exhaust camshaft and be sure to keep
the timing chain as tight as possible on the exhaust side.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
5-13
CAMSHAFT
ENG
d. Turn both camshafts opposite each other so
that the punch marks c in the camshaft are
aligned with the arrow marks d in the camshaft caps as shown.
e. While holding the camshafts, temporarily
tighten the camshaft sprocket bolts.
5. Install:
timing chain tensioner
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 .
b. With the timing chain tensioner rod turned all
the way into the timing chain tensioner housing (with the thin screwdriver still installed),
install the gasket and the timing chain tensioner 2 onto the cylinder block.
WARNING
Always use a new gasket.
c. Tighten the timing chain tensioner bolts 3 to
the specified torque.
Timing chain tensioner bolt
10 Nm (1.0 mkg)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.
Timing chain cap bolt
12 Nm (1.2 mkg)
6. Turn:
crankshaft
(several turns clockwise)
5-14
CAMSHAFT
ENG
7. Check:
“T” mark a
Make sure that the “T” mark a on the pickup
coil rotor is aligned with the crankcase mating surface b .
camshaft punch marks c
Make sure that the marks c on the camshaft
are aligned with the arrow marks d in the
comshaft caps.
Out of alignment Adjust.
Refer to the installation steps above.
8. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
9. Install:
timing mark accessing screw
15 Nm (15 mkg)
crankshaft end cover
5-15
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
1st 20 Nm (2.0 mkg)
2nd 50 Nm (5.0 mkg)
1st 20 Nm (2.0 mkg)
2nd 50 Nm (5.0 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
Job/Part
Removing the cylinder head
Engine
Intake and exhaust camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
1
1
2
For installation, reverse the removal
procedure.
5-16
CYLINDER HEAD
ENG
EAS00223
REMOVING THE CYLINDER HEADS
1. Remove:
cylinder head nuts
cylinder head cap nuts
cylinder head bolts
NOTE:
Loosen the nuts in the proper sequence as
shown.
Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00230
CHECKING THE CYLINDER HEADS
The following procedure applies to all of the cylinder heads.
1. Eliminate:
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
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylinder head.
Cylinder head warpage
Less than 0.1 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.
5-17
CYLINDER HEAD
ENG
EAS00233
INSTALLING THE CYLINDER HEAD
1. Install:
gasket New 1
dowel pins 2
2. Install:
cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
cylinder head nuts 1 X 10
1st
20 Nm (2.0 mkg)
2nd
50 Nm (5.0 mkg)
cylinder head bolt 11 12
NOTE:
First, tighten the nuts 1 X 10 to approximately 20 Nm (2.0 mkg) with a torque wrench.
Retighten the nuts to 50 Nm (5.0 mkg).
NOTE:
Apply engine oil onto the threads of the cylinder head nuts.
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
exhaust camshaft
intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
5-18
VALVES AND VALVE SPRINGS
ENG
EAS00236
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
12
12
24
12
12
12
12
12
12
5-19
VALVES AND VALVE SPRINGS
Order
10
11
12
13
14
15
16
17
18
Job/Part
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Q’ty
ENG
Remarks
8
8
16
8
8
8
8
8
8
For installation, reverse the removal
procedure.
5-20
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 lifter 1
valve pad 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.
NOTE:
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
90890-04019
Valve spring compressor
attachment
Intake valve
90890-04114
Exhaust valve
90890-04108
5-21
VALVES AND VALVE SPRINGS
ENG
4. Remove:
upper spring seat 1
valve spring 2
oil seal 3
lower spring seat 4
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:
valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter A –
Valve stem diameter B
Out of specification Replace the valve
guide.
Valve-stem-to-valve-guide
clearance
Intake
0.010 X 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.020 X 0.047 mm
<Limit>: 0.1 mm
5-22
VALVES AND VALVE SPRINGS
ENG
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.
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
Intake (4.0 mm)
90890-04111
Exhaust (4.5 mm)
90890-04116
Valve guide installer
Intake (4.0 mm)
90890-04112
Exhaust (4.5 mm)
90890-04117
Valve guide reamer
Intake
90890-04113
Exhaust
90890-04118
5-23
VALVES AND VALVE SPRINGS
ENG
3. Eliminate:
carbon deposits
(from the valve face and valve seat)
4. Check:
valve face
Pitting/wear Grind the valve face.
valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
0.5 X 0.9 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
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
Exhaust: 0.9 X 1.1 mm
5-24
VALVES AND VALVE SPRINGS
ENG
a. Apply Mechanic’s blueing dye (Dykem) 1
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.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your 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) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
5-25
VALVES AND VALVE SPRINGS
ENG
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
Intake spring
38.9 mm
Exhaust spring
40.67 mm
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
Compressed spring force
Intake
8.2 X 9.6 kg at 34.5 mm
Exhaust
11.0 X 12.6 kg at 35.0 mm
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
Spring tilt limit
Intake
1.7 mm
Exhaust
1.8 mm
5-26
VALVES AND VALVE SPRINGS
ENG
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.
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
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
valve 1
lower spring seat 2
oil seal 3
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
NOTE:
Make sure that each valve is installed in its original place. Refer to the following embossed
marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “5LV”
5-27
VALVES AND VALVE SPRINGS
ENG
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
90890-04019
Attachment
Intake valve
90890-04114
Exhaust valve
90890-04108
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 pad 1
valve lifter 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.
5-28
GENERATOR
ENG
EB410000
GENERATOR
14 Nm (1.4 mSkg)
65 Nm (6.5 mSlkg) + 60_
12 Nm (1.2 mSkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Removing the stator coil assembly
Rider seat and fuel tank
Bottom cowling
Engine oil
1
2
3
4
5
6
7
8
Generator rotor cover
Generator rotor cover gasket
Dowel pin
Generator rotor bolt
Generator rotor
Stator coil assembly coupler
Stator coil assembly lead holder
Stator coil assembly
Remarks
1
1
2
1
1
1
1
1
Disconnect.
For installation, reverse the removal
procedure.
5-29
GENERATOR
ENG
REMOVING THE GENERATOR
1. Remove:
generator rotor cover 1
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.
2. Remove:
generator rotor bolt 1
washer
NOTE:
While holding the generator rotor 2 with the rotor
holding tool 3 , loosen the generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
generator rotor 1
(with the flywheel puller 2 and rotor holding
tool 3 )
Flywheel puller
90890-01080
INSTALLING THE GENERATOR
1. Apply:
sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No. 1215
90890-85505
2. Install:
generator rotor
washer
generator rotor bolt
WARNING
Always use a new generator rotor bolt.
CAUTION:
Clean the tapered portion of the crankshaft
and the generator rotor hub with lacquer
thinner.
Lubricate the generator rotor bolt threads
with engine oil.
5-30
GENERATOR
ENG
3. Tighten:
S generator rotor bolt 1 New
65 Nm (6.5 mSkg) + 60_
NOTE:
S While holding the generator rotor 2 with the
rotor holding tool 3 , tighten the generator rotor bolt.
S After tightening to 65 Nm (6.5 mSkg), tighten
another 60_.
Rotor holding tool
90890-01235
4. Install:
S generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
5-31
PICKUP COIL
ENG
PICKUP COIL
60 Nm (6.0 mkg)
12 Nm (1.2 mkg)
15 Nm (1.5 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the pickup coil and
pickup coil rotor
Rider seat and fuel tank
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “GENERATOR”.
Bottom cowling and right side cowling
Engine oil
1
2
3
4
Generator rotor cover
Pickup coil lead holder
Pickup coil rotor cover
Pickup coil rotor cover gasket
Dowel pin
Remarks
1
1
1
2
5-32
PICKUP COIL
ENG
60 Nm (6.0 mkg)
12 Nm (1.2 mkg)
15 Nm (1.5 mkg)
10 Nm (1.0 mkg)
Order
5
6
7
Job/Part
Pickup coil coupler
Pickup coil
Pickup coil rotor
Q’ty
1
1
1
Remarks
Disconnect.
For installation, reverse the removal
procedure.
5-33
PICKUP COIL
ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:
pickup coil lead holder 1
pickup coil rotor cover 2
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.
2. Remove:
pickup coil rotor bolt 1
washer
pickup coil rotor 2
NOTE:
While holding the generator rotor 3 with the rotor holding tool 4 , loosen the pickup coil rotor
bolt.
Rotor holding tool
90890-01235
INSTALLING THE PICKUP COIL ROTOR
1. Install:
pickup coil rotor 1
washer
pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor, align the
pin 2 in the crankshaft sprocket with the groove
a in the pickup coil rotor.
5-34
PICKUP COIL
ENG
2. Tighten:
pickup coil rotor bolt 1
60 Nm (6.0 mkg)
NOTE:
While holding the generator rotor 2 with the rotor holding tool 3 , tighten the pickup coil rotor
bolt.
Rotor holding tool
90890-01235
3. Apply:
sealant
(onto the pickup coil lead grommet)
Yamaha bond No. 1215
90890-85505
4. Install:
pickup coil rotor cover
pickup coil lead holder
NOTE:
When installing the pickup coil rotor cover,
align the timing chain guide (intake side) pin 1
with the hole 2 in the pickup coil rotor cover.
Tighten the pickup coil rotor cover bolts in
stages and in a crisscross pattern.
5-35
CLUTCH
ENG
EAS00273
CLUTCH
CLUTCH COVER
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Removing the clutch cover
Engine oil
1
2
3
4
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Remarks
1
1
1
2
For installation, reverse the removal
procedure.
5-36
CLUTCH
ENG
EB405010
Order
1
2
3
4
5
6
Job/Part
Removing the pull lever shaft
Circlip
Pull lever
Pull lever spring
Pull lever shaft
Oil seal
Bearing
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
1
1
2
For installation, reverse the removal
procedure.
5-37
CLUTCH
ENG
EAS00274
CLUTCH
12 Nm (1.2 mkg)
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the clutch
Clutch cover
Pull rod
Friction plate
Clutch plate
Friction plate
Clutch plate
Friction plate
Friction plate
Clutch damper spring
Clutch damper spring seat
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
2
4
6
3
1
1
1
5-38
Select.
Color code: Black
Color code: Blue
Refer to “INSTALLING THE CLUTCH”.
CLUTCH
ENG
12 Nm (1.2 mkg)
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
Order
11
12
13
14
15
16
17
18
19
20
21
Job/Part
Clutch boss nut
Lock washer
Clutch boss
Thrust washer
Clutch housing
Bearing
Starter clutch gear
Bearing
Starter clutch assembly
Circlip
Starter clutch idle gear
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-39
CLUTCH
ENG
EAS00277
REMOVING THE CLUTCH
1. Straighten the lock washer tab.
2. Loosen:
clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3 , loosen the clutch boss nut.
Universal clutch holder
90890-04086
3. Remove:
clutch boss nut 1
lock washer 2
clutch boss 3
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.
5-40
CLUTCH
ENG
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
Friction plate a
3.42 X 3.58 mm
<Limit>: 3.32 mm
Friction plate b
2.92 X 3.08 mm
<Limit>: 2.82 mm
3. Measure:
assembly width a
Out of specification Adjust.
Assembly width
43.1 X 43.9 mm
a. Assembly width adjusted by clutch plate a
and b .
b. Select the clutch plate from the following
table.
Clutch plate a
Part No.
Thickness
168-16325-00
1.6 mm
31A-16325-00
2.0 mm
168-16324-00
2.3 mm
STD
Clutch plate b
Part No.
Thickness
31A-16325-00
2.0 mm
168-16324-00
2.3 mm
STD
NOTE:
When selecting a 2.3 mm clutch plate, make the
replacement giving priority to b .
5-41
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 0.1 mm
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
clutch spring free length
Out of specification Replace the clutch
springs as a set.
Clutch spring free length
50 mm
<Limit>: 47.5 mm
5-42
CLUTCH
ENG
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
clutch housing dogs
Damage/pitting/wear Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic clutch operation.
2. Check:
bearing
Damage/wear Replace the clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
clutch boss splines
Damage/pitting/wear Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
pressure plate 1
Cracks/damage Replace.
bearing 2
Damage/wear Replace.
EAS00287
CHECKING THE PULL LEVER AND PULL
ROD
1. Check:
pull lever 1
pull rod 2
Damage/wear Replace the pull rod and
pull lever pinion gear as a set.
5-43
CLUTCH
ENG
2. Check:
pull rod bearing
Damage/wear Replace.
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
starter clutch rollers
Damage/wear Replace.
2. Check:
starter clutch idle gear
starter clutch drive gear
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.
5-44
CLUTCH
ENG
4. Check:
starter clutch operation
a. Install the starter clutch drive gear 1 onto
the starter clutch 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.
EAS00299
INSTALLING THE CLUTCH
1. Install:
clutch housing
NOTE:
Make sure that the slots a in the clutch housing align with the tabs b on the oil/water pump
assembly drive sprocket.
Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
Make sure that the starter clutch gear teeth and
starter clutch idle gear teeth mesh correctly.
2. Install:
lock washer New
clutch boss nut 1
90 Nm (9.0 mkg)
NOTE:
While holding the clutch boss 2 with the universal clutch holder 3 , tighten the clutch boss nut.
Universal clutch holder
90890-04086
5-45
CLUTCH
ENG
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
5. Install:
friction plates
clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
a. Install the clutch damper spring seat 1 ,
clutch damper spring 2 and friction plate
(smaller size) 3 .
b. Install the clutch plate and friction plate at following the illustrated.
Friction plate 4 : Color code/Blue
Friction plate 5 : Color code/Black
Clutch plate 6 : 20 mm
Clutch plate 7 : Select. Refer to “CHECKING
THE FRICTION PLATE”
6. Measure:
assembly width a
Out of specification Adjust.
Refer to “CHECKING THE FRICTION
PLATE”.
Assembly width
43.1 43.6 mm
5-46
CLUTCH
ENG
7. Install:
pressure plate 1
NOTE:
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.
8. Install:
clutch springs
clutch spring bolts
8 Nm (0.8 mkg)
NOTE:
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
9. Install:
pull lever
NOTE:
Align the punch mark a in the pull lever shaft
with the mark b on the clutch cover.
10. Install:
dowel pins
gasket New
clutch cover
12 Nm (1.2 mkg)
NOTE:
When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod groove c
and pull lever shaft groove d are engaged.
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
5-47
SHIFT SHAFT
ENG
EAS00326
SHIFT SHAFT
GENERATOR ROTOR COVER
12 Nm (1.2 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the shift shaft and stopper
lever
Drive sprocket cover
Shift shaft cover
Shift shaft cover gasket
Dowel pin
Shift shaft
Shift shaft spring
Spacer
Stopper lever spring
Stopper lever
Collar
Shift shaft spring stopper
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
1
1
2
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-48
SHIFT SHAFT
ENG
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
shift shaft 1
Bends/damage/wear Replace.
shift shaft 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.
EAS00331
INSTALLING THE SHIFT SHAFT
1. Install:
shift shaft spring stopper 1
22 Nm (2.2 mkg)
stopper lever spring 2
stopper lever 3
NOTE:
Apply LOCTITE to the threads of the shift
shaft spring stopper.
Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss.
Mesh the stopper lever with the shift drum segment assembly.
2. Install:
shift shaft 1
spacer
NOTE:
Lubricate the oil seal lips with lithium soap
base grease.
Install the end of the shift shaft spring onto the
shift shaft spring stopper 2 .
5-49
OIL PAN AND OIL PUMP
ENG
EAS00356
OIL PAN AND OIL PUMP
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
43 Nm (4.3 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Removing the oil pan and oil pump
Engine oil
Coolant
1
2
3
4
5
6
Radiator assembly and water pump
outlet pipe
Exhaust pipe assembly
Oil level switch connector
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
1
1
1
1
1
2
5-50
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “RADIATOR” and “OIL COOLER”
in chapter 5.
Refer to “ENGINE”.
Disconnect.
OIL PAN AND OIL PUMP
ENG
EB411001
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
43 Nm (4.3 mkg)
10 Nm (1.0 mkg)
Order
7
8
9
10
11
12
13
14
Job/Part
Drain pipe
Oil strainer
Oil pipe
Oil delivery pipe
Oil/water pump assembly drive
sprocket cover
Dowel pin
Oil/water pump assembly
Relief valve assembly
Q’ty
Remarks
1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.
5-51
OIL PAN AND OIL PUMP
ENG
EAS00360
10 Nm (1.0 mkg)
15 Nm (1.5 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the oil pump
Oil/water pump assembly driven
sprocket
Washer
Oil pump housing
Bearing
Pin
Oil pump outer rotor
Oil pump inner rotor
Pin
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
2
1
1
1
For assembly, reverse the disassembly
procedure.
5-52
OIL PAN AND OIL PUMP
ENG
EAS00362
REMOVING THE OIL PAN
1. Remove:
oil level switch 1
oil pan 2
engine oil drain bolt 3
gasket
dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
EAS00364
CHECKING THE OIL PUMP
1. Check:
oil pump drive gear 1
oil pump driven gear 2
oil pump housing
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
0.09 0.15 mm
<Limit>: 0.23 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 0.08 mm
<Limit>: 0.15 mm
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.06 0.11 mm
<Limit>: 0.18 mm
3. Check:
oil pump operation
Unsmooth Repeat steps (1) and (2) or replace the defective part(-s).
5-53
OIL PAN AND OIL PUMP
ENG
EAS00365
CHECKING THE RELIEF VALVE
1. Check:
relief valve body 1
relief valve 2
spring 3
O-ring 4
Damage/wear Replace the defective
part(-s).
EAS00366
CHECKING THE OIL DELIVERY PIPE
1. Check:
oil delivery pipe 1
oil pipe 2
Damage Replace.
Obstruction Wash and blow out with compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
oil strainer 1
Damage Replace.
Contaminants Clean with engine oil.
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor
outer rotor
oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-54
OIL PAN AND OIL PUMP
ENG
2. Install:
pin 1
inner rotor 2
outer rotor 3
oil pump housing 4
Oil pump housing screw
10 Nm (1.0 mkg)
NOTE:
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove a on the inner rotor 2 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
oil pump
12 Nm (1.2 mkg)
NOTE:
Install the oil/water pump drive chain 1 onto
the oil/water pump driven sprocket 2 .
EAS00378
INSTALLING THE OIL STRAINER
1. Install:
10 Nm (1.0 mkg)
oil strainer housing 1
LOCTITE
NOTE:
The arrow a on the oil strainer housing must
point towards the front of the engine.
5-55
OIL PAN AND OIL PUMP
ENG
EAS00380
INSTALLING THE OIL PAN
1. Install:
dowel pins
gasket New
10 Nm (10 mkg)
oil pan 1
2
oil level switch
10 Nm (10 mkg)
engine oil drain bolt 3
43 Nm (4.3 mkg)
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.
5-56
CRANKCASE
ENG
EAS00381
CRANKCASE
CRANKCASE
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
Job/Part
Q’ty
Removing the crankcase
Engine
Cylinder head
Pickup coil and pickup coil rotor
Stator coil assembly
Clutch housing and starter clutch idle
gear
Oil/water pump assembly
Timing chain
Crankshaft sprocket
Pin
Oil/water pump assembly drive chain
guide
Oil/water pump assembly drive chain
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “PICKUP COIL”.
Refer to “GENERATOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
1
1
1
1
1
5-57
CRANKCASE
ENG
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
6
7
8
9
10
Job/Part
Oil/water pump assembly drive
sprocket
Washer
Plate
Lower crankcase
Dowel pin
Q’ty
Remarks
1
1
1
1
3
For installation, reverse the removal
procedure.
5-58
CRANKCASE
ENG
EAS00382
CONNECTING RODS AND PISTONS
36 Nm (3.6 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the connecting rods and
pistons
Connecting rod cap
Big end lower bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Big end upper bearing
Top ring
2nd ring
Oil ring
Remarks
Remove the parts in the order listed.
4
4
8
4
4
4
4
4
4
4
For installation, reverse the removal
procedure.
5-59
CRANKCASE
ENG
CRANKSHAFT
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
Removing the crankshaft assembly
Crankcase
Connecting rod caps
1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Remarks
1
5
5
For installation, reverse the removal
procedure.
5-60
CRANKCASE
ENG
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).
The numbers embossed on the crankcase indicate the crankcase tightening sequence.
3. Remove:
lower 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.
M9
125 mm bolts: 1 X 10
M8
125 mm bolts: 21 X 22
M6
100 mm bolts: 11 X 20 , 23 X 28
4. Remove:
dowel pins
O-ring
5. 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.
5-61
CRANKCASE
ENG
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
connecting rod cap 1
big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
piston pin clips 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
For reference during installation, put identification marks on the piston crown.
Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 1 .
Piston pin puller
90890-01304
5-62
CRANKCASE
ENG
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.
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
crankshaft assembly 1
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.
5-63
ENG
CRANKCASE
EAS00256
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.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Cylinder bore “C”
74.00 74.01 mm
Wear limit
74.06 mm
Taper limit “T”
0.05 mm
Out of round “R”
0.05 mm
“C” = maximum of D1 D6
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1 D3 or D5 – minimum of
D2 D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
5-64
CRANKCASE
ENG
c. Measure piston skirt diameter “P” with the
micrometer.
a 0.5 mm from the bottom edge of the piston.
Piston size “P”
73.955 73.970 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
0.030 0.055 mm
<Limit>: 0.12 mm
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance
Top ring
0.030 0.065 mm
2nd ring
0.020 0.055 mm
5-65
CRANKCASE
ENG
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the piston crown as shown.
a 5 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
0.32 0.44 mm
2nd ring
0.43 0.58 mm
Oil ring
0.10 0.35 mm
EAS00266
CHECKING THE PISTON PINS
The following procedure applies to all of the piston pins.
1. Check:
piston pin
Blue discoloration/grooves Replace the
piston pin and then check the lubrication system.
2. Measure:
piston pin outside diameter
Out of specification Replace the piston
pin.
Piston pin outside diameter
16.991 17.000 mm
5-66
CRANKCASE
ENG
3. Measure:
piston pin bore inside diameter
Out of specification → Replace the piston.
Piston pin bore inside diameter
17.002 17.013 mm
4. Calculate:
piston-pin-to-piston clearance
Out of specification Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 0.022 mm
<Limit>: 0.072 mm
EAS00395
CHECKING THE CRANKSHAFT AND CONNECTING RODS
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
0.029 0.053 mm
5-67
CRANKCASE
ENG
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.
NOTE:
Align the projections a of the crankshaft 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
1 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.
5-68
CRANKCASE
ENG
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase.
Crankcase bolt
Bolt 1 10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45 50_
Bolt 11 15 , 17 20 , 23 ,
25 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 22
24 Nm (24 mSkg)
NOTE:
Lubricate the crankcase bolt threads with engine oil.
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. Select:
S crankshaft journal bearings (J1 J5)
NOTE:
S 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.
S “J1 J5” refer to the bearings shown in the
crankshaft illustration.
S If “J1 J5” are the same, use the same size
for all of the bearings.
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is:
Bearing size for J1:
J1 (crankcase) – J1 (crankshaft web) –2 =
6 – 2 – 2 = 2 (Pink/black)
5-69
CRANKCASE
ENG
CRANKSHAFT JOURNAL BEARING
COLOR CODE
–1
Pink/violet
0
Pink/white
1
Pink/blue
2
Pink/black
3
Pink/brown
5. Measure:
crankshaft-pin-to-big-end-bearing
clearance
Out of specification Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing
clearance
0.031 0.055 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.
5-70
CRANKCASE
ENG
c. Put a piece of Plastigauge 1 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 c on the connecting rod faces towards the left side of the crankshaft.
Make sure that the characters d on both the
connecting rod and connecting rod cap are
aligned.
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 2.0 and 3.6 mkg.
Once you reach 2.0 mkg, DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted between 2.0 and 3.6 mkg, loosen the connecting rod nut to less than 2.0 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 on the crankshaft pin.
If the clearance is out of specification, select
replacement big end bearings.
5-71
CRANKCASE
ENG
6. Select:
big end bearings (P1 P4)
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” “P5” 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) –2 =
4 – 1 – 2 = 1 (Blue)
BIG END BEARING COLOR CODE
–1
Violet
0
White
1
Blue
2
Black
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly 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.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals
Damage/wear Replace.
5-72
CRANKCASE
ENG
CHECKING THE SPROCKETS AND CHAINS
1. Check:
crankshaft sprocket 1
oil/water pump assembly drive sprocket 2
Cracks/damage/wear Replace the defective part(-s).
2. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and crankshaft sprocket as a set.
oil/water pump assembly drive chain 2
Damage/stiffness Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
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:
crankshaft
5-73
CRANKCASE
ENG
EAS00268
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:
top ring 1
2nd ring 2
upper oil ring rail 3
oil ring expander 4
lower oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers a face up.
2. Install:
piston 1
(onto the respective connecting rod 2 )
piston pin 3
piston pin clip New 4
NOTE:
Apply engine oil onto the piston pin.
Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
e Oil ring expander
5-74
CRANKCASE
ENG
5. Lubricate:
crankshaft pins
big end bearings
connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:
big end bearings
connecting rod assembly
(into the cylinder and onto the crankshaft
pin).
connecting rod cap
(onto the connecting rod)
NOTE:
Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
Be sure to reinstall each big end bearing in its
original place.
While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
Make sure that the “Y” marks a on the connecting rods face towards the left side of the
crankshaft.
Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
7. Align:
bolt heads
(with the connecting rod caps)
8. Tighten:
connecting rod nuts
36 Nm (3.6 mkg)
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 2.0 and 3.6 mkg.
Once you reach 2.0 mkg DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted between 2.0 and 3.6 mkg, loosen the connecting rod nut to less than 2.0 mkg and
start again.
5-75
CRANKCASE
ENG
EAS00414
ASSEMBLING THE CRANKCASE
1. Lubricate:
crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 3 mm of
the crankshaft journal bearings.
3. Install:
dowel pin
4. Install:
crankshaft journal lower bearings 1
(into the lower crankcase)
NOTE:
Align the projections a on the crankshaft journal lower bearings with the notches b in the
crankcase.
Install each crankshaft journal lower bearing in
its original place.
5. Set the shift drum assembly and transmission gears in the neutral position.
5-76
CRANKCASE
ENG
6. Install:
S 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.
7. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Tighten the bolts in increasing numerical order.
S Install washers on bolts 1 X 10 .
M9
M8
M6
125 mm bolts: 1 X 10
125 mm bolts: 21 X 22
100 mm bolts: 11 X 20 , 23 X 28
Crankcase bolt
Bolt 1 X 10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45 X 50_
Bolt 11 X 15 , 17 X 20 , 23 ,
25 X 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 X 22
24 Nm (24 mSkg)
5-77
TRANSMISSION
ENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the transmission, shift
drum assembly, and shift forks
Crankcase
1
2
3
4
5
6
7
8
9
Stopper lever
Drive axle assembly
Circlip
Oil seal
Bearing
Shift drum retainer
Shift fork guide bar
Spring
Shift fork “L”
Shift fork “R”
Remarks
Separate.
Refer to “CRANKCASE”.
Refer to “SHIFT SHAFT”.
1
1
1
1
1
2
4
1
1
For installation, reverse the removal
procedure.
5-78
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Disassembling the main axle
assembly
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Toothed spacer
Toothed washer
Circlip
3rd/4th pinion gears
5th pinion gear
Collar
Q’ty
ENG
Remarks
Disassembly the parts in the order listed.
1
1
1
1
1
2
2
1
1
1
5-79
TRANSMISSION
Order
11
12
13
Job/Part
Main axle/1st pinion gear
Bearing
Main axle bearing housing
Q’ty
ENG
Remarks
1
1
1
For assembly, reverse the disassembly
procedure.
5-80
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Disassembling the drive axle
assembly
Washer
1st wheel gear
Spacer
5th wheel gear
Circlip
Washer
3rd wheel gear
Toothed spacer
Toothed lock washer
Toothed lock washer retainer
Q’ty
ENG
Remarks
Disassembly the parts in the order listed.
1
1
1
1
3
3
1
2
1
1
5-81
TRANSMISSION
Order
11
12
13
14
15
16
17
Job/Part
4th wheel gear
6th wheel gear
2nd wheel gear
Spacer
Drive axle
Bearing
Spacer
Q’ty
ENG
Remarks
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-82
TRANSMISSION
ENG
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
main axle assembly 1
(with the Torx wrench T30)
a. Insert two bolts 2 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
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.
5-83
TRANSMISSION
ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum.
shift drum segment 1
Damage/wear Replace.
shift drum bearing 2
Damage/pitting 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.
5-84
TRANSMISSION
ENG
EAS00428
INSTALLING THE TRANSMISSION
main axle assembly
shift fork “C”
shift drum assembly
shift fork “R”
shift fork “L”
springs
shift fork guide bars
drive axle assembly
NOTE:
Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip is
inserted into the grooves in the upper crankcase.
2. Check:
transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
5-85
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
6-6
6-6
6-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8
6-10
6-10
6-11
COOL
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Removing the radiator
Coolant
Water inlet hose
Carburetor hose
Oil cooler hose
Water outlet hose
Radiator
Fan motor
1
1
1
1
1
1
For installation, reverse the removal
procedure.
6-1
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
95 125 kPa
(0.95 1.25 kg/cm2)
a. Install the radiator cap tester 1 and adapter
2 to the radiator cap 3 .
Radiator cap tester
90890-01325
Adapter
90890-01352
b. Apply the specified pressure for ten seconds
and make sure that there is no drop in pressure.
4. Check:
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-2
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.
a. Attach the radiator cap tester 1 to the radiator.
Radiator cap tester:
90890-01325
b. Apply 100 kPa (1.0 kg/cm2) of pressure.
c. Measure the indicated pressure with the
gauge.
6-3
THERMOSTAT
COOL
EAS00460
THERMOSTAT
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT COWLING” in chapter 3.
Removing the thermostat
Front cowling
Coolant reservoir hose
Water inlet hose
Water outlet hose
Thermostat housing
1
1
1
1
For installation, reverse the removal
procedure.
6-4
THERMOSTAT
COOL
EAS00461
15 Nm (1.5 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Disassembling the thermostat housing
1
Thermostat housing cover
1/1
Thermostat /O-ring
1
Thermostat housing
1
Thermo unit
Remarks
Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
6-5
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
S thermostat
Does not open at 71 85_C Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermometer’s indicated temperature.
1
2
3
4
A
B
Thermometer
Water
Thermostat
Container
Closes
Opens
NOTE:
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.
EAS00464
ASSEMBLING THE THERMOSTAT
1. Install:
S thermostat housing 1
S thermostat 2
S O-ring New
S thermostat housing cover
NOTE:
Install the thermostat with its breather hole a
facing up.
6-6
THERMOSTAT
2. Install:
thermo unit 1
COOL
15 Nm (1.5 mkg)
CAUTION:
Use extreme care when handling the thermo
unit. 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.
6-7
WATER PUMP
COOL
EAS00469
WATER PUMP
10 Nm (1.0 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Disassembling the water pump
Disassemble the parts in the order listed.
NOTE:
The water pump and oil pump are
combined into one unit (oil/water pump
assembly).
It is not necessary to remove the
impeller shaft unless the coolant level
is extremely low or coolant leaks from
the oil pan.
Oil/water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)
Refer to “OIL PAN AND OIL PUMP” in
chapter 5.
6-8
1
1
2
1
WATER PUMP
COOL
10 Nm (1.0 mkg)
Order
5
6
7
Job/Part
Q’ty
Water pump seal
Oil seal
Bearing
Remarks
1
1
1
For assembly, reverse the disassembly
procedure.
6-9
WATER PUMP
COOL
EAS00470
DISASSEMBLING THE WATER PUMP
1. Remove:
water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
2 Water pump housing
2. Remove:
oil sesal 1
bearing 2
NOTE:
Tap out the bearing and oil seal from the outside
of the water pump housing.
3 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.
EAS00473
CHECKING THE WATER PUMP
1. Check:
water pump housing cover 1
water pump housing 2
impeller 3
rubber damper 4
rubber damper holder 5
2. Check:
water pump seal
oil seal
water pump inlet pipe
Crack/damage/wear ! Replace
bearing
Roughness ! Replace.
6-10
WATER PUMP
COOL
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
oil seal New 1
(to the water pump housing 2 )
NOTE:
Install the oil seal with a socket that matches its
outside diameter.
Before installing the oil seal, apply tap water or
coolant onto its outer surface.
2. Install:
water pump seal New 1
CAUTION:
Never apply oil or grease onto the water
pump seal surface.
NOTE:
Install the water pump seal with the water
pump seal installers.
Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .
Water pump seal installer 4
90890-04078
Middle driven shaft bearing
driver 5
90890-04058
Yamaha bond No.1215
90890-85505
A Push down
6-11
WATER PUMP
COOL
3. Install:
rubber damper New 1
rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
4. Measure:
tilt
Out of specification Repeat steps (3) and
(4).
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
6-12
CARB
CHAPTER 7
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-6
7-8
7-9
7-10
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . .
7-14
7-14
7-14
7-15
7-16
7-11
7-13
CARB
CARBURETORS
CARB
CARBURETORS
CARBURETORS
AIR FILTER CASE
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “FRONT COWLING/SEAT/
SIDE COVER/FUEL TANK” section in
chapter 3.
Refer to “CHANGING THE COOLANT”
section.
Removing the air filter case
Seat, fueltank and sidecovers
Drain the coolant
1
2
3
4
5
Air filter case panel (left/right)
Battery negative lead
Battery positive lead
Battery
Stay
Remarks
1/1
1
1
1
1
For installation, reverse the removal
procedure.
7-1
CARBURETORS
CARB
EAS00481
Order
1
2
3
4
5
6
Job/Part
Removing the carburetors
Throttle position sensor lead
Air filter joint screw
Carburetors joint screw
Carburetor inlet/outlet hose
Carburetors assembly
Starter cable
Throttle cable
Q’ty
Remarks
Remove the parts in the order listed.
Disconnect.
4
4
1/1
1
1
2
For installation, reverse the removal
procedure.
7-2
CARBURETORS
CARB
EAS00482
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Separating the carburetor
Throttle stop screw
Coolant hose
Starter plunger link
Connecting bolt
Spacer
Connecting bolt
Spacer
Fuel inlet pipe
Fuel feed pipe
Spring
Vacuum chamber air vent hose
Float chamber air vent hose
Throttle position sensor
Throttle position sensor bracket
Carburetor
1
1
1
1
1
1
3
1
2
2
2
2
1
1
4
For installation, reverse the removal
procedure.
7-3
CARBURETORS
CARB
EAS00484
Order
Job/Part
Q’ty
Disassemble the parts in the order listed.
NOTE:
The following procedure applies to all of
the carburetors.
Disassembling the carburetor
1
2
3
4
5
6
7
8
9
10
Remarks
1
1
1
1
1
1
1
1
1
1
Starter plunger
Pilot air jet
Vacuum chamber cover
Piston valve spring
Piston valve
Jet needle holder
Jet needle kit
Pilot screw
Fuel drain bolt
Float pin
7-4
CARBURETORS
Order
11
12
13
14
15
16
17
Job/Part
Q’ty
CARB
Remarks
1
1
1
1
1
1
1
Float
Needle valve
Needle valve seat
Main jet
Main jet holder
Pilot jet
Needle jet
For assembly, reverse the disassembly
procedure.
7-5
CARBURETORS
CARB
EAS00486
CHECKING THE CARBURETORS
The following procedure applies to all of the carburetors.
1. Check:
carburetor body
float chamber
jet housing
Cracks/damage Replace.
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic-carburetorcleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body 1
Dirt Clean.
4. Check:
float chamber rubber gasket 2
Cracks/damage/wear Replace.
5. Check:
float 1
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.
7-6
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 3
Cracks/damage Replace.
10. Check:
jet needle kit 1
needle jet 2
main jet 3
main jet holder 4
pilot jet 5
pilot screw 6
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.
13. Check:
fuel feed hoses
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
7-7
CARBURETORS
CARB
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:
jet needle kit
2. Install:
needle jet 1
pilot jet 2
main jet 3
3. Measure:
float height a
Out of specification Adjust.
Float height
12.5 13.5 mm
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,
check the needle valve seat and needle
valve.
7-8
CARBURETORS
CARB
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:
piston valve
piston valve spring
vacuum chamber cover
NOTE:
Align the tab a on the piston valve diaphragm
with the recess b in the carburetor body.
5. Install:
connecting bracket
NOTE:
After installing the connecting bracket, check
that the throttle cable lever and starter plunger
link operate smoothly.
EAS00493
INSTALLING THE CARBURETORS
1. Adjust:
carburetor synchronization
Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3.
2. Adjust:
engine idling speed
Engine idling speed
1,050 1,150 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)
3 5 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
7-9
CARBURETORS
CARB
EAS00495
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
fuel level a
Out of specification Adjust.
Fuel level (below the line on the
float chamber)
3.0 4.0 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
90890-01312
d. Loosen the fuel drain screw.
e. Hold the fuel level gauge vertically next to the
line on the float chamber 3 .
f. Measure the fuel level a on both sides of the
carburetor assembly.
NOTE:
The fuel level readings should be equal on both
sides.
2. Adjust:
fuel level
a. Remove the carburetor assembly.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slightly bending the float tang 1 .
e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
7-10
CARBURETORS
CARB
EAS00500
CHECKING
AND
ADJUSTING
THROTTLE POSITION SENSOR
THE
NOTE:
S Before adjusting the throttle position sensor,
the engine idling speed should be properly adjusted.
S When installing the throttle position sensor,
adjust its angle according to the RPM which is
displayed on the tachometer. Refer to the adjustment procedure below.
1. Check:
S throttle position sensor
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Tester positive lead Black/blue 1
Tester negative lead Blue 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
e. Install the throttle position sensor onto the
carburetor.
f. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Tester positive lead Yellow 3
Tester negative lead Blue 2
g. While slowly opening the throttle, check that
the throttle position sensor resistance is within the specified range.
Out of specification Replace the throttle
position sensor.
Throttle position sensor
resistance
0.4 X 5.4 kΩ at 20_C
7-11
CARBURETORS
CARB
2. Adjust:
throttle position sensor angle
a. Turn the main switch to “ON”.
b. Disconnect the throttle position sensor coupler.
c. Reconnect the throttle position sensor coupler.
NOTE:
After reconnecting the throttle position sensor
coupler, the tachometer switches to the throttle
position sensor adjustment mode.
d. Loosen the throttle position sensor screws
1.
e. Adjust the throttle position sensor angle according to the following table:
NOTE:
The angle of the throttle position sensor is indicated by the RPM which are displayed on the
tachometer.
Tachometer reading
Throttle position
sensor angle
0 r/min 1
Too small
5,000 r/min 2
Correct
10,000 r/min 3
Too large
f. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
NOTE:
To exit the throttle position sensor adjustment
mode, start the engine or turn the main switch to
“OFF”.
7-12
CARBURETORS
CARB
EAS00504
CHECKING THE FUEL PUMP
1. Check:
fuel pump 1
a. Place a container under the end of the fuel
hose.
b. Start the engine and check if fuel flows from
the fuel hose 2 .
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 2 .
7-13
Fuel stops flowing.
Fuel pump is OK.
Fuel flows.
Replace the fuel
pump.
AIR INDUCTION SYSTEM
CARB
EAS00507
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned exhaust gases by injecting fresh air (secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700_C.
EAS00508
AIR CUTOFF VALVE
The air cutoff valve is operated by the intake gas
pressure through the piston valve diaphragm.
Normally, the air cutoff valve is open to allow
fresh air to flow into the exhaust port. During
sudden deceleration (the throttle valve suddenly closes), negative pressure is generated and
the air cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cutoff valve automatically closes to guard against a loss of performance due to self-EGR.
VIEW 1. (NO FLOW)
VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the valve will
close.
VIEW 2. (FLOW)
During normal operation the valve is open.
A From the air cleaner
B To the reed valve
C To the carburetor joint
VIEW 2. (FLOW)
7-14
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1
2
3
4
A
B
C
D
E
Reed valve
Air cleaner
Air cutoff valve
Carburetor joint (cylinder #4)
To the air cutoff valve
To cylinder #1
To cylinder #2
To cylinder #3
To cylinder #4
7-15
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:
fibre reed 1
fibre reed stopper
reed valve seat
Cracks/damage Replace the reed valve.
3. Measure:
fibre reed bending limit a
Out of specification Replace the reed
valve.
Fibre reed bending limit
0.2 mm
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
7-16
ELEC
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
INSTRUMENT FUENCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . .
TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . .
8-10
8-10
8-11
8-12
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . .
8-17
8-17
8-18
8-19
8-22
8-24
8-25
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-46
8-46
8-47
8-48
8-50
ELEC
EXUP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
CIRCUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
Main switch
Fuel sender
Rear brake switch
Battery
Ignitor unit
Starter relay
7
8
9
10
11
Starting circuit cutoff relay
Flasher relay
Speed sensor
Sidestand switch
Neutral switch
8-1
12
13
14
15
16
17
18
Oil level gauge
Ignition coil
Rectifier/ Regulator
Thermo unit
Horn
Emargency stop switch
Fan motor relay
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
ELEC
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS
1
2
3
4
5
Thermo unit
T.P.S.
Starter motor
Pickup rotor
Pickup coil
8-2
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
1
2
3
4
5
6
7
8
9
Ignitor unit
Fuse box
Battery
Fuel pump
Fuel pump coupler
Brake light switch coupler
Newtral switch coupler
Pickup coil coupler
Speed sensor coupler
8-3
ELEC
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
1
2
3
4
Ignition coil #2.3
Ignition coil #1.4
Rectifier/ regulator
Stator coil
8-4
ELEC
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
1
2
3
4
5
6
7
8
9
Emargency stop switch
Flasher relay
Starter relay
Fan motor relay
Starting circuit cutoff relay
Stator coil coupler
Sidestand switch coupler
Fuel sender coupler
Oil level switch coupler
8-5
ELEC
INSTRUMENT FUNCTIONS
ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Turn indicator light “ ” “ ”
This indicator flashes when the turn switch is
moved to the left or right, and the hazard
switch is on.
Neutral indicator light “ ”
This indicator comes on when the transmission is in neutral.
High beam indicator light “ ”
This indicator comes on when the headlight
high beam is used.
1 Turn indicator light (left) “
”
2 Turn indicator light (right) “
”
3 Neutral indicator light “
”
4 High beam indicator light “
”
WARNING LIGHT
1 Oil level warning light “
”
2 Coolant temperature warning light “
3 Fuel level warning light “
Oil evel warning light “
”
This warning light comes on when the engine
oil level is low. If this symbol flashes, stop the
engine immediately and fill it with oil to the
specified level.
Coolant temperature warning light “ ”
This warning light comes on when the coolant temperature is too high.
Fuel level warning light “ ”
When the fuel level drops below approximately 5.5 L, this light will come on.When this
light comes on, fill the fuel tank at the first opportunity.
”
”
CAUTION:
Do not run the motorcycle until you know it
has sufficient engine oil.
Do not run the motorcycle if the engine is
overheated.
NOTE:
Even if the oil is filled to the specified level, the
warning light may flicker when riding on a slope
or during sudden acceleration or deceleration,
but this is normal.
8-6
INSTRUMENT FUNCTIONS
ELEC
DIGITAL CLOCK
Clock
To set the clock:
1. Push both the “SELECT” 1 and “RESET” 2
buttons for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button 2 to set the hours.
3. Push the “SELECT” button 1 to change the
minutes.
4. When the minute digits start flashing, push
the “RESET” button 2 to set the minutes.
5. Push the “SELECT” button 1 to start the
clock.
1 “SELECT” button
2 “RESET” button
NOTE:
After setting the clock, be sure to push the “SELECT” button 1 before turning the main switch
to “OFF”, otherwise the clock will not be set.
8-7
CHECKING SWITCH CONTINUITY
ELEC
EAS00730
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 blue/red and red
when the switch is set to “P”.
There is continuity between blue/red and blue
when the switch is set to “ON”.
8-8
CHECKING THE SWITCHES
ELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
1
2
3
4
5
6
Main switch
Pass switch
Dimmer switch
Horn switch
Clutch switch
Hazard switch
7
8
9
10
11
Turn signal switch
Front brake switch
Light switch
Engine stop switch
Start switch
8-9
12
13
14
15
16
Rear brake switch
Fuse
Side stand switch
Neutral 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 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 B is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
Bulbs C are used for meter and indicator lights
and can be removed from their respective
socket by carefully pulling them out.
8-10
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
bulb
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.
8-11
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.
CHECKING THE LEDs
The following procedures applies to all of the
LEDs.
1. Check:
LED (for proper operation)
Improper operation Replace.
a. Disconnect the meter assembly coupler (meter assembly side).
b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
c. When the jumper leads are connected to the
terminals the respective LED should illuminate.
Does not light Replace the meter assembly.
8-12
ELEC
IGNITION SYSTEM
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
5
7
15
16
17
18
41
58
8-13
Main switch
Battery
Fuse (main)
Ignitor
Ignition coil
Spark plug
Pickup coil
Engine stop switch
Fuse (ignition)
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. Main switch
8. Engine stop switch
9. Pickup coil resistance
10. Wiring connections
(of the entire ignition system)
Minimum 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) Seat
2) Fuel tank
3) Side cover
S Troubleshoot with the following special
tool(-s).
EAS00741
3. Spark plugs
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
90890-03112
Standard spark plug
CR9E (NGK)
U27ESR-N (DENSO)
Spark plug gap
0.7 X 0.8 mm
EAS00738
1. Main and ignition fuses
S Is the spark plug in good condition, it is of the
correct type, and is its gap within specification?
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
YES
S Are the main and ignition fuses OK?
YES
NO
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
8-14
ELEC
IGNITION SYSTEM
EAS00743
Spark plug cap resistance
10 kΩ at 20_C
4. Ignition spark gap
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 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
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.
Positive tester probe red/black
Negative tester probe orange (gray)
Minimum ignition spark gap
6.0 mm
S Is there a spark and is the spark gap within
specification?
NO
YES
S Measure the primary coil resistance.
Primary coil resistance
1.87 X 2.53 Ω at 20_C
The ignition system
is OK.
S Connect the pocket tester (Ω
ignition coil as shown.
EAS00745
5. Spark plug cap resistance
1k) to the
Posltlve tester probe spark plug lead
Negative tester probe spark plug lead
The following procedure applies to all of the
spark plug caps.
S Remove the spark plug cap from the spark
plug lead.
S Connect the pocket tester (“Ω
1k”) to the
spark plug cap as shown.
S Measure the spark plug cap resistance.
S Measure the secondary coil resistance.
8-15
ELEC
IGNITION SYSTEM
EAS00748
Secondary coil resistance
12 X 18 kΩ at 20_C
9. Pickup coil resistance
S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester (Ω
100) to the
pickup coil terminal as shown.
S Is the ignition coil OK?
YES
NO
Positive tester probe gray 1
Negative tester probe black 2
Replace the ignition
coil.
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
S Measure the pickup coil resistance.
Replace the main
switch.
Pickup coil resistance
248 X 372 Ω at 20_C
(between gray and black)
S Is the pickup coil OK?
EAS00750
8. Engine stop switch
YES
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the pickup
coil.
S Is the engine stop switch OK?
YES
NO
NO
EAS00754
10. Wiring
Replace the right
handlebar switch.
S Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the ignition system’s wiring properly connected and without defects?
NO
Properly connect or
repair the ignition
system’s wiring.
8-16
YES
Replace the ignitor
unit.
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
1
5
6
7
8
9
10
19
41
42
48
58
59
8-17
Main switch
Battery
Fuse (main)
Starter relay
Starter motor
Starting circuit cutoff relay
Side stand switch
Neutral switch
Engine stop switch
Start switch
Clutch switch
Fuse (ignition)
Alarm
ELECTRIC STARTING SYSTEM
ELEC
EAS00756
STARTING CIRCUIT CUTOFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
The starting circuit cutoff relay prevents the
starter motor from operating when neither of
these conditions has been met. In this instance,
the starting circuit cutoff relay is open so current
cannot reach the starter motor. When at least
one of the above conditions has been met the
starting circuit cutoff relay is closed and the engine can be started by pressing the 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
8-18
ELECTRIC STARTING SYSTEM
ELEC
EAS00739
EAS00757
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
The starter motor fails to turn.
Check:
1. Main and ignition fuses
2. Battery
3. Starter motor
4. Starting circuit cutoff relay
5. Starter relay
6. Main switch
7. Engine stop switch
8. Neutral switch
9. Sidestand switch
10. Clutch switch
11. Start switch
12. 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) Seat
2) Fuel tank
3) Side cover
S Troubleshoot with the following special tool(-s).
3. Starter motor
S Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
90890-03112
EAS00738
1. Main and ignition fuses
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
WARNING
S A wire that is used as a jumper lead must
have at least the same capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
S This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
S Are the main and ignition fuses OK?
YES
NO
Replace the fuse (s).
S Does the starter motor turn?
YES
NO
Repair or replace the
starter motor.
8-19
ELEC
ELECTRIC STARTING SYSTEM
EAS00759
4. Starting circuit cutoff relay
Disconnect the starting circuit cutoff relay
coupler from the wire harness.
Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cutoff relay
coupler as shown.
Positive battery lead red/black 1
Negative battery lead black/yellow 2
Does the starter relay have continuity between red and red?
Positive tester probe blue/white 3
Negative tester probe black 4
YES
NO
Replace the starter
relay.
EAS00749
6. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Does the starting circuit cutoff relay have
continuity between blue/white and black?
YES
Is the main switch OK?
YES
NO
NO
Replace the main
switch.
Replace the starting
circuit cutoff relay.
EAS00750
EAS00761
5. Starter relay
7. Engine stop switch
Disconnect the starter relay coupler from the
wireharness.
Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as
shown.
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
Positive battery lead blue/white 1
Negative battery lead red/white 2
NO
Replace the right
handlebar switch.
Positive tester probe red 3
Negative tester probe red 4
8-20
ELECTRIC STARTING SYSTEM
EAS00751
ELEC
EAS00766
8. Neutral switch
12. Wiring
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the neutral switch OK?
Is the starting system’s wiring properly connected and without defects?
YES
NO
YES
Replace the neutral
switch.
The starting system
circuit is OK?
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.
8-21
NO
Properly connect or
repair the starting
system’s wiring.
ELECTRIC STARTING SYSTEM
ELEC
EAS00767
STARTER MOTOR
Order
1
2
Job/Part
Removing the starter motor
Carburetor
Starter motor lead
Starter motor/O-ring
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CARBURETOR” in chapter 7.
1
1/1
For installation, reverse the removal
procedure.
8-22
ELECTRIC STARTING SYSTEM
ELEC
EAS00768
5 Nm (0.5 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Q’ty
Disassembling the starter motor
Starter motor front cover
Lock washer
Oil seal
Bearing
Washer set
Starter motor rear cover
Washer set
Brush seat (along with the brushes)
Armature assembly
Brush holder (along with the brushes)
O-ring
Starter motor yoke
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
2
1
Refer to “ASSEMBLING THE STARTER
MOTOR”.
NOTE:
Be sure to remove the installation nut on
brush #1 first.
For assembly reverse the disassembly
procedure.
8-23
ELECTRIC STARTING SYSTEM
ELEC
EAS00769
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 undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut
0.7 mm
NOTE:
The mica must be undercut to ensure proper operation of the commutator.
4. Measure:
S armature assembly resistances (commutator and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-08112
Armature coil
Commutator resistance 1
0.025 X 0.035 Ω at 20_C
Insulation resistance 2
Above 1M Ω at 20_C
8-24
ELECTRIC STARTING SYSTEM
ELEC
b. If any resistance is out of specification, replace the starter motor.
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Brush length wear limit
4 mm
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
Brush spring force
7.65 X 10.01 N
7. Check:
gear teeth
Damage/wear Replace the gear.
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
armature
brush seat 1
NOTE:
Align the tab a on the brush seat with the slot b
in the starter motor rear cover.
8-25
ELECTRIC STARTING SYSTEM
ELEC
2. Install:
starter motor front cover 1
starter motor rear cover 2
O-ring 3 New
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear covers.
8-26
CHARGING SYSTEM
ELEC
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
3
5
7
8-27
Rectifire/ reguretor
AC magneto
Battery
Fuse (main)
CHARGING SYSTEM
EAS00774
ELEC
YES
TROUBLESHOOTING
The battery is not being charged.
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
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) Seat
2) Fuel tank
3) Side cover
S Troubleshoot with the following special
tool(-s).
EAS00775
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead of cylinder #1.
S Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe positive battery terminal
Negative tester probe negative battery terminal
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
1. Main fuses
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
S Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
Charging voltage
14 V at 5,000 r/min
S Are the fuses OK?
YES
NOTE:
Make sure the battery is fully charged.
NO
S Is the charging voltage within specification?
Replace the fuse (s).
NO
EAS00739
YES
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
The charging circuit
is OK.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
8-28
CHARGING SYSTEM
EAS00776
4. Stator coil resistance
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the stator coils as shown.
Positive tester probe white 1
Negative tester probe white 2
Positive tester probe white 3
Negative tester probe white 1
S Measure the stator coil resistances.
Stator coil resistance
0.27 X 0.33 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.
8-29
ELEC
LIGHTING SYSTEM
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1
5
7
31
34
40
45
Main switch
Battery
Fuse (main)
Hi-beam indicator light
Meter light
Headlight switch
Pass switch
46
55
56
60
61
66
67
Dimmer switch
Headlight
Tail/ brake light
Fuse (Alarm)
Fuse (headlight)
Headlight relay (on / off)
Headlight relay (dimmer)
8-30
ELEC
ELEC
LIGHTING SYSTEM
EAS00781
NO
YES
TROUBLESHOOTING
Any of the following fail to light: headlight,
high beam indicator light, taillight, auxiliary light or meter light.
S Clean the battery
terminals.
S Recharge or replace the battery.
Check:
1. Main, headlight and alarm fuses
2. Battery
3. Main switch
4. Headlight switch
5. Dimmer switch
6. Pass switch
7. Headlight relay (on/off) (for EUR)
8. Headlight relay (dimmer)
9. Wiring connections
(of the entire charging system)
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Seat
2) Fuel tank
3) Side cover
S Troubleshoot with the following special
tool(-s).
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NO
YES
Replace the main
switch.
EAS00783
4. Headlight switch
S Check the headlight switch for continuity
Refer to “CHECKING THE SWITCHES”.
S Is the headlight switch OK?
Pocket tester
90890-03112
NO
YES
EAS00738
1. Main, headlight and alarm fuses
The headlight switch
is faulty. Replace the
right
handlebar
switch.
S Check the main, headlight and alarm fuses
for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
EAS00784
S Are the main, headlight and alarm fuses
OK?
YES
5. Dimmer switch
S Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
NO
S Is the dimmer switch OK?
Replace the fuse (s).
YES
NO
EAS00739
2. Battery
The dimmer switch is
faulty. Replace the
left handlebar switch.
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
8-31
LIGHTING SYSTEM
ELEC
EAS00786
Low-beam
Positive tester probe black/blue 1
Negative tester probe black/green 2
6. Pass switch
Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the pass switch OK?
NO
YES
The pass switch is
faulty.
Replace the left handlebar switch.
Hi-beam
Positive battery lead yellow 1
Negative battery lead black 2
7. Headlight relay (on/off) (for EUR)
Positive tester probe black/blue 3
Negative tester probe black/yellow 4
Disconnect the headlight relay (on/off) from
the coupler.
Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay (on/off)
coupler as shown.
Positive battery lead blue/black 1
Negative battery lead black 2
Positive tester probe red/yellow 3
Negative tester probe black/blue 4
Does the headlight rrelay (dimmer) have
continuity?
YES
NO
Replace the headlight relay (dimmer).
EAS00787
9. Wiring
Does the headlight relay (on/off) have continuity between red/yellow and black/blue?
YES
Check entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
NO
Is the lighting system’s wiring properly connected and without defects?
Replace the headlight relay (on/off).
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
8. Headlight relay (dimmer)
Disconnect the headlight relay (dimmer)
from the coupler.
Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay (dimmer)
coupler as shown.
8-32
NO
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
EAS00788
Set the main switch to “ON”.
Set the light switch to “ON”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) (wire harness
side).
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.
Is the voltage within specification?
YES
Are the headlight bulb and socket OK?
YES
NO
This circuit is OK.
Replace the headlight
bulb, socket or both
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
EAS00789
2. Voltage
2. The meter light fails to come on.
Connect the pocket tester (DC 20 V) 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
1. Meter light bulb and socket
Check the meter light bulb and socket for
continuity.
”.
”.
Are the meter light bulb and socket OK?
Headlight
Positive tester probe black/yellow 1 or black/green 2
Negative tester probe black 3
High beam indicator light
Positive tester probe black/yellow 4
Negative tester probe black 5
NO
YES
Replace the meter
light bulb, socket of
both.
2. Vollage
Headlight coupler (wire harness side)
Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
Positive tester probe blue 1
Negative tester probe black 2
Meter light coupler (wire harness side)
8-33
LIGHTING SYSTEM
Set the main switch to “ON”.
Set the light switch to “PO” or “ON”.
Measure the voltage (12 V) of blue 1 on the
meter light coupler (wire harness side).
Set the main switch to “ON”.
Set the light switch to “PO” or “ON”.
Measure the voltage (12 V) of blue/red 1 on
the tail/brake light coupler (tail/brake light
side).
Is the voltage within specification?
YES
Is the voltage within specification?
NO
YES
This circuit is OK.
The wiring circuit from
the main switch to the
meter light coupler 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 (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe blue/red 1
Negative tester probe black 2
8-34
NO
The wiring circuit from
the main switch to the
tail/brake light coupler
is faulty and must be
repaired.
SIGNAL SYSTEM
EAS00793
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-35
ELEC
SIGNAL SYSTEM
1
5
7
9
19
23
24
25
27
29
32
33
35
36
37
39
43
47
49
50
51
52
53
54
56
57
58
60
65
Main switch
Battery
Fuse (main)
Starting circuit cutoff relay
Neutral switch
Fuel level warning light
Oil level warning light
Neutral indicator light
Combination meter
Fuel gauge
Turn signal indicator light (left)
Turn signal indicator light (right)
Oil level gauge
Fuel sender
Turn signal relay
Front brake light switch
Horn
Horn switch
Hazard switch
Turn signal switch
Front turn signal light (left)
Front turn signal light (right)
Rear turn signal light (left)
Rear turn signal light (right)
Tail/ brake light
Fuse (turn signal)
Fuse (ignition)
Fuse (alarm)
Rear brake light switch
8-36
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, alarm and clock fuses
2. Battery
3. Main switch
4. Wiring connections
(of the entire signal system)
NOTE:
S Before troubleshooting, remove the following
part(s):
1) Seat
2) Fuel tank
3) Front cowling
4) Side cover
S Troubleshoot with the following special tool(s).
YES
NO
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
90890-03112
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
EAS00738
1. Main, signal, alarm and ignition fuses
S Check the main, signal, alarm and ignition
fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main, signal, alarm and ignition
fuses OK?
YES
Properly connect or
repair the signaling
system’s wiring.
EAS00796
CHECKING THE SIGNAL SYSTEM
1. The horn fails to sound.
NO
1. Horn switch
S Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the fuse (s).
S Is the horn switch OK?
EAS00739
2. Battery
YES
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Replace the left handlebar switch.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
NO
2. Voltage
S Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
8-37
SIGNAL SYSTEM
Positive tester probe pink 1
Negative tester probe black
ELEC
4. Voltage
Connect the pocket tester (DC 20 V) to the
horn connector at the black terminal as
shown.
Positive tester probe black 1
Negative tester probe ground
Set the main switch to “ON”.
Push the horn switch.
Measure the voltage (12 V) of pink at the
horn terminal.
Is the voltage within specification?
YES
Set the main switch to “ON”.
Measure the voltage (12 V) of black 1 at the
horn terminal.
NO
Is the voltage within specification?
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
YES
Repair or replace the
horn.
3. Horn
NO
Replace the horn.
EAS00797
2. The tail/brake light fails to come on.
Disconnect the black 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”.
Push the horn switch.
1. Tail/brake light bulb and socket.
Check the tail/brake light bulb and socket for
continuity.
Are the tail/brake light bulb and socket OK?
Does the horn sound?
YES
NO
Replace the tail/brake
light bulb, socket or
both.
2. Brake switches
Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
NO
Is the brake light switch OK?
YES
YES
NO
The horn is OK.
Replace the brake
light switch.
8-38
SIGNAL SYSTEM
ELEC
3. Voltage
2. Turn signal switch
Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the turn signal switch OK?
Positive tester probe yellow 1
Negative tester probe black 2
YES
NO
Replace the left handlebar switch.
3. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
Positive tester probe brown 1
Negative tester probe ground
Set the main switch to “ON”.
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.
NO
The wiring circuit from
the main switch to the
tail/brake light coupler
is faulty and must be
repaired.
Set the main switch to “ON”.
Measure the voltage (12 V) on brown 1 at
the turn signal relay coupler (wire harness
side).
EAS00799
Is the voltage within specification?
3. The turn signal light, turn signal indicator
light or both fail to blink.
YES
1. Turn signal indicator light bulb and socket
Check the turn signal light bulb and socket
for continuity.
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and must be repaired.
Are the turn signal light bulbs and socket OK?
YES
NO
NO
Replace the turn signal light bulb, socket
or both.
8-39
ELEC
SIGNAL SYSTEM
A
4. Voltage
B
Connect the pocket tester (DC 20 V) to the
flasher relay coupler (wire harness side) as
shown.
Positive tester probe brown/white 1
Negative tester probe ground
Set the main switch to “ON”.
Set the turn signal switch to “
” or “
”.
Measure the voltage (12 V) of the chocolate
1 or dark green 2 at the turn signal light
connector (wire harness side).
Is the voltage within specification?
Set the main switch to “ON”.
Set the turn signal switch to “
” or “
”.
Measure the voltage (12 V) on brown/white
1 at the turn signal relay coupler (wire harness side).
YES
This circuit is OK.
Is the voltage within specification?
YES
NO
NO
The wiring circuit
from the turn signal
switch to the turn signal light connector is
faulty and must be
repaired.
EAS00800
The turn signal relay
is faulty and must be
replaced.
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.
5. Voltage
Are the neutral indicator light bulb and socket OK?
Connect the pocket tester (DC 20 V) to the
turn signal light connector (wire harness
side) as shown.
YES
A Rear turn signal light
B Turn signal indicator light
NO
Replace the neutral
indicator light bulb,
socket or both.
Left turn signal light
Positive tester probe chocolate 1
Negative tester probe ground
Right turn signal light
Positive tester probe dark green 2
Negative tester probe ground
2. Neutral switch
Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
8-40
ELEC
SIGNAL SYSTEM
3. Voltage
2. Engine oil level switch
Connect the pocket tester (DC 20 V) to the
meter light bulb coupler (wire harness side)
as shown.
Drain the engine oil and remove the engine
oil level switch from the oil pan.
Check the engine oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Positive tester probe brown 1
Negative tester probe ground
Is the engine oil level switch OK?
YES
NO
Replace the engine
oil level switch.
EAS00795
3. Wiring
Set the main switch to “ON”.
Measure the voltage (12 V).
Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the voltage within specification?
YES
Is the signaling system’s wiring properly
connected and without defects?
NO
YES
This circuit is OK.
The wiring circuit
from the main switch
to the meter light bulb
coupler is faulty and
must be repaired.
Replace the meter
unit.
EAS00802
5. The oil level warning light fails to come on.
1. Oil level warning light bulb and socket
Check the oil level warning light bulb and
socket for continuity.
Are the oil level warning light bulb and socket OK?
YES
NO
Replace the oil level
warning light bulb,
socket or both.
8-41
NO
Properly connect or
repair the signaling
system’s wiring.
SIGNAL SYSTEM
EAS00804
ELEC
S Set the main switch to “ON”.
S Measure the voltage (12 V) of brown 1 on
the meter light coupler (wire harness side).
5. The fuel level gauge fails to operate.
1. Fuel sender
S Remove the fuel sender from the fuel tank.
S Connect the pocket tester to the fuel sender
coupler (wire harness side) as shown.
S Is the voltage within specification?
YES
Positive tester probe green 1
Negative tester probe black 2
NO
Check the wiring
connections of the
entire signaling system.
3. Fuel level gauge
S Set the main switch to “ON”.
S Move the float up 1 or down 2 .
S Check that the fuel level gauge needle
moves to “F” or “E”.
S Measure the fuel sender resistances.
Fuel sender resistance (up position
3 ) (Ω 1)
4 10 Ω at 20_C
Fuel sender resistance (down position 4 ) (Ω 10)
90 100 Ω at 20_C
S Is the fuel sender OK?
YES
NO
Replace
sender.
the
NOTE:
Before reading the fuel level gauge, leave
the float in one position (either up or down)
for at least three minutes.
fuel
S Does the fuel level gauge needle move appropriately?
2. Voltage
S Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
YES
Positive tester probe brown 1
Negative tester probe black 2
NO
Replace the fuel level gauge.
4. Wiring
S Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8-42
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
1
5
7
21
27
28
62
63
64
Main switch
Battery
Fuse (main)
Thermo unit
Combination meter
Water temp warning light
Fues (fan)
Fan motor relay
Fan motor
8-43
ELEC
ELEC
COOLING SYSTEM
EAS00808
S Is the battery OK?
TROUBLESHOOTING
S The radiator fan motor fails to turn.
S The water temperature gauge needle
fails to move when the engine is warm.
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
Check:
1. Main and radiator fan motor fuses
2. Battery
3. Main switch
4. Radiator fan motor
5. Thermo unit
6. 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?
NOTE:
S Before troubleshooting, remove the following
part(-s).
1) Seat
2) Fuel tank
S Troubleshoot with the following special tool(s).
NO
YES
Replace the main
switch.
EAS00809
Pocket tester
90890-03112
4. Radiator fan motor
S Disconnect the rediator fan motor coupler
from the wire harness.
S Connect the battery (12 V) as shown.
EAS00738
1. Main and radiator fan motor fuses
S Check the main and radiator fan motor fuses
for continuity.
Refert to “CHECKING THE FUSES” in
CHAPTER 3.
Positive battery lead blue 1
Negative battery lead black 2
S Are the main and radiator fan motor fuses
OK?
YES
NO
Replace the fuse (s).
EAS00739
S Does the rediator fan motor turn?
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
YES
NO
The radiator fan motor is faulty and must
be replaced.
Minimum open-circuit voltage
12.8 V or more at 20_C
8-44
COOLING SYSTEM
EAS00812
ELEC
EAS00759
5. Thermo unit
6. Fan motor relay
S Remove the thermo unit from the thermostat
housing.
S Connect the pocket tester (Ω 1) to the termo unit 1 as shown.
S Immerse the termo unit in a container filled
with coolant 2 .
NOTE:
Make sure the termo unit terminals do not
get wet.
S Disconnect the fan motor relay coupler from
the wire harness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the fan mtor relay coupler as
shown.
Positive battery terminal ! brown 1
Negative battery terminal !
green/black 2
Positive tester probe ! brown 3
Negative tester probe ! blue 4
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant, and then let it cool
to the specified temperature indicated in the
table.
S Check the thermo unit for continuity at the
temperatures indicated in the table.
S Does the fan motor relay have continuity between brown and blue?
YES
Termo unit resistance
80_C: 3.41 4.00 Ω
105_C: 1.65 1.86 Ω
NO
Replace the fan motor relay.
WARNING
S Handle the termo unit with special care.
S Never subject the thermo unit to strong
shocks. If the thermo unit is dropped, replace it.
EAS00813
7. Wiring
S Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the cooling system’s wiring properly connected and without defects?
Thermo unit
15 Nm (1.5 mSkg)
Three bond sealock 10
YES
NO
S Does the thetmo unit operate properly?
YES
This circuit is OK.
NO
Replace the thermo
unit.
8-45
Properly connect or
repair the cooling
system’s wiring.
FUEL PUMP SYSTEM
ELEC
EAS00814
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
1
5
7
9
11
15
41
51
8-46
Main switch
Battery
Fuse (main)
Starting circuit cutoff relay
Fuel pump
Ignitor
Engine stop switch
Fuse (ignition)
FUEL PUMP SYSTEM
EAS00815
FUEL PUMP CIRCUIT OPERATION
The ignitor unit includes the control unit for the
fuel pump.
1
2
3
4
5
6
7
8
8-47
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 cutoff 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) Seat
2) Fuel tank
3) Side cover
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
90890-03112
EAS00759
EAS00738
1. Main, and ignition fuses
5. Starting circuit cutoff relay
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Disconnect the starting circuit cutoff relay
coupler from the wire harness.
S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cutoff relay
coupler as shown.
S Are the main and ignition fuses OK?
YES
Positive battery lead red/black 1
Negative battery lead blue/red 2
NO
Positive tester probe red/black 3
Negative tester probe black/blue 4
Replace the fuse (s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
S Does the starting circuit cutoff relay have continuity between red/black and black/blue?
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
NO
Replace the starting
circuit cutoff relay.
8-48
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.
Positive tester probe black/blue 1
Negative tester 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.
8-49
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. Turn the fuel cock to “ON”.
d. Connect the battery (12 V) to the fuel pump
coupler as shown.
Positive battery lead black/blue 1
Negative battery lead black 2
e. If fuel flows out of the fuel hose, the fuel pump
is OK.
If fuel does not flow, replace the fuel pump.
B/L
8-50
EXUP SYSTEM
ELEC
EAS00827
EXUP SYSTEM
CIRCUIT DIAGRAM
1
5
7
12
15
58
8-51
Main switch
Battery
Fuse (main)
EXUP servomotor
Ignitor
Fuse (ignition)
EXUP SYSTEM
EAS00828
EAS00829
TROUBLESHOOTING
Procedure 1
ELEC
1. EXUP servomotor operation (with the
EXUP servomotor coupler connected to
the wire harness)
When the engine speed changes, the
EXUP servomotor does not operate.
Procedure 1
Check:
1. EXUP servomotor operation
(with the EXUP servomotor coupler connected to the wire harness)
2. Voltage
3. EXUP servomotor operation
(with the EXUP servomotor coupler disconnected from the wire harness)
4. EXUP servomotor resistance
(potentiometer resistance)
5. Wiring connections
(the entire EXUP system)
Procedure 2
Check:
1. Main and turn signal fuses
2. Battery
3. Main switch
4. Neutral switch
5. Engine stop switch
6. Wiring connections
(the entire EXUP system)
Disconnect the EXUP cables at the EXUP
servomotor pulley side.
Start the engine and rev it to 5,000 r/min.
Does the EXUP servomotor pulley turn?
NO
YES
Check that the EXUP
cables are properly
installed.
If the connections are
correct, check the
EXUP valve and
cables. Refer to “EXHAUST SYSTEM” in
chapter 5.
EAS00830
2. Voltage
NOTE:
Before troubleshooting, remove the following
part(s):
1) Seat
2) Fuel tank
Troubleshoot with the following special tool(s).
Connect the pocket tester (DC 20 V) to the
EXUP servomotor coupler as shown.
Positive tester probe black/red 1
Negative tester probe black/yellow 2
Pocket tester
90890-03112
Set the main switch to “ON”.
Measure the voltage (12 V) between
black/red 1 and black/yellow 2 .
Is the voltage within specification?
YES
NO
Go to Procedure 2.
8-52
EXUP SYSTEM
ELEC
EAS00831
3. EXUP servomotor operation (with the
servomotor coupler disconnected to the
wire harness)
Disconnect the EXUP cables from the EXUP
servomotor pulley.
Disconnect the EXUP servomotor coupler
from the wire harness.
Connect the battery leads to the EXUP servomotor coupler as shown.
Positive tester probe blue 1
Negative tester probe white/red 2
Positive battery lead black/yellow 1
Negative battery lead black/red 2
While slowly turning the EXUP servomotor
pulley, measure the EXUP servomotor resistance.
EXUP servomotor resistance
(when the pulley is turned once)
0 approximately 7.5 k Ω
(blue – white/red)
Is the EXUP servomotor OK?
YES
Check that the EXUP servomotor pulley rotates several times.
NO
The EXUP servomotor is faulty and must
be replaced.
CAUTION:
To prevent damaging the EXUP servomotor, perform this test within a few seconds
of connecting the battery.
EAS00833
5. Wiring
Does the EXUP servomotor pulley turn?
Check the entire EXUP system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
NO
YES
Is the EXUP system’s wiring properly connected and without defects?
Replace the EXUP
servomotor.
YES
EAS00832
Replace the ignitor
unit.
4. EXUP servomotor resistance
(potentiometer resistance)
Disconnect the EXUP servomotor coupler
from the wire harness.
Connect the pocket tester (Ω 1 k) to the
EXUP servomotor coupler.
8-53
NO
Properly connect or
repair the EXUP system’s wiring.
EXUP SYSTEM
ELEC
EAS00750
Procedure 2
4. Engine stop switch
EAS00738
1. Main and ignition fuses
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Is the engine stop switch OK?
YES
NO
S Are the main and ignition fuses OK?
Replace the right
handlebar switch.
NO
YES
Replace the fuse(s).
EAS00833
5. Wiring
EAS00739
S Check the entire EXUP system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
S Is the EXUP system’s wiring properly connected and without defects?
Minimum open-circuit voltage
12.8 V or more at 20_C
YES
Replace the ignitor
unit.
S Is the battery OK?
NO
YES
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
NO
YES
Replace
switch.
the
main
8-54
NO
Properly connect or
repair the EXUP system’s wiring.
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The FZS1000 features a self-diagnosing system for the following circuit(-s):
Throttle position sensor
EXUP
Speed sensor
Emargency stop switch
If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not)
Circuit
Defect(-s)
System response
Condition code
Throttle position sensor
Disconnected
Short-circuit
Locked
The ignitor unit stays set to the
wide-open throttle ignition timing.
The motorcycle can be ridden.
The tachometer displays the
condition code.
EXUP
Improper
connection
Short-circuit
The EXUP valve stays in the open 7,000 r/min
position for three seconds and
then the servomotor shuts off. The
motorcycle can be ridden.
The tachometer displays the
condition code.
Servomotor is
locked.
The servomotor’s power supply is
constantly inteerupted so that it
will not burn out. The motorcycle
can be ridden.
The tachometer displays the
condition code.
Speed sensor
Improper
connection
The tachometer displays the
condition code.
4,000 r/min
Emargency
stop switch
Disconnected
Short-circuit
Fail angle
The tachometer displays the
condition code.
Ignition system cutoff.
9,000 r/min
8-55
3,000 r/min
SELF-DIAGNOSIS
ELEC
Tachometer display sequence
Revolution
( 103 r / min)
1 0 r / min ... 3 seconds
2 Condition code ... 2.5 seconds
3 Engine speed ... 3 seconds
Tachometer display
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
8-56
ELEC
SELF-DIAGNOSIS
TROUBLESHOOTING
1. Wire harness
The tachometer starts to display the selfdiagnosis sequence.
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
Check:
1. Throttle position sensor
2. EXUP
3. Speed sensor
4. Emargency 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).
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
1. Throttle position sensor
CIRCUIT DIAGRAM
Replace the ignitor
unit.
13 Throttle position sensor
15 Ignitor unit
8-57
NO
Replace the throttle
position sensor.
SELF-DIAGNOSIS
2. EXUP
CIRCUIT DIAGRAM
2. EXUP servomotor
Check the EXUP servomotor for continuity.
Refer to “EXUP SYSTEM”.
Is the EXUP servomotor OK?
YES
Replace the ignitor
unit.
12 EXUP servomotor
15 Ignitor unit
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
ELEC
NO
Repair or replace the
wire harness.
8-58
NO
Replace the EXUP
servomotor.
ELEC
SELF-DIAGNOSIS
3. Speed sensor
CIRCUIT DIAGRAM
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Replace the speed
sensor.
BAD
Replace the ignitor
unit.
15 lgnitor unit
20 Speed sensor
8-59
Repair or replace the
wire harness.
ELEC
SELF-DIAGNOSIS
4. Emargency stop switch
CIRCUIT DIAGRAM
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Replace the emargency stop switch.
BAD
Replace the ignitor
unit.
14 Emargency stop switch
15 lgnitor unit
8-60
Repair or replace the
wire harness.
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING PROBLEMS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
INCORRECT ENGINE IDLING SPEED
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FAULTY CLUTCH
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
OVERHEATING
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4
9-4
9-4
9-4
9-4
OVERCOOLING
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
FAULTY FRONT FORK LEGS
LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . .
TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7
9-7
9-7
9-7
9-7
9-7
9-7
9-7
9-7
TROUBLESHOOTING
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE
Cylinder(s) and cylinder head(s)
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Piston(s) and piston ring(s)
Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter
Improperly installed air filter
Clogged air filter element
Crankcase and crankshaft
Improperly assembled crankcase
Seized crankshaft
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
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
Fuel pump
Faulty fuel pump
Faulty fuel pump relay
Fuel cock
Clogged or damaged fuel hose
9-1
TROUBLESHOOTING
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
TRBL
SHTG
Ignition system
Faulty ignitor unit
Faulty pickup coil
Broken generator rotor woodruff key
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
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
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cutoff relay
Faulty starter clutch
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder(s) and cylinder head(s)
Incorrect valve clearance
Damaged valve train components
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
Air filter
Clogged air filter element
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
FUEL SYSTEM
Carburetor(s)
Faulty starter plunger
Loose or clogged pilot jet
Loose or clogged pilot air jet
Damaged or loose carburetor joint
Improperly synchronized carburetors
Improperly adjusted engine idling speed
(throttle stop screw)
Improper throttle cable free play
Flooded carburetor
Faulty air induction system
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
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
Clogged air filter element
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”.
JUMPS OUT OF GEAR
Shift shaft
Incorrect shift pedal position
Improperly returned stopper lever
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Improperly adjusted shift rod
Bent shift shaft.
Shift forks
Worn shift fork
Shift drum
Incorrect axial play
Worn shift drum groove
Shift drum and shift forks
Foreign object in a shift drum groove
Seized shift fork
Bent shift fork guide bar
Transmission
Worn gear dog
Transmission
Seized transmission gear
Foreign object between transmission
gears
Improperly assembled transmission
9-3
TROUBLESHOOTING
TRBL
SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS
Clutch
Improperly assembled clutch
Improperly adjusted clutch cable
Loose or fatigued clutch spring
Worn friction plate
Worn clutch plate
CLUTCH DRAGS
Clutch
Unevenly tensioned clutch springs
Warped pressure plate
Bent clutch plate
Swollen friction plate
Bent clutch push rod
Broken clutch boss
Burnt primary driven gear bushing
Match marks not aligned
Engine oil
Incorrect oil level
Incorrect oil viscosity (low)
Deteriorated oil
Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages
Cylinder head(s) and piston(s)
Heavy carbon buildup
FUEL SYSTEM
Carburetor(s)
Incorrect main jet setting
Incorrect fuel level
Damaged or loose carburetor joint
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
Air filter
Clogged air filter element
CHASSIS
Brake(s)
Dragging brake
COOLING SYSTEM
Coolant
Low coolant level
ELECTRICAL SYSTEMS
Spark plug(s)
Incorrect spark plug gap
Incorrect spark plug heat range
Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fin
Ignition system
Faulty ignitor unit
Water pump
Damaged or faulty water pump
Thermostat
Thermostat stays closed
Oil cooler
Clogged or damaged oil cooler
Hose(s) and pipe(s)
Damaged hose
Improperly connected hose
Damaged pipe
Improperly connected pipe
9-4
TROUBLESHOOTING
TRBL
SHTG
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
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 or damaged inner tube
Bent or damaged outer tube
Damaged fork spring
Worn or damaged outer tube bushing
Bent or damaged damper rod
Incorrect oil viscosity
Incorrect oil level
9-5
TROUBLESHOOTING
TRBL
SHTG
EAS00862
UNSTABLE HANDLING
Handlebar
Bent or improperly installed handlebar
Rear shock absorber assembly(-ies)
Faulty rear shock absorber spring
Leaking oil or gas
Steering head components
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
Wheel(s)
Incorrect wheel balance
Deformed cast wheel
Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Front fork leg(s)
Uneven oil levels (both front fork legs)
Unevenly tensioned fork spring
(both front fork legs)
Broken fork spring
Bent or damaged inner tube
Bent or damaged outer tube
Frame
Bent frame
Damaged steering head pipe
Improperly installed bearing race
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
9-6
TROUBLESHOOTING
TRBL
SHTG
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Improperly grounded circuit
Poor contacts (main or light switch)
Burnt-out headlight bulb
TURN SIGNAL DOES NOT LIGHT
Faulty turn signal switch
Faulty turn signal relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or faulty wire harness
Improperly grounded circuit
Faulty battery
Blown, damaged or incorrect fuse
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier/regulator
Improperly grounded circuit
Faulty main switch
Faulty light switch
Headlight bulb life expired
TURN SIGNAL BLINKS SLOWLY
Faulty turn signal relay
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty turn signal relay
Burnt-out turn signal bulb
TAIL/BRAKE LIGHT DOES NOT LIGHT
Wrong tail/brake light bulb
Too many electrical accessories
Incorrect connection
Burnt-out tail/brake light bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty turn signal relay
Burnt-out turn signal bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
Wrong tail/brake light bulb
Faulty battery
Incorrectly adjusted rear brake light switch
Tail/brake light bulb life expired
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
9-7
FZS1000 2001 WIRING DIAGRAM (EUR)
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
Main switch
Rectifier/ regulator
AC magneto
Fuse (back up)
Battery
Starter relay
Fuse (main)
Starter motor
Starting circuit cutoff relay
Sidestand switch
Fuel pump
EXUP servo motor
T.P.S.
Emargency stop switch
Igniter
Ignition coil
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tacho meter
Combination meter
Water temp warning light
Fuel gauge
Speedometer
Hi-beam indicator light
Turn signal indicator light (left)
Turn signal indicator light (right)
Meter light
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ G . . . .
B/ L . . . . .
B/ R . . . . .
B/ W . . . .
B/ Y . . . . .
Br/ B . . . .
Br/ L . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Green
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Black
Brown/ Blue
35
36
37
38
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
Oil level gauge
Fuel sender
Turn signal relay
Handlebar switch (right)
Front brake light switch
Headlight switch
Engine stop switch
Start switch
Horn
Handlebar switch (left)
Pass switch
Dimmer switch
Horn switch
Clutch switch
Hazard switch
Turn signal switch
Front turn signal light (left)
Front turn signal light (right)
Rear turn signal light (left)
Rear turn signal light (right)
Headlight
Tail/ brake light
Fuse (turn signal)
Fuse (ignition)
Alarm
Fuse (alarm)
Fuse (headlight)
Fuse (fan)
Fan motor relay
Fan motor
Rear brake light switch
Headlight relay (on / off)
Head light relay (dimmer)
Br/ R . . . .
Br/ W . . .
G/B . . . .
G/R . . . .
G/W . . . .
G/Y . . . .
L/B . . . . .
L/R . . . . .
L/W . . . .
L/Y . . . . .
O/R . . . .
R/ B . . . . .
R/ G . . . .
R/ W . . . .
R/ Y . . . . .
Sb/ W . . .
W/ R . . . .
W/ Y . . . .
Y/ B . . . . .
Y/ G . . . .
Brown/ Red
Brown/ White
Green / Black
Green / Red
Green / White
Green / Yellow
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Red
Red/ Black
Red/ Green
Red/ White
Red/ Yellow
Sky blue / White
White/ Red
White/ Yellow
Yellow/ Black
Yellow/ Green
FZS1000 N 2001 WIRING DIAGRAM (OCE)
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
Main switch
Rectifier/ regulator
AC magneto
Fuse (back up)
Battery
Starter relay
Fuse (main)
Starter motor
Starting circuit cutoff relay
Sidestand switch
Fuel pump
EXUP servo motor
T.P.S.
Emargency stop switch
Igniter
Ignition coil
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tacho meter
Combination meter
Water temp warning light
Fuel gauge
Speedometer
Hi-beam indicator light
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ G . . . .
B/ L . . . . .
B/ R . . . . .
B/ W . . . .
B/ Y . . . . .
Br/ B . . . .
Br/ L . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Green
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Black
Brown/ Blue
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Turn signal indicator light (left)
Turn signal indicator light (right)
Meter light
Oil level gauge
Fuel sender
Turn signal relay
Handlebar switch (right)
Front brake light switch
Engine stop switch
Start switch
Horn
Handlebar switch (left)
Pass switch
Dimmer switch
Horn switch
Clutch switch
Turn signal switch
Front turn signal light (left)
Front turn signal light (right)
Rear turn signal light (left)
Rear turn signal light (right)
Headlight
Tail/ brake light
Fuse (ignition)
Fuse (turn signal)
Fuse (headlight)
Fuse (fan)
Fan motor relay
Fan motor
Rear brake light switch
Head light relay (dimmer)
Br/ R . . . .
Br/ W . . .
G/B . . . .
G/R . . . .
G/W . . . .
G/Y . . . .
L/B . . . . .
L/R . . . . .
L/W . . . .
L/Y . . . . .
O/R . . . .
R/ B . . . . .
R/ G . . . .
R/ W . . . .
R/ Y . . . . .
Sb/ W . . .
W/ R . . . .
W/ Y . . . .
Y/ B . . . . .
Y/ G . . . .
Brown/ Red
Brown/ White
Green / Black
Green / Red
Green / White
Green / Yellow
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Red
Red/ Black
Red/ Green
Red/ White
Red/ Yellow
Sky blue / White
White/ Red
White/ Yellow
Yellow/ Black
Yellow/ Green
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