Yamaha Dragstar 650 Service Manual

EB000000

XVS650SERVICE MANUAL

1996 by Yamaha Motor Co.Ltd.First edition, September 1996

All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe andunfit for use.

Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

12 6

3

5

4

7

8

EB002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of eachsection. It is located in the upper left corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6 . The meanings of the symbol marks are given on the next page.4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

1

3

5

7

9

11

13

15

18

2

4

8

10

12

14

16

6

21

24 25

17

19 20

22 23

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on thetop right of each page and indicate the subjectof each chapter.

1 General information2 Specifications3 Periodic inspections and adjustments4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting

Illustrated symbols 10 to 17 are used to identifythe specifications appearing in the text.

10 Can be serviced with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Torque15 Wear limit, clearance16 Engine speed17 Ω, V, A

Illustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication points.

18 Apply engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply locking agent 24

and when to install new parts 25 .

24 Apply locking agent (LOCTITE))25 Replace

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1SPEC 2INSPADJ 3ENG 4

CARB 5CHAS 6ELEC 7TRBLSHTG 8

E004000

CHAPTER TITLES

GENINFO

CHAPTER 1.GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . . REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENINFO

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.

MODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare parts.

1-2

IMPORTANT INFORMATIONGENINFO

EB101000

IMPORTANT INFORMATIONPREPARATION FOR REMOVALPROCEDURES

1. Remove all dirt, mud, dust and foreign ma-terial before removal and disassembly.

2. Use proper tools and cleaning equipment.Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, alwayskeep mated parts together. This includesgears, cylinders, pistons and other partsthat have been “mated” through normalwear. Mated parts must always be reusedor replaced as an assembly.

4. During machine disassembly, clean allparts and place them in trays in the order ofdisassembly. This will speed up assemblyand allow for the correct installation of allparts.

5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS1. Replace all gaskets, seals and O-rings

when overhauling the engine. All gasketsurfaces, oil seal lips and O-rings must becleaned.

2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal lips.

1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

EB101030

LOCK WASHERS/PLATES AND COTTERPINS

1. Replace all lock washers/plates 1 andcotter pins after removal. Bend lock tabsalong the bolt or nut flats after the bolt or nuthas been tightened to specification.

EB101040

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-ible. When installing oil seals, apply a lightcoating of lightweight lithium base greaseto the seal lips. Oil bearings liberally wheninstalling, if appropriate.

1 Oil seal

Do not use compressed air to spin the bear-ings dry. This will damage the bearing sur-faces.

1 Bearing

EB101050

CIRCLIPS1. Check all circlips carefully before reas-

sembly. Always replace piston pin clips af-ter one use. Replace distorted circlips.When installing a circlip 1 , make sure thatthe sharp-edged corner 2 is positioned op-posite the thrust 3 it receives. See section-al view.

4 Shaft

1-4

CHECKING OF CONNECTIONSGENINFO

NOTE:

NOTE:

EB801000

CHECKING OF CONNECTIONSCheck the connectors for stains, rust, moisture,etc.

1. Disconnect:Connector

2. Check:ConnectorMoisture Dry each terminal with an airblower.Stains/rust Connect and disconnectthe terminals several times.

3. Check:Connector leadsLooseness Bend up the pin 1 and con-nect the terminals.

4. Connect:Connector terminals

The two terminals “click” together.

5. Check:Continuity (using a pocket tester)

If there is no continuity, clean the terminals. When checking the wire harness be sure to

perform steps 1 to 3. As a quick remedy, use a contact revitalizer

available at most part stores. Check the connector with a pocket tester as

shown.

1-5

SPECIAL TOOLSGENINFO

EB102001

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools; this will help prevent damage caused by the use of inappropriate tools orimprovised techniques. Special tools may differ by shape and part number from country to country. Insuch a case, two types are provided.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/How to use Illustration

Weight90890-01084

Bolt90890-01085

Slide hammer bolt /weight

These tools are used to remove therocker arm shaft.

90890-01231

Final gear backlash band

This tool is needed when measuringfinal gear backlash.

90890-01304

Piston pin puller

This tool is used to remove thepiston pin.

90890-01312

Fuel level gauge

This gauge is used to measure thefuel level in the float chamber.

T-handle90890-01326

Holder90890-01388

T-handle/damper rod holder

These tools are needed to loosen andtighten the damper rod holding bolt.

Puller90890-01362

Adapter90890-04089

Flywheel puller/adapter

These tools are needed to removethe rotor.

Weight90890-01367

Adapter90890-01381

Fork seal driver weight/adapter

These tools are needed when installingthe slide metal, oil seal and dust seal intothe fork.

90890-01403

Ring nut wrench

This tool is needed to loosen and tightenthe steering stem ring nut.

1-6



90890-01701

Sheave holder

This tool is needed to hold the rotorwhen removing or installing the rotorbolt.

90890-03081

Compression gauge set

These tools are needed to measureengine compression.

90890-03094

Vacuum gauge

This gauge is needed for carburetorsynchronization.

90890-03112

Pocket tester

This instrument is needed for checkingthe electrical system.

90890-03113

Engine tachometer

This tool is needed for observingengine rpm.

90890-03141

Timing light

This tool is necessary for checkingignition timing.

90890-04018

Valve guide remover & installer

This tool is needed to remove andinstall the valve guide.

90890-04019

Valve spring compressor

This tool is needed to remove andinstall the valve assemblies.

90890-04050

Bearing retainer wrench

This tool is needed when removing orinstalling the final drive shaft bearing.

1-7



90890-04057

Bearing retainer wrench

This tool is needed when removing orinstalling the middle driven shaftbearing.

Driver90890-04058

Installer/remover

90890-04074

Middle driven shaft bearing driver Plain bearing installer/removerThese tools are needed when removingor installing the main journal bearing.

90890-04062

Universal joint holder

This tool is needed when removing orinstalling the driven pinion gear nut.

90890-04080

Middle gear backlash tool

This tool is needed for the gear backlashadjustment.

90890-04086

Clutch holding tool

This tool is needed to hold the clutchwhen removing or installing the clutchboss nut.

90890-04090

Damper spring compressor

This tool is needed when removing orinstalling the damper spring.

90890-06754

Ignition checker

This instrument is necessary for checkingthe ignition system components.

90890-85505

Yamaha bond No.1215

This sealant (bond) is used on crankcasemating surfaces, etc.

GENINFO

SPEC

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-19. . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-20. . . . . . . . . . . . . . . . ENGINE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC

2-1

GENERAL SPECIFICATIONS SPEC

Temp. C

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard

Model code: XVS650: 4VR1, 4VR2

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,340 mm2,880 mm1,065 mm2,695 mm1,610 mm2,140 mm3,100 mm

Basic weight:With oil and a full fuel tank 227 kg

Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting system

Air cooled 4-stroke, SOHCV-type 2-cylinder0.649 L81 63 mm9 : 11,000 kPa (10 kg/cm2, 10 bar) at 300 r/minElectric starter

Lubrication system: Wet sump

Oil type or grade:Engine oil

API standard: API SE or higher grade

Final gear oil: SAE80API “GL-4” Hypoid Gear Oil

Oil quantity:Engine oilPeriodic oil changeWith oil filter replacementTotal amount

Final gear case oilTotal amount

2.6 L2.8 L3.2 L

0.19 L

Air filter: Dry type element

Fuel:TypeFuel tank capacityFuel reserve amount

Regular unleaded gasoline16 L3.0 L

2-2


Item Standard

Carburetor:Type/quantityManufacturer

BDS28/2MIKUNI

Spark plug:TypeManufacturerSpark plug gap

DPR7EA-9/X22EPR-U9NGK/DENSO0.8 0.9 mm

Clutch type: Wet, multiple-disc

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st

2nd3rd4th5th

Spur gear68/38 (1.789)Shaft drive19/18 32/11 (3.071)Constant mesh 5-speedLeft foot operation38/14 (2.714)38/20 (1.900)35/24 (1.458)28/24 (1.167)29/30 (0.967)

Chassis:Frame typeCaster angleTrail

Double cradle35153 mm

Tire:TypeSize front

rearManufacturer front

rearType front

rear

With tube100/90-19 57S170/80-15M/C 77SBRIDGESTONE/DUNLOPBRIDGESTONE/DUNLOPL309/F24G546/K555

Maximum load-except motorcycle: 180 kg

Tire pressure (cold tire):0 90 kg load *

frontrear

90 kg Maximum load *frontrear

200 kPa (2.00 kg/cm2, 2.00 bar)225 kPa (2.25 kg/cm2, 2.25 bar)

200 kPa (2.00 kg/cm2, 2.00 bar)250 kPa (2.50 kg/cm2, 2.50 bar)* Load is the total weight of the cargo, rider,passenger and accessories.

Brake:Front brake type

operationRear brake type

operation

Single disc brakeRight hand operationDrum brakeRight foot operation

2-3


Item Standard

Suspension:Front suspensionRear suspension

Telescopic forkSwingarm (Monocross)

Shock absorber:Front shock absorberRear shock absorber

Coil spring/Oil damperCoil spring/Gas-oil damper

Wheel travel:Front wheel travelRear wheel travel

140 mm86 mm

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

T.C.I. (digital)A.C. magnetoGT12B-412 V 10 AH

Headlight type: Quartz bulb (halogen)

Bulb wattage quantity:HeadlightTail /brake lightTurn signalAuxiliary lightLicence lightMeter lightNeutral indicator lightHigh beam indicator lightTurn indicator light

12 V 60 W/55 W12 V 5 W/21 W12 V 21 W 412 V 4 W 112 V 5 W 112 V 1.7 W 112 V 3 W 112 V 1.7 W 112 V 3 W 1

2-4

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Cylinder head:Warp limit 0.03 mm

Cylinder:Bore sizeMeasuring point*

80.945 80.995 mm40 mm

81.1 mm

Camshaft:Drive methodCam cap inside diameterCamshaft outside diameterShaft-to-cap clearanceCam dimensions

Intake “A”“B”“C”

Exhaust “A”“B”“C”

Camshaft runout limit

Chain drive (left & right)28.000 28.021 mm27.96 27.98 mm0.020 0.061 mm

39.733 mm32.217 mm7.733 mm39.772 mm32.302 mm7.772 mm

39.63 mm32.12 mm

39.67 mm32.20 mm

0.03 mm

2-5


Head Dia Face width Seat Width Margin Thickness

Item Standard Limit

Timing chain:Timing chain type/No. of linksTiming chain adjustment method

SILENT CHAIN/118Automatic

Rocker arm/rocker arm shaft:Bearing inside diameterShaft outside diameterArm-to-shaft clearance

14.000 mm 14.018 mm13.980 mm 13.991 mm0.009 mm 0.038 mm

Valve, valve seat, valve guide:Valve clearance (cold) IN

EX0.07 0.12 mm0.12 0.17 mm

Valve dimensions:

“A” head diameter INEX

“B” face width INEX

“C” seat width INEX

“D” margin thickness INEX

Stem outside diameter INEX

Guide inside diameter INEX

Stem-to-guide clearance INEX

Stem runout limit

36.9 37.1 mm31.9 32.1 mm2.3 mm2.3 mm1.0 1.2 mm1.0 1.2 mm1.0 1.4 mm1.0 1.4 mm6.975 6.990 mm6.960 6.975 mm7.000 7.012 mm7.000 7.012 mm0.010 0.037 mm0.025 0.052 mm

1.8 mm1.8 mm0.8 mm0.8 mm6.955 mm6.935 mm7.042 mm7.042 mm0.08 mm0.10 mm0.03 mm

Valve seat width INEX

1.0 1.2 mm1.0 1.2 mm

1.8 mm1.8 mm

Valve spring:Free length IN

EXSet length (valve closed) IN

EX

43.2 mm43.2 mm37.1 mm37.1 mm

42.0 mm42.0 mm

2-6


Item Standard Limit

Compressed pressure IN(installed)

EXTilt limit * IN

EX

Direction of winding(top view)IN

EX

21.8 25.6 kg

21.8 25.6 kg

Counter clockwiseCounter clockwise

2.5 /1.9mm2.5 /1.9mm

Piston:Piston to cylinder clearancePiston size “D”

Measuring point “H”Oversize 2ndOversize 4thPiston off-setPiston pin bore inside diameterPiston pin outside diameter

0.035 0.055 mm80.90 80.95 mm

6 mm81.5 mm82 mm0 mm20.004 20.015 mm19.995 20.000 mm

0.15 mm

Piston rings:Top ring:

TypeDimensions (B T)End gap (installed)Side clearance (installed)

Plain1.2 3.2 mm0.15 0.30 mm0.03 0.07 mm

0.55 mm0.12 mm

2-7


1 2 3 4

Item Standard Limit

2nd ring:

TypeDimensions (B T)End gap (installed)Side clearance

Oil ring:

Dimensions (B T)End gap (installed)

Taper1.5 3.6 mm0.30 0.45 mm0.02 0.06 mm

2.5 3.1 mm0.2 0.7 mm

0.8 mm0.12 mm

Connecting rod:Oil clearanceColor code (corresponding size)

0.026 0.050 mmBlue Black Brown Green

Crankshaft:

Crank width “A”Runout limit “C”Big end side clearance “D”Big end radial clearance “E”Journal oil clearance

93.95 94.00 mm

0.270 0.424 mm0.026 0.050 mm0.020 0.052 mm

0.02 mm

Clutch:Friction plate thicknessQuantity

Clutch plate thicknessQuantity

Clutch spring free lengthQuantity

Clutch housing thrust clearanceClutch housing radial clearanceClutch release methodPush rod bending limit

2.9 3.1 mm71.5 1.7 mm639.5 mm50.10 0.37 mm0.015 0.043 mmInner push, cam push

2.6 mm

0.2 mm

38.5 mm

0.5 mm

2-8


Item Standard Limit

Transmission:Main axle deflection limitDrive axle deflection limit

0.06 mm0.06 mm

Shifter:Shifter type Guide bar

Carburetor:I. D. markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Pilot air jet (P.A.J.1)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Bypass 2 (B.P.2)Bypass 3 (B.P.3)Pilot screw (P.S)Valve seat size (V.S)Starter jet (G.S.1)Starter jet (G.S.2)Throttle valve size (Th.V)Fuel level (F.L)Engine idle speedIntake vacuumCO %Engine oil temperature

4VR 00#90#504CP10-3O-6#1000.85#200.80.80.821.0#17.50.9#1407.5 8.5 mm1,150 1,250 r/min29.0 kPa (0.29 kg/cm2, 220 mmHg)3 4 %80 90 C

Fuel pump:TypeModel/manufacturerConsumption amperage <max>Output pressure

Electrical typeUC-Z6M/MITSUBISHI0.8 A12 kPa (0.12 kg/cm2, 0.12 bar)

Lubrication system:Oil filter typeOil pump typeTip clearance “A” or “B”Side clearanceRelief valve operating pressure

Oil pressure (hot)

Pressure check location

Paper typeTrochoid type0.12 mm0.03 0.08 mm440 540 kPa (4.5 5.5 kg/cm2,4.5 5.5 bar)10 kPa (0.1 kg/cm2, 0.1 bar) at 1,200r/minH/C UNION BOLT

0.2 mm0.15 mm

Shaft drive:Middle gear backlashFinal gear backlash

0.05 0.10 mm0.1 0.2 mm

2-9


Splashed

Camshaft

Pressure feed

Rocker arm shaft

Piston

Middle gear housing Drive axle

Starter clutch Crankshaft

Main axle

Oil filter

Oil pump Relief valve

Oil strainer

Item Standard

Lubrication chart:

2-10

Left crankcase Right crankcase


Cylinder head tightening sequence:

Crankcase tightening sequence:

2-11


Tightening torques

Part to be tightened Part nameThread

sizeQ’ty

Tighteningtorque Remarksg

sizey

Nm mkg

Cylinder headCylinder headCylinder headCylinder head cover bracketCylinder head (exhaust pipe)Camshaft sprocket coverTappet coverRocker arm shaft (oil passage)Bearing retainer (camshaft)Spark plugCylinderLower cylinder head coverUpper cylinder head coverConnecting rodRotorValve adjusting locknutCamshaft sprocketTiming chain tensionerTiming chain guideOil pumpOil strainer coverOil filter coverCarburetor jointAir filter case stayAir filter case assemblyExhaust pipe joint (rear) andcylinder headExhaust pipe joint (rear) andmuffler assembly (rear)Exhaust pipe (front)Exhaust pipe and mufflerMufflerCrankcase (cylinder)Crankcase (cylinder)CrankcaseCrankcaseBearing retainer (middle drivepinion gear)Crankcase cover (left)Crankcase cover (right)ClampOne-way clutchPrimary drive gear

NutNutBoltNut

Stud boltBoltBoltBoltBolt—

BoltBolt

ScrewNutBoltNutBoltBoltBoltBoltBoltBoltBoltBoltBolt

Nut

Bolt

NutScrewBolt

Stud boltStud bolt

BoltBolt

Torx screw

BoltBoltBoltBoltNut

M10M8M8

M10M8M6M6

M16M8

M12M6M6M6M8

M10M6

M10M6M6M6M6M6M6M6M6

M8

M8

M8M8

M10M10M8M8M6

M8

M6M6M6M8

M10

8248448442268414244335422

2

2

222824

10

4

1311161

3520203515101038201810105

3680145512107

1010121212

20

20

25202520132410

25

1010102070

3.52.02.03.51.51.01.03.82.01.81.01.00.53.68.01.45.51.21.00.71.01.01.21.21.2

2.0

2.0

2.52.02.52.01.32.41.0

2.5

1.01.01.02.07.0

Use lock washer

Stake

Use lock washer

2-12


Part to be tightened Part nameThread

sizeQ’ty

Tighteningtorque Remarksg

sizey

Nm mkg

Clutch springClutch adjusterClutch bossPush lever axleMiddle drive pinion gearBearing retainer (middle drivenshaft)Yoke (middle driven shaft)Bearing housing (middle driveshaft)Shift lever stopperShift pedal linkShift pedal adjusterStator coilPickup coil

BoltNutNut

ScrewNut

—

Nut

Bolt

BoltBoltNut

ScrewScrew

M6M6

M20M8

M20

M65

M14

M8

M8M6M6M6M6

51111

1

1

4

11233

88

7012

120

110

90

25

2210777

0.80.87.01.2

12.0

11.0

9.0

2.5

2.21.00.70.70.7

Use lock washer

Stake

Use lock washer

1 of 2 has LHthread

2-13


CHASSIS

Item Standard Limit

Steering system:Steering bearing typeNo./size of steel ball (upper)

Ball & taper roller bearing19 pcs/0.25 in

Front suspension:Front fork travelFork spring free lengthFitting lengthSpring rate (K1)Stroke (K1)Optional springOil capacityOil levelOil grade

140 mm295 mm249.9 mm3.5 N/mm (0.35 kg/mm)0 140 mmNo0.454 L114 mmFork oil 10W or equivalent

289 mm

Rear suspension:Shock absorber travelSpring free lengthFitting lengthSpring rate (K1)Stroke (K1)Optional spring

37 mm168.5 mm160.5 mm186 N/mm (18.6 kg/mm)0 37 mmNo

165 mm

Swingarm:Free play limit end

side

1 mm1 mm

Front wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Spoke wheel19 MT2.50Steel1.0 mm0.5 mm

2 mm2 mm

Rear wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Spoke wheel15M/C MT3.50Steel1.0 mm0.5 mm

2 mm2 mm

Front brake:TypeDisc outside diameter thicknessPad thickness innerPad thickness outer

Single disk298 5 mm6.2 mm6.2 mm

0.8 mm0.8 mm

2-14


Item Standard Limit

Master cylinder inside diameterCaliper cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

12.7 mm30.1 mm33.3 mmDOT 4

Rear brake:TypeBrake drum inside diameterLining thicknessShoe spring free length

Leading, trailing200 mm4 mm68 mm

201 mm2 mm

Brake lever & brake pedal:Brake lever free play (at pivot)Brake lever free play (at lever end)Brake pedal positionBrake pedal free playClutch lever free play (at pivot)Clutch lever free play (at leverend)

1 2 mm10 15 mm85 m20 30 mm2 3 mm10 15 mm

2-15


Tightening torques

Part to be tightened Thread sizeTightening

torque RemarksgNm mkg

Upper bracket and inner tubeLower bracket and inner tubeUpper bracket and steering shaftRing nut (steering shaft)Handlebar holder (lower) and upper bracketHandlebar holder (lower) and handlebarholder (upper)Master cylinder (front brake)Union bolt (brake hose)Brake hose holder and lower bracketFront fender and outer tubeHeadlight stay and lower bracketHeadlight stay and headlightFront flasher light and lower bracketEngine mounting:

Frame and stay (front - upper)Frame and stay (front - lower)Stay and engine (front - upper)Stay and engine (front - lower)Frame and engine (rear - upper)Frame and engine (rear - lower)

Regulator stay and frameRegulator and regulator stayMuffler stay and frameRear shock absorber and swingarmRear shock absorber and framePivot shaft (left) and framePivot shaft (right) and framePivot shaft (right) and locknutFinal gear case and swingarmFuel tank and fuel cockFuel tank bracket and frameRider’s seatPassenger seatFrame and rear fender stayRear fender and rear fender stayRear fender and tail /brake lightRear fender stay and rear flasher lightSide cover (lower)Battery coverSide cover (right)Starter relay and leads

M8M10M22—

M12

M8

M6M10M6M8M6M6M6

M8M8

M10M10M10M12M6M6M8

M12M12M22M22M22M10M6M8M6M6

M10M8M6

M12M6M6M6M6

20301101820

23

10309

10787

403040404074137

306262

1007

100707

2377

26266

237777

2.03.011.01.82.0

2.3

1.03.00.91.00.70.80.7

4.03.04.04.04.07.41.30.73.06.26.2

10.00.7

10.07.00.72.30.70.72.62.60.62.30.70.70.70.7

See NOTE

2-16


NOTE:

Part to be tightened Thread sizeTightening

torque RemarksgNm mkg

Passenger footrest and frameSidestand bracket and frameSidestand and sidestand bracketSidestand switchBrake pedal/ footrest and frameFront wheel axleFront wheel axle pinch boltBrake caliperBrake disc and front wheelCaliper bleed screwRear wheel axle nutTension bar and swingarmTension bar and brake shoe plateBrake cam shaft leverClutch hub and damperFinal gear case (housing cover)Bearing housing (final gear case)Bearing housing (final gear case)Bearing retainer (final drive pinion gear)Oil filter bolt (final gear)Oil drain bolt (final gear)Housing cover

M8M10M10M5M6

M16M8

M10M8M7

M14M8M8M6

M10M10M8

M10M65M14M14M10

2664564

64592040236

9720201062182323115232342

2.66.45.60.46.45.92.04.02.30.69.72.02.01.06.21.82.32.311.52.32.34.2

LH thread

1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, then loosenthe ring nut completely.

2. Retighten the ring nut to specification.

2-17


ELECTRICAL

Item Standard Limit

Voltage: 12 V

Ignition system:Ignition timing (B.T.D.C.)Advancer type

12 at 1,200 r/minTPS and electrical type

T.C.I.:Pickup coil resistance/colorT.C.I. unit model/manufacturer

182 222 Ω at 20C/Gray – BlackJ4T079/MITSUBISHI

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

F6T541/MITSUBISHI6 mm3.8 4.6 Ω at 20C10.1 15.1 kΩ at 20C

Spark plug cap:TypeResistance

Resin type10 kΩ

Charging system:TypeModel/manufacturerNominal outputStator coil resistance/color

A.C. magnetoF4T459/MITSUBISHI14 V 20 A at 5,000 r/min0.50 0.62 Ω at 20C/White – White

Voltage regulator:TypeModel/manufacturerNo load regulated voltage

Semi-conductor, short-circuit typeSH650A-12/SHINDENGEN14.1 14.9 V

Rectifier:Model/manufacturerCapacityWithstand voltage

SH650A-12/SHINDENGEN25 A240 V

Battery:Specific gravity 1.320

Electric starter system:TypeStarter motor:

Model/manufacturerI.D.numberOutputBrush overall lengthCommutator diameterMica undercut

Starter relay:Model/manufacturerAmperage rating

Constant mesh type

SM-13/MITSUBASM-130.7 kW12.5 mm28 mm0.7 mm

MS-5F/JIDECO100 A

4 mm27 mm

2-18


Item Standard Limit

Horn:TypeQuantityModel/manufacturerMaximum amperage

Plane type1YF-12/NIKKO1.5 A

Flasher relay:TypeModel/manufacturerSelf cancelling deviceFlasher frequencyWattage

Full transistor typeFE246BH/DENSONo75 95 cycle/min21 W 2 + 3W

Fuel pump relay:Model/manufacturer G8R-30Y/OMRON

Circuit breaker:TypeAmperage for individual circuit

MAINHEAD LIGHTSIGNALSIGNITIONReserveReserveReserve

Fuse

30 A 115 A 110 A 110 A 130 A 115 A 110 A 1

2-19

GENERAL TORQUE SPECIFICATIONS SPEC

EB202001

GENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torquespecifications for special components or as-semblies are provided for each chapter of thismanual. To avoid warpage, tighten multi-fasten-er assemblies in a crisscross fashion, in pro-gressive stages, until the specified torque isreached. Unless otherwise specified, torquespecifications require clean, dry threads. Com-ponents should be at room temperature.

A: Distance between flatsB: Outside thread diameter

A(nut)

B(Bolt)

General torquespecifications

(nut) (Bolt)Nm mkg

10 mm 6 mm 6 0.6

12 mm 8 mm 15 1.5

14 mm 10 mm 30 3.0

17 mm 12 mm 55 5.5

19 mm 14 mm 85 8.5

22 mm 16 mm 130 13.0

2-20

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB203000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Symbol

Oil seal lips

O-ring

Bearing

Connecting rod bolt /nut

Connecting rod small end and big end

Crankshaft pin

Crankshaft journal/big end

Piston surface

Piston pin

Camshaft cam lobe/journal

Rocker arm shaft

Valve stem (IN, EX)

Valve stem end (IN, EX)

Oil pump rotor (inner/outer), housing

Idle gear surface

Starter idle gear

Starter idle gear shaft

Middle drive gear

Primary driven gear

Push rod 1

Transmission gear (wheel/pinion)

Shift cam

Shift fork/guide bar

Shift shaft assembly

Valve spring (intake)

Push rod ball

Push lever assembly

2-21

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB203010

CHASSIS

Lubrication point Symbol

Steering head pipe (upper/ lower), bearing

Steering head pipe, bearing cover lip

Steering head pipe, oil seal lip

Front wheel oil seal lip (right/ left)

Rear wheel oil seal lip

Clutch hub fitting area

Rear brake pedal shaft

Shift pedal shaft

Sidestand bolt, sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever pivot bolt, contact surface

Clutch lever pivot bolt, contact surface

Rear shock absorber (lower) oil seal lip

Swingarm pivot bearing inner surface

Swingarm pivot oil seal lip

2-22

LUBRICATION DIAGRAMS SPEC

7 Push rod 18 Oil pump

4 Drain bolt5 Oil strainer6 Push lever

1 Rocker arm (intake)2 Rocker arm (exhaust)3 Camshaft

EB205000

LUBRICATION DIAGRAMS

2-23

7 Oil filter8 Crankshaft


1 Rocker arm shaft (intake)2 Rocker arm shaft (exhaust)3 Camshaft

4 Drive axle5 Relief valve6 Oil pump

2-24


1 Crankshaft2 Oil filter3 Oil pump

2-25

4 Drive axle5 Main axle

1 Camshaft2 Rocker arm3 Starter idle gear


2-26

CABLE ROUTING SPEC

10 Horn11 Headlight lead12 Right handlebar switch lead13 Spark plug lead14 Fuel hose15 Main switch lead16 Fuel pump lead17 Main switch18 Fuel pump

1 Clutch cable2 Left handlebar switch lead3 Fuel tank breather hose4 Speedometer cable5 Speedometer6 Speedometer light leads7 Rectifier / regulator8 Rear brake switch lead9 Sidestand switch lead

EB206000

CABLE ROUTING

2-27

CABLE ROUTING SPEC

A Pass the front flasher light leads (left andright) and headlight lead through theheadlight cover hole.

B Pass the left handlebar switch lead behindthe upper bracket.

C Fasten the left handlebar switch lead with aplastic locking tie.

D Pass the speedometer cable, speedometerlight leads and fuel tank breather hosethrough the fuel tank hole.

E Connect the rear brake switch coupler in frontof the roll over valve stay.

F To the speedometer light leads.G Pass the right handlebar switch lead and head-

light lead over the other harness and leads.H Pass the clutch cable through the cable guide.I Fasten the sidestand switch lead and rectifier/

regulator lead with a plastic locking tie.J To the engine.K The sidestand switch lead should not touch

the shift rod.

2-28

Q Fasten the rear brake switch lead and rectifier/regulator lead with a plastic locking tie.

R Place the couplers behind the steering head.S Pass the speedometer cable through the

holder.T Pass the fuel tank breather hose through the

holder.U To the speedometer light leads.

L Fasten the sidestand switch lead with a metalclamp.

M Fasten the rear brake switch lead, sidestandswitch lead and rectifier / regulator lead witha metal clamp.

N Pass the speedometer cable through thespeedometer cable holder.

O To the rectifier / regulator.P Pass the rear brake switch lead between the

frame and rectifier / regulator. Do not pinchthe rear brake switch lead.

CABLE ROUTING SPEC

2-29

1 Frame bracket2 Wire harness3 Fuse box4 Battery positive (+) lead5 Spark plug lead6 Starter cable7 Right handlebar switch lead8 Brake hose9 Throttle cables10 Thermo switch lead11 Flasher light relay

CABLE ROUTING SPEC

12 Starter relay13 Carburetor heater relay14 Neutral switch lead15 Pickup coil lead16 A.C. magneto lead17 Battery negative (–) lead18 Starter motor lead19 Starting circuit cut-off relay20 Fuel tank breather hose21 Speedometer cable22 Ignitor unit

A Pass the tail/brake light leadbetween the frame bracket andbattery box.

B Fasten the tail/brake light leadwith a battery band. Do notpinch the harness and tail/brake light lead.

C To the ignition coil.D The end of the plastic locking

tie should face towards theunder the handlebar.

2-30

K Fasten the fuse box lead with a plastic lockingtie.

L Fasten the battery positive (+) lead with a bat-tery box clamp.

M The carburetor heater relay should not touchthe wire harness.

N Fasten the wire harness with a plastic lockingtie.

O From the engine.P Pass the starter motor lead over the battery

negative (–) lead.

E Fasten the right handlebar switch lead with aplastic locking tie.

F Pass the right handlebar switch lead behindthe upper bracket.

G Fasten the brake hose with a brake hoseholder.

H Pass the left handlebar switch lead under themain switch.

I Fasten the spark plug lead with a metal clamp.J Pass the ignition coil lead inside of the starter

cable.

CABLE ROUTING SPEC

2-31

V Fasten the starter cable with a plastic lockingtie.

W Inside the motorcycle.X Pass the fuel tank breather hose through the

holder.Y Fasten the fuel tank breather hose with a

metal clamp.Z Pass the speedometer cable through the

front side guide.a Fasten the wire harness and leads with a

plastic locking tie.

CABLE ROUTING SPEC

Q Fasten the pickup coil lead, A.C. magnetolead, neutral switch lead and starter motorlead with a plastic locking tie.

R Fasten the battery negative (–) lead, startermotor lead and wire harness with a plasticlocking tie.

S Fasten the wire harness with a battery band.T Pass the wire harness between the frame and

battery box.U Place the end of the plastic locking tie as

shown.

2-32

h To the flasher light relay.i To the rear fender.

To the battery negative (–) lead.k Pass the ignitor unit leads through the

battery box hole.

j

b Fasten the wire harness and leads with ametal clamp.

c To the carburetor heater relay.d Fasten the wire harness and leads with a

plastic locking tie.e Pass the plastic band through the frame hole.

Fasten the wire harness with a plastic band atthe point where the tape is located.

f The wire harness and leads should not touchthe rear shock absorber.

g To the starter relay.

CABLE ROUTING SPEC

2-33

12 Speedometer cable13 Neutral switch lead14 Pickup coil lead15 A.C. magneto lead16 Thermo switch lead17 Fuel tank breather hose18 Frame19 Wire harness20 Air filter case

1 Front flasher light (right)2 Throttle cables3 Brake hose4 Right handlebar switch lead5 Clutch cable6 Left handlebar switch lead7 Front flasher light (left)8 Ignition coil9 Spark plug lead10 Silencer11 Starter cable

CABLE ROUTING SPEC

A Pass the throttle cablesthrough the cable guide.

B Pass the brake hose in frontof the upper bracket.

C Pass the left handlebar switchlead over the right handlebarswitch lead.

D Pass the clutch cable throughthe cable guide.

E Fasten the handlebar switchleads with a plastic band.

F Fasten the wire harness witha plastic locking tie.

2-34

N 20 mmO Pass the thermo switch lead inside of the

silencer breather hose.P Place the end of the plastic locking tie as

shown.Q Inside the motorcycle.R Fasten the wire harness with a plastic locking

tie.S Pass the wire harness between the air filter

case groove and frame.

CABLE ROUTING SPEC

G To the ignition coil.H Pass the starter cable between the ignition

coil and spark plug lead.I To the throttle position sensor (TPS).J To the carburetor.K To the fuel tank.L Pass the neutral switch lead, pickup coil lead

and A.C. magneto lead under the ignition coillead, thermo switch lead and throttle positionsensor (TPS) lead.

M From the engine.

INSPADJ

CHAPTER 3.PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .

FUEL TANK AND SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR SYNCHRONIZATION 3-7. . . . . . . . . . . . . . . . . . . . . . . . . IDLING SPEED ADJUSTMENT 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE CABLE ADJUSTMENT 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING CHECK 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION PRESSURE MEASUREMENT 3-14. . . . . . . . . . . . . . . . ENGINE OIL LEVEL INSPECTION 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH ADJUSTMENT 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR JOINT INSPECTION 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LINE INSPECTION 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BREATHER HOSE INSPECTION 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM INSPECTION 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE ADJUSTMENT 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE ADJUSTMENT 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL INSPECTION 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD INSPECTION 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SHOE INSPECTION 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE LIGHT SWITCH ADJUSTMENT 3-25. . . . . . . . . . . . . . . . . . . . . . . BRAKE HOSE INSPECTION 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 3-26. . . . . . . . . . . . . . . SHIFT PEDAL ADJUSTMENT 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR OIL LEVEL INSPECTION 3-28. . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR OIL REPLACEMENT 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ADJUSTMENT 3-32. . . . . . . . . . . . . . . . . . . . TIRE INSPECTION 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPOKE INSPECTION AND TIGHTENING 3-35. . . . . . . . . . . . . . . . . . . . . CABLE INSPECTION AND LUBRICATION 3-35. . . . . . . . . . . . . . . . . . . . . LEVER AND PEDAL LUBRICATION 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND LUBRICATION 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPADJ

ELECTRICAL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY INSPECTION 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE INSPECTION 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT 3-44. . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REPLACEMENT 3-44. . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSPADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

BREAK INEVERY

ITEM ROUTINE BREAK-IN1,000 km 6,000 km

or6 months

12,000 kmor

12 months

* Fuel line Check fuel hoses for cracks or damage. Replace if necessary. √ √

Spark plugs Check condition. Clean or replace if necessary. √ √ √

* Valves Check valve clearance. Adjust if necessary. √ √ √

Air filter Clean or replace if necessary. √ √

* Battery Check loading condition. Recharge if necessary. √ √

Clutch Check operation. Adjust or replace cable. √ √

* Front brake Check operation and for fluid leakage. (See NOTE.) Replace pads if necessary. √ √

* Rear brake Check operation. Adjust or replace shoes if necessary. √ √

* Wheels Check balance, runout, spoke tightness and for

damage. Tighten spokes and rebalance / replace if necessary.

√ √

* Tires Check tread depth and for damage. Replace if necessary. √ √

* Wheel bearings Check bearing assembly for looseness or damage. Replace if damaged. √ √

* Swingarm pivotingpoint

Check swingarm assembly for looseness. Repair if necessary. Grease with molybdenum sulfide grease every

24,000 km or 24 months.

√

* Steering bearings Check steering for looseness and smooth operation. Repair if necessary. Grease with lithium soap base grease every

24,000 km or 24 months.

√ √

* Chassis fasteners Check all nuts, bolts and screws for tightness. Tighten if necessary. √ √ √

Sidestand Check operation. Repair if necessary. √ √ √

* Sidestand switch Check operation. Replace if necessary. √ √ √

* Front suspension Check front fork operation and for oil leakage. Repair if necessary. √ √

* Rear suspension Check operation and for shock absorber oil leakage. Replace if necessary. √ √

* Carburetors Check idle speed, synchronization and starter

operation. Adjust if necessary.

√ √ √

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ

NOTE:

BREAK INEVERY

ITEM ROUTINEBREAK -IN1,000 km 6,000 km

or6 months

12,000 kmor

12 months

Engine oil Replace. (Warm engine before draining.) √ √ √

Engine oil filter Replace. √ √

Final gear oil Check oil level and for oil leakage. Change every 24,000 km or 24 months. Replace √ √

Items marked with an asterisk (*) require special tools, data and technical skills for servicing.Take the motorcycle to a Yamaha dealer or refer to the Service Manual when servicing these items.

Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and add fluid as required.2. Replace the oil seals every two years on the inner parts of the master cylinder and caliper cylinder.3. Replace the brake hoses every four years, or if cracked or damaged.

3-3

Disconnect the speedometer cable from the front wheel side first.

Set the fuel cock to “OFF” before disconnecting the fuel hose.

For installation, reverse the removal procedure.

Order Job name/Part name Q’ty Remarks

1

234

56789

Fuel tank and seats removalFuel hose

Meter assemblyMeter lead couperSpeedometer cable

Starter knob bracketFuel tank assemblyPassenger seatSeat bracketRider’s seat

1

121

11111

Remove the parts in the order below.NOTE:

NOTE:

30 Nm (3.0 mkg)

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

FUEL TANK AND SEATSINSPADJ

FUEL TANK AND SEATS

3-4

VALVE CLEARANCE ADJUSTMENTINSPADJ

NOTE:

EB303003

ENGINEVALVE CLEARANCE ADJUSTMENT

Valve clearance adjustment should be madewith the engine cool, at room temperature.

When the valve clearance is to be measuredor adjusted, the piston must be at Top DeadCenter (T.D.C.) on the compression stroke.

1. Remove:Meter assemblyFuel tankRefer to “FUELTANK AND SEATS”.

2. Remove:Carburetor assemblyRefer to “CARBURETOR” in CHAPTER 5.

3. Disconnect:Spark plug caps

4. Remove:Spark plugs

5. Remove: Ignition coil 1

6. Remove:Cylinder head coversRefer to “ENGINE REMOVAL”.

Cylinder head cover bracketsRefer to “CYLINDER HEADS”.

7. Remove:Tappet covers 1

3-5

A B


*****************************************************

8. Remove:Camshaft sprocket covers 1

9. Remove:Timing plug 1Straight plug 2

10. Measure:Valve clearanceOut of specification Adjust.

Valve clearance (cold):Intake valve:

0.07 X 0.12 mmExhaust valve:

0.12 X 0.17 mm

Measuring steps: Turn the crankshaft clockwise with a wrench. Align the camshaft sprocket mark a with the

stationary pointer b on the cylinder head.When the mark is aligned with the pointer, thepiston is at Top Dead Center (TDC).

Check the front/rear cylinder timing mark con the rotor. If necessary, turn the crankshaftto align the timing mark with the pointer d onthe AC magneto cover.

A For rear cylinder (“TI” mark)B For front cylinder (“I” mark)

3-6


*****************************************************

*****************************************************

*****************************************************

NOTE:

Measure the valve clearance using a thick-ness gauge 1 .

11. Adjust:Valve clearance

Adjustment steps: Loosen the locknut 1 . Insert a thickness gauge between the adjust-

er end and the valve end. Turn the adjuster 2 in or out until the speci-

fied clearance is obtained.

Turning in:valve clearance isdecreased.

Turning out:valve clearance isincreased.

Hold the adjuster to prevent it from movingand tighten the locknut.

Locknut:14 Nm (1.4 mkg)

Measure the valve clearance again. If the clearance is still incorrect, repeat all the

clearance adjustment steps until the speci-fied clearance is obtained.

12. Install:All removed parts

Install all removed parts in the reverse order oftheir disassembly. Note the following points.

3-7

VALVE CLEARANCE ADJUSTMENT/CARBURETOR SYNCHRONIZATION

INSPADJ

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

18 Nm (1.8 mkg)

NOTE:

NOTE:

13. Install:Camshaft sprocket covers

Tappet coversCylinder head coverSpark plugs

EB303010

CARBURETOR SYNCHRONIZATION

Prior to synchronizing the carburetors, the valveclearance should be properly adjusted and theignition timing should be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:Vacuum plugs 1

3. Attach:Vacuum gauge 1Engine tachometer 2 (to the #1 spark plug lead)

Vacuum gauge:90890-03094

Engine tachometer:90890-03113

4. Start the engine and let it warm up for sev-eral minutes.

5. Check:Engine idling speedOut of specification Adjust.Refer to “IDLING SPEED ADJUST-MENT”.

Engine idling speed:1,150 1,250 r/min

3-8

CARBURETOR SYNCHRONIZATIONINSPADJ

*****************************************************

*****************************************************

NOTE:

6. Adjust:Carburetor synchronization

Adjustment steps: Synchronize carburetor #1 to carburetor #2

by turning the synchronizing screw 1 untilboth gauges read the same.

Rev the engine two or three times, each timefor less than a second, and check the syn-chronization again.

Vacuum pressure at idle speed:29.0 kPa (0.29 kg/cm 2, 220 mm Hg)

The difference between the two carburetorsshould not exceed 1.33 kPa (10 mm Hg).

7. Check:Engine idling speedOut of specification Adjust.

8. Stop the engine and detach the measuringequipment.

9. Adjust:Throttle cable free playRefer to “THROTTLE CABLE ADJUST-MENT”.

Free play (throttle cable):4 6 mmAt throttle grip flange

10. Install:Vacuum plugs

3-9

IDLING SPEED ADJUSTMENTINSPADJ

NOTE:

*****************************************************

*****************************************************

EB303021

IDLING SPEED ADJUSTMENT

Prior to adjusting the idling speed, the carbure-tor synchronization should be adjusted proper-ly, the air filter should be clean and the engineshould have adequate compression.


2. Attach:Engine tachometer(to the #1 spark plug lead)


3. Check:Engine idling speedOut of specification Adjust.


4. Adjust:Engine idling speed

Adjustment steps: Turn the throttle stop screw 1 in or out until

the specified idling speed is obtained.

Turning in: idling speed is increased.

Turning out: idling speed is decreased.

3-10

IDLING SPEED ADJUSTMENT/THROTTLE CABLE ADJUSTMENT

INSPADJ

NOTE:

*****************************************************

NOTE:

5. Adjust:Throttle cable free playRefer to “THROTTLE CABLE ADJUST-MENT”.


EB303030

THROTTLE CABLE ADJUSTMENT

Prior to adjusting the throttle cable free play, theengine idling speed and carburetor synchro-nization should be adjusted properly.

1. Check:Throttle cable free play aOut of specification Adjust.


2. Remove:Rider’s seatFuel tankRefer to “FUEL TANK AND SEATS”.

3. Adjust:Throttle cable free play

Adjustment steps:

When the motorcycle is accelerating, throttlecable #1 1 is pulled and throttle cable #2 2 ispushed.

3-11

THROTTLE CABLE ADJUSTMENT/SPARK PLUG INSPECTION

INSPADJ

NOTE:

*****************************************************

CAUTION:

1st step: Loosen the locknut 3 on throttle cable #1. Turn the adjuster 4 in or out until the speci-

fied free play is obtained.

Turning in: free play is increased.

Turning out: free play is decreased.

Tighten the locknuts.

If the specified free play cannot be obtained onthe carburetor end of the cable, use the adjusteron the handlebar end.

Additional step: Loosen the locknut 5 . Turn the adjuster 6 in or out until the speci-




Tighten the locknut.

After adjusting, turn the handlebars to theright and to the left to ensure that this doesnot cause the engine idling speed tochange.

4. Install:Fuel tankRider’s seatRefer to “FUEL TANK AND SEATS”.

EB303040

SPARK PLUG INSPECTION1. Remove:

Spark plug capsSpark plugs

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells, to prevent itfrom falling into the cylinders.

3-12

SPARK PLUG INSPECTION/IGNITION TIMING CHECKINSPADJ

18 Nm (1.8 mkg)

NOTE:

NOTE:

2. Check:Spark plug typeIncorrect Replace.

Standard spark plug:DPR7EA-9 (NGK)X22EPR-U9 (DENSO)

3. Inspect:Electrode 1Wear/damage Replace.

Insulator 2Abnormal color Replace.Normal color is a medium-to-light tan col-or.

4. Clean:Spark plug(with spark plug cleaner or wire brush)

5. Measure:Spark plug gap a(with a wire gauge)Out of specification Adjust gap.

Spark plug gap:0.8 0.9 mm

6. Install:Spark plug

Before installing a spark plug, clean the gasketsurface and the plug surface.

EB303051

IGNITION TIMING CHECK

Prior to checking the ignition timing, check allelectrical connections related to the ignitionsystem. Make sure all connections are tight andfree of corrosion and that all ground connec-tions are tight.

3-13

IGNITION TIMING CHECKINSPADJ

*****************************************************

*****************************************************NOTE:

1. Remove:Timing plug 1

2. Attach:Timing light 1Engine tachometer 2(to the #1 spark plug lead)

Timing light:90890-03141


3. Check: Ignition timing

Checking steps: Start the engine and let it warm up for several

minutes. Let the engine run at the specifiedspeed.


Check that the stationary pointer a is withinthe firing range b on the rotor. Incorrect firingrange Check the ignition system.

Ignition timing is not adjustable.

4. Install:Timing plug 1

3-14

COMPRESSION PRESSURE MEASUREMENTINSPADJ

NOTE:

CAUTION:

EB303060

COMPRESSION PRESSURE MEASUREMENT

Insufficient compression pressure will result in aloss of performance.

1. Check:Valve clearanceOut of specification Adjust.Refer to “VALVE CLEARANCE ADJUST-MENT”.


3. Stop the engine.

4. Remove:Spark plug capsSpark plugs

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells, to prevent itfrom falling into the cylinders.

5. Attach:Compression gauge 1

Compression gauge set:90890-03081

6. Measure:Compression pressureIf it exceeds the maximum pressure al-lowed Inspect the cylinder head, valvesurfaces and piston crown for carbon de-posits.If it is below the minimum pressure Squirt a few drops of oil into the affectedcylinder and measure again.

Refer to the table below.

3-15

COMPRESSION PRESSURE MEASUREMENTINSPADJ

*****************************************************

*****************************************************

NOTE:

18 Nm (1.8 mkg)

Compression pressure(with oil applied in the cylinder)

Reading Diagnosis

Higher thanwithout oil

Worn or damaged pistons Repair.

Same aswithout oil

Possible defective ring(s),valves, cylinder head gas-ket or piston Repair.

Compression pressure (at sea level)

Standard:1,100 kPa (11 kg/cm 2, 11 bar)

Minimum:1,000 kPa (10 kg/cm 2, 10 bar)

Maximum:1,200 kPa (12 kg/cm 2, 12 bar)

Measurement steps: Crank the engine with the throttle wide open

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

Repeat the previous steps for the other cylin-ders.

The difference in compression pressure be-tween the highest and lowest cylinder compres-sion readings should not exceed 100 kPa (1kg/cm2, 1 bar).

7. Install:Spark plugsSpark plug caps

3-16

Temp.

ENGINE OIL LEVEL INSPECTIONINSPADJ

NOTE:

CAUTION:

NOTE:

ENGINE OIL LEVEL INSPECTION1. Stand the motorcycle on a level surface.

Make sure the motorcycle is upright when in-specting the oil level.


2. Inspect:Oil levelOil level should be between the maximuma and minimum b marks.Oil level is below the minimum mark Add oil up to the proper level.

Recommended engine oil:Refer to the chart for selection of oils suited to the atmosperic temperature.

API Standard:API SE or higher grade

Do not put in any chemical additives oruse oils with a grade of CD a or higher.

Be sure not to use oils labeled “ENERGYCONSERVING ll” b or higher. Engine oilalso lubricates the clutch and additivescould cause clutch slippage.

Be sure no foreign material enters thecrankcase.


4. Stop the engine and inspect the oil levelonce again.

Wait until the oil settles before inspecting the oillevel.

3-17

ENGINE OIL REPLACEMENTINSPADJ

*****************************************************

*****************************************************

43 Nm (4.3 mkg)

NOTE:

EB303080

ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for sev-

eral minutes.2. Turn off the engine and place a container

under the drain bolt.3. Remove:

Oil filler plug 1O-ring 2Drain bolt 3GasketDrain the crankcase of its oil.

4. If the oil filter is to be replaced during thisprocedure, remove the following parts andreinstall them afterwards.

Replacement steps: Remove the oil filter element cover 1 and oil

filter element 2 . Check the O-ring 3 . If cracked or damaged,

replace them with new one. Install the oil filter element and oil filter ele-

ment cover.

Oil filter cover:10 Nm (1.0 mkg)

5. Install:Gasket Drain bolt

Inspect the drain bolt gasket. If it is damaged,replace it.

3-18

ENGINE OIL REPLACEMENTINSPADJ

*****************************************************

*****************************************************

6. Fill:CrankcaseRefer to “ENGINE OIL LEVEL INSPEC-TION”.

Oil quantity:Total amount:

3.2 L (2.8 Imp qt)Periodic oil change:

2.6 L (2.3 Imp qt)With oil filter replacement:

2.8 L (2.6 Imp qt)

7. Install:Oil filler plug,Warm up the engine for a few minutes,then turn it off.

8. Check:Engine (for oil leaks)Oil level

9. Check:Oil pressure

Checking steps: Slightly loosen the oil gallery bolt 1 . Start the engine and keep it idling until oil

starts to seep from the oil gallery bolt. If no oilcomes out after one minute, turn the engineoff so that it will not seize.

Check the oil passages, oil filter and oil pumpfor damage or leakage. Refer to “INSPEC-TION AND REPAIR” in CHAPTER 4.

Start the engine after solving the problem(s)and check the oil pressure again.

Tighten the oil gallery bolt to specification.

Oil gallery bolt:8 Nm (0.8 mkg)

3-19

A B

CLUTCH ADJUSTMENT/AIR FILTER CLEANINGINSPADJ

*****************************************************

*****************************************************

CAUTION:

EB303090

CLUTCH ADJUSTMENT1. Check:

Clutch cable free play aOut of specification Adjust.

Free play (clutch cable):10 15 mmAt clutch lever end

2. Adjust:Clutch cable free play

Adjustment steps: Loosen the locknuts 1 . Turn the adjusters 2 in or out until the speci-




Tighten the locknuts.

A Handlebar endB Engine end

EB303120

AIR FILTER CLEANING1. Remove:

Air filter case cover 12. Remove:

Air filter element 2

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the filter element will also affect thecarburetor tuning, leading to poor engineperformance and possible overheating.

3-20

AIR FILTER CLEANING/CARBURETOR JOINTINSPECTION/FUEL LINE INSPECTION

INSPADJ

NOTE:

3. Inspect:Air filter elementDamage Replace.

4. Clean:Air filter elementBlow off the dust from the outside of theelement using compressed air.

5. Install:Air filter elementAir filter case cover

When installing the element in its case, makesure its sealing surface matches the sealingsurface of the filter case so that no air can leakout.

EB303130

CARBURETOR JOINT INSPECTION1. Inspect:

Carburetor joints 1Cracks/damage Replace.Refer to “CARBURETOR” in CHAPTER 5.

EB303140

FUEL LINE INSPECTION1. Inspect:

Fuel hoseCracks/damage Replace.

Fuel filterContamination/damage Replace.

3-21

BREATHER HOSE INSPECTION/EXHAUST SYSTEM INSPECTION

INSPADJ

CAUTION:

20 Nm (2.0 mkg)

25 Nm (2.5 mkg)

20 Nm (2.0 mkg)

25 Nm (2.5 mkg)

20 Nm (2.0 mkg)

BREATHER HOSE INSPECTION1. Remove:

Cylinder head cover (rear cylinder)Refer to “ENGINE REMOVAL” in CHAP-TER 4.

2. Inspection:Breather hose 1Cracks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.

EB303160

EXHAUST SYSTEM INSPECTION1. Inspect:

Exhaust pipe (front) 1Exhaust pipe joint (rear) 2Muffler assembly (lower) 3Muffler assembly (upper) 4Cracks/damage Replace.

Gaskets 5Exhaust gas leaks Replace.

2. Check:Nut 6Nut 7Bolt 8Bolts 9Screws 10

3-22

FRONT BRAKE ADJUSTMENTINSPADJ

*****************************************************

*****************************************************

CAUTION:

EB304002

CHASSISFRONT BRAKE ADJUSTMENT

1. Check:Brake lever free play aOut of specification Adjust.

Free play (brake lever):10 15 mm(at brake lever end)

2. Adjust:Brake lever free play

Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out until the speci-


Turning in:brake lever free play isdecreased.

Turning out:brake lever free play isincreased.


After adjusting the front brake lever freeplay, make sure that there is no brake drag.

A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. This air must be removed by bleed-ing the brake system before the motorcycleis operated. Air in the brake system will con-siderably reduce braking performance andcould result in a loss of control and possiblyan accident. Inspect and if necessary, bleedthe brake system.

3-23

REAR BRAKE ADJUSTMENTINSPADJ

*****************************************************

*****************************************************

*****************************************************

*****************************************************

CAUTION:

EB304012

REAR BRAKE ADJUSTMENT1. Check:

Brake pedal height aOut of specification Adjust.

Brake pedal height:85 mm(above the top of the footrest)

2. Adjust:Brake pedal height

Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out until the speci-

fied pedal height is obtained.

Turning in:brake pedal height isdecreased.

Turning out:brake pedal height isincreased.


Locknut:7 Nm (0.7 mkg)

3. Check:Brake pedal free play aOut of specification Adjust.

Free play (brake pedal):20 30 mm

4. Adjust:Brake pedal free play

Adjustment steps: Turn the adjuster 1 in or out until the speci-


Turning in:brake pedal free play isdecreased.

Turning out:brake pedal free play isincreased.

Make sure that there is no brake drag afteradjusting the brake pedal height and thefree play.

3-24

REAR BRAKE ADJUSTMENT/BRAKE FLUID LEVEL INSPECTION

INSPADJ

NOTE:

NOTE:

CAUTION:

5. Adjust:Brake light switchRefer to “BRAKE LIGHT SWITCH AD-JUSTMENT”.

EB304020

BRAKE FLUID LEVEL INSPECTION1. Stand the motorcycle on a level surface.

When inspecting the brake fluid level, makesure the motorcycle is upright.


2. Inspect:Brake fluid levelBrake fluid level is below the “LOWER”level line a Fill to proper level.

Recommended brake fluid:DOT 4

For a correct reading of the brake fluid level,make sure the top of the handlebar brake fluidreservoir is horizontal.

Brake fluid may corrode painted surfaces orplastic parts. Always clean up any spilt fluidimmediately.

Use only the designated brake fluid. Otherfluids may deteriorate the rubber seals,causing leakage and poor brake perfor-mance.

Refill with the same type of fluid. Mixingfluids may result in a harmful chemicalreaction leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe fluid and may cause vapor lock.

3-25

BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT

INSPADJ

NOTE:

*****************************************************

*****************************************************

EB304030

BRAKE PAD INSPECTION1. Operate the brake lever.2. Inspect:

Brake padWear indicators 1 almost touch the brakedisc Replace the brake pads as a set.Refer to “REAR WHEEL AND REARBRAKE” in CHAPTER 6.

EB304040

BRAKE SHOE INSPECTION1. Operate the brake pedal.2. Inspect:

Brake shoesWear indicator 1 reaches the wear limitline 2 Replace the brake shoes as aset.Refer to “REAR WHEEL AND REARBRAKE” in CHAPTER 6.

EB304050

BRAKE LIGHT SWITCH ADJUSTMENT

The brake light switch is operated by movementof the brake pedal.Adjustment is correct when the brake lightcomes on just before the braking effect starts.

1. Check:Brake light operation timingIncorrect Adjust.

2. Adjust:Brake light operation timing

Adjustment steps: Hold the main body 1 of the switch so that it

does not rotate, and turn the adjuster 2 in orout until the proper operation timing is ob-tained.

Turning in:brake light comes onlater.

Turning out:brake light comes onsooner.

3-26

BRAKE HOSE INSPECTIONAIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

INSPADJ

*****************************************************

EB304060

BRAKE HOSE INSPECTION1. Inspect:

Brake hose(s)Cracks/wear/damage Replace.

2. Check:Brake hose clamp(s)Loose Tighten.

3. Hold the motorcycle upright and apply thefront or rear brake.

4. Check:Brake hose(s)Activate the brake lever several times.Brake fluid leakage Replace the faultyhose.Refer to “FRONT BRAKE” in CHAPTER 6.

EB304070

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

Bleed the brake system whenever: the system is disassembled a brake hose is loosened or removed the brake fluid level is very low brake operation is faultyIf the brake system is not properly bled, aloss of braking performance may occur.

1. Bleed:Brake system

Air bleeding steps:a. Fill the reservoir with the proper brake fluid.b. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.c. Connect a clear plastic hose 1 tightly to the

caliper bleed screw 2 .d. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake lever several times.f. Pull the lever in. Hold the lever in position.

3-27

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/SHIFT PEDAL ADJUSTMENT

INSPADJ

NOTE:

NOTE:

**************************************************

g. Loosen the bleed screw and allow the leverto travel towards its limit.

h. Tighten the bleed screw when the lever limithas been reached, then release the lever.

i. Repeat steps (e) to (h) until all the airbubbles have disappeared from the brakefluid.

When bleeding the brake system, make surethat there is always enough brake fluid in thebrake fluid reservoir, before applying the brakelever. Ignoring this precaution could allow air toenter the brake system, lengthening the bleed-ing procedure, considerably.

j. Tighten the bleed screw.

Bleed screw:6 Nm (0.6 mkg)

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeat thebleeding procedure when the tiny bubbles in thebrake system have disappeared.

k. Fill the brake fluid reservoir to the properlevel.Refer to “BRAKE FLUID LEVEL INSPEC-TION”.

After bleeding the brake system check thebrake operation.

EB304080

SHIFT PEDAL ADJUSTMENT1. Check:

Shift pedal positionCheck the shift pedal rod length a .If the position is incorrect Adjust.

Shift pedal rod length:188 mm

3-28

SHIFT PEDAL ADJUSTMENT/FINAL GEAR OIL LEVEL INSPECTION

INSPADJ

*****************************************************

*****************************************************

NOTE:

NOTE:

23 Nm (2.3 mkg)

2. Adjust:Shift pedal position

Adjustment steps: Loosen both locknuts 1 . To obtain the correct pedal position turn the

shift pedal rod 2 in or out.

Turning in: shift pedal is lowered.

Turning out: shift pedal is raised.

Tighten both locknuts.

EB304110

FINAL GEAR OIL LEVEL INSPECTION1. Stand the motorcycle on a level surface.

When inspecting the final gear oil level, makesure the motorcycle is upright.


2. Remove:Oil filler bolt 1

3. Inspect:Oil levelOil level should be to the bottom brim 2 ofthe hole.Oil level is too low Add oil to the properlevel.

Recommended oil:SAE 80 API “GL-4” Hypoid gear oilIf necessary an SAE 80W90 hypoid gear oil may be used for all conditions.

“GL-4” is a quality and additive rating. “GL-5” or“GL-6” rated hypoid gear oils may also be used.

4. Install:Oil filler bolt

3-29

FINAL GEAR OIL REPLACEMENT/STEERING HEAD INSPECTION

INSPADJ

23 Nm (2.3 mkg)

NOTE:

23 Nm (2.3 mkg)

NOTE:

EB304120

FINAL GEAR OIL REPLACEMENT1. Place a container under the final gear case.2. Remove:

Oil filler bolt 1Drain plug 2Drain the final gear case of its oil.

3. Install:Drain plug

Check the drain plug gasket. If it is damaged, re-place it.

4. Fill:Final gear case

Oil quantity:0.19 L

Refer to “FINAL GEAR OIL LEVEL IN-SPECTION”.

5. Install:Oil filler bolt

EB304130

STEERING HEAD INSPECTION

Securely support the motorcycle so thatthere is no danger of it falling over.

1. Stand the motorcycle on a level surface.


2. Elevate the front wheel by placing a suit-able stand under the engine.

3. Check:Steering assembly bearingsGrasp the bottom of the lower front forktubes and gently rock the fork assembly.Looseness Adjust the steering head.

3-30

STEERING HEAD INSPECTIONINSPADJ

*****************************************************

NOTE:

4. LoosenFront fork pinch bolts (upper) 1

5. RemoveSteering stem nut 2Upper bracket 3

6. Adjust:Steering head

Adjustment steps: Remove the lock washer 1 , the upper ring

nut 2 and the rubber washer 3 . Loosen the lower ring nut 4 . Tighten the lower ring nut using the ring nut

wrench 5 .

Set the torque wrench at a right angle to the ringnut wrench.

Ring nut wrench:90890-01403

Lower ring nut:(initial tightening):52 Nm (5.2 mkg)

Loosen the lower ring nut 4 completely, thentighten it to specification.

Do not overtighten the ring nut.

Lower ring nut:(final tightening):18 Nm (1.8 mkg)

3-31

STEERING HEAD INSPECTION/FRONT FORK INSPECTION

INSPADJ

*****************************************************

NOTE:

110 Nm (11.0 mkg)

20 Nm (2.0 mkg)

Check the steering head for looseness orbinding by turning it all the way, in both direc-tions. If it binds, remove the steering stem as-sembly and inspect the steering bearings.Refer to “STEERING HEAD AND HAN-DLEBAR” in CHAPTER 6.

Install the rubber washer 3 . Install the upper ring nut 2 . 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 upperring nut until their slots are aligned.

Install the lock washer 1 .

Make sure the lock washer tabs sit correctly inthe ring nut slots.

7. Install:Upper bracketSteering stem nutFront fork pinch bolts (upper)

EB304140

FRONT FORK INSPECTION


1. Stand the motorcycle on a level surface.2. Check:

Inner tubeScratches/damage Replace.

Oil sealExcessive oil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check:OperationPush down hard on the handlebars sever-al times.Unsmooth operation Repair.Refer to “FRONT FORK” in CHAPTER 6.

3-32

REAR SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION

INSPADJ

NOTE:

*****************************************************

*****************************************************

CAUTION:

EB304160

REAR SHOCK ABSORBER ADJUSTMENT


Spring preload1. Adjust:

Spring preload

Use the special wrench and extension bar in-cluded in the owner’s tool kit to adjust the springpreload.

Adjustment steps: Turn the adjuster 1 in or out.

Selecting alower number:

Spring preload is softer.

Selecting ahigher number:

Spring preload is harder.

Adjustment numbers:Standard number: 3Minimum number: 1Maximum number: 7

Never turn the adjuster beyond the maxi-mum or minimum adjustment number.

EB304170

TIRE INSPECTION1. Measure:

Tire inflation pressureOut of specification Adjust.

3-33

TIRE INSPECTIONINSPADJ

Tire inflation pressure should only bechecked and adjusted when the tire tem-perature equals the ambient air tempera-ture. Tire inflation pressure and suspen-sion must be adjusted according to thetotal weight of the cargo, rider, passengerand accessories (fairing, saddlebags,etc.if approved for this model), and ac-cording to whether the motorcycle will beoperated at high speed or not.

NEVER OVERLOAD THE MOTORCYCLE. Operation of an overloaded motorcycle

could cause tire damage, an accident orinjury.

Basic weight:With oil andfull fuel tank

227 kg

Maximumload*:

180 kg (except for CH)178 kg (for CH)

Cold tirepressure:

Front Rear

Up to 90 kgload*

200 kPa(2.00 kgf /cm 2,2.00 bar)

225kPa(2.25 kgf /cm 2,2.25 bar)

90 kg maximumload*

200 kPa(2.00 kgf /cm 2,2.00 bar)

250 kPa(2.50 kgf /cm 2,2.50 bar)

High speedriding

200 kPa(2.00 kgf /cm 2,2.00 bar)

250 kPa(2.50 kgf /cm 2,2.50 bar)

* Load is the total weight of the cargo, rider,passenger and accessories.

2. Inspect:Tire surfacesWear/damage Replace.

Minimum tire tread depth:(front and rear):

1.6 mm

1 Tread depth2 Side wall3 Wear indicator

3-34

A B

TIRE INSPECTIONINSPADJ

It is dangerous to ride with a worn–outtire. When the tire tread begins to showsigns of wear, replace the tire immediate-ly.

Do not use tubeless tires on a wheel de-signed for tube type tires only. Tire failureand personal injury may result from sud-den deflation.

A Tire B Wheel

Tube type wheel: tube type tire only

Tubeless typewheel:

tube type ortubeless tire

When using tube type tires be sure toinstall the correct tube.

After extensive tests, the tires listed be-low have been approved by Yamaha Mo-tor Co., Ltd. for this model. No guaranteeconcerning handling characteristics canbe given if a tire combination, other thanone approved by Yamaha, is used on thismotorcycle. The front and rear tiresshould always be by the same manufac-turer and of the same design.

FRONT TIRE:

Manufacturer Size Type

BRIDGESTONE 100/90-19 57S L309

DUNLOP 100/90-19 57S F24

REAR TIRE:

Manufacturer Size Type

BRIDGESTONE 170/80-15M/C77S

G546

DUNLOP 170/80-15M/C77S

K555

After mounting a tire, ride conservatively fora while to give the tire time to seat itselfproperly in the rim. Failure to do so couldlead to an accident with possible injury tothe rider or damage to the motorcycle.

3-35

WHEEL INSPECTION/SPOKE INSPECTION ANDTIGHTENING/CABLE INSPECTION AND LUBRICATION

INSPADJ

NOTE:

NOTE:

EB304180

WHEEL INSPECTION1. Inspect:

WheelsBends/damage Replace.

After a tire or wheel has been changed or re-placed always balance the wheel.

Never attempt to make any repairs to thewheels.

EB304190

SPOKE INSPECTION AND TIGHTENING2. Inspect:

Spokes 1Bending/damage Replace.Loose spoke Retighten.

3. Tighten:Spokes

2 Spoke wrench

Be sure to tighten the spokes before and afterbreak-in.

Nipple:3 Nm (0.3 mkg)

EB304200

CABLE INSPECTION AND LUBRICATION

Damaged cable sheaths may cause corro-sion and interfere with cable movements.Replace damaged cable sheaths and cablesas soon as possible.

3-36

CABLE INSPECTION AND LUBRICATION/LEVER ANDPEDAL LUBRICATION/SIDESTAND LUBRICATION

INSPADJ

NOTE:

1. Inspect:Cable sheathsDamage Replace.

2. Check:Cable operationUnsmooth operation Lubricate.

Recommended lubricant:Engine oil

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath.

EB304210

LEVER AND PEDAL LUBRICATIONLubricate the pivoting points on the levers andpedals.

Recommended lubricant:Lithium soap base grease

EB304220

SIDESTAND LUBRICATIONLubricate the pivoting point and the contact sur-faces on the sidestand.

Recommended lubricant:Lithium soap base grease

3-37

BATTERY INSPECTIONINSPADJ

NOTE:

CAUTION:

EB305000

ELECTRICALBATTERY INSPECTION

Since the MF battery is a sealed type battery, itis not possible to measure the specific gravity ofthe electrolyte in order to check the charge stateof the battery. Therefore the charge of the bat-tery has to be checked by measuring the volt-age at the battery terminals.

CHARGING METHOD This is a sealed type battery. Never re-

move the sealing caps. If the sealing capshave been removed, the balance will notbe maintained and battery performancewill deteriorate.

Charging time, charging current andcharging voltage for the MF battery aredifferent from those of general type bat-teries. The MF battery should be chargedas explained in “CHARGING METHOD”. Ifthe battery is overcharged, the electrolytelevel will drop considerably. Therefore,take special care when charging the bat-tery.

Battery electrolyte is dangerous; it containssulfuric acid which is poisonous and highlycaustic. Always follow these preventive measures: Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eyeinjury.

Wear protective eye gear when handlingor working near batteries.

Antidote (EXTERNAL): SKIN – Wash with water. EYES – Flush with water for 15 minutes

and get immediate medical attention.Antidote (INTERNAL): Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten eggor vegetable oil. Get immediate medicalattention.

3-38

Volt meter


CAUTION:

*****************************************************

NOTE:

Batteries generate explosive hydrogen gas.Always follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,lighted cigarettes, etc.)

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.

1. Remove:Rider’s seatRefer to “FUEL TANK AND SEATS”.

Battery cover 1

2. Disconnect:Battery leads

First disconnect the negative lead 1 , thendisconnect the positive lead 2 .

3. Remove:Battery bandBattery

4. Check:Battery condition

Battery condition checking steps: Connect a digital voltmeter to the battery ter-

minals.

Tester (+) lead battery (+) terminalTester (–) lead battery (–) terminal

The charge state of an MF battery can bechecked by measuring the open-circuit voltage(i.e. the voltage when the positive terminal isdisconnected).

Open-circuitvoltage

Charging time

12.8V or higherNo charging is

necessary.

3-39

Relationship between open-circuit voltage and charging time at 20C

Ope

n-ci

rcui

t vol

tage

Charging time (Hours)D This varies depending on the temperature, the state of

charge in battery plates and the electro lyte level.

Ope

n-ci

rcui

t vol

tage

(V

)

18

Condition of charge in battery (%)

Ambient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

17

16

15

14

13

12

11

10 0 10 20 30 40 50 60

Charging Ambient temperature20C

Check the Open-circuit voltage

Time (Minutes)


*****************************************************

CAUTION:

Check the condition of the battery using thefollowing charts.

Example: Open-circuit voltage = 12.0V Charging time = 6.5 hours Charge condition of the battery = 20 X 30% Charging method for MF batteries

If it is impossible to set the standardcharging current, be careful not to over-charge.

When charging the battery, be sure to re-move it from the motorcycle. (If charginghas to be done with the battery mountedon the motorcycle, be sure to disconnectthe wire at the negative terminal.)

Never remove the sealing caps of an MFbattery.

Make sure that the charging clips are infull contact with the terminal and that theyare not shorted together. (A corroded clipon the charger may cause the battery togenerate heat in the contact area. A weakclip spring may cause sparks.)

Before removing the clips from the bat-tery terminals, be sure to turn off the char-ger’s power switch.

The open-circuit voltage variation for theMF battery, after charging, is shown be-low. As shown in the figure, the open-cir-cuit voltage stabilizes about 30 minutesafter charging has been completed.Therefore, wait 30 minutes after chargingis completed before measuring the open-circuit voltage.

3-40

Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the batteryand start charging.

Make sure the current ishigher than the standardcharging current written onthe battery.

By turning the charging volt-age adjust dial, set the chargingvoltage at 20 25 V.

Adjust the voltage so that cur-rent is at standard charginglevel.

Monitor the amperage for 3 5 minutes to check if the stan-dard charging current isreached.

Set the timer according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps.”

If the current doesnot exceed stan-dard charging cur-rent after 5 minutes,replace the battery.

In case that charging requires more than 5 hours, it is advisable tocheck the charging current after a lapse of 5 hours. If there is anycharge in the amperage, readjust the voltage to obtain the standardcharging current.

Measure the battery open-circuit voltage after having left the batteryunused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.

YES NO

YES

NO

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

NOTE:Set the charging voltage at 16 X 17 V. (Ifthe setting is lower, charging will be in-sufficient. If too high, the battery will beover-charged.)

ChargerAMP meter


Charging method using a variable-current (voltage) type charger

3-41

Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the batteryand start charging.

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

Make sure the current ishigher than the standardcharging current written onthe battery.

Charge the battery until the battery’scharging voltage is 15 V.

This type of battery charger cannotcharge the MF battery. A variable volt-age charger is recommended.

Measure the battery open-circuitvoltage after having left the batteryunused for more than 30 minutes.12.8 V or more --- Charging is com-plete.12.7 V or less --- Recharging is re-quired.Under 12.0 V --- Replace the battery.

NOTE:Set the charging time at 20 hours (maxi-mum).

YES NO

Charging method using a constant-current type chargerThis type of battery charger cannot charge the MF battery.

Volt meter

Charger

AMP meter


Charging method using a constant-voltage type charger

3-42

BATTERY INSPECTION/FUSE INSPECTION

INSPADJ

NOTE:

CAUTION:

CAUTION:

*****************************************************

5. Inspect:Battery terminalsDirty Clean with a wire brush.Poor connection Correct.

After cleaning the terminals, apply a light coat ofgrease.

6. Install:BatteryBattery band

7. Connect:Battery leads

First, connect the positive lead 1 , then con-nect the negative lead 2 .

8. Install:Rider’s seatRefer to “FUEL TANK AND SEATS”.

EB305010

FUSE INSPECTION

When checking or replacing the fuse alwaysturn off the main switch. Otherwise, a shortcircuit may occur.

1. Remove:Battery cover

2. Inspect:Fuses

Inspection steps: Connect the pocket tester and check the fuse

for continuity.

3-43

FUSE INSPECTIONINSPADJ

NOTE:

*************************************

*****************************************************

*****************************************************

Set the tester selector to “Ω 1”.

Pocket tester:90890-03112

If the tester indicates ∞, replace the fuse.

3. Replace:Blown fuse

Replacement steps: Turn off the main switch. Install a new fuse with the proper current rat-

ing. Turn on switches to verify operation of related

electrical devices. If the fuse blows again, immediately check

the electrical circuit.

Description Current rating Quantity

Main 30A 1

Headlight 15A 1

Carburetorheater

15A 1

Signals 10A 1

Ignition 10A 1

Reserve 30A 1

Reserve 15A 1

Reserve 10A 1

Never use a fuse with a rating other than thatspecified. Never use other materials in placeof a fuse. An improper fuse may cause ex-tensive damage to the electrical system, amalfunction of the lighting and ignition sys-tems and could possibly cause a fire.

4. Install:Battery cover

3-44

HEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENT

INSPADJ

EB305020

HEADLIGHT BEAM ADJUSTMENT1. Adjust:

Headlight beam (vertically)Turn the adjuster 1 in or out.

Turning in: headlight beam is raised.

Turning out: headlight beam is lowered.

2. Adjust:Headlight beam (horizontally)Turn the adjuster 2 in or out.

Turning in: headlight beam to the left.

Turning out: headlight beam to the right.

EB305030

HEADLIGHT BULB REPLACEMENT1. Remove:

Headlight lens unit2. Disconnect:

Leads (in headlight body) 13. Remove:

Bulb cover 2

4. Unhook:Bulb holder 1

5. Remove:Bulb 2

Since the bulb may be hot, keep flammableproducts and your hands away from it. Donot touch the bulb until it has cooled down.

6. Install:Bulb (new)Secure the new bulb with the bulb holder.

3-45

HEADLIGHT BULB REPLACEMENTINSPADJ

CAUTION:

Avoid touching the glass part of the bulb.Keep it free from oil, otherwise the transpar-ency of the glass, life of the bulb and the lu-minous flux will be adversely affected. If oilgets on the bulb, thoroughly clean it with acloth moistened with alcohol or lacquerthinner.

7. Hook up:Bulb holder

8. Install:Bulb cover

9. Connect:Leads (in headlight body)

10. Install:Headlight lens unit

INSPADJ

ENG

CHAPTER 4.ENGINE

ENGINE REMOVAL 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLERS, BRAKE PEDAL AND SIDE COVER 4-1. . . . . . . . . . . . . . . CYLINDER HEAD COVERS 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND AND CRANKCASE COVER (LEFT) 4-5. . . . . . . . . . . . . . . ENGINE MOUNTING BOLTS 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL INSTALLATION 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PEDAL INSTALLATION 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEADS 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD REMOVAL 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSPECTION 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSTALLATION 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARMS AND CAMSHAFT 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND CAMSHAFT REMOVAL 4-18. . . . . . . . . . . . . . . . . . . ROCKER ARM AND CAMSHAFT INSPECTION 4-18. . . . . . . . . . . . . . . . ROCKER ARM AND CAMSHAFT INSTALLATION 4-19. . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE AND VALVE SPRING REMOVAL 4-22. . . . . . . . . . . . . . . . . . . . . . . VALVE AND VALVE SPRING INSPECTION 4-22. . . . . . . . . . . . . . . . . . . . VALVE AND VALVE SPRING INSTALLATION 4-26. . . . . . . . . . . . . . . . . .

CYLINDERS AND PISTONS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON REMOVAL 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER AND PISTON INSPECTION 4-29. . . . . . . . . . . . . . . . . . . . . . . PISTON RING INSPECTION 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON PIN INSPECTION 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER AND PISTON INSTALLATION 4-33. . . . . . . . . . . . . . . . . . . . .

CLUTCH 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE COVER (RIGHT) 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH ASSEMBLY 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH REMOVAL 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY DRIVE GEAR REMOVAL 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH INSPECTION 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH ROD INSPECTION 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY DRIVE GEAR INSTALLATION 4-40. . . . . . . . . . . . . . . . . . . . . . CLUTCH INSTALLATION 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT INSPECTION 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT INSTALLATION 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

OIL PUMP 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP INSPECTION 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC MAGNETO AND STARTER CLUTCH 4-48. . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL AND PICKUP COIL 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . AC MAGNETO AND STARTER CLUTCH 4-49. . . . . . . . . . . . . . . . . . . . . . AC MAGNETO REMOVAL 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH INSPECTION 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . AC MAGNETO INSTALLATION 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT AND CONNECTING RODS 4-53. . . . . . . . . . . . . . . . . . . . . . . CRANKCASE 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CONNECTING RODS 4-55. . . . . . . . . . . . . . . . . . . . CRANKCASE SEPARATION 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT REMOVAL 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSPECTION 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT INSTALLATION 4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE ASSEMBLY 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 4-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT CAM INSPECTION 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION INSPECTION 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION INSTALLATION 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MIDDLE GEAR 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVEN PINION GEAR 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVE PINION GEAR 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVEN PINION GEAR REMOVAL 4-72. . . . . . . . . . . . . . . . . . . MIDDLE DRIVE PINION GEAR REMOVAL 4-73. . . . . . . . . . . . . . . . . . . . . MIDDLE GEAR INSPECTION 4-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVE PINION GEAR INSTALLATION 4-74. . . . . . . . . . . . . . . . MIDDLE DRIVEN PINION GEAR INSTALLATION 4-75. . . . . . . . . . . . . . . MIDDLE DRIVE GEAR SHIM SELECTION 4-78. . . . . . . . . . . . . . . . . . . . . GEAR BACKLASH ADJUSTMENT 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1


1234

5678

Muffler, brake pedal and side coverremoval

Muffler assembly (upper)Muffler assembly (lower)Exhaust pipe gasketBrake pedal link

Rear brake switchBrake pedal/ footrest (right)Exhaust pipeExhaust pipe gasket

1111

11/111

Remove the parts in the order below.Stand the motorcycle on a level sur-face.

Securely support the motorcycle sothere is no danger of it falling over.

Refer to “BRAKE PEDAL INSTALLA-TION”.

64 Nm (6.4 m kg)

20 Nm (2.0 m kg)

25 Nm (2.5 m kg)

10 Nm (1.0 m kg) 20 Nm (2.0 m kg)

ENGINE REMOVAL ENG

ENGINEENGINE REMOVALMUFFLERS, BRAKE PEDAL AND SIDE COVER

4-2

ENGINE REMOVAL ENG


910

Battery coverSide cover (right)

11

For installation, reverse the removalprocedure.

64 Nm (6.4 m kg)

20 Nm (2.0 m kg)

25 Nm (2.5 m kg)

10 Nm (1.0 m kg) 20 Nm (2.0 m kg)

4-3


1

2345678

Cylinder head covers removalFuel tank

Carburetor assembly

Battery leads

Starter motor assemblySpark plug capIgnition coil (cylinder #1 side)Baffle coverUpper cylinder head cover (rear)Lower cylinder head cover (rear)Upper cylinder head cover (front)

2

1111111

Remove the parts in the order below.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.Refer to “CARBURETOR” in CHAPTER5.Disconnect

First, disconnect the negative lead,then disconnect the positive lead.

NOTE:

5 Nm (0.5 m kg)

10 Nm (1.0 m kg)10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

5 Nm (0.5 m kg)

ENGINE REMOVAL ENG

CYLINDER HEAD COVERS

4-4


9 Lower cylinder head cover (front) 1For installation, reverse the removalprocedure.

5 Nm (0.5 m kg)

10 Nm (1.0 m kg)10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

5 Nm (0.5 m kg)

ENGINE REMOVAL ENG

4-5


1234

56789

Side stand and crankcase cover(left) removalEngine oil

Side cover (left)Middle gear case coverSidestand assemblyShift pedal/ footrest (left)

Clutch cableNeutral switch leadCrankcase cover (left) /gasketDowel pinsRectifier/regulator

111

1/1

11

1/121

Remove the parts in the order below.

DrainRefer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Do not remove the “*” bolts.

Refer to “SHIFT PEDAL INSTALLA-TION”.

For installation, reverse the removal pro-cedure.

30 Nm (3.0 m kg)

13 Nm (1.3 m kg)10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

64 Nm (6.4 m kg)

ENGINE REMOVAL ENG

SIDESTAND AND CRANKCASE COVER (LEFT)

4-6


123456

7

Engine mounting bolt removal

Engine stay (front-upper/ left)Engine stay (front-upper/right)Cable holderEngine stay (front-lower/ left)Engine stay (front-lower/right)Engine mounting bolt (rear-upper/left)Engine mounting bolt (rear-upper/right)

111111

1

Remove the parts in the order below.Place a suitable stand under the frameand engine.


L=75 mm

L=60 mm

74 Nm (7.4 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

30 Nm (3.0 m kg)

30 Nm (3.0 m kg)

ENGINE REMOVAL ENG

ENGINE MOUNTING BOLTS

4-7


89

10

Engine mounting bolt (rear-lower)Rubber bootEngine assembly

111

L=150mm

Remove the engine assembly from theright side of the motorcycle.


NOTE:

74 Nm (7.4 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

40 Nm (4.0 m kg)40 Nm (4.0 m kg)

40 Nm (4.0 m kg)

30 Nm (3.0 m kg)

30 Nm (3.0 m kg)

ENGINE REMOVAL ENG

4-8

ENGINE REMOVAL ENG

10 Nm (1.0 mkg)

NOTE:

10 Nm (1.0 mkg)

NOTE:

SHIFT PEDAL INSTALLATION1. Connect

Shift pedal link 1

Align the punch mark a on the shift rod with theslot b on the shift pedal link

BRAKE PEDAL INSTALLATION1. Connect

Brake pedal link 1

Align the punch mark a on the brake rod withthe slot b on the brake pedal link

4-9

20 Nm (2.0 m kg)


12345

67

89

1011

Cylinder head removalEngine assemblyCylinder head cover bracketsTappet cover (exhaust)/O-ringTappet cover (intake)/O-ringCamshaft sprocket cover/O-ringBaffle plate/O-ring (only rear cylin-der head)Timing chain tensioner/gasketCamshaft sprocket plate (only rearcylinder head)Camshaft sprocketExhaust pipe joint (rear)/gasketCarburetor joint/O-ringCylinder head

21/11/11/11/1

1/11

11/11/11

Remove the parts in the order below.Refer to “ENGINE REMOVAL”.

Refer to “CYLINDER HEADREMOVAL/INSTALLATION”.

35 Nm (3.5 m kg)

10 Nm (1.0 m kg)

20 Nm (2.0 m kg)

12 Nm (1.2 m kg)

35 Nm (3.5 m kg)

20 Nm (2.0 m kg)

10 Nm (1.0 m kg)

55 Nm (5.5 m kg)

CYLINDER HEADS ENG

CYLINDER HEADS

4-10

20 Nm (2.0 m kg)


1213

Dowel pinsCylinder head gasket

21


35 Nm (3.5 m kg)

10 Nm (1.0 m kg)

20 Nm (2.0 m kg)

12 Nm (1.2 m kg)

35 Nm (3.5 m kg)

20 Nm (2.0 m kg)

10 Nm (1.0 m kg)

55 Nm (5.5 m kg)

CYLINDER HEADS ENG

4-11

CYLINDER HEADS ENG

*****************************************************

*****************************************************

NOTE:

NOTE:

CYLINDER HEAD REMOVALRear cylinder head

1. Align: “T” mark(with the stationary pointer)

Removal steps: Temporarily install the AC magneto cover

without the pickup coil and stator coil. Turn the crankshaft clockwise. Align the “T” mark a with the stationary

pointer b on the crankcase cover (left) whenthe rear piston is at TDC on the compressionstroke.

When the “T” mark is aligned with the station-ary pointer the punch mark c on the cam-shaft sprocket should be aligned with the sta-tionary pointer d on the cylinder head.

The rear piston is at TDC on the compressionstroke when there is clearance at both of therocker arms. If there is no clearance then turnthe crankshaft clockwise one full turn.

Check that the rear piston is at TDC in thecompression stroke.

2. Loosen:Bolt (camshaft sprocket) 1

Use the sheave holder 2 to hold the rotor.

Sheave holder:90890-01701

3. Loosen:Cap bolt (timing chain tensioner)

4. Remove:Timing chain tensionerGasket

5. Remove:Bolt (camshaft sprocket) 1Camshaft sprocket plate 2(only rear)

Camshaft sprocket 3

To prevent the timing chain from falling into thecrankcase fasten a wire to it.

4-12

CYLINDER HEADS ENG

NOTE:

NOTE:

*****************************************************

*****************************************************

NOTE:

6. Remove:Cylinder head

Loosen the bolts and nuts in the proper se-quence.

Follow the numerical order shown in the il-lustration. Loosen each bolt 1/4 of a turn at atime until all of the bolts are loose.

Front cylinder head

When removing the front cylinder head cam-shafts, repeat the rear cylinder head camshaftsremoval procedures. However, note the follow-ing points.

1. Align: “I” mark(with the stationary pointer)

Removal steps: Turn the crankshaft clockwise 290. Align the “I” mark a with the stationary point-

er b on the crankcase cover (left) when thefront piston is at TDC on the compressionstroke.

When the “I” mark is aligned with the station-ary pointer the punch mark c on the cam-shaft sprocket should be aligned with the sta-tionary pointer d on the cylinder head.

The front piston is at TDC on the compres-sion stroke when there is clearance at both ofthe rocker arms. If there is no clearance thenturn the crankshaft clockwise one full turn.

Check that the front piston is at TDC in thecompression stroke.

CYLINDER HEAD INSPECTION1. Eliminate:

Carbon deposits (from the combustionchambers)Use a rounded scraper.

Do not use a sharp instrument to avoid damag-ing or scratching: Spark plug threads Valve seats

2. Inspect:Cylinder headsScratches/damage Replace.

4-13

CYLINDER HEADS ENG

*****************************************************

*****************************************************

NOTE:

3. Measure:Cylinder head warpageOut of specification Resurface.

Cylinder head warpage:Less than 0.03 mm

Warpage measurement and resurfacementsteps: Place a straightedge 1 and a feeler gauge

2 across the cylinder head. Use a feeler gauge to measure the warpage. If the warpage is out of specification, resur-

face the cylinder head. Place a 400 600 grit wet sandpaper on the

surface plate, and resurface the head using afigure-eight sanding pattern.

To ensure an even surface rotate the cylinderhead several times.

4. Inspect:Camshaft sprocketsWear/damage Replace the camshaftsprockets and the timing chain as a set.

a 1/4 toothb Correct1 Roller2 Sprocket

5. Check:One-way cam operation (tensioner)Unsmooth operation Replace.

4-14

CYLINDER HEADS ENG

35 Nm (3.5 mkg)

20 Nm (2.0 mkg)

NOTE:

*****************************************************

*****************************************************

CYLINDER HEAD INSTALLATIONRear cylinder head

1. Install:Nuts (cylinder head) (M10: 1 4)

Bolts (cylinder head) (M8: 5 7)

Tighten the bolts and nuts in the proper se-quence.

Follow the numerical order shown in the il-lustration. Tighten the bolts and nuts in twostages.

2. Install:Camshaft sprocket

Installation steps: Turn the crankshaft clockwise. Align the “T” mark a with the stationary

pointer b on the crankcase cover (left). Install the camshaft sprocket with the timing

mark c facing out. Turn the camshaft just enough to remove any

slack from the exhaust side of the timingchain.

Insert your finger into the hole and timingchain tensioner hole and push the timingchain guide inward.

While pushing the timing chain guide, be surethat the timing mark c and the stationarypointer d are properly aligned at TDC.

4-15

CYLINDER HEADS ENG

*****************************************************

*****************************************************

55 Nm (5.5 mkg)

NOTE:

3. Install:Timing chain tensioner

Installation steps: Remove the tensioner cap bolt 1 , washer 2

and spring 3 . Release the timing chain tensioner one-way

cam 4 and push the tensioner rod 5 all theway in.

Install the tensioner 6 with a new gasket intothe cylinder.

Bolts (timing chain tensioner):12 Nm (1.2 mkg)

Always use a new gasket.

Install the spring, washer and cap bolt.

Cap bolt (timing chain tensioner):20 Nm (2.0 mkg)

4. Install:Camshaft sprocket plate 1Bolt (camshaft sprocket) 2

Be sure the projection on the camshaftsprocket plate is aligned with the hole in thesprocket.

Use the sheave holder 3 to hold the rotor.


5. Check:Alignment marksIf the marks do not aligh Adjust.

6. Measure:Valve clearanceOut of specification Adjust.Refer to “VALVE CLEARANCE AD-JUSTMENT” in CHAPTER 3.

4-16

CYLINDER HEADS ENG

NOTE:

*****************************************************

*****************************************************

Front cylinder head

When installing the front cylinder head cam-shafts, repeat the rear cylinder head camshaftsinstallation procedure. However, note the fol-lowing points.

1. Install:Camshaft sprocket

Installation steps: Turn the crankshaft clockwise 290. Align the “I” mark a with the stationary point-

er b on the crankcase cover (left). Install the camshaft sprocket with the timing

mark c facing out. Turn the camshaft just enough to remove any

slack from the intake side of the timing chain. Insert your finger into the hole and timing

chain tensioner hole and push the timingchain guide inward.

While pushing the timing chain guide, be surethat the timing mark c and the stationarypointer d are properly aligned at TDC.

4-17


123456789

Rocker arm and camshaft removalCylinder headsLock washerStopper plateUnion bolt /gasketRocker arm shaftsRocker armsCamshaft bushingCamshaft /dowel pinLocknutsValve adjusters

11

2/2221

1/122

Remove the parts in the order below.Refer to “CYLINDER HEAD”.

Refer to “ROCKER ARM AND CAM-SHAFT REMOVAL/INSTALLATION”.


38 Nm (3.8 m kg)

14 Nm (1.4 m kg)

14 Nm (1.4 m kg)

20 Nm (2.0 m kg)

ROCKER ARMS AND CAMSHAFT ENG

ROCKER ARMS AND CAMSHAFT

4-18


NOTE:

NOTE:

ROCKER ARM AND CAMSHAFT REMOVAL1. Remove:

Rocker arm shafts (intake and exhaust) 1Rocker arms 2

Use a slide hammer 3 to remove the rockerarm shafts.

Slide hammer bolt (M8):90890-01085

Weight:90890-01084

2. Remove:Camshaft bushing 1Camshaft 2

Screw a 10 mm bolt 3 into the threaded end ofthe camshaft and pull out the camshaft.

ROCKER ARM AND CAMSHAFTINSPECTION

1. Inspect:Camshaft bushingsDamage/wear Replace.

2. Inspect:Camshaft lobes 1Valve adjusters 2Blue discoloration/pitting/scratches

Replace.3. Measure:

Camshaft lobe length a and width bOut of specification Replace.

Camshaft lobe limit:Intake

a 39.63 mmb 32.12 mm

Exhausta 39.67 mmb 32.20 mm

4-19


*****************************************************

*****************************************************

20 Nm (2.0 mkg)

4. Inspect:Rocker armsRocker arm shaftsDamage/wear Replace.

Inspection steps: Inspect the two contact areas on the rocker

arms for signs of abnormal wear.1) Rocker arm shaft hole.2) Camshaft lobe contact surface.

Excessive wear Replace. Inspect the surface of the rocker arm shafts.

Blue discoloration/pitting/scratches Re-place/check lubrication.

Measure the inside diameter a of the rockerarm holes.Out of specification Replace.

Rocker arm inside diameter:14.000 14.018 mm

Measure the outside diameter b of the rock-er arm shafts.Out of specification Replace.

Rocker arm outside diameter:13.980 13.991 mm

Calculate the clearance by subtracting therocker arm shaft outside diameter from therocker arm inside diameter.Clearance greater than 0.08 mm Replacethe defective part(s).

Rocker arm to shaft standardclearance:

0.009 0.038 mm

ROCKER ARM AND CAMSHAFTINSTALLATION

1. Apply:Molybdenum disulfide oil(onto the camshaft journals)

2. Install:Camshaft 1Camshaft bushing 2Stopper plate 3Lock washer 4Bolts (stopper plate) 5

4-20


NOTE:

NOTE:

The dowel pin a on the end of the camshaftmust align with the timing mark b on the cyl-inder head.

Make sure that the No.1 camshaft 6 isinstalled in the rear cylinder head and theNo.2 camshaft 7 is installed in the front cyl-inder head.

3. Apply:Engine oil(onto the rocker arm shafts)

4. Install:Rocker arms 1Rocker arm shafts (intake and exhaust) 2

The thread hole a of the rocker arm shaftsmust face to the outside.

After installation, make sure that the threadhole a of the rocker arm shaft is positionedcorrectly, as shown in the illustration.

4-21

VALVES AND VALVE SPRINGS ENG


1

234567

Valve and valve spring removalCylinder headsRocker arms and camshafts

Valve cotters

Valve spring retainersValve springsValve (intake)Valve (exhaust)Valve stem sealsValve spring seats

4

221122

Remove the parts in the order below.Refer to “CYLINDER HEADS”.Refer to “ROCKER ARMS AND CAM-SHAFT”.Refer to “VALVE AND VALVE SPRINGREMOVAL/INSTALLATION”.

Refer to “VALVE AND VALVESPRING INSTALLATION”.


VALVES AND VALVE SPRINGS

4-22


*****************************************************

*****************************************************

NOTE:

ab

VALVE AND VALVE SPRING REMOVAL1. Check:

Valve sealingLeakage at the valve seat Inspect thevalve face, valve seat and valve seatwidth.Refer to “INSPECTION”.

Checking steps: Pour a clean solvent 1 into the intake and

exhaust ports. Check that the valve seals properly.

There should be no leakage at the valve seat2 .

2. Remove:Valve cotters

Attach a valve spring compressor 1 betweenthe valve spring retainer and the cylinder headto remove the valve cotters.

Valve spring compressor:90890-04019

VALVE AND VALVE SPRING INSPECTION1. Measure:

Stem-to-guide clearance

Stem-to-guide clearance =valve guide inside diameter –valve stem diameter

Out of specification Replace the valveguide.

Clearance (stem to guide):Intake:

0.010 0.037 mm<Limit>: 0.08 mm

Exhaust:0.025 0.052 mm<Limit>: 0.10 mm

4-23


*****************************************************

*****************************************************

NOTE:

NOTE:

2. Replace:Valve guide

Replacement steps:

To ease guide removal, installation and to main-tain correct fit heat the cylinder head in an ovento 100C.

Remove the valve guide using a valve guideremover 1 .

Install the new valve guide using a valveguide remover 1 and valve guide installer2 .

After installing the valve guide, bore the valveguide using a valve guide reamer 3 to obtainproper stem-to-guide clearance.

Valve guide remover & installer(7.0 mm):

90890-04018

After replacing the valve guide reface the valveseat.

3. Inspect:Valve facePitting/wear Grind the face.

Valve stem endMushroom shape or diameter larger thanthe body of the stem Replace.

4. Measure:Margin thickness aOut of specification Replace.

Margin thickness:Intake:

1.0 1.4 mm<Limit>: 0.8 mm


4-24

b


NOTE:

*****************************************************

*****************************************************

5. Measure:Runout (valve stem)Out of specification Replace.

Runout limit:0.03 mm

When installing a new valve always replacethe guide.

If the valve is removed or replaced always re-place the oil seal.

6. Eliminate:Carbon deposits(from the valve face and valve seat)

7. Inspect:Valve seatsPitting/wear Reface the valve seat.

8. Measure:Valve seat width aOut of specification Reface the valveseat.

Valve seat width:Intake:

1.0 1.2 mm<Limit>: 1.8 mm


Measurement steps: Apply Mechanic’s blueing dye (Dykem) b to

the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. Measure the valve seat width. Where the

valve seat and valve face made contact,blueing will have been removed.

If the valve seat is too wide, too narrow, or theseat is not centered, the valve seat must berefaced.

4-25


NOTE:

*****************************************************

*****************************************************

CAUTION:

NOTE:

NOTE:

9. Lap:Valve faceValve seat

After refacing the valve seat or replacing thevalve and valve guide, the valve seat and valveface should be lapped.

Lapping steps: Apply a coarse lapping compound to the

valve face.

Do not let the compound enter the gap be-tween the valve stem and the guide.

Apply molybdenum disulfide oil to the valvestem.

Install the valve into the cylinder head. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe compound.

For best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hands.

Apply a fine lapping compound to the valveface and repeat the above steps.

After every lapping operation be sure to cleanoff all of the compound from the valve face andvalve seat.

Apply Mechanic’s blueing dye (Dykem) to thevalve face.

Install the valve into the cylinder head. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. Measure the valve seat width again. If the

valve seat width is out of specification, refaceand relap the valve seat.

4-26


NOTE:

10. Measure:Valve spring free length aOut of specification Replace.

Free length (valve spring):43.2 mm<Limit>: 42.0 mm

11. Measure:Compressed spring force aOut of specification Replace.

b Installed length

Compressed spring force:21.8 25.6 kg at 37.1 mm

12. Measure:Spring tilt aOut of specification Replace.

Spring tilt limit:2.5 /1.9 mm

VALVE AND VALVE SPRING INSTALLATION1. Apply:

Molybdenum disulfide oil(onto the valve stem and valve stem seal)

2. Install:Valve spring seatsValve stem seals ValvesValve springsValve spring retainers

Install the valve springs with the larger pitch afacing upwards.

b Smaller pitch

4-27


NOTE:

CAUTION:

3. Install:Valve cotters

While compressing the valve spring with a valvespring compressor 1 install the valve cotters.

Valve spring compressor:90890-04019

4. To secure the valve cotters onto the valvestem lightly tap the valve tip with a piece ofwood.

Hitting the valve tip with excessive forcecould damage the valve.

4-28


1

2

3456789

Cylinder and piston removalCylinder headsTiming chain guide

Cylinder/O-ring

O-ring/collarDowel pinsCylinder gasketPiston pin clipsPiston pinPistonPiston ring set

1

1/1

1/1212111

Remove the parts in the order below.Refer to “CYLINDER HEADS”.The “up” mark should face towardsthe cylinder head.Refer to “CYLINDER AND PISTONINSTALLATION”.

Refer to “PISTON REMOVAL/CYLINDER AND PISTONINSTALLATION”.


10 Nm (1.0 m kg)

CYLINDERS AND PISTONS ENG

CYLINDERS AND PISTONS

4-29


NOTE:

CAUTION:

NOTE:

*****************************************************

PISTON REMOVAL1. Remove:

Piston pin clips 1Piston pin 2Piston 3

Put identification marks on each piston headfor reference during reinstallation.

Before removing each piston pin, deburr theclip groove and pin hole area. If the piston pingroove is deburred and the piston pin is stilldifficult to remove, use the piston pin puller4 .

Piston pin puller:90890-01304

Do not use a hammer to drive the piston pinout.

2. Remove:Piston rings

Spread the end gaps apart while at the sametime lifting the piston ring over the top of the pis-ton crown, as shown in the illustration.

CYLINDER AND PISTON INSPECTION1. Inspect:

Cylinder and piston wallsVertical scratches Rebore or replacethe cylinder and the piston.

2. Measure:Piston-to-cylinder clearance

Measurement steps:1st step: Measure the cylinder bore “C” with a cylinder

bore gauge.a 40 mm from the top of the cylinder

4-30


NOTE:

C =

*****************************************************

Measure the cylinder bore “C” horizontally andlaterally.

StandardWearlimit

Cylinderbore C:

80.965 81.015 mm 81.1 mm

X + YX 2 Y

Find the average of the measurements. If out of specification, rebore or replace the

cylinder and replace the piston and pistonrings as a set.

2nd step: Measure the piston skirt diameter “P” with a

micrometer.

b 6 mm from the piston bottom edge.

Piston size P

Standard 80.92 80.97 mm

If out of specification, replace the piston andthe piston rings as a set.

3rd step: Use the following formula to calculate the pis-

ton-to-cylinder clearance:

Piston-to-cylinder clearance =Cylinder bore “C” –

Piston skirt diameter “P”

Clearance (piston to cylinder):0.035 0.055 mm<Limit>: 0.15 mm

If out of specification, rebore or replace thecylinder and replace the piston and the pistonrings as a set.

4-31


NOTE:

NOTE:

NOTE:

PISTON RING INSPECTION1. Measure:

Side clearance (piston to piston rings)Out of specification Replace the pistonand the piston rings as a set.

Before measuring the side clearance removethe carbon deposits from the piston ringgrooves and rings.

Side clearance (piston ring):Top ring:

0.03 0.07 mm<Limit>: 0.12 mm

2nd ring:0.02 0.06 mm<Limit>: 0.12 mm

2. Position:Piston ring(into the cylinder)

Using the piston crown push the ring into thecylinder so that the ring will be at a right angle tothe cylinder bore.

a 40 mm

3. Measure:End gapOut of specification Replace.

You cannot measure the end gap on the expan-der spacer of the oil ring. If the oil ring rails showexcessive gap, replace all three rings.

End gap:Top ring:

0.15 0.30 mm<Limit>: 0.55 mm

2nd ring:0.30 0.45 mm<Limit>: 0.80 mm

Oil ring:0.2 0.7 mm

4-32


*****************************************************

*****************************************************

ba

PISTON PIN INSPECTION1. Inspect:

Piston pinBlue discoloration/grooves Replace,then inspect the lubrication system.

2. Measure:Piston pin-to-piston clearance

Measurement steps: Measure the piston pin outside diameter a .

If out of specification, replace the piston pin.

Outside diameter (piston pin):19.995 20.000 mm

Measure the piston inside diameter b . Calculate the piston pin-to-piston clearance

using the following formula:

Piston pin-to-piston clearance =Bore size (piston pins) –Outside diameter (piston pins)

If out of specification, replace the piston.

Clearance (piston pin to piston):

0.004 0.020 mm

4-33

CYLINDER AND PISTONS ENG

NOTE:

NOTE:

NOTE:

NOTE:

CYLINDER AND PISTON INSTALLATION1. Install:

Piston ring (top ring) 1Piston ring (second ring) 2

Be sure to install the piston rings so that themanufacturer’s marks or numbers are lo-cated on the upper side of the rings.

Lubricate the piston and piston rings liberallywith engine oil.

2. Position:Top ring 12nd ring 2Oil ring 3Offset the piston ring end gaps as shown.

a Top ring endb Oil ring end (lower)c Oil ring end (upper)d 2nd ring end3. Install:

Piston 1Piston pin 2Piston pin clips 3

Apply engine oil onto the piston pin, pistonring and piston.

Be sure that the piston is positioned correctly,as shown in the illustration.

a “EX” mark4. Lubricate:

PistonPiston ringsCylinder

Apply a liberal coating of engine oil.

5. Install:Cylinder

Install the cylinder with one hand while com-pressing the piston rings with the other hand.

4-34

Remove the parts in the order below.Stand the motorcycle on a level surface.


Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.

Refer to “ENGINE REMOVAL”.

L=70 mm 1, 65 mm 1, 25 mm 3

L=65 mm 1, 55 mm 1, 45 mm 4,30 mm 4


12345

Crankcase cover (right) removal

Engine oil

Muffler assembly 1,2Brake pedal linkOil filter cover plateOil filter coverO-ringOil filterCrankcase cover (right)

11111

10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

CLUTCH ENG

CLUTCHCRANKCASE COVER (RIGHT)

4-35

CLUTCH ENG


67

Dowel pinsCrankcase cover gasket

21


10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

4-36


1234567

89

10

1112

Clutch assembly removalOil pump driven gearClutch springsPressure platePush plate/push rod #1BallFriction platesClutch platesNut/ locknut

Clutch bossThrust washerNut (primary drive gear)

Clutch housingPush rod #2

51

1/1165

1/1

111

11

Remove the parts in the order below.Refer to “OIL PUMP”.

Refer to “CLUTCH INSTALLATION”.

Refer to “CLUTCH REMOVAL/INSTAL-LATION”.

Refer to “PRIMARY DRIVE GEARREMOVAL/INSTALLATION”.

Refer to “INSTALLATION”.

70 Nm (7.0 m kg)

70 Nm (7.0 m kg)

8 Nm (0.8 m kg) 8 Nm (0.8 m kg)

CLUTCH ENG

CLUTCH ASSEMBLY

4-37

CLUTCH ENG


1314151617

Lock washerClaw washerDrive gear (oil pump)Primary drive gearStraight key

11111


70 Nm (7.0 m kg)

70 Nm (7.0 m kg)

8 Nm (0.8 m kg) 8 Nm (0.8 m kg)

4-38

CLUTCH ENG

NOTE:

NOTE:

CLUTCH REMOVAL1. Straighten:

Lock washer tab2. Loosen:

Nut (clutch boss) 1

Loosen the nut (clutch boss) 1 while holdingthe clutch boss 2 with the clutch holding tool3 .

Clutch holding tool:90890-04086

PRIMARY DRIVE GEAR REMOVAL1. Straighten:

Lock washer tab2. Loosen:

Nut (primary drive gear) 1

Place a copper plate 2 between the teeth of theprimary drive gear 3 and primary driven gear tolock them.

CLUTCH INSPECTION1. Inspect:

Friction platesWear/damage Replace the frictionplates as a set.

2. Measure:Friction plate thicknessOut of specification Replace the frictionplates as a set.Measure at four places.

Thickness (friction plate):2.9 3.1 mm<Wear limit>: 2.6 mm

3. Inspect:Clutch plateDamage Replace the clutch plates as aset.

4. Measure:Clutch plate warpageOut of specification Replace the clutchplates as a set.Use a surface plate and a feeler gauge 1 .

Warp limit (clutch plate):Less than 0.2 mm

4-39

CLUTCH ENG

NOTE:

NOTE:

5. Inspect:Primary drive gear teethWear/damage Replace the clutchhousing.

6. Check:Circumferential playFree play Replace the clutch housing.

7. Inspect:Clutch springDamage Replace the clutch spring.

8. Measure:Clutch spring free lengthOut of specification Replace the clutchsprings as a set.

Free length (clutch spring):39.5 mm<Wear limit>: 38.5 mm

9. Inspect:Dogs (on the clutch housing)Pitting/wear/damage Deburr or re-place.

Clutch housing bearingWear/damage Replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic operation.

10. Inspect:Clutch boss splinesPitting/wear/damage Replace theclutch boss.

Pitting on the clutch boss splines will cause er-ratic operation.

11. Inspect:Pressure plateCracks/damage Replace.

4-40

CLUTCH ENG

70 Nm (7.0 mkg)

NOTE:

70 Nm (7.0 mkg)

NOTE:

*****************************************************

PUSH ROD INSPECTION1. Inspect:

Push rod #1 1O-ring Ball 2Push rod #2 3Cracks/wear/damage Replace.

PRIMARY DRIVE GEAR INSTALLATION1. Install:

Drive gear (oil pump) 1Claw washerLock washer Nut (primary drive gear)

Place a copper plate 2 between the teeth ofthe primary drive gear 3 and primary drivengear to lock them.

2. Bend: Lock washer tab (along a flat side of the nut)

CLUTCH INSTALLATION1. Install:

Lock washer 1 Nut (clutch boss) 2

Tighten the nut (clutch boss) 2 while holdingthe clutch boss with a clutch holding tool 3 .

Clutch holding tool:90890-04086

2. Bend:Lock washer tab (along a flat side of thenut)

3. Install:Friction plates 1Clutch plates 2

Installation steps: Install one friction plate and one clutch plate

alternately.

4-41

CLUTCH ENG

*****************************************************

NOTE:

NOTE:

8 Nm (0.8 mkg)

NOTE:

*****************************************************

*****************************************************

Apply engine oil onto the friction plates. Align the two slots a on the friction plates

with the two punch marks b on the clutchhousing.

4. Install:Push rod #2BallPush rod #1 1O-ring 2 Push plate 3Washer 4Nut 5

Apply lithium soap base grease onto the pushrod and the ball.

5. Install:Pressure plate 1Clutch springs 2Bolts 3

Tighten the pressure plate bolts in stages, usinga crisscross pattern.

6. Check:Push lever positionPush the push lever assembly in the direc-tion of the arrow and make sure that thematch marks are aligned.Match marks not aligned. Adjust.

a Match mark on the push lever assembly

b Match mark on the crankcase7. Adjust:

Push lever position

Adjustment steps: Loosen the nut 1 . Turn the push rod #1 2 clockwise or counter-

clockwise so that the match marks arealigned.

Tighten the nut 1 .

Nut (clutch adjuster):8 Nm (0.8 mkg)

4-42


123456789

Shift shaft removalEngine oil

Clutch assemblyCrankcase cover (left)CirclipWasherShift shaftWasherStopper leverTorsion spring (stopper lever)WasherCirclipTorsion spring (shift shaft)

111111111

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “CLUTCH”.Refer to “ENGINE REMOVAL”.

Refer to “SHIFT SHAFT INSTALLA-TION”.


SHIFT SHAFT ENG

SHIFT SHAFT

4-43

SHIFT SHAFT ENG

NOTE:

SHIFT SHAFT INSPECTION1. Inspect:

Shift shaft 1Shift pawls 2Return spring (shift arm) 3Bends/wear/damage Replace.

2. Inspect:Stopper leverRoller turns roughly Replace.Bends/damage Replace.

3. Inspect:Torsion spring (shift shaft) 1Torsion spring (stopper lever) 2Wear/damage Replace.

SHIFT SHAFT INSTALLATION1. Install:

Shift shaft 1Torsion spring (shift shaft) 2Washer 3Stopper lever 4Torsion spring (stopper lever) 5Washer 6

Hook the spring end on the stopper lever andthe crankcase boss.

Mesh the stopper lever 7 with the shift camstopper 8 .

4-44

SHIFT SHAFT ENG

NOTE:

2. Install:Shift lever

Insert the shift arm 1 between the pins on theshift cam segment.

4-45


1234

Oil pump removalCrankcase cover (right)CirclipDriven gear (oil pump)Oil pump assemblyO-rings/collar

111

2/1

Remove the parts in the order below.Refer to “CLUTCH”.


7 Nm (0.7 m kg)

OIL PUMP ENG

OIL PUMP

4-46

For assembly, reverse the disassembly procedure.


Oil pump disassembly

Spring retainerSpringRelief valveOil pump coverPinShaftInner rotorOuter rotorDowel pinsOil pump housing

1111111121

Disassembly the parts in the order below.

12345678910

OIL PUMP ENG

4-47

OIL PUMP ENG

OIL PUMP INSPECTION1. Inspect:

Drive gear (oil pump) 1Driven gear (oil pump) 2Cracks/wear/damage Replace.

2. Measure:Tip clearance a(between the inner rotor 1 and the outerrotor 2 )

Side clearance b(between the outer rotor 2 and the pumphousing 3 )Out of specification Replace the oilpump assembly.

Tip clearance:0.12 mm<Limit>: 0.2 mm

Side clearance:0.03 0.08 mm<Limit>: 0.15 mm

3. Check:Oil pump operationUnsmooth operation Replace.

4-48

7 Nm (0.7 m kg)

7 Nm (0.7 m kg)


12

Stator removalEngine oil

Crankcase cover (left)Rider’s seat

Stator coilPickup coil

11

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “CLUTCH”.Refer to “FUEL TANK AND SEATS” in CHAPTER 3.


AC MAGNETO AND STARTER CLUTCH ENG

AC MAGNETO AND STARTER CLUTCHSTATOR COIL AND PICKUP COIL

4-49

20 Nm (2.0 m kg)

80 Nm (8,0 m kg)


12345678

AC magneto and starter clutchremovalShaftStarter idler gearBoltsRotorWoodruff keyStarter wheel gearWasherStarter clutch assembly

11311111


Refer to “AC MAGNETO REMOVAL/INSTALLATION”.

Refer to “AC MAGNETO INSTALLATION”.



AC MAGNETO AND STARTER CLUTCH

4-50


*****************************************************

NOTE:

NOTE:

*****************************************************

AC MAGNETO REMOVAL1. Remove:

RotorWoodruff key

Removal steps: Remove the starter clutch bolts 1 . Remove the rotor bolt 2 and washer 3 .

Loosen the starter clutch bolts 1 and rotor bolt2 while holding the rotor with a sheave holder4 .


Flywheel puller:90890-01362

Adapter:90890-04089

Remove the rotor and the woodruff key.

When installing the flywheel puller removethree of the starter clutch bolts.

Remove the rotor by pushing back the rotor,the flywheel puller 5 and the adapter 6 .

Install the flywheel puller bolts and tighten thecenter bolt, making sure that the tool bodystays parallel to the rotor. If necessary, oneholding bolt may be backed out slightly for re-alignment of the tool.

STARTER CLUTCH INSPECTION1. Inspect:

Gear teeth (idler) 1Gear teeth (starter wheel) 2Burrs/chips/roughness/wear Re-place.

Shaft 3Bends/damage Replace.

4-51


*****************************************************

*****************************************************

NOTE:

2. Inspect:Oil passage (rotor bolt)Clogged Blow out with compressed air.

3. Inspect:Stator coilDamage Replace.

4. Check:Starter clutch assembly operation

Clutch operation checking steps:D Install the starter wheel gear to the starter

clutch, and hold the starter clutch. When turning the starter wheel gear clock-

wise a , the starter clutch and the starterwheel gear should be engaged.If not, the starter clutch is faulty. Replace it.

When turning the starter wheel gear counter-clockwise b , the starter wheel gear shouldturn freely.If not, the starter clutch is faulty. Replace it.

AC MAGNETO INSTALLATION1. Install:

Washer 1Starter wheel gear 2Woodruff key 3Rotor 4

Clean the tapered portion of the crankshaftand the rotor hub.

When installing the magneto rotor, makesure the woodruff key is properly seated inthe key way of the crankshaft.

4-52


80 Nm (8.0 mkg)

20 Nm (2.0 mkg)

NOTE:

2. Tighten:Bolt (rotor) 1Bolts (starter clutch) 2

Tighten the rotor bolt 1 and starter clutch bolts2 while holding the magneto rotor with asheave holder 3 .


4-53


12345

Crankcase separationEngine assemblyCylinder headCylinder and pistonClutch assemblyShift shaftOil pump assemblyAC magneto and starter clutch

Middle drive pinion gearTiming chain guide (rear-intake)Timing chain guide (front-exhaust)Timing chainsOil strainer coverOil seal

11211

Remove the parts in the order below.Refer to “ENGINE REMOVAL”.Refer to “CYLINDER HEADS”.Refer to “CYLINDERS AND PISTONS”.Refer to “CLUTCH”.Refer to “SHIFT SHAFT”.Refer to “OIL PUMP”.Refer to “AC MAGNETO AND STARTER CLUTCH”.Refer to “MIDDLE GEAR”.

10 Nm (1.0 m kg)

24 Nm (2.4 m kg)

24 Nm (2.4 m kg)

10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

24 Nm (2.4 m kg)10 Nm (1.0 m kg)

CRANKSHAFT AND CONNECTING RODS ENG

CRANKSHAFT AND CONNECTING RODSCRANKCASE

4-54



678

910

O-ringsOil strainerCrankcase (right)

Dowel pinsO-ring

211

31

Refer to “CRANKCASE SEPARATION/ASSEMBLY”.

For assembly, reverse the separation procedure.

10 Nm (1.0 m kg)

24 Nm (2.4 m kg)

24 Nm (2.4 m kg)

10 Nm (1.0 m kg)

10 Nm (1.0 m kg)

24 Nm (2.4 m kg)10 Nm (1.0 m kg)

4-55


1234567

Crankshaft and connecting rodremovalCrankshaft assemblyMain journal bearingsNuts (connecting rod caps)Connecting rod boltsConnecting rodsConnecting rod capsPlain bearings

1244224


Refer to “CRANKSHAFT REMOVAL/INSTALLATION”.


36 Nm (3.6 m kg)


CRANKSHAFT AND CONNECTING RODS

4-56

A

B


*****************************************************

NOTE:

NOTE:

CAUTION:

*****************************************************

CRANKCASE SEPARATION1. Separate:

Left crankcaseRight crankcase

Separation steps: Remove the crankcase bolts.

Loosen each bolt 1/4 of a turn at a time andafter all the bolts are loosened, remove them.

Loosen the bolts in numerical order (seenumbers on the illustration).

Turn the shift cam 15 to the position shown inthe figure so that it does not contact thecrankcase when separating the crankcase.

A Right crankcase

B Left crankcase Remove the right crankcase 16 .

For this removal, slits a in the crankcase canbe use as shown.

Use a soft hammer to tap on one side of thecrankcase. Tap only on reinforced portionsof the crankcase. Do not tap on the crank-case mating surfaces. Work slowly andcarefully. Make sure that the crankcasehalves separate evenly.

Remove the dowel pins and O-ring.

4-57


NOTE:

NOTE:

CRANKSHAFT REMOVAL1. Remove:

Main journal bearings 1

Remove the main journal bearings by the planebearing installer/remover 2 middle drivenshaft bearing driver 3 .

Plane bearing installer/remover:90890-04074

Middle driven shaft bearing driver:90890-04058

2. Remove:Connecting rod caps 1Connecting rod 2Plain bearings

Identify the position of each bearing very care-fully so that it can be reinstalled in its originalplace.

CRANKSHAFT INSPECTION1. Thoroughly wash the crankcase halves in

mild solvent.2. Thoroughly clean all the gasket mating sur-

faces and crankcase mating surfaces.3. Inspect:

CrankcaseCracks/damage Replace.

Oil delivery passagesBlockage Blow out the passages withcompressed air.

4. Measure:Runout (crankshaft)Out of specification Replace.

Runout limit:0.02 mm

4-58


*****************************************************

CAUTION:

NOTE:

NOTE:

5. Inspect:Crank pin surfacesBearing surfacesWear/scratches Replace.

6. Inspect:Timing chain sprockets 1Damage/wear Replace the crankshaft.

7. Measure:Oil clearance (crank pin)Out of specification Replace the bear-ing.

Oil clearance (crank pin):0.026 0.050 mm

Measurement steps:

Do not interchange the bearings and con-necting rods. To obtain the correct oil clear-ance and to prevent engine damage theymust be installed in their original positions.

Clean the bearings, crank pins and bearingportions of the connecting rods.

Install the upper half of the bearing into theconnecting rod and the lower half of the bear-ing into the connecting rod cap.

Align the projection a of the bearing with thenotch b of the connecting rod and its cap.

Put a piece of Plastigauge 1 on the crankpin.

Assemble the connecting rod halves.

Do not move the connecting rod or crank-shaft until the oil clearance measurementhas been completed.

Apply molybdenum disulfide grease to thebolts, threads and nut seats.

4-59


CAUTION:

*****************************************************

NOTE:

*****************************************************

The stamped “Y” mark 2 on the connect-ing rods should face towards the left sideof the crankcase.

Be sure that the characters 3 on the side ofthe cap and connecting rod are aligned.

Tighten the nuts.

Nuts (connecting rod caps):36 Nm (3.6 mkg)

When tightening the nuts be sure to usean F-type torque wrench.

Without pausing tighten to full torquespecifications. Apply continuous torquebetween 3.0 and 3.6 m kg. Once you reach3.0 mkg DO NOT STOP TIGHTENING un-til final torque is reached. If the tighteningis interrupted between 3.0 and 3.6 m kg,loosen the nut to less than 3.0 m kg andstart again.

Remove the connecting rods and bearings. On each crank pin measure the width of the

compressed Plastigauge 1 .If the oil clearance is out of specification, se-lect a replacement bearing.

8. Select:Crank pin bearing (P1)

The numbers 1 indicate crankshaft jour-nal sizes are stamped on the crankweb, asshown in the illustration.

The numbers 2 are stamped in ink on theconnecting rod and connecting rod cap, asshown in the illustration.

Selection of crank pin bearings: If “P1” on the connecting rod is “4” and “P1” on

the crankweb is “2”, then the bearing size for“P1” is:

Bearing size of P 1:Connecting rod P 1 – Crankweb P 1 =

4 – 2 = 2 (black)

4-60


*****************************************************

*****************************************************

CAUTION:

NOTE:

BEARING COLOR CODE

1 blue

2 black

3 brown

4 green

9. Measure:Oil clearance (main journal)Out of specification Replace the bear-ing.

Oil clearance (main journal):0.020 0.052 mm

Measurement steps:

On the journal, the larger value is used as abasis for calculation of the oil clearance,and on the journal bearing, the smaller valueis used.

Clean the surface of main journal and journalbearings.

Check the bearing surface. If the bearing sur-face is worn or scratched, the bearingsshould be replace.

If either of the right or left journal bearing is wornor scratched, both bearings should be replacedas a set.

Measure the outside diameter a of eachmain journal at two places. If it is out of speci-fication, replace the crankshaft.

Outside diameter limit (main journal):

44.95 mm

Measure the inside diameter b of each jour-nal bearing at two places.

4-61


*****************************************************

*****************************************************

NOTE:

CAUTION:

*****************************************************

If journal bearing inside diameter is “45.03”and crankshaft journal outside diameter is“44.98”, then the main journal oil clearanceis:

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, se-lect a replacement bearings.

10. Select:Main journal bearing

Selection of main journal bearings: Remove the main journal bearings out of

crankcase. Clean the bearing seat in the crankcase

where the bearing is fitted. Measure the diameter a of the bearing seat

at two places.

If the diameter of the bearing seat in the crank-case exceeds 49.02 mm, the crankcase shouldbe replaced with a new one. The new crankcaseincludes new journal bearings. The each insidediameter of bearing is normally 45.000 45.012 mm.

The average of the two values is used tochoose the bearing.

Select the proper oversized main journalbearing with the following table.

DIAMETER OFTHE BEARING SEAT

COLOR CODE

49.000 49.010 mm blue

49.011 49.020 mm green

4-62


NOTE:

NOTE:

NOTE:

NOTE:

CRANKSHAFT INSTALLATION1. Attach:

Main journal bearings 1

Attach the main journal bearing to the planebearing installer/remover 2 middle drivenshaft bearing driver 3 .

Align the projection a on the bearing with theprojection b and slot c on the special tools.

Plane bearing installer/remover:90890-04074

Middle driven shaft bearing driver:90890-04058

2. Install:Main journal bearings 1

Align the projection a on the bearing with theslit b on the crankcase.

3. Install:Connecting rod bearings 1

Align the projection a of the bearings withthe notches b in the connecting rod cap.

Install each bearing in its original place.

4. Install:Connecting rods 1

The stamped “Y” mark a on the connectingrods should face towards the left side of thecrankcase.

Install each connecting rod in its originalplace.

4-63


NOTE:

36 Nm (3.6 mkg)

NOTE:

CAUTION:

NOTE:

5. Install:Connecting rod cap 1

Be sure that the characters a on the side of thecap and connecting rod are aligned.

6. Tighten:Nuts (connecting rod cap)

Apply molybdenum disulfide grease to the rodcap bolt threads and nut surfaces.

When tightening the nuts be sure to usean F-type torque wrench.

Without pausing tighten to full torquespecification. Apply continuous torquebetween 3.0 and 3.6 m kg. Once you reach3.0 mkg DO NOT STOP TIGHTENING un-til final torque is reached. If the tighteningis interrupted between 3.0 and 3.6 m kg,loosen the nut to less than 3.0 m kg andstart again.

7. Install:Crankshaft 1

Align the left connecting rod with the rear cylin-der sleeve hole.

CRANKCASE ASSEMBLY1. Apply:

Engine oil(onto the main journal bearings)

Sealant(onto the crankcase mating surfaces)

Yamaha Bond No.1215:90890-85505

4-64


NOTE:

NOTE:

24 Nm (2.4 mkg)

10 Nm (1.0 mkg)

NOTE:

1 3 9 14

2

8

4 6

7

5

2. Install:Right crankcase(onto the left crankcase)

Turn the shift cam to the position shown in thefigure so that it does not contact the crankcasewhen installing the crankcase.

3. Tighten:Crankcase bolts(follow the proper tightening sequence)

The numbers embossed on the crankcase indi-cate the crankcase tightening sequence.

4 7 (M8) 1 3 , 8

14 (M6)

Lubricate the bolt threads with engine oil. Tighten the bolts in increasing numerical or-

der.

M6 45 mm , ,

M6 55 mm

M6 95 mm

M8 60 mm ,

M8 80 mm

M8 100 mm

4-65


123456789

1011

Transmission removalCrankcase separationGuide bar 1Guide bar 2Shift fork 2 “C”Shift fork 3 “R”Shift fork 1 “L”Shift camMain axle assemblyDrive axle assemblyBearing retainerBearingsShim

11111111241

Remove the parts in the order below.Refer to “CRANKSHAFT”.

Refer to “TRANSMISSION INSTALLATION”.


25 Nm (2.5 m kg)

TRANSMISSION ENG

TRANSMISSION

4-66

TRANSMISSION ENG

SHIFT FORK INSPECTION1. Inspect:

Shift fork cam follower 1Shift fork pawl 2Scoring/bends/wear/damage Re-place.

2. Inspect:Guide barRoll the guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent guidebar.

3. Check:Shift fork movement(on the guide bar)Unsmooth operation Replace the shiftfork and the guide bar.

SHIFT CAM INSPECTION1. Inspect:

Shift cam groovesScratches/wear/damage Replace.

Shift cam segment 1Wear/damage Replace.

Shift cam bearing 2Pitting/damage Replace.

TRANSMISSION INSPECTION1. Measure:

Axle runoutUse a centering device and a dial gauge.Out of specification Replace the bentaxle.

Runout limit (main and drive axle):

0.06 mm

4-67

TRANSMISSION ENG

*************************************

*************************************

2. Inspect:Gear teethBlue discoloration/pitting/wear Replace.

Mated dogsRounded edges/cracks/missing portions Replace.

3. Check:Proper pinion gear engagement (eachgear to its counter part)Incorrect Reassemble.

Gear movementRoughness Replace.

Transmission gear reassembling point:Press the 2nd pinion gear 1 into the 1st piniongear (main axle) 2 .

4. Inspect:CirclipBends/looseness/damage Replace.

5. Inspect:BearingsUnsmooth Replace.

4-68

TRANSMISSION ENG

25 Nm (2.5 mkg)

NOTE:

NOTE:

TRANSMISSION INSTALLATION1. Tighten:

Torx screws (bearing retainer) 1

Use #40 torx screw wrench.2. Lock the torx screw head with drift punch.

3. Install:Shift cam 1Shift fork 2 “C” 2Shift fork 3 “R” 3Shift fork 1 “L” 4Guide bar 1 5Guide bar 2 6

The number stamped into the shift fork must al-ways face towards the right side of the crank-case. Be sure that the shift fork guide pin isproperly seated in the shift drum groove.

4. Check:Shift operationUnsmooth operation Repair.

Oil each gear and bearing thoroughly. Before assembling the crankcase, be sure

that the transmission is in neutral and that thegears turn freely.

4-69


123456789

10111213

Middle driven pinion gear removalEngine assemblyBoltsShimCirclipsBearingsYokeNutYokeCollarBearing housing/O-ringSpring retainersSpring seatDamper springDamper cam

41441111

1/12111

Remove the parts in the order below.Refer to “ENGINE REMOVAL”.

Refer to “MIDDLE DRIVEN PINION GEAR REMOVAL/INSTALLATION”.

25 Nm (2.5 m kg)

90 Nm (9.0 m kg)

MIDDLE GEAR ENG

MIDDLE GEARMIDDLE DRIVEN PINION GEAR

4-70

MIDDLE GEAR ENG


1415

Middle driven pinion gearMiddle driven shaft

11

Refer to “MIDDLE DRIVEN PINION GEAR REMOVAL/INSTALLATION”.


25 Nm (2.5 m kg)

90 Nm (9.0 m kg)

4-71


12345678

Middle drive pinion gear removalMiddle gear cover/O-ringNutMiddle drive pinion gearScrew/gasketPush lever axleTorsion springWasherOil seal

1/111

1/11111


Refer to “MIDDLE DRIVE PINION GEAR REMOVAL/INSTALLATION”.


12 Nm (1.2 m kg)120 Nm (12.0 m kg)

MIDDLE GEAR ENG

MIDDLE DRIVE PINION GEAR

4-72

MIDDLE GEAR ENG

*****************************************************

NOTE:

*****************************************************

NOTE:

*****************************************************

CAUTION:

NOTE:

*****************************************************

MIDDLE DRIVEN PINION GEAR REMOVAL1. Remove:

Universal joint

Disassembly steps: Remove the circlips 1 . Place the universal joint in a press. Using a suitable diameter pipe beneath the

yoke, press the bearing into the pipe asshown.

It may be necessary to lightly tap the yoke with apunch.

Repeat the steps for the opposite bearing. Remove the yoke.

2. Loosen:Nut (middle driven shaft) 1

Use the universal joint holder 2 to hold theyoke 3 .

Universal joint holder:90890-04062

3. Remove:Bearing housing assembly 1

Removal steps: Clean the outside of the middle driven shaft. Place the middle driven shaft assembly onto

a hydraulic press.

Never directly press the shaft end with ahydraulic press, this will result in damageto the shaft thread.

Install the suitable socket 2 on the shaftend to protect the thread from damage.

When the middle driven shaft is removed fromthe bearing housing assembly, always replacethe bearing.

Press the shaft end, and remove the bearinghousing.

4-73

MIDDLE GEAR ENG

NOTE:

*****************************************************

CAUTION:

*****************************************************

NOTE:

4. Remove:Spring retainers

Attach the damper spring compressor 1 on thespring seat 2 and compress the damperspring, then remove the spring retainers.

Damper spring compressor:90890-04090

5. Remove:Bearing retainer 1Bearing

Removal steps: Attach the folded rag 2 . Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 3 .

Bearing retainer wrench:90890-04057

The middle driven shaft bearing retainer hasleft-handed threads. To loosen the retainerturn it clockwise.

Remove the bearing retainer and bearing.

MIDDLE DRIVE PINION GEAR REMOVAL1. Loosen:

Nut (middle drive pinion gear) 1

Flatten the punched position of the middledrive pinion gear nut using the drift punch.

Put the engine in 1st, and carry out the opera-tion.

Loosen the nut (middle drive pinion gear) 1while holding the rotor with the sheave holder2 .


4-74

MIDDLE GEAR ENG

120 Nm (12.0 mkg)

NOTE:

MIDDLE GEAR INSPECTION1. Inspect:

Damper cam surfaceWear/scratches Replace the dampercam as a set.

2. Inspect:Damper springDamage/cracks Replace.

3. Inspect:Middle driven pinion gear teeth 1Middle drive pinion gear teeth 2Pitting/galling/wear Replace themiddle gear as a set.

4. Inspect:BearingPitting/damage Replace the bearinghousing assembly.

O-ringsDamage Replace.

5. Check:Universal joint movementRoughness Replace the universal joint.

MIDDLE DRIVE PINION GEAR INSTALLATION

1. Install:Middle drive pinion gear 1Nut 2

Tighten the nut (middle drive pinion gear) 2while holding the rotor with the sheave holder3 .

To lock the threads stake them with a centerpunch.


4-75

MIDDLE GEAR ENG

NOTE:

*****************************************************

NOTE:

*****************************************************

CAUTION:

*****************************************************

CAUTION:

*****************************************************

MIDDLE DRIVEN PINION GEAR INSTALLATION

1. Install:Spring retainers

Attach the damper spring compressor 1 on thespring seat 2 and compress the damperspring, then install the spring retainers.

Damper spring compressor:90890-04090

2. Install:Bearing

Installation steps: Install the new bearing by reversing the re-

moval steps.

Use a socket 1 that matches the diameter ofthe outer bearing race and the oil seal.

Do not contact the bearing center race 2 orballs 3 . Contact should be made only withthe outer race 4 .

3. Install:Bearing retainer 1

Install steps: Attach the folded rag 2 . Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 3 .


Tighten the bearing retainer.

The middle driven shaft bearing retainer hasleft-handed threads. To tighten the retainerturn it counterclockwise.

Bearing retainer:110 Nm (11.0 mkg)

4-76

MIDDLE GEAR ENG

*****************************************************

CAUTION:

*****************************************************

90 Nm (9.0 mkg)

NOTE:

4. Install:Middle driven shaft assembly

Install steps: Clean the outside of the middle driven shaft

and the inside of the bearing. Fit the middle driven shaft assembly onto the

bearing housing. Place the middle driven shaft assembly onto

a hydraulic press.

Never directly press the shaft end with ahydraulic press, this will result in damageto the shaft thread.

Install the hand-made tool 1 to protectthe bearing and bearing housing fromdamage.

Install the wood piece 2 on the shaft endto protect the thread from damage.

Press the wood piece and secure the middledriven shaft assembly.

5. Tighten:Nut (middle driven pinion gear) 1

Use the universal joint holder 2 to hold theyoke 3 .

Universal joint holder:90890-04062

6. Install:Yoke (cross joint) 1(into the hole on yoke)

4-77

MIDDLE GEAR ENG

CAUTION:

NOTE:

NOTE:

25 Nm (2.5 mkg)

NOTE:

7. Install:Bearings 1(onto the cross joint)

The needles can easily fall out of their races,so check each bearing. Slide the universaljoint yoke back and forth on the bearings. Ifa needle is out of place the yoke will not goall the way onto the bearing.

8. Using a suitable socket press each bearinginto the hole on yoke.

The bearings must be inserted far enough intothe cross joint so that the circlips can beinstalled.

9. Install:Circlips 3(into the groove of each bearing)

10. Install:Middle driven pinion gear assembly

Just finger tighten the bolts at this stage.

11. Install:Shims 1Bolts

When installing the shims, make sure that thetabs a are positioned correctly.

4-78

MIDDLE GEAR ENG

NOTE:

NOTE:

*****************************************************

a b

Before tightening the bolts:1. Adjust the gear lash of the middle gear.

Refer to “GEAR BACKLASH ADJUST-MENT”.

2. Check the operation of the middle drivengear.

MIDDLE DRIVE GEAR SHIM SELECTION

Gear positioning is necessary when any of thefollowing parts are replaced. Crankcase assembly Middle gear assembly

1. Select:Middle drive gear shim 1

Middle drive gear shim selection steps: Position middle drive gear by using shims 1

with their respective thickness calculatedfrom information marked on crankcase, bear-ing housing and drive gear end.

1 Shim thickness “A” To find shim thickness “A” use following for-

mula:

Middle drive pinion gear shim thickness:“A” = –

Where:a = a numeral (usually a decimal num-

ber) on the middle drive pinion gear iseither added to or subtracted from“44”.

b = a numeral (usually a decimal num-ber) on the left crankcase specifies athickness of “43.5”.

Example:1) If the middle drive pinion gear is marked

“+03”a is 44.03. . .

2) If the crankcase (left) is marked “43.45”b is 43.45. . .

3) Therefore, the shim thickness is 0.58 mm

4-79

MIDDLE GEAR ENG

0.20 0.400.30

Middle drive pinion gear shim

Thickness (mm)

*****************************************************

NOTE:

NOTE:

A = 44.03 – 43.45= 0.58

6) Round off hundredths digit and selectappropriate shim(s).In the example above, the calculatedshim thickness is 0.58 mm. The chartinstructs you, however, to round off 8 to10.

Hundredths Round value

0, 1, 2, 3, 4 0

5, 6, 7, 8, 9 10

Shims are supplied in the following thickness.

GEAR BACKLASH ADJUSTMENT1. Install:

Middle gear backlash tool 1

This tool will prevent the drive axle from turning.

Middle gear backlash tool:90890-04080

2. Install:Bolts (driven gear bearing housing)

Just finger tighten the bolts at this stage. Clearance between the crankcase and the

driven bearing housing should be about 2mm.

Measure the gap with a feeler gauge 2 .

4-80

MIDDLE GEAR ENG

NOTE:

NOTE:

CAUTION:

NOTE:

3. Position:Dial gauge(onto the outside edge of the universaljoint)

Be sure that the gauge is positioned over thecenterline of the yoke bearing hole.

4. Rotate:Universal joint 1

Move the universal joint gently back and forth.

5. Measure:Gear backlashOver specification Follow the nextstepsUnder or same specification IncorrectCheck for faulty parts and/or reassemblethe bearing housing.

Backlash (gear):0.05 0.10 mm

Do not hammer the universal joint or the col-lapsible collar of the driven pinion gear maybe distorted. This will result in a change inthe standard spinning torque, requiring re-placement of the collapsible collar and reas-sembly of the driven gear assembly.

Check the gear backlash at four positions. Ro-tate the universal joint 90 each time and repeatthe gear backlash check.

4-81

MIDDLE GEAR ENG

25 Nm (2.5 mkg)

NOTE:

CAUTION:

*****************************************************

6. Tighten:Bolts (driven gear bearing housing) 1

Tighten the bolts carefully, one thread turn at atime, only. Push in the bearing housing andtighten the bearing housing bolts.

Do not overtighten the bearing housingbolts or you may obtain too little gear back-lash and cause damage to the gears. If overtightened, loosen the three bolts so that thecrankcase/bearing housing clearance isabout 2 mm and repeat all previous steps.

7. Repeat steps #4 and #5 until the correctgear backlash is achieved.

Backlash (gear):0.05 0.10 mm

8. Measure:Crankcase/bearing housing clearance Use a feeler gauge

9. Select:Shim(s)

Selection steps: For example, the clearance between the

crankcase and the bearing housing is 0.46mm.

The shim can only be selected in 0.05 mm in-crements, round off the hundredths digit andselect the appropriate shim(s).

Hundredths Rounded value

0, 1, 2 0

3, 4, 5, 6, 5

7, 8, 9 10

4-82

MIDDLE GEAR ENG

Middle drive pinion gear shim:

Thickness (mm) 0.10, 0.15, 0.20

*****************************************************

25 Nm (2.5 mkg)

Shims are supplied in the following thick-nesses.

10. Tighten:Bolts (driven gear bearing housing) 1

11. Measure:Gear backlash

CARB

CHAPTER 5.CARBURETION

CARBURETOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR INSPECTION 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR ASSEMBLY 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE POSITION SENSOR (TPS) INSPECTIONAAND ADJUSTMENT 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARB

5-1


123456789

10

Carburetor removalFuel tank

Air filter case assemblyAir ductCylinder head breather hoseThrottle position sensor leadThermo switch leadFuel hoseCarburetor assemblyStarter cableThrottle cables

Cover

111111112

1

Remove the parts in the order below.Refer to “FUEL TANK AND SEATS” inCHAPTER 3.

Disconnect

After removing the carburetorassembly, remove the starter cableand throttle cables.


NOTE:

CARBURETOR CARB

CARBURETIONCARBURETOR

5-2


12345678910

11

12

Carburetor disassembly

Carburetor heater leadCarburetor heaters 1Carburetor heaters 2Float chamberFloatNeedle valve setMain jetJet holderPilot jetJet needle setNeedle jetStarter plunger set

122111111111

Disassemble the parts in the orderbelow.

12V 15W12V 30W

Refer to “CARBURETORASSEMBLY”.

CARBURETOR CARB

5-3


13

14

15

16

Diaphragm setThrottle position sensor

Pilot screwMain air jet

11

11

Refer to “CARBURETOR ASSEMBLY”.Refer to “THROTTLE POSITIONSENSOR (TPS) INSPECTION ANDADJUSTMENT”.Refer to “CARBURETOR ASSEMBLY”.

For assembly, reverse the disassemblyprocedure.

CARBURETOR CARB

5-4

CARBURETOR CARB

*****************************************************

*****************************************************

EB600030

CARBURETOR INSPECTION1. Inspect:

Carburetor bodyFloat chamberJet housingCracks/damage Replace.

Fuel passageBlockage Clean as indicated.

Carburetor float chamber bodyContamination Clean.

Cleaning steps: Wash the carburetor in a petroleum based

solvent. (Do not use any caustic carburetorcleaning solution.)

Blow out all of the passages and jets withcompressed air.

2. Inspect:FloatDamage Replace.

3. Inspect:Needle valve 1Valve seat 2O-ring 3Contamination/wear/damage Re-place as a set.

4. Inspect:Piston valve 1Scratches/wear/damage Replace.

Rubber diaphragm 2Tears Replace.

5-5

CARBURETOR CARB

CAUTION:

5. Inspect:Vacuum chamber cover 1Springs 2Plastic bushing 3Plastic screw cap 4Cracks/damage Replace.

6. Inspect:Jet needle 1Main jet 2Main jet holder 3Pilot jet 4Needle jet 5Pilot air jet 6Pilot screw 7Starter plungerBends/wear/damage Replace.Blockage Blow out the jets with com-pressed air.

7. Check:Free movementInsert the throttle valve into the carburetorbody and check for free movement.Sticks/tight Replace.

8. Inspect:Joints (fuel) 1Joints (air vent hose-vacuum chamber) 2Joints (carburetor breather hose) 3Cracks/damage Replace.

CARBURETOR ASSEMBLY

Before reassembling, wash all of the parts ina clean petroleum based solvent.

5-6

CARBURETOR CARB

NOTE:

NOTE:

NOTE:

NOTE:

1. Install:Needle jet 1

Align the groove on the needle jet with theprojection on the carburetor body.

Install the needle jet from the piston valveside.

2. Install:Pilot screw 1

Pilot screw (turns out):2

3. Install:Jet needle

Align the projection a on the plastic stopperwith the hole b in the piston valve.

4. Install:Diaphragm 1

Match the tab on the diaphragm to the recess inthe carburetor body.

5. Install:Diaphragm 1Compression spring 2Cover 3

Match the tab on the diaphragm to the recess inthe carburetor body.

5-7

CARBURETOR CARB

*****************************************************

*****************************************************

FUEL LEVEL ADJUSTMENT1. Measure:

Fuel level aOut of specification Adjust

Fuel level:7.5 8.5 mm(below the float chamber line)

Measurement and adjustment steps: Place the motorcycle on a level surface. Put the motorcycle on a suitable stand to en-

sure that the carburetor assembly is posi-tioned vertically.

Connect the fuel level gauge 1 to the drainpipe.

Fuel level gauge:90890-01312

Loosen the drain screw 2 . Hold the gauge vertically next to the float

chamber line b . Measure the fuel level with the gauge. If the fuel level is incorrect, adjust it. Remove the carburetor assembly. Inspect the valve seat and needle valve. If either is worn, replace them both. If both are fine, adjust the float level by slightly

bending the float tang 3 . Install the carburetor assembly. Check the fuel level again.

5-8

CARBURETOR CARB

NOTE:

*****************************************************

*****************************************************

12

31

THROTTLE POSITION SENSOR (TPS) IN-SPECTION AND ADJUSTMENT

Before adjusting the TPS, the idling speedshould be properly adjusted.

1. Inspect:TPS resistance

Inspect steps: Disconnect the TPS coupler. Remove the TPS from the carburetor. Connect the pocket tester (Ω 1 k) to the

TPS connector.

Tester (+) lead Black terminal Tester (–) lead Blue terminal

Check the TPS resistance.

TPS resistance “R 1”:4.0 6.0 kΩ at 20C(Black — Blue)

Out of specification Replace the TPS. Connect the pocket tester (Ω 1 k) to the

TPS connector.

Tester (+) lead Yellow terminal Tester (–) lead Black terminal

While slowly turning the throttle check theTPS resistance.

TPS resistance “R 2”:0 5 ± 1.0 kΩ at 20C (Yellow — Black)

Out of specification Replace the TPS.

5-9

CARBURETOR CARB

*****************************************************

*****************************************************

2. Adjust:TPS position

Adjustment steps: Loosen the TPS mounting screws 1 . Adjust the TPS resistance by turning the sen-

sor body to the right or left. Stop turning thesensor body when the specified resistance isindicated on the tester.

Resistance when the throttle is closed =Resistance “R 1” (0.13 0.15)

Example: If “R1” = 5 kΩ:

5 (0.13 0.15) = 0.65 0.75The specified resistance when the throttle isclosed is 650 750 Ω.

Tighten the TPS mounting screws. Detach the pocket tester leads and connect

the TPS connector.

CARB

CHAS

CHAPTER 6.CHASSIS

FRONT WHEEL AND BRAKE DISC 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL DISASSEMBLY 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSPECTION 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISK INSPECTION 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL ASSEMBLY 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL INSTALLATION 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL STATIC BALANCE ADJUSTMENT 6-6. . . . . . . . . . . . .

FRONT BRAKE 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD REPLACEMENT 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSPECTION 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSTALLATION 6-14. . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE CALIPER 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER DISASSEMBLY 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSPECTION 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER ASSEMBLY 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSTALLATION 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL AND REAR BRAKE 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER AND REAR BRAKE ROD 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL REMOVAL 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL DISASSEMBLY 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL INSPECTION 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE INSPECTION 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL ASSEMBLY 6-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE ASSEMBLY 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL INSTALLATION 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL STATIC BALANCE ADJUSTMENT 6-29. . . . . . . . . . . . . .

FRONT FORK 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK DISASSEMBLY 6-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK ASSEMBLY 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSTALLATION 6-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 6-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSPECTION 6-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR INSTALLATION 6-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS

STEERING HEAD 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD REMOAL 6-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION 6-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSTALLATION 6-45. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER AND SWINGARM 6-46. . . . . . . . . . . . . . . . . . . . HANDLING NOTES 6-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTES ON DISPOSAL 6-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER INSPECTION 6-48. . . . . . . . . . . . . . . . . . . . . SWINGARM INSPECTION 6-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWINGARM INSTALLATION 6-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER INSTALLATION 6-50. . . . . . . . . . . . . . . . . . .

SHAFT DRIVE 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR BACKLASH MEASUREMENT 6-55. . . . . . . . . . . . . . . . . . . . FINAL GEAR BACKLASH ADJUSTMENT 6-56. . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT 6-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR 6-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE GEAR DISASSEMBLY 6-59. . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY 6-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE/RING GEAR POSITIONING 6-61. . . . . . . . . . . . . . . . . . . . . DEIVE SHAFT INSPECTION 6-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL GEAR CASE INSTALLATION 6-65. . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

59 Nm (5.9 m kg)

20 Nm (2.0 m kg)

23 Nm (2.3 m kg)

Remove the parts in the order below.Stand the motorcycle on a levelsurface.


1234567

Front wheel and brake disc removal

Speedometer cableFront wheel axle pinch boltFront wheel axleFront wheel assemblyCollarSpeedometer gear unitBrake disc

1111111


DisconnectLoosen

Refer to “FRONT WHEELINSTALLATION”.


FRONT WHEEL AND BRAKE DISC CHAS

CHASSISFRONT WHEEL AND BRAKE DISC

6-2


1234567

Front wheel disassembly

Oil sealsClutch retainerSpeedometer clutchOil sealBearingCollarBearing

1111111


Refer to “FRONT WHEELDISASSEMBLY/ASSEMBLY”.



6-3


*****************************************************

*****************************************************

NOTE:

NOTE:

FRONT WHEEL DISASSEMBLY1. Remove:

Oil sealsBearings 1Collar

Removal steps: Clean the outside of the front wheel hub. Use a flat-head screwdriver to remove the oil

seals.

To prevent damage place a rag between thescrewdriver and the wheel surface.

Remove the bearings using a standard bear-ing puller 2 .

FRONT WHEEL INSPECTION1. Inspect:

Front wheel axle(by rolling it on a flat surface)Bent Replace.

Do not attempt to straighten a bent axle.

2. Inspect:Front tireRefer to “TIRE INSPECTION” in CHAP-TER 3.

Front wheelRefer to “WHEEL INSPECTION” inCHAPTER 3.

3. Check:SpokesBends/damage Replace.Loose spokes Retighten.Turn the wheel and tap the spokes with ascrewdriver.

A tight spoke will emit a clear, ringing tone; aloose spoke will sound flat.

6-4


3 Nm (0.3 mkg)

NOTE:

4. Tighten:Loose spokes

After tightening the spokes check the frontwheel runout.

5. Measure:Front wheel runoutOver the specified limits Replace.

Front wheel runout limits:Radial 1 : 2.0 mmLateral 2 : 2.0 mm

6. Inspect:Front wheel bearingsBearings allow free play in the wheel hubor the wheel does not turn smoothly Re-place.

Oil sealsWear/damage Replace.

BRAKE DISK INSPECTION1. Inspect:

Brake discGalling/damage Replace.

2. Measure:Brake disc deflection a

Out of specification Inspect the wheelrunout.If wheel runout is within the limits, replacethe brake disc.

Brake disc maximum deflection:0.15 mm

Measuring point 2 mmBrake disc thickness bOut of specification Replace.

Brake disc minimum thickness:4.5 mm

6-5


*****************************************************

*****************************************************

NOTE:

CAUTION:

23 Nm (2.3 mkg)

NOTE:

NOTE:

59 Nm (5.9 mkg)

NOTE:

20 Nm (2.0 mkg)

FRONT WHEEL ASSEMBLY1. Install:

CollarBearingsOil seals

Installation steps: Install the new bearings and oil seals by re-

versing the removal steps.



FRONT WHEEL INSTALLATION1. Install:

Brake disc 1

Apply LOCTITE to the threads of the brakedisc bolts.

Tighten the brake disc bolts in stages using acrisscross pattern.

2. Install:Speedometer gear unit 1

Be sure that two projections a inside the wheelhub mesh with the two slots b in the gear unitassembly.

3. Tighten:Front wheelFront wheel axle

Be sure that the projection (torque stopper) aof the gear unit housing is positioned correctly.

Axle pinch bolt

6-6


NOTE:

*****************************************************

*****************************************************

*****************************************************

*****************************************************

NOTE:

EB700040

FRONT WHEEL STATIC BALANCEADJUSTMENT

After replacing the tire and/or rim, the wheelstatic balance should be adjusted.

Adjust the front wheel static balance with thebrake discs installed.

1. Remove:Balancing weight

2. Set:Front wheel (on a suitable stand)

3. Find:Heavy spot

Procedure:a. Spin the wheel and wait for it to rest.b. Put an “X1” mark on the wheel’s bottom

spot.c. Turn the wheel so that the “X1” mark is 90

up.d. Release the wheel and wait for it to rest. Put

an “X2” mark on the wheel’s bottom spot.e. Repeat steps (b), (c) and (d) several times

until all the marks come to the same spot.f. This spot is the wheel’s heavy spot “X”.

4. Adjust:Front wheel static balance

Adjusting steps: Install a balancing weight 1 onto the rim ex-

actly opposite to the heavy spot “X”.

Start with the smallest weight.

Turn the wheel so that the heavy spot is 90up.

Check that the heavy spot is at rest there. Ifnot, try another weight until the wheel is bal-anced.

6-7


*****************************************************

*****************************************************

5. Check:Front wheel static balance

Checking steps: Turn the wheel so that it comes to each point

as shown. Check that the wheel is at rest at each point. If

not, readjust the front wheel static balance.

6-8


1234

Front brake pad removalRetaining boltBrake caliperBrake padsPad spring

1121


Refer to “BRAKE PADREPLACEMENT”.


40 Nm (4.0 m kg)

23 Nm (2.3 m kg)

FRONT BRAKE CHAS

FRONT BRAKEFRONT BRAKE PADS

6-9

FRONT BRAKE CHAS

CAUTION:

NOTE:

NOTE:

*****************************************************

Disc brake components rarely require dis-assembly. DO NOT: disassemble components unless abso-

lutely necessary; use solvents on internal brake compo-

nents; use spent brake fluid for cleaning; (use

only clean brake fluid) allow brake fluid to come in contact with

the eyes, as this may cause eye injury; splash brake fluid onto painted surfaces

or plastic parts, as this may cause dam-age;

disconnect any hydraulic connection, asthis would require the entire brake systemto be disassembled, drained, cleaned,properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake cal-iper and brake hose to replace the brake pads.

1. Remove:Bolt (caliper support bolt) 1Move the direction brake caliper to the ar-row mark.

2. Remove:Brake pads 1

Install new brake pad springs when the brakepads have to be replaced.

Replace the brake pads as a set if either isfound to be worn to the wear limit.

3. Install:Brake padsBrake pads spring

Installation steps: Connect a suitable hose 1 tightly to the

brake caliper bleed screw 2 . Put the otherend of this hose into an open container.

6-10

FRONT BRAKE CHAS

*****************************************************

Loosen the brake caliper bleed screw and us-ing a finger push the caliper pistons into thebrake caliper.

Tighten the brake caliper bleed screw 2 .

Brake caliper bleed screw:6 Nm (0.6 mkg)

Install new brake pads and a new brake padspring.

Install the brake caliper 3 and retaining bolt4 .

Bolt (brake caliper):40 Nm (4.0 mkg)

Retaining bolt:23 Nm (2.3 mkg)

4. Inspect:Brake fluid levelRefer to “BRAKE FLUID INSPECTION” inCHAPTER 3.

a “LOWER” level line

5. Check:Brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.

6-11

10 Nm (1.0 m kg)

30 Nm (3.0 m kg)


12345678

Master cylinder removalBrake fluidRear view mirror (right)Brake lever/compression springFront brake switchUnion boltCopper washersBrake hoseMaster cylinder bracketMaster cylinder

11/1112111

Remove the parts in the order below.Drain

Refer to “MASTER CYLINDERINSTALLATION”.


FRONT BRAKE CHAS

MASTER CYLINDER

6-12


1234

Master cylinder disassembly

Dust bootCirclipMaster cylinder cup kitSpring

1111


Refer to “MASTER CYLINDERASSEMBLY”.


FRONT BRAKE CHAS

6-13

FRONT BRAKE CHAS

MASTER CYLINDER INSPECTION1. Inspect:

Master cylinderWear/scratches Replace the mastercylinder assembly.

Master cylinder bodyCracks/damage Replace.

Oil delivery passage(master cylinder body)Blockage Blow out with compressedair.

2. Inspect:Master cylinder cup kit 1Scratches/wear/damage Replace as aset.

3. Inspect:DiaphragmWear/damage Replace.

4. Inspect:Brake hoseCracks/wear/damage Replace.

EB702060

MASTER CYLINDER ASSEMBLY

All internal brake components should becleaned and lubricated with new brakefluid only before installation.


Whenever a master cylinder is disas-sembled replace the piston seals anddust seals.

1. Install:Spring 1Master cylinder cup kit 2

6-14

FRONT BRAKE CHAS

10 Nm (1.0 mkg)

CAUTION:

30 Nm (3.0 mkg)

NOTE:

2. Install:Circlip 1 Dust boot 2

MASTER CYLINDER INSTALLATION1. Install:

Master cylinder 1Master cylinder bracket 2

Install the master cylinder holder with the“UP” mark facing upward.

Align the end of the holder with the punchmark a on the handlebar.

First, tighten the upper bolt, then tightenthe lower bolt.

2. Install:Copper washers 1 Brake hose 2Union bolt 3

Tighten the union bolt while holding the brakehose as shown.

Turn the handlebar to the left and to the rightto check that the brake hose does not touchother parts (throttle cable, wire harness,leads, etc.). Correct if necessary.

Proper brake hose routing is essential toinsure safe motorcycle operation. Referto “CABLE ROUTING”.

Always use new copper washers.

6-15

FRONT BRAKE CHAS

CAUTION:

3. Fill:Reservoir tank


Brake fluid may damage painted surfaces orplastic parts. Always clean up spilled brakefluid immediately.

Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leakage andpoor brake performance.

Refill with the same type of brakefluid: mixing brake fluids may result in aharmful chemical reaction and lead topoor brake performance.

Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thebrake fluid and may result in vapor lock.

4. Air bleed:Brake systemRefer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.

5. Inspect:Brake fluid levelBrake fluid level is under the “LOWER”level line Fill up.Refer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3.


6-16

7 Nm (0.7 m kg)

30 Nm (3.0 m kg)

6 Nm (0.6 m kg)

40 Nm (4.0 m kg)

23 Nm (2.3 m kg)


123456

Front brake caliper removalBrake fluidBrake hose holderUnion boltsCopper washersBrake hoseRetaining boltBrake caliper assembly

112111

Remove the parts in the order below.Drain

Refer to “CALIPER INSTALLATION”.


FRONT BRAKE CHAS

FRONT BRAKE CALIPER

6-17

FRONT BRAKE CHAS


12345

Front brake caliper disassembly

Brake padsPad springBrake caliper pistonsDust sealsCaliper piston sealsBleed screw

12221

Disassemble the parts in the orderbelow.Refer to “FRONT BRAKE PADS”.

Refer to “CALIPER DISASSEMBLY/ASSEMBLY”.


6-18

FRONT BRAKE CHAS

*****************************************************

*****************************************************

CALIPER DISASSEMBLY1. Remove:

Brake caliper pistonsDust seals 1Caliper piston seals 2

Removal steps: Blow compressed air into the hose joint

opening to force out the caliper piston fromthe brake caliper body.

Never try to pry out the caliper pistons. Cover the caliper piston with a rag. Be

careful not to get injured when the pistonis expelled from the master cylinder.

Remove the caliper piston seals.

EB702040

CALIPER INSPECTION

Recommended brake componentreplacement schedule:

Brake pads As required

Piston seals, dustseals

Every two years

Brake hoses Every two years

Brake fluidReplace whenbrakes aredisassembled.

All internal brake components should becleaned in new brake fluid only. Do not usesolvents as they will cause seals to swelland distort.

1. Inspect:Brake caliper piston 1Scratches/rust/wear Replace thebrake caliper assembly.

Brake caliper cylinder 2Wear/scratches Replace the brake cal-iper assembly.

Brake caliper body 3Cracks/damage Replace.

6-19

FRONT BRAKE CHAS

23 Nm (2.3 mkg)

30 Nm (3.0 mkg)

Oil delivery passage (brake caliper body)Blockage Blow out with compressedair.

Replace the caliper piston seal and dustseal whenever the brake caliper is disas-sembled.

CALIPER ASSEMBLY

All internal brake components should becleaned and lubricated with new brakefluid only before installation.


Replace the caliper piston seals whenev-er a brake caliper is disassembled.

1. Install:Caliper piston seals 1 Dust seals 2

2. Install:Brake caliper pistons 1

CALIPER INSTALLATION1. Install:

Brake caliper 1Retaining bolt 2Brake hose 3Copper washers 4 Union bolt 5

6-20

FRONT BRAKE CHAS

CAUTION:

CAUTION:

When installing the brake hose on the brakecaliper, make sure that the brake pipetouches the projection a on the brake cali-per.

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

2. Fill:Brake reservoir


Brake fluid may damage painted surfaces orplastic parts. Always clean up spilled brakefluid immediately.

Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leakage andpoor brake performance.

Refill with the same type of brakefluid: mixing brake fluids may result in aharmful chemical reaction and lead topoor brake performance.

Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thebrake fluid and may result in vapor lock.

3. Air bleedBrake systemRefer to “AIR BLEEDING” in CHAPTER 3.

4. Inspect:Brake fluid levelBrake fluid level is under the “LOWER”level line Fill up.Refer to “BRAKE FLUID INSPECTION” inCHAPTER 3.


6-21

REAR WHEEL AND REAR BRAKE CHAS


12345678

Muffler and rear brake rod removalMufflerAdjusterPinCompression springCotter pinNut/plate washerBoltTension bar

11111

1/111



20 Nm (2.0 m kg)

20 Nm (2.0 m kg)

25 Nm (2.5 m kg)

REAR WHEEL AND REAR BRAKEMUFFLER AND REAR BRAKE ROD

6-22

Remove the parts in the order below.Stand the motorcycle on a levelsurface.


123

Rear wheel removal

Final gear oil

BoltsRear axle nut/washerRear wheel assembly

41/11


DrainRefer to “FINAL GEAR OILREPLACEMENT” in CHAPTER 3.

Refer to “REAR WHEEL REMOVAL/INSTALLATION”.


70 Nm (7.0 m kg)

92 Nm (9.2 m kg)


REAR WHEEL

6-23


1234567

Rear wheel disassembly

Lock washersClutch hubDampersO-ringsBearingSpacer/collarBearing

21621

1/11


Refer to “REAR WHEELDISASSEMBLY/ASSEMBLY”.


62 Nm (6.2 m kg)


6-24


1234567

Rear brake disassembly

Brake shoesTension springsBoltCamshaft leverWear indicatorCamshaftWasher

2211111


Refer to “REAR BRAKEASSEMBLY”.


10 Nm (1.0 m kg)


6-25


NOTE:

REAR WHEEL REMOVAL1. Stand the motorcycle on a level surface.

Securely support the motorcycle so there isno danger of it falling over.

2. Remove:Bolts (final gear case)

3. Loosen:Rear axle nut 1

4. Remove:Rear wheel assembly

Remove the rear wheel assembly, rear wheelaxle and drive shaft by pulling back on the rearwheel assembly.

REAR WHEEL DISASSEMBLY1. Remove:

Bearings 1Remove the bearings using a standardbearing puller 2 .

REAR WHEEL INSPECTION1. Inspect:

Rear wheel axleRefer to “FRONT WHEEL”.

Rear tireRefer to “TIRE INSPECTION” in CHAP-TER 3.

Rear wheelRefer to “WHEEL INSPECTION” inCHAPTER 3.

6-26


NOTE:

NOTE:

2. Check:SpokesRefer to “FRONT WHEEL”.

3. Tighten:Loose spokesRefer to “FRONT WHEEL”.

4. Measure:Rear wheel runoutRefer to “FRONT WHEEL”.

5. Inspect:Rear wheel bearingsRefer to “FRONT WHEEL”.

REAR BRAKE INSPECTION1. Inspect:

Brake lining surfaceGlazed areas Polish.Use coarse sandpaper.

Wipe the polished areas with a cloth.

2. Measure:Brake lining thickness aOut of specification Replace.

1 Measuring points

Replace the brake shoes as a set if either isfound to be worn to the wear limit.

Brake lining thickness:4.0 mm

Wear limit:2.0 mm

6-27


*****************************************************

*****************************************************

NOTE:

CAUTION:

3. Measure:Brake drum inside diameter aOut of specification Replace the wheel.

Brake drum inside diameter:200 mm

Wear limit:201 mm

4. Inspect:Brake drum inner surfaceOil /scratches Repair.

OilUse a rag soaked in lacquer

thinner or solvent.

ScratchesUse an emery cloth (polish

lightly and evenly)

5. Inspect:Camshaft faceWear Replace.

REAR WHEEL ASSEMBLY1. Install:

SpacerCollarBearings

Installation steps: Install the new bearings by reversing the re-

moval steps.



6-28


10 Nm (1.0 mkg)

NOTE:

NOTE:

92 Nm (9.2 mkg)

90 Nm (9.0 mkg)

REAR BRAKE ASSEMBLY1. Install:

Brake shoe plate 1Camshaft 2Wear indicator 3Camshaft lever 4

Apply lithium soap base grease onto the cam-shaft and pin.

After installing the spring and brake shoes,take care not to damage the spring.

REAR WHEEL INSTALLATION1. Install

Rear wheel assembly

Make sure that the splines of the clutch hub fitcorrectly into the final gear case.

2. Install:Rear wheel axleWasherRear wheel axle nutBolt

3. Adjust:Brake pedal free playRefer to “REAR BRAKE ADJUSTMENT”in CHAPTER 3.

6-29


NOTE:

EB701040

REAR WHEEL STATIC BALANCEADJUSTMENT

After replacing the tire and/or wheel, the stat-ic wheel balance should be adjusted.

Adjust the static wheel balance with the rearbrake disc and hub installed.

1. Adjust: Rear wheel static balance

Refer to “FRONT WHEEL”.

6-30

7 Nm (0.7 m kg)

20 Nm (2.0 m kg)

23 Nm (2.3 m kg)

30 Nm (3.0 m kg)

10 Nm (1.0 m kg)40 Nm (4.0 m kg)


12345678

Front fork removalFront wheelBrake hose holderBrake caliper assemblyFront fenderFront flasher light holder nutsUpper bracket boltsCap boltsLower bracket boltsFront forks

11122222

Remove the parts in the order below.Refer to “FRONT WHEEL”.

LoosenRefer to “FRONT FORKINSTALLATION”.


FRONT FORK CHAS

FRONT FORK

6-31


12345678910

11

Front fork disassembly

Cap boltO-ringSpacer collarSpring seatFork springDust sealRetaining clipDamper rod boltGasketDamper rod/rebound springOil seal

111111111

1/11


Refer to “FRONT FORK ASSEMBLY”.

Refer to “FRONT FORKDISASSEMBLY/ASSEMBLY”.

23 Nm (2.3 m kg)

30 Nm (3.0 m kg)

FRONT FORK CHAS

6-32

FRONT FORK CHAS


12

13

14

15

16

Seal spacerSlide metalInner tube/piston metalOil lock pieceOuter tube

11

1/111


Refer to “FRONT FORK ASSEMBLY”.

23 Nm (2.3 m kg)

30 Nm (3.0 m kg)

6-33

FRONT FORK CHAS

CAUTION:

NOTE:

*****************************************************

*****************************************************

CAUTION:

FRONT FORK DISASSEMBLY1. Remove:

Dust seal 1Retaining clip 2(use a slotted-head screwdriver)

Take care not to scratch the inner tube.

2. Remove:Damper rod bolt 1

Loosen the damper rod bolt while holding thedamper rod with the T-handle 2 and the damp-er rod holder 3 .

T-Handle:90890-01326

Damper rod holder:90890-01388

3. Remove:Damper rodRebound spring

4. Remove Inner tube

Removal steps: Hold the fork leg horizontally. Securely clamp the caliper mounting boss of

the outer tube in a vise with soft jaws. Separate the inner tube from the outer tube

by pulling forcefully but carefully on the innertube.

Excessive force will damage the oil seal

and/or the slide metal. A damaged oil

seal and metal must be replaced.

Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil lock piece will be damaged.

6-34

FRONT FORK CHAS

NOTE:

EB703030

FRONT FORK INSPECTION1. Inspect:

Inner tube 1Outer tube 2Scratches/bends/damage Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken thetube.

2. Measure:Fork spring length aOver the specified limit Replace.

Fork spring free length (limit):289 mm

3. Inspect:Damper rod 1Wear/damage Replace.Contamination Blow out all of the oilpassages with compressed air.

Oil lock piece 2Damage Replace.

4. Inspect:O-ring (cap bolt)Wear/damage Replace.

FRONT FORK ASSEMBLY

When reassembling the front fork, replacethe following parts.*Piston metal*Slide metal*Oil seal*Dust seal

Before reassembly make sure that all thecomponents are clean.

6-35

FRONT FORK CHAS

CAUTION:

30 Nm (3.0 mkg)

NOTE:

1. Install:Damper rod 1Rebound springOil lock piece 2 Inner tube 3

Allow the damper rod to slide slowly downthe inner tube until it protrudes from the bot-tom, being careful not to damage the innertube.

2. Lubricate: Inner tube (outer surface)

Recommended lubricant:Yamaha fork oil 10WT orequivalent

3. Install: Inner tube 1(to outer tube 2 )

4. Install:Gasket 1 Damper rod bolt 2

5. Tighten:Damper rod bolt 1

Apply LOCTITE to the threads of the damperrod holder. Tighten the damper rod bolt whileholding the damper rod with a T-handle 2 and adamper rod holder 3 .

T-handle:90890-01326

Damper rod holder:90890-01388

6-36

FRONT FORK CHAS

NOTE:

CAUTION:

NOTE:

6. Install:Slide metal 1 Seal spacerUse the fork seal driver weight 2 and theadapter 3 .

7. Install:Oil seal 1 Use the fork seal driver weight 2 and theadapter 3 .

Fork seal driver weight:90890-01367

Adapter:90890-01381

Before installing the oil seal, apply lithium soapbase grease onto the oil seal lips.

Make sure that the numbered side of the oilseal faces up.

8. Install:Retaining clip 1

Adjust the retaining clip so that it fits into the out-er tube groove.

9. Install:Dust seal 1Use the fork seal driver weight.

Fork seal driver weight:90890-01367

6-37

FRONT FORK CHAS

NOTE:

NOTE:

NOTE:

30 Nm (3.0 mkg)

23 Nm (2.3 mkg)

20 Nm (2.0 mkg)

10. Fill:Fork oil

Each fork:0.454L (454 cm 3)Yamaha fork oil 10WT or equiv-alent. After filling up, slowlypump the fork up and down todistribute the fork oil.

Oil level a :114 mm(from the top of the inner tubefully compressed and withoutthe fork spring)

Hold the fork in an upright position.

11. Install:Fork spring 1Spring seat 2Spacer collar 3O-ringCap bolt

Before installing the cap bolt, apply grease tothe O-ring.

Temporarily tighten the cap bolt.

FRONT FORK INSTALLATION1. Install:

Front forks 1

Make sure that the inner tube end is flush withthe top of the upper bracket.

2. Tighten:Lower bracket bolts 1

Cap bolts 2Upper bracket bolts 3

6-38

23 Nm (2.3 m kg)

10 Nm (1.0 m kg)

20 Nm (2.0 m kg)



1234

56789

10

Handlebar removal

Plastic locking tiesClutch cableClutch switch leadHandlebar switch (left)

Grip (left)Clutch lever assemblyMaster cylinder bracketMaster cylinder assemblyHandlebar switch (right)Throttle cables

4111

111112

Securely support the motorcycle sothat there is no danger of it falling over.

Refer to “HANDLEBAR INSTALLA-TION”.


HANDLEBAR CHAS

HANDLEBAR

6-39

23 Nm (2.3 m kg)

10 Nm (1.0 m kg)

20 Nm (2.0 m kg)




1112131415

Throttle grip assemblyCable guideHandlebar holder (upper)HandlebarHandlebar holder (lower)

11212

HANDLEBAR CHAS

6-40

HANDLEBAR CHAS

CAUTION:

*****************************************************

*****************************************************

NOTE:

NOTE:

23 Nm (2.3 mkg)

NOTE:

HANDLEBAR INSPECTION1. Inspect:

HandlebarBends/cracks/damage Replace.

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

Left handlebar grip replacement steps: Remove the handlebar grip. Apply a light coat of rubber adhesive on the

end of the handlebar. Install the handlebar grip.

Wipe off excess adhesive with a clean rag.

Do not touch the grip until the adhesive hasset.

HANDLEBAR INSTALLATION1. Install:

WashersHandlebar holder (lower) 1Cable guide 2

Temporarily tighten the nuts 3 .

2. Install:HandlebarHandlebar holder (upper)

The upper handlebar holder should beinstalled with the punch mark a forward A .

6-41

HANDLEBAR CHAS

CAUTION:

20 Nm (2.0 mkg)

NOTE:

NOTE:

Align the match marks b on the handlebarwith the lower handlebar holder bolt hole.

Apply a light coat of lithium soap base greaseonto the right end of the handlebar.

First tighten the bolts on the front side ofthe handlebar holder, and then tighten thebolts on the rear side.

Check the handlebar by turning it all theway to the left and then to the right. If thereis any contact with the fuel tank, adjustthe handlebar position.

3. Tighten:Nut (lower handlebar holder)

4. Install:Throttle cables 1Throttle grip assembly 2

Align the projection on the handlebar switch(right) 3 with the hole a in the handlebar 4 .

5. Install:Master cylinder (front brake)Refer to “MASTER CYLINDER (FRONTBRAKE)”.

6. Install:Clutch lever holder 1

Align the slit of clutch lever holder with thepunch mark a on the handlebar.

6-42

HANDLEBAR CHAS

NOTE:

7. Install:Handlebar switch (left) 1

Align the matching surface of the handlebarswitch (left) with the punch mark a on the han-dlebar.

8. Adjust:Throttle cable free playRefer to “THROTTLE CABLE ADJUST-MENT” in CHAPTER 3.

6-43

Refer to “FRONT FORK”.Refer to “HANDLEBAR”.

Disconnect


1234567

Steering head removal

Front forksHandlebarHeadlight lens unitLeads (in the headlight body)Front flasher light (left /right)Headlight bodyUpper bracketLock washerUpper ring nut

1–

1/11111


Securely support the motorcycle sothat there is no danger of it falling over.

52 Nm (5.2 m kg)

18 Nm (1.8 m kg)

110 Nm (11.0 m kg)

32 Nm (3.2 m kg)

STEERING HEAD CHAS

STEERING HEAD

6-44


89

1011121314

Rubber washerLower ring nut

Bearing coverLower bracketBearing (upper)Rubber sealBearing (lower)

11

11111

Refer to “STEERING HEAD REMOVAL/INSTALLATION”.


52 Nm (5.2 m kg)

18 Nm (1.8 m kg)

110 Nm (11.0 m kg)

32 Nm (3.2 m kg)

STEERING HEAD CHAS

6-45

STEERING HEAD CHAS

*****************************************************

*****************************************************

NOTE:

CAUTION:

STEERING HEAD REMOAL1. Remove:

Lower ring nut 1Use the ring nut wrench 2 .

Ring nut wrench:90890-01403

Support the lower bracket so that it does notfall down.

EB704020

STEERING HEAD INSPECTION1. Wash the bearings and the bearing races

with a solvent.2. Inspect:

BearingsPitting/damage Replace.

Bearing and bearing race replacementsteps: Remove the bearing races from the steering

head pipe using a long rod 1 and a hammer,as shown.

Remove the bearing race on the lower brack-et using a floor chisel 2 and a hammer, asshown.

Install the new rubber seal and races.

Always replace the bearings and bearingraces as a set.

Whenever the steering head is disassembledreplace the rubber seal.

If the bearing race is not fitted squarely, thesteering head pipe could be damaged.

3. Inspect:Upper bracketLower bracket(with the steering stem)Cracks/bends/damage Replace.

EB704030

STEERING HEAD INSTALLATION1. Tighten:

Ring nuts (lower and upper)Refer to “STEERING HEAD INSPEC-TION” in CHAPTER 3.

6-46


12

Rear shock absorber and swingarm removal

Seats

Rear wheelFinal gear caseMuffler assemblyBattery coverSide cover (right)Side cover (left)Tool box cover

11


Stand the motorcycle on a level surface.


Refer to “FUEL TANK AND SEATS” in CHAPTER 3.

Refer to “REAR WHEEL”.

Refer to “ENGINE REMOVAL” in CHAPTER 4.

Do not remove the “*”bolts.

100 Nm (10.0 m kg)

7 Nm (0.7 m kg)

62 Nm (6.2 m kg)

62 Nm (6.2 m kg)

100 Nm (10.0 m kg)

REAR SHOCK ABSORBER AND SWINGARM CHAS

REAR SHOCK ABSORBER AND SWINGARM

6-47


34

56789

101112131415

Tool boxBolt/nut (rear shock absorber -upper)Pivot shaft nutPivot shaft (right)Pivot shaft (left)SwingarmRear shock absorber

CollarsRubber bootBushingCollarsOil sealsBearings

11/1

11111

211222

LoosenRefer to “SWINGARM INSTALLA-TION”.

Refer to “REAR SHOCK ABSORBER INSTALLATION”.


100 Nm (10.0 m kg)

7 Nm (0.7 m kg)

62 Nm (6.2 m kg)

62 Nm (6.2 m kg)

100 Nm (10.0 m kg)


6-48


*****************************************************

*****************************************************

HANDLING NOTES

This shock absorber contains highly com-pressed nitrogen gas. Read and understandthe following information before handlingthe shock absorber. The manufacturer can-not be held responsible for property dam-age of personal injury that may result fromimproper handling.

1. Do not tamper or attempt to open thecylinder assembly.

2. Do not subject shock absorber to anopen flame or other high heat. Thismay cause the unit to explode due toexcessive gas pressure.

3. Do not deform or damage the cylinderin any way. Cylinder damage will re-sult in poor damping performance.

NOTES ON DISPOSAL

Shock absorber disposal steps: Gas pressure must be released before dis-

posing of the shock absorber. To do so, drill a2 3 mm hole through the cylinder wall asshown.

Wear eye protection to prevent eye damagefrom escaping gas and/or metal chips.

REAR SHOCK ABSORBER INSPECTION1. Inspect:

Rear shock absorber rodBends/damage Replace the rearshock absorber assembly.

Rear shock absorberOil leaks/gas leaks Replace the rearshock absorber assembly.

SpringWear/damage Replace the rear shockabsorber assembly.

BushingsCollarsDamage/scratches Replace.

Dust sealsWear/damage Replace.

BoltsWear/bends/damage Replace.

6-49


*****************************************************

*****************************************************

NOTE:

SWINGARM INSPECTION1. Check:

Swingarm free play

Inspection steps: Check the tightening torque of the swingarm

pivot shaft securing nuts.

Securing nut (swingarm pivot shaft):

Left:100 Nm (10 mkg)

Right:7 Nm (0.7 mkg)

Right - nut:100 Nm (10 mkg)

Check the swingarm side play A by movingthe swingarm from side to side.If side play is noticeable, check the inner col-lar, bearing, washer and thrust cover.

Side play (at swingarm end):Zero mm

Check the swingarm vertical movement Bby moving it up and down.If vertical movement is not smooth or if thereis binding, check the inner collar, bearing,washer and thrust cover.

2. Inspect:SwingarmCracks/bends/damage Replace.

3. Inspect:Pivot shaftsDamage/wear Replace.

Wash the swingarm pivoting parts in a solvent.

6-50


*****************************************************

*****************************************************

62 Nm (6.2 mkg)

NOTE:

4. Inspect:Collars 1Oil seals 2Bearings 3Rubber boot 4Wear/damage Replace.

SWINGARM INSTALLATION1. Install:

SwingarmPivot shaft (left) 1Pivot shaft (right) 2Pivot shaft nut 3

Tightening steps: Tighten the pivot shaft (left) 1 to specifica-

tion.

Pivot shaft (left):100 Nm (10 mkg)LOCTITE

Tighten the pivot shaft (right) 2 until it con-tacts the collar.

Pivot shaft (right):7 Nm (0.7 mkg)

Tighten the pivot shaft nut 3 to specification.

Pivot shaft nut:100 Nm (10 mkg)

REAR SHOCK ABSORBER INSTALLATION1. Install:

Rear shock absorber 1

Install the rear shock absorber with the warninglabel 2 facing up.

6-51

SHAFT DRIVE CHAS

NOTE:

SHAFT DRIVEEB707010

TROUBLESHOOTINGThe following conditions may indicate damaged shaft drive components:

A Symptoms B Possible causes

1. A pronounced hesitation or jerky movementduring acceleration, deceleration, or sus-tained speeds (This must not be confusedwith engine surging or transmission- relatedmovements.)

2. A rolling “rumble” noticeable at low speeds, ahigh-pitched whine, or a “clunk” from a shaftdrive component or area

3. A locked-up condition of the shaft drive mech-anism or no power transmitted from the en-gine to the rear wheel

A. Bearing damage

B. Improper gear lash

C.Damaged gear teeth

D.Broken drive shaft

E. Broken gear teeth

F. Seizure due to lack of lubrication

G.Small foreign objects lodged between moving

parts

Causes A, B and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficultto distinguish from normal operating noises. If there is reason to believe these components are dam-aged, remove them for individual inspection.

6-52

SHAFT DRIVE CHAS

*****************************************************

*****************************************************

CAUTION:

NOTE:

Inspection notes1. Investigate any unusual noises.

The following noises may indicate a me-chanical defect:a. A rolling “rumble” during coasting, accel-

eration, or deceleration. The noise in-creases with rear wheel speed, but doesnot increase with higher engine or trans-mission speeds.Diagnosis: Possible wheel bearing dam-age

b. A whining noise that varies with accelera-tion and deceleration.Diagnosis: Possible incorrect reassemb-ly, too little gear lash

Insufficient gear lash is extremely destruc-tive to the gear teeth. If a test ride followingreassembly indicates this condition, stopriding immediately to minimize gear dam-age.

c. A slight “clunk” evident at low speed opera-tion. This noise must be distinguished fromnormal motorcycle operation.Diagnosis: Possible broken gear teeth

Stop riding immediately if broken gear teethare suspected. This condition could resultin a locking of the shaft drive assembly,causing loss of control of the motorcycleand possible injury to the rider.

2. Inspect:Drained oilDrained oil contains a large amount ofmetal particles Check the bearing forseizure.

A small amount of metal particles in the oil isnormal.

6-53

SHAFT DRIVE CHAS

*****************************************************

*****************************************************

NOTE:

3. Inspect:Oil leakage

Inspection steps: Clean the entire motorcycle thoroughly, then

dry it. Apply a leak-locating compound or dry pow-

der spray to the shaft drive. Road test the motorcycle for the distance

necessary to locate the leak.Leakage Inspect the component housing,gasket and/or seal for damage.Damage Replace the component.

1 Oil seal2 O-ring3 ForwardA Middle gearB Final gear

An apparent oil leak on a new or nearly newmotorcycle may result from the application ofa rust preventive coating or excessive seallubrication.

Always clean the motorcycle and recheck thesuspected location of an apparent leak.

6-54

SHAFT DRIVE CHAS

YES

NO

NO

YES

YES

NO

Elevate and spin the front wheel. Feel forwheel bearing damage.

Check the rear wheel. Feel for bearing dam-age.

Replace the wheel bearing.Refer to “FRONT WHEEL”.

Rear wheel bearings and shaft drive bear-ings are probably not damaged. Repeat thetest or remove the individual components.

Remove the rear wheel. Check for wheelbearing damage.

Replace the rear wheel bearing.Refer to “REAR WHEEL”.

Remove the drive shaft components.

Troubleshooting chartWhen causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist,check the following points:

6-55

SHAFT DRIVE CHAS

NOTE:

NOTE:

EB707030

FINAL GEAR BACKLASH MEASUREMENT1. Secure the final drive gear case in a vise or

a similar supporting device.2. Remove:

Drain plugDrain the oil.

3. Install:Specified bolt 1(into the drain plug hole)

4. Finger tighten the bolt until it holds the ringgear.

Do not overtighten the bolt; just finger-tighten it.

5. Attach:Final gear backlash band 1Dial gauge 2

Final gear backlash band:90890-01231

Position mark a

6. Measure:Final gear backlashGently rotate the final drive gear couplingfrom engagement to engagement.Over the specified limit Adjust.

Final gear backlash:0.1 0.2 mm

Measure the final gear backlash at four posi-tions. Rotate the final drive shaft 90 each time.

6-56

SHAFT DRIVE CHAS

NOTE:

*****************************************************

*****************************************************

Ring gear shim

Thickness (mm) 0.25, 0.30, 0.40

Thrust washer

Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

EB707031

FINAL GEAR BACKLASH ADJUSTMENT1. Remove:

Bolts (bearing housing)

Working in a crisscross pattern, loosen each nut1 /4 of a turn. After all the nuts are loosened, re-move them.

2. Remove:Bearing housing 1Ring gear 2Thrust washer 3Shim(s) 4

3. Adjust:Final gear backlash

Adjustment steps: Use the following chart to select the suitable

shims and thrust washer.

Reducing the shim gear backlash isthickness: increased.

Increasing the gear backlash isshim thickness: decreased.

If it is necessary to increase the final gearbacklash by more than 0.1 mm:Reduce the thrust washer thickness by 0.1mm for every 0.1 mm increase of ring gearshim thickness.

If it is necessary to reduce the final gear back-lash by more than 0.1 mm:Increase the thrust washer thickness by 0.1mm for every 0.1 mm decrease of ring gearshim thickness.

6-57


123

4

Drive shaft removal

Rear wheel assemblyCollarDrive shaft assemblyFinal drive pinion gear assembly

Final gear assembly

111

1


Securely support the motorcycle so there is no danger of it falling over.

Refer to “REAR WHEEL”.

Refer to “FINAL DRIVE GEAR DISAS-SEMBLY”.


115 Nm (11.5 m kg)

23 Nm (2.3 m kg)

23 Nm (2.3 m kg)

42 Nm (4.2 m kg)

SHAFT DRIVE CHAS

DRIVE SHAFT

6-58


12

3456

Final gear disassembly

Bolts (bearing housing)Bolt (bearing housing)

Bearing housing/O-ringRing gearThrust washerShim(s)

26

1/1111

Disassemble the parts in the order below.NOTE:Working in a crisscross pattern, looseneach bolt 1/4 of a turn. After all the boltsare loosened, remove them.


23 Nm (2.3 m kg)

SHAFT DRIVE CHAS

FINAL GEAR

6-59

SHAFT DRIVE CHAS

CAUTION:

CAUTION:

NOTE:

FINAL DRIVE GEAR DISASSEMBLY1. Remove:

Bearing retainer (final drive shaft)Use a bearing retainer wrench 1 .


The final drive shaft bearing retainer hasleft-handed threads. To loosen the retainerturn it clockwise.

2. Remove:Final drive shaft assemblyWith a soft hammer lightly tap on the finaldrive shaft end.

Removal of the final drive shaft should onlybe performed if gear replacement is neces-sary.

Always use new bearings and races.

EB707033

FINAL DRIVE ROLLER BEARING REMOVALAND REASSEMBLY

1. Remove:Guide collar 1Oil seal 2Roller bearing 3Use a suitable press tool 4 and an ap-propriate support for the final gear case.

2. Inspect:Final drive roller bearing

The roller bearing can be reused, but Yamaharecommends installation of a new bearing. Donot reuse the oil seal.

6-60

SHAFT DRIVE CHAS

*****************************************************

*****************************************************

NOTE:

*****************************************************

*****************************************************

3. Remove:Final drive roller bearing 1

Removal steps: Heat the final gear case to 150C. Using an appropriately shaped punch 2 re-

move the roller bearing outer races. Remove the inner race from the final drive

shaft.

The removal of the final drive shaft roller bear-ing is a difficult procedure and is rarely neces-sary.

4. Install:Final drive roller bearing (new)

Installation steps: Heat the final gear case to 150C. Install the roller bearing outer races using the

proper adapter. Install the inner race onto the drive shaft.

5. Install:Guide collar 1Oil seal 2 Roller bearing (outer race) 3To install the above components into thefinal gear case use a suitable press tool 4and a press.

6-61

SHAFT DRIVE CHAS

NOTE:

*****************************************************

a b

Final drive gear shim

Thickness (mm) 0.40, 0.50

EB707034

FINAL DRIVE/RING GEAR POSITIONING

Ring gear positioning is necessary when any ofthe following parts are replaced: Final gear case Ring gear bearing housing Bearing(s)

1. Select:Final drive gear shim 1Ring gear shim 2

Selection steps: Position the final drive gear and the ring gear

by using shims 1 and 2 with their respec-tive thicknesses calculated from informationmarked on the final gear case and the drivegear end.

1 Final drive gear shim thickness “A”2 Ring gear shim thickness “B”3 Thrust washer “C” To find the final drive gear shim thickness “A”,

use the following formula

Final drive gear shim thickness: A = –

Where:a = a numeral (usually a decimal number) onthe final drive pinion gear is either added to orsubtracted from “80”.b = a numeral on the final drive gear case(i.e.79.50)Example:a is 80.01If the final gear case is marked “50” b. . . is 79.50.

“A” = 80.01 – 79.50= 0.51Therefore, final drive gear shim thickness is0.51 mm. Shim sizes are supplied in the fol-lowing thickness.

6-62

SHAFT DRIVE CHAS

c d e f

Since final drive gear shims can only be se-lected in 0.10 mm increments, round off thehundredths digit and select the appropriateshim(s).


0, 1, 2, 3, 4 0

5, 6, 7, 8, 9 10

In the example above, the calculated final drivegear shim thickness is 0.51 mm. The chartinstructs you to round off the 1 to 0. Thus youshould use a 0.50 mm final drive gear shim. To find the ring gear shim thickness “B”, use

the following formula.

Ring gear shim thickness: B = + – ( + )

Where:c = a numeral on the final gear case (i.e.45.55)d = a numeral on the bearing housing (i.e.1.35)e = a numeral (usually a decimalnumber) onthe inside of the ring gear either added to or sub-tracted from “35.40”.f = the ring gear bearing thickness (consid-

ered constant).

Ring gear bearing thickness f :11 mm

Example:If the final gear case is marked“55” c is 45.55. . . . . d is 1.35If the ring gear is marked “–05” e. . . . . . . is 35.35f is 11.00

“B” = 45.55 + 1.35 – (35.35 + 11.00)= 46.9 – (46.35)= 0.55

6-63

SHAFT DRIVE CHAS

Ring gear shim

Thickness (mm) 0.25, 0.30, 0.40

*****************************************************

115 Nm (11.5 mkg)

CAUTION:

Therefore, the ring gear shim thickness is0.55 mm. Shim sizes are supplied in the fol-lowing thickness.

Since ring gear shims can only be selected in0.10 mm increments, round off the hundredthsdigit and select the appropriate shim(s).


0, 1, 2, 3, 4 0

5, 6, 7, 8, 9 10

2. Install:Shims (proper size as calculated)Final drive shaft assemblyBearing retainer (final drive shaft)

Use a bearing retainer wrench.

The final drive shaft bearing retainer hasleft-hand threads. Turn the retainer counter-clockwise to tighten it.


3. Adjust:Gear backlashRefer to “FINAL GEAR BACKLASH MEA-SUREMENT” and “FINAL GEAR BACK-LASH ADJUSTMENT”.

4. Measure/select:Ring gear thrust washer clearance

6-64

SHAFT DRIVE CHAS

*****************************************************

NOTE:

Thrust washer

Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

*****************************************************

Ring gear thrust washer clearance mea-surement steps: Remove the ring gear assembly. Place four pieces of Plastigauge between

the originally installed ring gear thrust washerand the ring gear.

Install the ring gear assembly and tighten thebolts to specification.

Bolt (bearing housing):23 Nm (2.3 mkg)

When using Plastigauge to measure the ringgear thrust washer clearance do not turn theshaft drive and ring gear.

Remove the ring gear assembly. Measure the ring gear thrust washer clear-

ance and the width of the flattened Plasti-gauge 1 .

Ring gear thrust washer clearance:

0.1 0.2 mm

If the clearance is correct, install the ring gearassembly.

If out of specification, select the correct thrustwasher.

Ring gear thrust washer selection steps: Using the following chart select the suitable

thrust washer.

Repeat the measurement steps until the ringgear thrust washer clearance is within thespecified limits.

Ring gear thrust washer clearance:

0.1 0.2 mm

6-65

SHAFT DRIVE CHAS

EB707040

DEIVE SHAFT INSPECTION1. Inspect:

Drive shaft splinesWear/damage Replace.

FINAL GEAR CASE INSTALLATION1. Apply:

Sealant(onto the mating surface of both final gearcase halves)

Yamaha Bond No. 1215:90890-85505

CHAS

ELEC

CHAPTER 7.ELECTRICAL

ELECTRICAL COMPONENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH INSPECTION 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH INSPECTION 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTING A SWITCH SHOWN IN THE MANUAL 7-2. . . . . . . . . . . . SWITCH CONTINUITY INSPECTION 7-3. . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT OPERATION 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 7-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR INSPECTION 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR ASSEMBLY 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTING SYSTEM CHECK 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 7-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 7-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP TEST 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETOR HEATER SYSTEM 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELEC

SELF-DIAGNOSIS 7-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

ELECTRICAL COMPONENTS ELEC

IGNITION COIL:PRIMARY WINDING RESISTANCE:3.8 4.6 Ω at 20CSECONDARY WINDING RESISTANCE:10.1 15.1 kΩ at 20C

9 Starter relay10 Igniter unit11 Flasher relay12 Neutral switch13 Rear brake switch14 Side stand switch15 Rectifier/regulator16 Horn

1 Thermo switch2 Main switch3 Ignition coil4 Fuse5 Carburetor heater relay6 Relay unit7 Battery8 Headlight relay

EB800000

ELECTRICALELECTRICAL COMPONENTS

7-2

SWITCH INSPECTION ELEC

NOTE:

SWITCH INSPECTIONSWITCH INSPECTIONUse a pocket tester to check the terminals forcontinuity. If the continuity is faulty as any point,replace the switch.


Set the pocket tester to “0” before starting thetest.

The pocket tester should be set to the ” 1” Ωrange when testing the switch for continuity.

Turn the switch on and off a few times whenchecking it.

INSPECTING A SWITCH SHOWN IN THEMANUALThe terminal connections for switches (mainswitch, handlebar switch, engine stop switch,light switch, etc.) are shown in a chart similar tothe one on the left.This chart shows the switch positions in the col-umn and the switch lead colors in the top row.For each switch position, “ ” indicates theterminals with continuity.The example chart shows that:1 There is continuity between the “Black and

Black/White” leads when the switch is setto “OFF”.

2 There is continuity between the “Red andBrown” leads when the switch is set to“ON”.

7-3


SWITCH CONTINUITY INSPECTIONRefer to “SWITCH INSPECTION” and check for continuity between lead terminals.Poor connection, no continuity Correct or replace. The coupler locations are circled.

7-4

8 Engine stop switch9 Lights switch10 Start switch11 Fuse12 Rear brake switch13 Sidestand switch14 Neutral switch

1 Clutch switch2 Horn switch3 Dimmer switch4 Pass switch5 Turn switch6 Main switch7 Front brake switch


E

7-5

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witc

hIg

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itIg

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park

plu

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nitio

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ngin

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op s

witc

h

IGNITION SYSTEM ELEC

EB802000

IGNITION SYSTEMCIRCUIT DIAGRAM

7-6


NOTE:

EB802011

1. Fuses (main and ignition)

Refer to “SWITCH INSPECTION”.

Replace the fuses.

NO CONTINUITY

CONTINUITYEB802012

2. Battery

Check the battery condition.Refer to “BATTERY INSPECTION” inCHAPTER3.

Clean the battery terminals.Recharge or replace the battery.

INCORRECT

CORRECT

Open-circuit voltage:12.8 V or more at 20 C

EB802010

TROUBLESHOOTING

IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):

ProcedureCheck:

1. Fuses (main and ignition)2. Battery3. Spark plugs4. Ignition spark gap5. Spark plug cap resistance6. Ignition coil resistance7. Pickup coil resistance

8. Main switch9. Engine stop switch

10. Neutral switch11. Sidestand switch12. Relay unit (diode)13. Wiring connection (the entire ignition

system)

Remove the following part(s) before trouble-shooting:

1) Battery cover2) Rider’s seat3) Fuel tank4) Steering head side covers

Use the following special tool(s) for trouble-shooting.

Ignition checker:90890-06754


7-7


EB802013

3. Spark plugs

Check the spark plug condition.Check the spark plug type.Check the spark plug gap.Refer to “SPARK PLUG INSPECTION” inCHAPTER3.

Spark plug gap:0.8 0.9 mm

CORRECT Repair or replace the spark plugs.

INCORRECT

EB802014

4. Ignition spark gap

Disconnect the spark plug cap from thespark plug.

Connect the ignition checker as shown.Spark plug cap

Turn the main switch to “ON”.

12

Standard spark plug:DPR7EA-9/NGKX22EPR-U9/DENSO

Check the ignition spark gap .Crank the engine by pushing the starterswitch, and increase the spark gap until amisfire occurs.

MEETS SPECIFICATION

EB802015

5. Spark plug cap resistance

Remove the spark plug cap.Connect the pocket tester (Ω 1k) to thespark plug cap.

Minimum spark gap:6.0 mm

The ignition system is not faulty.

OUT OFSPECIFICATIONOR NO SPARK

a

7-8

MEETSSPECIFICATION

Check if the spark plug cap has the specifiedresistance.

Replace the spark plug cap.

OUT OF SPECIFICATION

Tester (+) lead Red/Black terminalTester (–) lead Orange (Gray) terminal

Spark plug cap resistance:10 kΩ at 20C

Tester (+) lead spark plug lead Tester (–) lead Red/Black terminal

EB802016

6. Ignition coil resistance

Disconnect the ignition coil connector fromthe wire harness.

Connect the pocket tester (Ω 1) to theignition coil.

Check if the primary coil has the specified re-sistance.

Primary coil resistance:3.8 4.6 Ω at 20C

Connect the pocket tester (Ω 1 k) to theignition coil.

Check if the secondary coil has the specifiedresistance.

Secondary coil resistance:10.1 15.1 kΩ at 20C

BOTH MEETSPECIFICATION

Replace the ignition coil.


12


7-9


EB80201C

7. Pickup coil resistance

Disconnect the pickup coil coupler from thewire harness.

Connect the pocket tester (Ω 100) to thepickup coil terminal.

Pickup coil resistance:182 222 Ω at 20C(Gray — Black)

8. Main switch


INCORRECT

Replace main switch.

Tester (+) lead Gray terminal Tester (–) lead Black terminal

12

Check if the pickup coil has the specified re-sistance.

MEETSSPECIFICATION

Replace the pickup coil.


CORRECT

9. Engine stop switch


INCORRECT

Replace handlebar switch (right).CORRECT

10. Neutral switch


INCORRECT

Replace neutral switch.CORRECT

11. Sidestand switch


INCORRECT

Replace sidestand switch.CORRECT

7-10

12. Relay unit (diode)

Remove the relay unit from the wire har-ness.

Check for continuity as follows:Sky blue – Blue/Yellow

EB80201D

13. Wiring connection

Check the connections of the entire ignitionsystem.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTION

Properly connect the ignition system.

Tester (+) lead Sky blue Tester (–) lead Blue/Yellow

Replace the relay unit.

INCORRECT

CORRECT

Tester (+) lead Blue/YellowTester (–) lead Sky blue

NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in theabove chart will be reversed.

CORRECT

Replace the ignitor unit.

Conti-nuity

No Con-tinuity

2

1

2

2

1


E

7-11

Sta

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rel

ay

3 4 6 8 10 16 43 46

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Bat

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Rel

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Sid

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witc

hN

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al s

witc

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Igni

tion

fuse

Eng

ine

stop

sw

itch

Mai

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se5

Sta

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mot

or7 30

Clu

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switc

h

48S

tart

sw

itch

ELECTRIC STARTING SYSTEM ELEC

EB803000

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

7-12


EB803010

STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and the starting cir-cuit cut-off relay. If the engine stop switch is on“RUN” and the main switch is on “ON” (bothswitches are closed), the starter motor can op-erate only if:

The transmission is in neutral (the neutralswitch is closed).

or if

The clutch lever is pulled to the handlebar(the clutch switch is closed) and the side-stand is up (the sidestand switch is closed).

The starting circuit cut-off relay prevents thestarter from operating when neither of theseconditions have been met. In this instance, thestarting circuit cut-off relay is open so currentcannot reach the starter motor.

When at least one of the above conditions havebeen met however, the starting circuit cut-offrelay is closed, and the engine can be started bypressing the starter switch.

WHEN THE TRANSMISSION IS INNEUTRAL

WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED IN

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Starting circuit cut-off relay7 Diode8 Clutch switch9 Sidestand switch10 Neutral switch11 Start switch12 Starter relay13 Starter motor

7-13


NOTE:

EB802011



Replace the fuses.

NO CONTINUITY

CONTINUITYEB802012

2. Battery

Check the battery condition.Refer to “BATTERY INSPECTION” inCHAPTER 3.


INCORRECT

CORRECT


EB803020

TROUBLESHOOTING

IF THE STARTER MOTOR FAILS TO OPERATE:

ProcedureCheck:

1. Fuses (main and ignition)2. Battery3. Starter motor4. Relay unit (starting circuit cut-off relay)5. Relay unit (diode)6. Starter relay7. Main switch

8. Engine stop switch9. Neutral switch

10. Sidestand switch11. Clutch switch12. Start switch13. Wiring connection (the entire starting

system)





7-14

EB803021

3. Starter motor

Connect the battery positive terminal andstarter motor cable using a jumper lead .

Check the operation of the starter motor.

Repair or replace the starter motor.

DOES NOT MOVE

EB803023

4. Relay unit (starting circuit cut-off relay)


Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit terminals.

Battery (+) terminal

Red/Black terminal Battery (–) terminal

Black/Yellow terminal

A wire that is used as a jumper lead musthave the equivalent capacity or more asthat of the battery lead, otherwise thejumper lead may burn.

This check is likely to produce sparks, sobe sure that no flammable gas or fluid isin the vicinity.

Tester (+) lead Blue terminal Tester (–) lead Blue/White terminal

MOVES


Check the starting circuit cut-off relay forcontinuity.

CONTINUITY

12 3

NO CONTINUITY

1

2

34


7-15

5. Relay unit (diode)


Check for continuity as follows:Sky blue – Black/Yellow Sky blue – Blue/Yellow

EB803024

6. Starter relay

Remove the starter relay from the wire har-ness.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starter relay terminals.

Tester (+) lead Sky blue Tester (–) lead Black/Yellow


INCORRECT

Tester (+) lead Black/Yellow Tester (–) lead Sky blue

NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in theabove chart will be reversed.

CORRECT

Conti-nuity

No Con-tinuity

Tester (+) lead Sky blue Tester (–) lead Blue/Yellow

Tester (+) lead Blue/Yellow Tester (–) lead Sky blue

Conti-nuity

No Con-tinuity


Red/White terminal Battery (–) terminal Blue terminal

Check the starter relay for continuity. Replace the starter relay.

NO CONTINUITY

Tester (+) lead Red terminal Tester (–) lead Black terminal

11

23

CONTINUITY

1

2

2

1

13

31

12

34


7-16

7. Main switch


INCORRECT

Replace main switch.

CORRECT



INCORRECT

Replace handlebar switch (right).

CORRECT

9. Neutral switch


INCORRECT

Replace neutral switch.

CORRECT

10. Sidestand switch


INCORRECT

Replace sidestand switch.CORRECT

11. Clutch switch


INCORRECT

Replace clutch switch.

CORRECTEB803028


Check the connections of the entire startingsystem.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTION

Properly connect the starting system.

12. Start switch


INCORRECT


CORRECT


7-17


12

Starter motor removalExhaust pipe assembly

Starter motor/O-ringStarter motor lead

1/11

Remove the parts in the order below.Refer to “ENGINE ASSEMBLY” inCHAPTER 4.

12345

6

Starter motor disassembly

Front bracketWasher kitRear bracketShimsBrush seat/Brush 1

Armature coil

1121

1/1

1


Refer to “STARTER MOTORASSEMBLY”.


Be sure to remove the installation nut onbrush #1 first.

NOTE:


STARTER MOTOR

E

7-18


NOTE:

*****************************************************

*****************************************************

EB803034

STARTER MOTOR INSPECTION1. Inspect:

CommutatorDirty Clean it with #600 grit sandpaper.

2. Measure:Commutator diameter aOut of specification Replace the startermotor.

Commutator wear limit:27 mm

3. Measure:Mica undercut bOut of specification Scrape the mica tothe proper measurement using a hacksawblade which has been grounded to fit thecommutator.

Mica undercut:0.7 mm

The mica insulation of the commutator must beundercut to ensure proper operation of the com-mutator.

4. Inspect:Armature coil resistances (insula-tion/continuity)Defects Replace the starter motor.

Inspection steps: Connect the pocket tester for the continuity

1 and insulation 2 checks.D Measure the armature coil resistances.

Armature coil continuityresistance 1 :

0 Ω at 20CArmature coil insulationresistance 2 :

More than 1 M Ω at 20C

D If the resistance is incorrect, replace thestarter motor.

7-19


NOTE:

5. Measure:Brush length aOut of specification Replace.

Brush length wear limit:4 mm

6. Measure:Brush spring forceFatigue/out of specification Replace asa set.

Brush spring force:520 920 g

7. Inspect:BearingRoughness Replace.

Oil sealBushingWear/damage Replace.

EB803036

STARTER MOTOR ASSEMBLYReverse the “Removal” procedure.Note the following points.

1. Install:Brush seat 1

Align the projection a on the brush seat withthe slot on the housing.

2. Install:Shims 1Armature coil 2

7-20


NOTE:

3. Install:Gasket 1Yoke 2Washer kit 3Brackets 4

Align the match marks a on the yoke with thematch marks b on the brackets.

E

7-21

1 AC magneto (stator coil)2 Rectifier / regulator4 Battery5 Main fuse

CHARGING SYSTEM ELEC

EB804000

CHARGING SYSTEMCIRCUIT DIAGRAM

7-22


NOTE:

EB802011

1. Fuses (main)


Replace the fuses.

NO CONTINUITY

CONTINUITYEB802012

2. Battery



INCORRECT

CORRECT


EB804011

3. Charging voltage

Connect the engine tachometer to the sparkplug lead #1.

Connect the pocket tester (DC 20 V) to thebattery.

Tester (+) lead Battery (+) terminalTester (–) lead Battery (–) terminal

EB804010

TROUBLESHOOTING

IF THE BATTERY IS NOT CHARGED:

ProcedureCheck:

1. Fuse (main)2. Battery3. Charging voltage

4. Stator coil resistance5. Wiring connections (the entire charging

system)


1) Battery cover2) Rider’s seat




7-23

Start the engine and accelerate to about5,000 r/min.

OUT OFSPECIFICATION

MEETS SPECIFICATION

NOTE:

Charging voltage:14 V at 5,000 r/min

Use a fully charged battery.

EB804012

4. Stator coil resistance

Disconnect the AC magneto coupler fromthe wire harness.

Connect the pocket tester (Ω 1) to the sta-tor coils.

Measure the stator coil resistance.

Replace the stator coil assembly.


Tester (+) lead White terminalTester (–) lead White terminal

Stator coil resistance:0.50 0.62 Ω at 20C

BOTH MEETSPECIFICATION

EB804015

5. Wiring connections

Check the connections of the entire charg-ing system.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTION

CORRECT

Properly connect the charging system.

Replace the rectifier/regulator.

Tester (+) lead White terminalTester (–) lead White terminal

The charging circuit is not faulty.

12

31


E

7-24

Mai

n fu

se

3 4 5 18 22 25 27 28 35 36 47

Mai

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Bat

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Met

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ght

Hig

h be

am in

dica

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light

Hea

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htP

ass

switc

hD

imm

er s

witc

hTa

il/b

rake

ligh

tA

uxili

ary

light

Ligh

ts s

witc

h42

Hea

dlig

ht fu

se

LIGHTING SYSTEM ELEC

EB805000

LIGHTING SYSTEMCIRCUIT DIAGRAM

7-25


NOTE:

EB802011

1. Fuses (main and head light)


Replace the fuses.

NO CONTINUITY

CONTINUITYEB802012

2. Battery



INCORRECT

CORRECT


EB805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAIL/BRAKE LIGHT, AUXILIARYLIGHT AND/OR METER LIGHT FAIL TO COME ON:

ProcedureCheck:

1. Fuses (main and head light)2. Battery3. Main switch4. Lights switch

5. Dimmer switch6. Pass switch7. Wiring connections

(the entire lighting system)


1) Battery cover2) Rider’s seat3) Fuel tank4) Steering head side covers5) Headlight lens unit6) Tail /brake light unit



7-26

3. Main switch


INCORRECT

Replace main switch.CORRECT

4. Lights switch

Lights switch is faulty, replace handlebarswitch (right).

5. Dimmer switch


INCORRECT

Dimmer switch is faulty, replace handlebarswitch (left).

CORRECT

6. Pass switch


INCORRECT

Pass switch is faulty, replace handlebarswitch (left).

CORRECT

EB805013


Check the connections of the entire lightingsystem.Refer to “WIRING DIAGRAM”.

POOR CONNECTION

Properly connect the lighting system.CORRECT

Check the condition of each of the lightingsystem’s circuits.Refer to “LIGHTING SYSTEM CHECK”.


CORRECT


7-27


1. Bulb and bulb socket

Check the bulb and bulb socket for continu-ity.

Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers.

When the dimmer switch is on “LO”.When the dimmer switch is on “HI”.

CONTINUITY

AB

Headlight:Tester (+) lead

Yellow terminal or Green terminal Tester (–) lead Black terminal

High beam indicator light:Tester (+) lead Yellow terminalTester (–) lead Black terminal

Turn the main switch to “ON”.Turn the dimmer switch to “LO” or “HI”.Check the voltage (12 V) of the “Green” and“Yellow” leads on the bulb socket connec-tor.

The wiring circuit from the main switch to thebulb socket connector is faulty, repair it.


This circuit is not faulty.

BHeadlight connector

4

13

2

5

Meter connector

MEETSSPECIFICATION

EB805020

LIGHTING SYSTEM CHECK1. If the headlight and the high beam indicator

light fail to come on:

7-28




NO CONTINUITY

2. Voltage

Connect the pocket tester (20 V) to the bulbsocket coupler.

Tester (+) lead Blue terminalTester (–) lead Black terminal

CONTINUITY

Turn the main switch to “ON”.Check the voltage (12 V) of the “blue” leadon the bulb socket connector.




MEETSSPECIFICATION

12



Check the bulb and bulb socket for continu-ity. Replace the bulb and/or bulb socket.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC 20 V) to thebulb socket connector.

Tester (+) lead Blue terminalTester (–) lead Black terminal

CONTINUITY

12

EB805021

2. If the meter light fails to come on:

EB805022

3. If the taillight fails to come on:

7-29

Turn the main switch to “ON”.Check the voltage (12 V) of the “blue” leadon the bulb socket connector.




MEETSSPECIFICATION





NO CONTINUITY

2. Voltage


Tester (+) lead Blue/Red lead Tester (–) lead Black lead

CONTINUITY

Turn the main switch to “ON”.Check the voltage (12 V) of the “Blue/Red”lead on the bulb socket connector.




MEETSSPECIFICATION

12

EB805023

4. If the auxiliary light fails to come on:

E

7-30

SIGNAL SYSTEM ELEC

EB806000

SIGNAL SYSTEMCIRCUIT DIAGRAM

7-31

3 Main switch4 Battery5 Main fuse12 Ignitor unit16 Neutral switch19 Engine indicator light20 Turn indicator light21 Neutral indicator light23 Front turn signal24 Rear turn signal29 Horn switch31 Turn switch32 Flasher relay33 Horn34 Rear brake switch35 Tail /brake light41 Signal system fuse45 Front brake switch

SIGNAL SYSTEM ELEC

7-32

SIGNAL SYSTEM ELEC

NOTE:

EB802011

1. Fuses (main and signals)


Replace the fuse(s).

NO CONTINUITY

CONTINUITYEB802012

2. Battery



INCORRECT

CORRECT


EB806010

TROUBLESHOOTING

IF THE TURN SIGNAL, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON:IF THE HORN FAILS TO SOUND:

ProcedureCheck:

1. Fuses (main and signals)2. Battery3. Main switch4. Wiring connections (the entire signal

system)


1) Battery cover2) Rider’s seat3) Fuel tank4) Steering head side covers5) Headlight lens unit6) Tail /brake light unit



7-33

3. Main switch


INCORRECT

Replace main switch.CORRECT

EB806011


Check the connections of the entire signalsystem.Refer to “CIRCUIT DIAGRAM”.

POOR CONNECTION

Properly connect the signal system.CORRECT

Check the condition of each of the signal sys-tem’s circuits.Refer to “SIGNAL SYSTEM CHECK”.

SIGNAL SYSTEM ELEC

7-34

SIGNAL SYSTEM ELEC

1. Horn switch


Replace the handlebar switch (left).

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC 20 V) to thehorn lead.

Tester (+) lead Black/White leadTester (–) lead Frame ground

CONTINUITY

Turn the main switch to “ON”.Check the voltage (12 V) of the “Black/White” lead at the horn terminal.

The wiring circuit from the main switch to thehorn terminal is faulty, repair it.


MEETSSPECIFICATION

1

3. Voltage

Connect the pocket tester (DC 20 V) to thehorn at the “Pink” terminal.

Tester (+) lead Pink leadTester (–) lead Frame ground

Turn the main switch to “ON”.Check the voltage (12 V) of the “Pink” leadat the horn terminal.

Replace the horn.


Adjust or replace the horn.

MEETSSPECIFICATION

1

EB806020

SIGNAL SYSTEM CHECK1. If the horn fails to sound:

7-35

1. Brake switch (front, rear)


Replace brake switch.

INCORRECT

2. Voltage


Tester (+) lead Yellow terminalTester (–) lead Black terminal

CORRECT

Turn the main switch to “ON”.The brake lever is pulled in or the brakepedal is pressed down.

Check the voltage (12 V) of the “Yellow”lead on the bulb socket connector.




MEETSSPECIFICATION

12

SIGNAL SYSTEM ELEC

1. Turn switch


Replace handlebar switch (left).

INCORRECT

2. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay coupler.

Tester (+) lead Brown terminalTester (–) lead Frame ground

CORRECT

1

EB806022

2. If the brake light fails to come on:

EB806023

3. If the turn signal and/or turn indicator lightfails to blink:

E

7-36

Turn the main switch to “ON”.Check the voltage (12 V) of the “Brown”

lead at the flasher relay terminal.

The wiring circuit from the main switch to theflasher relay connector is faulty, repair it.


MEETSSPECIFICATION

3. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay coupler.

Tester (+) lead Brown/White terminal

Tester (–) lead Frame ground

Turn the main switch to “ON”.Check the voltage (12 V) on the “Brown/White” lead at the flasher relay terminal.

The flasher relay is faulty, replace it.


MEETSSPECIFICATION

1

4. Voltage


At the flasher light (left):Tester (+) lead Chocolate leadTester (–) lead Frame ground

1

Flasher lightTurn indicator light

At the flasher light (right):Tester (+) lead Dark green leadTester (–) lead Frame ground

At turn indicator light:Tester (+) lead

Brown/White terminal Tester (–) lead Frame ground

AB

A B

1

1

2

3

SIGNAL SYSTEM ELEC

7-37

Turn the main switch to “ON”.Turn the turn switch to “L” or “R”.Check the voltage (12 V) of the “Chocolate”lead or “Dark green” lead on the bulb socketconnector.

The wiring circuit from the turn switch to thebulb socket connector is faulty, repair it.



MEETSSPECIFICATION

SIGNAL SYSTEM ELEC

1. Neutral switch


Replace the neutral switch.

NO CONTINUITY

2. Voltage

Connect the pocket tester (DC 20 V) to thebulb socket coupler.

Tester (+) lead Brown terminalTester (–) lead Sky/blue ground

CONTINUITY

Turn the main switch to “ON”.Check the voltage (12 V).




MEETSSPECIFICATION

12

EB806024

4. If the neutral indicator light fails to come on:

E

7-38

Mai

n fu

se

3 4 8 12 43 46

Mai

n sw

itch

Bat

tery

Igni

tor

unit

Igni

tion

fuse

Eng

ine

stop

sw

itch

Rel

ay u

nit (

fuel

pum

p re

lay)

5 9F

uel P

ump

FUEL PUMP SYSTEM ELEC

EB808000

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

7-39

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pump


EB808010

FUEL PUMP CIRCUIT OPERATIONThe fuel pump circuit consists of the fuel pumprelay, fuel pump, engine stop switch and ignitorunit.The ignitor unit includes the control unit for thefuel pump.

7-40


NOTE:

EB802011



Replace the fuse(s).

NO CONTINUITY

CONTINUITYEB802012

2. Battery



INCORRECT

CORRECT


EB808020

TROUBLESHOOTING

IF THE FUEL PUMP FAILS TO OPERATE:

ProcedureCheck:

1. Fuses (main and ignition)2. Battery3. Main switch4. Engine stop switch

5. Relay unit (fuel pump relay)6. Fuel pump7. Wiring connections (the entire fuel system)





7-41


Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit terminals.

3. Main switch

Refer to “SWITCH INSPECTION”.Replace main switch.

INCORRECT




INCORRECT

EB803023

5. Relay unit (fuel pump relay)


Red/Black terminalBattery (–) terminal

Blue/Red terminal

1

2

Check the fuel pump relay for continuity.

Tester (+) lead Red/Black terminalTester (–) lead Blue/Black terminal 3


NO CONTINUITY

CONTINUITYEB808021

6. Fuel pump resistance

Disconnect the fuel pump coupler from thewire harness.

Connect the pocket tester (Ω 1) to the fuelpump coupler terminals.

Tester (+) lead Blue/Black terminalTester (–) lead Black terminal

12

CORRECT

1


7-42

MEETSPECIFICATION

Check if the fuel pump has the specified re-sistance.

Replace the fuel pump.


Fuel pump resistance:1.6 2.2 Ω at 20C

EB808022


Check the connections of the entire fuelpump system.Refer to “CIRCUIT DIAGRAM”. Properly connect the fuel pump system.

POOR CONNECTION

CORRECT



7-43


*****************************************************

*****************************************************

12

EB808030

FUEL PUMP TEST

Gasoline is extremely flammable and undercertain circumstances there can be a dan-ger of an explosion or combustion. Be ex-tremely careful and note the followingpoints: Stop the engine before refuelling. Do not smoke and keep away from open

flames, sparks, or any other source of fire. Take care not to spill gasoline. If you do

accidentally spill some, wipe it up im-mediately with dry rags.

If gasoline touches the engine when theengine is still hot, there is a danger ofcombustion. Make sure that the engine iscompletely cool before performing thefollowing test.

1. Check:Fuel pump operation

Checking steps: Fill up the fuel tank. Put the end of the fuel hose into an open con-

tainer. Connect the battery (12 V) to the fuel pump

coupler terminals.

Battery (+) lead Blue/Black terminalBattery (–) lead Black terminal

If fuel flows out from the fuel hose, the fuelpump is good. If not, replace the fuel pumpassembly.

E

7-44

Mai

n fu

se

3 4 16 37 38

Mai

n sw

itch

Bat

tery

Neu

tral

sw

itch

Car

bure

tor

heat

erC

arbu

reto

r he

ater

rel

ay

5 39T

herm

o sw

itch

40C

arbu

reto

r he

ater

fuse

CARBURETOR HEATER SYSTEM ELEC

CARBURETOR HEATER SYSTEMCIRCUIT DIAGRAM

7-45


NOTE:

EB802011

1. Fuses (main and carburetor heater)


Replace the fuses.

NO CONTINUITY

CONTINUITYEB802012

2. Battery



INCORRECT

CORRECT


TROUBLESHOOTING

IF THE CARBURETER HEATER FAILS TO OPERATE:

ProcedureCheck:

1. Fuses (main and carburetor heater)2. Battery3. Main switch4. Neutral switch

5. Carburetor heater relay6. Thermo switch7. Carburetor heater8. Wiring connections

(the entire carburetor heater system)





7-46

Remove the carburetor heater relay fromthe wire harness.

Connect the pocket tester (Ω 1) and battery(12 V) to the carburetor heater relay termi-nals.

3. Main switch

Refer to “SWITCH INSPECTION”.Replace main switch.

INCORRECT

4. Neutral switch


Replace neutral switch.

INCORRECT

5. Caburetor heater relay.


Brown/Yellow terminalBattery (–) terminal

Sky blue terminal

1

2

Check the carburetor heater relay for nocontinuity.

Replace carburetor heater relay.

CONTINUITY

NO CONTINUITY

CORRECT

Tester (+) lead Brown/Black terminal

Tester (–) lead Black/Yellow terminal

3

4

CORRECT


E

7-47

6. Thermo switch

Remove the thermo switch from the thermoswitch plate.

Connect the pocket tester to the thermoswitch lead.

Tester (+) lead Brown/Yellow terminal

Tester (–) lead Black/Yellow terminal

1

Immerse the thermo switch in the water .Check the thermo switch for continuity. Notethe temperatures while heating the waterwith the temperature gauge .

2

If condition is not good, replace the thermoswitch.

CORRECT

7. Carburetor heater

Remove the carburetor heater from the car-buretor body.

Connect the pocket tester to the carburetorheater.

Replace thermo switch.

INCORRECT

Tester (+) lead Heater terminalTester (–) lead Heater body

Test step Water temperatureGood

condition

1

2

3

4

Less than 23 ± 3C

More than 23 ± 3C

More than 12 ± 4C

Less than 12 ± 4C

Test 1 & 2: Heat-up testTest 3 & 4: Cool-down test: Continuity : No continuity

3

4

12

OFF

ON

Thermoswitch 12 ± 4C

Thermoswitch 23 ± 3C


7-48

Measure the heater resistance.

Replace carburetor heater.

INCORRECT

Carburetor heater resistance:12V15W: 6 12 Ω at 20C12V30W: 6 10 Ω at 20C


Check the connections of the carburetorheater system.Refer to “CIRCUIT DIAGRAM”.

CORRECT

Properly connect the carburetor heatersystem.

POOR CONNECTION


7-49

SELF-DIAGNOSIS ELEC

NOTE:

Light on

LIght off

1 Light on (seconds) 0.5 seconds. . . . . 2 Light off (seconds) 0.5 seconds. . . . . 3 Number of blinks Fault code. . . . . . 4 Light off (seconds) 3 seconds. . . . .

Repetition1 2

3 4

SELF-DIAGNOSISThe XVS650 features self-diagnosis.When the main switch is turned to “ON”, the following items are monitored and the condition codes aredisplayed on the engine indicator light (irrespective of whether the engine is running or not). 1

The XVS650 features a self-diagnosing system.In the XVS650, when the main switch is turned on the “Engine indicator light” in the speedometercomes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds,goes off and then begins flashing. (However, it is on while the engine is running.)

Display conditioncode

Item Condition Response Whenengine isstationary

Whenengine isrunning

Throttle positionsensor (TPS)

DisconnectedShort-circuitLocked

Enables the motorcycle torun so that the ignition tim-ing is fixed when the throttleis fully opened.

Displays the condition codeon the engine indicator light.

Blinks in Light on

Display order on the engine indicator light

E

7-50

SELF-DIAGNOSIS ELEC

NOTE:

11 Throttle position sensor (TPS)12 Ignitor unit

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Repair or replace the wire harness.

NO CONTINUITY

CONTINUITY

2. TPS

Check the TPS for continuity.Refer to “THROTTLE POSITION SENSOR(TPS) INSPECTION AND ADJUSTMENT”in CHAPTER 5.

Replace the TPS.

BAD CONDITION

GOODCONDITION


TROUBLESHOOTING

The engine indicator light starts to display the self-diagnosis sequence.

Use the following special tool in this trouble-shooting.


1. Throttle position sensor (TPS)CIRCUIT DIAGRAM

TRBLSHTG

CHAPTER 8.TROUBLESHOOTING

STARTING FAILURE/HARD STARTING 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR IDLE SPEED PERFORMANCE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE 8-2. . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2. . . . . . . . . . . . . POOR MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2. . . . . . . . . .

FAULTY GEAR SHIFTING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARD SHIFTING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS-OUT-OF GEAR 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH SLIPPING/DRAGGING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPPING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGGING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEATING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY BRAKE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR BRAKING EFFECT 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8-4. MALFUNCTION 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEAKAGE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNSTABLE HANDLING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNSTABLE HANDLING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY LIGHTING AND SIGNAL SYSTEMS 8-5. . . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULB BURNT OUT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS SLOWLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER REMAINS LIT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS QUICKLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

8-1

STARTING FAILURE/HARD STARTINGTRBLSHTG

NOTE:

EB900000

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of problems. It should behelpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for in-spection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tank Empty Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Clogged roll-over valve Clogged roll-over valve breather hose Deteriorated or contaminated fuelFuel cock Clogged fuel hose

Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Faulty starter plunger Improperly adjusted starter cableAir filter Clogged air filter elementFuel pump Faulty fuel pump Faulty relay unit (fuel pump relay)

ELECTRICAL SYSTEMSpark plug Improper plug gap Worn electrodes Wire between terminals severed Improper heat range Faulty spark plug capIgnition coil Broken or shorted primary/secondary Faulty spark plug lead Broken bodyFull-transistor system Faulty ignitor unit Faulty pickup coil

Switch and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switchStarter motor Faulty starter motor Faulty starter relay Faulty relay unit (starter circuit cut-off relay) Faulty starter clutch

8-2

STARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

TRBLSHTG

COMPRESSION SYSTEMCylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Faulty cylinder head gasket Worn, damaged or seized cylinder Improperly sealed valve Improper valve-to-valve seat contact Improper valve timing Faulty valve spring

Piston and piston ring Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged pistonCrankcase and crankshaft Improperly seated crankcase Seized crankshaft

EB901000

POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor Improperly returned starter plunger Loose pilot jet Clogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed

(throttle stop screw) Improper throttle cable free play Flooded carburetor

Electrical system Faulty battery Faulty spark plug Faulty ignitor unit Faulty pickup coil Faulty ignition coilValve train Improperly adjusted valve clearanceAir filter Clogged air filter element

EB902000

POOR MEDIUM-AND HIGH-SPEED PERFORMANCEPOOR MEDIUM-AND HIGH-SPEED PERFORMANCERefer to “STARTING FAILURE/HARD STARTING”. (Fuel system, electrical system, compressionsystem and valve train)

Carburetor Faulty diaphragm Improperly adjusted fuel level Clogged or loose main jet

Air filter Clogged air filter elementFuel pump Faulty fuel pump

8-3

FAULTY GEAR SHIFTING/CLUTCH SLIPPING/DRAGGING

TRBLSHTG

EB903000

FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH DRAGGING”.

SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift pedal link Bent shift shaftShift cam, shift fork Groove jammed with impurities Seized shift fork Bent shift fork guide bar

Transmission Seized transmission gear Jammed impurities Incorrectly assembled transmission

JUMPS-OUT-OF GEARShift shaft Improperly adjusted shift lever position Improperly returned stopper leverShift fork Worn shift fork

Shift cam Improper thrust play Worn shift cam grooveTransmission Worn gear dog

EB904000

CLUTCH SLIPPING/DRAGGINGCLUTCH SLIPPINGClutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate/clutch plate Incorrectly assembled clutch

Engine oil Improper oil level Improper viscosity (low) Deterioration

CLUTCH DRAGGINGClutch Warped pressure plate Unevenly tensioned clutch springs Bent push rod Broken clutch boss Burnt primary driven gear bushing Bent clutch plate Swollen friction plate Match marks not aligned

Engine oil Improper oil level Improper viscosity (high) Deterioration

8-4

OVERHEATING/FAULTY BRAKE/FRONT FORK OILLEAKAGE AND FRONT FORK MALFUNCTION

TRBLSHTG

EB905000

OVERHEATINGOVERHEATINGIgnition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unitFuel system Improper carburetor main jet setting Improper fuel level Clogged air filter element

Compression system Heavy carbon build-upEngine oil Improper oil level Improper oil viscosity Inferior oil qualityBrake Brake drag

EB906001

FAULTY BRAKEPOOR BRAKING EFFECTDisc brake Worn brake pad Worn disc Air in brake fluid Leaking brake fluid Faulty cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose Oily or greasy disc/brake pad Improper brake fluid level

Drum brake Worn brake shoe Worn or rusty brake drum Improper brake free play adjustment Improper brake cam lever position Improper brake shoe position Fatigue/faulty return spring Oily or greasy brake shoe/brake drum Broken brake rod

EB907000

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTIONMALFUNCTION Bent, deformed or damaged inner tube Bent or deformed outer tube Damaged fork spring Worn or damaged slide metal Bent or damaged damper rod Improper oil viscosity Improper oil level

OIL LEAKAGE Bent, damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Improperly installed oil seal Improper oil level (too high) Loose damper rod holding bolt Broken cap bolt O-ring Loose drain bolt Damaged drain bolt gasket

8-5

UNSTABLE HANDLING/FAULTY LIGHTING AND SIGNAL SYSTEMS

TRBLSHTG

EB908000

UNSTABLE HANDLINGUNSTABLE HANDLINGHandlebar Improperly installed or bentSteering Improperly installed handlebar crown Bent steering stem Improperly installed steering shaft

(improperly tightened ring nut) Damaged ball bearing or bearing race

Front fork Uneven oil levels on both sides Uneven spring tension

(uneven damping force adjuster position) Broken spring Twisted front fork

Swingarm Worn bearing or bushing Bent or damagedRear shock absorber Faulty spring Oil and gas leakageTire Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear

Wheel Incorrect wheel balance Deformed cast wheel Damaged bearing Bent or loose wheel axle Excessive wheel runout Loosed spokeFrame Bent Damaged steering head tube Improperly installed bearing race

EB909000

FAULTY LIGHTING AND SIGNAL SYSTEMSHEADLIGHT DOES NOT LIGHT Improper bulb Too many electric accessories Hard charging (broken stator coil wire, faulty

rectifier /regulator) Incorrect connection Improperly grounded Poor contacts (main or lights switch) Bulb life expired

BULB BURNT OUT Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main and/or lights switch Bulb life expired

FLASHER DOES NOT LIGHT Improperly grounded Discharged battery Faulty turn switch Faulty flasher relay Faulty wire harness Loosely connected coupler Burnt-out bulb Faulty fuseFLASHER BLINKS SLOWLY Faulty flasher relay Faulty main and/or turn switch Improper bulb

FLASHER REMAINS LIT Faulty flasher relay Burnt-out bulbFLASHER BLINKS QUICKLY Improper bulb Faulty flasher relay Burnt-out bulbHORN DOES NOT SOUND Faulty battery Faulty fuse Faulty main and/or horn switch Improperly adjusted horn Faulty horn Broken wire harness

TRBLSHTG

1 A.C. magneto2 Rectifier / regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Relay unit9 Fuel pump10 Sidestand switch11 Throttle position sensor (TPS)12 Ignitor unit13 Ignition coil14 Spark plug15 Pickup coil16 Neutral switch17 Meter assembly18 Meter light19 Engine warning light20 Turn indicator light21 Neutral indicator light22 High beam indicator light23 Front turn signal24 Rear turn signal25 Headlight26 Left handlebar switch27 Pass switch28 Dimmer switch29 Horn switch30 Clutch switch31 Turn switch32 Flasher relay33 Horn34 Rear brake switch35 Tail /brake light36 Auxiliary light37 Carburetor heater38 Carburetor heater relay39 Thermo switch40 Carburetor heater fuse41 Signal system fuse42 Headlight fuse43 Ignition fuse44 Right handlebar switch45 Front brake switch46 Engine stop switch47 Lights switch48 Start switch

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .

L Blue. . . . . Lg Light green. . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . .

W White. . . . Y Yellow. . . . . B/L Black/Blue. . . B/W Black/White. . B/Y Black/Yellow. . . Br/B Brown/Black. .

Br/L Brown/Blue. . Br/W Brown/White. Br/Y Brown/Yellow. . G/Y Green/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . .

L/W Blue/White. . L/Y Blue/Yellow. . . R/B Red/Black. . . R/W Red/White. . R/Y Red/Yellow. . .

XVS650 ’97 WIRING DIAGRAM

Documents

Yamaha Dragstar 650 Service Manual