Yamaha BT1100 2002 Service Manual Download Page 1

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BT1100

SERVICE MANUAL

2002

5JN1-AE1

http://manuals.magnamaniac.com

Summary of Contents for BT1100 2002

Page 1: ...BT1100 SERVICEMANUAL 2002 5JN1 AE1 ...

Page 2: ...2002 SERVICE MANUAL 2001 by Belgarda S p A First edition November 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Belgarda S p A is expressly prohibited Printed in Italy ...

Page 3: ...ications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol me...

Page 4: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicate...

Page 5: ...with engine mounted 0 Filling fluid q Lubricant w Special tool e Torque r Wear limit clearance t Engine speed y Electrical data Illustrated symbols u to s in the exploded dia grams indicate the types of lubricants and lubrica tion points u Apply engine oil i Apply gear oil o Apply molybdenum disulfide oil p Apply wheel bearing grease a Apply lightweight lithium soap base grease s Apply molybdenum ...

Page 6: ...INFORMATION TABLE OF CONTENTS GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJ 3 ENGINE ENG 4 CARBURETION CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG 8 E004000 ...

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Page 8: ...1 GEN INFO http manuals magnamaniac com ...

Page 9: ...ER 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 http manuals magnamaniac com ...

Page 10: ...GEN INFO http manuals magnamaniac com ...

Page 11: ...CYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame under the seat MODEL LABEL The model label 1 is affixed to the frame under the seat This information will be needed to order spare parts http manuals magnamaniac com ...

Page 12: ...an all parts and place them in trays in the order of disas sembly This will speed up assembly and allow 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 replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but in...

Page 13: ...alling 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 CAUTION EB101050 CIRCLIPS 1 Check all circlips carefully before reassembly Always replace piston pin clips after one use Replace distorted circ...

Page 14: ...l times 3 Check connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect connector terminals NOTE The two terminals click together 5 Check continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to per form steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Check the conne...

Page 15: ... 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 middle gear backlash Installer pot 90890 01274 ...

Page 16: ...g stem ring nut 90890 01701 Sheave holder This tool is needed to hold the rotor when removing or installing the rotor bolt 90890 03081 Compression gauge set These tools are needed to measure engine compression 90890 03094 Vacuum gauge This gauge is needed for carburetor synchronization 90890 03112 Pocket tester This instrument is needed for checking the electrical system 90890 03113 Engine tachome...

Page 17: ...ng 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 remov ing or installing the middle drive shaft bearing 90890 04062 Universal joint holder This tool is needed when removing or installing the driven pinion gear nut 90890 04077 Bearing retainer wrench This tool is needed when removing or insta...

Page 18: ...tester Ignition checker This instrument is necessary for checking the ignition system compo nents 90890 85505 Yamaha bond No 1215 This sealant bond is used on crankcase mating surfaces etc Tool name How to use Illustration 90890 04086 Clutch holding tool This tool is needed to hold the clutch when removing or installing the clutch boss nut http manuals magnamaniac com ...

Page 19: ...2 SPEC http manuals magnamaniac com ...

Page 20: ...IONS 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 21: ...SPEC ...

Page 22: ...L Bore stroke 95 75 mm Compression ratio 8 3 1 Compression pressure STD 1 000 kPa 10 kg cm2 10 bar at 400 r min Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil Temp C API standard API Service SE SF SG or higher SAE 20W40SE or SAE 10W30SE ACEA standard G4 or G5 Final gear oil SAE80 API GL 4 Hypoid Gear Oil or multigrade hypoid gear oil SAE 80W 90 Oil quanti...

Page 23: ...th 32 31 1 032 5th 29 34 0 853 Chassis Frame type Twin tube Backbone Caster angle 25 Trail 106 mm Tire Type Tubeless Size front 120 70 ZR17 58W rear 170 60 ZR17 72W Manufacturer front DUNLOP METZELER rear DUNLOP METZELER Type front D205F TL MEZ3F TL rear D205 TL MEZ3 TL Maximum load except motorcycle 200 kg Tire pressure cold tire 0 90 kg load front 230 kPa 2 30 kg cm2 2 30 bar rear 250 kPa 2 50 k...

Page 24: ...heel travel 113 mm Electrical system Ignition system T C I digital Generator system A C magneto Battery type GT14B 4 Battery capacity 12V 12Ah Headlight type Quartz bulb halogen Bulb wattage quantity Headlight 12 V 60 W 55 W 1 Auxiliary light 12 V 5 W 1 Tail brake light 12 V 5 W 21 W 1 Turn signal 12 V 10 W 4 Licence light 12 V 5 W 1 Meter light 14 V 1 2 W 4 Neutral indicator light LED 1 High beam...

Page 25: ...e method Chain drive left right Cam cap inside diameter 25 000 25 021 mm Camshaft outside diameter 24 96 24 98 mm Shaft to cap clearance 0 020 0 061 mm Cam dimensions Intake A 39 112 39 212 mm 39 012 mm B 1 32 093 32 193 mm 1 31 993 mm 2 32 127 32 227 mm 2 32 027 mm C 7 162 mm 7 012 mm Exhaust A 39 145 39 245 mm 39 045 mm B 32 200 32 300 mm 32 100 mm C 7 195 mm 7 045 mm Camshaft runout limit 0 03 ...

Page 26: ... Valve valve seat valve guide Valve clearance cold IN 0 07 0 12 mm EX 0 12 0 17 mm Valve dimensions Head Diameter Face Width Seat Width Margin Thickness A head diameter IN 47 0 47 2 mm EX 39 0 39 2 mm B face width IN 2 1 mm EX 2 1 mm C seat width IN 1 2 1 4 mm 1 8 mm EX 1 2 1 4 mm 1 8 mm D margin thickness IN 1 1 1 5 mm 0 8 mm EX 1 1 1 5 mm 0 8 mm Stem outside diameter IN 7 975 7 990 mm EX 7 960 7...

Page 27: ...4 6 mm 43 5 mm EX 44 6 mm 43 5 mm Set length valve closed IN 40 mm EX 40 mm Compressed pressure installed IN 160 7 N 16 4 kg EX 160 7 N 16 4 kg Tilt limit IN 2 5 1 9 mm EX 2 5 1 9 mm Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 025 0 050 mm 0 15 mm Piston size D 94 960 94 975 mm Measuring point H 5 mm Piston off set 0 mm ...

Page 28: ... 8 mm Side clearance installed 0 04 0 08 mm 0 1 mm 2nd ring Type Taper Dimensions B x T 1 2 3 8 mm End gap installed 0 30 0 45 mm 0 8 mm Side clearance 0 03 0 07 mm 0 1 mm Oil ring Dimensions B x T 2 5 3 4 mm End gap installed 0 2 0 7 mm Connecting rod Oil clearance 0 044 0 073 mm Color code corresponding size 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Crankshaft Crank width A 101 95 102 00 mm Runout...

Page 29: ...n limit 0 08 mm Shifter Shifter type Guide bar Carburetor I D mark 5JN1 00 Main jet M J 125 Main air jet M A J 55 Jet needle J N 5DL39 53 3 Needle jet N J P 0M 826 Pilot air jet P A J 1 63 8 P A J 2 142 5 Pilot outlet P O 1 0 Pilot jet P J 17 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 3 0 Valve seat size V S 1 2 Starter jet G S 1 42 5 Starter jet G S 2 0 9 Throttle ...

Page 30: ...stem Oil filter type Paper type Oil pump type Trochoid type Tip clearance A or B 0 03 0 09 mm 0 15 mm Side clearance 0 03 0 08 mm 0 15 mm Relief valve operating pressure 450 550 kPa 4 5 5 5 kg cm2 Shaft drive Middle gear backlash 0 1 0 2 mm Final gear backlash 0 1 0 2 mm ...

Page 31: ...chart Needle bearing starter Connecting rod big end Crankshaft Main axle Drive axle Pinin drive Middle driveshaft Rocker arm IN Camshaft IN Camshaft EX Rocker arm IN Rocker arm EX Rocker arm EX Oil filter Oil pump Relief valve Oil pan Pressure feed Splashed Orifice ...

Page 32: ...SPEC MAINTENANCE SPECIFICATIONS 2 11 Cylinder head tightening sequence Crankcase tightening sequence Right crankcase Left crankcase ...

Page 33: ...alve adjusting locknut Nut M8 4 27 2 7 Camshaft sprocket Bolt M10 2 55 5 5 Timing chain tensioner Bolt M6 4 10 1 0 Timing chain tentioner cap Bolt M6 2 8 0 8 Timing chain guide Bolt M6 4 10 1 0 Oil pump Bolt M6 3 10 1 0 Oil strainer cover Bolt M6 3 10 1 0 Oil filter cover Bolt M6 5 10 1 0 Oil pump gear Bolt M6 1 12 1 2 Oil pump cap Bolt M6 1 10 1 0 Oil delivery pipe cylinder head Union M16 2 20 2 ...

Page 34: ...tch adjuster Nut M8 1 12 1 2 Clutch boss Nut M20 1 70 7 0 Use lock washer Push lever axle Screw M8 1 12 1 2 Middle drive pinion gear Nut M44 1 110 11 0 Stake Bearing retainer middle driven shaft Nut M88 1 110 11 0 Stake Yoke middle driven shaft Nut M14 1 Stake Bearing housing middle drive shaft Bolt M8 4 25 2 5 Shift lever stopper Bolt M8 1 22 2 2 Use lock washer Guide bar stopper Screw M6 2 7 0 7...

Page 35: ...al spring No Oil capacity 0 525 L Oil level 123 mm Oil grade Fork oil 10W or equivalent Rear suspension Shock absorber travel 60 mm Spring free length 175 mm Fitting length 162 mm Spring rate K1 120 N mm 12 23 kg mm Stroke K1 0 60 mm Optional spring No Swingarm Free play limit End 0 mm Front wheel Type Cast wheel Rim size 17 MT3 50 Rim material Aluminium Rim runout limit radial 1 0 mm lateral 0 5 ...

Page 36: ...er cylinder inside diameter 30 2 mm Caliper cylinder inside diameter 27 mm Brake fluid type DOT 4 Rear brake Type Single disc Disc outside diameter thickeness 267 5 mm 4 5 mm Disc deflection limit 0 15 mm Pad thickness inner 5 5 mm 0 5 mm outer 5 5 mm 0 5 mm Master cylinder inside diameter 13 mm Caliper cylinder inside dimeter 42 85 mm Brake fluid type DOT 4 Brake pedal position 43 mm Clutch lever...

Page 37: ...stening screw M6 7 0 7 Front wheel Front brake caliper right and left M10 42 4 2 Front brake disc right and left M8 25 2 5 Front wheel axle M18 75 7 5 Front wheel axle pinch bolt M8 25 2 5 Rear wheel Rear brake disc M8 25 2 5 Rear brake caliper M10 35 3 5 Rear wheel axle nut M16 110 11 0 Rear wheel axle pinch bolt M8 22 2 2 Dust cover fastening screw M5 4 5 0 45 Swingarm assembly Pivot shaft M16 9...

Page 38: ... Rear footrest bracket fastening screw M8 23 2 3 Rear lights Rear fender Panel assembly Side panel fastening screw M6 7 0 7 Battery receptacle fastening screws M6 7 0 7 Battery receptacle cover fastening screws M6 7 0 7 Plastic rear fender fastening screws M6 7 0 7 Plastic license bracket fastening screws M6 7 0 7 Rear fender cover fastening screw aluminium M8 23 2 3 Seat lock fastening screw M6 7...

Page 39: ...BISHI Nominal output 14V 350W at 5 000 r min Stator coil resistance color 0 36 0 44 Ω at 20 C White White Voltage regulator Type Semi conductor short circuit type Model manufacturer SH650D 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier Model manufacturer SH650D 11 SHINDENGEN Capacity 18 A Withstand voltage 200 V Battery Specific gravity 1 320 Electric starter system Type Constant me...

Page 40: ...PONDENSO Self cancelling device No Flasher frequency 75 95 cycle min Wattage 10 W 2 3 4 W Oil level gauge Model manufacturer 5EL DENSO Starting circuit cut off relay Model manufacturer G8R 30Y B OMRON Fuel pump relay Model manufacturer G8R 30Y B OMRON Circuit breaker Type Fuse Amperage for individual circuit Main 30 A 1 Back up 5 A 1 Ignition 10 A 1 Headlight 15 A 1 Carburetor heater 15 A 1 Signal...

Page 41: ...cifications N m m kg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 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 METRIC MULTIPLIER IMP mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMP Known Multip...

Page 42: ... 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 43: ...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 shaft spline Drive ...

Page 44: ...SPEC LUBRICATION DIAGRAMS 2 23 EB205000 LUBRICATION DIAGRAMS 1 Rocker arm shaft intake 2 Rocker arm shaft exhaust 3 Oil filter 4 Oil pump 5 Drive axle 6 Middle drive shaft ...

Page 45: ...SPEC LUBRICATION DIAGRAMS 2 24 1 Oil pump 2 Releaf valve 3 Oil filter 4 Middle drive shaft ...

Page 46: ...SPEC LUBRICATION DIAGRAMS 2 25 1 Camshaft 2 Crankshaft 3 Main axle 4 Middle drive shaft 5 Drive axle 6 Connecting rod big end ...

Page 47: ...p fuel drain pipe 0 Filler tank cap fuel drain pipe q Fuel hose carburetor 3 way w Handlebar switch leads left e Rectifier regulator r Spark plug cap front cilinder t Throttle cables y Wireharness u Clutch cable i Front brake cable left å Fix the wires of the left swicth assy to the handlebar by means of no 2 plastic clamps Fix the headlight leads to the clamp 3 4 9 0 5 8 6 i u r 7 1 2 t q e y w å...

Page 48: ... wiring connections s Horn d Front brake hose right f A I S pipe to the front cylinder g Starter motor h Starter motor lead j Oil level gauge k Rear brake hose l Brake fluid reservoir hose Ignition coil rear cylinder z Starter relay assy x Depression fuel cock ç x l z c o p a s ç m v n b d f g h j k ...

Page 49: ...m n Throttle position sensor TPS m Ignition coil front cylinder Handlebar switch leads right Throttle cables ç Check that the wires of the igni tion coil do not remain tensioned Fix the wires of the right switch assy to the handlebar by means of no 1 plastic clamp ç x l z c o p a s ç m v n b d f g h j k ...

Page 50: ...sion fuel cock Battery Fuel hose Spark plug lead rear Battery positive terminal Fuse box Battery negative terminal Igniter unit Q Fuel filter W Fuel pump E Fuel sender R Air intake pipe A I S system T Anti theft alarm connectors Position the spark plug wire of the rear cylinder below the fuel hose R E W Q T ...

Page 51: ...SPEC ...

Page 52: ...3 INSP ADJ http manuals magnamaniac com ...

Page 53: ...EANING THE AIR FILTER ELEMENT 3 18 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 19 CHECKING THE BREATHER HOSE 3 20 CHECKING THE EXHAUST SYSTEM 3 20 CHASSIS 3 21 ADJUSTING THE FRONT BRAKE 3 21 ADJUSTING THE REAR BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL 3 23 CHECKING THE BRAKE HOSES 3 24 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 24 ADJUSTING THE SHIFT PEDAL 3 26 CHECKING THE FINAL DRIVE OIL LEVE...

Page 54: ...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 46 ...

Page 55: ... valve clearance Adjust 5 Air filter element Clean Replace 6 Clutch Check operation Adjust Check operation fluid level and vehicle 7 Front brake for fluid leakeage See NOTE Replace brake pads Whenever worm to the limit Check operation fluid level and vehicle for fluid 8 Rear brake leakage See NOTE Replace brake pads Whenever worm to the limit 9 Brake hoses Check for cracks or damage Replace See NO...

Page 56: ...ut valve and reed valve for 26 Air induction damage system Replace the entire air induction system if necessary 27 Lights signals Check operation and switches Adjust headlight beam Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NOTE The annual checks must be performed every year except if a kilometer based maintenance is...

Page 57: ...me Part name Q ty Remarks Seat side covers and fuel tank Remove the parts in the order below removal 1 Seat 1 2 Side cover 2 3 Panel 2 4 Fuel overflow pipe 2 5 Fuel hose 1 6 Fuel hose 1 7 Fuel meter sender unit couper 1 8 Fuel tank assembly 1 For installation reverse the removal procedure ...

Page 58: ...ld 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 seat fuel tank Refer to SEAT SIDE COVERS AND FUEL TANK 2 Disconnect spark plug caps 3 Remove spark plugs 4 Remove air intake box 1 6 Remove tappet covers 1 5 Remove cylinder head cover rear cylinder 1 cylinder head cover front cylinder ...

Page 59: ...0 17 mm a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align either the camshaft sprock et plate hole a with the stationary pointer b on the cylinder head When the camshaft sprocket plate hole or camshaft sprocket punch mark is aligned with the stationary pointer the piston is at top dead center TDC c Align the TDC mark c on the generator rotor with t...

Page 60: ...Hold the adjusting screw to prevent it from moving and tighten the locknut to specification Direction a Valve clearance is decreased Direction b Valve clearance is increased e Measure the valve clearance again f If the valve clearance is still out of specification repeat all of the valve clearance adjustment steps until the specified clearance is obtained 11 Install all removed parts NOTE Install ...

Page 61: ... fuel tank Refer to SEAT SIDE COVERS AND FUEL TANK NOTE Do not disconnect the fuel hoses 5 Remove carburator side covers 4 6 Remove A I S hose 1 Connect vacuum hose 3 to the A I S sys tem hose connection on front cylinder n 2 Start the engine and fold up the fuel cock vacuum hose 2 on rear cylinder n 1 Fix the fuel cock vacuum hose by means of a plastic clamp to keep the fuel cock open 7 Remove fu...

Page 62: ...s than a second and check the syn chronization again NOTE The difference between the two carburetors should not exceed 1 33 kPa 10 mmHg 11 Check engine idling speed Out of specification Adjust 12 Stop the engine and remove the measuring equipment 13 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY 14 Install fuel cock vacuum hose A I S hose carburator covers fuel tan...

Page 63: ...e spark plug lead 2 of cyl 1 4 Check engine idling speed Out of specification Adjust 5 Adjust engine idling speed a Turn the pilot screw 1 in until it is lightly seat ed b Turn the pilot screw out the specified number of turns c Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained Engine tachometer 90890 03113 Engine idling speed 950 1 050 r min Pi...

Page 64: ... 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 c Tighten the locknuts NOTE If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a ...

Page 65: ... Tighten the locknut WARNING After adjusting the throttle cable free play turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change 5 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color 6 Clean spark plug with a spark plug cleaner or wire brush 7...

Page 66: ...ight 90890 03141 Engine tachometer 90890 03113 3 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the stationary pointer a is within the firing range b on the generator rotor Incorrect firing range Check the ignition system NOTE The ignition timing is not adjustable 4 Install timing plug Engine idling spe...

Page 67: ...utes and then turn it off 3 Disconnect spark plug cap 4 Remove spark plug 1 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 5 Install compression gauge 1 CAUTION 6 Measure compression pressure Above the maximum pressure Inspect the cylinder head valve surfaces and piston crown for carbon de...

Page 68: ...ssion pressure between cylinders should not exceed 100 kPa 1 kg cm2 1 bar Compression pressure with oil applied in the cylinder Reading Diagnosis Higher Piston wear or than without damage Repair oil Piston ring s valves Same as cylinder head gasket without oil 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 Ma...

Page 69: ...es the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERVING II b or higher Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again NOTE ...

Page 70: ...eplaced perform the following procedure WARNING Oil filter element replacement should be made at room temperature a Remove the oil filter element cover plate 1 element cover 2 and oil filter element 3 b Check the O ring 4 and replace it if it is cracked or damaged c Install the new oil filter element and the ele ment cover 6 Check engine oil drain bolt gasket Damage Replace 7 Install gasket engine...

Page 71: ...LUTCH CABLE FREE PLAY 1 Check clutch cable free play a Out of specification Adjust 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 c Tighten the locknut NOTE If the specified clutch cable free play cannot be obtained as described above perform the mech anism adjustment proc...

Page 72: ...y again and adjust it if necessary EASB0007 CLEANING THE AIR FILTER ELEMENT 1 Remove seat fuel tank panels 1 and 2 Refer to SEAT SIDE COVERS AND FUEL TANK 2 Remove fuel tank bolts 3 3 Lift fuel tank do not disconnect the fuel hoses WARNING Make sure that the fuel tank is securely sup ported Do not tilt or pull the fuel tank too much oth erwise the fuel hoses may come loose which could cause fuel l...

Page 73: ...r filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor turning leading to poor engine performance and possible overheating NOTE When installing the air filter element into the air fil ter case cover be sure their sealing surfaces are aligned to prevent any air leak...

Page 74: ...uted correctly CAUTION EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies 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 1 Exhaust pipe nut 4 20 Nm 2 0 m kg Exhaust pipe bracket bolt 5 25 Nm 2 5 m kg Exhaust pipe strap 6 18 Nm 1 8 m kg Muffler and passenger foo...

Page 75: ... on the brake lever holder is firm ly inserted in the hole in the adjusting dial WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem Before the vehicle is operated the air must be removed by bleeding the brake sys tem Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an acciden...

Page 76: ...ied brake pedal position is obtained then tighten the bolt 1 c Loosen the locknut 3 d Turn the adjusting bolt 4 in direction b or c until the correct free play between brake pedal and master cylinder is obtained e Tighten the locknut 1 to specification Brake pedal position below the top of the rider footrest 43 mm Brake pedal and master cylinder free play 2 3 mm at the front end of the brake pedal...

Page 77: ... 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 lock Brake fluid may damage pain...

Page 78: ...RNING Bleed the hydraulic brake system whenever the system was disassembled a brake hose was loosened or removed the brake fluid level is very low brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before ap...

Page 79: ... apply the brake several times f Fully squeeze the brake lever or fully depress the brake pedal and hold it in position g Loosen the bleed screw This will release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bub bles have disa...

Page 80: ...pedal position A a Shift pedal position below the top of the rider footrest 45 mm Direction b Shift pedal is raised Direction c Shift pedal is lowered EAS00144 CHECKING THE FINAL DRIVE OIL LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Remove final drive housing oil filler bolt 1 3 Check final drive oil level...

Page 81: ...housing of its oil 3 Check final drive housing oil drain bolt gasket Damage Replace 4 Install final drive housing oil drain bolt 5 Fill final drive housing to the bottom brim 3 of the filler hole with the specified amount of the recommended final drive oil 6 Install final drive housing oil filler bolt Refer to CHECKING THE FINAL DRIVE OIL LEVEL Recommended final drive oil SAE 80 hypoid gear oil gr...

Page 82: ...om of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head 3 Remove seat 4 Lift fuel tank Refer to SEAT SIDE COVERS AND FUEL TANK 5 Tilt forward cowling 6 Remove meter assy 7 Disconnect main switch coupler 8 Remove upper handle holder 1 handle 2 9 Remove steering crown nut 3 upper bracket 4 loosen bolts 5 10 Adjust steering head a Remove the lock washer ...

Page 83: ...ings Refer to STEERING HEAD AND HANDLEBAR in chapter 6 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure that the lock washer tabs a sit cor rectly in the ring nut slots b...

Page 84: ...NG Securely support the motorcycle so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the motorcycle upright and apply the front brake 4 Check operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Repair Refer to FRONT FORK in chapter 6 16 Install cowling fu...

Page 85: ...port the motorcycle so that there is no danger of it falling over Spring preload Marks are provided on adjusting bolts Never go beyond the maximum or minimum adjustment positions 1 Adjust spring preload CAUTION a Turn the adjusting bolt 1 in direction a or b a b 1 Spring preload is Direction a increased suspension is harder Spring preload Direction b is decreased suspension is softer Adjusting pos...

Page 86: ...ad NOTE Use the special wrench included in the owner s tool kit to make the adjustment CAUTION a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b c With each complete turn of the adjusting nut spring preload changes by 1 5 mm d Tighten the locknut Spring preload Direction a is increased suspension is harder Spring preload Direction b is decreased suspension is softer Preloaded s...

Page 87: ...nger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and 250 5 kg full fuel tank Maximum load 200 kg Cold tire pressure Front tire Rear tire Up to 90 kg load 230 kPa 250 kPa 2 30 kg cm2 2 50 kg cm2 2 30 bar 2 50 bar 90 kg 250 kPa 270 kPa maximum load 2 50 kg c...

Page 88: ...nd tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wheel After extensive tests the tires listed below have been approved by Belgarda S p A for this model Then front and rear tires should always be by the same manufacturer and of...

Page 89: ... with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage warpage Replace WARNING Do not attempt even the smallest repair to the wheel NOTE The wheel should be balanced whenever either the tire or wheel has been changed or replaced Manufacturer...

Page 90: ... 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal mov ing parts of the levers and pedals EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting po...

Page 91: ...lyte 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 caps becaus...

Page 92: ...can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of the battery 20 30 5 Charge battery refer to the a...

Page 93: ...Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery ter minal and that they are not shorted A cor roded battery charger lead clip may gener ate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any...

Page 94: ...5 V Monitor the amperage for 3 5 minutes to check if the standard charging current is reached Adjust the voltage so that current is at standard charg ing level Set the timer according to the charging time suitable for the open circuit voltage Refer to Battery condition checking steps If the current does not exceed standard charging current af ter 5 minutes re place the battery In case that chargin...

Page 95: ...s type of battery charger cannot charge the MF battery A variable volt age charger is recommended NOTE Voltage should be measured 30 min utes after the machine is stopped Measure the battery open circuit volt age 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 cha...

Page 96: ...t battery leads to the battery terminals First connect the positive lead 1 then the negative lead 2 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals CAUTION 10 Install storage compartment seat 1 2 Recommended lubricant Dielectric grease ...

Page 97: ...t the pocket tester selector to Ω 1 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 rat ing c Turn on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 Fuses Amperage Quantity rating Main 30 A 1 Back u...

Page 98: ...n and could possibly cause a fire 4 Install storage compartment seat EAS00182 REPLACING THE HEADLIGHT BULB Headlight 1 Remove cowling screws 1 tilt the cowling forward 2 Remove headlight bulb cover 2 3 Disconnect headlight coupler 3 4 Remove headlight bulb holder 4 5 Remove headlight bulb WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb ...

Page 99: ...er 9 Install headlight bulb cover cowling NOTE Before installing the headlight be sure to hook the headlight and auxiliary light bulb leads into the guide 1 to the left of the headlight as shown CAUTION Auxiliary light 1 Remove cowling screws 1 tilt the cowling forward 3 Install auxiliary light bulb into the bulb holder auxiliary light bulb holder into the headlight cowling NOTE Before installing ...

Page 100: ...T BEAM 3 46 INSP ADJ 1 a b EASB0013 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered ...

Page 101: ...4 ENG http manuals magnamaniac com ...

Page 102: ...CAMSHAFT 4 17 CHECKING THE CAMSHAFTS 4 17 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 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 PISTONS 4 29 CHECKING THE CYLINDERS...

Page 103: ...MOVING THE GENERATOR 4 49 CHECKING THE STARTER CLUTCH 4 50 INSTALLING THE GENERATOR 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 ...

Page 104: ...LE DRIVE SHAFT ASSEMBLY 4 75 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 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 ...

Page 105: ...ENG ...

Page 106: ...name Part name Q ty Remarks Removing the seat storage Remove the parts in the order listed compartment side covers fuel tank Stand the motorcycle on a level surface air filter case assembly carburetor assembly and exhaust system Seat 1 Storage compartment 1 4 Nm 0 4 m kg 7 Nm 0 7 m kg 5 WARNING Securely support the motorcycle so there is no danger of it falling over ...

Page 107: ...y Carburetor assembly 3 A I S system cover 1 4 A I S system 1 5 Muffler assembly 2 6 Exhaust pipes 2 For installation reverse the removal procedure Refer to SEAT SIDE COVERS AND FUEL TANK in Chapter 3 Refer to CARBURETOR in Chapter 5 NOTE First disconnect the negative lead then disconnect the positive lead 4 Nm 0 4 m kg 7 Nm 0 7 m kg 5 ...

Page 108: ...utch cable 1 AC magneto lead pickup lead 1 1 1 1 Disconnect side stand switch lead speed sensor lead neutral switch lead 2 Shift rod 1 Refer to INSTALLING THE ENGINE 3 Clutch adjusting cover 1 4 Clutch cable 1 Disconnect 5 Speed sensor 1 For installation reverse the removal procedure NOTE First remove the shift rod from shift pedal then remove the shift arm from engine ...

Page 109: ...ft the front fork upper bracket 1 Engine ground lead connector 1 Disconnect 2 Main footrest brackets 2 3 Engine stay bolt upper 1 4 Engine stay nut upper 4 5 Engine stay upper 1 6 Engine mount bolt rear lower 1 7 Engine mount bolts rear upper 2 8 Engine assembly 1 Refer to INSTALLING THE ENGINE For installation reverse the removal procedure Install the Ø 12mm washer under the head of bolt 7 CAUTIO...

Page 110: ...TING THE SHIFT PEDAL in Chapter 3 3 Check shift pedal position distance a from the top of the rider footrest to the top of the shift pedal Out of specification Adjust Bolt 1 65 Nm 6 5 m kg Bolt 2 65 Nm 6 5 m kg Nut 3 85 Nm 8 5 m kg Special screw 4 18 Nm 1 8 m kg Bolt 5 110 Nm 11 0 m kg Shift arm bolt 10 Nm 1 0 m kg Shift pedal position below the top of the rider footrest 45 mm 4 5 3 1 2 1 2 A a In...

Page 111: ...NE REMOVAL 1 Tappet cover exhaust O ring 1 1 2 Tappet cover intake O ring 1 1 3 Exhaust pipe joint gasket 1 1 4 Carburetor joint O ring 1 1 5 Oil delivery pipes 2 6 Camshaft sprocket cover O ring 1 1 7 Camshaft sprocket bolt 1 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 20 Nm 2 0 m kg 10 Nm 1 0 m kg 55 Nm 5 5 m kg ...

Page 112: ...NSTALLING THE 9 Camshaft sprocket 1 CYLINDER HEADS 10 Cylinder head 1 11 Dowel pins 2 Refer to INSTALLING THE CYLINDER 12 Cylinder head gasket 1 HEADS For installation reverse the removal procedure 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 20 Nm 2 0 m kg 10 Nm 1 0 m kg 55 Nm 5 5 m kg ...

Page 113: ...Refer to CLUTCH 1 Tappet cover exhaust O ring 1 1 2 Tappet cover intake O ring 1 1 3 Carburetor joint O ring 1 1 4 Camshaft sprocket cover O ring 1 1 Refer to INSTALLING THE CYLINDER 5 Baffle plate O ring 1 1 HEADS 6 Camshaft sprocket bolt 1 CYLINDER HEADS 4 8 ENG FRONT CYLINDER HEAD 10 Nm 1 0 m kg 10 Nm 1 0 m kg 50 Nm 5 0 m kg 35 Nm 3 5 m kg 20 Nm 2 0 m kg 55 Nm 5 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 ...

Page 114: ...m 1 0 m kg Order Job name Part name Q ty Remarks 7 Timing chain tensioner gasket 1 1 8 Camshaft sprocket plate 1 Refer to REMOVING INSTALLING THE 9 Camshaft sprocket 1 CYLINDER HEADS 10 Cylinder head 1 11 Dowel pins 2 Refer to INSTALLING THE CYLINDER 12 Cylinder head gasket 1 HEADS For installation reverse the removal procedure New ...

Page 115: ...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 camshaft sprocket ...

Page 116: ...ead NOTE When removing the front cylinder head repeat the rear cylinder head removal procedures However note the following points 1 Align I mark with the stationary pointer Removal steps Turn the crankshaft clockwise 290 Align 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 When the I mark is aligned with the stationa...

Page 117: ...ead Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head 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 cylinder head using a figure eight sanding pattern...

Page 118: ...r rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner hous ing smoothly If there is rough movement replace the timing chain tensioner EAS00234 INSTALLING THE CYLINDER HEADS Rear cylinder head 1 Install dowel pins gasket NOTE The 5EL mark on the gasket must face up side of the cylinder 2 Install nuts cylinder head M12 1 4 cap nut cylinder head M10 5 bolts cyl...

Page 119: ...g chain guide inward g While pushing the timing chain guide be sure that the timing mark c and the stationary 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 With the screwd...

Page 120: ...en installing the front cylinder head repeat the rear cylinder head installation procedure However note the following points 1 Install camshaft 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 out d Turn the camshaft just enough to remove any slack from the inta...

Page 121: ...efer to CYLINDER HEAD 1 Stopper plate 1 2 Camshaft bushing 1 Refer to REMOVING INSTALLING THE 3 Camshaft dowel pin 1 1 ROCKER ARM AND CAMSHAFT 4 Union bolt gasket 1 1 5 Rocker arm shafts 2 Refer to REMOVING INSTALLING THE 6 Rocker arms 2 ROCKER ARM AND CAMSHAFT 7 Locknuts 2 8 Valve adjusters 2 For installation reverse the removal procedure 27 Nm 2 7 m kg 37 5 Nm 3 75 m kg 20 Nm 2 0 m kg ...

Page 122: ...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 4 Check camshaft oil passage Obstruction Blow out with compressed air Slide hammer bolt M8 90890 01085 Weight 90890 010...

Page 123: ...Replace or check the lubrica tion system 3 Measure rocker arm inside diameter a Out of specification Replace 4 Measure rocker arm shaft outside diameter b Out of specification Replace 5 Calculate rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Above 0 086 mm Replace the defective part s R...

Page 124: ...shaft 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 4 Lubricate rocker arm shafts Recommended lubricant Camshaft Bushing Molybdenum disulfide oil Recommended lubricant Engine oil Stopper plate bolt 2 20 Nm 2 0 m kg ...

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

Page 126: ...prings Cylinder heads Refer to CYLINDER HEADS Rocker arms and camshafts Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotters 4 Refer to REMOVING INSTALLING THE VALVES 2 Valve spring retainers 2 3 Valve springs 2 4 Valve intake 1 Refer to INSTALLING THE VALVES 5 Valve exhaust 1 6 Valve stem seals 2 7 Valve spring seats 2 For installation reverse the removal procedure ...

Page 127: ...fer 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 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valve and va...

Page 128: ... After installing the valve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clear ance NOTE After replacing the valve guide reface the valve seat 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Rep...

Page 129: ...inate 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 a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the val...

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

Page 131: ...valve spring EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr valve stem end with an oil stone 2 Lubricate valve stem oil seal with the recommended lubricant New 3 Install valve lower spring seat oil seal valve spring upper spring seat into the cylinder head New Valve spring free length intake and exhaust 44 6 mm Limit 43 5 mm Comp...

Page 132: ...l valve cotters NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 1 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 CAUTION Valve spring compressor 90890 04019 ...

Page 133: ...s Refer to CYLINDER HEADS 1 Timing chain guide 1 The 5EL mark should face towards the cylinder head 2 Cylinder 1 Refer to INSTALLING THE PISTONS 3 Dowel pins 2 AND CYLINDERS 4 Cylinder gasket 1 5 Piston pin clips 2 6 Piston pin 1 Refer to REMOVING INSTALLING THE 7 Piston 1 CYLINDERS AND PISTONS 8 Piston ring set 1 For installation reverse the removal procedure 10 Nm 1 0 m kg ...

Page 134: ... 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 CAUTION 2 Remove top ring 2nd ring oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EB404405 CHECKING THE C...

Page 135: ...iston rings as a set c Measure piston skirt diameter P with the micrometer b 5 mm from the bottom edge of the piston 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 f If out of specification replace the cylinder and replace the piston and piston rings as a set Standard Wear limit Cylinder 95 00 95 01 mm ...

Page 136: ...ston crown pash the ring into the cylinder 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 NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is excessive replace all three piston rings Piston ring side clearance Top ring 0 04 0 08 mm...

Page 137: ...piston pin to piston clearance Out of specification Replace the piston pin EB404701 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install oil ring expander lower oil ring rail upper oil ring rail 2nd ring top ring NOTE Be sure to install the piston rings so that the man ufacuturer s marks or numbers face up Piston pin outside diameter 2...

Page 138: ...t the clip from falling into the crankcase 3 Install gasket New dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant 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 NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guid...

Page 139: ...assembly Refer to CLUTCH 1 Primary drive gear nut 1 2 Timing drive gear 1 Refer to REMOVING INSTALLING THE 3 Dowel pins 6 TIMING DRIVE GEARS 4 Springs 6 5 Timing chain drive gear shaft 1 6 Timing chain drive gear sprocket 1 1 Timing chain Refer to INSTALLING THE TIMING 7 Primary drive gear 1 DRIVE GEARS 8 Straight key 1 9 Timing chain guide 1 For installation reverse the removal procedure 10 Nm 1 ...

Page 140: ...ng gear removal pro cedure 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 timing chains camshaft sprockets and timing chain guides 1 Check timing chain 1 Damage sitffness Replace the timing...

Page 141: ...E GEARS 1 Install timing chain onto the timing chain drive gear sprocket NOTE 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 NOTE Make sure that the 2 mark on the timing chain drive gear sprocket is installed in the rear cylinder and the 3 mark on the timing chain drive gear sprocket is inst...

Page 142: ...g chain drive gear sprocket and the key posision e as shown 2 Install claw washer lock washer 1 primary drive gear nut 2 NOTE 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 NOTE When installing the rear cylinder timing gear repeat the front cylinder timing gear installation procedure ...

Page 143: ... Remove the parts in the order listed Stand the motorcycle on a level surface Engine oil Refer to ENGINE OIL REPLACEMENT in Chapter 3 1 Oil filter cover plate 1 2 Oil filter cover 1 3 O rings 3 4 Oil filter 1 5 Right crankcase cover 1 WARNING Securely support the motorcycle so there is no danger of it falling over ...

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

Page 145: ...ing plate 1 3 Clutch spring 1 4 Clutch spring seat 1 Refer to INSTALLING THE CLUTCH 5 Clutch pressure plate 1 6 Bearing shart clutch push rod 1 1 7 Friction plates 6 8 Clutch plates 5 9 Wire circlip 1 10 Clutch plate 1 11 Damper 1 Refer to REMOVING INSTALLING THE 12 Clutch damper plate 1 CLUTCH 13 Nut lock washer 1 1 14 Clutch boss 1 70 Nm 7 0 m kg 8 Nm 0 8 m kg ...

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

Page 147: ... plate 4 It is not necessary to remove the wire circlip 5 and disassemble the built in damper unless there is serious 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 specification Replace the friction plates as a se...

Page 148: ...pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause errat ic 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 defec tive 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: ...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 EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing d...

Page 150: ...ghten the clutch boss nut New 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 5 Lubricate friction plates clutch plates with the recommended lubricant 6 Install friction plates clutch plates long clutch push rod short clutch push rod bearing washer 70 Nm 7 0 m kg Clutch holding tool 90890 04086 Recommende...

Page 151: ...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 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern Clutch spring bolt 8 Nm 0 8 m kg ...

Page 152: ...e order listed Engine oil Refer to ENGINE OIL REPLACEMENT in Chapter 3 Left side cover AC magneto lead pickup lead sidestand switch lead Refer to ENGINE REMOVAL Shift pedal Clutch adjusting cover clutch cable 1 Left crankcase cover 1 2 Dowel pins 2 3 Gasket 1 4 Stator coil 1 5 Pickup coil 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg ...

Page 153: ...the parts in the order listed clutch 1 Rotor 1 2 Dowel pins 6 Refer to REMOVING INSTALLING THE 3 Springs 6 GENERATOR 4 Woodruff key 1 5 Shaft 1 6 Starter idler gear 1 7 Circlip 1 8 Starter clutch drive gear 1 Refer to INSTALLING THE 9 Starter clutch assembly 1 GENERATOR For installation reverse the removal procedure 12 Nm 1 2 m kg 175 Nm 17 5 m kg ...

Page 154: ...ompression 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 a is aligned with the station ary pointer the punch mark c on the camshaft sprocket should be aligned with the stationary pointer d on the cylinder head 3 Remove generator rotor nut 1 w...

Page 155: ...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 and starter clutch do not engage the starter clutch is faulty and must be re...

Page 156: ...d 3 Install rotor assembly NOTE 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 woodruff key is properly seated in the key way of the crankshaft 4 Tighten nut rotor 1 N...

Page 157: ... the marks do not align Adjust a Align the T mark a with the stationary point er b on the left crankcase cover b When the T mark is aligned with the station ary pointer the punch mark c on the camshaft sprocket should be aligned with the stationary pointer d on the cylinder head ...

Page 158: ...ed lever Engine oil Refer to ENGINE OIL REPLACEMENT in Chapter 3 Left crankcase cover Refer to GENERATOR AND STARTER Rotor assembly CLUTCH 1 Shift shaft 1 2 Circlip 1 3 Torsion spring stopper lever 1 Refer to INSTALLING THE SHIFT 4 Stopper lever 1 SHAFT 5 Circlip 1 6 Torsion spring shift shaft 1 For installation reverse the removal procedure ...

Page 159: ...CKING 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 NOTE 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: ...ed Rotor assembly Refer to GENERATOR AND STARTER CLUTCH Crankcase cover right Refer to CLUTCH 1 Driven gear cover 1 2 Driven gear oil pump 1 1 Oil pump drive chain 3 Oil pump assembly 1 4 O rings dowel pin 2 1 5 Oil delivery pipe 1 For installation reverse the removal procedure 12 Nm 1 2 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg ...

Page 161: ...l pump body 1 3 Oil pump rotor inner 1 4 Oil pump rotor outer 1 Refer to ASSEMBLING THE OIL PUMP 5 Pin 1 6 Oil pump body 1 7 Oil pump rotor inner 1 8 Oil pump rotor outer 1 Refer to ASSEMBLING THE OIL PUMP 9 Pin 1 0 Dowel pins 2 q Oil pump shaft 1 w Washer 1 e Circlip 1 r Oil strainer 1 For assembly reverse the disassembly procedure 10 Nm 1 0 m kg ...

Page 162: ...nner rotor 2 Outer rotor 3 Oil pump body EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil de livery pipes 1 Check oil delivery pipes 1 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil Inner rotor to outer rotor tip clearance 0 03 0 0...

Page 163: ...4 58 ENG EAS00376 ASSEMBLING THE OIL PUMP 1 Assemble oil pump After tightening the bolts make sure that the oil pump turns smoothly NOTE Align the pin a with the slots b on the inner rotor CAUTION 10 Nm 1 0 m kg ...

Page 164: ...r to CYLINDERS AND PISTONS Clutch assembly Refer to CLUTCH AC magneto and starter clutch Refer to GENERATOR AND STARTER CLUTCH Shift shaft Refer to SHIFT SHAFT Oil pump assembly Refer to OIL PUMP 1 Oil level gauge 1 2 Neutral switch 1 3 Shift shaft stopper plate 1 Refer to ASSEMBLING THE CRANKCASE 4 Crankcase right 1 Refer to DISASSEMBLING ASSEMBLING THE CRANKCASE 5 Dowel pins 3 6 Relief valve 1 F...

Page 165: ...r to REMOVING INSTALLING THE CRANKSHAFT 2 Oil pump drive sprocket 1 3 Bearing 1 4 Nuts connecting rod caps 4 Refer to INSTALLING THE 5 Connecting rod bolts 4 CRANKSHAFT 6 Connecting rods 2 7 Connecting rod caps 2 Refer to REMOVING THE CONNECTING 8 Plain bearings 4 RODS INSTALLING THE CRANKSHAFT For installation reverse the removal procedure 48 Nm 4 8 m kg CRANKSHAFT AND CONNECTING RODS ...

Page 166: ...osen the bolts in decreasing numerical order refer to the numbers in the illustration A Right crankcase B Left crankcase 2 Remove crankcase NOTE 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 crankcase mating surfaces Work slowly and carefully Make sure that the c...

Page 167: ...g 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 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings ...

Page 168: ... the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed Apply molybdenum disulfide grease onto the bolts threads and nut seats Make sure that the Y mark 2 on the connecting rod faces towards the left side of the crankshaft Make sure that the characters 3 on both the connecting rod and connecting rod cap are aligned e Tighten t...

Page 169: ...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 Rear cylinder lower bearing Front cylinder upper and lower bearing Rear cylinder upper bearing Connecting...

Page 170: ...f the bearings with the notches b in the connecting rod cap Install each bearing in its original place 2 Install connecting rods 1 NOTE 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 3 Install connecting rod cap 1 NOTE Be sure that the characters a on the side of the cap and connecting rod are aligned...

Page 171: ... 3 and 4 8 m kg loosen the nut to less than 4 3 m kg and start again 5 Install crankshaft installing tool NOTE Attach the spacer to the bearing inner race CAUTION 6 Install crankshaft 1 NOTE Align the left connecting rod with the rear cylinder sleeve hole ASSEMBLING THE CRANKCASE 1 Apply engine oil onto the main journal bearings sealant onto the crankcase mating surfaces Crankshaft installer pot 1...

Page 172: ...quence 4 6 M10 1 3 7 o M6 NOTE Lubricate the bolt threads with engine oil Tighten the bolts in increasing numerical order o with engine ground lead 3 Install shift shaft stopper plate 1 NOTE Install the shift shaft stopper plate as shown 38 5 Nm 3 85 m kg 10 Nm 1 0 m kg M6 30 mm 1 3 0 r u o M6 30 mm Chromium t y plated bolt M6 55 mm 8 M6 80 mm 7 9 M10 60 mm 5 M10 70 mm 4 M10 100 mm 6 ...

Page 173: ...parts in the order listed Crankcase separation Refer to CRANKSHAFT 1 Guide bar 1 2 Shift fork 1 R 1 3 Shift fork 2 C 1 4 Shift fork 3 L 1 Refer to INSTALLING THE 5 Shift drum 1 TRANSMISSION 6 Main axle assembly 1 7 Drive axle assembly 1 8 Middle driven gear 1 For installation reverse the removal procedure ...

Page 174: ...de bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set 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: ...Out of specification Replace the drive axle 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 6 Check bearings Unsmooth Replace Main axle runout limit 0 08 ...

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

Page 177: ...ECTING ROD 1 Bearing retainer 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH 2 Spring retainers 2 3 Spring seat 1 Refer to DISASSEMBLING 4 Damper spring 1 ASSEMBLING THE MIDDLE DRIVE 5 Damper cams 2 SHAFT ASSEMBLY 6 Nut 1 7 Bearing 1 8 Shim s 1 9 Middle drive pinion shaft 1 For installation reverse the removal procedure 110 Nm 11 ...

Page 178: ...to REMOVING THE MIDDLE 2 Circlips 2 DRIVEN SHAFT ASSEMBLY 3 Bearings 2 INSTALLING THE UNIVERSAL JOINT 4 Driven yoke 1 5 Nut 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH 6 Drive yoke 1 Refer to INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH 7 Bearing housing O ring 1 1 8 Washers 3 9 Collar 1 ...

Page 179: ... 10 Collapsible collar 1 Refer to INSTALLING THE MIDDLE 11 Middle driven shaft 1 GEAR ASSEMBLY AND ADJUSTING THE BACKLASH 12 Oil seal 1 Refer to ASSEMBLING THE MIDDLE 13 Bearing 1 DRIVEN SHAFT ASSEMBLY 14 Bearing For installation reverse the removal procedure ...

Page 180: ... damper spring compressor 2 remove the spring retain ers 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 b Secure the middle drive shaft holder in a vice c Loosen the middle drive shaft nut with the middle drive shaft nut wrench 5 d Remove the middle ...

Page 181: ...ate the universal joint yokes 2 Loosen middle driven shaft nut 1 NOTE While holding the universal joint driven yoke 2 with the universal joint holder 3 loosen the mid dle driven shaft nut EAS00438 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Check damper cam surface Scratches wear Replace the damper cam 2 Check spring Cracks damage Replace EAS00439 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check m...

Page 182: ...t 1 NOTE 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 2 Install spring retainers 1 NOTE While compress the spring with the damper spring compressor 2 and then install the spring retainers Middle drive shaft nut wrench 2 90890 04138 Middle drive shaft holder 3 90890 04055 Damper sprin...

Page 183: ...ave at least one extra col lapsible collar on hand 1 Install bearing outer race into the middle driven shaft bearing hous ing WARNING Do not press the bearing outer race During installation always press the bearing inner race carefully 2 Install middle driven shaft nut NOTE Finger tighten the middle driven shaft mut INSTALLING THE MIDDLE GEAR ASSEMBLY AND ADJUSTING THE BACKLASH NOTE When installin...

Page 184: ... band 2 as shown 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 LOCTITE on it d Reinstall the middle driven pinion gear nut e While measure the middle gear backlash tight en the middle driven pinion gear nut until spe cific backlash Bearing retainer wrench 90890 04...

Page 185: ...the standard spinning torque requiring replacement of the collapsi ble collar and reassembly 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 uni versal joint driven yoke assembly back and forth on the bearings If a needle is out of place the yoke will n...

Page 186: ...ckness 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 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 46 i e 42 00 0 46 42 46 A 43 00 42 46 0 54 ...

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

Page 188: ...5 CARB http manuals magnamaniac com ...

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: ...CARB ...

Page 191: ...er 3 1 Air filter case assembly 1 2 Air ducts 2 3 Cylinder head breather hose 1 Disconnect 4 Cover 1 5 Throttle position sensor lead 1 Disconnect 6 Carburetor heater lead 1 Disconnect 7 Fuel hoses 2 Disconnect 8 Carburetor assembly 1 9 Starter cable 1 10 Throttle cables 2 For installation reverse the removal procedure NOTE After removing the carburetor assembly remove the starter cable and throttl...

Page 192: ... Disassemble the parts in the order listed 1 Carburetor heater leads 2 2 Carburetor heaters 2 12V 30W 3 Float chamber gasket 1 4 Float 1 5 Needle valve set 1 6 Main jet 1 7 Jet holder 1 8 Pilot jet 1 9 Starter jet 1 Refer to CARBURETOR ASSEMBLY 0 Jet needle set 1 q Starter plunger set 1 ...

Page 193: ...Refer to ASSEMBLING THE CARBURETORS e Throttle position sensor 1 Refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR TPS r Pilot screw 1 t Main air jet 1 y Pilot air jet 1 1 u Pilot air jet 2 1 i Throttle stop screw set 1 For assembly reverse the disassembly procedure ...

Page 194: ...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 195: ...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 196: ... the coasting enricher position the throttle connecting arm 1 as shown 2 Install connecting bolts NOTE 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 CAUTION Refer to ADJUSTING ...

Page 197: ...ext to the upper face of the float chamber 4 f Measure the fuel level a NOTE Fuel level readings should be equal on both sides of the carburetor assembly 2 Adjust fuel level a Remove the carburetor assembly b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are fine adjust the float level by slight ly bending the float tang 1 e Install the carburetor...

Page 198: ...sition sensor 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 2 Adjust throttle position sensor angle a Loosen the throttle position sensor screws 1 b Turn the throttle position sensor in direction a or b until the specified closed throttle resist ance is indicated on t...

Page 199: ...RBURETOR 5 9 Closed throttle resistance 0 56 0 84 kΩ at 20 C 68 F yellow black c Tighten the throttle position sensor screws NOTE Remove the pocket tester leads and connect the throttle position sensor coupler ...

Page 200: ...ning the unburned exhaust gases is approximately 600 to 700 C AIR CUT OFF VALVE The air cut off valve is operated by intake gas pressure through the diaphragm Normally this valve is opened in order to allow fresh air to flow into the exhaust port When the throttle is rapidly closed negative pres sure is generated and the valve closes in order to prevent after burning VIEW 1 NO FLOW When decelerati...

Page 201: ...he front cylinder head B To the rear cylinder head 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 NOTE The orifice 3 should be installed with the arrow mark facing the AIS valve side ...

Page 202: ...CARB ...

Page 203: ...6 CHAS http manuals magnamaniac com ...

Page 204: ...KE PADS 6 18 FRONT BRAKE MASTER CYLINDER 6 20 REAR BRAKE MASTER CYLINDER 6 22 REMOVING THE FRONT BRAKE MASTER CYLINDER 6 24 REMOVING THE REAR BRAKE MASTER CYLINDER 6 24 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDER 6 25 INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 26 INSTALLING THE REAR BRAKE MASTER CYLINDER 6 28 FRONT BRAKE CALIPERS 6 30 REAR BRAKE CALIPER 6 32 REMOVING THE FRONT BRAKE CALIPE...

Page 205: ...6 65 CHECKING THE REAR SHGOCK ABSORBER AND GAS CYLINDER 6 66 CHECKING THE SWINGARM 6 66 INSTALLING THE REAR SHOCK ABSORBER 6 67 INSTALLING THE SWINGARM 6 67 SHAFT DRIVE 6 69 TROUBLESHOOTING 6 69 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 6 72 MEASURING THE RING GEAR BACKLASH 6 73 ADJUSTING THE RING GEAR BACKLASH 6 74 FINAL DRIVE ASSEMBLY AND DRIVE SHAFT...

Page 206: ... Brake hose holder right left 1 1 2 Brake caliper right left 1 1 Refer to REMOVING INSTALLING THE 3 Front wheel axle pinch bolt 1 FRONT WHEEL 4 Front wheel axle 1 5 Front wheel assembly 1 6 Collars 2 Refer to INSTALLING THE FRONT 7 Brake disc right left 1 1 WHEEL Securely support the motorcycle so there is no danger of it falling over WARNING For installation reverse the removal procedure ...

Page 207: ... BRAKE DISCS 6 2 CHAS Order Job name Part name Q ty Remarks Disassembling the front wheel Disassemble the parts in the order listed 1 Oil seals 2 2 Bearings 2 3 Collar 1 For assembly reverse the disassembly procedure ...

Page 208: ...and right NOTE Do not squeeze the brake lever when removing the brake calipers 3 Loosen pinch bolt front wheel axle 1 4 Remove front wheel axle 2 5 Remove front wheel EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage wear Replace Refer to CHECKING THE TIRES ...

Page 209: ...al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing center race 5 or balls 6 Contact should be made only with the outer race 7 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal CAUTION EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs ...

Page 210: ... disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc NOTE Tighten the brake disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjust...

Page 211: ...tern 3 Install front wheel assembly 4 Tighten wheel axle 2 wheel axle pinch bolt 1 Before tightening the wheel axle pinch bolt push down hard on the handlebar several times and check if the front fork rebounds smoothly CAUTION Recommended lubricant Lithium soap base grease Wheel axle 75 Nm 7 5 m kg Wheel axle pinch bolt 25 Nm 2 5 m kg 5 Install brake calipers right left WARNING Make sure that the ...

Page 212: ... Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps b through d several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front...

Page 213: ... heavy spot does not stay in that position install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check 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: ...level surface 1 Brake caliper tension bar front bolt 1 Loosen 2 Brake caliper bolt 2 3 Brake caliper tension bar rear bolt 1 4 Rear brake caliper 1 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle 1 7 Collars 2 8 Rear wheel assembly 1 Refer to REMOVING INSTALLING THE REAR WHEEL For installation reverse the removal procedure WARNING Securely support the motorcycle so there is no danger of it...

Page 215: ...ame Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Brake disc 1 2 Oil seal 1 3 Bearing 1 4 Spacer 1 5 Plate cover 1 6 Hub clutch 1 7 Bearings 2 8 Damper 6 9 Bearing 1 0 Collar 1 For assembly reverse the disassembly procedure ...

Page 216: ...cycle on a suitable stand so that the rear wheel is elevated 2 Loosen brake caliper tension bar front bolt 1 3 Remove brake caliper bolts 2 brake caliper tension bar rear bolt 3 rear brake caliper 4 4 Lift brake caliper tension bar NOTE Do not depress the brake pedal when removing the brake caliper 5 Loosen rear wheel axle pinch bolt 5 6 Remove rear wheel axle 6 7 Remove collar spacer rear wheel a...

Page 217: ...DISCS 2 Check tire Damage wear Replace Refer to CHECKING THE WHEELS in Chapter 3 3 Measure rear wheel radial runout rear wheel lateral runout Refer to FRONT WHEEL AND BRAKE DISCS EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check rear wheel drive hub Cracks damage Replace rear wheel drive hub dampers Damage wear Replace EASB0019 INSTALLING THE REAR WHEEL 1 Lubricate drive shaft splines wheel axle ...

Page 218: ...rque f Push down the brake caliper tension bar g Tighten the bolts 3 of rear brake caliper ten sion bar with specified torque EAS00575 ADJUSTING THE REAR WHEEL STATIC BAL ANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance Refe...

Page 219: ...name Part name Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake hose retainer 1 2 Brake caliper 1 3 Pad pin clip 2 4 Pad pin 1 Refer to REPLACING THE FRONT 5 Pad spring 1 BRAKE PADS 6 Brake pads 2 For installation reverse the removal procedure ...

Page 220: ... Part name Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Caliper 1 2 Cover 1 3 Pad pin clip 2 Refer to REPLACING THE REAR 4 Pad pin 2 BRAKE PADS 5 Pad spring 1 6 Brake pads shim 2 2 For installation reverse the removal procedure ...

Page 221: ...luid 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 immediate medical attention CAUTION EASB0020 REPLACING THE FRONT BRAKE PADS The follo...

Page 222: ...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 d Install new brake pad shims onto the new brake pads e Install new brake pads and a new brake pad spring 6 Install brake pad spring pad pin 1 pad pin clips 2 brake caliper NOTE...

Page 223: ...pad wear limit a Out of specification Replace the brake pads as a set 5 Install brake pad shims onto the brake pads brake pads brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set Brake pad wear limit 0 5 mm 1 3 2 7 Check brake fluid level Below the minimum lever mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FL...

Page 224: ...ation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in Chapter 3 35 Nm 3 5 m kg 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 d Install new brake pad shims 3 on...

Page 225: ...the order listed cylinder Drain the brake fluid 1 Brake lever 1 2 Front brake switch lead 2 3 Front brake switch 1 4 Union bolt 1 5 Copper washers brake hose 2 1 6 Master cylinder bracket 1 7 Master cylinder 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE MASTER CYLINDER 10 Nm 1 0 m kg 28 Nm 2 8 m kg New ...

Page 226: ... Order Job name Part name Q ty Remarks Disassembling the front brake Remove the parts in the order listed master cylinder 1 Dust boot 1 2 Circlip 1 3 Master cylinder cup 1 4 Spring 1 For assembly reverse the disassembly procedure New ...

Page 227: ...cylinder Side cover right Drain the brake fluid 1 Rear brake master cylinder bolts 2 2 Rear brake master cylinder cover 1 3 Union bolt brake switch 1 4 Copper washers brake hose 2 1 5 Clamps brake hose 2 1 6 Clip 1 7 Rear brake master cylinder 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE REAR BRAKE MASTER CYLINDER 24 Nm 2 4 m kg ...

Page 228: ... Job name Part name Q ty Remarks Disassembling the rear brake master Disassembly the parts in the order listed cylinder 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder cup 1 4 Spring 1 For assembly reverse the disassembly procedure ...

Page 229: ... 4 NOTE To collect any remaining brake fluid place a con tainer under the master cylinder and the end of the brake hose EASB0022 REMOVING THE REAR BRAKE MASTER CYLINDER Before removing the rear brake master cylinder drain the brake fluid from the entire brake system 1 Remove side cover right master cylinder cover 1 union bolt brake switch 2 copper washers 3 brake hose 4 NOTE To collect any remaini...

Page 230: ... fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace C Front D Rear 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check front brake fluid reservoir diaphragm 2 Cracks damage Replace 5 Check brake hoses C...

Page 231: ...cle operation Refer to CABLE ROUTING When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the projection a of the master cylin der NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts e g wire harness cables leads Correct if necessa...

Page 232: ...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 significantly lower the boiling point of the brake fluid and could cause vapor lock...

Page 233: ...rvoir to the maximum level mark a 24 Nm 2 4 m kg WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water...

Page 234: ...Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in Chapter 3 CAUTION 4 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in Chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in Chapter 3 A a Brake pedal position below the top of the rider footrest 43 mm ...

Page 235: ...rks Removing the front brake calipers Remove the parts in the order listed Drain the brake fluid 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Brake caliper assembly 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE CALIPERS 28 Nm 2 8 m kg ...

Page 236: ... parts in the order listed calipers 1 Pad pin clips 2 2 Pad pin 1 3 Pad spring 1 4 Brake pads 2 5 Bleed screw 1 6 Brake caliper pistons 4 7 Dust seals 4 8 Caliper piston seals 4 For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE FRONT BRAKE CALIPER Refer to REPLACING THE FRONT BRAKE PADS ...

Page 237: ... ty Remarks Removing the rear brake calipers Remove the parts in the order listed Drain the brake fluid 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Brake caliper assembly 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE REAR BRAKE CALIPERS ...

Page 238: ...assembly the parts in the order listed 1 Cover 1 2 Pin clips 2 3 Pad pins 2 4 Pad spring 1 5 Brake pads shim 2 2 6 Bleed screw 2 7 Caliper pistons 2 8 Dust seals 2 9 Piston seals 2 For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE REAR BRAKE CALIPER Refer to REPLACING THE REAR BRAKE PADS ...

Page 239: ... brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint b opening to force out the pistons from the brake caliper c Remove the brake caliper piston seals d Repeat the previous steps to force out the right side ...

Page 240: ...t the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper pistons seals 2 a Secure the right side brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side piston from the brake caliper WARNING Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove the brake caliper piston seals d Re...

Page 241: ... caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals A Front B Rear EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replace ment schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disa...

Page 242: ...caliper is disassembled replace the brake caliper piston seals 1 Install brake caliper 1 temporarily copper washers New 2 brake hose 3 union bolt 4 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper make sure that the brake pipe touch es the projection a on the brake caliper 2 Remove brake ...

Page 243: ...ed brake fluid WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the reservoir Wate...

Page 244: ...e caliper piston seals 1 Install brake caliper 1 temporarily copper washers New 2 brake hose 3 union bolt 4 WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper make sure that the brake pipe touch es the projection on the caliper 2 Remove brake caliper 3 Install brake pads shims pad spring pa...

Page 245: ...ul that water does not enter 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 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in Chapter 3 6 Check brake fluid level Below the minimum level mark a Add the...

Page 246: ...he order listed Front wheel Brake caliper assembly Cowling Lift forward 1 Bracket 2 2 Front fender 1 3 Upper bracket bolts 2 4 Cap bolts 2 5 Lower bracket bolts 4 6 Front fork legs 1 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS Refer to FRONT WHEEL AND BRAKE DISCS ...

Page 247: ...ts in the order listed 1 Cap bolt 2 2 O ring 2 3 Washer 2 4 Spacer 2 5 Spring seat 2 6 Fork spring 2 7 Piston ring 2 8 Rebound spring 2 9 Damper rod 2 0 Oil lock piece 2 q Inner tube 2 w Inner tube bushing 2 e Dust seal 2 r Oil seal clip 2 Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 30 Nm 3 0 m kg ...

Page 248: ...e Q ty Remarks t Oil seal 2 y Oil seal washer 2 u Outer tube bushing 2 i Damper rod bolt 2 o Gasket 2 p Outer tube 2 a Protector 2 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 30 Nm 3 0 m kg ...

Page 249: ... a suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 WARNING Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Loosen the spring preload adjusting bolt com ple...

Page 250: ...ont fork leg horizontally b Lock firmly the brake caliper fastener in a vice with protected jaws c Slowly push the inner tube into the outer tube and just before it bottoms out pull the inner tube back quickly Excessive force will damage the oil seal and bushing A damaged oil seal or bushing must be replaced Avoid bottoming the inner tube into the outer tube during the above procedure as the oil f...

Page 251: ...pecified limit Replace 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil lock piece 2 Damage Replace The front fork leg has a built in damper adjusting rod and a very sophisticated inter nal construction which are particularly sen sitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign mat...

Page 252: ...efore assembling the front fork leg make sure that all of the components are clean 1 Install damper rod 1 Allow the damper rod to slide slowly down the inner tube 2 until it protrudes from the bot tom of the inner tube Be careful not to dam age the inner tube 2 Lubricate inner tube s outer surface CAUTION 3 Tighten damper rod bolt 1 NOTE While holding the damper rod with the T handle 3 and damper ...

Page 253: ...f the oil seal faces up NOTE Before installing the oil seal apply lithium soap base grease onto its lips Lubricate the inner tube s outer surface 5 Install oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube groove CAUTION 6 Install dust seal 1 with the fork seal driver weight 2 Fork seal driver weight 90890 01367 Adapter 90890 01374 ...

Page 254: ...ter 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 10 Measure front fork leg oil level a Out of specification Correct CAUTION NOTE Hold the fork in an upright position 11 Install fork spring spring seat 1 spacer 2 washer 3 cap bolt 4 Quantity each front fork leg 0 525 L Recommended oil Yamaha fork and shock o...

Page 255: ...k leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure that the inner fork tube is flush with the top of the upper bracket 2 Tighten lower bracket pinch bolt 3 cap bolt 2 upper bracket pinch bolt 1 WARNING Make sure that the brake hoses are routed properly 3 Set spring preload adjusting bolt left and right Refer to ADJUSTING THE FRONT FORK LEGS in Chapter 3 1 2 3 Lower br...

Page 256: ... cable 1 3 Handlebar switch left 1 4 Grip left 1 5 Clutch lever assembly rear view mirror 1 1 6 Master cylinder bracket 1 7 Master cylinder assembly rear 1 1 view mirror 8 Handlebar switch right 1 9 Throttle cables 2 Refer to INSTALLING THE HANDLEBAR Refer to INSTALLING THE HANDLEBAR Refer to REMOVING THE HANDLEBAR WARNING Securely support the motorcycle so that there is no danger of it falling ov...

Page 257: ... Order Job name Part name Q ty Remarks 10 Throttle grip assembly 1 11 Handlebar holders upper 2 12 Handlebar 1 13 Handlebar holders lower 2 For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR ...

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

Page 259: ...E HANDLEBAR 1 Stand the motorcycle on a level surface WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 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 adjust the handlebar position NO...

Page 260: ...ake lever holder with the punch mark a in the handlebar 5 Install master cylinder holder 2 NOTE Install the master cylinder holder 2 with the mark UP facing up 6 Install clutch lever holder 1 NOTE Align the slit in the clutch lever a holder with the punch mark in the handlebar 7 Install left handlebar switch 2 NOTE Aligh the matching surface on the handlebar switches with the punch mark a on the h...

Page 261: ... 3 11 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in Chapter 3 Clutch cable free play at the end of the clutch lever 5 10 mm Throttle cable free play at the flange of the throttle grip 3 5 mm NOTE Apply a thin coat of lithium soap base grease onto the end of the clutch cable ...

Page 262: ...NT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK Handlebar Refer to HANDLEBAR 1 Crown nut washer plate 1 1 2 Upper bracket 1 3 Special washer 1 4 Upper ring nut 1 5 Rubber seal 1 6 Lower ring nut 1 7 Lower bracket 1 8 Rubber washer 1 9 Bearing cover 1 10 Bearing 1 Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD Refer to INSTALLING THE STEERING HEAD ...

Page 263: ...STEERING HEAD 6 58 CHAS Order Job name Part name Q ty Remarks 11 Bearing 1 12 Dust seal 1 13 Lower handlebar holder 2 For installation reverse the removal procedure ...

Page 264: ...lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench WARNING Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearings bearing races 2 Check bearings 1 Damage pitting Replace 3 Replace bearings bearing races Exhaust and steering nut wrench 90890 01268 Ring nut wrench 908...

Page 265: ...s disassembled replace the rubber seal CAUTION 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 2 Install lower ring nut 1 rubber washer 2 upper ring nut 3 lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in Chapter 3 3 Install upper bracket steerin...

Page 266: ...rm Stand the motorcycle on a level surface Place a suitable stand under the engine Seat Side covers Refer to SEAT SIDE COVERS AND FUEL TANK in Chapter 3 Muffler assembly exhaust system Refer to REMOVING THE ENGINE Rear wheel Refer to REAR WHEEL AND BRAKE DISC Rear brake caliper Refer to REAR BRAKE CALIPER WARNING Securely support the motorcycle so that there is no danger of it falling over ...

Page 267: ...TER CYLINDER Rear brake pedal Main footrest right and left Main footrest cover right Passenger footrest holder right and left 1 Brake caliper tension bar 1 2 Rear shock absorber lower bolt 1 3 Rear shock absorber upper bolt 1 4 Rear shock absorber 1 5 Connecting arms 2 6 Relay arm 1 7 Speed sensor 1 8 Pivot shaft 1 9 Swingarm 1 For installation reverse the removal procedure ...

Page 268: ...r shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR SHO...

Page 269: ...otorcycle so that there is no danger of it falling over NOTE Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear shock absorber assembly upper bolt rear shock absorber assembly lower bolt NOTE While removing the rear shock absorber assem bly upper bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber ...

Page 270: ...k swingarm side play swingarm vertical movement a Check the tightening torque of the swingarm pivot bolts b Check the swingarm side play by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers and bearings d Check the swingarm vertical movement by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is bindi...

Page 271: ...AS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly gas cylinder Damage gas leaks Replace bushings Damage wear Replace dust seals Damage wear Replace bolts Be...

Page 272: ...ALLING THE SWINGARM 2 Lubricate spacers bearings 3 Install rear shock absorber assembly NOTE When installing the rear shock absorber assem bly lift up the swingarm Recommended lubricant Molybdenum disulfide grease Rear shock absorber assembly Upper nut 42 Nm 4 2 m kg Lower nut 50 Nm 5 0 m kg Relay arm to frame nut 50 Nm 5 0 m kg ...

Page 273: ...ng arm right connecting arm 3 Install rear shock absorber Reter to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 Install rear wheel Refer to REAR WHEEL AND BRAKE DISC Recommended lubricant Molybdenum disulfide grease Rear shock absorber assembly Lower nut 1 50 Nm 5 0 m kg Connecting arm nuts 2 50 Nm 5 0 m kg Relay arm to frame nut 3 50 Nm 5 0 m kg ...

Page 274: ... movement during acceleration deceleration or sustained speeds not to be confused with engine surging or transmission related movements 2 A rolling rumble noticeable at low speeds a high pitched whine or a clunk from a shaft drive component or vicinity of the shaft drive 3 The shaft drive is locked up or no power is transmitted from the engine to the rear wheel B Possible causes A Bearing damage B...

Page 275: ...eceleration Diagnosis Possible incorrect reassembly or too little gear lash WARNING Insufficient gear lash is extremely destructive 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 operation not to be confused with normal motorcycle operation Diagnosis Possible broken gear teeth WARN...

Page 276: ...ged Replace the wheel bearing Refer to FRONT WHEEL AND BRAKE DISC Place the motorcycle on a suitable stand so that the rear wheel is elevated and then spin the rear wheel Is the wheel bearing dam aged 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 Rear wheel bearings and shaft drive...

Page 277: ...mal 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 locate a leak Oil leak Repair or replace the faulty part s 1 Oil seal 2 O ring 3 Forward NOTE What may appear to be an oil leak on a new or fairly new motorcycle may resul...

Page 278: ...of the specified size into the final drive oil filler hole b Finger tighten the bolt until it stops the ring gear from moving NOTE Do not overtighten the bolt c Install the final gear backlash band 2 and dial gauge 3 a Dial gauge plunger contact point 54 5 mm d Gently rotate the gear coupling from engage ment to engagement e Record the reading on the dial gauge f Remove the dial gauge special tool...

Page 279: ...R BACKLASH 1 Remove ring gear bearing housing nuts ring gear bearing housing bolts NOTE Working in a crisscross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos ened remove them and the bolts 2 Remove ring gear bearing housing 1 ring gear 2 ring gear shim s 3 thrust washer 4 3 Adjust ring gear backlash a Use the following chart to select the suitable shim s and thrust was...

Page 280: ...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 thickness Rig gear shims Thickness mm 0 25 0 30 0 40 0 50 Thrust washers Thickness mm 1 2 1 4 1 6 1 8 2 0 ...

Page 281: ...ycle on a level surface Rear wheel assembly Refer to REAR WHEEL AND BRAKE DISC 1 Collar 1 2 Drive shaft assembly 1 3 Final drive pinion gear assembly 1 Refer to DISASSEMBLING THE FINAL DRIVE ASSEMBLY ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR 4 Final gear assembly 1 For installation reverse the removal procedure WARNING Securely support the motorcycle so there is no danger of it falling ov...

Page 282: ...s in the order listed 1 Bolts bearing housing 2 2 Nuts bearing housing 6 3 Bearing housing O ring 1 1 4 Ring gear 1 5 Shim s 1 6 Thrust washer 1 For assembly reverse the disassembly procedure NOTE 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 ...

Page 283: ...nd nuts are fully loosened and remove them 2 Remove ring gear bearing housing 1 ring gear 2 ring gear shim s 3 thrust washer 4 3 Remove self locking nut coupling gear gear coupling with the special tool 1 4 Remove bearing retainer 2 with the special tool 3 The bearing retainer has left hand threads To loosen the bearing retainer turn it clockwise CAUTION Coupling gear middle shaft tool 90890 01229...

Page 284: ...NG AND INSTALLING THE RING GEAR BEARINGS 1 Remove collar 1 oil seal 2 bearing 3 with an appropriate press tool 4 and an appropriate support for the final drive hous ing 2 Check bearing Damage Replace 3 Remove bearing 1 a Heat the final gear case to approximately 150 C 302 F b Remove the bearing outer races with an appropriately shaped punch 2 c Remove the inner race from the final drive pin ion ge...

Page 285: ...FINAL DRIVE PINION GEAR AND RING GEAR NOTE Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced final drive housing any bearing 1 Select final drive pinion gear shim s 1 ring gear shim s 2 a Position the final drive pinion gear and the ring gear with shims 1 and 2 Calculate the respective thicknesses from information marked on the final drive...

Page 286: ...le in 0 10 mm increments round off to the hundredths digit In the example above the calculated final drive pinion gear shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Where c a numeral on the final drive housing d a numeral usually on the outside of th...

Page 287: ...gear shims are only available in 0 10 mm increments round off the hundredths digit 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 gear shim 2 Install shim s as calculated final drive pinion gear bearing retainer with the bearing retainer wrench The bearing retainer has left hand threads To ...

Page 288: ...rust washer clearance a Remove the ring gear bearing housing along with the ring gear b Place four pieces of Plastigauge between the original thrust washer and the ring gear c Install the ring gear bearing housing and tight en the bolts and nuts to specification NOTE Do not turn the final drive pinion gear and ring gear while measuring the ring gear to thrust washer clearance with Plastigauge Coup...

Page 289: ...arance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the fol lowing chart i Repeat the measurement steps until the ring gear to thrust washer clearance is within the specified limits EAS00727 CHECKING THE DRIVE SHAFT 1 Check drive shaft splines Damage wear Replace the drive shaft Ring gear to thrust washer clearance 0 1 0 2 mm Thrust w...

Page 290: ...lant onto both final drive housing mating sur faces 3 Install drive shaft to the final drive pinion gear 4 Tighten final bearing housing nuts 5 Install rear wheel assembly Refer to REAR WHEEL AND BRAKE DISC Recommended lubricant Molybdenum disulfide grease Yamaha bond No 1215 90890 85505 50 Nm 5 0 m kg ...

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Page 292: ...7 ELEC http manuals magnamaniac com ...

Page 293: ...LESHOOTING 7 10 ELECTRIC STARTING SYSTEM 7 14 CIRCUIT DIAGRAM 7 14 STARTING CIRCUIT OPERATION 7 15 TROUBLESHOOTING 7 16 STARTER MOTOR 7 20 CHARGING SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 TROUBLESHOOTING 7 26 LIGHTING SYSTEM 7 28 CIRCUIT DIAGRAM 7 28 TROUBLESHOOTING 7 29 CHECKING THE LIGHTING SYSTEM 7 30 SIGNALING SYSTEM 7 33 CIRCUIT DIAGRAM 7 33 TROUBLESHOOTING 7 35 CHECKING THE SIGNALING SYSTEM 7 36 FU...

Page 294: ...ELEC CARBURETOR HEATER SYSTEM 7 46 CIRCUIT DIAGRAM 7 46 TROUBLESHOOTING 7 47 SELF DIAGNOSIS 7 49 TROUBLESHOOTING 7 51 ...

Page 295: ...ELEC ELECTRICAL COMPONENTS 7 1 ELECTRICAL ELECTRICAL COMPONENTS 1 Ignition coils 2 Igniter unit 3 Speed sensor 4 Sidestand switch 5 Neutral switch 6 Oil level gauge assembly 7 Horn ...

Page 296: ...ELECTRICAL COMPONENTS 7 2 ELEC 8 Main switch 9 Thermo switch 0 Fuel meter senser unit q Battery w Starter relay e Relay assembly r Flasher relay t Diode y Fuse assembly u Rectifier regulator ...

Page 297: ...forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illus tration 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 NOTA The symbol indicates a continuity of elec tricity between switch terminals i ...

Page 298: ...heck 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: ...7 5 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 9 Engine stop switch 0 Start switch q Fuses w Rear brake switch e Sidestand switch r Neutral switch ...

Page 300: ...tra The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their respec tive socket by turning them counterclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushin...

Page 301: ... and the luminous flux will be adversely affect ed If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner CAUTION 2 Check bult for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω x 1 range a Connect the tester positive probe to terminal 1 and the tester negativ...

Page 302: ...er No continuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section howev er note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03...

Page 303: ... Pickup coil 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead 8 Starting circuit cut off relay 0 Igniter unit qw Ignition coil r Sidestand switch t Ignition fuse y Right handlebar switch j Neutral switch lead k Neutral switch Alarm system Option Diode ...

Page 304: ...on checker 90890 06754 Pocket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK Replace the fuse s EAS00738 EASB0030 TROUBLESHOOTING Check 1 Main and ignition fuses 2 Battery 3 Spark plugs 4 Ignition spark gap 5 Spark plug cap resistance 6 Ignition coil resistance 7 Pickup coil ...

Page 305: ...rk plug Connect the pocket tester 1k to the spark plug cap as shown Measure the spark plug cap resistance The ignition system is OK NO YES EAS00745 Spark plug cap resistance 10 k at 20 C 68 F Is the spark plug cap OK Replace the spark plug cap YES NO 6 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil connectors from the ignition coi...

Page 306: ...ue Is the pickup coil OK EAS00748 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EAS00749 YES NO 9 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EAS00750 YES NO 10 Neutral switch Check the neutral switch for...

Page 307: ...m the wire harness Check for continuity as follows Sky blue Blue Yellow 2 Tester lead Sky blue 1 Con Tester lead Blue Yellow 2 tinuity Tester lead Blue Yellow 2 No Con Tester lead Sky blue 1 tinuity NOTE When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed Is the starting circuit cut off relay diode OK Replace the starting circuit cut off rela...

Page 308: ...IRCUIT DIAGRAM 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead 7 Starter motor 8 Starting circuit cut off relay r Sidestand switch t Ignition fuse y Right handlebar switch d Clutch switch j Neutral switch lead k Neutral switch Alarm system Option Diode ...

Page 309: ...ent 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 press ing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off...

Page 310: ...or replace the battery Repair or replace the starter motor Pocket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in Chapter 3 Are the main and ignition fuses OK Replace the fuse s EAS00738 EASB0031 TROUBLESHOOTING Check 1 Main and ignition fuses 2 Battery 3 Starter motor 4 Starting circuit cutoff relay 5 Starting circuit c...

Page 311: ...0760 Replace the relay unit YES NO 5 Starting circuit cutoff relay diode Disconnect the starting circuit cutoff relay from the coupler Connect the pocket tester 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows Tester positive probe Sky blue 1 Continui Tester negative probe ty Black Yellow 2 Tester positive probe Black Yel...

Page 312: ...witch OK Replace the main switch EAS00749 YES NO 8 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right han dlebar switch EAS00750 YES NO 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch EAS00751 YES NO 10 Sidestand switc...

Page 313: ...h EAS00764 YES NO 13 Diode Check the diode for continuity Refer to IGNITION SYSTEM Is the diode OK Replace the diode YES NO 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 The starting system circuit is OK Properly connect or repair the starting system s wiring EAS00766 NO YES ...

Page 314: ...ad 1 2 Starter motor assembly 1 For installation reverse the removal procedure Disassembling the starter motor Disassembly the pats in the order listed 1 Circlip 1 2 Starter motor drive gear 1 3 Starter motor rear cover 1 Refer to Assembling the starter motor 4 Washer set 1 5 Starter motor front cover 1 Refer to Assembling the starter motor STARTER MOTOR ...

Page 315: ...me Q ty Remarks 6 Washer set 1 7 End bracket 1 Refer to Assembling the starter motor 8 Planetary gears 2 9 Armature assembly 1 0 Brush holder brush 1 1 q Starter motor yoke 1 For assembly reverse the disassembly procedure Refer to Assembling the starter motor ...

Page 316: ...o fit the commutator NOTE The mica must be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification replace the starter motor Min commutator diameter 27 mm Mica undercut 0 7 mm P...

Page 317: ...Check oil seal Damage wear Replace the defective part s EAS00772 Assembling the starter motor 1 Install brush holder 1 NOTE 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 NOTE Align the projection a on the front cover with the slot b on the end cover and starter motor yoke Min brush length 5...

Page 318: ...ELECTRIC STARTING SYSTEM 7 24 ELEC 3 Install starter motor rear cover 1 NOTE Align the match marks a on the rear cover with the match marks b on the front cover ...

Page 319: ...ELEC CHARGING SYSTEM 7 25 CHARGING SYSTEM CIRCUIT DIAGRAM 1 Pickup coil 2 Rectifier regulator 4 Starter relay 5 Battery 6 Wire minus lead ...

Page 320: ... r min Measure the charging voltage Charging voltage 14 V at 5 000 r min EAS00739 EAS00775 Clean the battery ter minals Recharge or replace the battery Engine tachometer 90890 03113 Pocket tester 90890 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in Chapter 3 Is the main fuse OK Replace the fuse EAS00738 EAS00774 TROUBLESHOOTING Check 1 main fuse 2 battery 3 cha...

Page 321: ... shown Tester positive probe White 1 Tester negative probe White 2 Tester positive probe White 1 Tester negative probe White 3 Measure the stator coil assembly resistanc es Stator coil resistance 0 36 0 44 at 20 C 68 F Is the stator coil assembly OK EAS00776 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly conecte...

Page 322: ...ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead y Right handlebar switch i Headlight fuse s Left handlebar switch h Speedometer l Headligh Tail brake light License plate light ...

Page 323: ...attery cover Troubleshoot with the following special tool s Any of the following fail to light headlight high beam indicator light license plate light or meter light YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or repla...

Page 324: ... lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM 1 Headlight bulb and socket Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both YES NO EAS00788 CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indicator light fail to came on 2 Voltage Connect...

Page 325: ...ht fails to come on YES NO The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired This circuit is OK YES NO 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown Tester positive probe Blue 1 Tester negative probe Black 2 Set the main switch to ON Set the light switch to 3 or 6 Measure the voltage 12 V of Bl...

Page 326: ...k the license plate light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK Replace the license plate light bulb socket or both EASB0034 4 The license plate light fails to come on YES NO The wiring circuit from the main switch to the license plate light coupler is faulty and must be re paired This circuit is OK YES NO 2 Volta...

Page 327: ...ELEC SIGNALING SYSTEM 7 33 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 328: ...fuse u Front brake switch o Signal fuse s Left handlebar switch f Horn g Flasher relay h Speedometer j Neutral switch lead k Neutral switch Front turn signal light L z Front turn signal light R x Rear turn signal light L c Rear turn signal light R Tail brake light Oil level gauge Rear brake switch ...

Page 329: ... following fail to light turn signal light brake light or an indicator light The horn fails to sound YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Min open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or replace the battery YES NO 3 Main switch Check the main switch for con...

Page 330: ...ter negative probe Ground Set the main switch to ON Measure the voltage 12 V of Brown at the horn terminal Is the voltage within specification The horn is OK NO YES 3 Horn Disconnect the Black connector at the horn terminal Connect a jumper lead 1 to the horn termi nal and Ground the jumper lead Set the main switch to ON Does the horn sound Replace the horn Repair or replace the horn YES NO 4 Volt...

Page 331: ...must be repaired This circuit is OK YES NO 3 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Tester positive probe Green Yellow 1 Tester negative probe Black 2 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 withi...

Page 332: ...tage within specification 4 Voltage Connect the pocket tester DC 20 V to the flasher relay coupler wire harness side as shown The flasher relay is faulty and must be replaced YES NO Tester positive probe Brown White 1 Tester negative probe Ground Set the main switch to ON Set the turn signal switch to Î or Measure the voltage 12 V of Brown White at the flasher relay coupler wire harness side Is th...

Page 333: ...he neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch YES NO The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired This circuit is OK YES NO 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe Brown 1 Tester negative p...

Page 334: ... NO 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe Red White 1 Tester negative probe Black White 2 Set the main switch to ON Measure the voltage 12 V of Brown 1 and Black White 2 at the meter assembly coupler Is the voltage within specification The wiring circuit from the main switch to the meter assem bly coupler is fault...

Page 335: ...L PUMP SYSTEM 7 41 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead 8 Starting circuit cut off relay 9 Fuel pump 0 Igniter unit t Ignition fuse y Right handlebar switch ...

Page 336: ...l pump circuit consists of the fuel pump re lay fuel pump engine stop switch and ignitor unit The ignitor unit includes the control unit for the fu el pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump ...

Page 337: ...vers 3 fuel tank lift 4 storage compartment battery cover Troubleshoot with the following special tool s The fuel pump fails to operate YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or replace the battery YES NO 3 Main switc...

Page 338: ...r to CIRCUIT DIAGRAM Is the fuel pump system s wiring properly connected and without defects Replace the ignitor unit Properly connect or repair the fuel pump system s wiring NO YES 5 Starting circuit cutoff relay fuel pump relay Remove the relay unit from the wire harness Connect the pocket tester 1 and bat tery 12 V to the relay unit terminals Battery terminal Red Black terminal 1 Battery termin...

Page 339: ... wipe it up immedi ately with dry rags If gasoline touches the engine when the engine 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 coupler terminals d Operate the en...

Page 340: ...TEM 7 46 ELEC CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead p Carburetor heater fuse v Thermo switch b Carburetor heater earth n Carburetor heater 1 m Carburetor heater 2 ...

Page 341: ...torage compartment battery cover Troubleshoot with the following special tool s The carburetor heater fails to operate YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in Chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK EAS00739 Clean the battery ter minals Recharge or replace the battery YES NO 3 Main switch Check the main ...

Page 342: ...ace the thermo switch YES NO Replace the carbure tor heater YES NO 5 Carburetor heater Remove the carburetor heater from the car buretor body Connect the pocket tester to the carburetor heater Tester lead Heater terminal 1 Tester lead Heater body 2 Measure the heater resistance Carburetor heater resistance 12 V 30 W 6 10 at 20 C 68 F Is the carburetor heater OK EASB0041 6 Wiring Check the entire c...

Page 343: ...chometer or speedometer needle does not move as described or either of the warning lights does not come on check the electrical circuits If the throttle position sensor or speed sensor are defective the tachometer will repeatedly display the fol lowing error code Use the chart below to identify the faulty electrical circuit When the tachometer displays the error code check the throttle position se...

Page 344: ...e Troubleshoot with the following special tool s The tachometer displays the throttle posi tion sensor speed sensor error code 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness YES NO 2 Throttle position sensor Check the throttle position sensor for conti nuity Refer to CHECKING AND ADJUSTING THE THROTTLE POSITIO...

Page 345: ...e the wire harness YES NO 2 Speed sensor Place the motorcycle on a suitable stand so that the rear wheel is elevated Connect the pocket tester DC 20 V to the speed sensor connector Tester lead White terminal 1 Tester lead Body earth Set the main switch to ON Turn the rear wheel slowly Check the tester voltage 0 V 5 V 0 V Is the speed sensor OK Replace the speed sensor Replace the ignitor unit YES ...

Page 346: ...ELEC ...

Page 347: ...8 TRBL SHTG http manuals magnamaniac com ...

Page 348: ...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...

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Page 350: ...r Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Faulty starter plunger Improperly adjusted starter cable Air filter Clogged air filter element Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals severed Improper h...

Page 351: ...urned starter plunger Loose pilot jet Clogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed throttle stop screw Improper throttle cable free play Flooded carburetor Electrical system Faulty battery Faulty spark plug Faulty ignitor unit Faulty pickup coil Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element Car...

Page 352: ...mproperly returned stopper lever Shift fork Worn shift fork Shift cam Improper thrust play Worn shift cam groove Transmission Worn gear dog Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate clutch plate Incorrectly assembled clutch Engine oil Improper oil level Improper viscosity low Deterioration CLUTCH DRAGGING Clutch Warped pressure plate Une...

Page 353: ...n brake pad Worn disc Air in brake fluid Leaking brake fluid Faulty cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose Oily or greasy disc brake pad Incorrect brake fluid level MALFUNCTION Bent deformed or damaged inner tube Bent or deformed outer tube Damaged fork spring Worn or damaged slide metal Bent or damaged damper rod Improper oil viscosity Improper oil level OIL L...

Page 354: ...ead tube Improperly installed bearing race HEADLIGHT DOES NOT LIGHT Improper bulb Too many electric accessories Hard charging broken stator coil wire faulty rec tifier regulator Incorrect connection Improperly grounded Poor contacts main or lights switch Bulb life expired FLASHER DOES NOT LIGHT Improperly grounded Discharged battery Faulty turn switch Faulty flasher relay Faulty wire harness Loose...

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Page 356: ... relay 9 Fuel pump 0 Igniter unit q Ignition coil 1 w Ignition coil 2 e Throttle position sensor r Sidestand switch t Ignition fuse y Right handlebar switch u Front brake switch i Headlight fuse o Signal fuse p Carburetor heater fuse a Backup fuse s Left handlebar switch d Clutch switch f Horn g Flasher relay h Speedometer j Neutral switch lead k Neutral switch l Headlight Front turn signal light ...

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Yamaha BT1100 2002, Service Manual

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