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Yamaha TW125 1999, Service Manual

The Yamaha TW125 1999 Service Manual is a comprehensive guide that allows you to maintain and repair your TW125 motorcycle with ease. This manual is available for free download from manualshive.com, providing you with step-by-step instructions, diagrams, and specifications to ensure seamless maintenance for your Yamaha TW125 1999.

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4-28

CYLINDER AND PISTON

ENG

NOTE:

New

NOTE:

New

Piston-pin-to-piston clearance =

Piston pin bore size 

b

 –

Piston pin outside diameter 

a

Piston-pin-to-piston clearance

0.010 

 0.026 mm

EAS00267

INSTALLING THE PISTON AND CYLINDER
1. Install:

top ring 

1

2nd ring 

2

lower oil ring rail 

3

upper oil ring rail 

4

oil ring expander 

5

Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.

2. Install:

piston 

1

piston pin 

2

piston pin clip 

3

 

Apply engine oil onto the poston pin.

Make sure that the arrow mark 

a

 on the piston

points towards the exhaust side of the cylinder.

Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.

3. Install:

gasket 

1

 

dowel pins 

2

4. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)

Recommended lubricant

Engine oil

Summary of Contents for TW125 1999

Page 1: ......

Page 2: ......

Page 3: ...000 TW125 SERVICE MANUAL 1998 by Yamaha Motor Co Ltd 1st Edition July 1998 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...l its models Modifications and signif icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00004 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safet...

Page 5: ...pections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspections and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 N...

Page 6: ...m 8 Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indi cate the types of lubricants and lubrication points 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21 L...

Page 7: ...NERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURATION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8 CHK ADJ INDEX ...

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ...ON NUMBER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 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 THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 11: ......

Page 12: ...OTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head EAS00018 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...y clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all re placements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and app...

Page 14: ...ers are vis ible When installing oil seals apply a light coat of lithium soap base grease onto the oil seal lips Oil bearings liberally when instal ling if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS 1 Before reassembly check all circlips careful ly and replace damaged or distorted circlips Always rep...

Page 15: ...ins Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with a pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quic...

Page 16: ...ools are used when removing or installing the rocker arm shafts 90890 01268 Ringnut wrench This tool is used to loosen and tighten the ex haust and steering ringnut 90890 01294 90890 01326 Damper rod holder T handle This tool is used for disassembling or assem bling the front fork 90890 01311 Valve adjusting tool This tool is necessary for adjusting valve clearance 90890 01312 Fuel level gauge Thi...

Page 17: ... needed for detecting engine rpm 90890 03141 Timing light This tool is necessary for checking ignition timing 90890 04019 90890 04108 Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring 90890 04064 Valve guide remover 6 mm This tool is used to remove the valve guide 90890 04065 Valve guide reamer 6 mm This tool is used to rebore the va...

Page 18: ...ion 90890 04101 Valve lapper This tool is used for lapping the valve 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components 90890 85505 Yamaha bond No 1215 This sealant bond is used for crankcase mating surface etc ...

Page 19: ...GEN INFO ...

Page 20: ...SPEC 2 ...

Page 21: ...ENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 9 ELECTRICAL 2 12 CONVERSION TABLE 2 14 CONVERSION TABLE 2 14 GENERAL TORQUE SPECIFICATIONS 2 14 LUBRICATION POINT AND GRADE OF LUBRICANT 2 15 ENGINE 2 15 CHASSIS 2 16 LUBRICATION DIAGRAM 2 17 CABLE ROUTING 2 19 ...

Page 22: ......

Page 23: ... arrangement Displacement Bore stroke Compression ratio Compression pressure STD Starting system Lubrication system Air cooled 4 stroke SOHC Forward inclined single cylinder 0 124 L 124 cm3 57 0 48 8 mm 10 0 1 1 200 kPa 12 0 kg cm2 12 0 bar at 1 000 r min Electric starter Wet sump Oil type or grade Engine oil API standard SE or higher grade ACEA standard G4 or G5 Periodic oil change With oil filte...

Page 24: ...26 23 29 0 793 Chassis Frame type Caster angle Trail Diamond 26 95 mm Tire Type Size front rear Manufacture front rear Type front rear Tube type 130 80 18 66P 180 80 14 M C 78P BRIDGESTONE BRIDGESTONE TW31 TW34 Tire pressure cold tire Maximum load except motorcycle Loading condition A front rear Loading condition B front rear Off road riding front rear High speed riding front rear 180 kg 0 X 80 kg...

Page 25: ...il spring Oil damper Coil gas spring Oil damper Wheel travel Front wheel travel Rear wheel travel 160 mm 150 mm Electrical Ignition system Generator system Battery type Battery capacity C D I C D I magneto GM 7CZ 3D 12 V 7 AH Headlight type Bulb type Bulb wattage quantity Headlight Auxiliary light Tail brake light Turn signal light Meter light High beam indicator Neutral indicator Turn signal indi...

Page 26: ... chain type No of links Cam chain adjustment DID 25SH 104 EDESOLES Automatic SSS SSS Rocker arm rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker armshaft clearance 12 000 X 12 018 mm 11 985 X 11 991 mm 0 009 X 0 033 mm 12 036 mm 11 950 mm SSS Valve valve seat valve guide Valve clearance cold IN EX 0 05 X 0 09 mm 0 11 X 0 15 mm SSS SSS Valve dimensions A...

Page 27: ...SS Clockwise Counterclockwise 33 5 mm 35 2 mm SSS SSS SSS SSS 2 5_ 1 5 mm 2 5_ 1 6 mm SSS SSS Piston Piston to cylinder clearance Piston size D Piston over size 1st Piston over size 2nd Measuring point H Piston off set Piston off set direction Piston pin bore inside diameter Piston pin outside diameter 0 035 X 0 055 mm 56 960 X 56 975 mm 57 25 mm 57 50 mm 7 0 mm 0 5 mm IN side 15 002 X 15 013 mm 1...

Page 28: ...Drive axle runout limit SSS SSS 0 08 mm 0 08 mm Carburetor Type I D mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Cut away C A Pilot air jet P A J Pilot outlet P O Pilot jet P J Bypass 1 B P 1 Pilot screw P S Valve seat size V S Starter jet 1 G S 1 Starter jet 2 G S 2 Float height F H Fuel level F L Engine idle speed Intake vacuum Y24P 5EK1 00 118 ø1 4 4C78 3 5 T00 2 5 ø1 3 0 ...

Page 29: ...er Starter clutch Primary drive gear Clutch spring Clutch boss Push lever axle Push lever adjuster Drive sprocket Shift cam Segment Shift pedal Pick up coil Neutral switch Stator coil Starter motor Screw Bolt Bolt Screw Bolt Bolt Bolt Nut Bolt Nut Bolt Bolt Bolt Screw Screw Bolt Screw Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Screw Screw Screw Screw Screw Bolt Nut Screw Nut Screw Nut Bolt Screw Bol...

Page 30: ...2 8 MAINTENANCE SPECIFICATIONS SPEC Tightening sequence Cylinder head Crankcase Item Standard Limit ...

Page 31: ... length Spring rate K1 Stroke K1 48 mm 193 mm 185 mm 100 N mm 10 0 kg mm 0 X 48 mm SSS 173 mm SSS SSS SSS Front wheel Type Rim size Rim material Rim runout limit radial lateral Spoke wheel 2 50 18 Aluminum SSS SSS SSS SSS SSS 2 mm 2 mm Rear wheel Type Rim size Rim material Rim runout limit radial lateral Spoke wheel 14 M C MT 4 50 Steel SSS SSS SSS SSS SSS 2 mm 2 mm Drive chain Type manufacturer N...

Page 32: ...pring free length Leading trailing 110 mm 4 mm 50 5 mm SSS 111 mm 2 mm SSS Brake lever Brake lever free play at lever end 2 X 5 mm SSS Brake pedal Brake pedal free play Brake pedal position 20 X 30 mm 30 mm SSS SSS Clutch lever Clutch lever free play at lever end 10 X 15 mm SSS Throttle cable free play 3 X 5 mm SSS ...

Page 33: ...t left Footrest right Rear footrest left Front wheel axle and nut Rear wheel axle and nut Brake caliper and front fork Brake disc and front wheel Rear wheel sprocket and hub Brake caliper bleed screw Brake cam lever M8 M14 M8 M25 M6 M10 M10 M8 M8 M8 M8 M8 M12 M10 M5 M10 M12 M10 M8 M14 M16 M10 M6 M8 M7 M6 23 90 20 18 7 26 30 33 33 33 33 33 80 56 5 40 60 45 15 90 90 30 13 35 6 9 2 3 9 0 2 0 1 8 0 7 ...

Page 34: ...Resistance Resin type 10 kΩ SSS SSS Charging system Type Model manufacturer Standard output Stator coil resistance color C D I magneto F5BT YAMAHA 12V 170 W 5 000 r min 0 48 X 0 72 Ω at 20_C White White SSS SSS SSS SSS SSS Rectifier regulator Model manufacturer Type regulator No load regulated voltage Capacity rectifier Withstand voltage SH629A 12 SHINDENGEN Semi conductor short circuit type 14 5 ...

Page 35: ...g resistance MS5F JIDECO 100 A 4 2 X 4 6 Ω at 20_C SSS SSS SSS Horn Model manufacturer Maximum amperage YF 12 NIKKO 3 A SSS SSS Flasher relay Type Model manufacturer Flasher frequency Full transistor type FE 246 BH DENSO 85 cycle min SSS SSS SSS Circuit breaker Type Main Reserve Fuse 20 A 1 pcs 20 A 1 pcs SSS SSS SSS ...

Page 36: ...r lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cuSin qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade 55 997 14 2234 9 5 _C 32 lb in psi lb in2 Fahrenheit _F EAS00029 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I S O pitch threads Torque specifica tions for special components or assemblies are included in the applicable sections ...

Page 37: ...Piston piston ring Buffer boss Valve stem valve guide IN EX Valve stem end IN EX Rocker arm shaft Cam and bearing camshaft Rocker arm inner surface Crankcase mating surfaces Yamaha bond No 1215 O ring all Starter idle gear thrust surfaces Starter clutch outer roller Starter wheel gear inner surface Push rod Primary driven gear inner surface Push lever axle Transmission gear inner surface Shift for...

Page 38: ... plate camshaft and pivoting pin Pivoting points brake pedal shaft and frame Sidestand sliding surface mounting bolt Tube guide throttle grip inner surface Brake lever bolt master cylinder sliding surface Clutch lever bolt collar cable sliding surface Brake pedal shaft surface Gear unit speedometer Swigarm insert surface bush thrust cover Pivot shaft surface Rear shock absorber lower pin surface d...

Page 39: ...2 17 1 Rocker arm IN 2 Rocker shaft 3 Rocker arm EX 4 Camshaft 5 Oil pump 6 Push lever LUBRICATION DIAGRAM SPEC LUBRICATION DIAGRAM ...

Page 40: ...2 18 1 Oil pump 2 Oil filter 3 Crankshaft 4 Main axle 5 Drive axle 6 Oil strainer LUBRICATION DIAGRAM SPEC ...

Page 41: ...adlight 12 Meter lead 13 Headlight coupler 14 Wireharness 15 Front turn signal light right 16 Front turn signal light lead right 1 Brake hose 2 Throttle cable 3 Front brake switch lead 4 Handlebar switch lead right 5 Handlebar switch lead left 6 Clutch cable 7 Clutch switch lead 8 Main switch lead 9 Speedometer cable 10 Starter cable 11 Indicator light lead CABLE ROUTING SPEC CABLE ROUTING ...

Page 42: ...right front brake switch lead throttle cable starter cable clutch switch lead and main switch lead to the frame with steel clamp C Route the wire harness handle bar switch right and front brake switch lead through the cable guide D Route the battery breather hose through the cable guide CABLE ROUTING SPEC 1 Battery positive lead 2 Starter relay 3 Starter motor lead 4 Clamp 5 Front brake switch lea...

Page 43: ...e down ward B Fasten the side stand switch lead with the steel clamp C Fasten the carburetor air vent hose carburetor over flow hose and starter motor lead with a plastic clamp D Route the side stand switch lead through the guide CABLE ROUTING SPEC 1 Starter cable 2 Throttle cable 3 Clutch switch lead 4 Main switch lead 5 Thermo switch lead 6 Sidestand switch lead 7 Carburetor over flow hose 8 Car...

Page 44: ... flow hose through the guide H Route the clutch cable through the cable guide I Route the brake hose and speed ometer cable through the cable guide J Fasten the brake hose and spee dometer cable to the front fork outer tube with a cable holder CABLE ROUTING SPEC ...

Page 45: ...ead to the frame with a plastic locking tie The end of plastic locking tie must face in side C Route the rear turn signal light lead inside of hose D Fasten the wire harness and rear turn signal light right with a steel clamp CABLE ROUTING SPEC 1 Clutch switch lead 2 Main switch lead 3 Starter motor lead 4 CDI magneto lead 5 Battery positive lead 6 Wire harness 7 Thermo switch lead 8 Sidestand swi...

Page 46: ...eft to the frame with a plastic locking tie The end of plastic locking tie must face rear ward H Fasten the thermo switch lead connectors to the frame with a plastic locking tie The end of plastic locking tie must face inside CABLE ROUTING SPEC ...

Page 47: ...CHK ADJ 3 ...

Page 48: ...ATHER HOSE 3 17 CHECKING THE EXHAUST SYSTEM 3 17 CHASSIS 3 19 ADJUSTING THE FRONT BRAKE 3 19 ADJUSTING THE REAR BRAKE 3 19 CHECKING THE BRAKE FLUID LEVEL 3 21 CHECKING THE BRAKE PADS 3 22 CHECKING THE BRAKE SHOES 3 22 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 22 CHECKING THE BRAKE HOSE 3 23 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 23 ADJUSTING THE DRIVE CHAIN SLACK 3 24 LUBRICATING THE DRIVE CHAIN 3 26...

Page 49: ......

Page 50: ...5 Battery Check electrolyte level and specific gravity Correct or recharge if necessary Make sure that the breather hose is properly routed 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation Adjust cable and replace brake shoes if necessary...

Page 51: ...idling speed and starter operation Adjust if necessary 21 Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining 22 Engine oil filter element Clean or replace if necessary 23 Engine oil strainer Clean or replace if necessary Since these items require special tools date and technical skills they should be serviced by a Ya maha dealer The air f...

Page 52: ...t Fuel hose Fuel tank Tail cover Side cover left Side cover right 1 1 1 1 1 1 Remove the parts in the order listed Before disconnecting the fuel hose turn the fuel cock off For installation reverse the removal procedure NOTE SEAT FUEL TANK AND SIDE COVER CHK ADJ SEAT FUEL TANK AND SIDE COVER ...

Page 53: ...tank Refer to SEAT FUEL TANK AND SIDE COVER 2 Remove spark plug cap 1 spark plug valve cover intake side 2 valve cover exhaust side 3 3 Remove timing check plug with O ring 1 center plug with O ring 2 4 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 05 0 09 mm Exhaust valve 0 11 0 15 mm a Turn the crankshaft counterclockwise b When the piston is at TDC on t...

Page 54: ...eased Direction Valve clearance is decreased Valve adjusting tool 90890 01311 d Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion Locknut 14 Nm 1 4 m kg e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 6 Install valve co...

Page 55: ...03113 3 Measure engine idling speed Out of specification Adjust Engine idling speed 1 300 1 500 r min 4 Adjust engine idling speed a Turn the pilot screw 1 in or out until it is light ly seated b Turn the pilot screw out the specified number of turns Pilot screw 2 turns out c Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained Direction Engine idl...

Page 56: ...cable b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased c Tighten the locknut 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 loc...

Page 57: ...Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fal ling into the cylinder 3 Check spark plug type Incorrect Change Spark plug type manufacturer DR8EA NGK 4 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color 5 Clean spark plug w...

Page 58: ...e that all connections are tight and free of corrosion 1 Remove timing check plug 2 Install timing light 1 engine tachometer 2 to the spark plug lead of cylinder 1 Timing light 1 90890 03141 Engine tachometer 2 90890 03113 3 Check ignition timing a Start the engine warm it up for several minutes and then let it run at the specified engine idling speed Engine idling speed 1 300 1 500 r min b Check ...

Page 59: ...y any dirt accumu lated in the spark plug well to prevent it from falling into the cylinder 5 Install compression gauge 1 Compression gauge 1 90890 03081 Adapter 2 90890 04082 6 Measure compression pressure Above the maximum pressure Inspect the cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the cylinder and measure again...

Page 60: ...Install spark plug 8 Connect spark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Let the engine idle for a few minutes 3 Check engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b Below the minimum level mark Add the ...

Page 61: ... engine oil level wait a few minutes until the oil has settled EAS00076 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove engine oil filler cap 1 engine oil drain bolt 2 4 Drain engine oil completely from the crankcase 5 If the oil filter element is also to be replaced perform the following p...

Page 62: ...e oil leaks 12 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 13 Check engine oil pressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until the engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check engine oil passages and oil pump for damage or leakage ...

Page 63: ...ntil the specified clutch cable free play is obtained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased c Tighten the locknut If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the speci...

Page 64: ...the entire sur face of the air filter element and then careful ly pat the air filter element on a clean cloth to remove the excess oil The air filter element should be wet but not dripping Recommended oil Engine oil 6 Install air filter element air filter case cover along with the gasket Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engi...

Page 65: ...e seat side cover fuel tank Refer to SEAT FUEL TANK AND SIDE COVER 2 Check carburetor joint 1 intake manifold 2 Cracks damage Replace Refer to CARBURETOR in chapter 5 3 Install fuel tank side cover seat Refer to SEAT FUEL TANK AND SIDE COVER EAS00096 CHECKING THE FUEL HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove seat side cover fuel tank Refer to SEAT FUEL TAN...

Page 66: ...cks damage Replace Loose connection Connect properly Make sure that the crankcase breather hose is routed correctly 3 Install fuel tank side cover seat Refer to SEAT FUEL TANK AND SIDE COVER EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes mufflers and gaskets 1 Remove seat rear cowling side cover right 2 Check exhaust pipe 1 silencer 2 Cracks damag...

Page 67: ...Check tightening torque Exhaust pipe 4 12 Nm 1 2 m kg Exhaust pipe and muffler bolt 5 20 Nm 2 0 m kg Muffler and muffler bracket bolt 6 20 Nm 2 7 m kg Muffler and muffler bracket bolt 7 27 Nm 2 7 m kg 4 Install side cover right rear cowling seat ...

Page 68: ...the locknut A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore inspect and if nec essary bleed the brake system After adjusting t...

Page 69: ...pecification 3 Measure brake pedal free play a Out of specification Adjust Brake pedal free play 20 30 mm 4 Adjust brake pedal free play a Turn the adjusting nut 2 in direction a or b until the specified brake pedal free play is ob tained Direction Brake pedal free play is increased Direction Brake pedal free play is decreased After adjusting the brake pedal position and free play make sure that t...

Page 70: ...the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor ...

Page 71: ...place the brake shoes as a set Refer to REAR WHEEL in chapter 7 EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timin...

Page 72: ...hydraulic brake system whenev er The system was disassembled A brake hose was loosened or removed The brake fluid level is very low Brake operation is faulty Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to over flow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before applying the brake Ignoring this precaution co...

Page 73: ...act the throttle grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0 6 m kg k Fill the reservoir to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL After bleeding the hydraulic brake system check the brake op...

Page 74: ...ication Adjust Drive chain slack 35 60 mm 4 Adjust drive chain slack a Loosen the wheel axle nut 1 b Turn the chain pullers 2 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain is tightened Direction Drive chain is loosened To maintain the proper wheel alignment adjust both sides evenly c Tighten the wheel axle nut Wheel axle nut 90 Nm 9 0 m kg Do not loos...

Page 75: ...e oil or chain lubricant that is suitable for non O ring chains Recommended lubricant Engine oil or chain lubricant sui table for non O ring chains EAS00146 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Ch...

Page 76: ...or looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and inspect the upper and lower bearings Refer to STEERING HEAD AND HAN DLEBAR in chapter 6 e Install the rubber washer f Install the upper ring nut 6 g Finger tighten the upper ring nut 6 then align the slots of both ring nuts If necessary hold the lower ring nut and ti...

Page 77: ... if the front fork rebounds smoothly Unsmooth operation Repair Refer to FRONT FORK in chapter 6 EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires 1 Measure tire pressure Out of specification Regulate The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted...

Page 78: ...tire immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden defla tion When using tube tires be sure to install the correct tube Always replace a new tube tire and a new tube as a set To av...

Page 79: ...ire Manufacturer Type Size BRIDGESTONE TW34 180 80 14 M C 78P After mounting a new tire ride conserva tively for a while to become accustomed to the feel of the new tire and to allow the tire to seat itself properly in the rim Failure to do so could lead to an accident with pos sible injury to the rider or damage to the motorcycle After a tire has been repaired or replaced be sure to tighten the t...

Page 80: ...re to tighten the spokes before and after break in Spoke nipple 2 Nm 0 2 m kg EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables Damaged cable sheaths may cause the cable to corrode and interfere with its move ment Replace damaged cable sheaths and cables as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation...

Page 81: ...etal moving parts of the levers and pedals Recommended lubricant Engine oil EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Engine oil EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfide oil ...

Page 82: ...rettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowe...

Page 83: ...aps SMake sure that the battery breather hose and battery vent are free of obstructions STo ensure maximum performance always charge a new battery before using it SDo not use a high rate battery charger They force a high amperage current into the battery quickly and can cause battery overheating and battery plate damage SIf it is impossible to regulate the charging current on the battery charger b...

Page 84: ... rise during charging sulphation of one or more battery cells occurs as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell specific gravity readings after a long slow charge indicate that one battery cell s charge is lower than the rest warpage or buckling of the battery plates or in sulators is evident 7 Check battery breather hose and battery...

Page 85: ...attery terminals Recommended lubricant Dielectric grease 13 Install side cover right seat EAS00181 CHECKING THE FUSE The following procedure applies to all of the fuses To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove seat side cover right 2 Check fuse a Connect the pocket tester to the fuse and check it for continuity Set the pocket tester sel...

Page 86: ... again check the electrical circuit Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install side cover right seat EAS00182 REPLACING THE HEADLIGHT BULB 1 Remove headlight cover 1 ...

Page 87: ...the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install headlight bulb holder 6 Connect headlight coupler 7 Install headlight unit headlight cover EAS00184 ADJUSTIN...

Page 88: ...JUSTING THE HEADLIGHT BEAM CHK ADJ a b 2 Adjust headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction Headlight beammoves to the right Direction Headlight beammoves to the left ...

Page 89: ...CHK ADJ ...

Page 90: ...ENG 4 ...

Page 91: ...OCKER ARMS AND ROCKER ARM SHAFTS 4 14 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 15 VALVES AND VALVE SPRINGS 4 17 REMOVING THE VALVES 4 18 CHECKING THE VALVES AND VALVE GUIDES 4 19 CHECKING THE VALVE SEATS 4 20 CHECKING THE VALVE SPRINGS 4 22 INSTALLING THE VALVES 4 23 CYLINDER AND PISTON 4 24 REMOVING THE PISTON AND PISTON RINGS 4 25 CHECKING THE CYLINDER AND PISTON 4 25 CHECKING THE PISTON RINGS ...

Page 92: ...4 50 STATOR COIL 4 51 STARTER CLUTCH AND GENERATOR 4 52 REMOVING THE GENERATOR ROTOR 4 53 CHECKING THE STARTER CLUTCH 4 53 INSTALLING THE STARTER CLUTCH 4 54 INSTALLING THE GENERATOR ROTOR 4 55 CRANKSHAFT 4 56 CRANKCASE 4 56 CRANKSHAFT AND BALANCER WEIGHT 4 58 DISASSEMBLING THE CRANKCASE 4 59 REMOVING THE PLUNGER SEAL 4 59 CHECKING THE CRANKSHAFT AND CONNECTING ROD 4 60 CHECKING THE BEARINGS AND O...

Page 93: ...CHECKING THE TRANSMISSION 4 66 INSTALLING THE TRANSMISSION SHIFT FORKS AND SHIFT DRUM ASSEMBLY 4 67 ...

Page 94: ......

Page 95: ... cap Muffler Exhaust pipe Gasket 1 1 1 1 1 1 Disconnect the parts in the order listed Refer to SEAT FUEL TANK AND SIDE COVER in CHAPTER 3 First disconnect the negative lead then the positive lead For connecting reverse the disconnection procedure CAUTION 12 Nm 1 2 m kg 20 Nm 2 0 m kg 27 Nm 2 7 m kg 20 Nm 2 0 m kg EAS00188 OVERHAULING THE ENGINE ENGINE LEAD AND EXHAUST PIPE ...

Page 96: ... Shift pedal Generator cover Rear wheel axle nut Sprocket holder Drive sprocket drive chain 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CARBURETOR in CHAPTER 5 Loosen the axle nut and slacken the drive chain For installation reverse the removal pro cedure NOTE 6 Nm 0 6 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg EAS00189 CARBURETOR AND DRIVE SPROCKET ...

Page 97: ...bolt rear under Engine 1 1 1 1 1 Remove the parts in the order listed Securely support the motorcycle so there is no danger of it falling over Refer to INSTALLING THE ENGINE For installation reverse the removal pro cedure 33 Nm 3 3 m kg 33 Nm 3 3 m kg 33 Nm 3 3 m kg 33 Nm 3 3 m kg 80 Nm 8 0 m kg ENGINE ENG EAS00192 ENGINE ...

Page 98: ...ine bracket bolt top 9 Do not fully tighten the bolts 2 Tighten the bolts in the following order Pivot shaft 1 80 Nm 8 0 m kg Engine mount bolt rear 2 33 Nm 3 3 m kg Engine mount bolt front 3 33 Nm 3 3 m kg Engine mount bolt front 4 33 Nm 3 3 m kg Engine mount bolt top 5 33 Nm 3 3 m kg Engine bracket bolt front 6 33 Nm 3 3 m kg Engine bracket bolt front 7 33 Nm 3 3 m kg Engine bracket bolt top 8 3...

Page 99: ...er intake side O ring Valve cover exhaust side O ring Intake manifold O ring Timing mark cap O ring Center cap O ring 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT FUEL TANK AND SIDE COVER in CHAPTER 3 Refer to ENGINE For installation reverse the removal procedure Refer to CARBURETOR in CHAPTER 5 Refer to ENGINE 10 Nm 1 0 m kg 18 Nm 1 8 m kg 10 NM 1 0 m kg 7 Nm 0 7 m...

Page 100: ...n Cylinder head Dowel pins Gasket Cylinder head gasket 1 1 1 1 3 1 1 Remove the parts in the order listed Refer to REMOVEING THE CYLINDER HEAD INSTALLING THE CAMSHAFT SPROCKET Refer to REMOVING INSTALLING THE CYLINDER HEAD For installation reverse the removal procedure 22 Nm 2 2 m kg 20 Nm 2 0 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg EAS00221 CYLINDER HEAD ...

Page 101: ...en the piston is at TDC on the compres sion stroke align the I mark c on the cam shaft sprocket with the mark d on the cylin der head 2 Loosen bolt 1 3 Remove cap bolt 1 timing chain tensioner 2 along with the gasket camshaft sprocket 3 timing chain 4 To prevent the timing chain from falling into the crankcase fasten it with a wire a While holding the generator rotor bolt with a wrench remove the ...

Page 102: ...spark plug threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 05 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet abrasive...

Page 103: ...ngs 1 Check tappet cover camshaft sprocket cover O ring Damage wear Replace the defective part s EAS00233 INSTALLING THE CYLINDER HEAD 1 Install dowel pins 1 O ring 2 gasket New 3 The UP mark on the gasket must face up 2 Install cylinder head Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two...

Page 104: ...he gen erator rotor with the mark b on the genera tor rotor cover Be sure to keep the timing chain as tight as pos sible 2 Install timing chain onto the camshaft sprocket camshaft sprocket onto the camshaft The notch a on the camshaft should face to wards the intake side of the engine Align the camshaft marks a with the edge of the cylinder head as shown Do not turn the crankshaft when installing ...

Page 105: ...e gasket and the timing chain tensioner 2 onto the cylinder block Always use a new gasket c Tighten the timing chain tensioner bolts to the specified torque Timing chain tensioner bolt 10 Nm 1 0 m kg d Remove the screwdriver make sure that the timing chain tensioner rod releases and then tighten the cap bolt 3 to the specified torque 6 Turn crankshaft Turn the crankshaft several full turns to make...

Page 106: ...er arm shaft intake side Rocker arm shaft exhaust side Rocker arm O ring Nut Adjuster 1 1 1 1 1 1 2 1 2 2 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT INSTALLING THE CAMSHAFT AND ROCKER ARMS For installation reverse the removal procedure 14 Nm 1 4 m kg 14 Nm 1 4 m kg 8 Nm 0 8 m kg EAS00195 CAMSHAFT ...

Page 107: ...camshaft and then pull out the camshaft 4 Remove intake rocker arm shaft exhaust rocker arm shaft intake rocker arm exhaust rocker arm Attach a rocker arm shaft puller bolt 1 and weight 2 to the rocker arm shaft and slide out the shaft Rocker arm shaft puller bolt 90890 01083 Weight 90890 01084 EAS00205 CHECKING THE CAMSHAFTS 1 Check camshaft bushings Damage wear Replace 2 Check camshaft lobes Blu...

Page 108: ...edure applies to all of the rocker arms and rocker arm shafts 1 Check rocker arm Damage wear Replace 2 Check rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or check the lu brication system 3 Check camshaft lobe Excessive wear Replace the camshaft 4 Measure rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm Limit 12 036...

Page 109: ...NG THE CAMSHAFT AND ROCK ER ARMS 1 Lubricate rocker arm shaft Recommended lubricant Molybdenum disulfide oil 2 Install exhaust rocker arm exhaust rocker arm shaft Make sure that the exhaust rocker arm shaft is completely pushed into the cylinder head 3 Install intake rocker arm intake rocker arm shaft 1 Insert a cylinder head bolt 2 into the hole in the cylinder head and the intake rocker arm shaf...

Page 110: ...4 16 CAMSHAFT ENG New 8 Nm 0 8 m kg NOTE 5 Install camshaft retainer 1 Lock washer 2 Bolt 3 Bend the lock washer tab along a flat side of the bolt 3 ...

Page 111: ...iner Valve spring inner Valve spring outer Valve exhaust Valve intake Valve guide stem seal Spring seat 4 2 2 2 1 1 2 2 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to CAMSHAFT For installation reverse the removal pro cedure Refer to REMOVING INSTALLING THE VALVES VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS ...

Page 112: ...valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 2 Remove valve cotters 1 Remove the valve cotters by compressing the valve springs with the valve spring compressor 2 and attachment 3 Valve spring compressor 90890 04019 Attachment 90890 04108 3 Remove up...

Page 113: ...t 0 025 0 052 mm Limit 0 10 mm 2 Replace Svalve guide To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100_C in an oven a Remove the valve guide with a valve guide remover 1 b Install the new valve guide with a valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with a valve guide reamer 3 t...

Page 114: ...m runout Out of specification Replace the valve When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the oil seal Valve stem runout Limit 0 03 mm EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wea...

Page 115: ...eat After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face...

Page 116: ...he valve seat EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Svalve spring free length a Out of specification Replace the valve spring Valve spring free length intake and exhaust Inner spring 35 5 mm Limit 33 5 mm Outer spring 37 2 mm Limit 35 2 mm 2 Measure Scompressed spring force a Out of specification Replace the valve spring b Install...

Page 117: ...l valve 1 lower spring seat 2 oil seal 3 valve springs 4 upper spring seat 5 into the cylinder head Install the valve springs with the larger pitch a facing up 4 Install valve cotters 1 Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and attachment 3 Valve spring compressor 90890 04019 Attachment 90890 04108 5 To secure the valve cotters onto the valve...

Page 118: ...ring Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring set 1 1 1 1 2 1 2 1 1 1 Remove the parts in the order listed Refer to CYLINDER HEAD For installation reverse the removal procedure Refer to REMOVING THE PISTON AND PISTON RINGS Refer to INSTALLING THE PISTON AND CYLINDER Refer to INSTALLING THE PISTON AND CYLINDER EAS00265 CYLINDER AND PISTON ...

Page 119: ...ush up the other side of the ring EAS00255 CHECKING THE CYLINDER AND PISTON 1 Check piston wall cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge Measure cylinder bore C by taking side to side and front to back measurements of the cylinder The...

Page 120: ...der clearance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 035 0 055 mm f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set Be...

Page 121: ...s sive replace all three piston rings Piston ring end gap Top ring 0 15 0 35 mm Limit 0 60 mm 2nd ring 0 15 0 35 mm Limit 0 60 mm Oil ring 0 3 0 9 mm EAS00265 CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diamet...

Page 122: ...install the piston rings so that the manufacturer s marks or numbers face up 2 Install piston 1 piston pin 2 piston pin clip 3 Apply engine oil onto the poston pin Make sure that the arrow mark a on the piston points towards the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase 3 Insta...

Page 123: ...a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6 Install cylinder 1 While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity ...

Page 124: ...the clutch cover Drain the engine oil Clutch cover Clutch cover gasket Dowel pins 1 1 2 Remove the parts in the order listed Refer to CHANGING THE ENGINE OIL in CHAPTER 3 For installation reverse the removal pro cedure 7 Nm 0 7 m kg EAS00273 CLUTCH CLUTCH COVER ...

Page 125: ...he order listed Removing the clutch Clutch springs Pressure plate Friction plates Clutch plates Nut Lock washer Clutch boss Thrust washer Clutch housing Ball Long clutch push rod Push lever screw Gasket 6 Nm 0 6 m kg 8 Nm 0 8 m kg 70 Nm 7 0 m kg 12 Nm 1 2 m kg Refer to REMOVING INSTALLING THE CLUTCH EAS00274 CLUTCH ...

Page 126: ...ion spring Circlip Oil seal Nut Washer Short clutch push rod O ring Push plate 1 1 1 1 1 1 1 1 1 Refer to INSTALLING THE CLUTCH Refer to INSTALLING THE CLUTCH For installation reverse the removal pro cedure 8 Nm 0 8 m kg 70 Nm 7 0 m kg 6 Nm 0 6 m kg 12 Nm 1 2 m kg CLUTCH ENG ...

Page 127: ... housing 5 EAS00280 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 set Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm Limit 2 7 mm EAS00281 CHECKING THE CLUTCH PLA...

Page 128: ...rings as a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free length 34 9 mm Limit 33 9 mm EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation EAS00285 CHECKING THE CLUT...

Page 129: ... EAS00298 INSTALLING THE CLUTCH 1 Install clutch housing 1 thrust washer 2 clutch boss 3 lock washer clutch boss nut Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss 2 Tighten clutch boss nut 1 While holding the clutch boss with the universal clutch holder 2 tighten the clutch boss nut Universal clutch holder 90890 04086 3 Bend the lock washer t...

Page 130: ...ssure plate 1 clutch springs 2 clutch spring bolts 3 Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Check push lever position Push lever mark a and crankcase mark b not aligned Correct Push the push lever in direction c and make sure that the marks are aligned 10 Adjust push lever position a Loosen the locknut 1 b Turn the adjusting screw 2 in or out until the marks are al...

Page 131: ...0 7 m kg NOTE Do not overtighten the locknut since this will remove the free play between both push rods Push lever lock nut 8Nm 0 8m kg 11 Install clutch cover 1 Tighten the clutch cover bolts in stages and in a crisscross pattern ...

Page 132: ...p per lever Clutch Shift pedal Shift shaft Plate washer Torsion spring Stopper lever Plate washer Circlip Torsion spring Collar Tension spring 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CLUTCH Refer to ENGINE Refer to INSTALLING THE SHIFT SHAFT 12 Nm 1 2 m kg EAS00327 SHIFT SHAFT AND STOPPER LEVER ...

Page 133: ... STOPPER LEVER ENG Order Job Part Q ty Remarks 10 11 12 13 Screw Segment Dowel pins short length Dowel pins long length 1 1 4 1 For installation reverse the removal pro cedure Refer to INSTALLING THE SEGMENT 12 Nm 1 2 m kg ...

Page 134: ...TOPPER LEVER 1 Check stopper lever Bends damage Replace Roller turns roughly Replace the stopper lever INSTALLING THE SEGMENT 1 Install segment 1 dowel pin 2 long length dowel pins 3 short length Install the dowel pin 2 long length into the hole beside the match mark a position 2 Install segment 1 Fit the dowel pin 2 long length on the seg ment to the locating hole a on the sift cam and install th...

Page 135: ...ring to the shift shaft b Mesh the stopper lever 1 with the shift cam segment c Install the shift lever 2 to the shift cam seg ment d After installing the shift shaft check the shift cam for smooth operation by turning the shift shaft with your hand 2 Check shift lever 1 position Gaps a and b are not equal Replace the defective parts ...

Page 136: ...ar Oil pump drive gear Oil pump cover Oil pump assembly Gasket oil pump cover 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CLUTCH Refer to REMOVING INSTALLING THE PRIMARY DRIVE GEAR Refer to INSTALLING THE OIL PUMP For installation reverse the removal procedure 50 Nm 5 0 m kg 7 Nm 0 7 m kg EAS00357 OIL PUMP ...

Page 137: ...l pump Oil pump housing Dowel pin Oil pump driven gear Dowel pins Inner rotor Outer rotor Housing 1 1 1 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure Refer to ASSEMBLING THE OIL PUMP 7 Nm 0 7 m kg OIL PUMP ENG EAS00360 ...

Page 138: ...4 Cracks damage wear Replace the de fective part s 2 Measure inner rotor to outer rotor tip clearance A outer rotor to oil pump housing clearance B oil pump housing to inner rotor and outer rotor clearance C Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip cle arance 0 03 0 09 mm Limit 0 14 mm Outer rotor to oil pump housing cl...

Page 139: ...oil pump shaft 1 to the oil pump cover 2 pin 3 inner rotor 4 outer rotor 5 pin 6 oil pump housing 7 screw 8 When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 oil pump drive gear 2 After tightening the bolts make sure that the oil...

Page 140: ...r 1 lock washer 2 primary drive gear nut 3 Place a folded aluminum plate a or copper washer between the teeth of the balancer drive gear 4 and the balancer driven gear 5 in order to lock them Do not damage the balancer drive and balanc er driven gear s teeth 2 Bend the lock washer tab along a flat side of the nut ...

Page 141: ...Claw washer Balancer drive gear Buffer boss Compression spring Dowel pins Woodruff key Plate washer 1 1 1 1 1 1 1 6 3 1 1 Remove the parts in the order listed Refer to CLUTCH Refer to OIL PUMP Refer to REMOVING INSTALLING THE BALANCER DRIVEN GEAR For installation reverse the removal pro cedure Refer to ASSEMBLING THE BALANC ER DRIVE GEAR ASSEMBLY 50 Nm 5 0 m kg BALANCER GEAR ...

Page 142: ...balancer drive gear 4 and balancer driven gear 3 SR CHECKING THE BALANCER DRIVE GEAR 1 Inspect balancer drive gear 1 buffer boss 2 compression spring 3 dowel pins 4 Wear Pitting Scratches Replace SR ASSEMBLING THE BALANCER DRIVE GEAR 1 Assembly dowel pins 1 compression springs 2 Install the dowel pins and compression springs alternately as shown as 2 Install buffer boss 1 Align the punched mark a ...

Page 143: ...ancer driven gear then mesh the balancer driven gear match mark a and ba lancer drive gear assembly match mark b 2 Install lock washer 1 nut balancer drive gear 2 Place a folded aluminium plate or copper washer a between the teeth of the balancer drive gear 3 and balancer driven gear 4 3 Bend the lock washer tab after tighten the nut flats ...

Page 144: ...oil Side cover Generator lead couplers Generator cover Gasket Dowel pins 1 1 1 2 Remove the parts in the orser listed Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Refer to SEAT FUEL TANK AND SIDE COVER in CHAPTER 3 For installation reverse the removal pro cedure 7 Nm 0 7 m kg STARTER CLUTCH AND GENERATOR GENERATOR COVER ...

Page 145: ...art Q ty Remarks 1 2 3 4 Removing the stator coil Clamp stator coil Clamp pickup coil Pickup coil Stator coil 1 1 1 1 Remove the parts in the order listed For installation reverse the removal pro cedure 3 Nm 0 3 m kg 7 Nm 0 7 m kg EAS00341 STATOR COIL ...

Page 146: ...ar Woodruff key Starter wheel gear Shim Dowel pins Inner Spring caps Compression springs Dowel pins outer Starter clutch 1 1 1 1 1 1 3 3 3 3 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE GENERATOR ROTOR Refer to INSTALLING THE STARTER CLUTCH For installation reverse the removal pro cedure 30 Nm 3 0 m kg 50 Nm 5 0 m kg EAS00343 STARTER CLUTCH AND GENERATOR ROTOR ...

Page 147: ...the rotor Sheave holder 90890 01701 2 Remove generator rotor 1 woodruff key Remove the rotor using sheave holder 2 rotor puller 3 and rotor puller attachment 4 Rotor puller 90890 01080 Rotor puller attachment 90890 04052 EAS00348 CHECKING THE STARTER CLUTCH 1 Check starter clutch idle gear 1 starter clutch drive gear 2 starter clutch gear 3 Burrs chips roughness wear Replace the defective part s 2...

Page 148: ...er clutch gear counter clockwise b it should turn freely If the starter clutch gear does not turn freely the starter clutch is faulty and must be re placed 3 Inspect dowel pins 1 compression springs 2 spring caps 3 Wear Damage Replace 4 Inspect starter wheel gear contacting surface Pitting Wear Damage Replace INSTALLING THE STARTER CLUTCH 1 Install starter clutch assembly 1 2 Unloosen the starter ...

Page 149: ...nerator rotor 1 Clean the tapered portion of the crankshaft and the rotor hub When installing the rotor make sure the wood ruff key is properly seated in the key way of the crankshaft and turning the starter wheel gear 2 clockwise 3 Tighten generator rotor 1 Tighten the bolt while holding the generator ro tor with the sheave holder 2 Sheave holder 90890 01701 ...

Page 150: ...hift shaft and segment Generator starter clutch Timing chain guide intake 1 Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to CYLINDER AND PISTON Refer to CLUTCH Refer to OIL PUMP Refer to BALANCER DRIVE GEAR Refer to SHIFT SHAFT Refer to STARTER CLUTCH AND GENERATOR 7 Nm 0 7 m kg 8 Nm 0 8 m kg CRANKSHAFT ENG CRANKSHAFT CRANKCASE ...

Page 151: ...er Job Part Q ty Remarks 2 3 4 Timing chain Crankcase Dowel pins 1 1 2 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE For installation reverse the removal pro cedure 8 Nm 0 8 m kg 7 Nm 0 7 m kg CRANKSHAFT ENG ...

Page 152: ... Crankshaft assembly Dowel pin Plunger seal Compression spring Bearings balancer weight Bearing crankshaft right 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to INSTALLING THE CRANK SHAFT Refer to REMOVING INSTALLING THE PLUNGER SEAL For installation reverse the removal pro cedure CRANKSHAFT AND BALANCER WEIGHT ...

Page 153: ...d on the crankcase in dicate the crankcase tightening sequence 2 Remove right crankcase Set the left crankcase half under then put in the flat head screw driver to the separating slit a First check that the shift drum segment s teeth and the drive axle circlip are properly positioned then remove the right crank case Do not damage the crankcase mating sur faces REMOVING THE PLUNGER SEAL 1 Remove Do...

Page 154: ...fication Replace the big end bearing crankshaft pin or connecting rod Big end axial clearance 0 35 0 65 mm Limit 1 0 mm 3 Measure crankshaft width Out of specification Replace the crank shaft Crankshaft width 55 95 56 00 mm 4 Check crankshaft sprocket 1 Damage wear Replace the crankshaft bearing 2 Cracks damage wear Replace the crankshaft 5 Check crankshaft journal Scratches wear Replace the crank...

Page 155: ...lace the timing chain and camshaft sprocket as a set 2 Check camshaft sprocket More than 1 4 tooth a wear Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check timing chain guide exhaust side timing chain guide intake side timing chain guide top side Damage wear Replace the defective part s SR INSTALLING THE PLUNGER SEAL...

Page 156: ... and apply en gine oil onto each bearing EAS00418 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Do not allow any sealant to come into contact with the oil gallery a 3 Install dowel pins right crankcase 4 Tighten crankcase right half Tighten the screws in de...

Page 157: ...Shift fork 1 C center Shift fork 2 R right Shift fork 3 L left Main axle assembly Plate washer Drive axle assembly Plate washer 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE AND CRANKSHAFT Refer to INSTALLING THE TRANSMISSION SHIFT FORK AND SHIFT DRUM ASSEMBLY For installation reverse the removal pro cedure Refer to REMOVING THE TRANSMIS SION TRANSMISSION TRANSMISSION...

Page 158: ...l gear Circlip washer Third wheel gear Forth wheel gear Drive axle Second pinion gear Forth pinion gear Third pinion gear Circlip washer Fifth pinion gear gear Main axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the removal pro cedure 8 1 2 3 4 5 6 7 9 10 11 12 13 DRIVE AXLE AND MAIN AXLE ...

Page 159: ...ds damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace 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 s...

Page 160: ... axle runout limit 0 08 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies When reassembling the main axle press the 2nd pinion gear 1 onto it ...

Page 161: ...side for the clutch side shift fork 1 C center 3 face the C side for the magneto side shift fork guide bar 1 4 long shift fork guide bar 2 5 short Install the shift forks with the embossed mark to the right and in sequence R C L beginning from the right 2 Check shift cam operation Unsmoothy operation Repair Check the transmission and shift forks for smooth operation by turning the shift cam with y...

Page 162: ...ENG ...

Page 163: ...CARB 5 ...

Page 164: ...URETOR CARBURETOR 5 1 CHECKING THE CARBURETOR 5 4 ASSEMBLING THE CARBURETOR 5 5 INSTALLING THE CARBURETOR 5 7 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHECKING THE FUEL COCK 5 8 CHECKING THE FUEL COCK OPERATION 5 8 ...

Page 165: ......

Page 166: ...ad Carburetor joint clamp screw Air filter joint clamp screw Carburetor assembly Carburetor top 1 1 1 1 Remove the parts in order listed NOTE Refer to SEAT FUEL TANK AND SIDE COVER in CHAPTER 3 Disconnect the cable from wireharness Loosen For installation reverse the removal procedure NOTE EAS00480 CARBURETOR CARBURETOR ...

Page 167: ...bly Throttle valve spring Mixing chamber top O ring Drain screw assembly Float chamber Gasket float chamber Float pin float Needle valve assembly Main jet Main nozzle O ring 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to ASSEMBLYING THE CARBURETOR 1 10 2 3 4 5 6 7 8 9 11 EAS00483 ...

Page 168: ... Remarks Pilot screw assembly Pilot jet Throttle stop screw assembly Starter plunger assembly Screw gasket Heater unit washer 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to ASSEMBLING THE CARBURETOR 12 13 14 15 16 17 ...

Page 169: ...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 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check gasket 3 Damage wear Replace the needle val...

Page 170: ... starter plunger spring 2 Bends cracks damage Replace 10 Check hose joints Cracks damage Replace 11 Check fuel hoses 1 Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air EAS00487 ASSEMBLING THE CARBURETOR Before assembling the carburetor wash all of the parts in a petroleum based solvent Always use a new gasket 1 Install main nozzle 1 main jet 2 pilot jet 3 ...

Page 171: ...OR CARB NOTE 2 Install needle valve seat 1 3 Install float 1 needle valve float pin 2 Install the float pin from the side opposite the ar row 4 Install float chamber 1 pilot screw 2 5 Install starter plunger kit 1 ...

Page 172: ...LAY in chapter 3 EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level below the float cham ber mating surface 0 2 0 mm a Stand the motorcycle on a level surface b Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c Install the fuel level gauge 1 to the fuel drain pipe 2 Fuel level gauge 90890 0131...

Page 173: ...f until the fuel level is within specification EAS00505 CHECKING THE FUEL COCK 1 Check fuel cock Cracks damage wear Replace 2 Check fuel cock strainer with compressed air Dirt obstruction Clean Damage Replace EAS00506 CHECKING THE FUEL COCK OPERATION After installing the fuel cock check its opera tion 1 Check that the fuel cock lever is positioned to ON or RESERVE 2 Place a container under the end...

Page 174: ...CHAS 6 ...

Page 175: ...8 FRONT BRAKE 6 19 FRONT BRAKE PADS 6 19 REPLACING THE FRONT BRAKE PADS 6 20 FRONT BRAKE MASTER CYLINDER 6 23 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6 25 CHECKING THE FRONT BRAKE MASTER CYLINDER 6 25 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 26 FRONT BRAKE CALIPER 6 28 DISASSEMBLING THE FRONT BRAKE CALIPER 6 30 CHECKING THE FRONT BRAKE CALIPER 6 30 ASSEMBLING AND INSTALLIN...

Page 176: ...BER 6 52 DISPOSING OF A REAR SHOCK ABSORBER 6 52 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 6 53 REMOVING THE DRIVE CHAIN 6 53 REMOVING THE SWINGARM 6 54 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 6 55 CHECKING THE SWINGARM 6 55 CHECKING THE DRIVE CHAIN 6 56 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 6 57 INSTALLING THE SWINGARM 6 58 INSTALLING THE DRIVE CHAIN 6 58 ...

Page 177: ... unit assembly Brake disc 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Refer to REMOVING INSTALLING THE FRONT WHEEL For installation reverse the removal procedure NOTE 13 Nm 1 3 m kg 90 Nm 9 0 m kg FRONT WHEEL AND BRAKE DISC CHAS EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC ...

Page 178: ...g the front wheel Oil seal Bearing Spacer Spacer flange Bearing Order Job Part Q ty Remarks 1 1 1 1 1 Disassemble the parts in the order listed Refer to ASSEMBLYNG DISASSEMBLING THE FRONT WHEEL For assembly reverse the disassembly procedure 1 2 3 4 5 ...

Page 179: ...elevated 2 Remove speedometer cable 1 brake caliper 2 wheel axle 3 Do not squeeze the brake lever when removing the brake caliper 3 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00526 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check tire front ...

Page 180: ...el lateral runout b Over the specified limits Replace Front wheel radial runout limit 2 mm Front wheel lateral runout limit 2 mm 6 Check collars Damage wear Replace Tire valve stem locknut After mounting a new tire ride conserva tively for a while to become accustomed to the feel of the new tire and to allow the tire to seat itself properly in the rim Failure to do so could lead to an accident wit...

Page 181: ...e oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 1 with a gener al bearing puller 2 d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing center race 1 or balls 2 Contact should be made only with the outer race 3 Use a socket ...

Page 182: ...bar to the left or right to ensure that the front wheel is station ary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit mini mum 3 mm 4 Ad...

Page 183: ...ips speedometer drive gear speedometer driven gear Recommended lubricant Lithium soap base grease 2 Install speedometer gear unit 1 Make sure that the speedometer gear unit and the wheel hub are installed with the three pro jections a meshed into the three slots b re spectively 3 Install front wheel Make sure that the slot a in the speedometer gear unit fits over the stopper b on the outer tube 4 ...

Page 184: ...pot a Spin the front wheel b When the front wheel stops put an 1 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 ...

Page 185: ...heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Sfront 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 186: ...rake rod Pin Compression spring Chain case Axle nut washer Chain pullers Wheel axle 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE REAR WHEEL Place the motorcycle on a suitable stand so that the rear wheel is elevated NOTE 90 Nm 9 0 m kg REAR WHEEL AND REAR BRAKE REAR WHEEL ...

Page 187: ...EAR WHEEL AND REAR BRAKE CHAS Order Job Part Q ty Remarks 9 10 Rear wheel assembly Collar O ring 1 1 1 Refer to REMOVING INSTALLING THE REAR WHEEL For installation reverse the removal procedure 90 Nm 9 0 m kg ...

Page 188: ... sprocket Shoe plate Nuts washers driven sprocket Bolts Driven sprocket 1 6 6 6 1 For installation reverse the removal procedure Refer to ASSEMBLYNG THE REAR WHEEL Remove the parts in the order listed 35 Nm 3 5 m kg REAR WHEEL AND REAR BRAKE CHAS REAR BRAKE AND REAR WHEEL SPROCKET ...

Page 189: ... REAR BRAKE CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Bearing Collar Spacer Oil seal Bearing 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 ...

Page 190: ...the brake shoe plate Brake shoe kit Tension springs Camshaft lever Indicator plate Camshaft 2 2 1 1 1 Disassemble the parts in the order listed Refer to REMOVING THE REAR WHEEL ASSEMBLYING THE BRAKE SHOE PLATE For assembly reverse the disassembly procedure 1 2 3 4 5 9 Nm 0 9 m kg ...

Page 191: ... the drive chain from the rear wheel sprocket 3 Remove brake shoe plate 4 Remove brake shoes 1 brake camshaft lever 2 Mark the position on the brake camshaft lever where it is aligned with the punch mark on the brake camshaft EB701401 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to CHECKING THE...

Page 192: ...el drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket Rear wheel sprocket self locking nut 35 Nm 3 5 m kg Tighten the self locking nuts in stages and in a crisscross pattern EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes 1 Check brake shoe lining Glazed areas Repair Sand the glazed areas with c...

Page 193: ...111 mm 4 Check brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth 5 Check brake camshaft Damage wear Replace EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1 Install brake camshaft 1 brake shoe wear indicator 2 a Align the projection a on the brake shoe wear indicator with...

Page 194: ...chain slack 35 60 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 3 Tighten wheel axle nut Make sure that the brake hose is routed properly EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel st...

Page 195: ... 3 Removing the front brake pads Bolt caliper support bolt Brake pads Pad springs 1 2 1 Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS For installation reverse the removal procedure 27 Nm 2 7 m kg FRONT BRAKE FRONT BRAKE PADS ...

Page 196: ...Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00581 REPLACING THE FRON...

Page 197: ...he bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install new brake pads and brake pad spring Make sure that the brake pad spring is installed correctly as shown 6 Lubricate brake caliper guide bar 1 brake pad bolts 2 Recommen...

Page 198: ...rake 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 9 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 199: ... compression spring Brake switch Union bolt Copper washers Brake hose Bracket master cylinder Master cylinder 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to DISASSEMBLING ASSEM BLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER For installation reverse the removal proce dure 26 Nm 2 6 m kg 2 Nm 0 2 m kg 7 Nm 0 7 m kg FRONT BRAKE MASTER CYLINDER ...

Page 200: ...Disassembling the front brake mas ter cylinder Rubber boots Circlip Master cylinder kit Spring Order Job Part Q ty Remarks 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the removal proce dure 1 2 3 4 ...

Page 201: ...hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00590 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check brake master cylinder 1 Damage scratches wear Replace brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check brake master cylinder kit 1 Damage scratches wear Replace 3 Ch...

Page 202: ...ver use solvents on internal brake com ponents Recommended brake fluid DOT 4 1 Install brake master cylinder 1 Install the brake master cylinder holder with the UP mark 2 facing up First tighten the upper bolt then the lower bolt 2 Install copper washers 1 brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing th...

Page 203: ...g brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer t...

Page 204: ...ke hose holder Union bolt Plain washer Brake hose Caliper support bolt Caliper assembly 1 1 1 1 1 1 Remove the parts in the order listed Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER For installation reverse the removal procedure 30 Nm 3 0 m kg 27 Nm 2 7 m kg 26 Nm 2 6 m kg FRONT BRAKE CALIPER ...

Page 205: ... brake cali per Brake pad Caliper pistons Dust seals Piston seals Bleed screw Cap 2 2 2 1 Disassemble the parts in the order listed Refer to BRAKE PAD section Refer to DISASSEMBLING THE FRONT BRAKE CALIPER For assembly reverse the disassembly procedure 1 2 3 4 6 Nm 0 6 m kg ...

Page 206: ... seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake caliper piston seals EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component ...

Page 207: ... caliper is disassembled replace the piston seals 2 Check brake caliper bracket 1 Cracks damage Replace EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake ...

Page 208: ...older Refer to REPLACING THE BRAKE PADS 4 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids ma...

Page 209: ...e system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 210: ... upper bracket Bolts under bracket Front fork assembly left Front fork assembly right 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISC Loosen the bolt NOTE Refer to REMOVING INSTALLING THE FRONT FORK For installation reverse the removal procedure 23 Nm 2 3 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg 5 23 Nm 2 3 m kg FRONT FORK ...

Page 211: ...rk Cap bolt O ring Collar washer Fork spring Boot Retaining clip Oil seal Damper rod bolt Inner tube assembly Oil seal Outer tube bushing Damper rod Rebound spring Outer tube 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Drain the fork oil NOTE Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK Refer to ASSEMBLING THE FRONT FORK 1 2 3 4 5 6 7 8 9 11 12 13 27 Nm 2 7 m kg 23 Nm 2 3 m kg ...

Page 212: ...table stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain fork oil While stroking the inner tube several times dra...

Page 213: ...S00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Over the specified limit Replace Spring free length limit 338 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow o...

Page 214: ... FRONT FORK LEGS The following procedure applies to both of the front fork legs Make sure that the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability When assembling the front fork leg be sure to replace the following parts outer tube bushing oil seal Before assembling the front fork leg make sure that all of the components are clean...

Page 215: ... 4 Install outer tube bushing 1 with the fork seal driver weight and adapter Fork seal driver weight 90890 01367 Adapter 90890 01368 5 Install oil seal 1 with the fork seal driver weight and adapter Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its lips Apply fork oil onto the outer surface of the in ner tube Before ins...

Page 216: ...g 0 243 L Yamaha fork and shock oil 10W or equivalent Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring 135 mm While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 9 Install spring 1 spring seat 2 spacer 3 cap bolt 4 Before installing the cap bolt...

Page 217: ...cedure applies to both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 Make sure that the brake hoses are routed properly ...

Page 218: ...moving the handlebar Master cylinder bracket Master cylinder Housing throttle grip Throttle grip assembly Handlebar switch right Clutch switch Clutch cable 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to INSTALLING THE HANDLE BAR 20 Nm 2 0 m kg HANDLEBAR ...

Page 219: ... 11 12 13 Handlebar switch left Grip left Clutch lever Starter cable holder Upper holders Handlebar 1 1 1 1 2 1 Refer to REMOVING THE HANDLEBAR section For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR section 20 Nm 2 0 m kg ...

Page 220: ...ip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken it 3 Install handlebar grip a Apply a light coat of rubber adhesive onto ...

Page 221: ...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 The upper handlebar holders should be installed with the arrows a facing forward a large b short Align the match marks c on the handlebar with the upper surface of the lower handlebar holders 3 Instal...

Page 222: ...y a thin coat of litium soap base grease onto the end of the clutch cable 8 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 15 mm 9 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 223: ...ter lead Meter assembly Headlight stay Steering stem nut Handlebar crown Lock washer Upper ring nut Rubber washer Lower ring nut Ball race cover Lower bracket 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT FORK Refer to HANDLEBAR Disconnect the connector Refer to INSTALLING THE STEERING HEAD NOTE 90 Nm 9 0 m kg 1st 38 Nm 3 8m kg 2nd 18 Nm 1 8 m kg 5 STEERING HE...

Page 224: ...art Q ty Remarks 16 17 18 19 20 Ball race upper Ball Ball Ball race center Ball race lower 1 22 19 1 1 For installation reverse the removal pro cedure Refer to INSTALLING THE STEERING 90 Nm 9 0 m kg 1st 38 Nm 3 8m kg 2nd 18 Nm 1 8 m kg 5 ...

Page 225: ...t and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 2 90897 01268 Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearing balls bearing races Recommended cleaning solvent Kerosine 2 Check bearing balls 1 bearing races 2 Damage pitting Replace 3 Replace bearing balls ...

Page 226: ... replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer upper ring nut 2 lock washer 3 Refer to INSPECTING THE STEERING HEAD in chapter 3 3 Install upper bracke...

Page 227: ...chain Nut Pivot shaft Swingarm Cover swingarm Bush 1 1 1 1 1 2 2 Remove the parts in order Refer to REMOVING INSTALLING THE REAR SHOCK ABSORBER Refer to REMOVING INSTALLING THE DRIVE CHAIN For installation reverse the removal procedure Refer to REAR WHEEL AND REAR BRAKE Refer to REMOVING INSTALLING THE SWINGARM 80 Nm 8 0 m kg 56 Nm 5 6 m kg REAR SHOCK ABSORBER AND SWINGARM ...

Page 228: ...tempt to open the rear shock absorber Do not subject the rear shock absorber 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 in any way If the rear shock ab sorber or both are damaged damping per formance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORB ER a Gas pressure must be re...

Page 229: ...y lower pin hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm EAS00706 REMOVING THE DRIVE CHAIN 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling ove...

Page 230: ... swingarm so that it does not drop down 3 Check swingarm side play A swingarm vertical movement B a Check the tightening torque of the pivot shaft nut Pivot shaft nut 80 Nm 8 0 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swi...

Page 231: ...orber assembly spring Damage wear Replace the rear shock absorber assembly bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers space...

Page 232: ...ction limit maximum 121 4 mm While measuring the 10 link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 11 as shown Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosine an...

Page 233: ...e chain Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket EAS00697 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate spacers bearings Recom...

Page 234: ...AIN SLACK in chapter 3 Drive chain slack 35 60 mm EAS00714 INSTALLING THE DRIVE CHAIN 1 Lubricate drive chain master link New Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains 2 Install master link 1 master link plate 2 3 Install master link clip 1 The closed end of the master link clip must face in the direction of drive chain rotation Never install a new drive ch...

Page 235: ... CHAS CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swin garm or cause an accident Therefore keep the drive chain slack within the specified limits ...

Page 236: ...CHAS ...

Page 237: ...ELEC 7 ...

Page 238: ...KETS 7 6 IGNITION SYSTEM 7 7 CIRCUIT DIAGRAM 7 7 TROUBLESHOOTING 7 8 ELECTRIC STARTING SYSTEM 7 12 CIRCUIT DIAGRAM 7 12 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 7 13 TROUBLESHOOTING 7 14 STARTER MOTOR 7 17 CHARGING SYSTEM 7 20 CIRCUIT DIAGRAM 7 20 TROUBLESHOOTING 7 21 LIGHTING SYSTEM 7 23 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 24 CHECKING THE LIGHTING SYSTEM 7 25 SIGNAL SYSTEM 7 28 CIRCUIT DIAGRAM...

Page 239: ......

Page 240: ...n switch 4 Fuse holder assembly 5 Starter relay 6 Rectifier Regulator 7 Battery 15 C D I unit 8 Neutral relay 9 Thermo switch 10 Sidestand switch 11 Rear brake switch 12 Neutral switch 13 Spark plug cap 14 Ignition coil EAS00729 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 241: ...king for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a continuity of electricity between s...

Page 242: ...stand switch 12 Rear brake switch 13 Fuse 14 Thermo switch SWITCH INSPECTION ELEC EAS00731 SWITCH CONTINUITY INSPECTION Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 243: ...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 re spective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise ...

Page 244: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 245: ... tester No continuity Replace Pocket tester 90890 03112 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb soc...

Page 246: ... Neutral switch 4 Battery 6 Fuse 10 Engine stop switch 11 Main switch 13 Diode 14 C D I unit 15 Ignition coil 16 Spark plug 21 Sidestand switch 22 Neutral relay IGNITION SYSTEM ELEC EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 247: ...n spark gap 6 mm Is there a spark and is the spark gap within specification NO The ignition system is OK YES 3 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance 1 2 a NOTE EAS00736 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 spark plug 2 ignition spa...

Page 248: ...he secondary coil resistance Tester positive probe spark plug lead Tester negative probe orange Secondary coil resistance 6 32 X 9 48 kΩ at 20_C SIs the ignition coil OK SDisconnect the pickup coil coupler from the wire harness SConnect the pocket tester Ω 100 to the pickup coil terminal as shown 5 Pickup coil resistance SMeasure the pickup coil resistance Pickup coil resistance 656 X 984 Ω at 20_...

Page 249: ...main switch NO SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK 8 Engine stop switch YES Replace the right handlebar switch NO SCheck the sidestand switch for continuity Refer to CHECKING THE SWITCHES SIs the sidestand switch OK 9 Sidestand switch YES Replace the side stand switch NO SCheck the neutral relay for continuity Refer to ELECTRIC ...

Page 250: ...be blue white 1 2 Continuity No continu ity Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects 13 Wiring NO Replace the CDI unit YES Properly connect or repair the ignition system s wiring YES Replace the relay unit NO NOTE When you switch the and leads of the digital pocket tester the readings in the above cha...

Page 251: ...tery 5 Starter relay 6 Fuse 7 Starter motor 9 Start switch 10 Engine stop switch 11 Main switch 12 Clutch switch 21 Sidestand switch 22 Neutral relay ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 252: ...d switch is closed The neutral relay prevents the starter motor from operating when neither of these conditions has been met In this instance the neutral relay is open so current cannot reach the starter mo tor When at least one of the above conditions has been met the neutral relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SI...

Page 253: ...This check is likely to produce sparks therefore make sure that no flammable gas or fluid is in the vicinity SDoes the starter motor turn ELECTRIC STARTING SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Fuse SCheck the fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the fuse OK EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 fuse 2 battery 3 starter motor 4 neutral...

Page 254: ...rown 1 2 Tester positive probe red Tester negative probe black 3 4 5 Starter relay Disconnect the starter relay from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay coupler as shown Does the starter relay have continuity be tween red and check YES Replace the starter relay NO 6 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the m...

Page 255: ...ity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES Replace the clutch switch NO 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES Replace the right handlebar switch NO 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects NO The st...

Page 256: ...rts in order Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 Reverse the removal procedure for installation Refer to Assembly section Starter motor disassembly Front cover Washer set Rear cover Armature coil Brush 1 1 1 1 1 Disassemble the parts in order Reverse the disassembly procedure for assembly 1 2 3 4 5 ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR ...

Page 257: ...cksaw blade which has been grounded to fit the commuta tor Mica undercut 1 5 mm The mica must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 Armature assembly Commutator resistance ...

Page 258: ...ush spring 14 5 mm 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s EAS00772 Assembling the starter motor 1 Install washer set Align the tabs a on the washer with the slots b in the starter motor front cover 2 Install starter motor yoke 1 O rings 2 starter motor front cover 3 starter motor rear cover 4 bolts Align the match marks a o...

Page 259: ...7 20 1 C D I magneto 3 Rectifier Regulator 4 Battery 6 Fuse CHARGING SYSTEM ELEC YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 260: ...se 1 Fuse SCheck the main fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuses OK YES NO 2 Battery SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Specific gravity 1 280 at 20_C S Is the battery OK SRefill the battery fl uid SClean the battery terminals SRecharge or repla ce the battery EAS00774 TROUBLESHOOTING The battery is...

Page 261: ... s wiring 4 Stator coil assembly resistance SDisconnect the starter coil coupler from the wire harness SConnect the pocket tester Ω 1 to the sta tor coil assembly coupler as shown Stator coil resistance 0 48 X 0 72 Ω at 20_C SIs the stator coil assembly OK YES Replace the stator coil assembly NO Tester positive probe white Tester negative probe white 1 2 SMeasure the stator coil assembly resis tan...

Page 262: ...y 6 Fuse 11 Main switch 25 Meter light 28 High beam indicator light 32 Lights switch 33 Dimmer switch 40 Headlight 41 Auxiliary light 42 Tail Brake light LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 263: ... the main switch OK YES Replace the main switch NO 3 Main switch EAS00783 SCheck the lights switch for continuity Refer to CHECKING THE SWITCHES SIs the lights switch OK YES The lights switch is faulty Replace the right handlebar switch NO 4 Lights switch EAS00781 TROUBLESHOOTING Any of the following fail to light head light high beam indicator light taillight auxiliary light or meter light Check ...

Page 264: ... of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES Replace the head light bulb socket or both NO 1 Headlight bulb and socket 2 Voltage Connect the pocket tester DC 20 V to the headlight and high beam indicator light cou plers as sho...

Page 265: ...er is faulty and must be re paired NO Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue on the meter assembly coupler wire harness side Is the voltage within specification This circuit is OK EAS00789 2 A meter light fails to come on 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are...

Page 266: ...on the tail brake light coupler wire harness side Is the voltage within specification 1 Replace the auxiliary light bulb socket or both NO EAS00791 4 The auxiliary light fails to come on 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the auxiliary light bulb and socket OK YES 1 2 Voltage Connect the pocket...

Page 267: ...ndicator light 27 Turn signal indicator light 30 Horn switch 31 Turn signal switch 34 Front brake switch 35 Rear brake switch 36 Rear turn signal light right 37 Front turn signal light right 38 Front turn signal light left 39 Rear turn signal light left 42 Tail Brake light SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 268: ...Wiring SCheck the entire signaling system s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wiring Check the condition of each of the signal ing system s circuits Refer to CHECKING THE SIGNALING SY STEM SIGNAL SYSTEM ELEC NOTE EAS00794 TROUBLESHOOTING SAny of the following fail to light ...

Page 269: ...the horn switch Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connector at the black terminal as shown Tester positive probe pink Tester negative probe ground 1 Set the main switch to ON Push the horn switch Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is fau...

Page 270: ...brake light co upler is faulty and must be repaired NO This circuit is OK Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification Replace the turn sig nal light bulb socket or both NO EAS00799 3 A turn signal light turn signal indicator light or both fa...

Page 271: ...flasher relay is faulty and must be re placed NO YES Set the main switch to ON Measure the voltage 12 V on brown white at the flasher relay coupler wire harness side Is the voltage within specification 6 Voltage Connect the pocket tester DC 20 V to the turn signal light connectors or the meter as sembly coupler wire harness side as shown Turn signal light Turn signal indicator light A B Left turn ...

Page 272: ...ecification 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe sky blue 1 2 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES Set the main switch to ON Measure the voltage 12 V of brown and sky blue ...

Page 273: ... heating element from the carburetor SConnect the pocket tester Ω 1 to the car buretor heating element Tester positive probe heating element Tester negative probe heating element body 1 2 Carburetor heating element resis tance 6 X 12 Ω 20_C YES Replace the carbure tor heater element NO SMeasure the carburetor heater resistance SIs the carburetor heating element OK This circuit is OK 8_C 4_C 19_C 3...

Page 274: ...TRBL SHTG 8 ...

Page 275: ...INCORRECT ENGINE IDLING SPEED 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 FAULTY CLUTCH 8 3 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT LEGS 8 4 UNSTABLE HANDLING 8 4 FAULTY LIGHTING AND SIGNALING SYSTEMS 8 5 ...

Page 276: ......

Page 277: ...ank breather hole Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose Carburetors Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Incorrectly installed needle valve seat Incorrect fuel level Incorrectly installed pilot jet Clogged starter jet Faulty starter plunger Incorrectly adjusted starter cable EL...

Page 278: ...nition coil Broken or shorted primary or secondary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty CDI unit Faulty pickup coil EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter Clogged air filter element FUEL SYSTEM Carburetors Faulty diaphragm Incorrect fuel level Loose or clogged main jet EAS00850 FAULTY GEAR SHIFTING SHIFTING ...

Page 279: ...utch push rod Damaged clutch boss Burnt primary driven gear bushing Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00854 OVERHEATING ENGINE Cylinder head s and piston s Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality FUEL SYSTEM Carburetors Incorrect main jet setting Incorrect fuel level Damag...

Page 280: ...ged cap bolt O ring MALFUNCTION Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube busing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS00864 UNSTABLE HANDLING Handlebar Bent or incorrectly installed handlebar Steering head components Incorrectly installed upper bracket Incorrectly installed lower bracket incorrectly tig...

Page 281: ...KE LIGHT BULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty flasher relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Incorrectly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWL...

Page 282: ...TRBL SHTG ...

Page 283: ...tart switch 10 Engine stop switch 11 Main switch 12 Clutch switch 13 Diode 14 C D I unit 15 Ignition coil 16 Spark plug 17 Thermo switch 18 Carbuletor heater 19 Horn 20 Flasher relay 21 Sidestand switch 22 Neutral relay 23 Speedometer 24 Reed switch for D 5EK2 25 Meter light 26 Neutral indicator light 27 Turn signal indicator light 28 Hi beam indicator light 29 Handlebar switches left 30 Horn swit...

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