eng overhauling the engine

eng overhauling the engine
EAS00000
XP500 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00005
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 scooter operator, a bystander or a person checking or repairing the scooter.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
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
8
4
5
7
EAS00008
1
SYMBOLS
2
GEN
INFO
SPEC
3
4
CHK
ADJ
CHAS
5
6
COOL
ENG
7
8
CARB
ELEC
Symbols 10 to 17 indicate the following.
10
9
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
21
24
22
23
25
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
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following:
24 Apply locking agent (LOCTITE)
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
SCOOTER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . .
CHAIN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM AND REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-3
1-3
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTERPINS . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
1-4
1-4
1-4
1-5
1-5
1-5
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
GEN
INFO
SCOOTER IDENTIFICATION
GEN
INFO
EAS00015
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the right side of the frame.
EAS00018
MODEL CODE
The model code label 2 is affixed to the luggage Box. This information will be needed to order spare parts.
1-1
FEATURES
GEN
INFO
FEATURES
CRANKSHAFT AND BALANCER SHAFT
An integrated crankshaft of a new design is used Horizontally opposed reciprocating balancers are
used. Layout free from primary inertial force, secondary inertial force, and a couple of force, and significant vibration reduction are implemented.
CHAIN DRIVE
The chain drive is newly designed. A non adjustable z-stage silent chain is used. A backlash free pivot
coaxial drive is used. The drive and the swingarm at the right are integrated to create rigidity. The rear
wheel swing system ensures high speed stability.
1-2
FEATURES
GEN
INFO
SWINGARM AND REAR SUSPENSION
A newly designed swingarm is used. A pull-type monocross suspension is used. These components
are located out under the engine.
INSTRUMENT FUNCTIONS
V-belt replacement indicator “V-BELT”
This indicator 1 flashes every 20,000 km
(12,000 mi) when the V-belt needs to be replaced.
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Turn the key to “ON” and make sure that the
engine stop switch is set to “ON”.
2. If the indicator does not come on, check the
electrical circuit. Refer to “SIGNALING SYSTEM” in chapter 8.
To reset the V-belt replacement indicator
1. Turn the key to “ON” and make sure that the
engine stop switch is set to “ON”.
2. Disconnect the V-belt replacement reset
coupler 1 for two to ten seconds.
3. And then, connect the V-belt replacement reset coupler, the V-belt replacement indicator
will come on for 1.4 seconds.
And the V-belt replacement indicator will
go off.
NOTE:
If the V-belt is replaced before the V-belt replacement indicator comes on (i.e. before the
V-belt replacement interval has been reached),
the indicator must be reset after the V-belt replacement for the next periodic V-belt replacement to be indicated at the correct time.
1-3
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with greace.
1-4
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock washer
tabs and the cotter pin ends along a flat of the
bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil
seal lips with a light coat of lithium soap base
grease. Oil bearings liberally when installing,
if appropriate.
1 Oil seal
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip 1 , make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-5
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect several times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
1-6
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
Flywheel puller
90890-01362
This tool is used to remove the generator
rotor.
T-handle
90890-01326
Damper rod
holder
90890-01294
T-handle
Damper rod holder
These tools are used to hold the cartridge
cylinder when loosening or tightening the
cartridge cylinder bolt.
Fuel level gauge
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Timing light
90890-03141
This tool is used to check the ignition
timing.
Locknut wrench
90890-03148
This tool is used to remove the sheave or
install the secondary sheave nut.
Fork seal
driver weight
90890-01367
Adapter
90890-01372
Fork seal driver weight
Adapter
These tools are used to install the front
fork’s oil seal and dust seal.
Ignition checker
90890-06754
This tool is used to check the ignition
system components.
Valve spring compressor
90890-04019
This tool is used to remove or install the
valve assemblies.
1-7
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve guide remover (4 mm)
90890-04111
This tool is used to remove or install the
valve guides.
Valve guide installer
90890-04112
This tool is used to install the valve guides.
Valve guide reamer
90890-04113
This tool is used to rebore the new valve
guides.
Primary/secondary sheave holder
90890-01481
90890-01701
This tool is used to hold the sheave assembly
when removing or installing the primary and
secondary sheave.
Sheave holder
This tool is used for hold the generator
rotor when removing or installing the
generator rotor bolt, generator shaft bolt or
pickup coil rotor bolt.
Piston pin puller set
90890-01304
This tool is used to remove the piston pins.
Micrometer (50~75 mm)
90890-03008
This tool is used to measure the piston skirt
diameter.
Cylinder bore gauge (50~100 mm)
90890-03017
This tool is used to measure the cylinder bore.
Pocket tester
90890-03112
This tool is used to check the electrical
system.
1-8
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Compression
gauge
90890-03081
Compression
gauge adapter
90890-04082
Tool name/Function
Compression gauge
These tools are used to measure engine
compression.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Oil filter wrench
90890-01469
This tool is needed to loosen or tighten
the oil filter cartridge.
Engine tachometer
90890-03113
This tool is used to check engine speed.
Yamaha bond No. 1215
90890-85505
Oil pressure
gauge
90890-03153
Adapter
90890-03124
This sealant is used to seal two mating
surfaces (e.g., crankcase mating surfaces).
Oil pressure gauge
This tool is used to measure the engine oil
pressure.
Plane bearing installer/remover
90890-04139
Sheave spring
compressor
90890-04134
Sheave fixed
block
90890-04135
This tool is used to install or remove the
bearing.
Sheave spring compressor
Sheave fixed block
This tool is used to remove spring.
Radiator cap tester
90890-01325
This tool is used to check the cooling system.
1-9
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Clutch spring compressor
90890-01482
This tool is used to remove or install the nut.
1-10
GEN
INFO
Illustration
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16
2-16
2-17
2-21
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23
OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
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
Standard
Limit
XP500 (N) : 5GJ1 (EUR)
5GJ2 (GBR)
5GJ3 (OCE)
2235 mm
775 mm
1410 mm
795 mm
1575 mm
130 mm
2800 mm
Weight
205 kg
Wet (with oil and a full fuel tank)
197 kg
Dry (without oil and fuel)
Maximum load (total of cargo, rider, 183 kg
passenger, and accessories)
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine tipe
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)
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Standard
Limit
66
73 mm
10.1
1150 X 1250 r/min
35 kPa (0.35 kg/cm2)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1450 kPa (14.5 kg/cm2) at 360 r/min
SSS
Regular unleaded gasoline
SSS
14L
SSS
Dry sump
SSS
SSS
Liquid-cooled, 4-stroke, DOHC
499 cm3
SAE10W30 or SAE10W40
API service SE, SF, SG type or higher
SSS
3.6 L
2.8 L
SSS
SSS
2.9 L
150 kPa at 1200 r/min
(1.50 kgf/cm2 at 1200 r/min)
450 X 550 kPa (4.5 X 5.5 kgf/cm2)
SSS
SSS
2-2
SSS
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
SPEC
Standard
Limit
Cartridge (paper)
80 120 kPa (0.8 1.2 kgf/cm2)
Trochoidal
0.04 0.12 mm
0.20 mm
0.045 0.085 mm
0.15 mm
1.5 L
107.9 137.3 kPa
(1.079 1.373 kgf/cm2)
330 mm
138 mm
24 mm
0.6 L
Single-suction centrifugal pump
23/19 (1.210)
Starting system type
Electric starter
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR 7E/NGK 2
0.7 0.8 mm
Cylinder head
Max. warpage
0.10 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
Standard
SPEC
Limit
Chain drive (left)
23.000 23.021 mm
22.967 22.980 mm
0.020 0.054 mm
0.08 mm
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
33.252 33.352 mm
24.956 25.056 mm
8.196 8.396 mm
33.152 mm
24.856 mm
Measurement A
Measurement B
Measurement C
Max. camshaft runout
33.252 33.352 mm
24.956 25.056 mm
8.196 8.396 mm
33.152 mm
24.856 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
SCR-0409SDH/132
Automatic
0.15 0.20 mm
0.25 0.30 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
24.9 25.1 mm
21.9 22.1 mm
1.14 1.98 mm
1.14 1.98 mm
0.9 1.1 mm
0.9 1.1 mm
1.6 mm
1.6 mm
0.6 0.8 mm
0.6 0.8 mm
0.5 mm
0.5 mm
3.975 3.990 mm
3.960 3.975 mm
3.95 mm
3.935 mm
4.000 4.012 mm
4.000 4.012 mm
4.05 mm
4.05 mm
0.010 0.037 mm
0.025 0.052 mm
0.08 mm
0.1 mm
0.04 mm
0.9 1.1 mm
0.9 1.1 mm
1.6 mm
1.6 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
Intake (inner)
Exhaust
Winding direction (top view)
Intake
Exhaust
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. taper
Max. out-of-round
SPEC
Standard
Limit
35.59 mm
35.59 mm
33.81 mm
33.81 mm
30.39 mm
30.39 mm
SSS
SSS
91.1 104.9 N (9.3 10.7 kgf) at 30.4 mm
91.1 104.9 N (9.3 10.7 kgf) at 30.4 mm
SSS
SSS
SSS
SSS
Clockwise
Clockwise
2.5_/1.6 mm
2.5_/1.6 mm
SSS
SSS
Forward-included parallel-2 cylinder
66.0 73.0 mm
10.1
66.00 66.01 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.05 mm
0.05 mm
2-6
ENGINE SPECIFICATIONS
Item
Pistons
Piston-to-cylinder clearance
Diameter D
SPEC
Standard
Limit
0.020 0.045 mm
65.965 65.980 mm
0.15 mm
9 mm
16.002 16.013 mm
0.5 mm
Intake side
15.991 16.000 mm
0.002 0.022 mm
0.072 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Barrel
0.80 2.45 mm
0.15 0.25 mm
0.030 0.065 mm
0.50 mm
0.115 mm
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Plain
0.8 2.5 mm
0.4 0.5 mm
0.020 0.055 mm
0.75 mm
0.105 mm
1.5 2.0 mm
0.10 0.35 mm
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
0.026 0.050 mm
1 = Blue 2 = Black 3 = Brown 4 = Green
118.55 118.60 mm
0.160 0.262 mm
0.026 0.050 mm
0.32 0.50 mm
0.040 0.082 mm
0.03 mm
1 = Blue 2 = Black 3 = Brown 4 = Green
Wet, multiple disc automatic
Automatic
2.75 3.05 mm
5
2.65 mm
1.8 2.0 mm
2
1.7 mm
1.3 1.5 mm
4
0.1 mm
25.9 mm
6
25.4 mm
32 mm
30.5 mm
Crankshaft
Width B
Max. runout C
Big end side clearance D
Big end radial clearance E
Small end free play F
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Bearing color code
Clutch
Clutch type
Clutch release method
Friction plates
Thickness
Plate quantity
Friction plate
Thickness
Plate quantity
Max. warpage
Clutch plate
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
V-belt
V-belt width
2-8
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Max. main axle runout
Max. drive axle runout
Spur gear/helical gear
52/32 36/22 (2.659)
Chain drive
41/25 40/29 (2.262)
0.08 mm
0.08 mm
Air filter type
Dry element
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
3LN (MITSUBISHI)
8.3 12.3 kPa (0.83 0.123 kgf/cm2)
BS30 (MIKUNI) 2
3 5 mm
5GJ1 00
#102.5
#100
4DK4-3/5
0-OM (#893)
#85
#170
0.8
#22.5
0.8
0.8
0.8
2
1.0
5.5 6.5 mm
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 air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Fuel level (below the line on the
float chamber)
2-9
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
90 197 kg
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
28_
95 mm
SSS
SSS
SSS
Cast wheel
SSS
14 MT3.50
Aluminum
120 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Cast wheel
SSS
14 MT4.50
Aluminum
120 mm
SSS
SSS
SSS
SSS
SSS
1 mm
0.5 mm
Tubeless
120/70-14
BRIDGESTONE HOOP B03
DUNLOP
D305FA
SSS
SSS
SSS
SSS
200 kPa (2.0 kg/cm2, 2.0 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
225 kPa (2.25 kg/cm2, 2.25 bar)
SSS
SSS
SSS
SSS
1.6 mm
2-10
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 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
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
150/70-14
BRIDGESTONE HOOP B02
DUNLOP
D305
225 kPa (2.25 kg/cm2, 2.25 bar)
250 kPa (2.50 kg/cm2, 2.50 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
1.6 mm
Single-disc brake
Right-hand operation
DOT 4
282 5 mm
6.0 mm
4.5 mm
0.15 mm
0.8 mm
14 mm
30.16 mm and 33.34 mm
Single-disc brake
Left-hand operation
DOT 4
267 5 mm
8.3 mm
3.5 mm
0.15 mm
0.8 mm
12.7 mm
38.1 mm
2-11
CHASSIS SPECIFICATION
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 rate (K3)
Spring stroke (K1)
Spring stroke (K2)
Spring stroke (K3)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the innertube,
with the inner tube fullycompressed,
and without thefork spring)
Steering
Steering bearing type
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
120 mm
428.5 mm
129.6 mm
419.5 mm
11.8 N/mm (1.2 kgf/mm)
15.7 N/mm (1.6kgf/mm)
19.6 N/mm (2 kgf/mm)
0 19 mm
19 83 mm
83 120 mm
No
419.9 mm
Suspension oil “01” or equivalent
402 cm3
135 mm
Angular ball bearings
Swingarm (link suspension)
Coil spring/gas-oil damper
44.5 mm
190 mm
180 mm
226 N/mm (23.05 kgf/mm)
294 N/mm (29.98 kgf/mm)
0 30 mm
30.0 44.5 mm
No
4.9 kPa (0.05 kg/cm2)
Drive chain
Model (manufacturer)
Link quantity
23RH303.5-82ASM (Borg warner)
82
Primary chain
Model (manufacturer)
Link quantity
89HV302.5RCF-66 (Borg warner)
66
Rear suspension
Suspension type
Rear shock absorber assemblytype
Rear shock absorber assemblytravel
Spring
Free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Standard spring preload gas/air
pressure
2-12
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
System voltage
12 V
SSS
Ignition system
Ignition system type
Ignition timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
T.C.I.
10_ BTDC at 1200 r/min
Digital
189 231 Ω/Gy-B
J4T120 (MITSUBISHI)
SSS
SSS
SSS
SSS
SSS
J0313
6 mm
1.87 2.53 Ω
12 18 kΩ
SSS
SSS
SSS
SSS
4 6 kΩ
SSS
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance
AC magneto
F4T373 (MITSUBISHI)
14 V/305W at 5,000 r/min
0.375 Ω
SSS
SSS
SSS
SSS
Voltage regulator
Regulator type
Model (manufacturer)
No-load regulated voltage
Semiconductor, short circuit type
SH650A-12 (SHINDENGEN)
14.1 14.9 V
SSS
SSS
SSS
Rectifier
Model
Rectifier capacity
Withstand voltage
SH650A-12
18 A
200 V
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity
GT9B-4
12 V/8 Ah
SSS
SSS
Headlight type
Halogen bulb
SSS
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light (Front)
Turn signal light (Rear)
12 V 60 W/55 W + 55 W
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W/ 5 W 2
12 V 21 W 2
SSS
SSS
SSS
SSS
SSS
Ignition coils
Model
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Throttle position sensor standard
resistance
2-13
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Limit
12 V 5 W 1
12 V 1.7 W 3
12 V 1.7 W 1
12 V 1.7 W 1
12 V 3.4 W 2
Constant mesh
SM-13 (MITSUBA)
0.7 kW
12 mm
7.65 10.01 N (780 1021 gf)
0.0015 0.0025 Ω
28 mm
0.7 mm
4.0 mm
27 mm
Starter relay
Model (manufacturer)
Amperage
Coil resistance
MS5F-561 (JIDECO)
180 A
4.18 4.62 Ω
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Plain
YF-12 (NIKKO) 2
3A
Flasher 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
5GJ (NIPPON SEIKI)
4 10 Ω
90 100 Ω
Sidestand relay
Model
Coil resistance
ACA12115-1
70 90 Ω
Fuel pump maximum amperage
1A
Fuel pump relay model
Resistance
ACA12115 MC2
70 90 Ω
Thermo switch model (manufacturer)
5GH, 5GJ (NIPPON TERMOSTAT)
License plate light
Meter light
High beam indicator light
Oil level indicator light
Turn signal indicator light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Fuel sender
Model (manufacturer)
Resistance
(Full)
(Empty)
2-14
ELECTRICAL SPECIFICATIONS
Item
Temperature sender
Resistance
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
Reserve fuse
SPEC
Standard
Limit
69 Ω at 80_C
22 Ω at 120_C
SSS
SSS
30 A 1
15 A 1
15 A 1
10 A 1
15 A 1
10 A 1
30 A 1
15 A 1
10 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
2-15
CONVERSION TABLE/TIGHTENING TORQUES
SPEC
EB202001
EB201000
CONVERSION TABLE
TIGHTENING TORQUES
All specification data in this manual are
listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data
to IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
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.
IMPERIAL
**mm
0.03937
=
**in
2 mm
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Tightening
torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km / hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume /
Capacity
cc (cm3)
cc (c
(cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(_C)
55.997
14.2234
9 / 5 + 32
lb / in
psi (lb / in2)
Fahrenheit
(_F)
A: Width across flats
B: Thread diameter
2-16
A
(nut)
B
(bolt)
10 mm
12 mm
14 mm
18 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
6
15
30
55
85
130
mSkg
0.6
1.5
3.0
5.5
8.5
13.0
TIGHTENING TORQUES
SPEC
ENGINE TIGHTENING TORQUES
Item
Spark plug
Cylinder head cover
Camshaft cap
Cylinder head and cylinder body
Cylinder head and cylinder body
Cylinder head and cylinder body
Cylinder head (exhaust pipe)
Cylinder body
Cylinder head (AI System)
Connecting rod cap
Connecting rod cap (balancer)
Cylinder (balancer)
Generator rotor
Chain tensioner
Chain tensioner cap bolt
Chain guide (intake side)
Water pump housing cover
Water pump assembly
Coolant pipe
Thermostat cover
Oil pump assembly
Oil strainer assembly
Oil cooler assembly
Oil filter
Oil delivery pipe
Carburetor intake manifold
Silencer assembly
Air filter case assembly
Exhaust pipe
Part name
–
Bolt
Bolt
Nut
Nut
Bolt
Stud bolt
Bolt
Stud bolt
Nut
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
–
Bolt
Bolt
Bolt
Bolt
Nut
2-17
Thread
size
Q’ty
y
M10
M6
M6
M9
M9
M6
M8
M6
M6
M7
M9
M10
M18
M6
M6
M6
M6
M6
M6
M6
M6
M6
M20
M20
M6
M6
M6
M6
M8
2
10
12
4
2
2
4
1
4
4
2
4
1
2
1
2
2
2
2
2
3
2
1
1
1
4
2
3
4
Tightening
torque
Nm
mkg
12.5 1.25
10
1.0
10
1.0
35
3.5
46
4.6
10
1.0
15
1.5
10
1.0
7
0.7
See NOTE*1
60
6.0
58
5.8
See NOTE*2
10
1.0
10
1.0
10
1.0
10
1.0
10
1.0
10
1.0
10
1.0
10
1.0
10
1.0
63
6.3
17
1.7
10
1.0
10
1.0
8.5 0.85
8.5 0.85
20
2.0
Remarks
TIGHTENING TORQUES
Item
Muffler
Muffler protector
A.I.System pipe
A.I.System reed valve assembly
Air cut valve assembly
Crankcase
Crankcase
Engine oil drain bolt
Engine oil sub tank cover
Stator coil base
Timing plug
Generator cover
Belt drive cover
Belt drive cover
Plate
Crankcase cover
Protector cover
Belt drive filter
Starter clutch
Clutch boss nut
Clutch housing assembly
Chian drive holder assembly
Chian drive drain bolt
Chian drive caes (outer)
Chian drive case cover
Stopper
Primary sheave assembly
Secondary sheave spring seat
Secondary sheave assembly
Part name
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Plug
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Nut
2-18
Thread
size
Q’ty
y
M10
M6
M6
M6
M6
M6
M8
M14
M6
M6
M16
M6
M6
M8
M6
M8
M6
M6
M8
M36
M16
M8
M12
M6
M6
M5
M20
M36
M18
1
3
4
3
1
13
8
1
7
3
1
19
4
6
3
2
3
2
3
1
1
3
1
18
2
8
1
1
1
SPEC
Tightening
torque
Nm
mkg
48
7
10
10
7
10
24
43
10
12
8
10
10
24
10
24
7
7
30
90
65
30
20
10
7
6
160
90
90
4.8
0.7
1.0
1.0
0.7
1.0
2.4
4.3
1.0
1.2
0.8
1.0
1.0
2.4
1.0
2.4
0.7
0.7
3.0
9.0
6.5
3.0
2.0
1.0
0.7
0.6
16
9.0
9.0
Remarks
TIGHTENING TORQUES
Item
Primary bearing cover plate
Secondary bearing cover plate
Stator coil assembly
Pickup coil
Starter motor
Thermo switch
Thermo unit
Ignitor unit
Part name
Screw
Screw
Bolt
Bolt
Bolt
–
–
Screw
Thread
size
Q’ty
y
M6
M6
M6
M5
M6
M18
PT 1/8
M6
1
1
3
2
2
2
1
2
NOTE:
*1: After tightening to 16 Nm (1.6 mSkg), tighten another 90_.
*2: After tightening to 60 Nm (6,0 mSkg), tighten another 120_.
2-19
SPEC
Tightening
torque
Nm
mSkg
10
12
10
7
10
18
8
3
1.0
1.2
1.0
0.7
1.0
1.8
0.8
0.3
Remarks
TIGHTENING TORQUES
SPEC
Crankcase tightening sequence:
1 8 M8 Bolt
9 21 M6 Bolt
Cylinder head tightening sequence:
2-20
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Thread size
Item
Upper bracket pinch bolt
Steering stem nut
Lower ring nut
Front fork cap bolt
Handlebar upper holder
Brake hose union bolt
Brake master cylinder holder
Master cylinder reservoir cap
Handlebar grip end
Engine mounting
Front mounting nut (upper)
Front mounting bolt (lower)
Front wheel axle shaft
Front wheel axle shaft pinch bolt
Rear wheel axle nut
Rear wheel axle shaft pinch bolt
Front brake caliper bracket
Front brake caliper bolt
Front brake disc
Rear brake caliper bracket
Rear brake caliper bolt
Rear brake disc
Brake caliper bleed screw
Swingarm and pivot shaft
Pivot shaft and lock nut
Chain drive and swingarm
Rear shock absorber (front)
Rear shock absorber (rear)
Nm
mkg
M8
M10
M6
M4
M16
30
110
19
24
23
30
10
1
26
3.0
11.0
1.9
2.4
2.3
3.0
1.0
0.1
2.6
M12
M10
M14
M8
M14
M8
M10
M10
M6
M10
M10
M6
M7
M22
M22
M10
M16
M12
87
48
59
20
104
17
40
27
18
40
27
18
6
7
100
40
67
52
8.7
4.8
5.9
2.0
10.4
1.7
4.0
2.7
1.8
4.0
2.7
1.8
0.6
0.7
10.0
4.0
6.7
5.2
M8
M22
M25
2-21
Tightening
torque
Remarks
See NOTE
TIGHTENING TORQUES
Item
Thread size
Fuel tank
Fuel sender
Grab bar
Seat lock
Box
Cover and panel
Cover and panel
Windshield
Coolant reservoir tank
Mainstand bracket
Mainstand
Sidestand (bolt and frame)
Sidestand (bolt and nut)
Rear footrest
M6
M5
M8
M6
M6
M8
M6
M5
M6
M10
M10
M10
M10
M8
SPEC
Tightening
torque
Nm
mkg
10
4
15
7
10
15
7
0.4
4
55
55
8
40
23
1.0
0.4
1.5
0.7
1.0
1.5
0.7
0.04
0.4
5.5
5.5
0.8
4.0
2.3
Remarks
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
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearing and bushes
Crankshaft pins
Piston surfaces
Piston pins
Balancer surface
Connecting rod bolts and nuts
Crankshaft journals
Camshaft lobs
Camshaft journals
Camshaft cap
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Cylinder head nut
Oil pump shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil cooler union bolt
Starter clutch idle gear inner surface
Starter clutch
Drive axle spline
Drive sprocket
Primary sheave spacer
Shell BT grease 3
Primary sheave nut
Shell BT grease 3
Secondary sheave nut
BEL-RAY
assembly lube
Secondary sheave
Swingarm pivot shaft bearing
Belt drive cover bearing
Crankcase mating surface
YAMAHA bond No.1215
A.C. magneto lead
YAMAHA bond No.1215
Cylinder head cover (gasket mating surface)
YAMAHA bond No.1215
Cylinder head cover (guide stopper mating surface)
YAMAHA bond No.1215
Crankcase cover 3 (air duct seal mating surface)
YAMAHA bond No.1215
2-23
OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1
2
3
4
5
6
7
Oil pump
Oil tank
Oil strainer
Relief valve
Oil cooler
Oil filter
Exhaust camshaft
8 Intake camshaft
9 Oil pipe
10 Oil delivery pipe
2-24
SPEC
OIL FLOW DIAGRAMS
1 Oil pan
2 Oil strainer
3 Crankshaft
2-25
SPEC
OIL FLOW DIAGRAMS
1 Clutch
2 Right main journal bearing
3 Main gallery bolt
2-26
SPEC
OIL FLOW DIAGRAMS
SPEC
Exhaust camshaft
Intake camshaft
Piston cooler
Crankshaft
Oil filter
Oil tank
Oil cooler
Relief valve
Check valve
Flush oil pump
Strainer
Suction oil pump
Oil pan
Strainer
2-27
COOLANT FLOW DIAGRAMS
COOLANT FLOW DIAGRAMS
1
2
3
4
5
6
Coolant reservoir tank
Thermostat
Radiator
Water pump
Cooling fan
Radiator cap
2-28
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1 Headlight lead
2 Horn (H mark on the back of the horn).
A Attach the wireharness clamp (protector
terminal) to the T stud.
B Install the wireharness to the top of the steering
after each coupler connection.
C Route the wireharness between brake hose and
upper bracket.
D Route the throttle cables between handle under
cover and upper bracket.
E Install a wireharness guide to hold down the
wireharness.
F Connect the brake light switch from the handlebar
switch side wiring.
G Route the throttle cables through the hole of the
handle under cover.
H Fasten the handlebar switch lead to the handlebar
using a plastic clamp.
The fastening location is the bend area on the
bottom of the handlebar.
I Connect the headlight sub-harness to the
wireharness on top of the stay (left and right)
After making the connection, push the coupler
between the front cowling and the air filter case.
2-29
CABLE ROUTING
J Connect the taped headlight lead coupler to the
headlight’s white marked side (left side: high beam
side).
(For UK, the right side is the high beam side.)
K Fasten the headlight sub-harness.
L Connect the turn signal light.
M Securely fasten the wire strap to the front cowling
hook to prevent it from being pulled out by the
headlight assembly.
N Route the horn lead through the wire guide.
O After passing the horn lead through the clamp,
crimp the clamp.
2-30
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Rectifier/ regulator
Starting circuit cut-off relay
Pump relay
Flasher relay
Fuel pump
Main switch
Meter assembly
Horn lead
Ignition coil
Battery negative lead
Frame
Seat lock cable
Starter motor lead
Wireharness
Fuel hose
Sub harness
Fan motor lead
V-belt reset coupler
SPEC
A The wireharness pass-through is change.
B Fasten the starter motor lead, battery negative lead
and seat lock cable (right side) to the frame with a
plastic clamp.
C Fasten the starter motor lead and battery negative
lead to the frame with a clamp.
2-31
CABLE ROUTING
D Fasten the starter motor lead, battery negative
lead, V-belt reset coupler, and seat lock cable to
the frame with a plastic band.
Position the band clasp on the bottom of the
frame and face the band end to the outside.
E Fasten the fuel sender lead and fuel pump lead
to the frame with a plastic clamp.
F Place the wireharness and seat lock cable in the
frame holder.
G Through the seat lock cable between
wireharness and frame.
SPEC
H Use the clamp on the back of the frame to hold the
side stand switch lead and fan motor lead.
I Connect the wireharness (wire taped area) to the
frame side T stud.
J After connecting the main switch lead, push it
between the seat lock cable adjustment area and
the frame.
K Through the main switch lead between frame and
seat lock cable.
L After connecting the wireharness and meter lead,
use a plastic clamp to connect them to stay 1.
M Connect to the headlight sub harness (left and
right)
2-32
CABLE ROUTING
N Fasten the headlight sub harness with a plastic
clamp.
O Fasten the igniter lead to the stay with a plastic
clamp.
P Fasten the horn lead with a clamp.
Q Fasten the fan motor lead, sidestand switch
lead, and thermo switch lead to the frame with a
plastic clamp.
R Use a plastic band to connect the wireharness
and relay lead to the frame.
Position the band clasp on the bottom of the
frame and face the band end to the outside.
S Insert the seat lock cable and the cylinder
mounting rubber into the frame stay.
SPEC
T Through the wireharness to the frame wireharness
holder.
U Route the wireharness and regulator lead through
the frame wire holder.
Place the regulator lead under the wireharness.
V The V-belt reset coupler position is change.
W After making the connections, push the couplers
into the space inside the frame above the
mudguard.
X To the tail / brake light.
Y Insert the tail / brake light cuplers between the
wireharness and the seat lock cable (left side).
Z To the starter relay.
2-33
CABLE ROUTING
AA After connecting the left headlight sub-harness
and wireharness (by matching the coupler
colors), fold back the lead facing to the right and
insert it into the air filter case rib.
AB Fasten the coolant reservoir hose to the stay with
a plastic clamp.
AC Route the ignition coil lead through the inside of
the bracket.
AD Route the seat lock cable through the frame
bracket side.
2-34
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
Air vent hose
Vacuum hose
A.C. magneto lead
Sidestand switch
Fan motor lead
Thermo switch lead
Stay 1
SPEC
A Route the wireharness through the frame guide.
At this time, place the protector (for the handle
cover inner side) on the bottom side.
B Fasten the rear brake hose and vacuum hose with
a plastic clamp.
The fastening position is 0 to 5 m from edge of the
frame bracket.
C Pass the wireharness by the outside of the rear
footrest mounting boss.
(When mounting the rear footrest, do not catch or
pinch the A.C. magneto lead in the bracket.)
2-35
CABLE ROUTING
D Fasten the wireharness to the frame with a
plastic clamp.
E Fasten the wireharness to the frame with a
plastic clamp.
F Pass the box light lead by the front of the frame
back stay pipe.
G Fasten the sidestand switch lead to the frame
with a plastic clamp.
H When adjusting the throttle cable, completely
tighten the hut on the throttle cable return side.
I Through the speed sensor lead to the lead
holder.
J Through the speed sensor lead between front
brake caliper and front brake caliper mounting
bolt.
SPEC
K Use this as a reference when adjusting the throttle
cable.
L After adjusting the throttle cables, make sure the
rubber cap is insert connectly.
2-36
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Fuel hose
Battery negative lead
Seat lock
Starter motor lead
Fuse box
Battery
Battery positive lead
Fuel sender
Breather hose
Lean angle cut-off switch lead
Wireharness
Seat lock cable
SPEC
A Route the wireharness against the stay wire guide.
B Fasten the wireharness branch wiring to the frame
with a plastic clamp.
C Fasten the wireharness to the frame with a plastic
clamp.
D Connect the black wire on the outside of the seat
lock cable to the right seat lock.
E Install the starter relay to the mad guard.
F Fasten the wireharness, battery positive lead and
seat lock cable to the mad guard with a clamp.
G Connect the gray wire on the outside of the seat
lock cable to the left seat lock.
2-37
CABLE ROUTING
H Install the box light to the box 1.
I Fasten the auto choke leads (left and right) and
throttle position sensor lead to the frame with a
clamp.
Leave some slack in the lead wires so that when
the vacuum hose is install it does not press
against them.
J Fasten the auto choke leads (left and right) to the
frame with a plastic clamp.
K Pass the auto choke lead (right side) and throttle
position sensor lead by the front bottom side of
the vacuum hose.
L Route the thermo switch lead through the guide.
M Insert the air vent hose through the hole on the
left side of the frame bracket.
SPEC
N Route the wireharness through the guide.
O Place the speed sensor lead between the ribs of
the air filter case.
P Fasten the lean angle cut-off switch lead to the stay
(2 locations). Face the end of the band downward.
Q Hang the wireharness and seat lock cable on the
wire holder on the back of the fuel pump
attachment stay.
R Fasten the battery negative lead and the starter
motor lead to the frame.
S Route the battery negative lead and the fuse box
lead from the box opening to the bottom of the
cross pipe.
T Pass the black seat lock cable beneath the battery
negative lead and starter motor lead and out to the
inside of the frame.
2-38
CABLE ROUTING
U Align the plastic clamp with the white tape on the
wireharness and fasten the wireharness to the
frame.
V Fasten the wireharness to the seat lock cable.
W Pass the wireharnesses past the outside of the
frame bracket.
X Apply silicone when inserting the starter relay.
Y Fasten the wireharness to the frame with a
plastic clamp.
Z Use a plastic band to hold the auto choke leads
(left and right), throttle position sensor lead, and
rear brake hose in a loose bandle. (The band
should be loose enough so that it can be turned.)
Pull the band end to the bottom.
SPEC
AA Pass the speed sensor lead under the stay and
cross pipe and then over the brake hose guide.
2-39
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
Vacuum hose
Rear brake hose
Switch assembly lead
Auto choke lead
Throttle position sensor lead
Fan motor lead
Air vent hose
Drain hoses
Sidestand switch lead
Thermo switch lead
High tension code
SPEC
A Route the throttle cable through the cable holder.
B Into the handle cover.
C Route the main switch lead through over the seat
lock cable.
D Fasten the sidestand switch lead and thermo
switch lead to the frame with a plastic clamp.
E Fasten the carburetor air vent hose to the frame
with a plastic clamp.
F Fasten the carburetor air vent hose and drain
hoses (2 hoses) to the frame.
G Drop the carburetor drain hose.
2-40
CABLE ROUTING
H Fasten the rear end of the carburetor air vent
hose to the frame with a plastic clamp. (The
distance from the end of clamp to the frame must
range from 0 to 5 mm.)
I Bundle the auto choke leads (left and right) and
the throttle position sensor lead with a plastic
clamp.
J Fasten the rear brake hose and vacuum hose
with a plastic clamp.
K Faster the rear brake hose to the stay 1 with a
plastic clamp.
L Pass the right carburetor drain hose and air vent
hose between the right and left high tension
cables.
SPEC
M Route the left carburetor drain hose through the
outside of the left high tension cable.
2-41
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . 3-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
COVER AND PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE COVER MOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR COVERS AND TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-4
3-5
3-6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . .
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE V-BELT CASE AIR FILTER ELEMENT . . . . . . . . .
CHECKING THE CARBURETOR JOINTS AND INTAKE
MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
3-8
3-13
3-15
3-16
3-18
3-19
3-20
3-22
3-23
3-25
3-27
3-28
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . .
CHECKING THE CHAIN DRIVE OIL LEVEL . . . . . . . . . . . . . . . . . . . .
CHANGING THE CHAIN DRIVE OIL . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . .
3-36
3-36
3-37
3-37
3-38
3-39
3-40
3-40
3-43
3-45
3-47
3-48
3-28
3-29
3-30
3-30
3-31
3-32
3-32
CHK
ADJ
LUBRICATING THE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE CENTERSTAND . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . .
3-48
3-48
3-48
3-49
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . .
3-50
3-50
3-55
3-57
3-58
INTRODUCTION/PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
ODOMETER READING (1,000 km)
NO
NO.
ITEM
1
1
*
Fuel lilne
(See page 3-29)
Check fuel hoses and vacuum hose for cracks or damage.
2
*
Fuel filter
(See page 3-29)
Check condition.
Spark plugs
(See page 3-18)
3
4
*
5
6
7
8
*
*
*
Valves (See page 3-8)
10
20
30
40
ANNUAL
CHECK
CHECK OR MAINTENANCE JOB
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Every 40,000 km
Air filter element
(See page 3-27)
Clean.
V-belt case air filter
elements
(See page 3-28)
Clean.
Front brake
(See page 3
3-36)
36)
(See page 3-37)
Check operation, fluid level and vehicle for fluid leakage.
Rear brake
(See page 3
3-36)
36)
(See page 3-37)
Check operation, fluid level and vehicle for fluid leakage.
Replace.
Replace.
Repalce brake pads.
Whenever worn to the limit
Replace brake pads.
Whenever worn to the limit
9
*
Brake hose
(See page 3-37)
Check for cracks or damage.
10
*
Wheels (See page 3-47)
Check runout and for damage.
Replace.
Every 4 years
11
*
Tires (See page 3-45)
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
12
*
Wheel bearings
(See page 4-4)
Check bearing for looseness or damage.
13
*
Steering
g bearings
g
(See page 3-40)
Check bearing play and steering for roughness.
*
Chassis fasteners
(See page 2-21)
Make sure that all nuts, bolts and screws are properly
tightened.
Sidestand / centerstand
(See page 3-48)
Check operation.
Lubricate.
14
15
Lubricate with lithium-soap-based grease.
Every 20,000 km
16
*
Sidestand switch
(See page 8-9)
Check operation.
17
*
Front fork
(See page 3-43)
Check operation and for oil leakage.
*
Rear shock absorber
assembly
(See page 3-49)
Check operation and shock absorber for oil leakage.
18
19
*
Carburetors
(See page 3-15)
Lubricate the pivoting points with lithium-soap-based
grease.
Adjust engine idling speed and synchronization.
3-1
PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
CHK
ADJ
ODOMETER READING (1,000 km)
NO
NO.
ITEM
CHECK OR MAINTENANCE JOB
1
20
Engine oil
(See page 3-23)
S Change.
21
Engine oil filter
cartridge
(See page 3-23)
S Repalce.
22
*
23
Chain drive oil
(See page 3-39)
(See page 3-40)
S Check vehicle for oil leakage.
S Change.
S Change.
V-belt (See page 5-48)
S Replace.
25
*
Front and rear brake
switches
(See page 8-9)
S Check operation.
26
Moving parts and
cables (See page 3-48)
S Lubricate.
27
Lights, signals and
switches
(See page 3-57)
(See page 3-58)
S Check operation.
S Adjust headlight beam.
30
40
ANNUAL
CHECK
4,000 km after initial 1,000 km
S Check coolant level and vehicle for coolant leakage.
*
20
When the oil change indicator light comes on
(every 5,000 km)
Cooling
g system
y
(See page 3-32)
24
*
10
Every 3 years
When the V-Belt replacement indication light comes
on (every 20,000 km)
EAU03541
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S Regularly check and, if necessary, correct the brake fluid level.
S Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
3-2
SEAT AND FUEL LID
CHK
ADJ
SEAT
SEAT AND FUEL LID
Order
1
2
Job/Part
Q’ty
Removing the seat and fuel lid
Seat
Fuel lid
Remarks
Removing the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
FRONT COWLING
CHK
ADJ
COVER AND PANEL
FRONT COWLING
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Refer to parts in the order listed.
Removing the front cowling
Front side cover mole
Rear view mirror
Front cowling upper cover
Windshield
Front cowling inner panel
Front cowling
2
2
1
1
1
1
For installation, reverse the removal
procedure.
3-4
SIDE COVER MOLES
CHK
ADJ
SIDE COVER MOLES
Order
1
2
3
4
5
6
7
8
9
Job/Part
Q’ty
Remarks
Removing the parts in the order listed.
Removing the side cover moles
Mat (left and right)
Upper side cover mole (left and right)
Lower side cover mole (left and right)
Center cover
Hinge cover
Side cover (left and right)
Footrest board (left and right)
Legshield
Inner fender
2
2
2
1
1
2
2
1
1
For installation, reverse the removal
procedure.
3-5
REAR COVERS AND TAILLIGHT
CHK
ADJ
REAR COVERS AND TAILLIGHT
15 Nm (1.5 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Removing the parts in the order listed.
Removing the rear covers and
taillight
Grab bar
Rear cover
Rear side cover (left and right)
Taillight assembly
1
1
2
1
For installation, reverse the removal
procedure.
3-6
FUEL TANK
CHK
ADJ
FUEL TANK
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the fuel tank
Battery
Fuse box coupler
Battery positive lead
Luggage box mat
Luggage box
Hinge and domper
Fuel tank cover
Fuel tank
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
3-7
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:
footrest boards
front cowling
legshield
Refer to “COVER AND PANEL”.
2. Remove:
radiator
Refer to “RADIATOR” in chapter 6.
3. Remove:
carburetor
spark plug
cylinder head cover 1
cylinder head cover gasket 2
intake manfold
Refer to “CARBURETORS” in chapter 7.
4. Remove:
timing plug 1
5. Measure:
valve clearance
Out of specification ! Adjust.
Valve clearance (cold)
Intake valve
0.15 X 0.20 mm
Exhaust valve
0.25 X 0.30 mm
3-8
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
generator rotor with the mark b on the generator cover.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thickness gauge 1 .
NOTE:
S If the valve clearance is incorrect, record the
measured reading.
S Measure the valve clearance in the following
sequence.
d. Turn the crankshaft 360_ counterclockwise
and check the valve clearance of piston #2.
6. Remove:
CAUTION:
When removing the camshaft from the cylinder head, first tip up the chassis front side at
least 25_ from the chassis level position.
S intake camshaft
S exhaust camshaft
NOTE:
S Refer to “CAMSHAFTS” 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 cramkcase.
7. Adjust:
S valve clearance
a. Remove the valve lifter 1 and the valve pad
2.
NOTE:
S Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
3-9
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
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.
e. Install the new valve pad 1 and the valve lifter 2 .
3-10
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
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 “CAMSHAFTS” in chapter 5.
Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
Align the camshaft markswith the cylinder
head.
Turn the crankshaft counterclockwise 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.
3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE PAD SELECTION TABLE
INTAKE
B
A ORIGINAL VALVE PAD NUMBER
MEASURED
VALVE CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.10
0.11 X 0.20
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
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
C STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
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
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
Example:
230 235 240
Valve Clearance (cold)
235 240
240
0.11 X 0.20 mm
220
205
210
215
225
210
215
220
230
215
220
225
235 240
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
Rounded value 150
Measured valve clearance is 0.24 mm
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm
Pad No. 160 = 1.60 mm
Always install the valve pad with the
number facing down.
EXHAUST
B
A ORIGINAL VALVE PAD NUMBER
MEASURED
VALVE CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.12
0.13 X 0.17
0.18 X 0.20
0.21 X 0.30
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
1.03 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
1.38 X 1.42
1.43 X 1.47
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
C STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
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
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
Example:
230 235 240
235 240
Valve Clearance (cold)
240
0.21 X 0.30 mm
220
195
200
205
210
215
225
200
205
210
215
220
230
205
210
215
220
225
235 240
210 215
215 220
220 225
225 230
230 235
225 230 235 240
230 235 240
235 240
240
Rounded value 175
Measured valve clearance is 0.35 mm
Replace pad 150 with pad 185
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm
Always install the valve pad with the
number facing down.
3-12
ADJSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
8. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
EAS00051
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 scooter on a level surface.
NOTE:
Place the scooter on a suitable stand.
2. Remove:
center cover
side covers (left and right)
Refer to “COVER AND PANEL”.
3. Stop air induction system operation and take
ameasurement.
NOTE:
Crimp the hose a running from the lead valve to
the air cut off valve to prevent the air cut off valve
from operating.
Make sure not to damage the hose while crimping it.
4. Install:
engine tachometer 1
(onto the spark plug lead of cylinder. #1)
vacuum gauge 2
Engine tachometer
90890-03113
Vacuum gauge
90890-03094
3-13
SYNCHRONIZING THE CARBURETORS
CHK
ADJ
5. Start the engine and let it warm up for several
minutes.
6. Check:
engine idling speed
Out of specification ! Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1150 X 1250 r/min
7. 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.
b. Rev the engine two or three times, each time
for less than a second, and check the synchronization again.
Vacuum pressure at engine idling
speed
35 kPa (263 mm Hg, 10.4 in Hg)
NOTE:
The difference between the two carburetors
should not exceed 1.33 kPa (10 mm Hg, 0.4 in
Hg).
8. Measure:
engine idling speed (adjust while the air induction system is operating)
Out of specification ! Adjust.
9. Stop the engine and remove the measuring
equipment.
10. 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
11. Install:
side covers (left and right)
center cover
Refer to “COVER AND PANEL”.
3-14
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. Remove:
center cover
side cover (left and right)
Refer to “COVER AND PANEL”.
3. Install:
engine tochometer
(onto the spark plug lead of cylinder. #1)
Engine tachometer
90890-03113
4. Measure:
engine idling speed
Out of spcification ! adjust
Engine idling speed
1150 X 1250 r/min
5. 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.
Pilot screw
2 turns out
3-15
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.
6. 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
7. Install:
side covers (left and right)
center cover
Refer to “COVER AND PANEL”.
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:
center cover
side cover (left)
Refer to “COVER AND PANEL”.
3. Adjust:
throttle cable free play
NOTE:
When the scooter is accelerating, the accelerator cable 1 is pulled.
3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
Carburetor side
a. Loosen the locknut 1 on the decelerator
cable.
b. Turn the adjusting nut 2 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 3 on the accelerator
cable.
d. Turn the adjusting nut 4 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 1 .
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.
4. Install:
side cover (left)
center cover
Refer to “COVER AND PANEL”.
3-17
CHECKING THE SPARK PLUGS
CHK
ADJ
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
center cover
side cover (left and right)
Refer to “COVER AND PANEL”.
2. Disconnect:
spark plug cap
3. 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.
4. Check:
spark plug type
Incorrect ! Change.
Spark plug type (manufacturer)
CR7E (NGK)
5. 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.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire gauge)
Out of specification ! Regap.
Spark plug gap
0.7 X 0.8 mm
8. Install:
spark plug
Spark plug
12.5 Nm (1.25 mkg)
3-18
CHECKING THE SPARK PLUGS/
CHECKING THE IGNITION TIMING
CHK
ADJ
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
spark plug cap
10. Install:
center cover
side cover (left and right)
Refer to “COVER AND PANEL”.
EAS00062
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:
footrest board (left)
center cover
side cover (left)
Refer to “COVER AND PANEL”.
2. Remove:
timing plug 1
3. Install:
timing light 1
engine tachometer
(onto the spark plug lead of cylinder. #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3-19
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
4. 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
1150 X 1250 r/min
b. Check that the mark a on the generator rotor is within the firing range b on the generator cover.
Incorrect firing range ! Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
5. Install:
timing plug
footrest board (left)
side cover (left)
center cover
Refer to “COVER AND PANEL”.
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. Remove:
legshield.
inner fender (rear)
Refer to “COVER AND PANEL”.
2. Measure:
valve clearance
Out of specification ! Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE”.
3-20
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Disconnect:
spark plug cap
5. 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.
6. Install:
compression gauge 1
Compression gauge
90890-03081
Adapter
90890-04082
7. Measure:
compression pressure
Out of specification ! Refer to steps (c) and
(d).
Compression pressure at
360 r/min (at sea level)
Minimum
1,400 kPa (14.0 kg/cm2,
14.0 bar)
Standard
1,450 kPa (14.5 kg/cm2,
14.5 bar)
Maximum
1,500 kPa (15.0 kg/cm2,
15.0 bar)
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure between cylinders should not exceed 100 kPa
(1 kg/cm2, 1 bar).
3-21
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston wear or
damage ! Repair.
Same as without
oil
Piston ring(-s),
valve(-s), cylinder
head gasket or
piston possibly
defective !
Repair.
8. Install:
spark plug
9. Install:
legshield
12.5 Nm (1.25 mkg)
EB303070
CHECKING THE ENGINE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
Place the scooter on a suitable stand.
Make sure that the motorcycle is upright.
2. Start the engine when the engine is cool, let it
idle for two minutes, and then stop it.
3. Wait two minutes until the oil settles, and
then check the oil level through the check
window located at the bottom-left side of the
crankcase.
4. Check:
engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b .
Below the minimum level mark ! Add the
recommended engine oil to the proper level.
3-22
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
Recommended oil
SAE10W30 or SAE 10W40
API standard
SE, SF, SG or higher grade
(Non-Friction modified)
CAUTION:
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and do
not use oils labeled “ENERGY CONSERVING II” d or higher.
Do not allow foreign materials to enter the
crankcase.
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 3 with an oil
filter wrench.
Oil filter wrench
90890-01469
b. Lubricate the O-ring of the new oil filter cartridge with a thin coat of engine oil.
CAUTION:
Make sure that the O-ring is positioned correctly in the groove of the oil filter cartridge.
3-23
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 washer
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
3.6 L
Without oil filter cartridge
replacement
2.8 L
With oil filter cartridge
replacement
2.9 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. Reset:
Oil change indicator light perform the following procedure.
1. Turn the key to “ON”.
2. Hold the reset button pushed for two to five
seconds.
3. Release the reset button 1 and the oil
change indicator light will go off.
NOTE:
If the engine oil is changed before the oil change
indicator light comes on (i.e. before the periodic
oil change interval has been reached), the indicator light must be resert after the oil change for
the next periodic oil change to be indicated at
the correct time. To reset the oil change indicator light before the periodic oil change interval
has been reached, follow the above procedure,
but note that the indicator light will come on for
1.4 seconds after releasing the reset button,
otherwise repeat the procedure.
3-24
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:
S engine oil level
Below the minimum level mark ! Add the
recommended engine oil to the proper level.
2. Remove:
S lower side cover mole
Refer to “COVER AND PANEL”.
3. Start the engine, warm it up for several minutes, and then turn it off.
CAUTION:
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
4. Remove:
S main gallery bolt 1
WARNING
The engine, muffler and engine oil are extremely hot.
5. Install:
S oil pressure gauge 1
S adapter 2
Oil pressure gauge
90890-03153
Adapter
90890-03124
6. Measure:
S engine oil pressure
(at the following conditions)
Out of specification ³ Replace.
Engine oil pressure
150 kPa (1.5 kg/cm2)
Engine speed
Approx. 1200 r/min
Engine oil temperature
80_C
3-25
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
Engine oil pressure
Possible causes
Below specification
Faulty oil pump
Clogged oil filter
Leaking oil passage
Broken or damaged
oil seal
Leaking oil passage
Above specification Faulty oil filter
Oil viscosity too high
7. Install:
main gallery bolt 1
3-26
20 Nm (2.0 mkg)
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
CLEANING THE AIR FILTER ELEMENT
1. Remove:
front cowling upper cover
windshield
front cowling inner panel
Refer to “COVER AND PANEL”.
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.
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:
front cowling inner panel
windshield
front cowling upper cover
3-27
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/CHECKING
THE CARBURETOR JOINTS AND INTAKE MANIFOLDS
CHK
ADJ
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
1. Remove:
upper side cover mole (left)
footrest board (left)
Refer to “COVER AND PANEL”.
2. Remove:
V-velt case air filter element 1 and 2
3. Clean:
V-velt case air filter element
Apply compressed air to the inner surface of
V-velt case air filter element.
4. Check:
V-velt case air filter element
Damage ! Replace.
CAUTION:
Since the V-belt case air filter element is a dry
type, do not let grease or water contact it.
5. Install:
footrest board (left)
upper side cover mole (left)
CHECKING THE CARBURETOR JOINTS
AND INTAKE MANIFOLDS
The following procedure applies to all of the carburetor joints.
1. Remove:
legshield
Refer to “COVER AND PANEL”.
3-28
CHECKING THE CARBURETOR JOINTS AND INTAKE
MANIFOLDS/CHECKING THE FUEL HOSES AND FUEL FILTER
CHK
ADJ
2. Check:
carburetor joints 1
Cracks/damage ! Replace.
Refer to “CARBURETOR” in chapter 7.
3. Install:
legshield
EAS00097
CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of the fuel
hoses.
1. Remove:
footrest board (right)
upper side cover mole (right)
Refer to “COVER AND PANEL”.
2. Check:
fuel hose 1
Cracks/damage ! Replace.
fuel filter 2
Damage/dirt ! Replace.
NOTE:
Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident.
The arrow mark on the fuel filter should face to
the side of the fuel pump 3 .
3. Install:
upper side cover mole (right)
footrest board
Refer to “COVER AND PANEL”.
3-29
CHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
legshield
Refer to “COVER AND PANEL”.
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:
legshield
Refer to “COVER AND PANEL”.
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the exhaust pipes and gaskets.
1. Remove:
lower side cover mole (right)
Refer to “COVER AND PANEL”.
2. Check:
exhaust pipe 1
muffler 2
Cracks/damage ! Replace.
gasket 3 New
Exhaust gas leaks ! Replace.
3. Check:
tightening torque
Exhaust pipe nut 4
20 Nm (2.0 mkg)
Muffler and muffler bracket bolt 5
48 Nm (4.8 mkg)
4. Install:
lower side cover mole (right)
Refer to “COVER AND PANEL”.
3-30
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00103
CHECKING THE COOLANT LEVEL
1. Stand the scooter on a level surface.
NOTE:
Place the scooter on a suitable stand.
Make sure that the scooter is upright.
2. Remove:
lower side cover mole (right)
3. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
Below the minimum level mark ! Add the
recommended coolant to the proper level.
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
6. Install:
lower side cover mole (right)
3-31
CHECKING THE COOLING SYSTEM/
CHANGING THE COOLANT
CHK
ADJ
CHECKING THE COOLING SYSTEM
1. Remove:
footrest board (left and right)
legshield
Refer to “COVER AND PANEL”.
2. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
oil cooler inlet hose 4
oil cooler outlet hose 5
Cracks/damage ! Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
legshield
footrest board
Refer to “COVER AND PANEL”.
CHANGING THE COOLANT
1. Remove:
lower side cover mole (right)
front side cover mole (right)
Refer to “COVER AND PANEL”.
2. Disconnect:
coolant reservoir bolts 1
coolant reservoir cap 2
NOTE:
When draining the coolant from the coolant reservoir, be sure to tilt the reservoir so that coolant
cannot flow through the coolant reservoir
breather hose.
3-32
CHANGING THE COOLANT
CHK
ADJ
3. Drain:
S coolant (from the coolant reservoir)
4. Install:
S coolant reservoir bolts
5. Remove:
S front side cover mole (right)
Refer to “COVER AND PANEL”.
S 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.
6. Remove:
S coolant drain bolt 1
(along with the rubber washer)
7. Drain:
S coolant
8. Check:
S rubber washer 1
S drain bolt 2
9. Install:
S drain bolt 2
3-33
16 Nm (1.6 mSkg)
CHANGING THE COOLANT
CHK
ADJ
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
1.5 L
Coolant reservoir capacity
0.6 L
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
If coolant splashes on your clothes, quickly wash it away with water and then with
soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
If coolant comes into contact with painted
surfaces, immediately wash them with water.
Do not mix different types of antifreeze.
11. Install:
radiator cap
3-34
CHANGING THE COOLANT
CHK
ADJ
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:
lower side cover mole (right)
side cover mole (right)
3-35
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
CHASSIS
EAS00116
CHECKING THE BRAKE FLUID LEVEL
1. Stand the scooter on a level surface.
NOTE:
Place the scooter on a suitable stand.
Make sure that the scooter is upright.
2. Check:
brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
A
Recommended brake fluid
DOT 4
A Front brake
B Rear brake
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the reservoir. Water will significantly lower the boiling point of the brake
fluid and could cause vapor lock.
B
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.
3-36
CHECKING THE BRAKE PADS/
CHECKING THE BRAKE HOSES
CHK
ADJ
EB304032
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
Brake pad wear limit a
Wear limit reached ! Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
B
Brake pad wear limit
0.8 mm
A Front brake
B Rear brake
EAS00132
A
CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and clamps.
1. Check:
brake hose 1
A Front
B Rear
Cracks/damage/wear ! Replace.
2. Check:
brake hose clamp
Loose connection ! Tighten.
3. Hold the scooter upright and apply the brake.
4. Check:
brake hose
Activate the brake several times.
Brake fluid leakage ! Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
B
3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00135
BLEEDING THE HYDRAULIC BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system whenever:
the system was disassembled,
a brake hose was loosened or removed,
the brake fluid level is very low,
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake 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.
1. Bleed:
hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake fluid reservoir diaphragm.
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.
A
B
3-38
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
CHECKING THE CHAIN DRIVE OIL LEVEL
CHK
ADJ
Bleed screw
6 Nm (0.6 mSkg)
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 .
CHECKING THE CHAIN DRIVE OIL LEVEL
1. Stand the scooter on a level surface.
NOTE:
S Place the scooter on a suitable stand.
S Make sure that the scooter up right.
2. Remove:
S chain drive oil filler cap 1
3. Check:
S chain drive oil level
Wipe the dipstick clean, insert it into the oil
filler hole (without screw it in), and then remove it to check the oil level.
The chain drive oil level should be between
the minimum level mark a and maximum
level mark b .
Below the minimum level mark ! Add the
recommended transfer oil to the proper level.
A
Recommended chain drive oil
SAE 80 hypoid gear oil graded
“GL-4”
B
A SJ011-018730 and before,
SJ012-000065 and before
B SJ011-018731 and later,
SJ012-000066 and later
4. Install:
S chain drive oil filler cap
3-39
CHANGING THE CHAIN DRIVE OIL/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
CHANGING THE CHAIN DRIVE OIL
1. Place a container under the chain drive.
2. Remove:
chain drive oil drain bolt 1
chain drive oil filler cap
Completely drain the chain drive of its oil.
3. Check:
drain bolt gasket
Damage ! Replace.
4. Install:
chain drive oil drain bolt
20 Nm (2.0 mkg)
5. Fill:
chain drive oil
(with the specified amount of the recomended chain drive oil)
Quantity
0.7 L
6. Check:
chain drive oil level
Refer to “CHECKING THE CHAIN DRIVE
OIL LEVEL”.
EAS00146
CHECKING AND ADJUSTING THE STEERING HEAD
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
3-40
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
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:
handlebar
Refer to “HANDLEBAR” in chapter 4.
4. Loosen:
upper bracket pinch bolts 1
5. Remove:
steering stem nut 1
upper bracket 2
6. Adjust:
steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
NOTE:
Set the torque wrench at a right angle to the ring
nut wrench.
Ring nut wrench
90890-01408
Lower ring nut (initial tightening
torque)
52 Nm (5.2 mkg)
3-41
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
c. Loosen the lower ring nut 4 completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
19 Nm (1.9 mkg)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to “STEERING HEAD AND HANDLEBAR” in chapter 7.
e. Install the rubber washer 3 .
f. Install the upper ring nut 2 .
g. Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 1 .
NOTE:
Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
7. Install:
upper bracket 1
steering stem nut 2
8. Tighten:
upper bracket pinch bolt
30 Nm (3.0 mkg)
steering stem nut
110 Nm (11.0 mkg)
3-42
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
CHK
ADJ
9. Measure:
S steering head tension
(with the motorcycle still on the stand)
NOTE:
Make sure that all of the cables and wires are
properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge 2 onto the plastic locking tie.
d. Hold the spring gauge at a 45_ angle from the
handlebar, pull the spring gauge, and record
the measurement when the handlebar starts
to turn.
Steering head tension
200 X 500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specification (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steering head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding ! Adjust the steering
head.
EAS00149
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
3-43
CHECKING THE FRONT FORK
CHK
ADJ
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.
3-44
CHECKING THE TIRES
CHK
ADJ
EB304170
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 scooter could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE SCOOTER.
Basic
weight
(with oil
and a full
fuel tank)
217 kg
Maximum
load*
372 kg
Cold tire
pressure
Front
Rear
Up to 90 kg
load*
200 kPa
(2.0 kgf/cm2,
2.0 bar)
225 kPa
(2.25 kgf/cm2,
2.25 bar)
90 kg X
maximum
load*
225 kPa
(2.25 kgf/cm2,
2.25 bar)
250 kPa
(2.5 kgf/cm2,
2.5 bar)
High-speed
riding
225 kPa
(2.25 kgf/cm2,
2.25 bar)
250 kPa
(2.5 kgf/cm2,
2.5 bar)
* total of cargo, rider, passenger and accessories
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-45
CHECKING THE TIRES
CHK
ADJ
2. Check:
tire surfaces
Damage/wear ! Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Side wall
WARNING
A
Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure
and personal injury from sudden deflation.
When using 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
B
Tube wheel
Tube tire only
Tubeless wheel
Tube or tubeless
tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this scooter.
Front tire
3-46
Manufacturer
Size
Model
BRIDGESTONE
120/70-14
M/C 55S
HOOP
BO3
DUNLOP
120/70-14
M/C 55S
D305FA
CHECKING THE TIRES/CHECKING THE WHEELS
CHK
ADJ
Rear tire
Manufacturer
Size
Model
BRIDGESTONE
150/70-14
M/C 66S
HOOP
BO2
DUNLOP
150/70-14
M/C 66S
D305
WARNING
After mounting a new tire, ride conservatively for a while to become accustomed to the
“feel” of the new tire and to allow the tire to
seat itself properly in the rim. Failure to do
so could lead to an accident with possible
injury to the rider or damage to the motorcycle.
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.
EB304180
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:
wheel
Damage/out-of-round ! Replace.
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
3-47
CHECKING AND LUBRICATING THE CABLES /LUBRICATING THE LEVERS
LUBRICATING THE CENTERSTAND/ LUBRICATING THE SIDESTAND
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.
EB304210
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Lithium soap base grease
EAS00173
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
Engine oil
EB304220
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of sidestand
Recommended lubricant
Lithium soap base grease
3-48
LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum disulfide grease
3-49
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EB305020
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 an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
3-50
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
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. Measure:
S battery charge
a. Connect a digital voltmeter to the battery terminals.
Open-circuit voltage (V)
Tester positive probe ! battery positive
terminal
Tester negative probe ! battery negative terminal
13.0
NOTE:
S The charge state of an 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
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 X 30%
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
3-51
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.
CAUTION:
Time (minutes)
Check the open-circuit
voltage.
S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger
since it forces 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 an 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 (%)
3-52
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Charging method using a variable-voltage charger
Charger
Ammeter
Measure the open-circuit
voltage prior to charging.
Connect a charger and ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
NOTE:
Leave the battery unused for more than
30 minutes before measuring its opencircuit voltage.
NOTE:
Set the charging voltage to 16 X 17 V.
(If the charging voltage is lower charging will be insufficient, if it is higher, the
battery will be over-charged.)
NO
Adjust the charging voltage to
20 X 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for 3 X
5 minutes. Is the standard
charging amperage exceeded?
NO
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the amperage does not
exceed the standard charging amperage after 5 minutes, replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.
12.8 V ! Charging is complete.
12.0 X 12.7 V ! Recharging is required.
Under 12.0 V ! Replace the battery.
3-53
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant-voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for more than
30 minutes before measuring its opencircuit voltage.
Connect a charger and ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variablevoltage charger is recommended.
NOTE:
Set the charging time to a maximum of
20 hours.
Leave the battery unused for more
than 30 minutes before measuring its
open-circuit voltage.
12.8 V ! Charging is complete.
12.0 X 12.7 V ! Recharging is required.
Under 12.0 V ! Replace the battery.
Charger
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF battries.
3-54
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
CHK
ADJ
6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
8. Check:
battery terminals
Dirt ! Clean with a wire brush.
Loose connection ! Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10. Install:
seat
battery cover
EB305040
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
seat
battery cover
2. Check:
continuity
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace the
fuse.
3-55
CHECKING THE FUSES
CHK
ADJ
3. Replace:
blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set the main switch to “ON” and verify if the
electrical circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Item
Amperage
Q’ty
Main fuse
30 A
1
Headlight
fuse
15 A
1
Signaling
system fuse
15 A
1
Ignition
fuse
10 A
1
Radiator
fan motor
fuse
15 A
1
Backup fuse
10 A
1
WARNING
Never use a fuse with an amperage 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:
battery cover
seat
3-56
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:
headlight coupler 1
headlight bulb holder cover 2
2. Detach:
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. Attach:
headlight bulb holder
6. Install:
headlight bulb holder cover
7. Connect:
headlight coupler
3-57
ADJUSTING THE HEADLIGHT BEAM
CHK
ADJ
EAS00184
ADJUSTING THE HEADLIGHT BEAM
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 2 in direction a or
b.
3-58
Direction a
Headlight beam moves to
the right.
Direction b
Headlight beam moves to
the left.
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . .
4-1
4-3
4-3
4-4
4-5
4-7
4-7
4-9
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . .
4-11
4-11
4-13
4-13
4-13
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
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 AND INSTALLING THE REAR BRAKE
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPER . . . . . . . . .
ASSEMBLING AND INSTALLILNG THE FRONT
BRAKE CALILPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14
4-14
4-15
4-16
4-18
4-21
4-23
4-25
4-25
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLILNG THE FRONT FORK LEGS . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
4-45
4-49
4-50
4-51
4-52
4-55
4-26
4-27
4-30
4-33
4-35
4-37
4-37
4-38
4-40
4-42
CHAS
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-56
4-58
4-58
4-59
STEEIRNG HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
4-62
4-62
4-64
4-64
4-65
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLILNDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . .
4-67
4-68
4-68
4-69
4-69
4-70
FRONT WHEEL AND BRAKE DISC
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
59 Nm (5.9 mSkg)
27 Nm (2.7 mSkg)
20 Nm (2.0 mSkg)
18 Nm (1.8 mSkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand
so that the front wheel is elevented.
Removing the front wheel and brake
disc
1
2
3
4
5
6
7
8
Remarks
1
1
1
1
1
1
1
1
Front brake caliper
Front wheel axle pinch bolt
Front wheel axle
Cap
Front wheel assembly
Speed sensor
Collar
Brake disc
For installation, reverse the removal
procedure.
4-1
FRONT WHEEL AND BRAKE DISC
Order
1
2
3
4
Job/Part
Q’ty
CHAS
Remarks
Disassemble the parts in the order listed.
Disassembling the front wheel
Dust seal
Oil seal
Bearing
Collar
1
1
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00520
REMOVING THE FRONT WHEEL
1. Stand the scooter on a level surface.
WARNING
Securely support the 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:
front brake caliper
front wheel axle
NOTE:
Do not squeeze the brake lever when removing
the brake caliper.
3. Elevate:
front wheel
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
EB700110
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 flathead
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 DISC
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 DISC
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
4 or balls 5 . Contact should be made only
with the outer race 6 .
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
EAS00528
CHECKING THE BRAKE DISC
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.
Max. brake disc deflection
Front: 0.15 mm
Rear: 0.15 mm
a. Place the scooter on a suitable stand so that
the front 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 DISC
CHAS
3. Measure:
S brake disc thickness a
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Min. brake disc thickness
Front: 4.5 mm
Rear: 3.5 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.
4-6
FRONT WHEEL AND BRAKE DISC
CHAS
EB700711
ASSEMBLING THE FRONT WHEEL
1. Install:
wheel bearings
a. 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.
2. Install:
oil seal New 1
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
wheel axle
oil seal lips
speedometer drive gear
speedometer driven gear
Recommended lubricant
Lithium soap base grease
2. Install:
speed sensor
NOTE:
Make sure that the speed sensor unit and the
wheel hub are installed with the two projections meshed into the two slots respectively.
Make sure that the slot a in the speed sensor
fits over the stopper b on the outer tube.
4-7
FRONT WHEEL AND BRAKE DISC
CHAS
3. Install:
S brake disc
18 Nm (1.8 mSkg)
NOTE:
S Apply LOCTITE 648 to the threads of the
brake disc bolts.
S Tighten the brake disc bolts in stages and in a
crisscross pattern.
4. Install:
S front wheel
S front wheel axle
S wheel axle pinch bolt
NOTE:
Make sure that the slot in the speedometer gear
unit fits over the stopper on the outer tube.
5. Tighten:
S front wheel axle 1
S wheel axle pinch bolt 2
59 Nm (5.9 mSkg)
20 Nm (2.0 mSkg)
CAUTION:
Before tightening the wheel axle pinch bolt,
push down hand on the handlebar several
times and check if the front fork rebounds
smoothly.
6. Install:
S front brake caliper 1
WARNING
Make sure that the brake cable is routed
properly.
7. Tighten:
S front brake caliper bolt 2
27 Nm (2.7 mSkg)
4-8
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
S After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
S Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
S balancing weight(-s)
2. Find:
S front wheel’s heavy spot
a. Place the front wheel on a suitable balancing
stand.
b. Spin the front wheel.
c. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
d. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an “X2” mark
at the bottom of the wheel.
g. Repeat steps (a) through (d) several times
until all the marks come to rest at the same
spot.
h. 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.
4-9
FRONT WHEEL AND BRAKE DISC
CHAS
4. Check:
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.
4-10
REAR WHEEL AND BRAKE DISC
CHAS
REAR WHEEL AND BRAKE DISC
REAR WHEEL
17 Nm (1.7 mSkg)
7 Nm (0.7 mSkg)
104 Nm (10.4 mSkg)
27 Nm (2.7 mSkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the scooter on a suitable stand
so that the rear wheel is elevated.
Removing the rear wheel
1
2
3
4
5
6
Rear brake caliper
Chain drive case cover
Swingarm pinch bolt
Rear wheel axle/nut/washer
Collar
Rear wheel
Remarks
1
1
Loosen.
1
1/1/1
1
1
For installation, reverse the removal
procedure.
4-11
REAR WHEEL AND BRAKE DISC
CHAS
18 Nm (1.8 mkg)
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear wheel
Brake disc
Rear wheel drive hub
O-ring
Dust seal
Oil seal
Bearing
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
2
For assembly, reverse the disassembly
procedure.
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.
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
rear wheel static balance
Refer to “FRONT WHEEL”.
4-13
FRONT AND REAR BRAKES
CHAS
FRONT AND REAR BRAKES
FRONT BRAKE PADS
27 Nm (2.7 mSkg)
Order
1
2
3
4
Job/Part
Removing the fornt brake pads
Front brake caliper bolt
Brake caliper
Brake pad
Brake pad spring
Q’ty
Remarks
Remove the parts in the order listed.
2
1
2
1
For installation, reverse the removal
procedure.
4-14
FRONT AND REAR BRAKES
CHAS
REAR BRAKE PADS
27 Nm (2.7 mSkg)
Order
1
2
3
4
5
Job/Part
Removing the rear brake pads
Rear brake caliper bolt
Brake caliper
Brake pad
Brake pad shim
Brake pad spring
Q’ty
Remarks
Remove the parts in the order listed.
2
1
2
2
2
For installation, reverse the removal
procedure.
4-15
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.
EAS00581
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
front brake caliper bolt 1
brake caliper 2
2. Remove:
brake pad spring 1
brake pads 2
4-16
FRONT AND REAR BRAKES
CHAS
3. Measure:
brake pad thickness a
Out of specification Replace the brake
pads as a set.
Minimum brake pad thickness
0.8 mm
4. Install:
brake pad spring 1
brake pads 2
NOTE:
Always install new brake pads and a new brake
pad shim as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg)
d. Install new brake pads and brake pad spring.
5. Lubricate:
brake caliper bolts
Recommended lubricant
Lithium soap base grease
CAUTION:
Do not allow grease to contact the brake
pads.
Remove any excess grease.
4-17
FRONT AND REAR BRAKES
6. Install:
S brake caliper 1
S brake caliper bolts 2
CHAS
27 Nm (2.7 mSkg)
7. Check:
S 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:
S 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:
S brake caliper bolt 1
S brake caliper 2
2. Remove:
S brake pads 1
S brake pad shim 2
S brake pad spring 3
4-18
FRONT AND REAR BRAKES
CHAS
3. Measure:
brake pad thickness a
Out of specification Replace the brake
pads as a set.
Minimum brake pad thickness
0.8 mm
4. Install:
brake pads 1
brake pad spring 2
brake pad shim 3
NOTE:
Always install new brake pads and a brake pad
spring as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg)
d. Install new brake pads and a new brake pad
spring.
5. Lubricate:
brake caliper bolts
Recommended lubricant
Lithium soap base grease
CAUTION:
Do not allow grease to contact the brake
pads.
Remove any excess grease.
4-19
FRONT AND REAR BRAKES
6. Install:
brake caliper
brake caliper bolt
CHAS
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 pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-20
FRONT AND REAR BRAKES
CHAS
FRONT BRAKE MASTER CYLINDER
1 Nm (0.1 mkg)
30 Nm (3.0 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the front brake master
cylinder
Brake fluid
Brake master cylinder reservoir cap
Brake master cylinder reservoir
diaphram
Brake lever
Front brake light switch connector
Union bolt
Brake hose
Copper washer
Brake master cylinder holder
Brake master cylinder
Front brake light switch
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
2
1
1
2
1
1
1
Disconnect.
For installation, reverse the removal
procedure.
4-21
FRONT AND REAR BRAKES
Order
1
2
3
4
Job/Part
Disassembling the front brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Q’ty
CHAS
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-22
FRONT AND REAR BRAKES
CHAS
REAR BRAKE MSTER CYLINDER
30 Nm (3.0 mkg)
1 Nm (0.1 mkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the rear brake master
cylinder
Brake fluid
Brake master cylinder reservoir cap
Brake master cylinder reservoir
diaphram
Brake lever
Rear brake light switch connector
Union bolt
Brake hose
Copper washer
Brake master cylinder holder
Brake master cylinder
Rear brake light switch
Q’ty
10 Nm (1.0 mkg)
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
2
1
1
2
1
1
1
Disconnect.
For installation, reverse the removal
procedure.
4-23
FRONT AND REAR BRAKES
Order
1
2
3
4
Job/Part
Disassembling the rear brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Q’ty
CHAS
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-24
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:
front brake light switch connector
(from the brake light switch)
2. Remove:
union bolt 1
copper washers 2
brake hoses 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER
NOTE:
Before disassembling the rear brake master cylinder, drain the brake fluid from the entire brake
system.
1. Disconnect:
rear brake light switch connector
(from the brake light 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.
4-25
FRONT AND REAR BRAKES
CHAS
EAS00592
A
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
brake master cylinder 1
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
A Front
B Rear
B
2. Check:
brake master cylinder kit 1
Damage/scratches/wear Replace.
3. Check:
front brake master cylinder reservoir cap 1
Cracks/damage Replace.
front brake master cylinder reservoir diaphragm 2
Damage/wear Replace.
4. Check:
rear brake master cylinder reservoir cap 1
Cracks/damage Replace.
rear brake master cylinder reservoir diaphragm 2
Damage/wear Replace.
4-26
FRONT AND REAR BRAKES
CHAS
5. Check:
brake hoses 1
Cracks/damage/wear Replace.
EAS00596
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 kit 1
circlip 2 New
dust boot 3
2. Install:
front brake light switch 1
3. Install:
brake lever
4-27
FRONT AND REAR BRAKES
CHAS
4. Install:
brake master cylinder 1
brake master cylinder holder 2
holder bolts
10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up a .
Align the end of the brake master cylinder holder with the punch mark b in the handlebar.
First, tighten the upper bolt, then the lower bolt.
5. Install:
copper washers 2 New
brake hose 3
union bolt 1
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe scooter 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.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
4-28
FRONT AND REAR BRAKES
CHAS
6. Connect:
front brake light switch connector
7. 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.
8. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. 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.
10. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-29
FRONT AND REAR BRAKES
CHAS
EAS00600
ASSEMBLING AND INSTALLING THE REAR
BRAKE MASTER CYLINDER
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
1. Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3
2. Install:
rear brake light switch 1
3. Install:
brake lever
4-30
FRONT AND REAR BRAKES
CHAS
4. Install:
brake master cylinder 1
brake master cylinder holder 2
holder bolts
10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up a .
Align the end of the brake master cylinder holder with the punch mark b on the handlebar.
First, tighten the upper bolt, then the lower bolt.
5. Install:
copper washer 2 New
brake hose 3
union bolt 1
30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to insure safe scooter 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.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
4-31
FRONT AND REAR BRAKES
CHAS
6. Connect:
rear brake light switch connector
7. 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.
8. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. 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.
10. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-32
FRONT AND REAR BRAKES
CHAS
FRONT BRAKE CALIPER
30 Nm (3.0 mSkg)
40 Nm (4.0 mSkg)
Order
1
2
3
4
5
Job/Part
Removing the front brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bracket bolt
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
2
1
For installation, reverse the removal
procedure.
4-33
FRONT AND REAR BRAKES
CHAS
6 Nm (0.6 mSkg)
27 Nm (2.7 mSkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Disassembling the front brake
caliper
Brake caliper bolt
Brake caliper bracket
Bleed screw
Brake pad
Brake pad spring
Brake pad crip
Brake caliper piston
Dust seal
Piston seal
Brake caliper body
Q’ty
Remarks
Disassemble the parts in the order listed.
2
1
1
2
1
2
2
2
2
1
For assembly, reverse the disassembly
procedure.
4-34
FRONT AND REAR BRAKES
CHAS
REAR BRAKE CALIPER
30 Nm (3.0 mSkg)
40 Nm (4.0 mSkg)
Order
1
2
3
4
5
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bracket bolt
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
2
1
For installation, reverse the removal
procedure.
4-35
FRONT AND REAR BRAKES
CHAS
6 Nm (0.6 mSkg)
27 Nm (2.7 mSkg)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Disassembling the rear brake
caliper
Brake caliper bolt
Brake caliper bracket
Bleed screw
Brake pad
Brake pad spring
Brake pad shim
Brake caliper piston
Dust seal
Piston seal
Brake caliper body
Q’ty
Remarks
Disassemble the parts in the order listed.
2
1
1
2
2
2
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-36
FRONT AND REAR BRAKES
CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening b to force out the pistons from
the brake caliper.
WARNING
Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pistons are expelled from the brake caliper.
Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
EAS00626
DISASSEMBLING THE REAR BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
4-37
FRONT AND REAR BRAKES
CHAS
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 piston 1
brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the piston from
the brake caliper.
WARNING
Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
Never try to pry out the brake caliper piston.
b. Remove the brake caliper piston seals.
EAS00631
CHECKING THE FRONT AND REAR BRAKE
CALIPER
Recommended brake component
replacement schedule
4-38
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.
FRONT AND REAR BRAKES
CHAS
1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake caliper.
brake caliper body 3
Cracks/damage Replace the brake caliper.
brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
A
B
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
A Front
B Rear
2. Check:
brake caliper bracket 1
Cracks/damage Replace.
A Front
B Rear
A
B
4-39
FRONT AND REAR BRAKES
CHAS
EAS00635
ASSEMBLING AND INSTALLING
FRONT BRAKE CALIPER
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 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:
bleed screw
piston seals 1 New
dust seals 2 New
caliper pistons 3
2. Install:
brake pad spring 1
brake pads 2
NOTE:
Install the brake pad with the attached brake
pad spring.
4-40
FRONT AND REAR BRAKES
3. Install:
S brake caliper
S brake caliper bolt
CHAS
27 Nm (2.7 mSkg)
4. Install:
S brake hose 1
S copper washers 2 New
S union bolt 3
30 Nm (3.0 mSkg)
WARNING
Proper brake hose routing is essential to insure safe scooter operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
5. Fill:
S brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S 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.
S 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.
4-41
FRONT AND REAR BRAKES
CHAS
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
6. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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.
EAS00643
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
bleed screw
piston seals 1 New
dust seals 2 New
caliper piston
4-42
FRONT AND REAR BRAKES
CHAS
2. Install:
S brake pad shim 1
S brake pad spring 2
S brake pad 3
NOTE:
Install the brake pad with the attached brake
pad shim.
3. Install:
S brake caliper
S brake caliper bolt
27 Nm (2.7 mSkg)
4. Install:
S brake hose 1
S copper washers 2 New
S union bolt 3
30 Nm (3.0 mSkg)
WARNING
Proper brake hose routing is essential to insure safe scooter operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
4-43
FRONT AND REAR BRAKES
CHAS
5. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the reservoir. Water will significantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
6. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-44
FRONT FORK
CHAS
FRONT FORK
30 Nm (3.0 mSkg)
24 Nm (2.4 mSkg)
30 Nm
(3.0 mSkg)
40 Nm (4.0 mSkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
The following procedure applies to both of
the front fork legs.
Refer to “COVER AND PANEL” in chapter
3.
Removing the front fork
Front cowling
Handle cover (upper)
Handle cover (under)
Meter
Leg shield
Front wheel
1
2
Front fender
Front brake caliper
Remarks
Refer to “HANDLEBAR”.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
1
1
4-45
FRONT FORK
30 Nm (3.0 mSkg)
CHAS
24 Nm (2.4 mSkg)
30 Nm
(3.0 mSkg)
40 Nm (4.0 mSkg)
Order
3
4
5
6
7
8
Job/Part
Brake hose holder
Speed sensor holder
Cap bolt
Upper bracket pinch bolt
Lower bracket pinch bolt
Front fork leg
Q’ty
1
1
1
2
2
1
Remarks
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-46
FRONT FORK
CHAS
20 Nm (2.0 mkg)
Order
Job/Part
Q’ty
Disassemble the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Disassembling the front fork leg
1
2
3
4
5
6
7
8
9
10
11
Cap bolt
O-ring
Spacer
Fork spring seat
Fork spring
Damper rod assembly bolt
Copper washer
Damper rod assembly
Rebound spring
Oil flow stopper
Inner tube
Remarks
1
1
1
1
1
1
1
1
1
1
1
4-47
FRONT FORK
CHAS
20 Nm (2.0 mkg)
Order
12
13
14
15
16
17
Job/Part
Inner tube bushing
Dust seal
Oil seal clip
Oil seal
Washer
Outer tube bushing
Q’ty
Remarks
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-48
FRONT FORK
CHAS
EAS00651
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
2. Remove:
front cowling
handle cover
meter
legshield
front wheel
front fender
3. Loosen:
cap bolt 1
4. Loosen:
upper bracket pinch bolts 2
5. Loosen:
lower bracket pinch bolts. 1
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
6. Remove:
front fork leg
4-49
FRONT FORK
CHAS
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
dust seal 1
oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
2. Drain:
fork oil
NOTE:
Stroke the outer tube several times while draining the fork oil.
3. Remove:
damper rod assembly bolt
NOTE:
While holding the cartridge cylinder with the
damper rod holder 1 and T-handle 2 , loosen
the cartridge cylinder bolt.
Damper rod holder
90890-01294
T-handle
90890-01326
4. Remove:
inner tube
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but carefully.
CAUTION:
Excessive force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.
4-50
FRONT FORK
CHAS
EAS00656
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
420 mm
3. Check:
damper rod 1
Damage/wear Replace.
Obstruction Blow out all of the oil passages with compressed air.
oil flow stopper 2
Damage Replace.
4. Check:
cap bolt O-ring
Damage/wear Replace.
4-51
FRONT FORK
CHAS
EAS00659
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
rebound spring 2
CAUTION:
Allow the damper rod to slide slowly down
the inner tube 3 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Install:
oil flow stopper 1
3. Lubricate:
inner tube’s outer surface 2
Recommended lubricant
Fork oil 5 W or equivalent
4. Install:
outer tube (onto the inner tube)
copper washer New
damper rod bolt
4-52
FRONT FORK
CHAS
5. Tighten:
damper rod bolt 1
20 Nm (2.0 mkg)
NOTE:
Apply the locking agent (LOCTITE 204) to
the threads of the damper rod bolt.
While holding the damper rod with the damper
rod holder 2 and T-handle 3 , tighten the
damper rod bolt.
Damper rod holder
90890–01294
T-handle
90890–01326
6. Install:
outer tube bushing 1 New
washer 2
(with the fork seal driver weight 3 and adapter 4 )
Fork seal driver weight
90890–01367
Adapter
90890–01372
7. Install:
Oil seal 1 New
(with the fork seal driver weight 2 and adapter 3 )
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 4 to protect
the oil seal during installation.
4-53
FRONT FORK
CHAS
8. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
1 tube’s groove.
9. Install:
dust seal 1 New
(with the fork seal driver weight)
Fork seal driver weight 2
90890–01367
10. Fill:
front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
402 cm3
Front fork leg oil level a
(from the top of the inner tube,
with the inner tube fully compressed and without the fork
spring)
135 mm
Recommended oil
Yamaha fork shock oil 5 WT
or equivalent
NOTE:
While filling the front fork leg, keep it upright.
After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
11. Install:
fork spring
spacer
fork spring seat
O-ring New
NOTE:
Install the spring with the smaller pitch facing
down.
Before installing the cap bolt, lubricate its Oring with grease.
Temporarily tighten the cap bolt.
4-54
FRONT FORK
CHAS
EAS00663
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
front fork leg
NOTE:
Pull up the inner tube until it stops.
2. Tighten:
cap bolt 1
45 Nm (4.5 mkg)
3
lower bracket pinch bolt
30 Nm (3.0 mkg)
upper bracket pinch bolt 2
30 Nm (3.0 mkg)
3. Install:
front fender
legshield
meter
handle cover
front cowling
front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
4-55
HANDLEBAR
CHAS
HANDLEBAR
26 Nm (2.6 mkg)
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the handlebar
Handle cover (upper)
Handle cover (lower)
Band
Front brake light switch connecter
Right handlebar switch
Throttle cable
Throttle grip
Front brake master cylinder
Front brake master cylinder holder
Rear brake light switch connecter
Left handlebar switch
Left handlebar grip
Rear brake master cylinder
Rear brake master cylinder holder
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
2
1
1
1
1
1
1
1
1
4-56
Disconnect.
Disconnect.
HANDLEBAR
CHAS
26 Nm (2.6 mkg)
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
Order
13
14
15
Job/Part
Handlebar upper holder
Grip end
Handlebar
Q’ty
Remarks
2
2
1
For installation, reverse the removal
procedure.
4-57
HANDLEBAR
CHAS
EAS00666
REMOVING THE HANDLEBAR
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2. Remove:
right handlebar switch 1
throttle cable
throttle grip 2
front brake master cylinder 3
grip end 4
3. Remove:
left handlebar switch 1
left handlebar grip 2
rear brake master cylinder 3
grip end 4
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
CHECKING THE HANDLEBAR
1. Check:
handlebar
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
4-58
HANDLEBAR
CHAS
EAS00671
INSTALLING THE HANDLEBAR
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2. Install:
handlebar 1
handlebar upper holders 2
23 Nm (2.3 mkg)
WARNING
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:
The upper handlebar holders should be
installed with the arrows a facing forward A .
Align the match marks b on the handlebar
with the upper surface of the lower handlebar
holders.
3. Install:
front brake master cylinder 1
front brake master cylinder holder 2
10 Nm (1.0 mkg)
holder bolt
NOTE:
Install the front brake master cylinder holder
with the “UP” a mark facing up.
4-59
HANDLEBAR
CHAS
First, tighten the upper bolt, then the lower bolt.
4. Install:
throttle cable
throttle grip
grip end
5. Install:
right handlebar switch 1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
6. Connect:
front brake light switch
7. Install:
rear brake master cylinder 1
rear brake master cylinder holder 2
10 Nm (1.0 mkg)
NOTE:
Install the rear brake master cylinder holder
with the “UP” mark facing up a .
Align the end of the rear brake master cylinder
holder with the punch mark b in the handlebar.
First, tighten the upper bolt, then the lower bolt.
8. Install:
left handlebar switch 1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
4-60
HANDLEBAR
CHAS
9. Install:
left handlebar grip
grip end
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
10. Connect:
rear brake light switch
11. 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
4-61
STEERING HEAD
CHAS
STEERING HEAD
LOWER BRACKET
1st 52 Nm (5.2 mkg)
2nd 19 Nm (1.9 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “COVER AND PANEL” in
chapter 3.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “FRONT FORK”.
Refer to “HANDLEBAR”.
Removing the lower bracket
Front cowling
Front wheel
1
2
3
4
5
6
7
8
Front fork legs
HANDLEBAR
Horn
Horn bracket
Brake hose holder
Steering stem nut
Upper bracket
Lock washer
Upper ring nut
Rubber washer
Remarks
2
1
1
1
1
1
1
1
4-62
STEERING HEAD
CHAS
1st 52 Nm (5.2 mkg)
2nd 19 Nm (1.9 mkg)
Order
9
10
11
12
13
14
15
16
17
18
Job/Part
Lower ring nut
Bearing cover
Bearing inner race
Upper bearing
Bearing outer race
Bearing inner race
Lower bearing
Bearing outer race
Oil seal
Lower bracket
Q’ty
Remarks
1
1
1
1
1
2
1
1
1
1
For installation, reverse the removal
procedure.
4-63
STEERING HEAD
CHAS
EAS00678
REMOVING THE LOWER BRACKET
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
2. Remove:
upper bracket
3. Remove:
lock washer 1
upper ring nut 2
rubber washer 3
lower ring nut 4
(with the special tool)
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.
4-64
STEERING HEAD
CHAS
3. Replace:
bearings
bearing races
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00684
INSTALLING THE STEERING HEAD
1. Lubricate:
upper bearing
lower bearing
bearing races
Recommended lubricant
Lithium soap base grease
2. Install:
oil seal
lower bearing
outer race
3. Install:
lower bracket
4-65
STEERING HEAD
CHAS
4. Install:
upper bearing
bearing cover
5. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
6. Install:
upper bracket 1
steering stem nut 2
7. Tighten:
steering stem nut 2
4-66
110 Nm (11.0 mkg)
REAR SHOCK ABSORBER
CHAS
REAR SHOCK ABSORBER
52 Nm (5.2 mkg)
67 Nm (6.7 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the rear shock absorber
assembly
Muffler
1
2
3
4
5
6
7
8
Lock washer
Bolt
Bolt/nut
Rear shock absorber
Bush
Washer
Spacer
Bearing
Remarks
Refer to “MUFFLER ASSEMBLY” in
chapter 5.
1
1
1/1
1
1
1
1
2
For installation, reverse the removal
procedure.
4-67
REAR SHOCK ABSORBER
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.
4-68
REAR SHOCK ABSORBER
CHAS
EAS00693
REMOVING THE REAR SHOCK ABSORBER
1. Stand the scooter on a level surface.
WARNING
Securely support the scooter so that there is
no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the
rear wheel is elevated.
2. Remove:
bolts 1
NOTE:
When removing the bolts 1 , hold the swingarm so that it does not drop down.
3. Remove:
rear shock absorber.
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
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.
gas cylinder
Damage/gas leaks Replace.
bushings
Damage/wear Replace.
dust seals
Damage/wear Replace.
bolts
Bends/damage/wear Replace.
4-69
REAR SHOCK ABSORBER
CHAS
INSTALLING THE REAR SHOCK ABSORBER
1. Lubricate:
spacer
bearings
Recommended lubricant
Molybdenum disulfide grease
2. Install:
bush 1
washer 2
bearings 3
spacer 4
3. Install:
rear shock absorber 1
bolt (rear side) 2
4. Install:
bolt (front side) 1
lock washer 2
52 Nm (5.2 mkg)
67 Nm (6.7 mkg)
NOTE:
When installing the bolt 1 , hold the swingarm
so that it does not drop down.
Bend the lock washer 2 tab along a flat side of
the bolt 1 .
4-70
ENG
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAD AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-4
5-5
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
5-6
5-7
5-8
5-9
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15
5-16
5-16
5-17
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5-19
5-20
5-22
5-24
5-25
5-25
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-28
5-30
5-31
5-31
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPES . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-33
5-36
5-36
5-37
5-37
5-37
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SPRINGS AND CLUTCH SPRINGS . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .
5-38
5-41
5-42
5-42
5-42
5-43
5-11
5-11
5-12
ENG
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CHECKING THE WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
BELT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT DRIVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY
SHEAVE ASSEMBLY AND V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY THE PRIMARY SHEAVE . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY THE SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . .
CHECKING THE V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRIMARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SLIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE PRIMARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . . .
INSTALLING THE BELT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-44
5-44
5-45
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PISTONS AND CYLINDERS . . . . . . . . . . . . . . . . .
5-55
5-56
5-57
5-58
5-59
5-60
CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT JOURNAL BEARING . . . . . . . . . .
REMOVING THE CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . .
INSTALLING THE CRANKSHAFT JOURNAL BEARING . . . . . . . . .
INSTALLING THE CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-62
5-62
5-64
5-65
5-65
5-66
5-66
5-66
5-71
5-71
5-73
5-73
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-74
5-75
5-75
5-76
CHAIN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CHAIN DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . .
INSTALLING THE CHAIN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-77
5-80
5-80
5-81
5-48
5-49
5-49
5-49
5-50
5-50
5-50
5-50
5-51
5-52
5-53
ENGINE
ENG
OVERHAULING THE ENGINE
ENGINE
MUFFLER ASSEMBLY
48 Nm (4.8 mkg)
20 Nm (2.0 mkg)
Order
1
2
Job/Part
Q’ty
Removing the muffler assembly
Lower side cover mole (right)
Muffler assembly
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
5-1
ENGINE
ENG
LEADS AND HOSES
Order
Job/Part
Q’ty
Disconnect the parts in the order listed.
Refer to “COVER AND PANEL” in
chapter 3.
Refer to “MUFFLER ASSEMBLY”.
Refer to “REAR SHOCK ABSORBER” in
chapter 4.
Drain.
Refer to “CHAIN DRIVE”.
Drain.
Refer to “RADIATOR” in chapter 5.
Refer to “CARBURETOR” in chapter 7.
Drain.
Disconnecting the leads and hoses
Legshield
Footrest board
Muffler assembly
Rear shock absorber
1
2
3
4
Chain drive oil
Chain drive assembly
Coolant
Cooling system
Carburetor
Engine oil
Battery negative lead
Battery positive lead
Thermo unit coupler
Thermo switch coupler
1
1
1
1
5-2
Remarks
ENGINE
Order
5
6
7
Job/Part
Q’ty
A.C. magneto lead
Hose
Air induction system
1
1
1
5-3
ENG
Remarks
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
For installation, reverse the removal
procedure.
ENGINE
ENG
ENGINE
87 Nm (8.7 mkg)
87 Nm (8.7 mkg)
48 Nm (4.8 mkg)
Order
1
2
3
4
Job/Part
Removing the engine
Upper mounting bolt/nut
Lower mounting bolts/washers
Collar
Rear mounting bolt/nut
Q’ty
Remarks
Remove the parts in the order listed.
1/1
4/4
1
1/1
For installation, reverse the removal
procedure.
5-4
ENGINE
ENG
INSTALLING THE ENGINE
1. Install:
front mounting bolt/nut 1
front mounting bolts (lower) 2
collar 3
rear mounting bolt/nut 4
NOTE:
Do not fully tighten the bolts.
2. Tighten:
front mounting nut (upper) 1
87 Nm (8.7 mkg)
front mounting bolts (lower) 2
48 Nm (4.8 mkg)
rear mounting nut 4
5-5
87 Nm (8.7 mkg)
CAMSHAFTS
ENG
CAMSHAFTS
CYLINDER HEAD COVER
12.5 Nm (1.25 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “CARBURETOR” in chapter 7.
Drain.
Refer to “RADIATOR AND OIL COOLER”
in chapter 6.
Removing the cylinder head cover
Carburetor assembly
Coolant
Radiator assembly
1
2
3
Remarks
2
1
1
Spark plugs
Cylinder head cover
Cylinder head cover gasket
For installation, reverse the removal
procedure.
5-6
CAMSHAFTS
ENG
CAMSHAFTS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
1
2
3
4
Removing the camshafts
Timing chain tensioner
Timing chain tensioner gasket
Camshaft caps
Dowel pins
1
1
2
4
5
6
In take camshaft
Exhaust camshaft
1
1
NOTE:
During removal, the dowel pins may still be
connected to the camshaft cap.
For installation, reverse the removal
procedure.
5-7
CAMSHAFTS
ENG
REMOVING THE CAMSHAFTS
1. Remove:
S timing plug 1
2. Align:
S “I” mark a (with the stationary pointer b )
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
stationary pointer b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3. Remove:
S timing chain tensioner 1
S timing chain tensioner gasket 2
4. Remove:
CAUTION:
When removing the camshaft from the cylinder head, first tip up the chassis front side at
least 25_ from the chassis level position.
S camshaft caps 1 (intake and exhaust)
S 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.
5-8
CAMSHAFTS
ENG
5. Remove:
intake camshaft 1
exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, faster it with a wire 3 .
6. Remove:
timing chain guide (exhaust side)
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 33.252 33.352 mm
b 24.956 25.056 mm
Exhaust
a 33.252 33.352 mm
b 24.956 25.056 mm
3. Measure:
camshaft runout
Out of specification Replace.
Max. camshaft runout
0.03 mm
5-9
CAMSHAFTS
ENG
4. Measure:
S camshaft-journal-to-camshaft-cap
clearance
Out of specification Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.020 0.054 mm
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of 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 1 .
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
22,967 22,980 mm
5-10
CAMSHAFTS
ENG
CHECKING THE CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
camshaft sprocket
More than 1/4 tooth wear a Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
2. Check:
timing chain guide (exhaust side) 2
timing chain guide (intake side) 1
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
timing chain tensioner
Cracks/damage/rough movement Replace.
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.
5-11
CAMSHAFTS
ENG
INSTALLING THE CAMSHAFTS
1. Install:
timing chain guide (exhaust side)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
stationary pointer b .
2. Install:
intake camshaft 1
exhaust camshaft 2
3. Install:
intake camshaft cap 1
exhaust camshaft cap 2
a. Install the timing chain onto both camshaft
sprockets.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
b. Install the exhaust and intake camshaft cap.
Camshaft cap bolt
10 Nm (1.0 mkg)
NOTE:
Make sure that camshaft sprocket timing hole
a are aligned with the cylinder head edge b .
Out of alignment Reinstall.
c. Remove the wire from the timing chain.
5-12
CAMSHAFTS
ENG
4. Install:
chair guide (exhaust side)
timing chain tensioner gasket
timing chain tensioner
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner
rod, wind it clockwise with a thin screwdriver
1 until if stops.
c. With the screwdriver still inserted into the
timing chain tensioner, install the timing
chain tensioner 2 , gasket onto the cylinder
block. Then, tighten the timing chain tensioner bolts 3 to the specified torque.
WARNING
Always use a new gasket.
Timing chain tensioner bolt
10 Nm (1.0 mkg)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.
Cap bolt
10 Nm (1.0 mkg)
5. Turn:
crankshaft (several turns counterclockwise)
6. Check:
TDC mark a
Make sure that the TDC mark is aligned with
the crankcase mating surface b .
camshaft sprocket timing mark c
Make sure that the camshaft sprocket timing
mark is aligned with the cylinder head edge
d.
Out of alignment Adjust.
Refer to the installation steps above.
7. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
5-13
CAMSHAFTS
ENG
8. Install:
cylinder head cover gasket
cylinder head cover
NOTE:
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
5-14
CYLINDER HEAD
ENG
CYLINDER HEAD
46 Nm (4.6 mSkg)
10 Nm (1.0 mSkg)
35 Nm (3.5 mSkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Removing the cylinder head
Legshield
Footrest board
1
2
3
Carburetors
Intake and exhaust camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Remarks
Refer to “COVER AND PANEL” in
chapter 3.
Refer to “CARBURETOR” in chapter 7.
Refer to “CAMSHAFTS”.
1
1
2
For installation, reverse the removal
procedure.
5-15
CYLINDER HEAD
ENG
REMOVING THE CYLINDER HEAD
1. Remove:
cylinder head bolts 1
cylinder head nuts 2
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.
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
combustion chamber carbon deposits
(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.
Max. cylinder head warpage
0.10 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 400 600 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.
5-16
CYLINDER HEAD
ENG
INSTALLING THE CYLINDER HEAD
1. Install:
dowel pins
gasket New
2. Install:
cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
cylinder head nuts 1
cylinder head nuts 2
cylinder head bolts 3
35 Nm (3.5 mkg)
46 Nm (4.6 mkg)
10 Nm (1.0 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”.
5-17
VALVES AND VALVE SPRINGS
ENG
VALVES AND VALVE SPRINGS
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the valves and valve
springs
Cylinder head
Valve lifter
Valve pad
Valve cotter
Valve retainer
Valve spring
Intake valve stem seal
Exhaust valve stem seal
Valve spring seat
Intake valve guide
Exhaust valve guide
Valve
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
8
8
16
8
8
4
4
8
4
4
8
For installation, reverse the removal
procedure.
5-18
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 .
5-19
VALVES AND VALVE SPRINGS
ENG
Valve spring compressor
90890-04109
Attachment
90890-04114
4. Remove:
valve retainer 1
valve spring 2
oil seal 3
valve 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 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 0.052 mm
<Limit>: 0.10 mm
5-20
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_ 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 (4mm)
90890-04111
Valve guide installer (4mm)
90890-04112
Valve guide reamer (4mm)
90890-04113
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
S valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
0.6 0.8 mm
<Limit>: 0.5 mm
5-21
VALVES AND VALVE SPRINGS
ENG
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always replace the oil seal.
Valve stem runout
0.04 mm
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
carbon deposits
(from the valve face and valve seat)
2. Check:
valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
Valve seat width
Intake: 0.9 1.1 mm
<Limit>: 1.6 mm
Exhaust: 0.9 1.1 mm
<Limit>: 1.6 mm
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
d. Measure the valve seat width.
5-22
VALVES AND VALVE SPRINGS
ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
5-23
VALVES AND VALVE SPRINGS
ENG
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
valve spring free length a
Out of specification Replace the valve
spring.
Valve spring free length
(intake and exhaust)
35.59 mm
<Limit>: 33.81 mm
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
5-24
VALVES AND VALVE SPRINGS
ENG
Compressed spring force
Intake valve spring
9.3 10.7 kg at 30.4 mm
Exhaust valve spring
9.3 10.7 kg at 30.4 mm
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
Max. spring tilt
Intake valve spring
1.6 mm
Exhaust valve spring
1.6 mm
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:
valve lifter
Damage/scratches Replace the valve lifters and cylinder head.
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
5-25
VALVES AND VALVE SPRINGS
ENG
3. Install:
valve 1
valve spring seat 2
oil seal 3 New
valve spring 4
valve retainer 5
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place.
Install the valve spring with the larger pich a
facing up.
b Smaller pitch
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor
90890-04109
Attachment
90890-04114
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
5-26
VALVES AND VALVE SPRINGS
ENG
6. Lubricate:
valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
valve pad
valve lifter
CAUTION:
After making sure that the valve pads are fully inserted, install the valve lifter taking care
so that the pads do not fall.
NOTE:
The valve lifter must move smoothly when rotated with a finger.
Each valve lifter and valve pad must be reinstalled in its original position.
5-27
STARTER CLUTCH AND GENERATOR
ENG
STARTER CLUTCH AND GENERATOR
10 Nm (1.0 mSkg)
7 Nm (0.7 mSkg)
30 Nm (3.0 mSkg)
Order
Job/Part
60 Nm (6.0 mSkg) + 120_
Q’ty
10 Nm (1.0 mSkg)
Remarks
Remove the parts in the order listed.
Removing the starter clutch and
generator
Side panel (left)
Lower cover
Footrest board
Water pump
Coolant
Engine oil
1
2
Starter coil assembly coupler
Generator cover
1
1
3
4
Generator cover gasket
Dowel pin
1
2
5-28
Refer to “WATER PUMP” in chapter 5.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
Refer to “REMOVING/INSTALLING THE
GENERATOR”.
STARTER CLUTCH AND GENERATOR
ENG
10 Nm (1.0 mSkg)
7 Nm (0.7 mSkg)
30 Nm (3.0 mSkg)
Order
5
6
7
8
9
10
11
12
13
Job/Part
Starter coil assembly
Nut
Spacer
Generator rotor
Starter clutch
Idler gear shaft
Idler gear
Starter clutch gear
Washer
60 Nm (6.0 mSkg) + 120_
Q’ty
10 Nm (1.0 mSkg)
Remarks
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-29
STARTER CLUTCH AND GENERATOR
ENG
REMOVING THE GENERATOR
1. Remove:
generator rotor cover
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 loosend, remove
them.
2. Remove:
generator rotor nut 1
spacer 2
NOTE:
While holding the generator rotor 3 with the
sheave holder 4 , loosen the generator rotor
nut.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
3. Remove:
generator rotor 1
(with the flywheel puller set 2 )
woodruff key
NOTE:
Remove the rotor 1 using the flywheel puller.
Center the flywheel puller over the rotor.
Make sure after installing the holding bolts that
the clearance between the flywheel puller and
the rotor is the same everywhere. If necessary,
one holding bolt maybe turned out slightly to
adjust the flywheel puuler’s position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller set
90890-01362
5-30
STARTER CLUTCH AND GENERATOR
ENG
CHECKING THE STARTER CLUTCH
1. Check:
starter clutch
Damage/wear Replace.
2. Check:
idle gear
idle gear shaft
starter clutch gear
Pitting/burrs/chips/roughness/wear Replace the defective parts.
3. 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
counterclockwise B , 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
clockwise A , it should turn freely.
If the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.
INSTALLING THE GENERATOR
1. Install:
woodruff key
generator rotor 1
spacer 2
nut 3
NOTE:
Clean the tapered portion of the crankshaft
and the generator rotor hub.
When installing the generator rotor, make sure
the woodruff key is properly seated in the key
way of the crankshaft.
5-31
ENG
STARTER CLUTCH AND GENERATOR
2. Tighten:
S generator rotor nut 1
60 Nm (6.0 mSkg) + 120_
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
CAUTION:
S When tightening the generator rotor nut, be
sure to use an F-type torque wrench.
S After tightening the generator rotor nut, to
the specified torque, turn the connecting
rod nut another + 120_.
3. Apply:
S sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No1215
90890-85505
4. Install:
S stator coil
5. Install:
S generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
5-32
OIL PUMP
ENG
OIL PUMP
10 Nm (1.0 mkg)
Order
Job/Part
Q’ty
Removing the parts in the order listed.
Removing the oil pump
Side panel (left)
Lower cover
Footrest board
Coolant
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Engine oil
1
2
Generator cover
Starter clutch gear
Oil pump drive chain
Oil pump
Remarks
1
5-33
OIL PUMP
ENG
10 Nm (1.0 mkg)
Order
3
4
5
6
Job/Part
O-ring
Oil pipe
Oil pipe
Relief valve assembly
Q’ty
Remarks
2
1
1
1
For installation, reverse the removal
procedure.
5-34
OIL PUMP
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the oil pump
Oil pump housing
Oil pump outer rotor
Oil pump inner rotor
Pin
Dowel pin
Oil pump housing center
Oil pump cover
Oil pump driven gear
Q’ty
ENG
Remarks
Disassemble the parts in the order listed.
1
2
2
2
4
1
1
1
For assembly, reverse the disassembly
procedure.
5-35
OIL PUMP
ENG
CHECKING THE OIL PUMP
1. Check:
oil pump driven gear 1
oil pump housing 2
oil pump cover 3
Cracks/damage/wear Replace the defective part(-s).
2. Measure:
inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-housing clearance
b
Out of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.04 0.12 mm
<Limit>: 0.20 mm
Outer-rotor-to-oil-pump-housing
clearance
0.045 0.085 mm
<Limit>: 0.15 mm
3. Check:
oil pump operation
Unsmooth Repear or replace the defective part(-s).
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).
5-36
OIL PUMP
ENG
EAS00367
CHECKING THE OIL DELIVERY PIPES
The following procedure applies to all of the oil
delivery pipes.
1. Check:
oil delivery pipe 1
Damage Replace.
Obstruction Wash and blow out with compressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
oil strainer
Damage Replace.
Contaminants Clean with engine oil.
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor 1
outer rotor 2
oil pump driven gear 3
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:
oil pump housing 1
10 Nm (1.0 mkg)
outer rotor 2
inner rotor 3
pins 4
oil pump cover 5
oil pump driven gear 6
NOTE:
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove 2 on the inner rotor 3 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
5-37
CLUTCH
ENG
CLUTCH
65 Nm (6.5 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Removing the clutch assembly
Generator cover
1
2
Nut
Clutch assembly
Remarks
1
1
For installation, reverse the removal
procedure.
5-38
CLUTCH
ENG
90 Nm (9.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Job/Part
Disassembling the clutch
Primary drive gear
Rollar bearing
Circlip
Bearing
Collar
Nut
Clutch boss
Circlip
Spring plate stopper
Clutch spring 2
Pressure plate
Clutch plate 2
Friction plate
Clutch plate 1
Clutch spring
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
2
5
4
6
5-39
CLUTCH
ENG
90 Nm (9.0 mkg)
Order
16
17
18
19
Job/Part
Spring
Thrust plate
Weight
Clutch housing
Q’ty
Remarks
6
1
12
1
For assembly, reverse the disassembly
procedure.
5-40
CLUTCH
ENG
REMOVING THE CLUTCH
1. Remove:
generator cover 1
Refer to “STARTER CLUTCH AND GENERATOR”.
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:
nut 1
clutch assembly 2
clutch boss
NOTE:
Before removal, apply a and b alignment
marks.
Align these marks during reassembly.
3. Remove:
circlip 1
NOTE:
Install the clutch spring holder 2 onto the clutch
assembly as shown. Then, compress the
spring, and remove the circlip 1 .
Clutch spring compressor
90890-01482
4. Remove:
spring plate stopper
clutch spring
pressure plate
friction and clutch plates
weight thrust plate
weights
springs
5-41
CLUTCH
ENG
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the friction plates.
1. Check:
friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.75 3.05 mm
<Limit>: 2.65 mm
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
clutch plate
Damage Replace the clutch plates as a
set.
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge 1 )
Out of specification Replace the clutch
plates as a set.
Max. clutch plate warpage
0.1 mm
CHECKING THE SPRINGS AND CLUTCH
SPRINGS
The following procedure applies to all of the
springs.
1. Measure:
spring free length a
Out of specification Replace the spring.
Spring Limit
25.4 mm
2. Measure:
clutch spring b
Out of specification Replace the clutch
spring
Clutch spring limit
2.9 mm
5-42
CLUTCH
ENG
3. Measure:
clutch spring 2 c
Out of specification Replace the clutch
spring 2
Clutch spring 2 limit
4.4 mm
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
clutch housing dogs
Damage/pitting/wear Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause erratic clutch operation.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
clutch boss splines
Damage/pitting/wear Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause erratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
pressure plate
thrust plate
Cracks/damage Replace.
CHECKING THE WEIGHT
Check:
weight
Cracks/wear/scaling/chipping Replace.
Out of specification Replace.
Weight outside diameter:
16.0 mm
<Limit>: 15.5 mm
5-43
BELT DRIVE
ENG
BELT DRIVE
BELT DRIVE COVER
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the belt drive cover
Side panel (right)
Lower cover
Footrest board
Protector cover 1
Protector cover 2
Filter cover
Filter
Belt drive cover
Belt drive cover gasket
Bearing cover plate
Bearing
Circlip
Oil seal
Bearing
(M6)
(M8)
Q’ty
10 Nm (1.0 mSkg)
24 Nm (2.4 mSkg)
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-44
BELT DRIVE
BELT DRIVE
ENG
: Shell BT grease 3
24 Nm (2.4 mSkg)
10 Nm (1.0 mSkg)
24 Nm (2.4 mSkg)
10 Nm (1.0 mSkg)
:
:
90 Nm (9.0 mSkg)
:
160 Nm (16.0 mSkg)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Part
Removing the belt drive
Primary sheave nut
Spacer
O-ring
Primary sheave assembly
Primary fixed sheave
Secondary sheave nut
Secondary sheave assembly
Collar
O-ring
Cover
Plate
Air duct seal
Belt
Q’ty
Remarks
Remove the parts in the order listed.
1
1
2
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-45
BELT DRIVE
ENG
: Shell BT grease 3
:
:
:
:
6 Nm (0.6 mSkg)
Order
1
2
3
4
5
6
7
Job/Part
Q’ty
Disassembling the primary sheave
Stopper
Cam
Slider
Weight
Primary sliding sheave
Collar
O ring
Remarks
Dissassemble the parts in the order listed.
1
1
8
8
1
1
1
For assembly, reverse the disassembly
procedure.
5-46
BELT DRIVE
ENG
: BEL-RAY assembly lube
:
:
90 Nm (9.0 mSkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
Disassembly the secondary sheave
Nut
Upper spring seat
Compression spring
Spring seat
Secondary sliding sheave
Oil seal
Guide pin
Secondary fixed sheave
Collar
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
4
1
1
For assembly, reverse the disassembly
procedure.
5-47
BELT DRIVE
ENG
REMOVING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT
1. Remove:
primary sheave nut 1
secondary sheave nut 2
NOTE:
While holding the primary and secondary
sheave with the sheave holder, loosen the nut.
Sheave holder
90890-01481
2. Install:
bolts 1
NOTE:
Insert M6 bolts (more than 45 mm) into the holes
of the secondary sheave assembly, and then
thighten the bolts to open the secondary sheave
assembly.
3. Remove:
primary sliding sheave 2
secondary sheave assembly 1
V-velt 3
NOTE:
Before removal, apply a and b alignment
marks.
Align these marks during reassembly.
Remove the primary sliding sheave, secondary sheave assembly and V-belt together.
4. Remove:
primary fixed sheave 1
5-48
BELT DRIVE
ENG
DISASSEMBLING THE PRIMARY SHEAVE
1. Remove:
cam 1
slider 2
weight 3
DISASSEMBLING
THE
SHEAVE
1. Remove:
secondary sheave nut 1
SECONDARY
NOTE:
Install the sheave spring compresser 2 onto
the secondary sheave as shown. Then, compress the spring, and remove the secondary
pulley nut 1 with locknut wrench 3 .
Sheave spring compressor 2
90890-04134
Locknut wrench 3
90890-01348
Sheave fixed block 4
90890-04135
CHECKING THE V-BELT
1. Check:
V-belt 1
Cracks/damage/wear Replace.
Grease/oil Check the primary and secondary pulleys.
2. Measure:
V-belt width 2
Out of specification Replace.
V-belt width
32 mm
<Limit>: 30.5 mm
5-49
BELT DRIVE
ENG
CHECKING THE PRIMARY SHEAVE
1. Check:
primary sliding sheave 1
primary fixed sheave 2
Cracks/damage/wear Replace the primary sliding sheave and primary fixed
sheave as a set.
CHECKING THE WEIGHT
1. Check:
weight 1
Cracks/wear/scaling/chipping Replace.
Out of specification Replace.
Weight outside diameter:
25.0 mm
<Limit>: 24.5 mm
CHECKING THE SLIDER
1. Check:
slider 1
Cracks/damage/wear Repalce
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
secondary fixed sheave
secondary sliding sheave
Cracks/damage/wear Replace the secondary fixed and sliding sheaves as a set.
2. Check:
torque cam groove 1
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
guide pin 2
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
5-50
BELT DRIVE
ENG
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
primary fixed sheave
primary sliding sheave
collar
weight
slider
cam
stopper
NOTE:
Remove any excess grease.
2. Install:
weight 1
slider 2
cam 3
NOTE:
Before installing the weights, lubricate the inside and outside of each weight with Shell BT
grease 3.
Put in approximately 80 g of grease.
Recommended lubricant
Shell BT grease 3
3. Install:
primary sliding sheave cap 1
6.0 Nm (0.6 mkg)
collar 2
5-51
BELT DRIVE
ENG
EAS00324
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
secondary fixed sheave’s outer and inner
surface 1
secondary sliding sheave’s outer and inner
surface 2
grease nipple groove
oil seals
bearings
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
2. Install:
secondary sliding sheave 1
3. Install:
guide pin 2
4. Lubricate:
guide pin groove 3
oil seal New
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
5. Install:
spring seat 1
compression spring 2
upper spring seat 3
NOTE:
Attach the sheave spring compresser 2 onto
the secondary sheave as shown.
Then compress the spring, and tighten the secondary sheave nut 1 with locknut wrench 3 .
5-52
BELT DRIVE
ENG
Sheave spring compresser 2
90890-04134
Locknut wrench 3
90890-01348
Sheave fixed block 4
90890-04135
6. Tighten:
nut
90 Nm (9.0 mkg)
INSTALLING THE BELT DRIVE
1. Install:
primary fixed sheave 1
V-belt 2
secondary sheave assembly 3
CAUTION:
Do not allow grease to contact the V-belt and
secondary pulley
NOTE:
When installing the belt, screw M6 (more than
45 mm) bolts 4 to spread apart the secondary
sheave and then install the belt. Make sure the
belt pullout direction is correct.
Install the V-belt and secondary sheave assembly onto the primary sheave side.
Align the a and b during reassembly.
2. Tighten:
secondary sheave nut 1
90 Nm (9.0 mkg)
NOTE:
While holding the secondary sheave with the
primary /secondary sheave holder 2 , tighten
the secondary sheave nut 1 .
Sheave holder
90890-01481
3. Install:
primary sliding sheave 1
spacer
primary sheave nut 2
5-53
BELT DRIVE
4. Tighten:
primary sheave nut 1
ENG
160 Nm (16.0 mkg)
CAUTION:
Before tightening the nut to remount the
primary sheave, make sure that the serration of the cam brinells deeply into the
serration of the crankshaft.
Also, fully tighten the nut as far as the
clepths while holding down the cam so as
not to allow the serration to disengage.
Apply grease to the thread and seat of the
primary sheave nut.
Recommended lubricant
Shell BT grease 3
NOTE:
While holding the primary sheave with the primary/secondary sheave holder 2 , tighten the
primary sheave nut 1 .
Sheave holder
90890-01481
5-54
CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the cylinder and piston
Cylinder head
Timing chain guide (exhaust side)
Cylinder
Cylinder gasket
Dowel pin
Circlip
Piston pin
Piston
Piston ring set
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
1
1
1
2
4
2
2
2
For installation, reverse the removal
procedure.
5-55
CYLINDER AND PISTON
ENG
REMOVING THE CYLINDER AND PISTON
The following procedure applies to all of the pistons.
1. Remove:
piston pin clip 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 4 .
Piston pin puller
90890-01304
2. 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.
5-56
ENG
CYLILNDER AND PISTON
EAS00261
CHECKING THE CYLINDER AND PISTON
1. Check:
piston wall
cylinder wall
Vertical scratches Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
bore gauge.
a 10 mm from the top of the cylinder
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Cylinder bore gauge
90890-03017
Cylinder bore “C”
66.0066.01mm
Max. taper “T”
0.05 mm
Out of round “R”
0.05 mm
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
Micrometer
90890-03008
b. 9 mm from the bottom edge of the piston
Piston size “P”
Standard
65.965 65.980 mm
d. If out of specification, replace the piston and
piston rings as a set.
5-57
CYLILNDER AND PISTON
ENG
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
0.020 0.045 mm
<Limit>: 0.15 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
<Limit>: 0.115 mm
2nd ring
0.020 0.055 mm
<Limit>: 0.105 mm
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the piston crown as shown.
a 10 mm
5-58
CYLINDER AND PISTON
ENG
3. Measure:
piston ring end gap
Out of specification Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring end gap
Top ring
0.15 0.25 mm
<Limit>: 0.5 mm
2nd ring
0.4 0.5 mm
<Limit>: 0.75 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 a
Out of specification Replace the piston
pin.
Piston pin outside diameter 1
15.991 16.000 mm
3. Measure:
piston pin bore diameter b (in the piston)
Out of specification → Replace the piston
pin.
Piston pin bore diameter
16.002 16.013 mm
5-59
CYLINDER AND PISTON
ENG
4. Calculate:
piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston
pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter (in the piston)
–
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.002 0.022 mm
<Limit>: 0.072 mm
EAS00271
INSTALLING THE PISTONS AND CYLINDERS
The following procedure applies to all of the pistons and cylinders.
1. Install:
top ring
2nd ring
oil ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
A Intake side
5-60
CYLINDER AND PISTON
ENG
3. Lubricate:
piston
piston pin
Recommended lubricant
Engine oil
4. Install:
piston 3
piston pin 2
piston pin clip New 1
NOTE:
Apply engine oil onto the piston pin.
Make sure that the arrow mark a on the piston
points towards the exhaust side of the cylinder.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
5. Install:
gasket New 1
dowel pins
6. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
cylinder
timing chain guide (exhaust side)
NOTE:
Pass the timing chain through the timing chain
cavity.
5-61
CRANKCASE AND CRANKSHAFT
ENG
CRANKCASE AND CRANKSHAFT
CRANKSHAFT ASSEMBLY
58 Nm (5.8 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
Order
Job/Part
Q’ty
1
2
Removing the crankshaft assembly
Engine
Cylinder head
Cylinder
Piston
Belt drive
Starter clutch
Generator
Clutch
Oil pump
Timing chain
Timing chain guide (intake side)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “CYLINDER AND PISTON”.
Refer to “BELT DRIVE”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “CLUTCH”.
Refer to “OIL PUMP”.
1
1
5-62
CRANKCASE AND CRANKSHAFT
ENG
58 Nm (5.8 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
Order
3
4
5
6
Job/Part
Crankcase (left)
Crankshaft
Cylinder (barancer)
Main journal bearing
Q’ty
Remarks
1
1
1
2
For installation, reverse the removal
procedure.
5-63
CRANKCASE AND CRANKSHAFT
ENG
CONNECTING ROD
16 Nm (1.6 mSkg) + 90_
16 Nm (1.6 mSkg) + 90_
60 Nm (6.0 mSkg)
Order
1
2
3
4
5
6
7
Job/Part
Removing the connecting rod
Connecting rod
Connecting rod (balancer)
Crankshaft
Connecting rod cap
Circlip
Piston pin
Balancer piston
Q’ty
Remarks
Remove the parts in the order listed.
2
1
1
3
2
1
1
For installation, reverse the removal
procedure.
5-64
CRANKCASE AND CRANKSHAFT
ENG
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).
The numbers embossed on the crankcase indicate the crankcase tightening sequence.
2. Remove:
right crankcase
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
3. Remove:
dowel pins
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.
5-65
CRANKCASE AND CRANKSHAFT
ENG
EAS00387
REMOVING THE CRANKSHAFT JOURNAL
BEARING
1. Remove:
S crankshaft assembly
S crankshaft main journal bearings 1
NOTE:
Remove the main journal bearing by the plane
bearing installer/remover 2 .
Plane bearing installer/remover
90890-04139
NOTE:
Identify the position of each crankshaft main
journal bearing so that it can be reinstalled in its
original place.
EAS00391
REMOVING THE CONNECTING RODS
The following procedure applies to all of the
connecting rods.
1. Remove:
S connecting rod 1
S big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
EB413404
CHECKING THE CRANKSHAFT AND CONNECTING RODS
1. Measure:
S crankshaft runout
Out of specification ! Replace the crankshaft.
Crankshaft runout
Less than 0.05 mm
2. Check:
S crankshaft journal surfaces
S crankshaft pin surfaces
S bearing surfaces
Scratches/wear ! Replace the crankshaft.
3. Measure:
S crankshaft-pin-to-big-end-bearing
clearance
Out of specification ! Replace the big end
bearings.
5-66
CRANKCASE AND CRANKSHAFT
ENG
Crankshaft-pin-to-big-end-bearing
clearance
0.026 0.050 mm
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage, the big
end bearings must be installed in their original positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the connecting rod and the big end lower bearing
into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.
c. Put a piece of Plastigauge on the crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
Apply molybdenum disulfide grease onto the
bolts, threads, and nut seats.
Make sure that the “Y” mark 2 on the connecting rod faces towards the left side of the crankshaft.
Make sure that the characters 3 on both the
connecting rod and connecting rod cap are
aligned.
e. Tighten the connecting rod nuts.
5-67
CRANKCASE AND CRANKSHAFT
ENG
CAUTION:
S When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
S After tightening the connecting rod nut to
the specified torque, turn the connecting
rod nut another+90_.
Refer to “INSTALLING THE CONNECTING
RODS”.
Connecting rod nut
16 Nm (1.6 mSkg)+90_
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS”.
g. Measure the compressed Plastigauge
width 1 on each crankshaft pin.
If the clearance is out of specification, select
replacement big end bearings.
4. Select:
S big end bearings (P1,P2,P3)
NOTE:
S The numbers 1 stamped into the crankshaft
web and the numbers 2 on the connecting
rods are used to determine the replacement
big end bearing sizes.
S “P1,P2” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and the
crankshaft web “P1” numbers are “4” and “2” respectively, then the bearing size for “P1” is:
Bearing size for “P1”:
“P1” (connecting rod) – “P1”
(crankshaft web) =
4 – 2 = 2 (black)
5-68
CRANKCASE AND CRANKSHAFT
ENG
BEARING COLOR CODE
1
blue
2
black
3
brown
4
green
5. Measure:
crankshaft-journal-to-crankshaft-journalbearing clearance.
Out of specification Replace the crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance
0.04 0.082 mm
The following procedure applies to all of the
journal bearing.
CAUTION:
On the journal, the larger value is used as a
basis for calculation of the oil clearance, and
on the journal bearing, the smaller value is
used.
a. Clean the surface of main journal and journal
bearings.
b. Check the bearing surface. If the bearing surface is worn or scratched, the bearings
should be replace.
NOTE:
If either of the right or left journal bearing is worn
or scratched, both bearings should be replaced
as a set.
c. Measure the outside diameter a of each
main journal at two places. If it is out of specification, replace the crankshaft.
d. Measure the inside diameter b of each journal bearing at two places.
5-69
CRANKCASE AND CRANKSHAFT
ENG
e. If journal bearing inside diameter is “45.03”
and crankshaft journal outside diameter is
“44.98”, then the main journal oil clearance
is:
Main journal oil clearance:
Journal bearing inside diameter –
Main journal outside diameter =
45.03 – 44.98 = 0.05 mm
If the oil clearance is out of specification, select a replacement bearings.
6. Select:
crankshaft journal bearings (J1, J2)
NOTE:
The numbers 1 stamped into the crankshaft
web and the numbers 2 on the crankcase are
used to determine the replacement crankshaft
journal bearing size.
“P1” refer to the bearings shown in the crankshaft illustration.
For example, if the crankcase “J1” and the
crankshaft web “J1” numbers are “4” and “2”
respectively, then the bearing size for “J1” is:
Bearing size for “J1”:
“J1” (crankcase) – “J1”
(crankshaft web) = 4 – 2 = 2 (black)
BEARING COLOR CODE
5-70
1
blue
2
black
3
brown
4
green
CRANKCASE AND CRANKSHAFT
ENG
INSTALLING THE CRANKSHAFT JOURNAL
BEARING
1. Attach:
S crankshaft journal bearings
NOTE:
S Attach the crankshaft journal bearing to the installer 1 .
Plane bearing installer/remover
90890-04139
2. Install:
S crankshaft journal bearings 2
NOTE:
S align the projection a on the bearing with the
projection b on the crankcase.
S Place an iron 3 plate beneath the crankcase
and press fit until the end of the plain bearing
installer touches the iron plate.
INSTALLING THE CONNECTING RODS
1. Install:
S connecting rod bearings 1
NOTE:
S Align the projection a of the bearings with the
notches b in the connecting rod cap.
S Install each bearing in its original place.
2. Install:
S connecting rods 1
NOTE:
S The stamped “Y” mark a on the connecting
rods should face towards the left side of the
crankcase.
S Install each connecting rod in its original place.
5-71
CRANKCASE AND CRANKSHAFT
ENG
3. Install:
S Connecting rod cap 1
NOTE:
Be sure that the characters on the side of the
cap and connecting rod are aligned.
4. Tighten:
S nuts (connecting rod cap)
16 Nm (1.6 mSkg)+90_
NOTE:
Apply molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.
a. Replace the connecting rod bolts and nuts
with new ones.
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts.
d. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
e. Tighten the nut further to reach the specified
angle (90_).
WARNING
When the nut is tightened more than the specified angle, do not loosen the nut and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
5-72
CRANKCASE AND CRANKSHAFT
5. Install:
balancer connecting rod
connecting rod cap
ENG
60 Nm (6.0 mkg)
CAUTION:
When tightening the nuts be sure to use an
F-type torque wrench.
Without pausing, tighten to full torque
specification. Apply continuous torque between 57 and 63 Nm (5.7 6.3 mkg). Once
you reach 57 Nm (5.7 mkg) DO NOT STOP
TIGHTENING until final torque is reached. If
the tightening is interrupted between 57
and 63 Nm (5.7 6.3 mkg) loosen the nut
to less than 57 Nm (5.7 mkg) and start
again.
INSTALLILNG THE CRANKSHAFT
1. Install:
crankshaft assembly 1
balanser piston cylinder 2
58 Nm (5.8 mkg)
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, apply
grease onto the oil seal lips and apply engine oil onto each bearing.
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
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.
3. Install:
dowel pins
crankcase (left)
5-73
TRANSMISSION
ENG
TRANSMISSION
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “CRANKCASE AND
CRANKSHAFT”.
Removing the transmission
Crankcase (left)
1
2
3
4
5
6
7
8
9
10
Secondary shaft
Main axle
Primary driven gear
First pinion gear
Washer
Drive axle
First wheel gear
Circlip
Bearing
Oil seal
Remarks
1
1
1
1
1
1
1
1
5
2
For installation, reverse the removal
procedure.
5-74
TRANSMISSION
ENG
REMOVING THE TRANSMISSION
1. Remove:
crankcase (left)
Refer to “CRANKCASE AND CRANKSHAFT”.
2. Remove:
secondary shaft 1
main axle 2
drive axle 3
primary driven gear 4
first pinion gear 5
first wheel gear 6
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
main axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the main
axle.
Max. main axle runout
0.08 mm
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
Max. drive axle runout
0.08 mm
3. Measure:
secondary shaft runout
(with a centering device and dial gauge 1 )
Out of specification Replace the secondary shaft.
Max. secondary shaft runout limit
0.08 mm
5-75
TRANSMISSION
ENG
4. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(-s).
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Damage/bends/looseness Replace.
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
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.
3. Install:
dowel pins
crankcase (left)
5-76
CHAIN DRIVE
ENG
CHAIN DRIVE
30 Nm (3.0 mkg)
23 Nm (2.3 mkg)
7 Nm (0.7 mkg)
100 Nm (10.0 mkg)
40 Nm (4.0 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE TRANSFER
OIL” in chapter 3.
Refer to “REAR SHOCK ABSORBER” in
chapter 4.
Refer to “REAR WHEEL AND BRAKE
DISC” in chapter 4.
Removing the chain drive assembly
Chain drive oil
Rear shock absorber
Rear wheel
1
2
3
4
5
6
Rear footrest (right)
Cover
Swingarm
Nut
Washer
Pivot shaft
Remarks
1
1
1
1
1
1
5-77
CHAIN DRIVE
30 Nm (3.0 mkg)
ENG
23 Nm (2.3 mkg)
7 Nm (0.7 mkg)
100 Nm (10.0 mkg)
40 Nm (4.0 mkg)
Order
7
8
9
10
11
12
Job/Part
Collar
Oil seal
Bearing
Chain drive assembly
Holder
O ring
Q’ty
Remarks
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-78
CHAIN DRIVE
ENG
10 Nm (1.0 mkg)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Disassembling the chain drive
assembly
Chain drive case (outer)
Secondary drive chain
Secondary drive gear
Secondary driven gear
Primary drive chain
Primary drive gear
Primary driven gear
Bearing
Oil seal
Chain drive case (inner)
Retainer
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
5
4
1
1
For assembly, reverse the disassembly
procedure.
5-79
TRANSFER
ENG
CHECKING THE SWINGARM
1. Check:
swingarm 1
Damage/wear Replace.
2. Check:
pivot shaft 1
collar
bearing
oil seal
Damage/wear Replace.
CHECKING THE CHAIN DRIVE ASSEMBLY
1. Check:
primary drive chain 1
secondary drive chain 2
Damage/stiffness Replace the drive
chain and its respective gears as a set.
2. Check:
primary /secondary drive gear 3
primary /secondary driven gear 4
Damage/wear Replace the respective
drive gears and respective drive chains as a
set.
5-80
CHAIN DRIVE
ENG
INSTALLING THE CHAIN DRIVE
1. Install:
chain drive assembly
swingarm
2. Tighten:
swingarm bolt
40 Nm (4.0 mkg)
3. Adjust:
pivot shaft
NOTE:
With your fingers, screw in the pivot shaft until
it touches the collar and then tighten the pivot
shaft to the tightening torque.
Tighten the nut to the tightening torque.
Install the shock absorber and rear wheel after
the swingarm is installed.
4. Fill:
chain drive oil
5. Check:
chain drive oil level
Refer to “CHECKING THE TRANSFER OIL
LEVEL” in chapter 3.
5-81
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLILNG THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-3
6-4
6-4
6-4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
COOL
RADIATOR
COOL
COOLING SYSTEM
RADIATOR
RADIATOR AND OIL COOLER
63 Nm (6.3 mkg)
17 Nm (1.7 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
Removing the radiator and oil cooler
Footrest board
Lower cover
Side panel
Leg shield
Coolant
Inner fender (rear)
Radiator hose
Radiator outlet hose
Coolant reservoir tank
Coolant reservoir hose
Thermo
6-1
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL” in
chapter 3.
Drain.
1
2
1
1
1
1
RADIATOR
63 Nm (6.3 mkg)
Order
7
8
9
10
11
12
13
14
15
COOL
17 Nm (1.7 mkg)
Job/Part
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
Radiator
Radiator fan coupler
Radiator fan
Oil cooler inlet hose
Oil cooler outlet hose
Oil filter
Bolt
Oil cooler
O-ring
For installation, reverse the removal
procedure.
6-2
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
Cracks/damage Replace.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Radiator cap opening pressure
107.9 137.3 kPa
(1.08 1.37 kg/cm2)
a. Install the radiator cap tester 1 and adapter
2 onto 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.
6-3
RADIATOR
COOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:
cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
cooling system
Leaks Repair or replace any faulty part.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
EAS00458
CHECKING THE OIL COOLER
1. Check:
oil cooler
Cracks/damage Replace.
2. Check:
oil cooler inlet hose
oil cooler outlet hose
Cracks/damage/wear Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:
mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
O-ring New
oil cooler 1
bolt 2
63 Nm (6.3 mkg)
NOTE:
Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.
Make sure that the O-ring is positioned properly.
Align the projection a on the oil cooler with the
slot b in the crankcase.
6-4
RADIATOR
COOL
3. Bend the lock washer tab along a flat side of
the bolt.
4. Fill:
cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Check:
cooling system
Leaks Repair or replace any faulty part.
6. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-5
THERMOSTAT
COOL
THERMOSTAT
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the thermostat
Footrest board
Leg shield
Side panel
Lower cover
Coolant
Carburetor assembly
Radiator outlet hose
Thermo switch
Thermostat cover
Thermostat
Refer to “COVER AND PANEL” in
chapter 3.
Drain.
Refer to “CARBURETORS” in chapter 7.
1
1
1
1
Disconnect.
For installation, reverse the removal
procedure.
6-6
THERMOSTAT
COOL
EAS00462
CHECKING THE THERMOSTAT
1. Check:
S thermostat 1
Does not open at 80 84_C
Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
1
2
3
4
A
B
Thermostat
Thermometer
Water
Container
Fully closed
Fully opens
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
mm
82 ± 2_C
2. Check:
S thermostat housing cover
S thermostat housing
Cracks/damage Replace.
95_C
EAS00467
INSTALLING THE THERMOSTAT
1. Install:
S thermostat
NOTE:
Install the thermostat with its breather hole a
facing up.
6-7
THERMOSTAT
2. Install
thermostat cover
COOL
10 Nm (1.0 mkg)
NOTE:
Befor installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat of
litium soap base grease.
3. Fill:
cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:
cooling system
Leaks Repair or replace any faulty part.
5. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-8
WATER PUMP
COOL
WATER PUMP
10 Nm (1.0 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the water pump
Footrest board
Lower cover
Side panel (left)
Leg shield
Coolant
Pipe 1
O-ring
Water pump
Pipe 2
1
1
1
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
6-9
WATER PUMP
Order
Job/Part
Q’ty
4
5
6
7
8
Water pump cover
Cir clip
Impeller shaft
(along with the impeller)
Water pump seal
Bearing
Oil seal
O-ring
Water pump housing
Remarks
Disassemble the parts in the order listed.
NOTE:
It is not necessary to remove the impeller
shaft, unless the coolant level is extremely
low or coolant contains to engine oil.
Disassembling the water pump
1
2
3
COOL
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
6-10
WATER PUMP
COOL
EAS00474
CHECKING THE WATER PUMP
1. Check:
water pump housing cover 1
water pump housing 2
impeller shaft 3
water pump seal 4
oil seal 5
Cracks/damage/wear Replace.
2. Check:
water pump seal 1
oil seal
Cracks/damage/wear Replace.
3. Check:
bearing
Roughness Replace.
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
oil seal New
(to the water pump housing)
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:
bearing 1
6-11
WATER PUMP
COOL
3. 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
90890-04078 4
90890-04058 5
Yamaha bond No.1215
90890-85505
A Push down
4. 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.
5. 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.
Max. impeller shaft tilt
0.15 mm
1 Straightedge
2 Impeller
6-12
CARB
CHAPTER 7
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLILNG THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-5
7-7
7-8
7-9
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . .
7-13
7-13
7-13
7-14
7-15
7-10
7-12
CARB
CARBURETORS
CARB
CARBURETORS
CARBURETORS
10 Nm (1.0 mkg)
85 Nm (8.5 mkg)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Remarks
Remove the parts in the order listed.
Removing the carburetors
Footrest board
Leg shield
Center cover
Silencer
Fuel hose
Throttle position sensor coupler
Coolant hose
Carburetor joint cramp
Throttle cable
Carburetor assembly
Heat protector
Intake manifold
Refer to “COVER AND PANEL” in
chapter 3.
1
1
1
4
2
1
1
2
Disconnect.
Loosen.
For installation, reverse the removal
procedure.
7-1
CARBURETORS
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
CARB
Remarks
Remove the parts in the order listed.
Separating the carburetors
Bracket
Throttle stop screw
Throttle stop screw bracket
Spring
Pipe
Hose joint
Float chamber air vent hose
Throttle position sensor
1
1
1
1
2
1
1
1
For installation, reverse the removal
procedure.
7-2
CARBURETORS
Order
Job/Part
Q’ty
10
11
Remarks
Disassembly 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
CARB
1
1
1
1
1
1
1
1
1
1
1
Starter plunger
Vacuum chamber cover
Piston valve spring
Jet needle kit
Piston valve
Screw plug
Pilot screw
Fuel drain bolt
Float chamber cover
Float chamber gasket
Float pivot pin
7-3
CARBURETORS
Order
12
13
14
15
16
17
Job/Part
Q’ty
CARB
Remarks
1
1
1
1
1
1
Float
Needle valve
Needle valve seat
Main jet
Main jet holder
Pilot jet
For assembly, reverse the disassembly
procedure.
7-4
CARBURETORS
CARB
EB600031
CHECKING THE CARBURETORS
The following procedure applies to all of the carburetors.
1. Check:
carburetor body
float chamber
Cracks/damage Replace.
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleumbased
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket 1
Cracks/damage/wear Replace.
5. Check:
float
Damage Replace.
6. Check:
needle valve 1
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.
7-5
CARBURETORS
CARB
8. Check:
piston valve 1
Damage/scratches/wear Replace.
piston valve diaphragm 2
Cracks/tears Replace.
9. Check:
vacuum chamber cover 1
piston valve spring 2
Cracks/damage Replace.
10. Check:
jet needle 1
main jet 2
main jet holder 3
pilot jet 4
pilot screw 5
pilot air jet 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:
pipes 1
hose joints 2
Cracks/damage Replace.
Obstruction Clean.
Blow out the pipes with compressed air.
7-6
CARBURETORS
CARB
13. Check:
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
EAS00488
ASSEMBLING THE CARBURETORS
The following procedure applies to all of the carburetors.
CAUTION:
Before assembling the carburetors, wash
all of the parts in a petroleum-based solvent.
Always use a new gasket.
1. Install:
O-ring New
washer
pilot screw spring
pilot screw 1
Pilot screw
2 turns out
2. Install:
piston valve
jet needle kit
jet needle holder
piston valve spring
vacuum chamber cover
NOTE:
Insert the end of the piston valve spring onto
the spring guide on the vacuum chamber cover.
Align the tab on the piston valve diaphragm
with the recess in the carburetor body.
7-7
CARBURETORS
CARB
3. Install:
pipe
fuel feed pipes
spring
float chamber air vent hoses
hose joint
copper washer
throttle stop screw
NOTE:
Install the throttle valve lever 1 onto carburetors #1, and #2 between the spring 2 and synchronizing screw 3 .
4. Install:
auto choke unit 1
EB600051
INSTALLING THE CARBURETORS
1. Adjust:
carburetor synchronization
Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3.
2. Adjust:
engine idling speed
Engine idling speed
1,150 1,250 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.
7-8
CARBURETORS
CARB
EAS00496
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
fuel level a
Out of specification Adjust
Fuel level (below the float
chamber mating surface)
5.5 6.5 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 to the fuel drain
pipe.
Fuel level gauge
90890-01312
d. Loosen the fuel drain screw.
e. Hold the fuel level gauge vertically next to the
float chamber.
f. Measure the fuel level a .
NOTE:
Fuel level readings should be equal on both
sides of the carburetor assembly.
2. Adjust:
fuel level
a. Remove the carburetor assembly.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by 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.
7-9
CARBURETORS
CARB
EB600071
CHECKING
AND
ADJUSTING
THROTTLE POSITION SENSOR
THE
NOTE:
S Before adjusting the throttle position sensor,
the engine idling speed should be properly adjusted.
1. Check:
S throttle position sensor
a. Disconnect the throttle position sensor coupler.
b. Connect the pocket tester (Ω
1k) to the
throttle position sensor.
Tester positive lead blue 1
Tester negative lead black 2
c. Check the throttle position sensor resistance
“R1”.
Out of specification Replace the throttle
position sensor.
Throttle position sensor
resistance “R1”
4 X 6 kΩ at 20_C
(blue – black)
d. Connect the pocket tester (Ω
throttle position sensor.
1k) to the
Tester positive lead yellow 3
Tester negative lead black 2
e. While slowly opening the throttle, check that
the throttle position sensor resistance “R2” is
within the specified range.
Out of specification Replace the throttle
position sensor.
Throttle position sensor
resistance “R2”
0.56 X 0.84 kΩ to 3.01 X
4.51 kΩ at 20_C
(yellow – black)
2. Adjust:
S throttle position sensor angle
a. Loosen the throttle position sensor screws
1.
b. Turn the throttle position sensor in direction
a or b until the specified closed-throttle resistance is indicated on the pocket tester.
7-10
CARBURETORS
CARB
Closed-throttle resistance
0.56 0.84 kΩ at 20°C
(yellow – black)
c. Tighten the throttle position sensor screws.
NOTE:
Remove the pocket tester leads and connect
the throttle position sensor coupler.
7-11
CARBURETORS
CARB
CHECKING THE FUEL PUMP
1. Check:
fuel pump 1
a. Disconnect the fuel pump to carburetor fuel
hose 2 from the carburetor.
b. Place a container under the end of the fuel
hose.
c. Start the engine and check if fuel folws from
the fuel hose 2 .
Fuel folws.
Fuel pump is OK.
F el does not flow.
Fuel
flow
Replace
p
the fuel
pump.
d. Stop The engine and check if the fuel stops
flowing from the fuel hose 2 .
7-12
Fuel stops flowing.
Fuel pump is OK.
F el flows.
Fuel
flows
Replace
p
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.
(This “low-boost close” function is the same as
on the FZR600 (3HW).)
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 filter
B To the reed valve
C To the carburetor joint
7-13
AIR INDUCTION SYSTEM
CARB
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
10 Nm
(1.0 mkg)
1 Reed valve
2 Air filter
3 Air cutoff valve
7-14
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:
reed valve 1
reed valve stopper
reed valve seat
Cracks/damage Replace the reed valve.
3. Measure:
reed valve bending a
Out of specification Replace the reed
valve.
Maximum reed valve bending
0.4 mm
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
7-15
ELEC
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHECKING THE 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
8-10
8-12
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
ELECTRICAL STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT OFF SYSTEM OPERATION . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . .
8-17
8-17
8-19
8-20
8-23
8-25
8-26
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
8-31
8-31
8-32
8-34
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-37
8-37
8-39
8-39
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
ELEC
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-50
8-50
8-51
8-52
8-54
AUTO CHOKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
ELECTRICAL COMPONENTS
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
10
11
12
Front brake light switch
Rear brake light switch
Thermo unit
Fuel sender
Starting circuit cut-off relay
Fuel pump relay
Flasher relay
Battery
Fuse box
Starter relay
Rectifire/ regulator
Sidestand switch
13
14
15
16
17
18
19
20
21
22
Pickup coil
Stator coil
Thermo switch
Radiator fan
Speed sensor
Horn
Throttle position sensor
Ignition coil
Lean angle cut-off switch
Main switch
8-1
ELEC
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
ELEC
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS
1
2
3
4
5
6
Headlight couplers
Handlebar switch couplers
Lean angle cut-off switch
Meter
Horns
Speed sensor
8-2
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
1
2
3
4
5
Main switch
Ignition coils
Fuel sender
Fuel pump
Reset coupler
6
7
8
9
Starting circuit cut-off relay
Turn signal relay
Pump relay
Rectifier/ regulator
1
2
3
4
5
Radiator fan motor
Thermo switch (fan motor)
Sidestand switch
Auto chokes
Thermo switch (auto choke)
6
7
8
9
Throttle position sensor
Thermo unit
Pickup coil
A.C. magneto
8-3
ELEC
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS
1
2
3
4
5
Fuse box
Battery negative lead
Battery positive lead
Tail/ brake light coupler
Starter relay
6 Box light
8-4
ELEC
INSTRUMENT FUNCTIONS
ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Engine oil change indicator light
(display functions based on the oil indicator)
The display functions based on the engine oil
change indicator can be divided into three major
types:
1. Bulbs disconnections confirmation (light ON)
by main switch ON.
Main switch on activates the oil indicator for
1.4 seconds to allow the user to check if bulb
disconnections have occurred.
2. Oil replacement timing notification (light on)
Turn the key to “ON”.
Hold the reset botton pushed for two to five
seconds.
Release the reset button, and the oil change
indicator light will go off.
NOTE:
If the engine oil is changed before the oil change
indicator light comes on (i.e. before the periodic
oil change interval has been reached), the indicator light must be reset after the oil change for
the next periodic oil change to be indicated at
the correct time. To reset the oil change indicator light before the periodic oil change interval
has been reached, follow the above procedure,
but note that the indicator light will come on for
1.4 seconds after releasing the reset button,
otherwise repeat the procedure.
Setting the indicator light on distance
The indicator initially light up at 1,000 km.
It light up at 5,000 km next time.
Subseguently, the indicator repeat lighting
up every 5,000 km after it has been reset.
Detection of initial reset switch on operation
before arrival at 1,000 km. (When the indicator is off)
When 2 5 second reset switch on is detected, the indicator will light on for 1.4 seconds and initial 1,000 km judgment will not
occur (the indicator will not light on at 1,000
km).
Detection of reset switch on operation during
the time from initial 1,000 km judgment to arrival at 5,000 km.
(When the indicator is light on)
When 2 5 second reset switch on is detected, the indicator will go off.
Cumulative distance data will not be reset.
8-5
INSTRUMENT FUNCTIONS
ELEC
Detection of the second and subsequent reset switch on operations with the indicator
light off when 2 5 second reset switch on is
cletected, the indicator will light on for 1.4 seconds and then after it has gone off, cumulative distance data will be reset.
Detection of the second and subsequent reset switch on operations with the indicator on
when 2 5 second reset switch on is detected, the indicator will go off and cumulative distance data will be reset.
3. Fault code display (blinks) based on self
diagnostics.
If it detects the follwing faults, the igniter will
blink the display of a 5 second ON/OFF code
and then blink the engine oil chamge indicator light at intervals of 3.0 seconds. If multiple
faults are detected, the appropriate faults
codes will be displayed in order of occurrence.
Detected fault
Throttle position sensor
Speed sensor
Lean angle cutt-off switch
NOTE:
The fault code is reset by main switch off (igniter unit power off). Also, the display off the fault
code is terminated with the recovery of the circuits from the fault.
8-6
INSTRUMENT FUNCTIONS
ELEC
V-belt indicator light
Indicates V-belt change timing every 20,000 km
(the V-belt indicator light reset connecter is located in the side cover at right).
When change the V-belt, temporarily disconnect the short connector of the double-pole for
about 2 5 seconds and then reconnect the
connecter to complete the resetting operation.
8-7
SWITCHES
ELEC
EAS00730
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
CAUTION:
Never insert the tester probes into the coupler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between brown/blue and
red, and between blue and blue/red 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
Pass switch
Dimmer switch
Horn switch
Turn signal switch
Rear brake light switch
Main switch
7
8
9
10
11
12
Start switch
Engine stop switch
Light switch
Front brake light switch
Sidestand switch
Box light switch
8-9
CHECKING THE BULBS AND BULB SOCKETS
ELEC
EAS00732
CHECKING THE
BULB SOCKETS
BULBS
AND
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity between the terminals.
Damage/wear Repair or replace the bulb,
bulb socket or both.
Improperly connected Properly connect.
Incorrect continuity reading Repair or replace
the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
Bulbs A and B are used for headlights and
usually use a bulb holder which must be detached before removing the bulb. The majority
of these bulbs can be removed from their respective socket by turning them counterclockwise.
Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.
CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
bulb
8-10
CHECKING THE BULBS AND BULB SOCKETS
ELEC
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bulb (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , 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.
8-12
IGNITION SYSTEM
ELEC
DAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
6
7
8
19
20
21
23
35
71
8-13
Pickup coil
Main switch
Battery
Main fuse
Igniter unit
Ignition coil
Spark plug
Lean angle cut-off switch
Engine stop switch
Ignition fuse
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. Main and ignition fuses
2. Battery
3. Spark plugs
4. Ignition spark gap
5. Spark plug cap resistance
6. Ignition coil resistance
7. Pickup coil resistance
8. Main switch
9. Engine stop switch
10. Sidestand switch
11. Lean angle cut-off switch
12. Wiring connections
(of the entire ignition system)
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
S Clean the battery
terminals.
S Recharge or replace
the battery.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Leg shield
2) Footrest board
S Troubleshoot with the following special
tool(-s).
EAS00741
3. Spark plugs
S The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in CHAPTER 3.
Ignition checker
90890-06754
Pocket tester
90890-03112
Standard spark plug
CR7E (NGK)
Spark plug gap
0.7 0.8 mm
EAS00738
1. Main and ignition fuses
S Is the spark plug in good condition, it is of the
correct type, and its gap within specification?
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main and ignition fuses OK?
YES
NO
YES
NO
NO
Re-gap or replace
the spark plug.
Replace the fuse(-s).
8-14
ELEC
IGNITION SYSTEM
EAS00743
Spark plug cap resistance
10 kΩ at 20_C
4. Ignition spark gap
S The following procedure applies to all of the
spark plugs.
S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 as shown.
S 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 start switch
and gradually increase the spark gap until a
misfire occurs.
S Is the spark plug cap OK?
YES
NO
Replace the spark
plug cap.
EAS00747
6. Ignition coil resistance
S The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil leads from the
wireharness.
S Connect the pocket tester (Ω
1) to the
ignition coil as shown.
Tester positive probe ! red/black
Tester negative probe ! orange (gray)
Minimum ignition spark gap
0.8 mm
S Is there a spark and is the spark gap within
specification?
NO
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
1k) to the
ignition coil as shown.
S Measure the secondary coil for the specified
resistance.
EAS00745
5. Spark plug cap resistance
S The following procedure applies to all of the
spark plug caps.
S Remove the spark plug cap.
S Connect the pocket tester (Ω 1k range) to
the spark plug cap as shown.
S Measure the spark plug cap resistance.
Tester posltlve probe ! red/black
Tester negative probe ! spark plug lead
8-15
IGNITION SYSTEM
ELEC
EAS00750
Secondary coil resistance
12 X 18 kΩ at 20_C
9. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
S Is the ignition coil OK?
YES
NO
YES
Replace the ignition
coil.
NO
Replace the right
handlebar switch.
EAS00748
7. Pickup coil resistance
EAS00751
S Disconnect the pickup coil coupler from the
wireharness.
S Connect the pocket tester (Ω
100) to the
pickup coil terminal as shown.
10. Sidestand switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
Tester positive probe – gray 1
Tester negative probe – black/blue 2
YES
NO
Replace the
sidestand switch.
B/L
11. Lean angle cut-off switch
S Check the lean angle cut-off switch.
Refer to “SELF-DIAGNOSIS.
S Is the lean angle cut-off switch OK?
S Measure the pickup coil resistance.
YES
Pickup coil resistance
189 X 231 Ω at 20_C
(between gray and black/blue)
Replace the lean
angle cut-off switch.
S Is the pickup coil OK?
YES
EAS00754
NO
12. Wiring
S Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the ignition system’s wiring properly connected and without defects?
Replace the pickup
coil.
EAS00749
8. Main switch
NO
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
Properly connect or
repair the ignition
system’s wiring.
NO
Replace the main
switch.
8-16
YES
Replace the ignitor
unit.
ELECTRIC STARTING SYSTEM
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
8-17
ELEC
ELECTORIC STARTING SYSTEM
6
7
8
9
10
11
12
18
34
35
37
43
69
71
Main switch
Battery
Main fuse
Starter relay
Starter motor
Diode
Starting circuit cut-off relay
Sidestand switch
Start switch
Engine stop switch
Front brake light switch
Rear brake light switch
Signal fuse
Ignition fuse
8-18
ELEC
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 operate
The brake light switch lever is pulled to the
handlebar (the brake light switch switch is
closed) and the sidestand is up (the sidestand
switch is closed).
1 Battery
2 Fuse (main)
3 Main switch
4 Fuse (signal)
5 Front brake light switch
6 Rear brake light switch
7 Starting circuit cut-off switch
8 Ignition fuse
9 Engine stop switch
10 Sidestand switch
11 Start switch
12 Starter relay
13 Starter motor
14 Diode
8-19
ELECTRIC STARTING SYSTEM
ELEC
EAS00739
EAS00757
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20_C
The starter motor fails to turn.
Check:
1. Main, signal and ignition fuses
2. Battery
3. Starter motor
4. Starting circuit cut-off relay
5. Starter relay
6. Main switch
7. Engine stop switch
8. Brake light switch (front and rear)
9. Sidestand switch
10. Start switch
11. 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.
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Leg shield
2) Footrest board
3) Fuel tank
S Troubleshoot with the following special tool(-s).
EAS00758
3. Starter motor
S Connect the battery positive terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
90890-03112
EAS00738
1. Main, signal and ignition fuses
S Check the main, signal and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
WARNING
S A wire that is used as a jumper lead must
have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
S This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
S Are the main and ignition fuses OK?
YES
NO
Replace the fuse (-s).
S Does the starter motor turn?
YES
NO
Repair or replace the
starter motor.
8-20
ELEC
ELECTRIC STARTING SYSTEM
EAS00759
Does the starter relay have continuity between red and black?
4. Starting circuit cut-off relay
Disconnect the starting circuit cut-off relay
coupler from the wireharness.
Connect the pocket tester (Ω
1) and battery (12 V) to the starting circuit cut-off relay
coupler as shown.
Battery positive terminal red/black 1
Battery negative terminal light green 2
YES
NO
Replace the starter
relay.
EAS00749
6. Main switch
Tester positive probe green/yellow 3
Tester negative probe green/yellow 4
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES
NO
Replace the main
switch.
EAS00750
7. Engine stop switch
Does the starting circuit cut-off relay have
continuity between green/yellow 3 and
green/yellow 4 ?
YES
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
NO
YES
Replace the starting
circuit cut-off relay.
NO
Replace the right
handlebar switch.
EAS00761
5. Starter relay
EAS00751
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.
8. Brake light switch (front and rear)
Check the brake light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake switch OK?
Battery positive terminal green/yellow 1
Battery negative terminal black 2
YES
Tester positive probe red 3
Tester negative probe black 4
NO
Replace the brake
light switch.
8-21
ELECTRIC STARTING SYSTEM
EAS00752
9. Sidestand switch
Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES
NO
Replace the
sidestand switch.
EAS00764
10. Start switch
Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
11. Wiring
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly connected and without defects?
YES
The starting system
circuit is OK?
NO
Properly connect or
repair the starting
system’s wiring.
8-22
ELEC
ELECTRIC STARTING SYSTEM
ELEC
STARTER MOTOR
10 Nm (1.0 mkg)
Order
1
2
Job/Part
Removing the starter motor
Fuel tank
Battery negative lead
Starter motor lead
Starter motor
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
1
1
For installation, reverse the removal
procedure.
8-23
ELECTRIC STARTING SYSTEM
Order
1
2
3
4
5
6
7
8
9
Job/Part
Disassembling the starter motor
Front bracket
Bearing
Oil seal
Wahser kit
Starter motor yoke
Armature assembly
Washer kit
Brush holder
Rear bracket
Q’ty
ELEC
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
For assembly reverse the disassembly
procedure.
8-24
ELECTRIC STARTING SYSTEM
ELEC
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Commutator wear limit
27 mm
3. Measure:
S mica (insulation) undercut a
Out of specification Scrape the mica (insulation) to the proper measurement with a
hacksaw blade which has been grounded to
fit the commutator.
Mica (insulation) undercut
0.7 mm
NOTE:
The mica (insulation) of the commutator must
be undercut to ensure proper operation of the
commutator.
4. Measure:
S armature coil resistances (continuity and insulation)
Out of specification Replace the starter
motor.
a. Check the continuity resistance 1 and mica
(insulation) resistances 2 with a pocket tester.
Pocket tester
90890-03112
b. Measure the armature coil resistances.
Armature coil continuity resistance
0.015 0.025 Ω at 20_C
Armature coil insulation resistance
Above 1MΩ at 20_C
c. If any resistance is out of specification, replace the starter motor.
8-25
ELECTRIC STARTING SYSTEM
ELEC
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Brush length wear limit
4.0 mm
6. Measure:
brush spring force
Fatigue/out of specification Replace the
brush springs as a set.
Brush spring force
7.65 10.01 N
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing 1
oil seal 2
bushing 3
Damage/wear Replace the defective
part(-s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
brush seat 1
2. Install:
washers 1
armature coil 2
o-ring 3
starter motor yoke 4
NOTE:
To prevent damaging the brushes during installation push down on the brush springs.
8-26
ELECTRIC STARTING SYSTEM
ELEC
3. Install:
o-ring 1 New
washers 2
front bracket 3
o-ring 4 New
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.
4. Install:
bolts 1
8-27
7 Nm (0.7 mkg)
ELEC
CHARGING SYSTEM
YP80400
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
3
7
8
8-28
A.C. magneto
Rectifire/ regulator
Battery
Main fuse
ELEC
CHARGING SYSTEM
EAS00774
EAS00775
TROUBLESHOOTING
3. Charging voltage
S Connect the engine tachometer to the spark
plug lead of cylinder #1.
S Connect the pocket tester (20 V DC) to the
battery as shown.
The battery is not being charged.
Check:
1. Main fuse
2. Battery
3. Charging voltage
4. Stator coil resistance
5. Wiring connections
(of the entire charging system)
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Left side cover mole
2) Footrest board
S Troubleshoot with the following special
tool(-s).
Tester positive probe battery positive terminal
Tester negative probe battery negative terminal
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
Engine tachometer
90890-03113
Pocket tester
90890-03112
Charging voltage
14 V at 5,000 r/min
EAS00738
NOTE:
Make sure that the battery is fully charged.
1. Main fuses
S Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Is the charging voltage within specification?
NO
S Are the fuses OK?
YES
The charging circuit
is OK.
NO
EAS00776
Replace the fuse (-s).
4. Stator coil resistance
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the stator coils as shown.
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Tester positive probe white 1
Tester negative probe white 2
Tester positive probe white 3
Tester negative probe white 1
Open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES
YES
NO
S Clean the battery
terminals.
S Recharge or
replace the battery.
8-29
CHARGING SYSTEM
S Measure the stator coil resistances.
Stator coil resistance
0.338 0.413 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.
8-30
ELEC
LIGHTING SYSTEM
ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4
5
6
7
8
36
39
40
8-31
Box light switch
Box light
Main switch
Battery
Main fuse
Light switch
Pass swtich
Dimmer switch
46
47
48
53
54
57
58
70
Headlight (Hi)
Headlight (Lo)
Auxiliary light
Tail/ brake light
Licence plate ligtht
Hi beam indicator light
Meter light
Headlight fuse
ELEC
LIGHTING SYSTEM
EB805010
EB802401
TROUBLESHOOTING
2. Battery
Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Any of the following fail to light: headlight,
high beam indicator light, taillight, auxiliary light or meter light.
Open-circuit voltage
12.8 V or more at 20C
Check:
1. Main, and headlight fuses
2. Battery
3. Main switch
4. Light switch
5. Dimmer switch
6. Pass switch
7. Box light switch
8. Wiring
(of the entire charging system)
Is the battery OK?
YES
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Front cawling
2) Handlebar cover
Troubleshoot with the following special
tool(-s).
NO
Clean the battery
terminals.
Recharge or
replace the battery.
EB802411
3. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
Pocket tester
90890-03112
YES
NO
Replace the main
switch.
EB802400
1. Main, and headlight fuses
Check the main, and headlight fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
Are the main, signaling system, and headlight fuses OK?
YES
EB805400
4. Light switch (for Europe)
Check the lights switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the lights switch OK?
YES
NO
NO
The lights switch is
faulty. Replace the
right handlebar
switch.
Replace the fuse(-s).
8-32
LIGHTING SYSTEM
ELEC
EB805401
YES
5. Dimmer switch
Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the dimmer switch OK?
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING
THE LIGHTING
SYSTEM”.
NO
The dimmer switch is
faulty. Replace the
left handlebar switch.
EB805403
6. Pass switch
Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the pass switch OK?
YES
NO
The pass switch is
faulty. Replace the
left handlebar switch.
EB805403
7. Box light switch
Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the box light switch OK?
YES
NO
Replace the box light
swtich
EB805404
8. Wiring
Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the lighting system’s wiring properly connected and without defects?
8-33
NO
Properly connect or
repair the lighting
system’s wiring.
LIGHTING SYSTEM
ELEC
EB805410
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
Headlight
Tester positive probe yellow 1 or green 2
Tester negative probe black 3
High beam indicator light
Tester positive probe yellow 1
Tester negative probe black 3
1. Headlight bulb and socket
Check the headlight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the headlight bulb and socket OK?
YES
Meter assembly coupler (wireharness side)
NO
Replace the
headlight bulb,
socket or both.
2. High beam indicator light bulb and socket
Set the main switch to “ON”.
Set the light switch to “
”.
Set the dimmer switch to “
” or “
”.
Measure the voltage (12 V) of yellow (green)
2 on the headlight coupler (headlight side).
Is the voltage within specification?
Check the high beam indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Is the high beam indicator light bulb and socket OK?
YES
NO
YES
NO
This circuit is OK.
Replace the high
beam indicator bulb,
socket or both.
The wiring circuit
from the main switch
to the headlight
coupler is faulty and
must be repaired.
3. Voltage
EB805411
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 set to “
2. Meter light fails to come on.
1. Meter light bulb and socket.
Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the meter light bulb and socket OK?
”
”
Headlight coupler (wireharness side)
B
A
YES
NO
Replace the meter
light bulb, socket or
both.
8-34
LIGHTING SYSTEM
ELEC
2. Voltage
2. Voltage
Connect the pocket tester (20 V) to the meter
assembly coupler (wireharness side) as
shown.
Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wireharness side) as
shown.
Tester positive probe blue 1
Tester negative probe black 2
Tester positive probe blue/red 1
Tester negative probe black 2
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue 1 on the
meter assembly coupler (wireharness side).
Is the voltage within specification?
YES
This circuit is OK.
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue/red 1 on
the tail/brake light coupler (wireharness
side).
Is the voltage within specification?
NO
YES
This circuit is OK.
The wiring circuit
from the main switch
to the meter
assembly coupler is
faulty and must
be repaired.
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
EB805412
EB805413
3. A tail/brake light fails to come on.
4. The auxiliary light fails to come on.
(for Europe)
1. Tail/brake light bulb and socket
Check the tail/brake light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the tail/brake light bulb and socket OK?
YES
1. Auxiliary light bulb and socket
Check the auxiliary light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
Are the auxiliary light bulb and socket OK?
NO
YES
Replace the tail/
brake light bulb,
socket or both.
NO
Replace the auxiliary
light bulb, socket or
both.
8-35
LIGHTING SYSTEM
ELEC
2. Voltage
2. Voltage
Connect the pocket tester (DC 20 V) to the
auxiliary light couplers (wireharness side) as
shown.
Connect the pocket tester (20 V) to the licence plate light coupler (wireharness side)
as shown.
Tester positive probe blue/red 1
Tester negative probe black 2
Tester positive probe blue/red 1
Tester negative probe black 2
Set the main switch to “ON”.
Set the light switch to “
” or “
”.
Measure the voltage (12 V) of blue/red 1 on
the auxiliary light couplers (wireharness
side).
Is the voltage within specification?
Set the main switch to “ON”.
Measure the voltage (12 V) of blue/red 1 on
the meter light coupler (wireharness side).
Is the voltage within specification?
YES
YES
This circuit is OK.
This circuit is OK.
The wiring circuit
from the main switch
to the auxiliary light
coupler is faulty and
must be repaired.
5. Licence plate light fails to come on.
1. Licence plate light bulb and socket
Check the licence plate light and socket for
continuity.
Are the licence plate light bulb and socket OK?
YES
NO
NO
NO
Replace the licence
plate light bulb,
socket or both.
8-36
The wiring circuit
from the main switch
to the licence plate
light coupler is faulty
and must be
repaired.
SIGNAL SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-37
ELEC
SIGNAL SYSTEM
6
7
8
19
24
25
37
41
42
43
44
45
49
50
51
52
53
56
59
60
61
62
63
64
65
66
68
69
71
Main switch
Battery
Main fuse
Igniter unit
Reset coupler
Speed sensor
Front brake light switch
Horn switch
Turn signal switch
Rear brake light switch
Horn
Flasher relay
Front turn signal light (Left)
Front turn signal light (Right)
Rear turn signal light (Left)
Rear turn signal light (Right)
Tail/ brake light
Turn signal indicator light
V-belt indicator light
Engine oil change indicator light
Clock
Speedometer
Water temperature gauge
Fuel gauge
Thermo unit
Fuel level sender
Backup fuse
Signal fuse
Ignition fuse
8-38
ELEC
ELEC
SIGNAL SYSTEM
EAS00794
EAS00749
TROUBLESHOOTING
3. Main switch
Any of the following fail to come on: turn
signal light, brake light or indicator light.
The horn fails to sound.
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
Check:
1. Main, signal and ignition fuses
2. Battery
3. Main switch
4. Wiring connections
(of the entire signal system)
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Front cowling
2) Handlebar cover
Troubleshoot with the following special tool(-s).
YES
Replace the main
switch.
EAS00795
4. Wiring
Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the signaling system’s wiring properly
connected and without defects?
Pocket tester
90890-03112
NO
YES
Check the condition
of each of the signal
system’s circuits.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
EAS00738
1. Main, signal and ignition fuses
Check the main, signal and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
Are the main, signal and ignition fuses OK?
YES
NO
Properly connect or
repair the signal
system’s wiring.
EAS00796
CHECKING THE SIGNAL SYSTEM
1. The horn fails to sound.
NO
1. Horn switch
Replace the fuse (-s).
Refer to “CHECKING THE SWITCHES”.
EAS00739
YES
2. Battery
Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Replace the left handlebar switch.
Open-circuit voltage
12.8 V or more at 20C
2. Voltage
Connect the pocket tester (20 V DC) to the
horn lead (at the horn terminal) as shown.
Is the battery OK?
YES
NO
NO
Clean the battery
terminals.
Recharge or
replace the battery.
8-39
SIGNAL SYSTEM
Tester positive probe brown 1
Tester negative probe ground
Br
Tester positive probe pink 1
Tester negative probe ground
P
Br
Set the main switch to “ON”.
Measure the voltage (12 V) of the brown
connecter at the horn terminal.
Is the voltage within specification?
YES
ELEC
Set the main switch to “ON”.
Measure the voltage (12 V) of pink 1 at the
horn terminal.
Is the voltage within specification?
NO
The wiring circuit
from the main switch
to the horn terminal is
faulty and must be
repaired.
P
YES
Repair or adjust the
horn.
NO
Replace the horn.
EAS00797
2. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket.
3. Horn
Check the tail/brake light bulb and socket for
continuity.
Are the tail/brake light bulb and socket OK?
Disconnect the P connecter at the horn terminal.
Connect a jumper lead 1 to the horn terminal and ground the jumper lead.
Set the main switch to “ON”.
Does the horn sound?
YES
NO
Replace the tail/brake
light bulb, socket or
both.
Br
2. Brakelight switch
Check the brakelight switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake switch OK?
YES
YES
NO
NO
Replace the
brakelight switch.
Replace the horn.
4. Voltage
3. Voltage
Connect the pocket tester (20 V DC) to the
horn at the pink terminal as shown.
Connect the pocket tester (20 V DC) to the
tail/brake light coupler (wireharness side)
as shown.
8-40
SIGNAL SYSTEM
Tester positive probe green/yellow 1
Tester negative probe black 2
ELEC
3. Voltage
Connect the pocket tester (20 V DC) to the
flasher relay coupler (flasher relay side) as
shown.
Tester positive probe brown 1
Tester negative probe ground
Set the main switch to “ON”.
Pull in the brake lever (front or rear).
Measure the voltage (12 V) of green/yellow
1 on the tail/brake light coupler (wireharness side).
Is the voltage within specification?
YES
This circuit is OK.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 at
the flasher relay coupler (wireharness
side).
Is the voltage within specification?
NO
YES
The wiring circuit from
the main switch to the
tail/brake light coupler
(wireharness side) is
faulty and must
be repaired.
The wiring circuit
from the main switch
to the flasher relay
coupler (wireharness side) is faulty
and must be
repaired.
EAS00799
3. The turn signal light, turn signal indicator
light or both fail to blink.
4. Voltage
1. Turn signal indicator light bulb and socket
Connect the pocket tester (20 V DC) to the
flasher relay coupler (wireharness side) as
shown.
Check the turn signal light bulb and socket
for continuity.
Are the turn signal light bulbs and socket OK?
YES
Tester positive probe brown/white 1
Tester negative probe ground
NO
Replace the turn
signal light bulb,
socket or both.
2. Turn signal switch
Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the turn signal switch OK?
YES
NO
NO
Replace the left
handlebar switch.
8-41
SIGNAL SYSTEM
Set the main switch to “ON”.
Measure the voltage (12 V) on brown/white
1 at the flasher relay coupler (wireharness
side).
Is the voltage within specification?
YES
ELEC
6. Voltage
Connect the pocket tester (20 VDC) to the
meter assembly coupler (wireharness side)
as shown.
Left turn signal indicator light
Tester positive probe chocolate 1
Tester negative probe ground
Right turn signal indicator light
Tester positive probe dark green 2
Tester negative probe ground
NO
The flasher relay is
faulty and must be
replaced.
5. Voltage
Connect the pocket tester (20 V DC) to the
turn signal light coupler (wireharness side)
as shown.
A Front turn signal light
B Rear turn signal light
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 on the meter assembly coupler (wireharness side).
Is the voltage iwthin specification?
Left turn signal light
Tester positive probe chocolate 1
Tester negative probe ground
Right turn signal light
Tester positive probe dark green 2
Tester negative probe ground
B
A
YES
This circuit is OK.
Set the main switch to “ON”.
Set the turn sighal switch to “
” or “
”.
Measure the voltage (12 V) of the chocolate
1 or dark green 2 on the turn signal light
coupler (wireharness side).
Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the turn signal
switch to the turn signal light connecter
(wireharness side) is
faulty and must be
repaired.
8-42
NO
The wiring circuit
from the turn signal
switch to the meter
assembly coupler
(wireharness side) is
foulty and must be
repaired.
ELEC
SIGNAL SYSTEM
4. The V-belt indicator light fails to come on.
5. Fuel gauge fails to operate
1. V-belt indicator light bulb and socket
1. Fuel sender
Check the V-belt indicator light bulb and
socket for continuity.
Are the V-belt indicator light bulb and socket
OK?
Remove the fuel sender from the fuel tank.
Disconnect the fuel sender coupler from the
wireharness.
Connect the pocket tester (Ω 10) to the
fuel sender coupler lead.
YES
NO
Tester positive probe green 1
Tester negative probe ground
Replace the V-belt
indicator light bulb,
socket or both.
2. V-belt indicator reset coupler
Check the V-belt indicator reset coupler for
continuity.
Is the V-belt reset coupler OK?
YES
Measure the fuel sender resistance.
NO
Float position resistance
UP 4 10 Ω
DOWN 90 100 Ω
Replace the V-belt
reset coupler.
Is the fuel sender OK?
3. Voltage
YES
Connect the pocket tester (20 V DC) to the
meter assembly coupler (wireharness side)
as shown.
NO
Replace the fuel
sender.
Tester positive probe light green 1
Tester negative probe ground
2. Voltage
Connect the pocket tester (20 V DC) to the
meter assembly coupler (wireharness side)
as shown.
Tester positive probe brown 1
Tester negative probe ground
Set the main switch to “ON”.
Measure the voltage (12 V) of light green 1
at the meter assembly coupler.
Is the voltage within specification?
YES
Replace the meter
assembly.
NO
The wiring circuit
from the igniter unit
to the meter assembly coupler (wireharness side) is
faulty and must be
repaired.
8-43
ELEC
SIGNAL SYSTEM
6. Water temperature gauge fails to operate
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 at
the meter assembly coupler.
(wireharness side)
Is the voltage within specification?
YES
1. Thermo unit
Remove the thermo unit from the cylinder
head.
Connect the pocket tester (Ω 10) to the
thermo unit.
NO
Tester positive probe Thermo unit terminal 1
Tester negative probe Thermo unit body 2
The wiring circuit
from the signal fuse
to the meter
assembly coupler
(wireharness side) is
faulty and must be
repaired.
3. Fuel gauge
Measure the thermo unit resistance.
Connect the fuel sender coupler.
Move the float to “UP” 1 or “DOWN” 2 .
Thermo unit resistance:
69 Ω at 80C
22 Ω at 120C
Is the thermo unit OK?
YES
NO
Thermo unit replace.
Set the main switch to “ON”.
Check the fuel gauge needle moves “F” or
“E”.
Is the fuel gauge OK?
YES
This circuit is OK.
2. Voltage
Connect the pocket tester (20 V DC) to the
meter assembly coupler (wireharness side)
as shown.
NO
Tester positive probe brown 1
Tester negative probe ground
Replace the fuel
gauge.
Set the main switch to “ON”.
Measure the voltage (12 V) of brown 1 at
the meter assembly coupler. (wireharness
side)
Is the voltage within specification?
8-44
SIGNAL SYSTEM
YES
NO
The wiring circuit
from the signal fuse
to the meter
assembly coupler
(wireharness side) is
faulty and must be
repaired.
3. Water temperature gauge
Disconnect the thermo unit connecter.
Set the main switch to “ON”.
Connect the thermo unit connecter lead
green/red 1 and ground with a jumper lead
2 as shown.
Is the water temperature gauge OK?
YES
This circuit is OK.
NO
Replace the water
temperature gauge.
8-45
ELEC
COOLING SYSTEM
ELEC
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
6 Main switch
7 Battery
8 Main fuse
31 Thermo switch
32 Fan motor
63 Water temperature gauge
65 Thermo unit
69 Signal fuse
72 Radiator fan fuse
8-46
COOLING SYSTEM
EB807010
ELEC
Is the battery OK?
TROUBLESHOOTING
The radiator fan motor fails to turn.
Check:
1. Main, and radiator fan motor fuses
2. Battery
3. Main switch
4. Radiator fan motor
5. Thermo switch
6. Wiring
(the entire cooling system)
YES
Clean the battery
terminals.
Recharge or
replace the battery.
EB802411
3. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Footrest board
2) Legshield
Truobleshooting with the following special tool
(-s).
Pocket tester
90890-03112
YES
NO
Replace the main
switch.
EB807400
4. Radiator fan motor (test 1)
Disconnect the radiator fan motor coupler
from the wireharness.
Connect the battery (12 V) as shown.
EB802400
1. Main, and radiator fan motor fuses
Check the main, and radiator fan motor
fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
Are the main, and radiator fan motor fuses
OK?
YES
NO
Battery positive lead blue 1
Battery negative lead black 2
NO
Replace the fuse(-s).
EB802401
2. Battery
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Does the radiator fan motor turn?
YES
Open-circuit voltage
12.8 V or more at 20C
NO
The radiator fan
motor is faulty and
must be replaced.
8-47
COOLING SYSTEM
EB807400
5. Radiator fan motor (test 2)
Disconnect the thermo switch coupler.
Set the main switch to “ON”.
Connect the brown/red 1 and blue 2 terminals with a jumper lead 3 as shown.
ELEC
Test
step
Coolant temperature
Thermo switch
Continuity
*1*
*2*
*3*
*4*
0 92 ± 3C
NO
More than 98 ± 3C
YES
98 ± 3C to 92 ± 3C
YES
Less than 92 ± 3C
NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
Does the radiator fan motor turn?
YES
NO
The wiring circuit
from the main switch
to the radiator fan motor coupler is faulty
and must be repaired.
EB807402
6. Thermo switch
Remove the thermo switch from the radiator.
Connect the pocket tester (Ω 1) to the thermo switch 1 as shown.
Immerse the thermo switch in a container
filled with coolant 2 .
NOTE:
Make sure that the thermo switch terminals
do not get wet.
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Place a thermometer 3 in the coolant.
Slowly heat the coolant, then let it cool to the
specified temperature as indicated in the
table.
Check the thermo switch for continuity at the
temperatures indicated in the table.
Thermo switch
23 Nm (2.3 mkg)
Three bond sealock 10
A The thermo switch circuit is open and the radiator fan is off.
B The thermo switch circuit is closed and the
radiator fan is on.
8-48
COOLING SYSTEM
92 ± 3 C
98 ± 3 C
Does the thermo switch operate properly as
described above?
YES
NO
Replace the thermo
switch.
EB807403
7. Wiring
Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the cooling system’s wiring properly connected and without defects?
YES
This circuit is OK.
NO
Properly connect or
repair the cooling
system’s wiring.
8-49
ELEC
ELEC
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
6
7
8
13
17
19
35
71
8-50
Main switch
Battery
Main fuse
Fuel pump relay
Fuel pump
Ignitor unit
Engine stop switch
Ignition fuse
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The fuel pump circuit consists of the fuel pump
relay, fuel pump, engine stop switch and ignitor
unit.
The ignitor unit includes the control unit for the
fuel pump.
1
2
3
4
5
6
7
8
9
8-51
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Ignitor unit
Fuel pump relay
Fuel pump
Lean angle cut-off switch
ELEC
ELEC
FUEL PUMP SYSTEM
EAS00816
EAS00749
TROUBLESHOOTING
3. Main switch
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. Fuel pump relay
6. Fuel pump
7. Lean angle cut-off switch
8. Wiring connections
(the entire fuel pump system)
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Footrest board
2) Rear side cover (right)
3) Handlebar cover
Troubleshoot with the following special tool(-s).
Is the main switch OK?
NO
YES
Replace the main
switch.
EAS00750
4. Engine stop switch
Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the engine stop switch OK?
YES
NO
Replace the right
handlebar switch.
Pocket tester
90890-03112
EAS00759
EAS00738
1. Main, and ignition fuses
5. Fuel pump relay
Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
Disconnect the fuel pump relay coupler
from the wireharness.
Connect the pocket tester (Ω 1) and battery (12 V) to the fuel pump relay coupler as
shown.
Are the main and ignition fuses OK?
Battery positive terminal red/black 1
Battery negative terminal blue/red 2
NO
YES
Tester positive probe red/black 3
Tester negative probe blue/black 4
Replace the fuse (-s).
EAS00739
2. Battery
Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20C
Is the battery OK?
YES
Does the fuel pump relay have continuity
between red/black and blue/black?
NO
YES
Clean the battery
terminals.
Recharge or
replace the battery.
NO
Replace the fuel
pump relay.
8-52
FUEL PUMP SYSTEM
EAS00817
6. Fuel pump resistance
Disconnect the fuel pump coupler from the
wireharness.
Connect the pocket tester (Ω 1) to the fuel
pump coupler as shown.
Tester positive probe black/blue 1
Tester negative probe black 2
Measure the fuel pump resistance.
Fuel pump resistance
4 X 30 Ω at 20C
Is the fuel pump OK?
NO
YES
Replace the fuel
pump.
7. Lean angle cut-off switch
Check the lean angle cut -off switch.
Refer to “SELF-DIAGNOSIS.
Is the lean angle cut-off siwtch OK?
YES
NO
Replace the lean
angle cut-off switch.
EAS00818
8. Wiring
Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the fuel pump system’s wiring properly
connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the fuel pump
system’s wiring.
8-53
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
hot, 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 up the fuel tank.
b. Put the end of the fuel hose into an open container.
c. Connect the battery (12 V) to the fuel pump
coupler as shown.
Battery positive lead black/blue 1
Battery negative lead black 2
d. If fuel flows out of the fuel hose, the fuel pump
is OK.
If fuel does not flow, replace the fuel pump.
B/L
8-54
AUTO CHOKE SYSTEM
ELEC
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
Battery
Main fuse
Thermo switch
Auto choke 1
Auto choke 2
19 Igniter
68 Backup fuse
7
8
14
15
16
8-55
AUTO CHOKE SYSTEM
ELEC
EAS00821
3. Thermo switch
TROUBLESHOOTING
Remove the thermo switch from the thermostat housing.
Connect the pocket tester (Ω 1) to the thermo switch 1 as shown.
Immerse the thermo switch in a container
filled with coolant 2 .
NOTE:
Make sure that the thermo switch terminals
do not get wet.
The auto choke system fails to operate.
Check:
1. Main and backup fuses
2. Battery
3. Thermo switch
4. Auto choke 1. 2
5. Igniter unit
6. Wiring connections
(of the entire auto choke system)
Place a thermometer 3 in the coolant.
Slowly heat the coolant, then let it cool to the
specified temperature as indicated in the
table.
Check the thermo switch for continuity at the
temperatures indicated in the table.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Leg shield
Troubleshoot with the following special tool(-s).
Pocket tester
90890-03112
EAS00738
1. Main, and backup fuses
Check the main and backup fuses for continuity.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
NO
Replace the fuse
(-s).
EAS00739
2. Battery
Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20C
Is the battery OK?
YES
Coolant temperature
Thermo switch
Continuity
*1*
*2*
*3*
*4*
0 X 55C
NO
More than 60C
YES
60 to 55C
YES
Less than 55C
NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
Are the main and backup fuses OK?
YES
Test
step
NO
Clean the battery
terminals.
Recharge or
replace the battery.
8-56
ELEC
AUTO CHOKE SYSTEM
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Thermo switch
23 Nm (2.3 mkg)
Three bond sealock 10
Measure the auto choke unit resistance.
Auto choke resistance
16 X 24 Ω at 20C
A COOL DOWN
B HEAT UP
Is the auto choke OK?
YES
NO
Replace the auto
choke.
55 C
60 ± 3 C
5. Igniter unit
When the engine is running at a speed of at
least 800 r/min.
OK if one of the auto chokes is on.
Does the thermo switch operate properly as
described above?
YES
NO
NO
Replace the thermo
switch.
Replace the igniter
unit.
EAS00826
6. Wiring
EAS00825
Check the entire auto choke system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the auto choke system’s wiring properly
connected and without defects?
The following procedure applies to all to the
auto choke unit.
4. Auto choke unit
Remove the auto choke unit from the carburetor.
Connect the pocket tester to the auto choke
unit coupler as shown.
NO
Tester positive probe black 1
Tester negative probe black 2
Properly connect or
repair the auto choke
system’s wiring.
8-57
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The XP500 features a self-diagnosing system for following circuit (-s).
1. Throttle position sensor (TPS)
2. Speed sensor
3. Lean angle cut-off switch
1. ENGINE TROUBLE INDICATOR LIGHT
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine oil change indicator light (irrespective of whether the engine is running or not).
NOTE:
The XP500 features a self-diagnosing system.
In the XP500, when the main switch is turned on the “Engine oil change indicator light” in the meter
assembly comes on for 0.5 seconds then goes off. However, if there is a malfunction, it comes on for 0.5
seconds, goes off and then begins flashing. (However, it is on while the engine is running.)
Item
Condition
Response
Res
onse
Display
Dis
lay condition code
Throttle position
sensor (TPS)
Disconnected
Short-circuit
Locked
Enables the motorcycle to
run so that the ignition timing is fixed when the
throttle is fully opened.
Displays the condition
code on the engine oil
change indicator light.
Speed sensor
Illegality pulse
Disconnected
Short-circuit
Displays the condition code
on the engine oil change
indicator light.
Blinks in
Fault code [2]
Lean angle cut-off
switch
Disconnected
Short-circuit
Displays the condition code
on the engine oil change
indicator light.
Blinks in
Fault code [3]
8-58
Blinks in
Fault code [1]
SELF-DIAGNOSIS
ELEC
Display order on the engine warning light
When one item being monitored
Repetition
Repetition
Repetition
1 0.5 seconds
2 0.5 seconds
3 3 seconds
When more than one item is being monitored
1
2
3
4
5
Light on (seconds) . . . . . . .
Light off (seconds) . . . . . . .
Number of blinks . . . . . . . .
Light off (seconds) . . . . . . .
Number of blinks . . . . . . . .
0.5 seconds
0.5 seconds
Fault code [4]
3 seconds
Fault code [3]
Light on
Light off
Repetition
8-59
A Light on
B Light off
ELEC
SELF-DIAGNOSIS
EAS00835
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
The tachometer starts to display the selfdiagnosis sequence.
Check:
1. Throttle position sensor
2. Speed sensor
3. Lean angle cut-off switch
YES
NO
Repair or replace the
wire harness.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Front cowling
2) Footrest board
Troubleshoot with the following special
tool(-s).
EB812401
2. Throttle position sensor
Check the throttle position sensor for continuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
Is the throttle position sensor OK?
Pocket tester
90890-03112
YES
EAS00836
NO
1. Throttle position sensor
CIRCUIT DIAGRAM
Replace the igniter
unit.
19 Igniter unit
22 Throttle position sensor
8-60
Replace the throttle
position sensor.
ELEC
SELF-DIAGNOSIS
EB812401
2. Speed sensor
CIRCUIT DIAGRAM
2. Speedometer
Check the speedometer operation.
Is the speedometer OK?
YES
Replace the igniter
unit.
NO
Replace the speed
sensor.
3. Lean angle cut-off switch
CIRCUIT DIAGRAM
19 Igniter unit
23 Lean angle cut-off suitch
1. Wireharness
Check the wireharness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wireharness OK?
19 Igniter unit
25 Speed sensor
1. Wireharness
YES
Check the wireharness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wireharness OK?
YES
NO
Repair or replace the
wireharness.
NO
Repair or replace the
wireharness.
8-61
SELF-DIAGNOSIS
EB812401
2. Lean angle cut-off switch
Replace with a lean angle cut-off switch that
is operating correctly, and if the diagnosis
generates a lean angle cut-off switch condition code again, replace the lean angle cutoff switch.
Is the leam angle cut-off switch OK?
YES
Replace the igniter
unit.
NO
Replace the lean
angle cut-off switch.
8-62
ELEC
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-2
9-2
9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 9-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OPERATE BUT SCOOTER WILL NOT MOVE . . . . . . . . . .
POOR STARTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLILNG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
9-3
9-3
9-3
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5
9-5
9-5
9-5
9-5
9-5
9-5
9-5
TRBL
SHTG
STARTING FAILURE/HARD STARTING
TRBL
SHTG
EAS00845
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
inspection, adjustment, and replacement of parts.
STARTING FAILURE/HARD STARTING
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 tank cap breather hole
Deteriorated or contaminated fuel
Clogged or damaged fuel hose
Fuel pump
Faulty fuel pump
Faulty fuel pump relay
Damaged vacuum hose
Improperly routed hose
Carburetor(-s)
Deteriorated or contaminated fuel
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Damaged float
Worn needle valve
Improperly installed needle valve seat
Incorrect fuel level
Improperly adjusted pilot air screw
Improperly installed pilot jet
Clogged starter jet
Clogged emulsion tube
Autochoke unit
Faulty starter plunger
Improperly adjusted starter cable
Faulty igniter unit
Faulty thermo switch
ELECTRICAL SYSTEMS
Battery
Improperly charged battery
Faulty battery
Fuse(-s)
Blown, damaged or incorrect fuse
Improperly installed fuse
Spark plug(-s)
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coil(-s)
Broken or shorted primary or secondary coils
Faulty spark plug lead
Cracked or broken ignition coil body
Ignition system
Faulty ignitor unit
Faulty pickup coil
Broken generator rotor woodruff key
9-1
INCORRECT ENGINE IDLING SPEED/ POOR
MEDIUM-AND-HIGH-SPEED PERFORMANCE
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty front, rear or both brake switches
Faulty start switch
Faulty sidestand switch
Improperly grounded circuit
Loose connections
TRBL
SHTG
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cut-off relay
Faulty starter clutch
EAS00847
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
Improperly charged battery
Faulty battery
Spark plug(-s)
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coil(-s)
Faulty spark plug lead
Ignition system
Faulty ignitor unit
Faulty pickup coil
ENGINE
Cylinder(-s) and cylinder head(-s)
Incorrect valve clearance
Damaged valve train components
Air filter
Clogged air filter element
FUEL SYSTEM
Carburetor(-s)
Faulty starter plunger
Loose or clogged pilot jet
Loose or clogged pilot air jet
Damaged or loose carburetor joint
Improperly synchronized carburetors
Improperly adjusted engine idling speed
(throttle stop screw)
Improper throttle cable free play (at the
flange of the throttle grip)
Flooded carburetor
Autochoke unit
Faulty starter plunger
Improperly adjusted starter cable
Faulty ignitor unit
EAS00849
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter
Clogged air filter element
Air intake system
Bent, clogged or disconnected carburetor air
vent hose
Clogged or leaking air duct
FUEL SYSTEM
Carburetor(-s)
Faulty diaphragm
Incorrect fuel level
Loose or clogged main jet
Fuel pump
Faulty fuel pump
9-2
FAULTY CLUTCH/OVERHEATING/
OVERCOOLING
TRBL
SHTG
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL
NOT MOVE
V-belt
Bent, damaged or worn V-belt
Slipping V-belt
Primary pulley cam and primary pulley slider
Damaged or worn primary pulley cam
Damaged or worn primary pulley slider
Clutch spring(-s)
Damaged clutch spring
Transmission gear(-s)
Damaged transmission gear
CLUTCH SLIPS
Clutch shoe spring(-s)
Damaged, loose or worn clutch shoe spring
Clutch shoe(-s)
Damaged or worn clutch shoe
Primary sliding sheave
Seized primary sliding sheave
POOR STARTING PERFORMANCE
V-belt
V-belt slips
Oil or grease on the V-belt
Primary sliding sheave
Faulty operation
Worn pin groove
Worn pin
Clutch shoe(-s)
Bent, damaged or worn clutch shoe
POOR SPEED PERFORMANCE
V-belt
Oil or grease on the V-belt
Primary pulley weight(-s)
Faulty operation
Worn primary pulley weight
Primary fixed sheave
Worn primary fixed sheave
Primary sliding sheave
Worn primary sliding sheave
Secondary fixed sheave
Worn secondary fixed sheave
Secondary sliding sheave
Worn secondary sliding sheave
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages
Cylinder head(-s) and piston(-s)
Heavy carbon buildup
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
COOLING SYSTEM
Coolant
Low coolant level
Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fins
Water pump
Damaged or defective water pump
Thermostat
Thermostat stays closed
Oil cooler
Clogged or damaged oil cooler
Hose(-s) and pipe(-s)
Damaged hose
Improperly connected hose
Damaged pipe
Improperly connected pipe
FUEL SYSTEM
Carburetor(-s)
Incorrect main jet setting
Incorrect fuel level
Air leak at carburetor joint
Air filter
Clogged air filter element
CHASSIS
Brake(-s)
Dragging brake
ELECTRICAL SYSTEMS
Spark plug(-s)
Incorrect spark plug gap
Incorrect spark plug heat range
Ignition system
Faulty ignitor unit
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
9-3
POOR BRAKING PERFORMANCE/FAULTY
FRONT FORK LEGS/UNSTABLE HANDLING
TRBL
SHTG
EAS00857
EAS00861
POOR BRAKING PERFORMANCE
FAULTY FRONT FORK LEGS
Disc brake
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper kit
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
LEAKING OIL
Bent, damaged or rusty inner tube
Cracked or damaged outer tube
Improperly installed oil seal.
Damaged oil seal lip
Incorrect oil level (high)
Loose damper rod bolt
Damaged damper rod bolt copper washer
Cracked or damaged cap bolt O-ring
MALFUNCTION
Bent, deformed or damaged inner tube
Bent, deformed or damaged outer tube
Damaged fork spring
Worn or damaged outer tube bushing
Bent or damaged damper rod
Incorrect oil viscosity
Incorrect oil level
EAS00862
UNSTABLE HANDLING
Tire(-s)
Uneven tire pressures (front and rear)
Incorrect tire pressure
Uneven tire wear
Wheel(-s)
Incorrect wheel balance
Deformed cast wheel
Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Improperly installed bearing race
Handlebar
Bent or improperly installed handlebar
Steering
Improperly installed upper bracket
Improperly installed lower bracket
(improperly tightened ring nut)
Bent steering stem
Damaged ball bearing or bearing race
Front fork leg(-s)
Uneven oil levels (both front fork legs)
Uneven fork spring tension (both front fork
legs)
Broken fork spring
Bent or damaged inner tube
Bent or damaged outer tube
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
Rear shock absorber assembly(-ies)
Faulty rear shock absorber spring
Leaking oil or gas
9-4
FAULTY SIGNALING SYSTEM
EAS00866
FAULTY SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Incorrect ground
Poor contacts (main or light switch)
Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier/regulator
Incorrect ground
Faulty main switch
Faulty light switch
Headlight bulb life expired
TURN SIGNAL DOES NOT LIGHT
Faulty turn signal switch
Faulty flasher relay
Burnt-out turn signal bulb
Incorrect connection
Damaged or defective wire harness
Incorrect ground
Discharged battery
Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
Faulty flasher relay
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
Faulty flasher relay
Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
Incorrect turn signal bulb
Faulty flasher relay
Burnt-out turn signal bulb
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
9-5
TRBL
SHTG
XP500 WIRING DIAGRAM (for 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
32
33
34
35
37
Pickup coil
A.C.magneto
Rectifier / regulator
Box light switch
Box light
Main switch
Battery
Main fuse
Starter relay
Starter motor
Diode
Starting circuit cut-off relay
Fuel pump relay
Thermo switch (Auto choke)
Auto choke 1
Auto choke 2
Fuel pump
Sidestand switch
Igniter unit
Ignition coil
Spark pulg
Throttle position sensor
Lean angle cut-off switch
Reset coupler
Speed sensor
Grip warmer switch (OPTION)
Grip warmer relay (OPTION)
Grip warmer (OPTION)
DC outlet fuse
DC outlet
Thermo switch (Fan)
Radiator fan motor
Right handlebar switch
Start switch
Engine stop switch
Front brake light switch
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
68
69
70
71
72
Left handlebar switch
Pass switch
Dimmer switch
Horn switch
Turn signal switch
Rear brake light switch
Horn
Flasher relay
Headlight (Hi)
Headlight (Low)
Auxiliary light
Front turn signal light (Left)
Front turn signal light (Right)
Rear turn signal light (Left)
Rear turn signal light (Right)
Tail / brake light
License plate light
Meter assembly
Trun signal indicator light
Hi beam indicator light
Meter light
V-belt indicator light
Engine oil change indicator light
Clock
Speedometer
Water temperature gauge
Fuel gauge
Thermo unit (Water temperature)
Fuel level sender
Fuse box
Backup fuse
Signal fuse
Headlight fuse
Ignition fuse
Radiator fan fuse
COLOR CODE
B ........
Br . . . . . . .
Ch . . . . . .
Dg . . . . . .
G .......
Gy . . . . . .
L ........
Lg . . . . . . .
O .......
P ........
R........
Y ........
W .......
B/R. . . . . .
B/Y . . . . . .
B/W . . . . .
B/L . . . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Yellow
White
Black / Red
Black / Yellow
Black / White
Black / Blue
Br / G . . . . .
Br / L . . . . .
Br / R . . . . .
Br / Y . . . . .
Br / W . . . . .
G/R . . . . .
G / Y. . . . . .
L/B . . . . . .
L/G . . . . . .
L/R . . . . . .
L/Y . . . . . .
L/W . . . . .
R/B. . . . . .
R/Y. . . . . .
R/W . . . . .
Y/B . . . . . .
Y/R. . . . . .
Brown / Green
Brown / Blue
Brown / Red
Brown / Yellow
Brown / White
Green / Red
Green / Yellow
Blue / Black
Blue / Green
Blue / Red
Blue / Yellow
Blue / White
Red / Black
Red / Yellow
Red / White
Yellow / Black
Yellow / Red
XP500 WIRING DIAGRAM (for 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
35
36
37
Pickup coil
A.C.magneto
Rectifier / regulator
Box light switch
Box light
Main switch
Battery
Main fuse
Starter relay
Starter motor
Diode
Starting circuit cut-off relay
Fuel pump relay
Thermo switch (Auto choke)
Auto choke 1
Auto choke 2
Fuel pump
Sidestand switch
Igniter unit
Ignition coil
Spark pulg
Throttle position sensor
Lean angle cut-off switch
Reset coupler
Speed sensor
Grip warmer switch (OPTION)
Grip warmer relay (OPTION)
Grip warmer (OPTION)
DC outlet fuse
DC outlet
Thermo switch (Fan)
Radiator fan motor
Right handlebar switch
Start switch
Engine stop switch
Light switch
Front brake light switch
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
68
69
70
71
72
73
Left handlebar switch
Pass switch
Dimmer switch
Horn switch
Turn signal switch
Rear brake light switch
Horn
Flasher relay
Headlight (Hi)
Headlight (Low)
Auxiliary light
Front turn signal light (Left)
Front turn signal light (Right)
Rear turn signal light (Left)
Rear turn signal light (Right)
Tail / brake light
License plate light
Meter assembly
Trun signal indicator light
Hi beam indicator light
Meter light
V-belt indicator light
Engine oil change indicator light
Clock
Speedometer
Water temperature gauge
Fuel gauge
Thermo unit (Water temperature)
Fuel level sender
Fuse box
Backup fuse
Signal fuse
Headlight fuse
Ignition fuse
Radiator fan fuse
Alarm (OPTION)
COLOR CODE
B ........
Br . . . . . . .
Ch . . . . . .
Dg . . . . . .
G .......
Gy . . . . . .
L ........
Lg . . . . . . .
O .......
P ........
R........
Y ........
W .......
B/R. . . . . .
B/Y . . . . . .
B/W . . . . .
B/L . . . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Yellow
White
Black / Red
Black / Yellow
Black / White
Black / Blue
Br / G . . . . .
Br / L . . . . .
Br / R . . . . .
Br / Y . . . . .
Br / W . . . . .
G/R . . . . .
G / Y. . . . . .
L/B . . . . . .
L/G . . . . . .
L/R . . . . . .
L/Y . . . . . .
L/W . . . . .
R/B. . . . . .
R/Y. . . . . .
R/W . . . . .
Y/B . . . . . .
Y/R. . . . . .
Brown / Green
Brown / Blue
Brown / Red
Brown / Yellow
Brown / White
Green / Red
Green / Yellow
Blue / Black
Blue / Green
Blue / Red
Blue / Yellow
Blue / White
Red / Black
Red / Yellow
Red / White
Yellow / Black
Yellow / Red
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