Yamaha 1999 XVS1100 Service Manual Download Page 15

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1-7

SPECIAL TOOLS

GEN

INFO

Tool No.

Tool name / How to use

Illustration

90890-03141

Timing light

This tool is necessary for checking ignition
timing.

90890-04014

Valve guide remover & installer

This tool is needed to remove and install the
valve guide.

90890-04019

Valve spring compressor

This tool is needed to remove and install the
valve assemblies.

Adapter

90890-01277

Shock puller

90890-01290

Weight

90890-01291

Crankshaft installer bolt adapter / armature
shock puller / weight

These tools are needed when removing the
final pinion shaft.

90890-04137

Bearing retainer wrench

This tool is needed when removing or instal-
ling the middle drive shaft assembly.

Wrench

90890-04138

Holder

90890-04055

Middle drive shaft nut wrench / Middle drive
shaft holder

These tools are needed when removing or
installing the middle drive shaft bearing.

90890-04062

Universal joint holder

This tool is needed when removing or instal-
ling the driven pinion gear nut.

90890-04077

Bearing retainer wrench

This tool is needed when removing or instal-
ling the final drive pinion gear assembly.

90890-04086

Clutch holding tool

This tool is needed to hold the clutch when re-
moving or installing the clutch boss nut.

Summary of Contents for 1999 XVS1100

Page 1: ......

Page 2: ...S1100 L SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First edition October 1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...ll its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert ...

Page 4: ...help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval 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 ...

Page 5: ...earing in the text 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Torque 15 Wear limit clearance 16 Engine speed 17 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 oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing grease 22 Apply lightweight li...

Page 6: ...J GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8 CHAPTER TITLES ...

Page 7: ...GEN INFO 1 ...

Page 8: ...IFICATION 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 ...

Page 9: ...TION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 10: ...disassembly clean all parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 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 and ...

Page 11: ...s are vis ible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing 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 CIRCLIPS 1 Check all circlips carefully before reassemb ly Always replace piston pin clips after one use Repla...

Page 12: ...nect the terminals several times 3 Check Connector leads Looseness 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 C...

Page 13: ...ese tools are used to remove the rocker arm shaft 90890 01135 Crankcase separating tool This tool is used to remove the crankshaft 90890 01229 Coupling gear Middle shaft tool This tool is needed when removing or installing the final pinion shaft nut Final gear backlash band 90890 01230 Middle gear backlash band 90890 01231 Final gear backlash band This tool is needed when measuring final gear midd...

Page 14: ... seal and dust seal into the fork Ring nut wrench 90890 01403 Exhaust nut wrench 90890 01268 Ring nut wrench ehaust and steering nut wrench This tool is needed to loosen and tighten the steering stem ring nut 90890 01701 Sheave holder This tool is needed to hold the rotor when re moving or installing the rotor bolt 90890 03081 Compression gauge set These tools are needed to measure engine compress...

Page 15: ...needed when removing the final pinion shaft 90890 04137 Bearing retainer wrench This tool is needed when removing or instal ling the middle drive shaft assembly Wrench 90890 04138 Holder 90890 04055 Middle drive shaft nut wrench Middle drive shaft holder These tools are needed when removing or installing the middle drive shaft bearing 90890 04062 Universal joint holder This tool is needed when rem...

Page 16: ...g compressor This tool is needed when removing or instal ling the damper spring 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components 90890 85505 Yamaha bond No 1215 This sealant bond is used on crankcase mat ing surfaces etc ...

Page 17: ...SPEC 2 ...

Page 18: ...TIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 GENERAL TORQUE SPECIFICATIONS 2 20 CONVERSION TABLE 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING 2 26 ...

Page 19: ...r arrangement Displacement Bore stroke Compression ratio Compression pressure STD Starting system Air cooled 4 stroke SOHC V type 2 cylinder 1 063 L 95 75mm 8 3 1 1 000 kPa 10 kg cm2 10 bar at 400 r min Electric starter Lubrication system Wet sump Oil type or grade Engine oil API standard SE or higher grade ACEA standard G4 or G5 Final gear oil SAE80API GL 4 Hypoid Gear Oil Oil quantity Engine oil...

Page 20: ...36 28 1 286 32 31 1 032 29 34 0 853 Chassis Frame type Caster angle Trail Double cradle 33 136 mm Tire Type Size front rear Manufacturer front rear Type front rear With tube 110 90 18 61S 170 80 15M C 77S BRIDGESTONE DUNLOP BRIDGESTONE DUNLOP EXEDRA L309 K555F EXEDRA G546 K555 Maximum load except motorcycle 201 kg 5EL2 200kg Tire pressure cold tire 0 X 90 kg 0 X 198 lb load front rear 90 kg 198 lb...

Page 21: ...cal Ignition system Generator system Battery type Battery capacity T C I digital A C magneto GT14B 4 12 V 12 AH Headlight type Quartz bulb halogen Bulb wattage quantity Headlight Auxiliary light Tail brake light Turn signal Licence light Meter light Neutral indicator light High beam indicator light Turn indicator light Oil level caution light Engine warning light 12 V 60 W 55 W 1 12 V 4 W 1 12 V 5...

Page 22: ...cap inside diameter Camshaft outside diameter Shaft to cap clearance Cam dimensions Intake A B C Exhaust A B C Camshaft runout limit Chain drive left right 25 000 X 25 021 mm 24 96 X 24 98 mm 0 020 X 0 061 mm 39 112 X 39 212 mm 1 32 093 X 32 193 mm 2 32 127 X 32 227 mm 7 162 mm 39 145 X 39 245 mm 32 200 X 32 300 mm 7 195 mm SSS SSS SSS SSS SSS 39 012 mm 1 31 993 mm 2 32 027 mm 7 012 mm 39 045 mm 3...

Page 23: ...036 mm 13 95 mm 0 086 mm Valve valve seat valve guide Valve clearance cold IN EX 0 07 X 0 12 mm 0 12 X 0 17 mm SSS SSS Valve dimensions A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem outside diameter IN EX Guide inside diameter IN EX Stem to guide clearance IN EX 47 0 X 47 2 mm 39 0 X 39 2 mm 2 1 mm 2 1 mm 1 2 X 1 4 mm 1 2 X 1 4 mm 1 1 X 1 5 mm 1 1 X 1 5 ...

Page 24: ...losed IN EX Compressed pressure IN installed EX Tilt limit IN EX Direction of winding top view IN EX 44 6 mm 44 6 mm 40 mm 40 mm 160 7 N 16 4 kg 160 7 N 16 4 kg SSS SSS Clockwise Clockwise 43 5 mm 43 5 mm SSS SSS SSS SSS 2 5_ 1 9mm 2 5_ 1 9mm SSS SSS Piston Piston to cylinder clearance Piston size D Measuring point H Piston off set 0 025 X 0 050 mm 94 960 X 94 975 mm 5 mm 0 mm 0 15 mm SSS SSS SSS ...

Page 25: ... B T End gap installed Side clearance Oil ring Dimensions B T End gap installed Plain 1 5 3 8 mm 0 3 X 0 5 mm 0 04 X 0 08 mm Taper 1 2 3 8 mm 0 30 X 0 45 mm 0 03 X 0 07 mm 2 5 3 4 mm 0 2 X 0 7 mm SSS SSS 0 8 mm 0 1 mm SSS SSS 0 8 mm 0 1 mm SSS SSS Connecting rod Oil clearance Color code corresponding size 0 044 X 0 073 mm Blue Black Brown Green Yellow SSS SSS Crankshaft Crank width A Runout limit ...

Page 26: ...r type Guide bar SSS Carburetor I D mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot air jet P A J 1 P A J 2 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 speed Intake vacuum Engine oil temperature 5EL1 00 1 110 2 112 5 55...

Page 27: ...type Oil pump type Tip clearance A or B Side clearance Relief valve operating pressure Paper type Trochoid type 0 03 X 0 09 mm 0 03 X 0 08 mm 450 X 550 kPa 4 5 X 5 5 kg cm2 SSS SSS 0 15 mm 0 15 mm SSS Shaft drive Middle gear backlash Final gear backlash 0 1 X 0 2 mm 0 1 X 0 2 mm SSS SSS ...

Page 28: ...2 10 MAINTENANCE SPECIFICATIONS SPEC Item Standard Lubrication chart ...

Page 29: ...Left crankcase Right crankcase MAINTENANCE SPECIFICATIONS SPEC 2 11 Cylinder head tightening sequence Crankcase tightening sequence ...

Page 30: ...case cylinder Crankcase cylinder Crankcase Crankcase Bearing retainer middle drive pinion gear Crankcase cover left Crankcase cover right Clamp One way clutch Primary drive gear Nut Nut Bolt Screw Stud bolt Union bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Nut Nut Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Union bolt Union bolt Bolt Bolt Bolt Nut Bolt Bolt Stud bolt Stud bolt Bolt Bolt Bolt Bol...

Page 31: ...de bar stopper Shift dram segment Shift arm Shift pedal adjuster Stator coil Pickup coil Starter motor Neutral switch Ignition coil Speed sensor Bolt Nut Nut Screw Nut Nut Nut Bolt Bolt Screw Screw Bolt Nut Screw Screw Bolt Screw Bolt M6 M8 M20 M8 M44 M88 M14 M8 M8 M6 M5 M6 M6 M6 M5 M6 M10 M5 M6 6 1 1 1 1 1 1 4 1 2 1 1 2 3 2 2 1 4 1 8 12 70 12 110 110 25 22 7 4 10 10 10 7 10 20 2 5 7 0 8 1 2 7 0 1...

Page 32: ...o 0 464 L 108 mm Fork oil 10W or equivalent SSS 350 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Rear suspension Shock absorber travel Spring free length Fitting length Spring rate K1 Stroke K1 Optional spring 113 mm 179 5 mm 163 mm 117 7 N mm 12 kg mm 0 X 50 mm No SSS SSS SSS SSS SSS SSS Swingarm Free play limit end SSS 0 mm Front wheel Type Rim size Rim material Rim runout limit radial lateral Spo...

Page 33: ... SSS 4 5 mm 0 15 mm 0 8 mm 0 8 mm SSS SSS SSS SSS Rear brake Type Disc outside diameter thickeness Disc deflection limit Pad thickness inner outer Master cylinder inside diameter Caliper cylinder inside dimeter Brake fluid type Single disc 282 6 mm SSS 5 55 mm 5 55 mm 12 7 mm 42 9 mm DOT 4 SSS 5 5 mm 0 15 mm 0 5 mm 0 5 mm SSS SSS Brake lever brake pedal Brake lever free play at lever end Brake ped...

Page 34: ...er stay and frame Rear shock absorber and relay arm Rear shock absorber and frame Pivot shaft and swingarm Relay arm and frame Connecting arm and relay arm Connecting arm and swingarm Final gear case and swingarm Swingarm end and holder Fuel tank and fuel cock Fuel tank bracket and frame Rider s seat Passenger seat Fuel tank and top cover Licence bracket and rear fender stay Rear fender and rear f...

Page 35: ... hose union bolt Caliper bleed screw Clutch hub and damper Final gear case stud bolt Final gear case stud bolt Bearing housing final gear case Bearing housing final gear case Drive pinion Bearing retainer final drive pinion gear Oil filter bolt final gear Oil drain bolt final gear Housing cover M8 M10 M10 M5 M6 M8 M8 M10 M16 M8 M10 M8 M7 M16 M10 M10 M10 M8 M10 M10 M8 M8 M10 M14 M65 M14 M14 M10 26 ...

Page 36: ...nce color A C magneto F4T654 MITSUBISHI 14 V 350 W at 5 000 r min 0 36 X 0 44 Ω at 20_C White White SSS SSS SSS SSS Voltage regulator Type Model manufacturer No load regulated voltage Semi conductor short circuit type SH650D 11 SHINDENGEN 14 1 X 14 9 V SSS SSS SSS Rectifier Model manufacturer Capacity Withstand voltage SH650D 11 SHINDENGEN 18 A 200 V SSS SSS SSS Battery Specific gravity 1 320 SSS ...

Page 37: ...75 X 95 cycle min 21 W 2 3 4W SSS SSS SSS SSS SSS Oil level gauge Model manufacturer 5EL DENSO SSS Starting circuit cut off relay Model manufacturer G8R 30Y B OMRON SSS Fuel pump relay Model manufacturer G8R 30Y B OMRON SSS Circuit breaker Type Amperage for individual circuit MAIN HEAD LIGHT SIGNALS IGNITION BACK UP Carburetor heater Reserve Reserve Reserve Reserve Fuse 30 A 1 15 A 1 10 A 1 10 A 1...

Page 38: ...10 mm 30 3 0 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 17 mm 12 mm 55 5 5 A nut B Bolt General torque specifications Nm mSkg EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex CONVERSION TABLE EB202001 METRIC MULTIPLIER IMP mm x 0 03937 in 2 mm x 0 03937 0 08 in METRIC TO IMP Known Mult...

Page 39: ... journal big end Piston surface Piston pin Camshaft cam lobe journal Rocker arm shaft Valve stem IN EX Valve stem end IN EX Timing chain drive gear shafts sprokets Oil pump rotor inner outer housing Idle gear surface Starter idle gear Starter idle gear shaft Starter oneway cam Middle drive gear Primary driven gear Push rod 1 2 Transmission gear wheel pinion Shift cam Shift fork guide bar Shift sha...

Page 40: ...ft 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 Relay arm bearing collar and oil seal Drive s...

Page 41: ...2 23 LUBRICATION DIAGRAMS SPEC 4 Oil pump 5 Drive axle 6 Middle drive shaft 1 Rocker arm shaft intake 2 Rocker arm shaft exhaust 3 Oil filter EB205000 LUBRICATION DIAGRAMS ...

Page 42: ...2 24 4 Middle drive shaft 1 Oil pump 2 Releaf valve 3 Oil filter LUBRICATION DIAGRAMS SPEC ...

Page 43: ...2 25 4 Middle drive shaft 5 Drive axle 6 Connecting rod big end 1 Camshaft 2 Crankshaft 3 Main axle LUBRICATION DIAGRAMS SPEC ...

Page 44: ... for California 10 Alarm connector 11 Fuel pump lead 12 Speed sensor lead 13 Sidestand switch lead 14 Neutral switch lead 15 Pickup coil lead 16 AC magneto lead 17 Ventilation hose 18 Sensing hose AIS carburetor joint 1 Clutch cable 2 Starter cable 3 Handlebar switch lead left 4 Handlebar switch lead right 5 High tension code 6 Starter cable 7 Throttle cable 8 Fuel hose fuel cock fuel filter 9 Fus...

Page 45: ...on the throttle cable and starter cable as shown and clamp them with holder C Clamp the wire harness with the hook of frame side D When installing the pipe of throttle cables press it inside E Connect the sensing hose carburetor joint AIS side with a nozzle 26 Purge hose carburetor solenoid valve for California A Fasten the handlebar switch leads left and right to the handlebar with plastic lockin...

Page 46: ...nd on the lid J Fasten the handlebar switch leads left and right under the handle crown with a plastic band Set the band at four notches and install it no slacking K Route the each hoses through the frame guide and do not pinch it L When installing the fitting plate do not pinch the each hoses and wire harness CABLE ROUTING SPEC ...

Page 47: ...tion coil 13 Master cylinder reservoir hose 14 Breather hose 15 Air filter drain hose 16 Battery negative lead 17 Rear brake switch lead 18 Rear brake hose 19 Carburetor heater connector 20 Rectifier regulator 21 Main switch lead 22 Flasher relay 1 Battery 2 Battery positive lead 3 Starter motor positive lead 4 Speedometer lead 5 Fuel hose carburetor fuel pump 6 High tension code 7 Main switch lea...

Page 48: ...joint for California E Route the front turn signal light lead and headlight lead through the rear of headlight body hole F Connect the ignition coil lead at red tape to the right side G Fasten the rear brake switch lead to the brake switch bracket with a plastic locking tie A Clamp the battery positive lead to the battery with battery band B Connect the battery negative lead connector and push it ...

Page 49: ...d to the frame with a holder M Arrange the throttle position sensor connector carburetor heater connector and thermo switch connector between the starting circuit cutoff relay and high tension code N Fasten the rear brake switch to the down tube with a plastic locking tie CABLE ROUTING SPEC ...

Page 50: ...tor 12 Battery 13 Battery positive lead 14 Taillight lead 15 Starter relay 16 Starter motor positive lead 17 Speedometer lead connector 18 Fuel tank breather hose fuel tank roll over valve for California 19 Ventilation hose 1 Brake hose 2 Throttle cable 3 Master cylinder reservoir hose 4 High tension code 5 Purge hose carburetor solenoid valve for California 6 Rear brake switch lead 7 Brake hose 8...

Page 51: ...amp the igniter unit lead to the frame with a holder H To the rear fender I Route the fuel tank breather hose under the fuel filter and connect it fuel tank side roll over valve side with a joint Position the end of clip outside B Route the rear brake switch lead under the master cylinder reservoir hose C Position the band end of right side bracket D Position the steel band end to forward E Positi...

Page 52: ... the taillight lead with a holder on the mud guard L Route wire harness outside of the guide on the frame M Clamp the clutch cable and starter cable with a holder Position the end of holder down side N Route the throttle position sensor lead and carburetor heater lead left side of the tappet cover O To the wire harness CABLE ROUTING SPEC ...

Page 53: ... 1 Throttle cable 2 Starter cable 3 Clutch cable 4 Handlebar switch lead left 5 Headlight lead 6 Brake hose A Route the handlebar switch lead right rear side of the throttle cable 2 35 CABLE ROUTING SPEC ...

Page 54: ...INSP ADJ 3 ...

Page 55: ...CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 20 CHECKING THE BREATHER HOSE 3 20 CHECKING THE EXHAUST SYSTEM 3 21 CHASSIS 3 22 ADJUSTING THE FRONT BRAKE 3 22 ADJUSTING THE REAR BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 24 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 25 CHECKING THE BRAKE HOSES 3 25 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 26 ADJUSTING THE SHIFT PEDAL 3 27 CHECKING THE FINAL DRIVE ...

Page 56: ...INSP ADJ ELECTRICAL SYSTEM 3 37 CHECKING AND CHARGING THE BATTERY 3 37 CHECKING THE FUSES 3 43 REPLACING THE HEADLIGHT BULB 3 44 ADJUSTING THE HEADLIGHT BEAM 3 45 ...

Page 57: ...ry 5 Air filter Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake disc Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Repalce brake pads if necessary 8 Rear brake disc Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 9 Wheels spoke Check balance r...

Page 58: ... necessary Change Warm engine before draining 21 Engine oil filter element Replace 22 Final gear oil Check oil level and vehicle for oil leakage Change oil at initial 1 000 km and thereafter every 24 000 km or 24 months whichever comes first Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer The air filter needs more frequent service if you...

Page 59: ...uel hose Ignitor plate Mud guard Meter lead couper Fuel tank assembly 1 1 1 1 1 1 1 1 Remove the parts in the order below Set the fuel cock to OFF before dis connecting the fuel hose For installation reverse the removal procedure NOTE 7 Nm 0 7m kg 23Nm 2 3m kg 7 Nm 0 7m kg 3 3 FUEL TANK AND SEATS INSP ADJ FUEL TANK AND SEATS ...

Page 60: ...ter in with a screwdriver then pull the fastener out INSTALLATION 1 Install Ignitor plate To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cowling and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 61: ...e made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider s seat fuel tank Refer to FUEL TANK AND SEATS 2 Disconnect spark plug caps 3 Remove spark plugs 4 Remove air intake box 1 5 Remove cylinder head cover rear cylinder 1 cylinder head cover front cylinder ...

Page 62: ...overs 1 7 Remove camshaft sprocket cover rear cylinder 1 camshaft sprocket cover front cylinder 8 Remove timing plug 1 straight plug 2 9 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 07 0 12 mm Exhaust valve 0 12 0 17 mm ...

Page 63: ...otor with the stationary pointer d on the crank case A Rear cylinder TI mark B Front cylinder I mark d Measure the valve clearance with a thick ness gauge 1 e Turn the crankshaft crockwise 290_ and then measure the front cylinder 10 Adjust Svalve clearance a Loosen the locknut 1 b Insert a thickness gauge between the end of the adjusting screw and the valve tip c Turn the adjusting screw 2 in dire...

Page 64: ...all all removed parts Install all removed parts in the reverse order of their disassembly Note the following points camshaft sprocket covers tappet covers spark plugs EAS00051 SYNCHRONIZING THE CARBURETORS Prior to synchronizing the carburetors the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level sur...

Page 65: ...retor synchronization a Synchronize carburetor 1 to carburetor 2 by turning the synchronizing screw 1 in ei ther direction until both gauges read the same b Rev the engine two or three times each time for less than a second and check the syn chronization again Vacuum pressure at idle speed 34 7 37 3 kPa 260 280 mmHg The difference between the two carburetors should not exceed 1 33 kPa 10 mmHg 9 Ch...

Page 66: ... 1 Start the engine and let it warm up for several minutes 2 Remove cylinder head cover 1 3 Install engine tachometer to the spark plug lead of cyl 1 Engine tachometer 90890 03113 4 Check engine idling speed Out of specification Adjust Engine idling speed 950 1 050 r min 5 Adjust engine idling speed a Turn the pilot screw 1 in until it is lightly seated b Turn the pilot screw out the specified num...

Page 67: ...hrottle cable free play at the flange of the throttle grip 4 6 mm 2 Remove rider s seat fuel tank Refer to FUEL TANK AND SEATS 3 Adjust throttle cable free play When the motorcycle is accelerating the accel erator cable 1 is pulled Carburetor side a Loosen the locknut 2 on the accelerator cable b Turn the adjusting nut 3 in direction a or b until the specified throttle cable free play is obtained ...

Page 68: ...s not cause the en gine idling speed to change EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove cylinder head covers 1 2 Disconnect spark plug cap 3 Remove spark plug Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal ling into the cylinders 4 Check spark plug type Inc...

Page 69: ...the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap EAS00064 CHECKING THE IGNITION TIMING Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure that all connections are tight and free of corrosion 1 Remove timing plug 1 2 Install timing light 1 engine tachometer 2 to the spark plug lead of cyl 1 Timing light 90890 031...

Page 70: ...e b on the generator rotor Incorrect firing range Check the ignition system The ignition timing is not adjustable 4 Install timing plug 1 EAS00065 MEASURING THE COMPRESSION PRES SURE The following procedure applies to all of the cyl inders Insufficient compression pressure will result in a loss of performance 1 Check valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR AN...

Page 71: ...nd measure again Refer to the following table Compression pressure with oil applied in the cylinder Reading Diagnosis Higher than without oil Piston wear or damage Repair Same as without oil Piston ring s valves cylin der head gasket or piston possibly defective Repair Compression pressure at sea level Standard 1 000 kPa 10 kg cm2 10 bar Minimum 900 kPa 9 kg cm2 9 bar Maximum 1 100 kPa 11 kg cm2 1...

Page 72: ...he minimum level marks a and maximum level marks b Below the minimum level mark Add the recommended engine oil to the proper level Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade ACEA standard G4 or G5 Engine oil also lubricates the clutch and the wrong oil types or additives could cause cl...

Page 73: ...so to be replaced perform the following procedure Oil filter element replacement should be made cold exhaust pipe and muffler at room temperature a Remove the muffler 1 rear brake reservoir tank 2 element cover 3 and exhaust pipe front cylinder 4 b Remove the oil filter element cover plate 5 element cover 6 and oil filter element 7 c Check the O ring 8 and replace it if it is cracked or damaged d ...

Page 74: ...NG THE CLUTCH CABLE FREE PLAY 1 Check clutch cable free play a Out of specification Adjust Clutch cable free play at the end of the clutch lever 5 10 mm 2 Adjust clutch cable free play Handlebar side a Loosen the locknut 1 b Turn the adjusting screw 2 in direction b or c until the specified clutch cable free play is obtained Direction Clutch cable free play is increased Direction Clutch cable free...

Page 75: ... the adjusting screw out 1 4 of a turn d Tighten the locknut e Check the clutch cable free play again and ajust it if necessary EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove air filter case cover 1 air filter element 2 2 Clean air filter element Apply compressed air to the outer surface of the air filter element 3 Check air filter element Damage Replace 4 Install air filter element air filter ...

Page 76: ... turning leading to poor engine performance and possible overheating When installing the air filter element into the air filter case cover be sure their sealing surfaces are aligned to prevent any air leaks EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1 Check carburetor joint 1 Cracks damage Replace Refer to CARBURETOR in chapter 6 EAS00098 CHECKING THE BREATHER HOSE 1 Remove cylinde...

Page 77: ...pplies to all of the ex haust pipes mufflers and gaskets 1 Check exhaust pipes 1 muffler 2 Cracks damage Replace gaskets 3 Exhaust gas leaks Replace 2 Check tightening torque Exhaust pipe nut 4 20 Nm 2 0 m kg Exhaust pipe and muffler bolt 5 20 Nm 2 0 m kg Muffler and muffler bracket bolt 6 25 Nm 2 5 m kg ...

Page 78: ...b tained Direction Brake lever free play is increased Direction Brake lever free play is decreased c Tighten the locknut A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of ...

Page 79: ...owered After adjusting the brake pedal position check that the end of the adjusting bolt 2 is visible through the hole d c Tighten the locknut 1 to specification Locknut 16 Nm 1 6 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consi...

Page 80: ...luids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and co...

Page 81: ...ain body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction Brake light comes on later EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps 1 Check brake hose Cracks damage wear Replace 2 C...

Page 82: ...eding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Stand the motorcycle on alevel surface Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Bleed hydraulic brake system a Add the recommended brake fluid to the proper level b Install the diaphragm br...

Page 83: ... Fill the reservoir to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake operation EAS00137 ADJUSTING THE SHIFT PEDAL The shift pedal position is determined by the ad justing bolt length a 1 Measure adjusting the length a Incorrect Adjust Adjusting bolt length 114 7 mm 2 Adjust adjusting bolt length a a Loosen both locknuts 1 b Turn ...

Page 84: ...m brim Add the recom mended final drive oil to the proper level Recommended final drive oil SAE 80 hypoid gear oil graded GL 4 GL 5 or GL 6 or multi purpose SAE 80W90 hypoid gear oil 4 Install final drive housing oil filler bolt EAS00145 CHANGING THE FINAL DRIVE OIL 1 Place a container under the final drive hous ing 2 Remove final drive housing oil filler bolt 1 final drive housing oil drain bolt ...

Page 85: ...rely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head 3 Remove upper bracket pinch bolt 1 steering stem nut 2 upper bracket 3 4 Adjust steering head a Remove the lo...

Page 86: ...ening torque 18 Nm 1 8 m kg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and inspect the upper and lower bearings Refer to STEERING HEAD AND HAN DLEBAR in chapter 7 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of b...

Page 87: ...scratches Replace oil seal Oil leakage Replace 3 Hold the motorcycle upright and apply the front brake 4 Check operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Repair Refer to FRONT FORK in chapter 7 EAS00159 ADJUSTING THE REAR SHOCK ABSORB ER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling ov...

Page 88: ... hard EB304174 CHECKING THE TIRES The following procedure applies to both of the tires 1 Measure tire pressure Out of specification Regulate The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the an...

Page 89: ...rous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden defla tion When using a tube tire be sur...

Page 90: ...uld always be by the same manufactur er and of the same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Front tire Manufactur er Type Size BRIDGE STONE 110 90 18 61S EXEDRA L309 DUNLOP 110 90 18 61S K555F Rear tire Manufactur er Type Size BRIDGE STONE 170 80 15 M C 77S EXEDRA G546 DUNLOP 170 80 ...

Page 91: ...rotation Align the mark 2 with the valve installation point EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check spoke 1 Bends damage Replace Loose Tighten Tap the spokes with a screwdriver A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tighten spoke with a spoke wrench 2 Be sure to tighten the spokes before and afte...

Page 92: ...oth operation Lubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Engine oil EAS00172 LUBRICATING THE SIDESTAND ...

Page 93: ...with electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion This is a sealed battery Never remove the sealing...

Page 94: ...onnect Sbattery leads from the battery terminals First disconnect the negative lead 1 then the positive lead 2 3 Remove Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive terminal Tester negative lead battery negative terminal SThe charge state of a MF battery can be checked by measuring its open circuit voltage i e the voltag...

Page 95: ...one with the battery mounted on the motorcycle disconnect the negative lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure that the battery charger lead clips are in f...

Page 96: ...rent after 5 min utes replace the battery In case that charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any charge in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charging is complete...

Page 97: ...r cannot charge the MF battery A variable volt age charger is recommended Measure the battery open circuit voltage after having left the battery unused 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 charger This ...

Page 98: ... allow electrolyte or hydrogen gas from the bat tery to contact the frame the motorcycle and its finish may be damaged Make sure that the battery breather hose is properly routed away from the drive chain and from below the swingarm 8 Connect battery leads to the battery terminals First connect the positive lead 1 then the negative lead 2 9 Check battery terminals Dirt Clean with a wire brush Loos...

Page 99: ...nd check it for continuity Set the pocket tester selector to Ω 1 Pocket tester 90890 03112 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Turn off the ignition b Install a new fuse of the correct amperage rating c Turn on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Fuses Amperage rating...

Page 100: ...ition systems to malfunction and could possibly cause a fire 4 Install tool box cover ignitor plate rider s seat EAS00182 REPLACING THE HEADLIGHT BULB 1 Disconnect connectors 1 2 Remove headlight bulb cover 2 3 Remove headlight bulb holder 1 4 Remove headlight bulb 2 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 5 Ins...

Page 101: ...roughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install headlight bulb holder 6 Install headlight bulb cover 7 Connect leads EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust headlight beam horizontally a Turn the adjustin...

Page 102: ...ENG 4 ...

Page 103: ...CKING THE ROCKER ARMS AND ROCKER ARM SHAFTRS 4 18 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 19 VALVES AND VALVE SPRINGS 4 21 REMOVING THE VALVES 4 22 CHECKING THE VALVES AND VALVE GUIDES 4 22 CHECKING THE VALVE SEATS 4 24 CHECKING THE VALVE SPRINGS 4 26 INSTALLING THE VALVES 4 26 CYLINDERS AND PISTONS 4 28 REMOVING THE CYLINDERS AND PISTONS 4 29 CHECKING THE CYLINDERS AND PISTONS 4 29 CHECKING THE...

Page 104: ...ENERATOR 4 51 SHIFT SHAFT 4 53 CHECKING THE SHIFT SHAFT 4 54 CHECKING THE STOPPER LEVER 4 54 INSTALLING THE SHIFT SHAFT 4 54 OIL PUMP 4 55 CHECKING THE OIL PUMP 4 57 CHECKING THE OIL DELIVERY PIPES 4 57 CHECKING THE OIL STRAINER 4 57 INSTALLING THE OIL PUMP 4 58 CRANKSHAFT AND CONNECTING RODS 4 59 CRANKCASE 4 59 CRANKSHAFT AND CONNECTING RODS 4 60 DISASSEMBLING THE CRANKCASE 4 61 REMOVING THE CRAN...

Page 105: ...4 75 REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 76 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 4 76 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 76 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 4 77 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 78 INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH 4 78 INSTALLING THE UNIVERSAL JOINT 4 80 ALIGNING THE MIDDLE GEAR 4 81 ...

Page 106: ...ootrest brake pedal 1 1 1 2 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer FUEL TANK AND SEATS in Chapter 3 Disconnect Refer to CARBURETOR in Chapter 5 WARNING 23 Nm 2 3 m kg 64 Nm 6 4 m kg 25 Nm 2 5 m kg 20 Nm 2 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg ENGINE REMOVAL ENG ENGINE ENGINE RE...

Page 107: ...Battery leads Right side cover Starter motor Cylinder head covers Spark plug caps 1 1 1 2 1 1 4 4 Disconnect First disconnect the negative lead then disconnect the positive lead Disconnect For installation reverse the removal procedure NOTE 23 Nm 2 3 m kg 64 Nm 6 4 m kg 25 Nm 2 5 m kg 20 Nm 2 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg ...

Page 108: ...ead Neutral switch lead Footrest shift pedal Sidestand Clutch adjusting cover Clutch cable Speed sensor Fuel tank fitting knobs Steering head side covers 1 1 1 1 1 1 1 1 1 1 1 1 2 2 Remove the parts in the order listed Disconnect Disconnect Refer to INSTALLING THE ENGINE Disconnect For installation reverse the removal procedure 64 Nm 6 4 m kg 64 Nm 6 4 m kg ENGINE REMOVAL ENG LEADS SHIFT PEDL AND ...

Page 109: ... mount bolt rear lower Engine stays rear upper lower Engine assembly 1 1 1 1 4 2 1 1 1 1 Remove the parts in the order below Place a suitable stand under the frame and engine Refer to GENERATOR AND STARTER CLUTCH Refer to REAR SHOCK ABSORBER AND SWINGARM in Chapter 6 For installation reverse the removal procedure Refer to INSTALLING THE ENGINE 48 Nm 4 8 m kg 48 Nm 4 8 m kg 48 Nm 4 8 m kg 74 Nm 7 4...

Page 110: ...t 2 48 Nm 4 8 m kg Bolt 3 48 Nm 4 8 m kg Bolt 4 48 Nm 4 8 m kg Bolt 5 48 Nm 4 8 m kg 2 Install shift arm 1 Align the punch mark a in the shift shaft with the slot in the shift arm Adjust the adjusting bolt length b Refer to ADJUSTING THE SHIFT PEDAL in chapter 3 Shift arm bolt 10Nm 1 0m kg Adjusting bolt length 114 7mm ...

Page 111: ...O ring Oil delivery pipes Camshaft sprocket cover O ring Camshaft sprocket bolt 1 1 1 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to GENERATOR AND STARTER CLUTCH Refer to INSTALLING THE CYLINDER HEADS 35 Nm 3 5 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 55 Nm 5 5 m kg 20 Nm 2 0 m kg 50 Nm 5 0 m kg 20 Nm 2 0 m kg CYLINDER HEADS ENG CYLINDER HEADS REAR...

Page 112: ... Dowel pins Cylinder head gasket 1 1 1 1 2 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CYLINDER HEADS Refer to INSTALLING THE CYLINDER HEADS 20 Nm 2 0 m kg 50 Nm 5 0 m kg 35 Nm 3 5 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 55 Nm 5 5 m kg 20 Nm 2 0 m kg CYLINDER HEADS ENG ...

Page 113: ... ring Camshaft sprocket cover O ring Baffle plate O ring Camshaft sprocket bolt 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to REAR CYLINDER HEAD Refer to CLUTCH Refer to INSTALLING THE CYLINDER HEADS New 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg 50 Nm 5 0 m kg 55 Nm 5 5 m kg 35 Nm 3 5 m kg CYLINDER HEADS ENG FRONT CYLIN...

Page 114: ...linder head Dowel pins Cylinder head gasket 1 1 1 1 1 2 1 For installationreverse the removal procedure Refer to REMOVING INSTALLING THE CYLINDER HEADS Refer to INSTALLING THE CYLINDER HEADS New 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg 50 Nm 5 0 m kg 55 Nm 5 5 m kg 35 Nm 3 5 m kg CYLINDER HEADS ENG ...

Page 115: ...ft when the rear piston is at TDC on the compression stroke d Check that the rear piston is at TDC in the compression stroke e The rear piston is at TDC on the compression stroke when there is clearance at both of the rocker arms If there is no clearance then turn the crankshaft clockwise one full turn f When to T mark is aligned with the station ary pointer the punch mark c on the cam shaft sproc...

Page 116: ...der head When removing the front cylinder head repeat the rear cylinder head removal procedures However note the following points 1 Align S I mark with the stationary pointer Removal steps STurn the crankshaft clockwise 290_ SAlign the I mark a with the stationary pointer b on the crankcase cover left when the front piston is at TDC on the compression stroke SWhen the I mark is aligned with the st...

Page 117: ...nder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 03 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cylin der head as follows d Place 400 600 grit wet sandpaper on the surface plate and resurface the cyli...

Page 118: ...crewdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS00234 INSTALLING THE CYLINDER HEADS Rear cylinder head 1 Install dowel pins gasket The 5EL mark on the gasket must face up side of the cylinder 2 Install nuts cylinder ...

Page 119: ...ush the timing chain guide inward g While pushing the timing chain guide be sure that the timing mark c and the station ary pointer d are properly aligned at TDC 4 Install timing chain tensioner a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand b While pressing the timing chain tensioner rod wind it clockwise with a thin screwdriver 1 until it stops c W...

Page 120: ...DJUSTING THE VALVE CLEAR ANCE in CHAPTER 3 Front cylinder head When installing the front cylinder head repeat the rear cylinder head installation procedure However note the following points 1 Install Scamshaft sprocket a Turn the crankshaft clockwise 290_ b Align the I mark a with the stationary point er b on the crankcase cover left c Install the camshaft sprocket with the timing mark c facing ou...

Page 121: ...rm shafts Rocker arms Locknuts Valve adjusters 1 1 1 1 1 1 2 2 2 2 Remove the parts in the order listed Refer to CYLINDER HEAD For installation reverse the removal procedure Refer to REMOVING INSTALLING THE ROCKER ARM AND CAMSHAFT Refer to REMOVING INSTALLING THE ROCKER ARM AND CAMSHAFT 37 5 Nm 3 75 m kg 20 Nm 2 0 m kg 27 Nm 2 7 m kg ROCKER ARMS AND CAMSHAFT ENG ROCKER ARMS AND CAMSHAFT ...

Page 122: ... 2 Screw a 10 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft EAS00205 CHECKING THE CAMSHAFTS 1 Check camshaft bushings Damage wear Replace 2 Check camshaft lobes Blue discoloration pitting scratches Re place the camshaft 3 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake a 39 012 mm b 1 31 993 mm 2 3...

Page 123: ...hes Replace or check the lu brication system 3 Measure rocker arm inside diameter a Out of specification Replace Rocker arm inside diameter 14 036 mm 4 Measure rocker arm shaft outside diameter b Out of specification Replace Rocker arm shaft outside diameter 13 95 mm 5 Calculate rocker arm to rocker arm shaft clearance Calculate the clearance by subtracting the rock er arm shaft outside diameter f...

Page 124: ...mshaft 1 camshaft bushing 2 The dowel pin a on the end of the camshaft must align with the timing mark b on the cylin der head Make sure that the No 1 camshaft 3 is installed in the rear cylinder head and the No 2 camshaft 4 is installed in the front cylinder head 3 Install stopper plate 1 Stopper plate bolt 2 20 Nm 2 0 m kg 4 Lubricate rocker arm shafts Recommended lubricant Engine oil ...

Page 125: ...4 20 ROCKER ARMS AND CAMSHAFTS ENG NOTE 5 Install rocker arms rocker arm shafts Make sure that the rocker arm shafts is com pletely pushed into the cylinder head ...

Page 126: ...etainers Valve springs Valve intake Valve exhaust Valve stem seals Valve spring seats 4 2 2 1 1 2 2 Remove the parts in the order listed Refer to CYLINDER HEADS Refer to ROCKER ARMS AND CAMSHAFT Refer to REMOVING INSTALLING THE VALVES For installation reverse the removal procedure Refer to INSTALLING THE VALVES VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS ...

Page 127: ...dth Refer to CHECKING THE VALVE SEATS a Pour a clean solvent 1 into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 2 2 Remove valve cotters Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 Valve spring compressor 90890 04019 EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedu...

Page 128: ...h a valve guide remover 1 b Install the new valve guide with a valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover and installer 8 mm 90890 04014 3 Eliminate Scarbon deposits from the val...

Page 129: ... procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head Valve seat width limit Intake 1 8 mm Exhaust 1 8 mm a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinde...

Page 130: ... seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hand e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blue...

Page 131: ...ompressed spring force Intake and exhaust spring 160 7 N 16 4 kg at 40 mm 3 Measure Svalve spring tilt c Out of specification Replace the valve spring Spring tilt limit Intake and exhaust valve spring 2 5_ 1 9 mm EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Svalve stem end with an oil stone 2 Lubricate Svalve stem Soil seal New...

Page 132: ...itch 4 Install valve cotters Install the valve cotters by compressing the valve spring with the valve spring compressor 1 Valve spring compressor 90890 04019 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive force could damage the valve ...

Page 133: ...me Part name Q ty Remarks 1 2 3 4 5 6 7 8 Removing the cylinders and pistons Cylinder heads Timing chain guide Cylinder Dowel pins Cylinder gasket Piston pin clips Piston pin Piston Piston ring set 1 1 2 1 2 1 1 1 Refer to INSTALLING THE PISTONS AND CYLINDERS 10 Nm 1 0 m kg Refer to REMOVING INSTALLING THE CYLINDERS AND PISTONS CYLINDERS AND PISTONS ENG CYLINDERS AND PISTONS ...

Page 134: ...n crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller 90890 01304 2 Remove top ring 2nd ring oil ring When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the pisto...

Page 135: ...fication rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer b 5 mm from the bottom edge of the piston Piston size P Standard 94 960 94 975 mm d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cyl...

Page 136: ...m Limit 0 1 mm 2nd ring 0 03 0 07 mm Limit 0 1 mm 2 Install piston ring into the cylinder Using the piston crown pash the ring into the cyl inder so that the ring will be at a right angle to the cylinder bore a 40 mm from the top of the cylinder 3 Measure piston ring end gap Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail ...

Page 137: ...ut of specification Replace the piston Piston pin bore inside diameter 22 004 22 015 mm 4 Calculate piston pin to piston clearance Out of specification Replace the piston pin Piston pin to piston clearance Piston pin bore size b Piston pin outside diameter a Piston pin to piston clearance 0 004 0 024 mm EB404701 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis...

Page 138: ...revent the clip from falling into the crankcase 3 Install gasket New dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6 Install cylinder While compressing the piston rings with one hand install the cylinder with the other hand Pass the t...

Page 139: ...ng chain drive gear sprocket Timing chain Primary drive gear Straight key Timing chain guide 1 1 6 6 1 1 1 1 1 1 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to CYLINDERS AND PISTONS Refer to CLUTCH For installation reverse the removal procedure Refer to REMOVING INSTALLING THE TIMING DRIVE GEARS Refer to INSTALLING THE TIMING DRIVE GEARS 10 Nm 1 0 m kg 110 Nm 11 0 m kg TIMING...

Page 140: ...ng gear removal procedure However note the following points 1 Remove rotor assembly dowel pins springs timing drive gear Refer to GENERATOR AND STARTER CLUTCH EB401422 CHECKING THE TIMING CHAINS CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES The following procedure applies to all of the tim ing chains camshaft sprockets and timing chain guides 1 Check timing chain 1 Damage sitffness Replace the timing...

Page 141: ...set INSTALLING THE TIMING DRIVE GEARS 1 Install timing chain onto the timing chain drive gear sprocket To prevent the timing chain from falling into the crankcase fasten it with a wire 2 Install timing chain drive gear sprocket timing chain drive gear shaft Make sure that the 2 mark on the timing chain drive gear sprocket is installed in the rear cylin der and the 3 mark on the timing chain drive ...

Page 142: ... punch mark d on the timing chain drive gear sprocket and the key posision e as shown 2 Install claw washer lock washer 1 New primary drive gear nut 2 While holding the generator retor with the sheave holder tighten the primary drive gear nut 3 Bend the lock washer tab along a flat side of the nut Rear cylinder When installing the rear cylinder timing gear re peat the front cylinder timing gear in...

Page 143: ...ket Oil filter cover plate Oil filter cover O rings Oil filter Right crankcase cover 1 1 3 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 Refer to ENGINE REMOVAL WARNING New 10 Nm 1 0 m kg CLUTCH ENG CLUTCH RIGHT CRANKCASE COVER ...

Page 144: ...4 39 Order Job name Part name Q ty Remarks 6 7 Dowel pins Crankcase cover gasket 2 1 For installation reverse the removal procedure New 10 Nm 1 0 m kg CLUTCH ENG ...

Page 145: ... seat Clutch pressure plate Bearing shart clutch push rod Friction plates Clutch plates Wire circlip Clutch plate Damper Clutch damper plate Nut lock washer Clutch boss 6 1 1 1 1 1 1 6 5 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH Refer to REMOVING INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg CLUTCH ENG CLUTCH ASSEMBLY ...

Page 146: ...4 41 Order Job name Part name Q ty Remarks 15 16 17 Thrust washer Clutch housing Long clutch push rod 1 1 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 8 Nm 0 8 m kg CLUTCH ENG ...

Page 147: ...en the clutch boss 3 and the clutch plate 4 It is not neces sary to remove the wire circlip 5 and disas semble the built in damper unless there is seri ous clutch chattering EAS00281 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specificati...

Page 148: ...mage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00288 CHECKING THE CLUTCH PUSH RODS 1 Check short clutch push rod 1 long clutch push rod 2 Cracks damage wear Replace the de fective part s 2 Measure long clutch push rod bending limit Out of specification Replace the long clutch push rod Long clutch push rod bending limit 0 5 mm ...

Page 149: ...ge limit Less than 0 1 mm EAS00283 CHECKING THE CLUTCH SPRING AND CLUTCH SPRING SEAT PLATE 1 Check clutch spring plate Damage Replace 2 Check clutch spring plate seat Damage Replace 3 Measure clutch spring free height Out of specificatrion Replace the clutch spring Clutch spring free height 7 2 mm Limit 6 5 mm EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deb...

Page 150: ...holding tool 2 tighten the clutch boss nut Clutch holding tool 90890 04086 3 Bend the lock washer tab along a flat side of the nut 4 Lubricate long clutch push rod short clutch push rod with the recommended lubricant Recommended lubricant Lithium soap base grease 5 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 6 Install friction plates clut...

Page 151: ...ion plate is aligned with the mark b on the clutch housing 7 Install clutch pressure plate clutch spring plate seat clutch spring 1 clutch spring plate 2 clutch spring bolts 3 Tighten the clutch spring bolts in stages and in a crisscross pattern Clutch spring bolt 8 Nm 0 8 m kg ...

Page 152: ...l Sidestand Clutch adjusting cover clutch cable Left crankcase cover Dowel pins Gasket Stator coil Pickup coil 1 2 1 1 1 Remove the parts in the order listed Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 For installation reverse the removal procedure Refer to ENGINE REMOVAL 10 Nm 1 0 m kg 7 Nm 0 7 m kg GENERATOR AND STARTER CLUTCH ENG GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL ...

Page 153: ...Starter idler gear Circlip Starter clutch drive gear Starter clutch assembly 1 6 6 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Refer to REMOVING INSTALLING THE GENERATOR Refer to INSTALLING THE GENERATOR 175 Nm 17 5 m kg 12 Nm 1 2 m kg GENERATOR AND STARTER CLUTCH ENG GENERATOR AND STARTER CLUTCH ...

Page 154: ...the compression stroke e The rear piston is at TDC on the compression stroke when there is clearance at both of the rocker arms If there is no clearance then turn the crankshaft clockwise one full turn f 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 3 Remove generator rotor nu...

Page 155: ...heel puller 90890 01362 Adapter 90890 04131 EAS00349 CHECKING THE STARTER CLUTCH 1 Check starter clutch idle gear 1 starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s 2 Check starter clutch operation a When turning the starter clutch drive gear counter clockwise b the starter clutch and the starter clutch drive gear should engage If the starter clutch drive gear an...

Page 156: ...lide b Push the projections c on the timing drive gear into the space d 3 Install rotor assembly Insert the suitable pin 1 into the hole of timing chain drive gear sprocket and match the gear teeth Align the punch mark a on the timing drive gear 2 the punch mark b on the timing chain drive gear sprocket and the key position c as shown When installing the rotor make sure the wood ruff key is proper...

Page 157: ... the marks do not align Adjust a Align the T mark a with the stationary pointer b on the left crankcase cover b 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 ...

Page 158: ...ly Shift shaft Circlip Torsion spring stopper lever Stopper lever Circlip Torsion spring shift shaft 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 For installation reverse the removal procedure Refer to INSTALLING THE SHIFT SHAFT Refer to GENERATOR AND STARTER CLUTCH SHIFT SHAFT ENG SHIFT SHAFT ...

Page 159: ...0 CHECKING THE STOPPER LEVER 1 Check stopper lever Bends damage Replace Roller turns roughly Replace the stopper lever EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 shift shaft lever 3 Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly ...

Page 160: ...ar cover Driven gear oil pump Oil pump drive chain Oil pump assembly O rings dowel pin Oil delivery pipe 1 1 1 1 2 1 1 Remove the parts in the order listed Refer to GENERATOR AND STARTER CLUTCH Refer to CLUTCH For installation reverse the removal procedure 12 Nm 1 2 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg OIL PUMP ENG OIL PUMP ...

Page 161: ...ter Pin Oil pump body Oil pump rotor inner Oil pump rotor outer Pin Dowel pins Oil pump shaft Washer Circlip Oil strainer 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure Refer to ASSEMBLING THE OIL PUMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Refer to ASSEMBLING THE OIL PUMP 10 Nm 1 0 m kg ...

Page 162: ...Inner rotor 2 Outer rotor 3 Oil pump body Inner rotor to outer rotor tip clearance 0 03 0 09 mm Limit 0 15 mm Outer rotor to oil pump body side clearance 0 03 0 08 mm Limit 0 15 mm Oil pump body to inner rotor and outer rotor clealance 0 03 0 08 mm Limit 0 15 mm EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery pipes 1 Da...

Page 163: ...UMP ENG 10 Nm 1 0 m kg CAUTION NOTE EAS00376 ASSEMBLING THE OIL PUMP 1 Assemble oil pump After tightening the bolts make sure that the oil pump turns smoothly Align the pin a with the slots b on the inner ro tor ...

Page 164: ...l pins Relief valve 1 1 1 1 3 1 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to CYLINDER HEADS Refer to CYLINDERS AND PISTONS Refer to CLUTCH Refer to GENERATOR AND STARTER CLUTCH Refer to SHIFT SHAFT Refer to OIL PUMP Refer to ASSEMBLING THE CRANKCASE Refer to DISASSEMBLING ASSEMBLING THE CRANKCASE For installation reverse the removal procedure 38 5 Nm 3 85 m kg 20 Nm 2 0 m ...

Page 165: ...od bolts Connecting rods Connecting rod caps Plain bearings 1 1 1 4 4 2 2 4 Remove the parts in the order listed Refer to REMOVING INSTALLING THE CRANKSHAFT For installation reverse the removal procedure Refer to INSTALLING THE CRANKSHAFT 48 Nm 4 8 m kg Refer to REMOVING THE CONNECTING RODS INSTALLING THE CRANKSHAFT CRANKSHAFT AND CONNECTING RODS ENG 4 60 CRANKSHAFT AND CONNECTING RODS ...

Page 166: ...emove them Loosen the bolts in decreasing numerical or der refer to the numbers in the illustration A Right crankcase B Left crankcase 2 Remove right crankcase For this removal slits a in the crankcase can be use as shown Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make...

Page 167: ...fy the position of each big end bearing so that it can be reinstalled in its original place EB413404 CHECKING THE CRANKSHAFT AND CON NECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Crankshaft runout Less than 0 02 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft pin to bi...

Page 168: ...shaft pin d Assemble the connecting rod halves Do not move the connecting rod or crankshaft until the clearance measurement has been completed Apply molybdenum disulfide grease onto the bolts threads and nut seats Make sure that the Y mark 2 on the connect ing rod faces towards the left side of the crank shaft Make sure that the characters 3 on both the connecting rod and connecting rod cap are al...

Page 169: ...ed into the crankshaft web and the numbers 2 on the connecting rods are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 4 and 1 re spectively then the bearing size for P1 is Bearing size for P1 P1 connecting rod P1 crankshaft web 4 1 3 brown Rear cylin...

Page 170: ...ngs 1 Align the projection a of the bearings with the 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 connecting rods should face towards the left side of the crankcase Install each connecting rod in its original place 5 Install connecting rod cap 1 Be sure that the characters a on the side of the cap and connec...

Page 171: ...terrupted between 4 3 and 4 8 m kg loosen the nut to less than 4 3 m kg and start again 7 Install crankshaft installing tool Attach the spacer to the bearing inner race Crankshaft installer pot 1 90890 01274 Crankshaft installer bolt 2 90890 01275 Adapter 3 90890 04130 Spacer 4 90890 04060 8 Install crankshaft 1 Align the left connecting rod with the rear cylin der sleeve hole ASSEMBLING THE CRANK...

Page 172: ...rs embossed on the crankcase indi cate the crankcase tightening sequence 4 X 6 M10 1 X 3 7 X 19 M6 Lubricate the bolt threads with engine oil Tighten the bolts in increasing numerical order M6 30 mm X X X M6 30 mm Chromium plated bolt M6 55 mm M6 80 mm M10 60 mm M10 70 mm M10 100 mm 19 with engine ground lead 3 Install shift shaft stopper plate 1 Install the shift shaft stopper plate as shown ...

Page 173: ...e bar Shift fork 1 R Shift fork 2 C Shift fork 3 L Shift drum Main axle assembly Drive axle assembly Middle driven gear 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKSHAFT For installation reverse the removal procedure Refer to INSTALLING THE TRANSMISSION TRANSMISSION ENG TRANSMISSION ...

Page 174: ...fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum shift drum segment 1 Da...

Page 175: ...entering device and dial gauge Out of specification Replace the drive axle Drive axle runout limit 0 08 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear movement Rough movement Replace the defective part s 5 Check washers Damage bends looseness Replace...

Page 176: ...embly 2 shift fork L 3 shift fork C 4 shift fork R 5 shift fork guide bars 6 The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L When installing the middle drive gear 7 align the slit a on the guide bar with the middle drive gear Always use new circlips 3 Check transmission Rough movement Repair Oil each gear shaft and beari...

Page 177: ...ive pinion shaft 1 2 1 1 2 1 1 1 1 Remove the parts in the order listed Refer to CRANKSHAFT AND CONNECTING ROD Refer to REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 110 Nm 11 0 m kg 110 Nm 11 0 m kg MIDDLE GEAR ENG MIDDLE GEAR M...

Page 178: ...shers Collar 3 2 2 1 1 1 1 1 3 1 Remove the parts in the order listed Refer to REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY INSTALING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH Refer to INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH Refer to REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY INSTALLING THE UNIVERSAL JOINT MIDDLE GEAR ENG MIDDLE DRIVEN PINION GEAR ...

Page 179: ...psible collar Middle driven shaft Oil seal Bearing Bearing 1 1 1 1 For installation reverse the removal procedure Refer to ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY Refer to INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH MIDDLE GEAR ENG 4 74 ...

Page 180: ... While compressing the spring with a damper spring compressor 2 remove the spring re tainers Damper spring compressor 90890 04090 2 Straighten the thread on the middle drive shaft nut 3 Remove middle drive shaft nut 1 bearing 2 middle drive shaft 3 a Attach the middle drive shaft holder 4 onto the middle drive shaft as shown Middle drive shaft holder 90890 04055 b Secure the middle drive shaft hol...

Page 181: ...Separate the universal joint yokes 2 Loosen middle driven shaft nut 1 While holding the universal joint driven yoke 2 with the universal joint holder 3 loosen the middle driven shaft nut Universal joint holder 90890 04062 EAS00438 CHECKING THE MIDDLE DRIVE SHAFT AS SEMBLY 1 Check damper cam surface Scratches wear Replace the damper cam 2 Check spring Cracks damage Replace EAS00439 CHECKING THE MID...

Page 182: ...ghten middle drive shaft nut 1 Set the torque wrench at a right angle to the middle drive shaft nut wrench 2 Lock the threads on the middle drive shaft nut by staking them with a center punch Middle drive shaft nut wrench 2 90890 04138 Middle drive shaft holder 3 90890 04055 2 Install spring retainers 1 While compress the spring with the damper spring compressor 2 and then install the spring retai...

Page 183: ...e for the first time be sure to have at least one extra collaps ible collar on hand 1 Install bearing outer race into the middle driven shaft bearing hous ing Do not press the bearing outer race During installation always press the bearing inner race carefully 2 Install middle driven shaft nut Finger tighten the middle driven shaft mut INSTALLING THE MIDDLE GEAR AS SEMBLY AND ADJUSTING THE BACKLAS...

Page 184: ...acklash Middle gear backlash 0 1 0 2 mm a Install the universal joint holder 1 and middle gear backlash band 2 as shown Universal joint holder 90890 04062 Middle gear backlash band 90890 01231 b Make sure that the dial gauge plunger on the middle gear backlash band as shown a Dial gauge plunger contact point 68 2 mm c Remove the middle driven pinion gear nut and apply the LOCKTITE on it d Reinstal...

Page 185: ...result in a change in the standard spinning torque requiring re placement of the collapsible collar and reas sembly of the middle driven shaft assembly 2 Install bearings 2 onto the universal joint driven yoke cross joint The needles can easily fall out of their races so check each bearing carefully Slide the universal joint driven yoke assembly back and forth on the bearings If a needle is out of...

Page 186: ...e thickness calculated from information marked on the crankcase and the end of the middle drive gear b To find middle drive gear shim thickness A use the following formula Middle drive gear shim thickness A a c a 43 00 b a numeral on the upper crankcase near the main bearing selection numbers and which is added to the nominal size 42 Example a is 43 00 If the upper crankcase is marked 46 b c is 42...

Page 187: ...4 82 MIDDLE GEAR ENG Middle drive pinion gear shim Thickness mm 0 10 0 15 0 20 Hundredths Rounded value 0 1 2 0 3 4 5 6 5 7 8 9 10 Shims are supplied in the following thickness ...

Page 188: ...CARB 5 ...

Page 189: ...4 ASSEMBLING THE CARBURETORS 5 6 INSTALLING THE CARBURETORS 5 6 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 5 8 AIR INDUCTION SYSTEM AIS 5 10 AIR INDUCTION 5 10 AIR CUT OFF VALVE 5 10 AIR INDUCTION SYSTEM INSPECTION 5 11 ...

Page 190: ...rburetor heater lead Fuel hoses Carburetor assembly Starter cable Throttle cables 1 3 1 1 1 1 1 2 1 1 2 Remove the parts in the order listed Refer to FUEL TANK AND SEATS in CHAPTER 3 Disconnect Disconnect Disconnect Disconnect After removing the carburetor assembly remove the starter cable and throttle cables For installation reverse the removal procedure NOTE 10 Nm 1 0 m kg CARBURETOR CARB CARBUR...

Page 191: ...r leads Carburetor heaters Float chamber gasket Float Needle valve set Main jet Jet holder Pilot jet Starter jet Jet needle set Starter plunger set 2 2 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 12V 30W Refer to CARBURETOR ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 CARBURETOR CARB ...

Page 192: ... Pilot screw Main air jet Pilot air jet 1 Pilot air jet 2 Throttle stop screw set 1 1 1 1 1 1 1 Refer to ASSEMBLING THE CARBURE TORS Refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR TPS For assembly reverse the disassembly procedure 12 13 14 15 16 17 18 CARBURETOR CARB ...

Page 193: ...t Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat 2 O ring 3 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check piston va...

Page 194: ...wear Replace Obstruction Clean Blow out the jets with compressed air 10 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 11 Check fuel feed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 12 Check fuel feed hoses fuel hoses Cracks damage wear Replace Obstruction Cl...

Page 195: ...en installing the coasting enricher position the throttle connecting arm 1 as shown 2 Install connecting bolts After installing the connecting bolts check that the throttle cable lever and starter plunger link operate smoothly EB600051 INSTALLING THE CARBURETORS 1 Adjust carburetor synchronization Refer to SYNCHRONIZING THE CARBU RETORS in chapter 3 2 Adjust engine idling speed Engine idling speed...

Page 196: ...uge 90890 01312 d Loosen the fuel drain screw 3 e Hold the fuel level gauge vertically next to the upper face of the float chamber 4 f Measure the fuel level a Fuel level readings should be equal on both sides of the carburetor assembly 2 Adjust fuel level a Remove the carburetor assembly b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are fine ad...

Page 197: ...sor Throttle position sensor resistance R1 4 X 6 kΩ at 20_C 68_F blue black d Connect the pocket tester Ω 1k to the throttle position sensor Tester positive lead yellow 3 Tester negative lead black 2 e While slowly opening the throttle check that the throttle position sensor resistance R2 is within the specified range Out of specification Replace the throttle position sensor Throttle position sens...

Page 198: ...ARBURETOR CARB NOTE Closed throttle resistance 0 56 0 84 kΩ at 20 C yellow black c Tighten the throttle position sensor screws Remove the pocket tester leads and connect the throttle position sensor coupler ...

Page 199: ...rature for burning the un burned exhaust gases is approximately 600_ to 700_C AIR CUT OFF VALVE The air cut off valve is operated by intake gas pressure through the diaphragm Normally this valve is opened in order to allow fresh air to flow into the exhaust port When the throttle is rapidly closed negative pressure is generated and the valve closes in order to prevent after burning VIEW 1 NO FLOW ...

Page 200: ...tor joint rear cylinder To the AIS valve 1 2 3 A B 4 C D E AIR INDUCTION SYSTEM AIS CARB NOTE AIR INDUCTION SYSTEM INSPECTION 1 Inspect hose connections Poor connections Properly connect hoses reed valves air cut off valve air filter Cracks damage Replace Clogged Clean The orifice 3 should be installed with the arrow mark facing the AIS valve side ...

Page 201: ...CARB ...

Page 202: ...CHAS 6 ...

Page 203: ...CING THE REAR BRAKE PADS 6 20 FRONT BRAKE MASTER CYLINDER 6 22 REAR BRAKE MASTER CYLINDER 6 24 REMOVING THE FRONT BRAKE MASTER CYLINDER 6 26 REMOVING THE REAR BRAKE MASTER CYLINDER 6 26 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDER 6 27 INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 28 INSTALLING THE REAR BRAKE MASTER CYLINDER 6 30 FRONT BRAKE CALIPERS 6 32 REAR BRAKE CALIPER 6 34 REMOVING THE F...

Page 204: ...ING THE REAR SHOCK ABSORBER 6 67 REMOVING THE SWINGARM 6 68 CHECKING THE REAR SHGOCK ABSORBER AND GAS CYLINDER 6 69 CHECKING THE SWINGARM 6 69 INSTALLING THE REAR SHOCK ABSORBER 6 70 INSTALLING THE SWINGARM 6 70 SHAFT DRIVE 6 72 TROUBLESHOOTING 6 72 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 6 75 MEASURING THE RING GEAR BACKLASH 6 76 ADJUSTING THE RING ...

Page 205: ...move the parts in the order listed Stand the motorcycle on a level surface For installation reverse the removal procedure Refer to INSTALLING THE FRONT WHEEL WARNING Securely support the motorcycle so there is no danger of it falling over 59 Nm 5 9 m kg 20 Nm 2 0 m kg 40 Nm 4 0 m kg 23 Nm 2 3 m kg Refer to REMOVING INSTALLING THE FRONT WHEEL FRONT WHEEL AND BRAKE DISCS CHAS CHASSIS FRONT WHEEL AND...

Page 206: ... BRAKE DISCS CHAS Order Job name Part name Q ty Remarks Disassembling the front wheel Oil seals Bearings Collar 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 6 2 ...

Page 207: ...ze the brake lever when removing the brake calipers 3 Loosen pinch bolt front wheel axle 1 front wheel axle 2 4 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00526 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage wear Re...

Page 208: ... specified limits Replace Front wheel radial runout limit 1 0 mm Front wheel lateral runout limit 0 5 mm 6 Check collars Damage wear Replace New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any highspeed riding is done 7 Check wheel bearings Front wheel turns roughly or is loose Re p...

Page 209: ... should be made only with the outer race 6 Use a socket 3 that matches the diameter of the wheel bearing outer race and oil seal EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection 1 Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection ...

Page 210: ...e Brake disc thickness limit minimum Front 4 5 mm Rear 5 5 mm 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Tighten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 23 Nm 2 3 m kg LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc ...

Page 211: ...le oil seallips Recommended lubricant Lithium soap base grease 2 Install front wheel assembly The arrow mark a on the tire must point in the direction of the wheel 3 Tighten wheel axle 1 wheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly 4 Install brake caliper Make sure that the brake hose is rou...

Page 212: ...n the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps b through d several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Sfront wheel static balance a Install a balancing weight 1 onto th...

Page 213: ...L AND BRAKE DISCS CHAS 4 Check front wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 214: ...y Brake hose holder Brake caliper 1 1 1 1 Remove the parts in the order listed Refer to REMOVING THE REAR WHEEL For installation reverse the removal procedure 40 Nm 4 0m kg 25 Nm 2 5m kg 20 Nm 2 0m kg 30 Nm 3 0m kg 20 Nm 2 0m kg REAR WHEEL AND BRAKE DISC CHAS REAR WHEEL AND BRAKE DISC MUFFLER AND BRAKE CALIPER ...

Page 215: ...ollar 1 4 1 1 2 1 1 1 1 Remove the parts in the order listed Securely support the motorcycle so there is no danger of it falling over Drain Refer to FINAL GEAR OIL REPLACE MENT in CHAPTER 3 Refer to FUEL TANK AND SEATS in CHAPTER 3 Loosen For installation reverse the removal procedure Refer to REMOVING INSTAL LING THE REAR WHEEL WARNING 40 Nm 4 0m kg 23 Nm 2 3m kg 23 Nm 2 3m kg 90 Nm 9 0m kg 107 N...

Page 216: ...ty Remarks Rear wheel disassembly Disassembling the rear wheel Lock washers Clutch hub Dampers O rings Oil seal Bearing Spacer Bearing 2 1 6 2 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 62 Nm 6 2m kg ...

Page 217: ...er bracket bolt Do not depress the brake pedai when removing the brake caliper 4 Remove wheel axle nut washer 5 Remove rear axle end nut 2 6 Remove rear axle holder 3 7 Remove rear wheel EAS00566 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL AND BRAKE DISCS 2 Check tire Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in ...

Page 218: ... rear wheel assembly a Install the rear wheel assembly 1 with the rear brake caliper bracket 2 and hold the bracket to keep the specified position b After installation of the rear axle shaft 3 slide the wheel assembly to forward direc tion c To make sure the caliper bracket mounts on the swingarm and then fix the holder of swin garm temporally The holder should installed with the punch mark a faci...

Page 219: ... m kg h Install the rear brake caliper on the bracket and tighten the bolts with specified tightening torque Brake caliper bolt 40 Nm 4 0 m kg EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static b...

Page 220: ...rake pads Retaining bolt Brake caliper Brake pads Pad spring 1 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure Refer to REPLACING THE FRONT BRAKE PADS 23 Nm 2 3 m kg FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 221: ... Brake hose holder Caliper Cover Clips Pad pins Pad spring Brake pads 1 1 1 2 2 1 2 Remove the parts in the order listed For installation reverse the removal procedure Refer to REPLACING THE REAR BRAKE PADS Refer to REAR WHEEL AND BRAKE DISC 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS ...

Page 222: ...nents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00582 REPLACING TH...

Page 223: ...ng Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install new brake pad shims onto the new brake pad...

Page 224: ... BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake hose holder 1 brake caliper 2 2 Remove brake pad cover brake pad clips brake pad pins brake pad spring 3 Remove brake pads along with the brake pad shims 4 Measure brake pad wear lim...

Page 225: ...finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install new brake pad shims onto the new brake pads e Install new brake pads and a new brake pad spring The longer tangs a on the brake pad spring must point in the direction of disc rotation 6 Install brake pad pins brake pad clips brake pad cover brake caliper 7 Check brake fluid level Below the minimum level mark a Add the recommended...

Page 226: ...h Union bolt Copper washers Brake hose Master cylinder bracket Master cylinder 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Reter to INSTALLING THE FRONT BRAKE MASTER CYLINDER 10 Nm 1 0 m kg 30 Nm 3 0 m kg Refer to REMOVING INSTALLING THE FRONT BRAKE MASTER CYLINDER FRONT AND REAR BRAKES CHAS FRONT BRAKE MASTER CYLINDER ...

Page 227: ... Q ty Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder cup Spring 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS ...

Page 228: ... Union bolt Copper washers brake hose Clips reservoir hose Master cylinder assembly Reservoir tank 1 1 1 1 2 1 1 2 1 2 1 1 1 Remove the parts in the order listed Drain Disconnect For installation reverse removal procedure Refer to REMOVING INSTALLING THE REAR BRAKE MASTER CYLINDER 64 Nm 6 4 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 229: ...marks Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder cup Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS ...

Page 230: ...place a container under the master cylinder and the end of the brake hose 3 Remove master cylinder bracket master cylinder EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove brake switch connector cotter pin washer pin bolt brake pedal assembly 2 Remove union bolt 1 copper washers 2 brake hose...

Page 231: ...der 1 Damage scratches wear Replace brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace A Front B Rear 3 Check brake fluid reservoir 1 Cracks damage Replace brake fluid reservoir diaphragm 2 Cracks damage Replace A Front B Rear 4 Check brake hoses 1 Cracks damage wear Re...

Page 232: ...ark facing up Align the end of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install copper washers New 1 brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left...

Page 233: ...ter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid ...

Page 234: ...e rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor loc...

Page 235: ...st brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest 81 8 mm 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 ...

Page 236: ...nion bolt Copper washers Brake hose Retaining bolt Brake caliper assembly 1 1 2 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE CALIPERS 30 Nm 3 0 m kg 23 Nm 2 3 m kg 6 Nm 0 6 m kg FRONT AND REAR BRAKES CHAS FRONT BRAKE CALIPERS ...

Page 237: ...t brake calipers Pad spring Brake caliper pistons Dust seals Caliper piston seals Bleed screw 1 2 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure Refer to REMOVING THE FRONT BRAKE CALIPERS 1 2 3 4 5 FRONT AND REAR BRAKES CHAS ...

Page 238: ... holder Union bolt Copper washers Brake hose Caliper ass y 1 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING INSTALLING THE REAR BRAKE CALIPER Refer to REAR WHEEL AND BRAKE DISC 40 Nm 4 0 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS ESA00616 REAR BRAKE CALIPER ...

Page 239: ... Clips Pad pins Pad spring Brake pads Caliper pistons Dust seals Piston seals Bleed screw 1 2 2 1 2 2 2 2 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE REAR BRAKE CALIPER 1 2 3 4 5 6 7 8 9 FRONT AND REAR BRAKES CHAS ...

Page 240: ...ntainer and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper Cover the brake caliper piston with a rag Be carful not to get injured when the piston is expelled from the brake caliper cylinder Never try to pry out the brake caliper pis tons b Remove...

Page 241: ...to the brake hose joint opening b to force out the left side pis ton from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts c Remove the brake caliper piston seals d Repeat the previous steps to force out the right side piston from the brake caliper EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pad...

Page 242: ...iper is disassembled replace the brake caliper piston seals A Front B Rear 2 Check brake caliper brackets Cracks damage Replace EAS00638 INSTALLING THE FRONT BRAKE CAL IPERS The following procedure applies to both of the brake calipers Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents a...

Page 243: ...t brake hose holder Refer to FRONT BRAKE PADS 3 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu...

Page 244: ...fer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00642 INSTALLING THE REAR BRAKE CALIPER Before installaiton all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they w...

Page 245: ... hose holder Refer to REAR BRAKE PADS 3 Fill brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in ...

Page 246: ... suitable stand Make sure that the motorcycle is upright Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake pedal operation Soft or spongy feeling bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM i...

Page 247: ...light bolts Upper bracket bolts Cap bolts Lower bracket bolts Front fork legs 2 2 1 2 2 2 2 2 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS 20 Nm 2 0 m kg 7 Nm 0 7 m kg 30 Nm 3 0 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg FRONT FORK CHAS FRONT FORK ...

Page 248: ...eat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod rebound spring Oil seal 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 1 2 3 4 5 9 6 7 8 10 11 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK CHAS 6 44 ...

Page 249: ...cer Outer tube bushing Inner tube inner tube bushing Oil lock piece Outer tube 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 12 13 14 15 16 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK CHAS ...

Page 250: ... that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 turn signal light bolt 3 lower bracket pinch bolt 4 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt O ring spacer spring seat fork spri...

Page 251: ...nner tube a Hold the front fork leg horizontally b Slowly push A the inner tube into the outer tube and just before it bottoms out pull B the inner tube back quickly c Repeat this step until the inner tube sepa rates from the outer tube EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Repla...

Page 252: ...edure applies to both of the front fork legs Make sure that the oil levels both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability When assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Instal...

Page 253: ... 3 T handle 90890 01326 Damper rod holder 90890 01460 4 Install outer tube bushing 1 seal spacer with the fork seal driver weight 2 and adapt er 3 Fork seal driver weight 90890 01367 Adapter 90890 01381 5 Install oil seal 1 with the fork seal driver weight and adapter Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its li...

Page 254: ...sembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 After filling the front fork leg slowly stroke the inner tube up and down at least ten times to distribute the fork oil Be sure to stroke the inner tube slowly because the fork oil may spurt out 10 Measure front fork leg oil level a Out of specification Correct Front fork leg oil level from the ...

Page 255: ...he cap bolt EAS00662 INSTALLING THE FRONT FORK LEGS The fllowing procedure applies to both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the upper bracket 2 Tighten lower bracket pinch bolt 1 front turn signal light bolt 2 cap bolt 3 upper bracket pinch bolt 4 Make sure that th...

Page 256: ... bracket Master cylinder assembly Handlebar switch right Throttle cables 4 1 1 1 1 1 1 1 1 1 2 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to INSTALLING THE HANDLEBAR Refer to REMOVING THE HANDLEBAR Refer to INSTALLING THE HANDLEBAR WARNING 28 Nm 2 8 m kg 10 Nm 1 0 m kg 32 Nm 3 2 m ...

Page 257: ...Order Job name Part name Q ty Remarks 12 13 14 15 16 Throttle grip assembly Handlebar holders upper Handlebar Cable guide Handlebar holders lower 1 2 1 1 2 For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR HANDLEBAR CHAS ...

Page 258: ...p left 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken it...

Page 259: ... has fully dried EAS00670 INSTALLING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar upper handlebar holders First tighten the bolts on the front side of the handlebar holder then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank a...

Page 260: ...hole b in the handlebar 4 Install master cylinder Refer to FRONT AND REAR BRAKES 5 Install clutch lever holder 1 Align the slit in the clutch lever holder with the punch mark a in the handlebar 6 Install left handlebar switch 1 Aligh the matching surface on the handlebar switches with the punch mark a on the handle bar 7 Install clutch cable 8 Connect clutch switch coupler Apply a thin coat of lit...

Page 261: ...ING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 5 10 mm 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 4 6 mm ...

Page 262: ...ht body Brake hose joint holder Upper bracket Lock washer Upper ring nut 1 1 1 1 1 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to FRONT FORK Refer to HANDLEBAR Disconnect WARNING 7 Nm 0 7 m kg 1st 110 Nm 11 0 m kg 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg STEERING HEAD CHAS STEERING H...

Page 263: ...g nut Bearing cover Lower bracket Bearing upper Rubber seal Bearing lower 1 1 1 1 1 1 1 For installaiton reverse the removal procedure 7 Nm 0 7 m kg 1st 110 Nm 11 0 m kg 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD STEERING HEAD CHAS ...

Page 264: ...lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 90890 01268 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosine 2 Check bearings 1 bearing races 2 D...

Page 265: ...aged Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install Lower ring nut 1 rubber washer ...

Page 266: ...6 62 STEERING HEAD CHAS NOTE NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK Temporarily tighten the upper and lower bracket pinch bolts ...

Page 267: ...Remove the parts in the order listed Stand the motorcycle on a level surface Refer to FUEL TANK AND SEATS in CHAPTER 3 Refer to REAR WHEEL AND BRAKE DISC Refer to REMOVING INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY For installation reverse the removal procedure 7 Nm 0 7 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM RIGHT SIDE COVER AND BATTERY BOX ...

Page 268: ... box Tool box cover Left side cover Owner s tool kit Connector s Fuel hose holder Fuel hoses Tool box 1 1 1 1 2 1 Remove the parts in order listed Disconnect Disconnect For installation reverse the removal procedure 7 Nm 0 7 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS LEFT SIDE COVER AND TOOL BOX ...

Page 269: ...ay arm Pivot shaft Swingarm 2 2 1 1 1 1 1 Remove the parts in order listed Refer to REAR WHEEL AND BRAKE DISC For installation reverse the removal procedure 40 Nm 4 0 m kg 48 Nm 4 8 m kg 48 Nm 4 8 m kg 90 Nm 9 0 m kg 48 Nm 4 8 m kg Refer to REMOVING INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY Refer to REMOVING INSTALLING THE SWINGARM REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SW...

Page 270: ...he rear shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A RE...

Page 271: ...r Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Disconnect battery leads from the battery terminals First disconnect the negative lead 1 then the positive lead 2 3 Remove connecting arm bolt swingarm side 1 rear shock absorber assembly lower bolt While removing the connecting arm bolt swin garm side hold the swingarm so that it does not drop down 4 Remove rear shock...

Page 272: ...swingarm side play swingarm vertical movement a Check the tightening torque of the swingarm pivot bolts and locknut Locknut 90 Nm 9 0 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers and bearings Swingarm side play at the end of the swingarm 0 mm d Check the swingarm vertical movement B by moving t...

Page 273: ...leaks oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock ab sorber assembly gas cylinder Damage gas leaks Replace bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace EAS00708 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Damage wear Replace 3 Check collars 1 oilseals 2 bearing...

Page 274: ...k absorber assembly upper nut 40 Nm 4 0 m kg Rear shock absorber assembly lower nut 48 Nm 4 8 m kg Relay arm to frame nut 48 Nm 4 8 m kg When installing the rear shock absorber as sembly lift up the swingarm Install the connecting arm front bolt from the right 4 Connect battery leads to the battery terminals First connect the positive lead 1 then the negative lead 2 EAS00712 INSTALLING THE SWINGAR...

Page 275: ...t connecting arm Rear shock absorber assembly lower nut 1 48 Nm 4 8 m kg Connecting arm nuts 2 48 Nm 4 8 m kg Relay arm to frame nut 3 48 Nm 4 8 m kg 3 Install rear shock absorber Reter to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 Install rear wheel Refer to REAR WHEEL AND BRAKE DISC ...

Page 276: ...ne or a clunk from a shaft drive component or vicinity of the shaft drive 3 The shaft drive is locked up or no power is transmitted from the engine 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 t...

Page 277: ...eration and deceleration Diagnosis Possible incorrect reassembly or too little gear lash Insufficient gear lash is extremely destruc tive to the gear teeth If a test ride following reassembly indicates these symptoms stop riding immediately to minimize gear damage c A slight clunk evident at low speed opera tion not to be confused with normal motor cycle operation Diagnosis Possible broken gear te...

Page 278: ... the wheel bearing Refer to FRONT WHEEL AND BRAKE DISC Rear wheel bearings and shaft drive bearings are probably not damaged Repeat the test or remove and check the components Remove the rear wheel Is the wheel bearing damaged Replace the rear wheel bearing Refer to REAR WHEEL AND BRAKE DISC Remove and inspect the drive shaft compo nents SHAFT DRIVE CHAS EAS00716 Troubleshooting chart When causes ...

Page 279: ... normal 3 Check shaft drive housing for oil leaks a Thoroughly clean the entire motorcycle and then completely dry it b Apply a leak locating compound or dry pow der spray to the shaft drive c Test ride the motorcycle long enough to lo cate a leak Oil leak Repair or replace the faulty part s 1 Oil seal 2 O ring 3 Forward What may appear to be an oil leak on a new or fairly new motorcycle may resul...

Page 280: ...st Ring gear backlash 0 1 0 2 mm a Install a bolt 1 of the specified size into the final drive oil filler hole b Finger tighten the bolt until it stops the ring gear from moving Do not overtighten the bolt c Install the final gear backlash band 2 and dial gauge 3 Final gear backlash band 90890 01230 a Dial gauge plunger contact point 54 5 mm d Gently rotate the gear coupling from engage ment to en...

Page 281: ...EAR BACKLASH 1 Remove Sring gear bearing housing nuts Sring gear bearing housing bolts Working in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos ened remove them and the bolts 2 Remove Sring gear bearing housing 1 Sring gear 2 Sthrust washer 3 Sring gear shim s 4 3 Adjust Sring gear backlash a Use the following chart to select the suitable shim s and thrust...

Page 282: ...ry to increase the ring gear backlash by more than 0 2 mm reduce the thrust washer thickness by 0 2 mm for every 0 2 mm increase of ring gear shim thickness c If it is necessary to reduce the ring gear back lash by more than 0 2 mm increase the thrust washer thickness by 0 2 mm for every 0 2 mm decrease of ring gear shim thick ness ...

Page 283: ...listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to REAR WHEEL AND BRAKE DISC Refer to DISASSEMBLING THE FINAL DRIVE ASSEMBLY ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR For installation reverse the removal procedure WARNING 23 Nm 2 3 m kg 23 Nm 2 3 m kg 42 Nm 4 2 m kg 115 Nm 11 5 m kg 130 Nm 13 0 m kg SHAFT DRIVE ...

Page 284: ...ring housing O ring Ring gear Shim s Thrust washer 2 6 1 1 1 1 1 Disassemble the parts in the order listed Working in a crisscross pattern loosen each bolt and nut 1 4 of a turn After all the bolts and nuts are loosened remove them For assembly reverse the disassembly procedure NOTE 1 2 3 4 5 6 23 Nm 2 3 m kg 40 Nm 4 0 m kg FINAL GEAR ...

Page 285: ... gear coupling with the special tool 1 Coupling gear middle shaft tool 90890 01229 3 Remove bearing retainer 2 with the special tool 3 Bearing retainer wrench 90890 04077 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove final drive pinion gear with the special tools Crankshaft installer bolt adapter 1 90890 01277 Armature shock puller 2 90890 01...

Page 286: ...proximately 150 _C 302 _F b Remove the bearing outer races with an ap propriately shaped punch 2 c Remove the inner race from the final drive pinion gear The removal of the final drive pinion gear bear ing is a difficult procedure and is rarely neces sary 4 Install Sbearing New a Heat the final gear case to approximately 150_C 302_F b Install the bearing outer races with a socket or appropriate to...

Page 287: ... any of the following parts are replaced Final drive housing Any bearing 1 Select final drive pinion gear shim s 1 ring gear shim s 2 a Position the final drive pinion gear and the ring gear with shims 1 and 2 Calculate the respective thicknesses from information marked on the final drive housing and the drive pinion gear 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b To find fi...

Page 288: ... Since the final drive pinion gear shims are only available in 0 10 mm increments round off to the hundredths digit Hundredths Rounded value 0 1 2 3 4 0 5 6 7 8 9 10 In the example above the calculated final drive pinion gear shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use ...

Page 289: ...lated ring gear shim thick ness is 0 51 mm Shim sizes are supplied in the following thick ness Since the ring gear shims are only available in 0 10 mm increments round off the hundredths digit Hundredths Rounded value 0 1 2 3 4 0 5 6 7 8 9 10 In the example above the calculated final gear shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm ring g...

Page 290: ...ring housing along with the ring gear b Place four pieces of Plastigauge between the original thrust washer and the ring gear c Install the ring gear bearing housing and tighten the bolts and nuts to specification Ring gear bearing housing bolt M10 40 Nm 4 0 m kg Ring gear bearing housing nut M8 23 Nm 2 3 m kg Do not turn the final drive pinion gear and ring gear while measuring the ring gear to t...

Page 291: ...l the ring gear to thrust washer clearance is with in the specified limits Ring gear to thrust washer clearance 0 2 mm EAS00727 CHECKING THE DRIVE SHAFT 1 Check drive shaft splines Damage wear Replace the drive shaft EAS00728 INSTALLING THE DRIVE SHAFT 1 Lubricate drive shaft splines Recommended lubricant Molybdenum disulfide grease 2 Apply sealant onto both final drive housing mating sur faces Ya...

Page 292: ...6 88 SHAFT DRIVE CHAS 42 Nm 4 3 m kg 4 Tighten final bearing housing nuts 5 Install rear wheel assembly Refer to REAR WHEEL AND BRAKE DISC ...

Page 293: ...ELEC 7 ...

Page 294: ...UBLESHOOTING 7 9 ELECTRIC STARTING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 STARTING CIRCUIT OPERATION 7 14 TROUBLESHOOTING 7 15 STARTER MOTOR 7 19 CHARGING SYSTEM 7 23 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 24 LIGHTING SYSTEM 7 26 CIRCUIT DIAGRAM 7 26 TROUBLESHOOTING 7 27 CHECKING THE LIGHTING SYSTEM 7 28 SIGNAL SYSTEM 7 31 CIRCUIT DIAGRAM 7 31 TROUBLESHOOTING 7 33 CHECKING THE SIGNALING SYSTEM 7 34 FUEL...

Page 295: ...ELEC CARBURETOR HEATER SYSTEM 7 44 CIRCUIT DIAGRAM 7 44 TROUBLESHOOTING 7 45 SELF DIAGNOSIS 7 48 TROUBLESHOOTING 7 49 ...

Page 296: ...3 Flasher relay 4 Starting circuit cut off relay 5 Ignition coil 6 Starter relay 7 Fuse 8 Igniter unit 9 Side stand switch 10 Neutral switch 11 Rectifier regulator 12 Oil lamp relay 13 Battery 14 Rear brake switch 15 Horn EB800000 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 297: ...checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a continuity of electricity betwe...

Page 298: ... Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 299: ...use 12 Rear brake switch 13 Sidestand switch 14 Neutral switch 1 for Europe 2 for AUS 1 Clutch switch 2 Pass switch 3 Horn switch 4 Dimmer switch 5 Turn switch 6 Main switch 7 Front brake switch 8 Lights switch for Europe CECKING THE SWITCHES ELEC ...

Page 300: ...own in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their re spective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise Bu...

Page 301: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 302: ... tester No continuity Replace Pocket tester 90890 03112 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb soc...

Page 303: ...itch Alam system option Ignition fuse Battery Main fuse Starting circuit cut off relay Ignitor unit Ignition coil Spark plug Sidestand switch Neutral switch Engine stop switch 20 38 Diode 60 IGNITION SYSTEM ELEC EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 304: ...YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EAS00737 EAS00739 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 spark plug cap resistance 6 ignition c...

Page 305: ...he spark plug SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20 _C SIs the spark plug cap OK YES Replace the spark plug cap NO EAS00747 Tester positive probe spark plug lead Tester negative probe Orange gray lead 1 1 2 a 2 6 Ignition coil resistance The following procedure applies to all of the ignition coils...

Page 306: ...ure the pickup coil resistance EAS00749 SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EAS00750 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES Replace the right handlebar switch NO 9 Engine stop switch EAS00751 SCheck the neutral switch for contin...

Page 307: ...f the digital pocket tester the readings in the above chart will be reversed SIs the diode OK YES Properly connect or repair the ignition system s wiring NO Replace the ignitor unit 13 Starting circuit cut off relay diode SRemove the relay unit from the wire har ness SCheck for continuity as follows Sky blue Blue Yellow 2 Tester lead SKy blue Tester lead Blue Yellow 1 2 Tester lead Blue Yellow Tes...

Page 308: ... Ignition fuse Battery Main fuse Starter relay Starter motor Starting circuit cut off relay Neutral switch Sidestand switch Start switch Clutch switch Engine stop switch 36 38 Diode 60 ELECTRIC STARTING SYSTEM ELEC EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 309: ...closed The starting circuit cut off relay prevents the starter from operating when neither of these conditions have been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHE...

Page 310: ... or fluid is in the vicinity SDoes the starter motor turn WARNING NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EAS00757 EAS00739 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 starter motor 4 starting circuit cutof...

Page 311: ...ircuit cutoff relay Diode Disconnect the starting circuit cutoff relay from the coupler Connect the pocket tester Ω 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows YES Replace the relay unit NO Tester positive probe sky blue Tester negative probe black yellow 1 2 Continuity NOTE When you switch the and leads of the digit...

Page 312: ...NG THE SWITCHES Is the sidestand switch OK YES Replace the side stand switch NO 10 Sidestand switch EAS00763 Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES Replace the clutch switch NO 11 Clutch switch 1 Tester positive probe red Tester negative probe black 3 4 Does the starter relay have continuity be tween red and black EAS00749 Check the main s...

Page 313: ...he start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK 14 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects YES Replace the diode NO 13 Diode Check the diode for continuity Refer to IGNITION SYSTEM Is the diode OK ELECTRIC STARTING SYSTEM ELEC EAS00764 ...

Page 314: ...Planetary gears Armature assembly Brush holder brush Starter motor yoke 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Disassembly the pats in the order listed Refer to Assembling the starter motor Refer to Assembling the starter motor Refer to Assembling the starter motor For assembly reverse the disassembly procedure 10 Nm 1 0 m kg...

Page 315: ...saw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper op eration of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 Armature assembly Armature coil resistanc...

Page 316: ... 65 X 10 01 N 780 X 1 020 g 7 Check gear teeth Damage wear Replace the gear 8 Check oil seal Damage wear Replace the defective part s EAS00772 Assembling the starter motor 1 Install brush holder 1 Align the tab a on the brush holder with the slot in the starter motor rear cover 2 Install starter motor yoke 1 end bracket 2 starter motor front cover 3 Align the projection a on the front cover with t...

Page 317: ...7 22 ELECTRIC STARTING SYSTEM ELEC NOTE 3 Install Starter motor rear cover 1 Align the match marks a on the rear cover with the match marks b on the front cover ...

Page 318: ...7 23 CHARGING SYSTEM ELEC AC magneto stator coil Rectifier regulator Battery Main fuse 2 3 7 8 EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 319: ...inal Tester negative probe battery negative terminal SStart the engine and let it run at approximate ly 5 000 r min SMeasure the charging voltage 7 24 NOTE YES NO Replace the fuse 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK EAS00774 EAS00739 TROUBLESHOOTING The battery is not being sharged Check 1 main fuses 2 battery 3 charging vo...

Page 320: ...SIs the stator coil assembly OK YES Replace the stator coil assembly NO Tester positive probe White Tester negative probe white 1 2 SMeasure the stator coil assembly resis tances Tester positive probe white Tester negative probe white 1 3 5 Wiring NO Replace the rectifi er regulator YES EAS00779 SCheck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging s...

Page 321: ... 46 4 7 8 25 27 48 44 50 52 Auxiliary light Pass switch Main switch Battery Main fuse Meter light High beam indicator Headlight Dimmer switch Tail brake light Headlight fuse Light switch 39 EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 322: ...the battery OK NO EAS00783 4 Lights switch for Europe SCheck the lights switch for continuity Refer to CHECKING THE SWITCHES SIs the lights switch OK YES The lights switch is faulty Replace the right handlebar switch NOTE EAS00781 EAS00739 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight auxilia ry light for Europe or meter light Check 1 main and hea...

Page 323: ...f each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES Replace the head light bulb socket or both NO 1 Headlight bulb and socket 2 Voltage Connect the pocket tester DC 20 V to the headlight and high beam indicator light cou plers as show...

Page 324: ...ust be repaired NO YES 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown Tester positive probe blue Tester negative probe black 1 2 This circuit is OK Replace the tail brake lightbulb sock et or both NO YES The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired NO This circuit is OK EAS00790 3 A tail br...

Page 325: ...3 4 The auxiliary light fails to come on for Eu rope 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the auxiliary light bulb and socket OK YES 2 Voltage Connect the pocket tester DC 20 V to the auxiliary light couplers wire harness side as shown Tester positive probe blue red Tester negative probe black 1 ...

Page 326: ...7 31 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 327: ...22 Oil warning light 24 Turn signal indicator light 26 Neutral indicator light 30 Flasher relay 31 Turn signal switch 32 Rear turn signal light R 33 Rear turn signal light L 34 Front turn signal light R 35 Front turn signal light L 40 Front brake switch 42 Horn 43 Horn switch 45 Rear brake switch 50 Tail brake light 53 Signal fuse ...

Page 328: ...EAS00795 4 Wiring SCheck the entire signaling system s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wring Check the condition of each of the signal ing system s circuits Refer to CHECKING THE SIGNALING SYSTEM NOTE EB806010 EAS00739 TROUBLESHOOTING SAny of the following fail to light t...

Page 329: ...ad Set the main switch to ON Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connecter at the black terminal as shown Tester positive probe black Tester negative probe ground 1 Set the main switch to ON Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connecter is faulty and...

Page 330: ...HE SWITCHES Is the brake light switch OK YES 2 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must bne repaired NO This circuit is OK Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification Replace the turn sig...

Page 331: ...rness side Is the voltage within specification 1 4 Voltage Connect the tester DC 20 V to the flasher relay coupler wire harness side as shown The flasher relay is faulty and must be re placed NO YES 1 Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V or brown white at the flasher relay coupler wire harness side Is the voltage within specification Tester positive p...

Page 332: ...ltage within specification 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES 3 Voltage Connect the pockt tester DC 20V to the me ter assembly coupler wire harness side as shwon 1 2 YES The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be re paired NO This ci...

Page 333: ...he pocket tester Ω 1 and bat tery 12 V to the oil lamp relay terminals as shown YES Replace the oil lamp relay NO Battery positive terminal red white Battery negative terminal black red 1 2 Tester positive probe black white Tester negative probe black 3 4 Does the oil lamp relay have continuity be tween red blue and black 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wi...

Page 334: ... 39 FUEL PUMP SYSTEM ELEC 4 6 7 8 13 14 16 38 Main switch Ignition fuse Battery Main fuse Starting circuit cutoff relay Fuel pump Ignitor unit Engine stop switch EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 335: ...ion fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay fuel pump engine stop switch and ignitor unit The ignitor unit includes the control unit for the fuel pump ...

Page 336: ...p switch OK YES Replace the right handlebar switch NO 4 Engine stop switch NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Reger to CHECKING THE FUSES in chapter 3 SAre the main and ignition fuses OK EAS00781 EAS00739 TROUBLESHOOTING The fuel pump fails to operate Check 1 main and ignition fuses 2 battery 3 main switch 4 engine stop switc...

Page 337: ...ect the pocket tester Ω 1 and bat tery 12 V to the relay unit terminals 6 Fuel pump resistance SDisconnect the fuel pump coupler from the wire harness SConnect the pocket tester Ω 1 to the fuel pump coupler terminals Fuel pump resistance 1 6 X 2 2 Ω at 20_C 68_F SMeasure the fuel pump resistance S Is the fuel pump OK YES Replace the fuel pump NO SCheck the entire fuel pump system s wiring Refer to...

Page 338: ...ou do ac cidentally spill some wipe it up immediate ly with dry rags If gasoline touches the engine when the en gine is still hot there is a danger of com bustion Make sure that the engine is com pletely cool before performing the following test 1 Check Fuel pump operation a Fill up the fuel tank b Put the end of the fuel hose into an open con tainer c Connect the battery 12 V to the fuel pump cou...

Page 339: ...ch Battery Main fuse Neutral switch Carburetor heater fuse Thermo switch Carburetor heater relay Carburetor heater 1 58 Carburetor heater 2 59 Carburetor heater earth CARBURETOR HEATER SYSTEM ELEC CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM ...

Page 340: ... switch NO 4 Neutral switch CARBURETOR HEATER SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Main and carburetor heater fuses SCheck the main and carburetor heater fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and carburetor heater fuses OK EAS00781 TROUBLESHOOTING The carburetor heater fails to operate Check 1 main and carburetor heater 2 battery 3 main switch 4 neatr...

Page 341: ...he carburetor heater relay from the wire harness SConnect the pocket tester Ω 1 and bat tery 12 V to the carburetor heater relay ter minals 3 4 Tester lead Brown Yellow terminal Tester lead Black Yellow terminal 1 2 SImmerse the thermo switch in the water SCheck the thermo switch for continuity Note the temperatures while heating the wa ter with the temperature gauge 3 4 Test step Water temperatur...

Page 342: ...he carbure tor heater NO 8 Wiring SCheck the entire carburetor heater system s wiring Refer to CIRCUIT DIAGRAM SIs the carburetor heater system s wiring properly connected and without defects SMeasure the heater resistance Carburetor heater resistance 12 V 30 W 6 X 10 Ω at 20_C SIs the carburetor heater OK EAS00766 YES The carburetor heat er system circuit is OK NO Properly connect or repair the c...

Page 343: ...e indicator light in the speedometer comes 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 condition code Item Condition Response When engine is stationary When engine is running Throttle position sensor TPS Disconnected Short circuit Locked Enables the motorcycle t...

Page 344: ...nsor OK YES Replace the throttle position sensor Replace the ignitor unit EB812401 SELF DIAGNOSIS ELEC NOTE 15 Throttle position sensor 16 Ignitor unit EAS00835 TROUBLESHOOTING The engine warning light starts to display the self diagnosis sequence Check 1 throttle position sensor 2 speed sensor Before troubleshooting remove the following part s 1 rider seat 2 fuel tank 3 air filter case 4 left sid...

Page 345: ...r unit 19 Speed sensor YES NO Repair or replace the wire harness 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK 2 Speed sensor Place the motorcycle on a suitable stand so that the rear wheel is elevated Connect the pocket tester DC 20V to the speed sensor connector Tester lead White terminal Tester lead Body earth 1 2 Speed sensor CIRCUIT DIAGR...

Page 346: ...TRBL SHTG 8 ...

Page 347: ...AL 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 PERFORMANCE 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 O...

Page 348: ...Faulty relay unit starting circuit cut off relay Faulty starter clutch EB900000 TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of problems It should be helpful however as a guide to troubleshooting Refer to the relative procedure in this manual for inspection adjustment and replacement of parts STARTING FAILURE HARD STARTING FUEL SYSTEM Fuel tank Emp...

Page 349: ...linder 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 EB901000 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot air jet Improperly sy...

Page 350: ...erly adjusted shift pedal link Bent shift shaft Shift cam shift fork Groove jammed with impurities Seized shift fork Bent shift fork guide bar JUMPS OUT OF GEAR Shift shaft Improperly adjusted shift lever position Improperly returned stopper lever Shift fork Worn shift fork EB904000 CLUTCH SLIPPING DRAGGING CLUTCH SLIPPING Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch...

Page 351: ...G Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor main jet setting Improper fuel level Clogged air filter element EB906001 FAULTY BRAKE POOR BRAKING PERFORMANCE Disc 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 o...

Page 352: ...roken wire harness EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Improperly installed or bent Steering Improperly installed handlebar crown Bent steering stem Improperly installed steering shaft improperly tightened ring nut Damaged ball bearing or bearing race Swingarm Worn bearing or bushing Bent or damaged Rear Shock absorber Faulty spring Oil and gas leakage Tire Uneven tire pressures...

Page 353: ...eed sensor 20 Neutral switch 21 Engine warning light 22 Oil warning light 23 Speedometer 24 Turn signal indicator light 25 Meter light 26 Neutral indicator light 27 High beam indicator light 28 Trip switch 29 Sidestand switch 30 Flasher relay 31 Turn signal switch 32 Rear turn signal light right 33 Rear turn signal light left 34 Front turn signal light right 35 Front turn signal light left 36 Clut...

Page 354: ...ug 19 Speed sensor 20 Neutral switch 21 Engine warning light 22 Oil warning light 23 Speedometer 24 Turn signal indicator light 25 Meter light 26 Neutral indicator light 27 High beam indicator light 28 Trip switch 29 Sidestand switch 30 Flasher relay 31 Turn signal switch 32 Rear turn signal light right 33 Rear turn signal light left 34 Front turn signal light right 35 Front turn signal light left...

Page 355: ...ward CABLE ROUTING SPEC E Position the steel band end to right side F Route the battery positive lead through the slit of the bat tery box G Clamp the igniter unit lead to the frame with a holder H To the rear fender I Connect the wireharness to the ignitar unit through the hole of LID 2 J Route the fuel tank breather hose under the fuel filter and connect it fuel tank sideroll over valve side wit...

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Yamaha 1999 XVS1100, Service Manual

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