Yamaha Vmax VMX12N Supplementary Service Manual Download Page 163

Page: 163 / 405

INSPECTION A N D REPAIR

P l

7. Remove:

rod cap

Use care in removing.

Width of Plastigage®

Measure:

Out of specification

Replace bearings

and/or replace crankshaft if necessary.

Connecting

Rod BearingClearance:

0.021

-0.045

(0.0008 0.0018 in)

Crankshaft Main and Connecting Rod Bearing
Selection

used to indicate crankshaft journal

sizes

are stamped on the crankweb. The first

two

are main bearingjournal numbers,

starting with the left journal. The four

(4)

rod bearing journal numbers follow in

the same sequence.

lower crankcase half

i s numbered

J2,

J3, and J4 on the front left boss as shown.

connecting rods are numbered

3 or

The

numbers

are stamped in ink on the rod.

3-39

Summary of Contents for Vmax VMX12N

Page 1: ...VMXl2N NC K KC ...

Page 2: ...LIT 11616 10 12 ...

Page 3: ... this Supplementary Service Manual together with the following manual I 1 VMX12N SERVICE MANUAL 2WE 28197 10 VMXl2F SUPPLEMENTARY SERVICE MANUAL 2WE 28197 11 I I VMX12H VMX12HC SUPPLEMENTARY SERVICE MANUAL 01995 by Yamaha Motor Co Ltd 1st Edition July 1995 All rights resewed Any reprinting or unauthorizeduse without the written permissionof Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...r for any service ronmental quality objectives NOTE For USA California This Service Manual contains information regarding periodic maintenance to the emission control system Please read this material carefully PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation a SAFETY I S INVOLVED The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR Failure to follow W...

Page 5: ...mechanic with an easy to read handy refer ence that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure is placed between a line of asterisks each procedure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol An encircled numeral indicates a part name and an encircled a...

Page 6: ...pecifications appearing in the text Filling fluid Lubricant Special tool Wear limit clearance Engine speed V A Illustratedsymbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply wheel bearing grease Apply lightweight lithium soap base grease Apply molybdenum disulfide grease Illustrated symbols to in the exploded diagrams in...

Page 7: ... NUMBER 1 SPECIAL TOOLS 2 SPECIFICATIONS 3 GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 3 ENGINE 3 ELECTRICAL 4 PERIODIC INSPECTION AND ADJUSTMENT 5 ENGINE 5 ENGINE OIL REPLACEMENT 5 ENGINE OVERHAUL 7 INSPECTION AND REPAIR 7 CRANKSHAFTAND CONNECTING ROD 7 BALANCER SHAFT 11 MIDDLE GEAR SERVICE 13 CHASSIS 14 SHAFT DRIVE 14 ...

Page 8: ... state FRAME SERIAL NUMBER The frame serial number is stamped into the right side of the steering pipe Starting serial number 1 2EN 042101 EUR I I NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase Starting serial number 2WE 050101 USA 2WF 012101 C...

Page 9: ...he correct special tool will help prevent damage caused by the use of improper tools or improvised techniques The shape and part number used for the special tool differ by country so two types are provided FOR ENGINE SERVICE when placing an order P N 90890 YM Exceptfor US CDN Oil filter wrench YU 38411 P N 1426 This tool is used to remove and install the oil Ifilter 2 ...

Page 10: ...jet Jet needle Needle jet Pilot jet Pilot air jet Pilot screw Pilot outlet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Fuel level Engine idling speed Vacuum pressure at idling speed N J P J P A J 1 PS P O B P l B P 2 B P 3 V S G S 1 G S 2 Th V F L VMX12 1FK02 USA 2WF 02 California 3LR 01 EUR 152 5 USA California 150 EUR 82 0 5EZ43 1 USA 5EZ50 1 California...

Page 11: ...r output Brush overall length Limit Commutator diameter Wear Iimit Mica undercut Starter switch Model manufacturer Amperage rating Coil winding resistance Thermostatic switch Model manufacturer Constant mesh type SM 13 MITSUBA 0 65 kW 12 5 mm 0 49 in 5 0 mm 0 20 in 28 mm 1 10 in 27 mm 1 06 in 0 7 m m 0 03 in MS5D 191 HlTACHl 100A 3 9 4 7 at 20 C 68 F 2EL USA 47X California EUR NIHON THERMOSTAT 4 ...

Page 12: ... Drain bolt with gasket Drain the crankcase of its oil the oil filter is to be replaced during this oil change remove the following parts and reinstall them Replacementsteps the oil filter using the oil filter wrench Oil filter wrench YU 38411 90890 01426 engine oil to the O ring of the new oil filter NOTE Make sure the O ring is positioned cor rectly the oil filter using the oil filter wrench Oil...

Page 13: ...3 8 L 3 3 Imp qt 4 0 US qt Oil quantity Total amount Periodic oil change With oil filter replacement NOTE Recommended oil classification API Ser vice SE SF and SG type or equiva Ient e g SF SE SF SE CC SF SE SD etc Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material t o enter the crankcase 8 1nstaII 9 Warm ...

Page 14: ...fication Replace bearing 0 020 0 038 mm 0 0008 0 0015 in Measurement steps Do not interchange the bearings and con necting rod They must be installedin their original positions or the correct oil clear ance may not be obtained causing engine damage the bearings main journals and bearing portions of the crankcase the crankcase upper on a bench in an upside down position the upper half of the bearin...

Page 15: ...t s t o speci f i cat i on i n t he t i ght eni ng sequence cast on t he cr ank case Bol t Cr ankcase M 10 40 Nm 4 0 29 ft l b W i t h a washer Rem ove t he cr ankcase l ower and l ower hal foft he bear i ng M easur e t he com pr essed Pl ast i gauge wi dt h on each m ai n j our nal I f oi l cl ear ance i s out of speci f i cat i on sel ecta r epl acem entbear i ng 4 M easur e O i lcl ear ance cr ...

Page 16: ...enum disulfide grease to the bolts threads and nut seats Make sure the Y marks on the connect ing rods face the left side of the crank shaft Make sure that the letters on both compo nents align to from a perfect character the nuts 3 6 m kg 25 I Tighten to full torque specificationwithout pausing Apply continuoustorque between 3 0 and 3 8 Once you reach 3 0 DO NOT STOP TIGHTENING until final torque...

Page 17: ...ng P Sel ect i on of beari ngs Exam pl e 1 M ai n j ournal beari ng J on t he cr ankcase i s 6 and 1 on t he cr ankweb t hen t he bear i ng si ze f or i s Exam pl e 2 Crank pi n beari ng on t he connect i ng r od i s 4 and 2 on t he cr ankweb t hen t he bear i ng si ze f or i s ...

Page 18: ...r shaft and bearing portions of the crankcase the crankcase upper on a bench in an upside down position the upper half of the bearings and the balancer shaft into the crankcase upper a piece of Plastigauge on each bal ancer shaft journal the lower half of the bearings into the crankcase lower and assemble the crankcase halves NOTE Do not move the balancer shaft until the oil clearance measurement ...

Page 19: ...r shaft bearing Selection of bearings Example on the crankcase is 6 and 2 on the balancer shaft then the bearing size for J is Bearing size of Crankcase Balancershaft No 6 2 4 Green BEARINGCOLOR CODE 1 Blue I 2 I Black 3 Brown 4 Green Yellow Pink 12 ...

Page 20: ...ERVICE Universaljoint Dust seal Housing O ring Thrust washer Bearing Retainer Collapsible collar Bearing Middle drive shaft Middle driven pinion gear Spring seat Damper spring Damper cam Middle drive pinion gear 13 ...

Page 21: ...g Oil seal Ring gear shim Bearing Ring gear Thrust washer Bearing Oil seal Collar CHASSIS Bearing Bearing Drive pinion gear Final drive gear shim Bearing Bearing retainer O ring Oil seal Coupling gear Spring Circlip Drive shaft Oil seal 27Washer Circlip Bearing Circlip Universal joint 23 Nm 2 3 17 ...

Page 22: ...VAMAHA MOTOR CO LTD PRINTEDI N U S A ...

Page 23: ...E LIT 11616 08 77 ...

Page 24: ... with the following manual VMX12N VMX12NC SERVICE MANUAL LIT 11616 04 67 VMX12S VMX12SC SUPPLEMENTARY SERVICE MANUAL LIT 11616 04 98 VMX12U VMX12UC SUPPLEMENTARY SERVICE MANUAL LIT I1616 06 08 VMXl2E VMXl2EC SUPPLEMENTARY SERVICE MANUAL 1992 by Yamaha Motor Co Ltd 1st Edition November 1992 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd ...

Page 25: ...del This policy is intended to providethe customer with the most satisfaction from his motorcycleand to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be for warded to all Authorized Yamaha dealers and will where applicable ...

Page 26: ...icwith an easy to read handy reference thatcontainscomprehensiveexplanationsofalldisassembly repair assembly andinspections A set of particularly important procedure is placedbetweena line of asterisks with each procedure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol An encirclednumeral indicates a part name and an encircledalphabeticallet...

Page 27: ...bleshooting Illustrated symbols to are usedto iden tify the specifications appearing in the text Filling fluid Lubricant Specialtool limit clearance Engine speed V A Illustrated symbols to in the exploded diagram indicategrade of lubricant and loca tion of lubrication point Apply engine oil Apply gear oil Apply molybdenum disufide oil wheel bearing grease lightweight lithium soap base grease Apply...

Page 28: ...CE 2 SPECIFICATIONS 3 GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 4 ENGINE 4 CHASSIS 4 ELECTRICAL 5 CHASSIS 6 FRONT AND REAR BRAKE 6 FRONT FORK 7 REMOVAL 8 DISASSEMBLY 9 INSPECTION 10 ASSEMBLY 11 INSTALLATION 14 ELECTRICAL 16 CIRCUIT DIAGRAM 16 IGNITION SYSTEM 18 DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION 18 OPERATION 18 WIRING DIAGRAM ...

Page 29: ...umber is used to identify your motorcycle and may be usedto register your motorcycle with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number is stamped into the left side of the engine Starting serial number VMX12E 2WE 035101 NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number Designs and sp...

Page 30: ...vent damage caused by the use of im CDN proper tools or improvisedtechniques The shape and part number used for the special tool differ by country so two types are provided ForEUR AUS FOR CHASSIS SERVICE Front fork seal driver Adapter 43 weight YM 33963 90890 01367 YM 8020 YM 01326 90890 01326 For damper rod holder 29 YM 33962 90890 01375 These tools are used to loosen andtighten the front fork da...

Page 31: ... With oil and full fuel tank Up to 90 kg 198lb load 90 kg 198 Ib Maximum load Electrical Ignition system Generator system Battery type or model Battery capacity 2WE 035101 2WF 008101 BDS 35 x 4 MlKUNl I Tubeless 110 90V 18 BRIDGESTONE G525AW DUNLOP F20 150 90V 15 BRIDGESTONEG526BW DUNLOP K525 1 0 mm 0 04 in 283 kg 624Ib 216 kg 476Ib Front 284 kg 626Ib 215 kg 474Ib 225 kPa I 225 kPa I 2 25 kg cm 32...

Page 32: ...ate K2 Stroke K2 Optional spring Oil capacity Oil level Oil grade Enclosed air pressure standard Front disc brake Disc outside diameter x thickness Pad thickness Inner Limit Pad thickness Outer Master cylinder inside diameter Caliper cyIinder inside diameter Brake fluid type VMX12EC 2WE01 5EZ50 100 1050 1150 r min 250mm Hg 9 84 inHg VMX12E EC 140 mm 5 51 in 386 5 m m 15 2 in 381 5 m m 15 0 in 245 ...

Page 33: ... output Stater coil resistance FL13 HI 14V 25A at 5 000 r min 1 2 3 4 5 6 Engine speed 0 26 at 20 C White White Starter relay Model Manufacturer Amperage rating Coil winding resistance Flasher relay Type Mode nufacturer Self cancelling device Flasher frequency Wattaae Self cancelling unit Model Manufacturer 9 1OOA 3 9 at 20 C 68 F Semi transister type IPPONDENSO Yes 75 95 2 1 w x 2 3 4 w IPPONDENS...

Page 34: ...RAKE CHASSIS FRONT AND REAR BRAKE Air bleed screw Retaining pin Dust seal Piston seat Piston Brake pad Pad spring Caliper assembly Brake disc The arrow mark on the pad spring must point in the disc rotating direction 6 ...

Page 35: ...Oil seal Collar Slide metal Outer fork tube Oil lock piece Damper rod Fork spring Spring seat Seal spacer Cap bolt Fork cap CAPACITY 619 21 8 Imp oz 20 9 US Yamaha Fork Oil 1Owt or equivalent 23 Nm 2 3 m kg 17 r STD AIR PRESSURE 39 2 0 4 5 7 psi MIN TO MAX AIR PRESSURE 0 4 1 0 5 7 14 2 psi E 39 2 98 1 I ...

Page 36: ...er the engine 3 Remove Caliper assembly Brake hose holder 4 Disconnect Speedometer cable NOTE Do not depress the brake lever when the wheel is off the motorcycle otherwise the brake pads will be forced shut 5 Loosen Pinch bolt wheel axle 6 Remove Wheel axle Front wheel assembly 7 Remove Front fender Fork brace 8 Remove Fork cap Depress the valve until all of the air has been released 8 ...

Page 37: ...Cap bolt Spacer Spring seat Spring 2 Drain Fork oil 3 Remove Dust seal Retaining clip Use a thin slotted head screw driver Take care not to scratch the inner tube 4 Remove Bolt damper rod Copper washer NOTE Loosen the bolt damper rod while holding the damper rodwith the T handle and holder Holder 29 mm 90890 01326 YM 33962 90890 01375 5 Remove Inner fork tube 9 ...

Page 38: ...nner tube Excessive force will damage the oil seal and or the bushes Damage oil seal and bushing must be replaced Avoid bottoming the innertubeinthe outer tube duringthe aboveprocedure asthe oil lock piece will be damaged 6 Remove Oil seal Seal spacer Slide metal Piston metal Damper rod Oil lock piece INSPECTION 1 Inspect Innerfork tube Outer fork tube Scratches Bends Damage Replace Do not attempt...

Page 39: ...sethe DISASSEMBLY procedure Notethe following points NOTE In front fork reassembly be sure to use following new parts Piston metal Slide metal Oil seal Dust seal before reassembly Make sure that all components are clean 1 lnstall Damper rod Allow the damper rod to slide slowly down the inner fork tube until it protrudes from the bottom being careful not to damage the inner fork tube 11 ...

Page 40: ...LOCTITE NOTE Tighten the bolt damper rod while holding the damper rodwith theT handle and holder 5 lnstall Slide metal Seal spacer Oil seal Usetheforkseal driver weight andadapter Fork seal driver weight YM 33963 90890 01367 YM 8020 90890 01374 Adapter 43 mm NOTE Beforeinstallingthe oil seal apply the lithium soap base grease onto the oil seal lips Be sure that the oil seal numbered side face upwa...

Page 41: ...ump the fork up and down to distribute oil Oil level from the top of inner fork tube 123 mm 4 8 in I fully compressed without spring NOTE Place the front fork on upright position 9 Install Fork spring Spring seat Spacer collar Cap bolt NOTE Fork spring must be installed with the Before installing the cap bolt apply the Temporarily tighten the cap bolt smaller pitch upward grease to the O ring 13 ...

Page 42: ...olts under bracket Cap bolt frontfork Pinch holt handle crown Pinch bolt lower bracket Cap bolt front fork Pinch bolt handle crown 23 Nm 2 3 m kg 17 ft 23 Nm 2 3m kg 17 ft 23 Nm 2 3 m kg 17 ft 3 Adjust Frontfork air pressure Refer to FRONT FORK ADJUSTMENT in the CHAPTER 2 4 Install Fork brace Frontfender 5 Install Frontwheel Front wheel axle Pinch bolt wheel axle 60 Nm 6 0 m kg 43 ft Ib 20 Nm 2 0 ...

Page 43: ...FRONT FORK 6 Install Caliper assembly Bolt caliper bracket 35 Nm 3 5 m kg 25 ft Ib Brake hose holder Speedometer cable I Make sure that the brake hose are routed properly 15 ...

Page 44: ...CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM I I 1 ...

Page 45: ...gnition coil 4 Fuse FAN Thermo switch Fuel pump relay Fan motor FUEL RESERVE switch Fuel pump Fuse HEAD Control unit Starter motor Servo motor Starter relay START switch LIGHTS Dimmer switch Starting circuit cut off relay Head light Diode Clutch switch Meter light Sidestand switch Auxiliary light Neutral switch Battery NEUTRAL indicator light Oil level gauge Diode assembly OIL LEVEL warning indica...

Page 46: ...control unit for the electric fuel pump programed ignition advance curve tal ignitor unit Clutch switch Side stand switch Pressure sensor Pick up coil CPU microprocessor Digital ignitor unit Fuel pump Fuel pump control relay Ignition coil OPERATION The following operations are digitally per formed by signal from the pickup coil signal 1 Determing proper ignition timing 2 Sensing the engine revolut...

Page 47: ... Headlight Front flasher light START switch ENGINE STOP switch FUEL switch Front brake switch Speedometer Meter light switch Ignitor Thermo switch Thermo unit Fan motor Ignitioncoil Spark plug Fuel sender Rear brake switch Starter relay Starter motor Battery Main fuse Earth Fuse Rearflasher light light Rearflasher light Neutral switch Oil level gauge up coil Sidestand switch Fuel pump Control unit...

Page 48: ...VAMAHA MOTOR CO LTD PRINTED IN U S A ...

Page 49: ...I LIT I1616 06 08 ...

Page 50: ... Manual together with following manual VMX12N NC Service Manual LIT 11616 04 67 VMX12S SC Supplementary Service Manual LIT 11616 04 98 VMX12U UC SUPPLEMENTARY SERVICE MANUAL 1987 by Yamaha Motor Corporation U S A 1st Edition August 1987 All rights reserved Any reprinting or unauthorizeduse without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N...

Page 51: ... will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual NOTE This Service Manual contains information regarding periodic maintenance to the emission control system for the VMX12N NC Please read this material carefully TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLES OPERATIONS YAMAHA MOTOR CO LTD HOW TO USE THIS MANUAL PARTICULARLY ...

Page 52: ...s Electrical Appendices Illustrated symbols to are used to iden tify the specifications appearing Filling fluid Lubricant Tightening limit clearance Engine speed V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point engine oil gear oil Apply molybdenum disulfide oil Apply wheel bearinggrease Apply lightweight lithium soapbase grease Apply ...

Page 53: ... be used to register your motorcycle with the licensing authority in your state Starting Serial Number VMX12U JYA2WEE0 VMX12UC JYA2WFC0 ENGINE SERIAL NUMBER The engine serial number is stamped into the left side of the engine NOTE The first three digits of these numbers are for model identifications the remaining digits are the unit production number VMXl2U 2WE 000101 VMX12UC 2WF 000101 NOTE Desig...

Page 54: ...ECIFICATIONS Engine Model Drive Method Cam Cap Inside Dia Camshaft Outside Dia Shaft to Cap Clearance Cam Dimensions Intake A Limit Intake B Limit 2WE 2WF JYA2WEEO J 01 283 624 284 626 2WE 000101 2WF 000101 283 624 216 476 284 626 215 474 235 255 Dual disc brake Right hand operation Single disc brake Right foot operation DOT If DOT is not available can be used Chain drive Center 25 000 25 021 0 98...

Page 55: ...ine Idling Speed Vacuum Pressure a t Idling Speed Vacuum Synchronous Difference P A J B P 1 2 B P 3 G S 1 G S 2 36 25 36 35 mm 1 427 1 431 in 36 15 mm 1 423 in 28 02 28 12 mm 1 103 1 107 in 27 92 mm 1 099 in 27 97 28 07 mm 1 101 1 105 in 27 87 mm 1 097 in 0 03 mm 0 0012 in 1FKOO 152 5 90 100 Preset 0 9 0 8 0 8 0 9 1 5 45 0 8 15 5 16 5 mm 0 61 0 65 in 950 1 050 1 050 1 150 Above 200 mm Hg 7 90 in H...

Page 56: ...TO IWATA JAPAN PRINTED IN U S A ...

Page 57: ...LIT 1 ...

Page 58: ...Y SERVICE MANUAL 1985 by Yamaha Motor Corporation U S A 1 Edition September 1985 All rights reserved Any reprintingor unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 04 98 ...

Page 59: ...in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual NOTE This Service Manual contains information regarding periodic maintenance to the emission control system for the Please read this material carefully TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLES OPERATIONS MOTOR CO LTD HOW TO USE THIS MANUAL...

Page 60: ...t Engine system Carburetion Electrical Illustrated symbols to are used identify the specifications appearing 0 fluid clearance speed V A Illustrated symbols to in the ex ploded diagram indicate grade of lubricant and location of lubrication engine gear molybdenum disulfide oil Apply wheel bearing grease molybdenum disulfide grease Apply locking agent Apply lightweight lithium soap base grease ...

Page 61: ...ing head pipe NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number is stamped into the left side of the engine NOTE Starting Serial Number VMX UT 000101 VMX UR 000101 NOTE Designs and specifications are subject to change without notice ...

Page 62: ...l Gear Case Total Amount Radiator Capacity Air Filter Fuel Including All routes Tank Capacity Total Reserve VMX 1UT 1UT 000101 2 300 mm 90 6 in 795 mm 31 3 in 1 160 mm 45 7 in 765 mm 30 1 in 1 590 mm 62 6 in 145 mm 5 7 in 282 622 I 283 624 2 790 mm 110 in Liquid cooled 4 stroke gasoline DOHC V 4 cylinder 1 198 76 x 66 mm 2 992 x 2 598 in 10 5 1 1 422 14 5 206 psi Electric starter Wep sump 4 cycle ...

Page 63: ...um Load Cold Tire Pressure With Oil and Full Fuel Tank Up to 90 198 Load 90 198 216 476 Load High Speed Riding Brake Front on Rear Operation Suspension Front Suspension Rear Suspension VMX BDS 34 x DPR GK PR IPPONDENSO 0 8 0 9 mm 0 031 0 035 in Wet multiple disc Spar gear 87 49 1 775 Shaft drive 21 27 x 2 851 Constant mesh 5 speed Left foot operation 43 17 2 529 39 22 31 23 1 347 28 26 1 076 26 28...

Page 64: ...IWATA JAPAN PRINTED IN U S A ...

Page 65: ... I Serr ice L 1616 04 67 ...

Page 67: ...s or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual NOTE This Service Manual contains information regarding periodic maintenance to the emission control system for the Please read this material carefully TECHNlCAL PUBLICATIONS SERVICE DIVISION MOTORCYCLES OPERATIONS MOTOR CO LTD HOW TO USE THIS MANUAL PARTICULARLY IM...

Page 68: ...Appendices Illustrated are used to identify the specificationsappearing in the text Filling fluid Lubricant Tightening Wear limit clearance Engine speed Illustrated symbols in the exploded dia gram indicate grade of lubricant and location of lubrication point Apply engine oil gear Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap base grease Apply molybdenum ...

Page 69: ... obviously prefer a quality product 2 Authentic not artificial 3 Yamaha PARTS ACCESSORIES Don t compromise the quality and performance of your Yamaha with off brand alternatives You ll be getting exactly what you re paying for ...

Page 70: ... I EX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL APPENDICES ...

Page 71: ...ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 A L L REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 CIRCLIPS 1 3 1 3 FOR 1 3 FOR ENGINE SERVICE 1 4 FOR CHASSIS SERVICE 1 8 FOR MIDDLE GEAR SERVICE 1 9 FOR ELECTRICAL COMPONENTS 1 10 ...

Page 72: ...identification number is stamped into the steering head pipe NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state Starting Serial Number FK 000101 JH 000101 NOTE Designs and specifications are subject to change without notice 1 1 ...

Page 73: ...ments Use oil and or grease recommended by Yamaha for assem bly and adjustment GASKETS OIL SEALS AND O RINGS 1 All gaskets seals and O rings should be replaced when an engine is overhauled All gasket surfaces oil seal lips and O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips LOCK COTTER PINS 1 All lock and cotter pins must be ...

Page 74: ...OLS The proper special tools are necessary for com plete and accurate tune up and assembly Using the correct special tool will help prevent damage caused by the use of improper tools or improvis ed techniques FOR TUNE UP Inductive Tachometer P N YU 08036 This tool i s needed for detectingengine rpm 2 Inductive Timing Light P N YU 08037 This tool is necessary for checking ignition timing 3 Compress...

Page 75: ...ded for carburetor nization 6 Radiator Cap Tester P N YU 24460 This tester is needed for checking the cooling system FOR ENGINE SERVICE 1 Clutch Holder P N YM 91042 This tool is used to hold the clutch when re movingor installing the clutch boss locknut 2 Tappet Adjusting Tool P N YM 33961 This tool is necessary to replace valve adjusting pads 1 4 ...

Page 76: ...over 5 5 mm P N YM 01122 This tool is used to remove the valve guides 5 Valve Guide Reamer 5 5 mm P N YM 01196 This tool is used to new valve guide 6 Valve Guide Installer P N YM 01129 This tool is needed to install the valve guides properly 7 Valve Seat Cutter Set P N YM 91043 This tool is needed to resurface the valve seat I I 1 5 ...

Page 77: ...loosen or tighten thecylinder head securing nut 10 Piston Ring Compressor This tool is used when installing the piston into the cylinder P N YM 8037 11 Water Pump Seal Installer Handle P N YM 04085 1 Adapter P N YM 33221 This tool is needed for proper installation of the water pump seal 12 Piston Pin Puller This tool is used to remove the piston pin P N YU 01304 1 6 ...

Page 78: ...o loosen or tighten the drive axle bearing retainer bolt P N YU 29843 6 15 25 Torx Driver This tool is used to loosen or tighten the shift cam segment securingbolt P N YU 29843 4 16 Set Green This gauge is needed to measure the clearance for the connecting rod bearing P N YU 33210 17 Special Torx Driver This tool is used when overhauling the car buretors YU 25359 2 ...

Page 79: ... used to loosen and tighten the front fork cylinder holding bolt 2 Front Fork Cap Socket mm P N YM 01104 This tool is neededwhen looseningand tightening the front fork cap bolt 3 Front Fork Seal Driver Weight P N YM 33963 Adapter 40 mm P N YM 33964 These tools are used when installing the fork seaI 4 Ring Nut Wrench P N YU 01268 This tool is used to loosen and tighten the steering ring nut 1 8 ...

Page 80: ...ool is needed when measuring the middle gear lash 3 Damper Spring Plate P N YM 33286 This tool is used with a middle drive gear holder to disassemble and reassemble the middle gear damper 4 Dial Gauge P N YU 03097 This tool is used to measure the gear lash for the middle gear and final gear 5 55 mm Offset Wrench P N YM 04054 This tool is used to loosen and tighten the drive shaft nut 1 9 ...

Page 81: ...remove and install the bearing retainer P N YM 04050 8 Gear Lash MeasurementTool P N YM 01230 This tool is used to measure gear lash FOR ELECTRICAL COMPONENTS 1 Electro Tester P N YU 33260 This instrument is necessary for checking the ignition system components 2 Pocket Tester P N YU 33263 or P N YU 03112 This instrument is invaluable for checking the electrical system 1 10 ...

Page 82: ...IL REPLACEMENT 2 14 COOLANT LEVEL INSPECTION 2 16 COOLING SYSTEM INSPECTION 2 16 COMPRESSION PRESSURE MEASUREMENT CHASSIS FINAL GEAR OIL LEVEL INSPECTION FINAL GEAR OIL REPLACEMENT AIR FILTER CLEANING BRAKE FLUID LEVEL INSPECTION FRONT AND REAR BRAKE PAD INSPECTION FRONT BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT CABLE INSPECTION AND LUBRICATION BRAKE AND CHANGE AND CLUTCH LEVERS LUBRICATION CENTERSTA...

Page 83: ...ELECTRICAL 2 34 CHECK 2 34 BATTERY INSPECTION 2 35 BRAKE SWITCH ADJUSTMENT 2 37 SPAR PLUG INSPECTION 2 37 HEADLIGHT BULB REPLACEMENT 2 38 HEADLIGHT BEAM ADJUSTMENT 2 39 FUSE INSPECTION 2 39 ...

Page 84: ...ly 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months 600 mi 4 400 mi 8 200 mi Remarks PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM Check and adjust valve clearance when engine is cold I I Every 42 000 km 26 600 mi 2 Check condition Adjust gap and clean Replace at and thereafter every 12 000 km or 12 months Spark plug 1...

Page 85: ... 24 000 km or 24 months 0 0 0 0 0 Check 80 GL 4 gear Yamaha chain and cable lube 1OW30 motor oil Final gear oil Replace 0 Control and meter cable Apply chain lube 0 0 0 0 0 0 Check bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Medium weight wheel bearing grease Yamaha chain and cable lube or SAE motor oil Yamaha chain and cable lube or SAE 1OW30 motor oil Yamaha chain ...

Page 86: ...odometer reading repeat the above maintenance at the period established Every 6 000 km 3 800 mi Every 12 000 km 7 600 mi and Every 24 000 km 15 200 mi intervals When disassembling the master cylinder or caliper cylinder replace the brake fluid Normally Brake fluid replacement brake and clutch check the brake fluid level and add the fluid as required On the inner parts of the master cylinder and ca...

Page 87: ...trical components board electrical component leads 3 Disconnect 4 Remove covers radiator radiator NOTE It is not necessary to remove the radiator completely from the motorcycle 5 Disconnect 6 Remove plug caps baffle plate rear 7 Remove head covers NOTE Be sure you do not lose the oil plugs on the camshaft caps 2 4 ...

Page 88: ...m 1 26 in socket wrench NOTE Valve clearance must be measured when the engine is cool to the touch Align the mark for the No 1cylinder on the flywheel with the stationary pointer on the crankcase cover When the mark is aligned with the stationary pointer the piston is at top dead center TDC Note marks on flywheel to obtain correct valve clearance measurements TDC for No 1 cylinder TDC for No 2 cyl...

Page 89: ...ion Adjust clearance Front FiringSequence 1 3 4 2 2 Adjust Valve clearance By the following adjustment steps Valve clearance adjustment steps the valve lifter slots intake and Install the Tappet Adjusting Tool exhaust side opposite each other 33961 onto the camshaft Turn the crankshaft until the lobe of the tool depresses the valve lifters Cylinder head Pad 2 6 ...

Page 90: ...d valve Remove the pads from the lifters Use a small screwdriver and a magnetic rod for removal pad numbers the proper valve adjusting pad from the chart below 0 or 2 5 Pad Availability 25 increments Pad range 0 NOT ROUNDED OFF mm 0 002in incre 8 10 ...

Page 91: ...MENT 1 06 1 10 1 11 1 15 1 16 1 20 1 21 1 25 1 26 1 30 1 31 1 35 1 36 1 40 INTAKE 290 295 300 305 310 31513201 295 300 305 310 315 3201 Measured clearance is 0 32 mm 0 013 in Replace 250 pad with 265 pad Pad No 250 2 50 mm 0 098 in Pad No 255 2 55 mm 0 100 in Pad number example 300 305 310 315 320 305 310 315 320 310 315 320 315 320 320 Always install pad with number down VALVE CLEARANCE cold Exam...

Page 92: ...with oil plug Arrow mark on the cover should face Inspect the head cover gasket and replace it if toward the exhaust side damaged 2 Tighten Bolts cylinder head cover I Bolts Cylinder Head Cover 10 Nm 1 0 7 2 3 Tighten Bolts radiator Bolts Radiator 7 Nm 0 7 5 1 CRANKCASE VENTILATION SYSTEM INSPECTION 1 Inspect Crankcase ventilation hose Replace FUEL LINE INSPECTION 1 Inspect Fuel hoses Vacuum lines...

Page 93: ...er Replace 3 Install Components in above list step 1 INTAKE MANIFOLD INSPECTION 2 Tighten Carburetor clamps joint bolts Carburetor joint nuts Inspect joint Gaskets Replace EXHAUST SYSTEM INSPECTION 1 Inpsect pipe clamp Damage Replace pipe bolts bolts 2 Tighten 7 Nm 0 7 5 1 Exhaust Pipe Flange 20 Nm 2 0 14 20 Nm 2 0 14 Muffler Clamp 2 10 ...

Page 94: ...IZATION CANISTER INSPECTION FOR CALIFORNIA ONLY 1 Inspect Hose connection Hoses Canister Poor condition Correct Replace Clogs Clean To carburetor From fuel tank Canister To atmosphere CARBURETOR SYNCHRONIZATION OPEN CLOSE 2 11 ...

Page 95: ...e for a fraction of a second two or three times and check the synchro nization again NOTE Valve clearance must be set properly before synchronizingthe carburetors 1 Remove Carburetor joint covers left and right plugs left and right hose 2 Attach Gauge YU 08030 3 Start the engine and let it warm up To the vacuum plugs 4 Adjust speed Out of specification Turn the throttle stop screw to adjust ...

Page 96: ... i lbot h gauges read t he sam e I DLE SPEED ADJUSTM ENT 1 Adj ust I dl e speed W arm up t he engi ne and t urn t he t hrot t l e st op screw t o adj ust THRO TTLE CABLE ADJUSTM ENT NO TE B efore adjusting the throttle cable free play the engi ne i dl i ng speed shoul d be adj ust ed 1 Check Throt t l e cabl e f ree pal y O utofspeci f i cat i on Adj ust 2 Adj ust Throt t l e cabl e f ree pl ay B ...

Page 97: ... hen check i ng oi l l evel a sl i ght t i l t t o t he si de can produce f al se readi ngs St op t he engi ne and vi sual l y check t he oi l l evel t hrough t he l evel wi ndow M axim um M i ni m um ENG I NE O I L REPLACEM ENT Engi ne O i lRepl acem ent W i t houtO i lFi l t er 1 W ar m up t he engi ne f or sever al m i nut es t hen pl ace a recept acl e under t he engi ne 2 R em ove O i lf i l ...

Page 98: ... engi ne oi l 3 Rem ove f i l t er cover 4 I nst al l Dr ai n pl ug f i l t er new O r i ng new f i l t er cover NO TE Be sur e t he O r i ng i s posi t i oned pr oper l y 5 Ti ght en Bol t oi l f i l t er R ecom m ended O il At5 C 40 F orHi gher Yam alube 4 cycle O il or SAE 20W 40 Type SE M ot or O i l At15 C 60 F or Low er SAE 10W 30 Type SE M ot or O i l W ith O il Filter R eplacem ent 6 Fi l ...

Page 99: ...s Refer to Chapter 4 COOLING SYSTEM for more detail FULL level LOW Do not remove the radiator cap when the engine is hot Hard water or salt water is harmful to the engine parts use boiled or distilled water if you can t get soft water Total Amount Reservoir Tank Capacity From LOW to FULL Level 3 05L 2 69Imp qt 3 22US 0 30L 0 26Imp qt 0 32US 0 20 L 0 18 Imp qt 0 21 US qt COOLING SYSTEM INSPECTION 1...

Page 100: ...the electric starter be sure the battery is fully charged with the throttle wide open until the com pression readingon the gauge stabilizes with specified levels See chart Compression Pressure at sea level 980 10 142 psi 882 9 128 psi 12 171 Standard Minimum Maximum When cranking the engine ground all of the spark plug leads to prevent sparking the previous steps for the other pressure falls bello...

Page 101: ...Lessthan 98 1 14 psi CHASSIS 1 Inspect FINAL GEAR OIL LEVEL INSPECTION gear oil level Oil level low Add sufficient oil By the following inspectionsteps Final gear oil level visual inspection steps the motorcycle on a level area and the oil filler cap check the oil level Correct oil level should be at the brim of the hole the oil level is low add sufficient oil the oil filler cap to specification O...

Page 102: ...sired an SAE Hypoid gear oil may be used for all conditions I Do not allow the gear oil to contact the tire or wheel 5 Install filler cap Oil Filler Cap Final Gear 23 Nm 2 3 17 AIR FILTER CLEANING 1 Remove cover 2 Remove filter case cover filter element The engine should never be run without the air filter element installed excessive piston and or cylinder wear may result 2 19 ...

Page 103: ...EL INSPECTION Brake Inspection 1 Inspect fluid level brake master cylinder Level low Replenish fluid Lower NOTE Be sure that fluid is cleaned up immediately to pre vent painted surfaces or plastic parts from erodina Use only the designated quality brake fluid otherwise poor brake performancewill result Water does not enter the master cylinder when refilling otherwise poor brake performance 2 20 ...

Page 104: ...ch master cylinder Level low Replenishfluid Lower NOTE Be sure that only the designated quality brake fluid does not enter the master cylinder when refiIIing Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding FRONT AND REAR BRAKE PAD INSPECTION 1 Activate the brake lever or brake pedal 2 Inspect indicator Indicator almost contacts disc Replace pads Re...

Page 105: ...ystem before the motorcycle is operated Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident Inspect and bleed the system if necessary 3 Tighten Locknut REAR BRAKE ADJUSTMENT 1 Loosen 2 Adjust Locknut Brake pedal height Turn the adjuster until the brake pedal position is at the specified height Brake Pedal Height 20 mm 0 8 in Below th...

Page 106: ...ottle twist grip with suitable all purpose grease to minimize friction for damage to cable insulation Replace any corroded or obstructed cables Lubricate any cables that do not operate smoothly I Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil BRAKE AND CHANGE PEDALS BRAKE AND CLUTCH LEVERS LUBRICATION Lubricate pivoting parts of each lever and pedal Yamaha Chain and Cable Lubeor SAE 10W30 Moto...

Page 107: ...eep the valve open by pressing it for several seconds so that the air can be let out of the inner tube 3 Loosen 4 Remove bolts steeringcrown bolts Use the Front Fork Cap Socket YM 01104 Collars 5 Place a receptacles under the drain screws 6 Remove screws Drain the fork oil Do not allow any oil to contact the disc brake components If oil is discovered be sure to remove it otherwise diminished braki...

Page 108: ...Cap Bolt 23 Nrn 2 3 17 Pinch Bolts SteeringCrown 20 Nrn 2 0 14 I 11 Adjust Front fork air pressure Refer to FRONT FORK ADJUSTMENT section FRONT FORK ADJUSTMENT stand under the engine 1 Elevate the front wheel by placing a suitable NOTE When checking and adjusting the air pressure there should be no weight on the front end of the motorcycle 2 Adjust pressure NOTE The air pressure of the front forks...

Page 109: ...andard Air Pressure Maximum Air Pressure 39 2 kPa 0 4 kg cm 5 7 psi 98 1 kPa 1 0 kg cm 14 2 psi Never exceed the maximum pressure or oil seal damage may occur the valve cap securely REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust preload Damping NOTE The spring preload and damping of the rear shock absorbers can be adjusted to suit rider s preference weight and the course condition Always adjust rear shoc...

Page 110: ... A Position 5 Maximum 4 3 2 1 Minimum Standard Standard Position Minimum Position Maximum Position 1 5 Never attempt to turn the spring seat beyond the maximum or minimum setting Dampingadjustment steps the damping with the damping adjuster Stiffer Increasethe damping Turn the adjuster clockwise Decrease bhe damping Turn the adjuster counter clockwise Standard Position Minimum Position Maximum Pos...

Page 111: ...eat Solo rider 39 2 58 8 0 4 0 6 5 7 8 5 psi Loadingcondition 1or I I B 39 2 98 1 0 4 1 0 5 7 14 2 psi 3 5 39 2 98 1 5 7 14 2 psi 0 4 5 STEERING HEAD INSPECTION Securely support the motorcycle so there is no danaer of it fallina over 1 Place the motorcycle on its centerstand 2 Check then elevate the front wheel assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back ...

Page 112: ...isconnect lens unit leads in the headlight body 4 Remove Bolt headlight body bracket Emblem 5 Remove Flasher light bracket assembly 6 Remove holder assembly 7 Loosen 8 Remove Pinch bolts steeringcrown steeringstem Steering crown 2 29 ...

Page 113: ...g 50 Nm 5 0 36 the ring nut completely and retighten it to specification Do not over tightening Ring Nut Final Tightening 3 Nm 0 3m kg 2 2 ft lb the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering barings Refer to CHAPTER 6 STEERING HEAD for more details the washer the ring nut upper NOTE The tapered side of ring nut must ...

Page 114: ... Nm 4 0 m kg 29 ft lb WHEEL BEARINGS CHECK Front Wheel 1 Check Front wheel bearings Raise the front end of the motorcycle and spin the wheel by hand Touch the axle or front fender while spinning the wheel Excessivevibration Replace bearings Rear Wheel 1 Remove 2 Check Rear wheel movement With the fingers Roughness Wear Replace TIRES CHECK Do not attempt to use tubeless tires on a wheel designed fo...

Page 115: ...use V range tires in tire re placement S or H tires may be in danger of burstingat super high speeds tires have a relatively poor adhesion on the road surface so do not allow them to be subjected to high speed load from maximum speed until after a break in run of approx 100km 60mi any high speedruns remember to allow a sufficient warm up time for the tires use the correct tire inflation pressure a...

Page 116: ...destribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an overloaded motorcycle could cause tir...

Page 117: ...CAL IGNITION TIMING CHECK 1 Check Ignition timing By the following steps Ignition timing check steps the timing plug the Timing Light YU 08037 to No 1 or No 2 cylinder spark plug lead up the engine and let it idle at the specified idle speed of 1 000 r min check the stationary pointer in the timing window to vertify it is within the required firing range indicated on the flywheel Incorrect firing ...

Page 118: ...ns or permanent eye injury working near batteries Antidote EXTERNAL Flush with water Flush with water for 15 minutes and Antidote INTERNAL large quantities of water or milk follow with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventivemeasures batteries in a well ventilated ...

Page 119: ...attery 5 Connect Breather hose Be sure the hose is properly attached and routed When inspecting the battery be sure the breather hose is routed correctly If the breather hose touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motorcycle can occur Battery Pass through guide 6 Inspect hose Obstruction Remove Da...

Page 120: ...rmal condition is a medium to light tan color Distinctly different color Check the engine condition Spark plug gap 2 Clean plug Clean the spark plug with a spark plug cleaner or wire brush 3 Inspect plug type Incorrect Replace Standard Spark Plug DPR8EA 9 NGK X24EPR U9 N D 4 Measure plug gap Out of specification Regap Use a wire gauge Spark Plug Gap 0 8 0 9 mm 0 031 0 035 in 5 Tighten Plug NOTE Be...

Page 121: ... lens unit lens unit leads 3 Remove Turn the bulb holder counterclockwise to release bulb Do not touch headlight bulb when it is on as the bulb generates enormous heat keep flammable objects away 4 Install new Secure the new bulb with the bulb holder Avoid touching glass part of bulb Also keep it free from oil otherwise transparency of glass bulb life and illuminous flux will be adversely affected...

Page 122: ...15A 1 10A 1 10A 2 Adjust beam vertically 1 I Vertical Adjustment I I Turn the adjusting screw clock I Turn the adjusting screw counter Iclockwise Lower FUSE INSPECTION The fuse panel is located under the top cover and seat 1 Inspect fuse Defective Replace Blown fuse new Inspect circuit Do not use fuses of higher amperage rating than those recommended Substitution of a fuse of improper rating can c...

Page 123: ...PUMP DRIVE GEAR 3 12 WATER PUMP AND THERMOSTATIC VALVE 3 13 STARTER MOTOR AND BREATHER COVER 3 14 OIL PAN AND OIL PUMP 3 14 CRANKCASE DISASSEMBLY 3 15 UPPER CRANKCASE 3 16 TRANSMISSION 3 17 LOWER CRANKCASE 3 17 INSPECTION AND REPAIR CYLINDER HEAD VALVE VALVE GUIDE AND VALVE SEAT 3 20 CAMSHAFT CAM CHAIN AND CAM SPROCKET PISTON PISTON RING AND PISTON PIN STARTER DRIVES PRIMARY GEARS CLUTCH 3 33 OIL ...

Page 124: ...KCASE ASSEMBLY TRANSMISSION OIL PUMP AND OIL PAN BREATHER COVER AND STARTER MOTOR WATER PUMP AND THERMOSTATIC VALVE CLUTCH AND OIL PUMP DRIVE GEAR FLYWHEEL AND STARTER IDLE GEAR CYLINDER HEAD AND CAMSHAFT OIL DELIVERY PIPE AND CYLINDER HEAD V BOOST REMOUNTING ENGINE _ ...

Page 125: ...en disassemblingthe engine keep mated parts together This includesgears cylinders pistons and other parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 3 During engine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine...

Page 126: ... left and right 2 Remove 3 Loosen carburetor overflow hose air cleaner joint 4 Remove hose crankcase cleaner assembly 5 Disconnect hose 6 Disconnect 7 Loosen 8 Remove hose ignition advance carburetor joint joint cover left and right 3 2 ...

Page 127: ...onnect 11 Remove assembly NOTE Cover the carburetor with a clean rag to prevent dirt or foreign matter into the carburetor RADIATOR 1 Remove Radiator covers 2 Remove 3 Disconnect Bolts radiator Upper hose Lower hoses 4 Disconnect Fan motor coupler 5 Remove Radiator assembly Horn 3 3 ...

Page 128: ...OST CONTROL CABLE AND AIR BAFFLE PLATE 1 Disconnect Control cable V boost 2 Disconnect 3 Straighten Spark plug caps Tabs front baffle plate 4 Remove baffle plate front baffle plate rear FOOTREST RIGHT AND BRAKE PEDAL 1 Remove Footrest right pedal assembly Brake master cylinder 3 4 ...

Page 129: ...Remove FOOTREST LEFT AND CLUTCH RELEASE CYLINDER 1 Remove Footrest left pedal assembly gear case cover 2 Remove Seat cover left leads engine 3 Disconnect 4 Remove 5 Remove release cylinder 6 Remove 7 Disconnect Rubber boot 3 5 ...

Page 130: ...xhaust pipe 2 Loosen 3 Remove Bolts front exhaust pipe Front exhaust pipes 4 Remove 5 Loosen 6 Remove Bolt muffler chamber Bolts muffler Bolts muffler bracket 7 Remove Screws rear exhaust protector rear exhaust 8 Remove rear exhaust pipes Protector Rear exhaust pipes 3 6 ...

Page 131: ...er the engine 2 Remove Bolt engine Bolts down tube Down tube frame right 3 Remove Engine assembly from right side NOTE Remove the rear cylinder head cover if diffi culties are encountered with any of the previous steps V BOOST 1 Remove assembly NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 3 7 ...

Page 132: ... rearand front Gaskets plugs Front Front cylinder Rear cylinder 2 Remove cover plate washer plug NOTE Check for clog of oil passage in the bolt If any clean the oil passage 3 Align T 1 mark with stationary pointer on crankcase cover 4 Remove chain tensioner rear 5 Remove guides caps They was marked 1 2 and E 2 3 8 ...

Page 133: ...ft cam lobes do not touching valve lifters 8 Remove Camshafts Sprockets Slip the sprockets from mounting boss on camshaft NOTE Fasten a safety wire to the cam chain 9 Remove pin Water jacket joint 10 Remove cylinder head Use 8 mm Wrench Adapter YM 28897 NOTE by loosening each nut 1 2 turn until all are loose Follow numerical order shown in photo Start 3 9 ...

Page 134: ...rear Gasket pins Front Cylinder Head When removing the front cylinder head repeat the rear cylinder head removal procedure However note the following points 1 Rotate Counterclockwise 360 plus an added 430 total from the mark 2 Align Flywheel T 2 mark with stationary pointer on crankcase cover 3 Mark Pistons With piston number designations as shown 3 10 ...

Page 135: ...heel Plain washer NOTE Check for clog of oil passage in the bolt If any clean the oil passage 4 Remove Flywheel Use the Flywheel Puller YU 33270 with the Puller Adapter YM 33282 NOTE When removing the flywheel do not allow the oil baffle plate to touch the projections on the flywheel 3 11 ...

Page 136: ...Oil baffle plate CLUTCH AND OIL PUMP DRIVE GEAR 1 Remove Crankcase cover right NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened pins 2 Remove clutch spring washer spring seat plate Friction plate plates plates rod 3 12 ...

Page 137: ...clutch boss Use the Clutch Holder YM 91042 to hold the clutch boss 5 Remove clutch boss washer boss washer housing 6 Remove pump drive gear WATER PUMP AND THERMOSTATIC VALVE 1 Remove pump cover Water pump cable Gasket pins 2 Remove assembly 3 13 ...

Page 138: ...ISASSEMBLY STARTER MOTOR AND BREATHER COVER 1 Remove motor 2 Remove Breather cover Breather cover spacer pipe OIL PAN AND OIL PUMP filter cover 1 Remove 2 Remove pan Gasket pins 3 Remove pump assembly pins 3 14 ...

Page 139: ...SASSEMBLY 4 Straighten the bracket tabs 5 Remove pipe oil gallery pipe 6 Remove oil pump pipe pump pipe CRANKCASE DISASSEMBLY 1 Remove main axle bearing middle gear bearing Use the 40 Torx Driver YU 29843 7 3 15 ...

Page 140: ...rankcase designate the crankcase tightening sequence With washer LOWER CASE UPPER CASE 3 Remove upper Use a soft hammer NOTE Pull out the crankcase upper while pulling up the cam chain pins UPPER CRANKCASE 1 Remove rod caps rod Piston assembly Do not hammer out the connecting bolts to remove the connecting rod assembly 3 16 ...

Page 141: ...e reinstalled in its original pIace 3 Remove pin clip pin Piston TRANSMI ON 1 Remove shaft Drive axle assembly driven gear assembly Plane bearings shaft Main axle assembly NOTE Identify each plane bearing position very care fully so that it can be reinstalled in its original place LOWER CRANKCASE 1 Remove Shift shaft assembly Shift lever 1 Shift lever 2 3 17 ...

Page 142: ... Remove spring cam stopper lever 4 Remove retainer shift cam bars forks cam NOTE Note the position of each part Pay particular attention to the location and direction of shift forks 5 Remove pump idle gear 3 18 ...

Page 143: ... can be reinstalled in its original place Deburr Valve stem 4 Eliminate deposit Use rounded scraper 2 Attach 0 Valve Spring Compressor 3 Remove retainers spring seat 0 springs seal 0 spring seat NOTE Deburr any deformed valve stem end Use an oil stone to smooth the stem end NOTE Do not use a sharp instrument and avoid damag ing or scratching plug threads 0 Valve seat Cylinder head 3 19 ...

Page 144: ...lve face Stem end of specification Replace Minimum Thickness Service limit Beveled 0 5 mm 0 020 in 0 7 mm 0 028 in I limit I 4 0 mm 0 16 in 2 Measure Valve stem clearance Out of specification Replaceeither valve and or guide Use the Micrometer and Bore Gauge I I 0 010 0 037 mm 0 0004 0 0015 in 0 0031in Intake I I 0 025 0 052 mm 0 0010 0 0020 in 0 0039 in Exhaust Bore Gauge Valve stem outside diame...

Page 145: ...lve Guide NOTE replace valve guide if valve is replaced replace oil seal if valve is removed 1 Inspect guide into cylinder Replace Remove guide Use the Valve Guide Remover NOTE Heat the head in an oven to 100 C 212 F to ease guide removal and installation and to maintain correct interference fit 3 Install new guide Oversize Use the Valve Guide Remover with the Valve Guide Installer 01129 3 21 ...

Page 146: ...ut t er YM 91043 W hen t w i st i ng cut t er keep an even dow nw ard pressure t o prevent chat t er m arks Cut sect i ons as f ol l ows Sect i on Cut t er A 30 1 B 45 C 60 2 M easure Val ve seat wi dth 3 Appl y M echani cs bl ui ng dye Dykem To val ve and seat Fi ne gr i ndi ng com pound sm al lam ount Gr ound sur f ace of val ve f ace 4 Posi t i on I nt o cyl i nder head Spi n i t r api dl y bac...

Page 147: ... recut t i ng st eps are necessary i f Val ve seat i s uni f or m ar ound per i m et er of val ve f ace but t oo wi de or not cent er ed on val ve f ace To cent er t he seat or t o r educe i t s wi dt h f ace i ndi cat es t hat val ve seat i s cent er ed on val ve f ace but i s t oo wi de see a di agr am seat i s i n t he m i ddl e of t he val ve f ace but t oo nar r ow see b di agr am ve seat I S...

Page 148: ... until valve and valve seat are evenly polished then clean off all compound 4 Apply lapping compound small amount To valve face 5 Repeat steps 2 and 3 NOTE Be sure to clean off all compound from valve face after every lapping operation 6 Inspect face Not yet uniformly smooth Repeat proce dure from step 1 7 Apply Mechanics bluing dye To valve face and seat 8 Rotate 9 Inspect face Dykem Valve must m...

Page 149: ...eps head parts Repeat lapping steps using fine lapping com all parts thoroughly and check for leakage again steps as often as necessary to effect pound using solvent a satisfactory seal Valve Spring This engine uses two springs of different sizes to prevent valve float or surging Valve spring specifications show the basic value character istics Outer spring spring 1 Measure free length Out of spec...

Page 150: ... 8 mm 1 75 in Valve Lifter 1 Inspect lifter wall Scratches Damage Replace both lifter and cylinder head Valve Installation 1 Lubricate Valve stem seal High Quality Molybdenum Disulfide Motor Oil or Molybdenum Disulfide Grease 2 Install spring seat seal springs spring seat retainers NOTE Install springs with wider gapped coils facing upwards as shown Larger pitch Smaller pitch 3 26 ...

Page 151: ...ft C ap C learance M easurem ent 1 I nst al l Cam shaf t 2 At t ach VU 33210 O nt o cam shaf t ForExhaust For I nt ake 3 At t ach Cam shaf t cap l 3 or E 3 4 I nst al l Cam shaf t caps ot her s 5 Ti ght en Cam shaf t cap bol t s Fi r st Ti ght en t he Nos 2 4 and 1 cap bol t s i n t hator der t hen t he No 3 cap bol t s ot her w i se t he No 3 caps m ay be dam aged or bent N O TE D o not t urn t h...

Page 152: ...outside diameter Use a micrometer Out of specification Replace camshaft Within specification Replace cylinder head Camshaft Outside Diameter Standard 24 967 24 980 mm 0 9830 0 9835 in Cam Cap Inside Diameter Standard 25 000 25 021 mm 0 9851 in Cam Chains 1 Inspect chains Chain Replace Cam Sprockets 1 Inspect sprockets Replace Chain Dampers 1 Inspect Upper damper damper Rear damper Wear Replace 3 2...

Page 153: ...r rod CYLI NDER 1 I nspect Cyl i nder wal l W ear Scr at ches Rebor e or r epl ace 2 Measur e bor e C Use t he Cyl i nder Bor e Gauge Out of speci f i cat i on Rebor e C M axi m um D T M axi m um or M i ni m um or PI STO N PI STON RI NG AND PI STO N PI N Piston 1 I nspect Pi st on wal l W ear Scr at ches Dam age Repl ace 2 Measur e Pi st on out si de di amet er P Use a Mi cr omet er Out of speci f...

Page 154: ...learance I 75 905 75 955 mm 2 9884 2 9903 in Standard 2nd Ring 0 02 0 06 mm 0 0008 0 0047 in 0 12 mm 0 0024 in 3 Measure clearance Out of specification cylinder or replace piston Piston Clearance C P 0 055 0 075 mm 0 0022 0 0030 C Cylinder bore P Piston outside Piston Ring 1 Measure clearance Use the Feeler Gauge Out of specification Replace piston and or rings 0 0047 in 0 0028 in 3 30 ...

Page 155: ...i lRi ng O OO8O 0 032 i n Over si z e Pi st on Ri ngs The over si ze t op and m i ddl e r i ng si zes ar e st am ped on t op of t he ri ng Over si ze 1 0 25 m m 0 0098 i n Over si ze 2 0 50 mm 0 0197 i n The expander spacer of t he bot t om r i ng oi l cont r ol r i ng i s col or coded t o i dent i f y si zes The col or m ar k i s pai nt ed on t he expander spacer Pi st on Pi n 1 Lubri cate Pi st ...

Page 156: ...tion pin Into piston 5 Check play When pin is in place in piston Free play Replace piston pin and or piston STARTER DRIVES Electric Starter Clutch Check operation cap operation operation Unsmooth operation Replace one way clutch 2 Check housing Rubber dampers Replace 3 Install damper housing clutch one way clutch 4 Tighten 24 Nm 2 4 17 ...

Page 157: ... Scratches Wear Damage Replace crank shaft Scratches Wear Damage Replace clutch housingassembly gear CLUTCH Clutch Housing 1 Inspect on the housing housing bearing Cracks Wear Damage Deburr or replace Chafing Wear Damage Replace Clutch Boss The clutch boss contains a built in damper beneath the friction plate and clutch plate It is not necessary to remove the wire circlip and disassemble the built...

Page 158: ...iction plate as a set 2 Measure 0 Friction plate thickness Measureat all four points Out of specification Replace friction plate as a set Wear Limit 2 8 mm 0 11 in Clutch Plates 1 Measure plate warpage Use the surface plate and the Feeler Gauge Out of specification Replace Warp Limit 0 2mm 0 008 in Push Rod 1 Measure rod runout Use V Blocks and the Dial Gauge Out of specification Replace YU 03097 ...

Page 159: ... Out of specification Replace 6 5 mm 0 26 in Clutch Spring Minimum Height 3 Measure spring warpage Use a surface plate and the Feeler Gauge Out of specification Replace Clutch Spring Seat 1 Inspect spring seat Wear Bends Damage Replace OIL PUMP 1 Measure Outer rotor clearance Use the Feeler Gauge Out of specification Replace oil pump assembly Side Clearance Limit 0 08 mm 0 0031 in I 3 35 ...

Page 160: ...place Cracks Damage Replace CRANKSHAFT Crankshaft 1 Measure Runout Use the V Blocks and Dial Gauge Out of specification Replace YU 03097 Runout Limit 0 03 mrn 0 0012 in 2 Inspect Crankshaft bearing surfaces Wear Scratches Replace Crankshaft Main BearingClearance Measurement 1 Clean all parts 2 Position Crankcase half upper Place on a bench in an upside down posi tion 3 Install Bearings Crankshaft ...

Page 161: ... Bearings lower crankcase 6 Tighten Tighten to full torque in torque sequence as shown 10 mm Bolts Crankcase 40 Nm 4 0m kg 29 ft lb With a washer 7 Remove Crankcase lower Reverse assembly order Use care in removing 8 Measure Width of Out of specification Replace bearings repIace crankshaft if necessary Main BearingOil Clearance 0 020 0 044 mm 0 0008 0 0017 in 3 37 ...

Page 162: ...Lubricate Bolt threads connecting rod MolybdenumDisulfide Grease 6 Tighten Nuts connecting rod cap NOTE Do not turn connecting rod until clearance measurement has been completed Tighten to full torque specification without pausing Apply continuous torque between 3 0 and 3 8 m kg Once you reach 3 0 m kg DO NOT STOP TIGHTENING until final torque is reached If tightening is interrupted between 3 0 an...

Page 163: ... 0018 in Crankshaft Main and Connecting Rod Bearing Selection used to indicate crankshaft journal sizes are stamped on the crankweb The first two are mainbearingjournal numbers starting with the left journal The four 4 rod bearing journal numbers follow in the same sequence J3 i lower crankcase half is numbered J2 J3 and J4 on the front left boss as shown connecting rods are numbered 3 or 4 The nu...

Page 164: ... 5 N o 6 G reen Yel l ow Pi nk Exam pl e 2 Sel ect i on of t he connect i ng rod bearing t he connect i ng r od P1 and cr ankshaf t P1 si zes ar e No 4 and No 1 r espect i vel y t he bear i ng si ze No i s Beari ng Si ze No Connect i ng rod No Crankshaf tNo 4 1 3 Brow n BEARI NG CO LO R CO DE N o 6 N o 7 Pi nk R ed BALANCER SHAFT Bal ancer Shaf tBeari ng Cl earance M easurem ent 1 Cl ean sur f ace...

Page 165: ...ment has been completed 6 Install Bearings Into lower crankcase 7 Tighten Bolts crankcase Tighten to full torque in torque sequence cast on the crankcase I 8 mm Bolt Crankcase 24 Nm 2 4 kg 9 6 8 Remove Bolts lower Reverse assembly order Use care in removing width 9 Measure Out of specification Replace bearings replace balancer shaft in necessary Balancer Shaft Bearing Oil Clearance 0 020 0 048 mm ...

Page 166: ...as shown Exam pl e Sel ect i on of t he bal ancer shaf t bear ngs I ft he cr ankcase J5 and l ef tbal ancer shaf t si zes ar e No 4 and No 1 r espect i vel y t he l ef t bal ancer bear i ng si ze No i s Beari ng Si ze No C rankcase N o B alancer Shaft N o 4 1 3 Br ow n BEARI NG CO LO R CO DE TRANSM I SSI O N Shi f t For k 1 Inspect Shi f t f or ks O n t he gear and shi f t cam cont act sur f aces ...

Page 167: ...e the centering device and Dial Gauge Out of specification Replace YU 03097 Runout Limit 0 08 mm 0 0031 in Gears 1 Inspect Gears 2 Check Damage Wear Replace Gear movement Unsmooth operation Replace 3 Inspect Mating dogs Cracks Wear Damage Replace BEARINGS 1 Inspect Axle bearings Shift cam bearing Pitting Damage Replace ClRCLlPS AND WASHERS 1 Inspect Circlips Washers Damage Looseness Bends Replace ...

Page 168: ...MIDDLE GEAR SERVICE MIDDLE GEAR SERVICE joint Dust seal washer Retainer Collapsible collar Middle drive shaft Middle driven pinion gear Spring seat Damper spring Damper cam Middle drive pinion gear 3 44 ...

Page 169: ...earingretainer Bearing Bearing housing Middle drive pinion gear Driven pinion gear shim Always use a new one Nut driven pinion gear Spacer Bearing stopper Middle driven pinion gear O ring Universal joint Collapsible collar Nut drive pinion gear 0 28 0 35 I 3 45 ...

Page 170: ...place Refer to Drive Pinion Gear Shim Selection and Middle Gear Lash Adjustment section Drive pinion gear Driven pinion gear A Drive pinion gear shim Driven pinion gear shim Drive Pinion Gear Shim Selection 54 5 plus or minusthe number stamped on the drive pinion gear 53 plus the number stamped on the left side rear of the upper crankcase 3 46 ...

Page 171: ...erefore T A B 54 53 53 95 0 58 m m cal cul at ed shi m t hi ckness i s 0 58 m m Because shi m can onl y be sel ect ed i n 0 05 m m i ncr em ent s use t he f ol l owi ng char t t o r ound of ft he hundr edt hs di gi toft he cal cu l at ed t hi ckness and sel est t he appr opr i at e shi m t he above exam pl e t he cal cul at ed shi m t hi ckness of0 58 m m i s r ounded of ft o 0 60 m m Ther ef or e...

Page 172: ...er line of the yoke bearing hole 4 Rotate U joint 5 Measure Move it gently back and forth Gear lash Over specification Follow next steps Under or same specification Incorrect check for faulty parts and or reassemble bearing housing Middle Gear Lash 0 05 0 12 mm 0 002 0 005 in Do not hammer the U joint or the collapsible collar of the driven pinion gear may bedistorted This will result in a change ...

Page 173: ...Repeat steps 4 and 5 until correct gear lash is achieved 0 10 0 15 0 30 0 50 0 60 Middle Gear Lash 0 05 0 12 mm 0 002 0 005 in 8 Measure Crankcase bearing housingclearance Use a Feeler Gauge 9 Select By the following steps Example Selection of the driven pinion gear shim If the clearance is 0 46 mm shim can only be selected in 0 05 mm increments round off hundredths digit and select appropriateshi...

Page 174: ...ts to the upper crankcase 11 Measure Gear lash REMOVAL 1 Remove Drive axle assembly 2 Attach Damper Spring Plate Middle Drive Gear Holder YM 33222 Onto drive pinion 3 Position Drive axle shaft assembly Onto a Hydraulic Press 4 Compress the damper spring on the drive axle shaft assembly 5 Remove Washer Drive pinion gear Damper cam Damper spring Spring seat Bearing 3 50 ...

Page 175: ...urfaces Replacedamper anddrive pinion gear as a set 2 Inspect Damper spring Replace ASSEMBLY 1 Install Shim Nut drive gear Bearing Use the Offset Wrench YM 04054 110 Nm 11 kg 80 LOCTI 2 Lock the threads with center punch as shown 3 install Bearing Spring seat Damper spring Damper cam Drive gear assembly Washer 3 51 ...

Page 176: ...e performed only if the middle driven gear or middle drive shaft must be replaced Universal Joint Removal 1 Remove Universal joint By the following Universal joint removal steps Remove the Place the U joint in a press a suitable diameter pipe beneath the yoke press the bearing into the pipe as shown NOTE It may be necessary to lightly tap the yoke with a punch Repeat the steps for the opposite bea...

Page 177: ...bly 1 Install Bearing outer race the bearing housing Do not press the bearing outer race Always pressthe inner race with care when installing 2 Install Inner bearing Spacer Collapsible collar new Bearing housing bearing Dust seal Yoke Washer Nut driven pinion gear Universal Joint Holder YM 04062 3 Attach Onto the universal joint yoke 4 Tighten Nut drivenpinion gear Torque nut carefully little by l...

Page 178: ...y To reassemble you must replace the collapsible collar and repeat the steps in 4 and 5 to obtain the standard starting torque 6 Position Yoke 7 Lubricate Bearings Into the U joint Wheel Bearing Grease 8 Install Bearings Onto the yoke Check each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a ...

Page 179: ...1 2 begining from the left 3 Install 4 Tighten Bearing retainer shift cam bearing retainer Screws Bearing Retainer LOCTI 7 Nm 0 7 5 1 5 Rotate the shift cam to neutral position 6 Install cam stopper lever spring Washer Bolt shift cam stopper lever 7 Tighten Bolt shift cam stopper lever Bolt Shift Cam Stopper Lever 8 Nm 0 8 kg 5 8 LOCTI NOTE Check for smooth operation after tightening the stopper l...

Page 180: ...ENGINE ASSEMBLY AND ADJUSTMENT NG Piston ring Y mark Matching mark Connecting rod bearing size Projection Journal bearing size Crank pin size Balancer matching mark Washer U 3 56 ...

Page 181: ...TRANSMISSION Bearing 1stwheel gear 4th wheel gear Washer 3rd wheel gear Drive axle Plug 2nd wheel gear 3rd pinion gear 5th pinion gear 5th wheel gear Washer Bearing Bearing axle pinion gear 3 57 ...

Page 182: ...ive axle assembly NOTE the bearing circlips completely into lower crankcase positioning grooves Position the bearing pin as shown 3 Install Middle driven pinion gear assembly NOTE careful not to damage the O ring during arrow mark on the bearing housing installation points to the upper crankcase 4 Install rod support bearing NOTE the bearing pin into the crankcase hole the oil seal snugly against ...

Page 183: ...e balancer shaft gear UPPER CRANKCASE 1 Install Plane bearings gear NOTE Identify each planebearingpositionvery carefuly so that it can be reinstalled in its original place 2 Install Piston rings Be sure to install rings so that Manufacturer s marks or numbers are located on the top side of the rings 3 Oil liberally Pistons Rings Cylinders Piston ring ends 4 Set Make sure the ends of the oil ring ...

Page 184: ...ction 6 Install rod assembly 1 Into the upper crankcase By the following steps rod assembly installation steps the Piston Ring Compressor Install the piston to the cylinder 8037 to the piston NOTE stamped mark on the No 2 and No 4 connecting rods should face towards the RIGHT side of the crankcase stamped mark on the No 1 and No 3 connecting rods should face towards the LEFT side of the crankcase ...

Page 185: ...ains on timing gear sprockets Before tightening the crankcase bolts check the following points sure the gear shifts correctly while turning the shift cam Be sure the balancer shaft gear is alignedsothat the dot mark lines up between the triangular timing marks on the upper crankcase when the No 1piston is at TDC Balancer shaft mark Triangular timing marks 4 Finger tighten the several crankcase bol...

Page 186: ... until final torque is reached If tightening is interrupted between 3 0 and 3 8 loosen the nut to less than 3 0 and start again Tighten to full torque specifi cation without pausing 7 Tighten Bolts crankcase NOTE Tighten the bolts starting with the lowest numbered one With washer LOWERCASE UPPERCASE 6 mm Bolt 8 mm Bolt 10 mm Bolt 12 Nm 1 2 kg 8 7 24 Nm 2 4 kg 17 40 Nm 4 0 kg 29 NOTE Install the oi...

Page 187: ...mainaxle bearing NOTE Be sure that the groove in the shaft mesh with the slot in the retainer Retainer Main Axle Bearing 7 Nm 0 7 5 1 I I 11 Install Retainers middlegear bearing Use the 40 Torx Drive YU 29843 7 Stake screw head with center punch to lock Retainers Middle Gear Bearing 25 Nm 2 5 18 OIL PUMP AND OIL PAN 1 Install Damper oil pump pipe pump pipe 3 63 ...

Page 188: ...mainoil gallery pipe 6 mm Flange Bolt 8 mm Union Bolt 12 Nm 1 2 8 7 I 18 Nm 1 8 14 I 4 Bend the bracket tabs 5 Install pins pump assembly NOTE sure the correct O ring is installed on oil pump pipe arrow mark on the oil should face toward the rear Oil Pump Nm 1 0 7 2 6 Install Gasket Dowel pins pan Nm 1 0 7 2 7 Clamp the oil level gauge lead 3 64 ...

Page 189: ...e slots on the crankcase Water Pump Case and Housing 10 Nrn 1 0 kg 7 2 Oil Filter Cover 32 Nrn 3 2 kg 23 BREATHER COVER AND STARTER MOTOR 1 Install pipe Breather cover spacer Breather cover Bolt Breather Cover Nrn 1 0 7 2 O ring 2 Install Starter motor WATER PUMP AND THERMOSTATIC VALVE 1 Install Thermostat assembly Thermostatic Valve Housing 10 1 0 7 2 3 65 ...

Page 190: ...ss 3 Tighten clutch boss Use the Clutch Holder to hold the clutch boss Nut Clutch Boss 70 Nm 7 0 50 4 Bend the lock washer tabs along the nut flat Install rod Friction plates plates NOTE Install the friction plates and clutch plates alternately on the clutch boss starting with a friction plate and ending with a friction plate By the following installation steps 3 66 ...

Page 191: ...L PUMP DRIVE GEAR Clutch spring Spring seat Pressure plate Friction plate pcs plate 7 pcs Friction plate 6 pcs Bearing rod No 1 Ball Push rod No 2 pump washer boss Thrust washer tch housing pump drive gear axle pin pump driven gear 6 5 mm 0 26 in ...

Page 192: ...e to hard meshing between the friction plates and the clutch housing check to see if any of the friction plates fit too snugly into the clutch housing Any tight fitting friction plates must be repositioned as follows 1 Remove the friction plates and the clutch plates 2 Install the six friction plate with the double semi circular slots and the six clutch plates NOTE Invert the friction plates sure ...

Page 193: ...ressure plate 7 Install 0 Spring seat 0 Clutch spring Plate washer Bolts clutch spring Bolt Clutch Spring 8 0 8 kg 5 8 8 Install pins 0 Gasket Crankcase cover right NOTE Tighten the bolts in a crisscross pattern Crankcase Cover Right 10 Nm 1 0 7 2 FLYWHEEL AND STARTER IDLE GEAR 1 Install 0 Oil baffle plate Oil Baffle Plate 7 Nm 0 7 kg 5 1 3 69 ...

Page 194: ... When installing the flywheel do not allow the oil baffle plate to touch the projections on the flywheel 4 Install Plain washer Bolt flywheel NOTE Check for clot of oil passage in the bolt If any clean the oil passage Bolt Flywheel 130 Nm 13 0 94 5 Install idle gears 6 Install pins Gasket Crankcase cover left NOTE Tighten the bolts in a crisscross pattern I Crankcase Cover Left 10 Nm 1 0 7 2 3 70 ...

Page 195: ...ard cam chain guide slot in the crankcase Cylinder head Pass cam chain through cam chain cavity 2 Nuts cylinder head Use 8 mm Wrench Adapter YM 28897 NOTE sequence as shown and torque nuts in two stages Never lubricate the bolt threads with engine oil Nuts Cylinder Head 43 Nm 4 3 kg 31 3 Install Water jacket joints NOTE Be sure each joint passes through its correspond ing cam chain Lock pin O ring...

Page 196: ...LINDER HEAD AND CAMSHAFT Washer Rubber washer Pad Valve lifter Valve retainer Spring seat spring Outer spring Spring seat seal Valve Gasket plug Joint O ring plug Valve guide 15 Nm 1 5 I CYLINDER HEAD WARP LIMIT I0 03 mm 0 0012 in 3 72 ...

Page 197: ...ockets onto the camshafts VOTE sure the REAR mark on the cam sprockets face away from the IN nark and EX mark on the camshafts engine oil to the camshaft bearing surfaces Install the IN marked camshaft onto the intake side and EX marked camshaft onto the exhaust side the camshafts by hand so that the timing markes small hole on the camshaft face upward Install the dowel pins into the cam caps the ...

Page 198: ...e crank case cover use 32 mm wrench turn the flywheel installing bolt Rotating the bolt may loosen it causing the rotor to fall out not turn the crankshaft during the sprocket installation the cam chain onto the intake sprocket Install the sprocket with the punched mark REAR facing outward and finger tighten the sprocket bolts Align the IN mark hole on the sprocket the thread hole on the camshaft ...

Page 199: ... to remove all the cam chain slack your finger into the cam chain tensioner hole and push the cam chain guide inward pushing the cam chain guide be sure camshaft embossed match marks align with the timing marks on the camshaft marks do not align change the meshing position of sprocket and cam chain 6 Install Cam chain tensioner By the following installation steps Cam chain tensioner installation s...

Page 200: ...Head When installing the front cylinder head repeat the rear cylinder head installation procedure However note the following points 1 Install Camshafts 1 Rotate the crankshaft counterclockwise 360 plus and added 70 total from the mark 2 Align the mark on the flywheel with the stationary pointer on the crankcase cover use 32 mm wrench 3 Install the cam chain sprockets onto the camshafts NOTE Make s...

Page 201: ...g hole on the camshaft with the embossed match the camshaft caps 1 4and E 4 3 Measure Valve clearance Out of specification Adjust Refer to CHAPTER 2 VALVE CLEAR ANCE ADJUSTMENT section Valve Clearance Cold Intake 0 11 0 15 mm 0 004 0 006 in I Exhaust 0 26 0 30 mm I 0 010 0 012 in OIL DELIVERY PIPE AND CYLINDER HEAD COVER Install delivery pipe NOTE Tighten the three union bolts evenly then torque t...

Page 202: ...cylinder head cover Spark plugs Cylinder Head Cover 10 Nm 1 0 7 2 I Spark Plug I 17 5 Nm 1 75 12 5 4 Install plug Special washer Crankcase cover plate NOTE Check for clog of oil passage in the bolt If any clean the oil passage V BOOST Install V boost assembly NOTE the O ring on the V boost and the bolts in a crisscross pattern replace it if damaged 10 Nm 1 0 7 2 3 78 ...

Page 203: ...ing the engine reverse the 1 Install Down tube frame right Bolts down tube Bolts engine NOTE Tighten the bolts 1 9 in that order Engine Mounting Bolts Down Tube 45 Nm 4 5 kg 32 Bolts Engine 70 Nm 7 0 50 Bolts Engine 40 Nm 4 0 29 Bolts Down Tube 15 Nm 1 5 11 2 Tighten Exhaust pipes Muffler pipe Muffler 3 79 ...

Page 204: ...8 7 10 Nm 1 0 7 2 10 Nm 1 0 7 2 40 Nm 4 0 29 23 Nm 2 3 17 23 Nm 2 3 17 4 Adjust 0 Rear brake switch Refer to CHAPTER 2 REAR BRAKE SWITCH ADJUSTMENT section 5 Bend the tabs on the air baffle plate front as shown 6 Adjust cable V boost Refer to CHAPTER CARBURETION V BOOST section 7 Tighten nuts or bolts By the following specification torque 7 Nm 0 7 5 1 4 Nm 0 4 kg 2 9 10 Nm 1 0 7 2 Radiator Cover C...

Page 205: ...HAPTER 4 COOLING SYSTEM RADIATOR AND CONDUIT section 9 Adjust cable free play Refer to CHAPTER 5 CARBURETION THROTTLE CABLE CYLINDER section Add Engine oil Refer to CHAPTER 2 ENGINE OIL REPLACEMENT section 11 Add Coolant Refer to CHAPTER 4 COOLING SYSTEM COOLANT section 3 81 ...

Page 206: ...ENGINE ASSEMBLY AND ADJUSTMENT MEMO 3 82 ...

Page 207: ...ND SEAL REPLACEMENT 4 5 ASSEMBLY 4 7 THERMOSTATIC VALVE 4 8 REMOVAL 4 8 INSPECTION AND ASSEMBLY 4 8 COOLANT DRAIN VALVE 4 9 DISASSEMBLY 4 9 INSPECTION 4 9 ASSEMBLY 4 9 CYLINDER HEAD WATER JACKET JOINT REMOVAL INSPECTION 4 10 ASSEMBLY 4 10 RADIATOR AND CONDUIT 4 10 DISASSEMBLY 4 10 INSPECTION 4 11 ASSEMBLY 4 12 I ...

Page 208: ... SYSTEM COOLANT COOLANT FLOW Radiator Coolant drain valve Bypass pipe to the coolant drain valve Bypass pipe to the thermostatic valve Thermostatic valve Water pump To the reservoir tank Thermostat housing Conduit 4 1 ...

Page 209: ...hick rag like a towel over the radiator cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it 1 Place a receptacle under the coolant drain bolt 2 Remove Cover right cover Radiator cap Feed hose reservoirtank 3 Align drain valve ON mark with ...

Page 210: ... NO TE Thor oughl y f l ush t he cool i ng syst em wi t h cl ean t ap wat er 8 I nspect Rubber pl ugs Dam age Repl ace 9 Ti ght en bol t Dr ai n Bol t 43 Nm 4 3 m kg 31 f t l b I R ecom m ended C oolant Hi gh Q ual i t y Et hyl ene G l ycol A nti Freeze C ontaining Ant i Cor r osi on f orAl um i num Engi ne I nhi bi t or s C oolant and W ater M ixed R atio 50 50 Tot al Am ount 3 05 L 2 69 I m p qt...

Page 211: ...e conduit until the Start the engine coolant level decreases conduit is full Always check level and check for coolant leakage before starting engine the coolant while engine is running Stop the engine when coolant level stabilizes the coolant again to specified level Install the radiator cap Align the coolant drain valve OFF mark with the match mark on drain valve housing 11 Connect Feed hose rese...

Page 212: ...move Drive gear Gear stopper pin Impeller shaft 2 Eliminate From the impeller and water pump housing INSPECTION 1 Inspect Bearing seal Impeller Water pump seal set Replace Replace Replace Replace BEARING AND SEAL REPLACEMENT 1 Remove Bearing Tap off both components from water pump seal side Crankcase cover 2 Remove Water pump seal crankcase side Tap it off from the cover 4 5 ...

Page 213: ...careful not to scratch or bend the impeller shaft Damper rubber 5 Apply or coolant To outer surface of damper rubber and impeller hub Never apply oil or grease to water pump seal surfaces 6 Assemble No rubber To impeller hub Slip ring APPLICATION OF WATER OR COOLANT 7 Measure Tilt Out of specification Repeat the above steps 4 6 NOTE Be sure seal No 2 fits squarely Tilt Limit 0 15 mm 0 006 in I I S...

Page 214: ...seal seat Bearing Gear stopper pin Drivengear Drive gear Water pump cover O ring Crankcase cover FRONT FROM RADIATOR Impeller shaft Gear stopper pin gear sure not to scratch the water pump any scratched seal seal while installing 4 7 ...

Page 215: ...llowing inspection steps Thermostatic valve inspectionsteps thermostatic valve in a vessel or reliable thermometer in water water slowly thermometer while stirring water water continuaII Thermometer Water Full open Thermostatic valve Openingsequence begins Vessel OPEN CLOSE NOTE Thermostat is sealed and its setting is specialized work If its accuracy is in doubt always replace it A faulty unit cou...

Page 216: ...le with the housing projection cover housing COOLANT DRAIN VALVE DISASSEMBLY 1 Remove Retaining screw assembly INSPECTION 1 Inspect O ring Stopper ball Replace Damage Replace Replace ASSEMBLY 1 Install assembly Be sure stopper ball falls into body cavity 2 Secure valve assembly with retaining screw 4 9 ...

Page 217: ...nt will flow into the crankcase not remove the water jacket joints unless absolutely essential when overhauling the engine REMOVAL 1 Remove Stopper pins jacket joints INSPECTION 1 Inspect jacket joint Stopper pin Clogging Clean Replace Replace ASSEMBLY 1 Install jacket joints pins RADIATOR AND CONDUIT DISASSEMBLY 1 Drain completely Refer to COOLANT REPLACEMENT section 4 10 ...

Page 218: ...es 4 Disconnect 5 Remove motor coupler Radiator assembly 6 Disconnect 7 Remove hoses and leads conduit conduit 8 Remove motor assembly INSPECTION 1 Inspect Obstruction Blow out with compressed air through rear of radiator Flattened fins Repair hoses Replace 4 11 ...

Page 219: ...the Radiator Cap Tester YU 24460 Valve opens at pressure below specified valve or defective Replace Valve Opening Pressure 73 6 103 0 0 75 1 05 10 7 14 9 ASSEMBLY When installing the radiator and conduit reverse the removal procedure Note the following points Conduit 1 Install Screws Conduit 7 Nm 0 7 5 1 2 Connect hoses and leads conduit NOTE Align the hose match marks with the match marks on the ...

Page 220: ...nspect Cooling system By the following inspection steps I Cooling system inspectionsteps Connect Radiator Cap Tester Apply 1 0 14 pressure Measure pressure with gauge Decrease of pressure leaks Repair at required 4 13 ...

Page 221: ...5 3 DISASSEMBLY 5 3 INSPECTION 5 6 ASSEMBLY 5 7 INSTALLATION 5 8 ADJUSTMENT 5 9 THROTTLE CABLE CYLINDER 5 10 ADJUSTMENT 5 10 V BOOST 5 13 REMOVAL 5 13 INSPECTION 5 13 ADJUSTMENT 5 13 INSTALLATION 5 15 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 5 16 ...

Page 222: ...w hose Fuel feed hose rod Float needle valve Needle jet screw Float Main jet Main bleed pipe Rubber plug Fuel drain hose jet Jet shaft Fuel overflow hose Fuel feed hose air jet Coastingenrichment valve assembly Pilot air jet No 2 Piston valve assembly Tamper proof screw Starter plunger assembly Starter body valve center mark 3 150 2 0 Y 0 37 5 16 1 0 mm 0 63 0 04 in Preset 1 5 1 000 50 1 mm 0 63 0...

Page 223: ... Main air jet Jet needle Pilot air jet No 2 Piston valve Diaphragm Purge jet No 2 Purge jet No 1 screw Bypass hole Pilot outlet Purge hole Throttle valve Pilot jet Main jet Main bleed pipe Needle jet 0 0 0 0 0 0 0 0 0 0 0 I I I I I I I I I 5 2 ...

Page 224: ...SASSEMBLY The plastic piston valve is fragile and highly susceptible to damage Be sure to handle with extreme care Do not drop the valve or subject it to undue abuse as this can cause cracks that could severely weaken the piston valve 1 2 3 4 Remove lines Number each carburetor before removing it from carburetor bracket Remove brackets FRONT Remove brackets 5 3 ...

Page 225: ...screws Synchronization rod NOTE When separating the carburetors be sure not to lose the small spring that may fall out This spring connects the throttle levers 8 Remove plunger plunger body Nut Spring 9 Remove Vacuum chamber cover Use the Special Torx Driver U 25359 2 screw 5 4 ...

Page 226: ...r i ng Pi l otai rj etNo 2 11 Rem ove Coast i ng enr i chm ent cover Di aphr agm 12 Rem ove Fl oat cham ber cover Needl e val ve 13 Rem ove M ai n j et bl ock 14 Rem ove G asket Needl e j et NO TE M ove t he needl e j et t owar d t he vacuum pi st on ...

Page 227: ...oleum based solvent for cleaning Blow out all passages and jets with compressed air 2 Inspect Float valve Damage Replace Wea ntamination RepIace 3 Inspect piston Cracks Replace NOTE If you suspect the piston valve has been dam aged check the component for cracks by pouring gasoline into the valve If it leaks replace with a new piston valve 5 6 ...

Page 228: ...pect Damage Replace ASSEMBLY To assemble the carburetors reverse the disas sembly procedures Note the following points reassembling wash all parts in clean use a new gasket gasoline 1 Install jet NOTE Make sure the projections on the carburetor body are meshed with the holes on the gasket 5 7 ...

Page 229: ...ragm and a matching recess in the carburetor body to accept the diaphragm tab 4 Install lever shafts Apply to the starter plunger lever securing screws 5 Install brackets Apply to the bracket securing screws NOTE When reassembling the surface plate should be used for proper carburetor alignment Screws Mounting Brackets 5 Nm 0 5 3 6 INSTALLAT N 1 Install Reversethe removal steps 5 8 ...

Page 230: ...lly the Fuel Level Gauge YM 01312 to the drain pipe using a level gauge adapter the drain screw and warm up the engine for several minutes the fuel level with the gauge Piston valve center mark the above procedure for other carburetors the fuel is incorrect adjust the fuel 2 Adjust level By the following adjustment steps Fuel level adjustment steps Remove the carburetors the needle valve it is wor...

Page 231: ...uretor side Free play Locknut Carburetor side Throttle stop screw Cable adjustment mark Close side Cable adjuster Turning direction Throttle grip ADJUSTMENT 1 Loosen Throttle stop screw To set the throttle valve to full closed 2 Adjust Between the threaded end of the tubular control cable guide and the adjuster Standard Carburetor Side Adjuster Distance 15 mm 0 59 in 5 10 ...

Page 232: ...djust THROTTLE VALVE FULLY OPEN THROTTLE VALVE FULLY CLOSED 5 Adjust 2 carburetor throttle valve operation By the following adjustment steps No 2 carburetor throttle valve operation adjustment steps First step a Loosen the locknut carburetorside b Turn the adjuster carburetor side clock wise a little c Turn the adjuster throttle grip side coun terclockwise and adjust free play throttle grip to wit...

Page 233: ...valve fails to operate at full open or full closed Performthe next step Third step to see if throttle cable installation is correct NOTE Be sure that the silver throttle cable is po sitioned opposite the adjusters Check the position of the control cable sliders in the throttle cable cylinder NOTE sure the open side slider silver cable side falls between the three adjustment marks on the carburetor...

Page 234: ... not necessary to disassemble the V boost INSPECTION 1 Inspect Contamination Clean Use a petroleum based solvent Replace V boost assembly valves ADJUSTMENT NOTE These adjustments are only required when following is replaced motor cable cable joint Carburetor joint Control Cable Adjustment 1 Turn on the main switch for the servo motor initial operation valve closed po sition 5 13 ...

Page 235: ...on the main switch for the servo motor NOTE By performing these steps and appropriate tension for the control cable 1 can be obtain with the spring in the joint initial operation valve closed position the lock bolt to specification Lock Bolt 3 5 Nm 0 35 2 5 the clearance If not perform Second step Loosen the locknut the adjuster clockwise or counter clockwise until proper clearance is attained the...

Page 236: ... 0 004 in a 2 Adjust By the following adjustment steps V boost synchronization adjustment step the locknut the adjuster clockwise or counter clockwise until proper clearance is attained the clearance If not repeat above step the locknut Apply to the locknut INSTAL ON 1 Install V boost assembly Reverse the removal steps 5 15 ...

Page 237: ...AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR CLEANER AND CRANKCASE VENTILATION SYSTEM Refer to CHAPTER 2 for the air cleaner maintenance Air cleaner Carburetor 5 16 ...

Page 238: ...ASSEMBLY MASTER CYLINDER DISASSEMBLY BRAKE INSPECTION AND BRAKE REASSEMBLY AIR BLEEDING BRAKE DISC INSTALLATION HYDRAULIC CLUTCH CLUTCH RELEASE DISASSEMBLY MASTER CYLINDER DISASSEMBLY CLUTCH INSPECTION AND R CLUTCH REASSEMBLY AIR FRONT FORK REMOVAL INSPECTION ASSEMBLY INSTALLATION STEERING HEAD REMOVAL INSPECTION INSTALLATION REAR SHOCK ABSORBER REMOVAL INSPECTION INSTALLATION ...

Page 239: ... 6 43 FREE PLAY INSPECTION 6 44 REMOVAL 44 INSPECTION 6 45 INSTALLATION SHAFT DRIVE 6 47 TROUBLESHOOTING FINAL DRIVE GEAR DRIVE SHAFT ...

Page 240: ...FRONT WHEEL CHASSIS FRONT WHEEL Collar seal clutch Bearing Clutch retainer seal unit assembly 6 1 ...

Page 241: ...ine Front axle Front wheel 5 Elevate the front wheel by placing a suitable 6 Remove Lower the wheel until the brake discs come off the calipers Turn the brake calipers out ward so they do not obstruct the wheel NOTE Do not squeeze the brake lever while the wheel is off the motorcycle INSPECTION 1 Inspect Tire tread shows crosswise lines minimum tread Repalce Minimum Tire Tread Depth 1 0 mm 0 04 in...

Page 242: ... balance Out of balance Adjust Balance wheels with the brake discs installed Be sure the valve stem locknut is tightened securely after repairing or replacing a tire and or wheel Ride conservatively after installing a tire to allow the tire to seat itself correctly on the rim 6 Inspect Wheel bearings Bearings allow play in the wheel hub or wheel turns roughly Repalce By the following replacement s...

Page 243: ... the outer race 7 Inspect Brake disc specified limit Replace Maximum Deflection Front and Rear 0 15 mm 0 006 in Minimum Disc Thickness Front and Rear 7 0 mm 0 28 in INSTALLATION When installing the front wheel reverse the removal procedure Note the following points 1 Apply Lithium base grease Lightly grease to the oil seal and gear unit 2 Install Gear unit assembly NOTE Be sure that the two projec...

Page 244: ...per of the gear unit housing is ed correctly Compress the front forks several times to con firm proper fork operation before tightening the pinch bolt 4 Tighten Front axle 60 6 0 43 5 Tighten Pinch bolt front axle Fork brace Front fender 20 Nm 2 0 14 9 Nrn 0 9 6 5 Nuts Fork Brace 6 5 ...

Page 245: ...REAR WHEEL REAR WHEEL seat seal Bearing Clutch hub Spacer Damper Spacer Cylinder bearing Hub dust seal TIRE SIZE 1 0 mm 0 04 in RIM SIZE M73 50 x 15 RIM RADIAL LATERAL 2 0 mm 0 08 in 120 Nm 12 0 85 6 6 ...

Page 246: ...be forced 4 Loosen 5 Remove Pinch bolt rear axle Rear axle While supporting the brake caliper pull out the rear axle Move the wheel to the right side to separate it from the final gear case Rear wheel INSPECTION Inspect Tire Rear axle Wheel bearings Brake disc Wheel Refer to FRONT WHEEL INSPEC TION section 2 Measure Wheel Refer to FRONT WHEEL INSPEC TION section 3 Check Wheel balance Refer to FRON...

Page 247: ...e grease Lightly grease to the final gear case splines 2 Install Rear wheel assembly NOTE Be sure the splines on the wheel hub fit intofinal gear case 3 Tighten Wheel axle 120 Nm 12 0 85 20Nm 2 0 14 Pinch Bolt Rear Wheel I Always usea newcotter pin on the rear axle nut 4 Tighten Tension bar Rear caliper 45 Nm 4 5 32 6 8 ...

Page 248: ...RONT AND REAR BRAKE FRONT AND REAR BRAKE Air bleed screw Retaining pin disc rotating direction Dust seal Install the pad spring with its longer in the Piston seal Piston A FRONT CALIPER 5 Nm 0 5 3 6 6 9 ...

Page 249: ...ad spring with its longer tangs in the disc Dust seal rotating direction Piston Shim rotation Piston seal F Be sure to position the shim that its arrow mark points in the rotating direction of the disc plate B REPLACEASASET 5 Nm 0 5 3 6 REAR CALIPER 45 Nm 4 5 32 6 10 ...

Page 250: ...move Retaining clips Retaining pins spring 3 Remove Pads NOTE the pad spring if pad replacement is required be worn to the wear limit Replace the pads as a set if either is found to Wear Limit 0 5 mm 0 02 in 4 Install in above list steps 3 1 NOTE AND REAR BRAKE Install the pad spring with its longer tangs facing towards the disc rotating direction 6 11 ...

Page 251: ...iner and pump the old fluid out carefully 3 Remove Caliper Never loosen the bridge bolts on either side of the caliper 4 Remove Dust seals Piston seals By the following removal steps Caliper piston removal steps a of wooden board into the caliper to lock the right side piston compressed air into the tube joint opening to force out the left side piston from the caliper body Repeat previous step to ...

Page 252: ...ND REAR BRAKE MASTER CYLINDER DISASSEMBLY Master cylinder cap Rubber seal cylinder kit 4 Copper washer joint BRAKE FLUID TYPE DOT 3 1 Nm 0 9 m kg 6 5 ft lb 1 25 Nm 2 5 m kg 18ft Ib 25 Nm 2 5 m kg 18 ft lb 6 13 ...

Page 253: ...i t Locknut Adj ust i ng r od Forbr ake pedalhei ght D BRAKE HOSE ROUTI NG W hen i nst al l i ng t he rear brake hose al i gn t he br ake pi pe wi t h t he f r ont pr oj ect i on 2 on t he m ast ercyl i nder A REAR M ASTER CYLI NDER B BRAKE FLUI D TYPE DO T 3 25 Nm 2 5 m kg 6 14 ...

Page 254: ...ing master cylinder Dust boot Piston Piston cups Return spring Washer Seat A MASTER CYLINDER KIT Replace as a set 1 Remove Brake light switch leads Brake lever Lever spring 2 Disconnect Brake hose Drain the fluid 3 Remove Master cylinder Master cylinder cap 4 Remove Dust boot Master cylinder kit 6 15 ...

Page 255: ...t Brake hose Spring Piston cup Piston Adjusting rod Circlip Dust boot MASTER CYLINDER K I T Replace as a set 3 Remove Master cylinder Fluid reservoir tank Drain the fluid 4 Disconnect hose 5 Remove Dust boot rod Master cylinder kit Drain the excess fluid BRAKE INSPECTION AND REPAIR Recommended Brake Component Replace ment Schedule Brakepads As required I Brake fluid I I Replace only when brakes ar...

Page 256: ... seal Damage Repl ace Repl ace t he pi st on and dust seal s w henever a cal i per i s di sassem bl ed M ast er cyl i nder ki t Mast er cyl i nder body Scr at ches W ear Repl ace N O TE Cl ean al l passages wi t h new br ake f l ui d Oi l baf f l e pl at e Br akehose Cracks W ear Dam age Repl ace BRAKE REASSEM BLY Al l i nt er nal part s shoul d be cl eaned i n new brake fluid only I nt ernal part...

Page 257: ... air completely from the brake system Master Cylinder Reassembly When assembling the master cylinder reverse the disassembly procedure Note the following points 1 Install Master cylinder kit Internal parts should be lubricated with brake fluid when installed 2 Install Master cylinders front and rear Brake hoses 23 Nm 2 3 m kg 17 ft lb 25 Nm 2 5 rn kg 18 ft lb Brake Hose I I When installing the rea...

Page 258: ...ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube tightly to the caliper bleed screw d Place the other end of the tube into a container e Slowly apply the brake lever or pedal severaI times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever ...

Page 259: ...rocedure when the tiny bubbles in the system have pered j Add brake fluid to the level line on the reservoir BRAKE DISC INSTALLATION 1 Install Brake NOTE brake disc should be installed with the arrow mark on the disc must point arrow mark face outward toward the rotating direction of the wheel 2 Tighten Bolts disc Bolts Brake Disc 20 Nm 2 0 14 6 20 ...

Page 260: ...HYDRAULIC CLUTCH HYDRAULIC CLUTCH Copper washer Master cylinder kit Replace as a set 1 Nm 0 1 0 7 U A CLUTCH FLUID TYPE DOT 6 21 ...

Page 261: ...le gear case cover be sure oil does not leak out of the case 2 Remove hose Drain the fluid release assembly Remove Dust seal Piston assembly MASTER CYLINDER DISASSEMBLY NOTE Drain the clutch fluid before removing master cylinder Bush Push rod Dust boot Piston cup Piston Return spring Master cylinder kit Replace as a set 6 22 ...

Page 262: ...luid Remove Master cylinder Drain the excess fluid 3 Remove boot rod Circlip Master cylinder kit CLUTCH INSPECTION AND REPAIR I Recommended Clutch Component Replacement Schedule Clutch fluid 1 Replace only when clutch is disassmbled 1 Inspect Cylinder body Replace NOTE Clean all passages with new brake fluid hoses Replace 6 23 ...

Page 263: ...Clutch Release Reassembly When assembling the clutch release reverse the disassembly procedure Note the following points 1 Install Clutch release assembly Clutch hose Clutch Release Assembly Clutch Hose 12 Nm 1 2 8 7 25 Nm 2 5 18 I Master Cylinder Reassembly When assembling the master cylinder reverse the disassembly procedure Note the following points 1 Install Master cylinder Clutch hose 6 24 ...

Page 264: ...brakefluid By the following steps Air bleeding steps a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to over flow c Connect the clear plastic hose to the bleed screw d Place the other end of the tube into a container e Slowly apply the clutch lever several times f Pull in the lever and hold it in position g Loosen the bleed...

Page 265: ...yst em NO TE I f bl eedi ng i s di f f i cul t i t m ay be necessar y t o l et t he cl ut ch f l ui d syst em st abi l i ze f or a f ew hour s Repeat t he bl eedi ng pr ocedur e when t he t i ny bubbl es i n t he syst em have di sappeared j Add br ake f l ui d t o t he l evel l i ne on t he r eser voi r 6 26 ...

Page 266: ...Damper Air joint O ring Air valve Fork cap O ring Cap bolt Spring seat Fork spring Rebound spring complete Oil lock piece Inner fork tube Guide bush Dust cover Retainingclip seal spacer bush Outer fork tube Drain screw 6 27 ...

Page 267: ... 1 Remove Front wheel 0 Brake calipers Cable holders valve cap left cap Refer to FRONT WHEEL seciton 2 Remove Depress the valve until all of the air has been released 3 Loosen 0 Pinch bolt steeringcrown bolt Use the Front Fork Cap Socket 01104 4 Loosen bolts under bracket 5 Remove Rubber damper joint bracket 0 Front 6 28 ...

Page 268: ...ylinder complete Use the Damper Rod Holder to lock the damper rod and the T Handle 4 Remove Damper rod cylinder complete Reboundspring 5 Remove Inner fork tube By the following removal steps inner fork tube removal steps Hold fork leg horizontally the caliper mounting bossof the outer tube securely in a vise with soft jaws out the inner fork tube from the outer tube by forcefully but carefully wit...

Page 269: ... l be damaged 6 Rem ove Oi lseal Sealspacer Sl i de bush Gui debush Oi ll ock pi ece I NSPECTI O N I nspect I nner f or k t ube Scr at ches Bends Repl ace Do not at t em pt t o st r ai ght en a bent i nner f or k t uba as t hi s m ay dangerousl y weaken t he t ube Out erf or k t ube Scr at ches Bends Damage Repl ace For k spr i ng Over speci f i ed l i mi t Repl ace 2 I nspect Ai rj oi ntbr acket ...

Page 270: ... inspect all parts and replacewhen necessary NOTE In front fork assembly be sure to use following new parts Do not reuse them bush Guide bush seal Dust seal 1 Install Rebound spring Damper rod Allow the rod to slide slowly down the tube until the it protrudes from the bottom Fit oil lock piece over damper rod sticking out of the inner fork tube Oil lock 2 Install Inner fork tube Into outer tube 6 ...

Page 271: ...964 inner tube Outer tube 5 Install spacer seal On top of the slide bush Use the Fork Seal Driver Weight 33963 and the Adapter and install with numbered side up inner tube Outer tube 6 Install Retaining clip seal Use the Special Tools YM 33963 YM 33964 inner tube Outer tube 7 Fill Front fork Each Fork 451 15 9 Imp 15 3 US Fork Oil or equivalent After filling slowly pump the fork up and down to dis...

Page 272: ... Rubber damper Over inner fork tube 2 Tighten Pinch bolts under bracket Temporarily tighten the pinch bolts NOTE Position the inner tube end so that it is flush with the top of the steering crown 3 Tighten Pinch bolts under bracket Pinch Bolts Under Bracket 23 Nm 2 3 17 NOTE Do not tighten the pinch bolt steering crown in this stage 4 Tighten bolt Use the Front Fork Cap Socket 01104 Pinch bolt ste...

Page 273: ...ust Front fork air pressure Refer to CHAPTER 2 FRONT FORK ADJUSTMENT section 6 Install valve cap Fork cap Brake calipers Cable holders Refer to FRONT AND REAR BRAKE section Refer to FRONT WHEEL section Front wheel 6 34 ...

Page 274: ...G HEAD Steering stem nut Ring nut Lower Lock washer Bearing cover nut Upper Bearing Upper Washer Bearing Lower Nrn 2 0 14 11 20 2 0 14 40 4 0 29 1 TIGHTEN RING 50 5 0 36 LOOSEN IT COMPLETY 3 Nrn 0 3 2 2 3 RETIGHTEN IT 6 35 ...

Page 275: ...o danger of it falling over 1 Remove Front wheel Front forks Headlight lens unit leads in the headlight body 2 Remove 3 Disconnect 4 Remove Bolt headlight body bracket Emblem 5 Remove Flasher light bracket assembly 6 Remove Handlebar holder assembly 6 36 ...

Page 276: ...e Nut st eer i ng cr own St eer i ng cr own 9 R em ove Lock washer r i ng nut Ri ng nut upper W asher Ri ng nut l ower Suppor t t he under br acket so t hat i t m ay not f al ldown 10 R em ove St eer i ng st em Bear i ng cover Bear i ng upper Bear i ng l ower ...

Page 277: ... set INSTALLATI0N 1 Lubricate Bearing and races 2 Install lower Onto steering stem stem Hold the steering stem until it is secured Ring nuts tightening steps Install the ring nut lower NOTE The tapered side of ring nut must face down ward the ring nut using the Ring Nut Wrench Ring Nut Initial Tightening 50 Nm 5 0 36 the ring nut completely and retighten it to specification not over tightening Rin...

Page 278: ...ng nut then align the slots of both ring nuts If not aligned hold the lower ring nut and tighten the other until they are aligned Install the lock NOTE Make sure the lock washer tab is placed in the slots the steering crown and tighten the steering stem nut to specification Nut Steering Stem 110 Nm 11 0 80 the pinch bolts to specification Pinch Bolt Steering Crown 20 Nm 2 0 14 5 Install Components...

Page 279: ...REAR SHOCK ABSORBER REAR SHOCK ABSORBER shock absorber assembly 20 Nm 2 0 14 SPRING PRELOAD POSITION STANDARD 1 DAMPING POSITION STANDARD 1 20 Nm 2 0 14 6 40 ...

Page 280: ...ear shock absorber INSPECTION 1 Inspect Shock absorber rod absorber assembly Oil leakes Replace the shock absorber assembly Fatigue Replace the shock absorber assembly Move the spring up and down Replace the shock Shock absorber Spring INSTALLATION When installing the rear shock absorber reverse the removal procedure Note the following points 1 Apply Lithium base grease To the pivot points 6 41 ...

Page 281: ...TMENT section 2 Install Rear shock absorber NOTE The rear shock absorber should be installed so that the damping match mark on the shock absorber faces outward 3 Tighten Bolt shock absorber top Nut shock absorber bottom Bolt Shock Absorber Top 20 Nm 2 0 14 Nut Shock Absorber Bottom I 30 Nm 3 0 22 I 6 42 ...

Page 282: ...SWINGARM Locknut Pivot shaft right Collar seal Taper roller bearing Pivot shaft left Lock washer Collar seal Taper roller bearing Rubber boot 20Nm 2 0 14 100 Nm 10 0 72 6 Nm 0 6 4 3 100 Nm 10 0 72 6 43 ...

Page 283: ...collars Move swingarm from side to side There should be no noticeableside play 3 Check Swingarm vertical movement spots Replace bearings Move the swingarm up and down REMOVAL 1 Remove Rear wheel Rear shock absorbers Pivot shaft caps Lock washer tab 2 Flatten Use a blunt chisel 3 Remove shaft left Lock washer I 4 Remove Pivot shaft right 6 44 ...

Page 284: ...er boot Bolts muffler 6 Remove Push down the muffler 7 Remove Final gear assembly INSPECTION 1 Wash the bearings in a solvent 2 Inspect Bearings seals Replace Damage Replace 3 Inspect Rubber boot Damage Replace 6 45 ...

Page 285: ...steps the pivot shaft left to specifi cation Pivot Shaft Left 100 Nm 10 0 72 the pivot shaft right until contacts the collar Pivot Shaft Right 6 Nm 0 6 kg 4 3 nut right pivot shaft to cation Nut Right Pivot Shaft 100 Nm 10 0 72 the lock washer tab along the nut flat 4 Apply Quick Gasket To the mating surfaces of both case halves 5 Install Final gear assembly Nuts Final Gear Case 42 Nm 4 2 30 6 Che...

Page 286: ...earing housing Drive pinion gear Ring gear Stopper shim Ring gear stopper Bearing O ring Bearing retainer seal O ring Ring gear shim seal Bearing Coupling gear Ring gear Spring Thrust washer Bearing Drive shaft seal seal Washer Bearing 23 Nm 2 3 17 6 47 ...

Page 287: ... or area 3 A locked up condition of the shaft drive mechanism no power transmitted from engine to rear wheel NOTE Areas A B and C above may be extremely dif ficult to diagnose The symptoms are quite subtle and difficult to distinguish from normal motorcycle operating noise If there is reason to believe these components are damaged remove the components for specific inspection Possible Causes A Bea...

Page 288: ... gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimizegear damage c A slight thunk evident a t low speed operation This noise must be distinguished from normal motorcycleoperation Diagnosis Possible broken gear teeth Stop riding immediately if broken gear teeth are suspected This condition could result ...

Page 289: ...en dry it powder spray to the shaft drive necessary to locate the leak Leakage Inspectcomponent housing Damage Replace component seat O ring Forward NOTE apparent oil leak on a new or nearly new motorcycle may be the result of a rest preventative coating or excessive seal lubrication clean the motorcycle and recheck the suspected location of an apparent leakage gasket and or seal for damage 6 50 ...

Page 290: ...g points Replace the wheel bearing Refer to CHAPTER 5 FRONT Rear wheel bearings and shaft drive bearings probably not damaged Repeat test or remove individual components Check the rear wheel Feel for bearing damage Replace the rear wheel bearing Refer 5 REAR WHEEL section Remove the rear wheel Check for wheel bearing damage the drive shaft components 6 51 ...

Page 291: ...e bolt finger tight is sufficient 5 Attach Lash Measurement Tool Dial Gauge YU 03097 01230 Position mark 6 Measure lash Gently rotate the gear coupling from engagement to engagement Over specified limit Adjust Final Gear Lash 0 10 0 20 mm 0 004 0 008 in NOTE Measure the gear lash at 4 positions Rotate the shaft 90 each time Gear Lash Adjustment 1 Remove Nuts bearinghousing Bolts bearinghousing NOT...

Page 292: ...har t Too l i t t l e gear l ash Reduce shi m t hi ckness Too l arge gear l ash I ncrease shi m t hi ckness To Add or Reduce Ri ng Gear Shi m Thi ckness I ncrease by m ore Reduce by m ore t han 0 1 m m 0 004 i n t han 0 1 m m 0 004 i n gearshi m i ncrease Thrust W asher 1 4 1 5 1 6 Thickness m m 1 7 1 8 1 9 2 0 2 1 2 2 2 3 R ing G ear Stopper C learance M easurem ent 1 R em ove Bear i ng housi ng ...

Page 293: ...024 in Ring gear stopper Ring gear 3 Install in above list step 3 Install Bearing housing with ring gear Ring Gear Stopper Clearance Adjustment 1 Remove Ring gear Ring gear stopper Bearing housing Left hand threads 2 Select By the following chart Shim Thickness I 0 40 0 50 Ring Gear Stopper 9 Nm 0 9 6 5 LOCTIT 4 Measure Ring gear stopper clearance 54 ...

Page 294: ...upling gear Use a Final Drive Shaft Holder Coupling gear Remove Bearing retainer final drive shaft Use a Final Drive Shaft Bearing Retainer YM 04050 Finaldr ng retainer has Ieft hand threads Turn retainer clockwise to loosen it Final drive shaft assembly Tap lightly on the final drive shaft end with a soft hammer Final drive shaft removal should be performed only if gearing replacement is necessar...

Page 295: ...nal drive shaft roller bearing removal steps Heat the bare housingto 150 C 302 Remove the roller bearing outer race with an Remove the inner race from the final drive appropriately shaped punch shaft NOTE The removal of the final drive shaft roller bearing is difficult and seldom necessary 4 Install final drive shaft roller bearing new By the following installation steps Final drive shaft roller b...

Page 296: ...rts are replaced 0 Final gear case 0 Ring gear bearing housing 1 Select Final drive gear shim Ring gear shim By the following selection steps Final gear shim selection steps final drive shaft gear and ring gear by using shims and with their re spective thicknesses calculated from infor mation marked on final gear case and drive gear end thickness A thickness B washer find shim thickness A use foll...

Page 297: ... ckness i s 0 51 mm Shi m si t es ar e suppl i ed i n f ol l owi ng t hi ck nesses Because shi ms can onl y be sel ect ed i n O O5 mm i ncr ement s r ound of f hundr edt hs di gi t and sel ect appr opr i at e shi m s Hundr edt hs Round val ue 0 1 2 0 3 4 5 6 7 5 I n t he exampl e above t he cal cul at ed shi m t hi ckness i s 0 51 m m The char t i nst r uct you however t o r ound of f t he 1 t o 0...

Page 298: ...nt Bearing Thickness f 13 00 mm Example 1 If gear case is marked 45 52 c is 45 52 If ring gear bearing housing is marked 35 d is 0 35 3 3 35 3 If ring gear is marked is 35 40 0 01 35 41 4 f is 13 00 45 52 3 35 35 41 13 00 48 87 48 41 0 46 shim thickness is 0 46 mm Shim sizes are supplied in following thick ness 0 25 0 30 0 35 0 40 0 45 0 50 Thickness mm Because shims can only be selected in 0 05 m...

Page 299: ...embly Bearing retainer final drive shaft Use a Final Drive Shaft Bearing Retainer Wrench NOTE The bearing retainer has left hand threads turn retainer counterclockwise to tighten it Bearing Retainer 110 Nm 11 0 Install Coupling gear nut coupling gear Use a Final Drive Shaft Holder 01 4 Install 5 Adjust Ring gear assembly without thrust washer lash Refer to Gear Lash Measurement and Adjustment sect...

Page 300: ...uring clearance with Remove the ring gear assembly Measure the thrust clearance Calculate width of flattened Ring Gear Thrust Clearance 0 1 0 2 mm 0 004 0 008 in 0 If the correct clearance install the ring gear If the out of specification select the correct mbIy washer Thrust washer selection steps the suitable thrust washer by the following chart Thrust Washer 1 4 1 5 1 6 1 7 1 8 1 9 I 2 0 2 1 2 ...

Page 301: ...ng the dirve shaft reverse the removal procedure Note the following points 1 Lubricate splines Molybdenum DisuIfide Grease 2 Install Drive shaft Before installing first set the universal joint in place on the middle case side 3 Apply Sealant Quick To the matingsurfaces of both case halves 4 Tighten Nuts final gear case I Nuts Final Gear Case 42 Nm 4 2 30 6 62 ...

Page 302: ...17 RoUBLESHOOTING CIRCUIT DIAGRAM 7 17 CHARGING VOLTAGE TEST 7 20 BATTERY INSPECTION 7 20 STATOR COIL RESISTANCE TEST 7 20 7 21 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 25 DESCRIPTION 7 27 OPERATION 7 27 IGNITION SPARK GAP TEST 7 28 IGNITION COIL RESISTANCE TEST 7 28 PRESSURE SENSOR 7 29 7 29 PICKUP COIL RESISTANCE TEST LIGHTING SYSTEM 7 31 CIRCUITDIAGRAM 7 31 7 33 LIGHTING TESTS AND CHECKS 7 37 7 3...

Page 303: ...ERMOMETER 7 49 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7 51 FUEL PUMP CIRCUIT OPERATION 7 53 TROUBLESHOOTING 7 54 FUEL RESERVE SWITCH TEST 7 57 FUEL PUMP RELAY TEST 7 57 FUEL PUMP TEST 7 57 FUEL SENDER UNIT TEST 7 58 V BOOST SYSTEM 7 59 CIRCUIT DIAGRAM 7 59 V BOOST SYSTEM 7 61 TROUBLESHOOTING 7 64 SERVO MOTOR TEST 7 66 ...

Page 304: ...CIRCUIT DIAGRAM I I ELECTRICAL CIRCUIT DIAGRAM w w 7 1 ...

Page 305: ...rvo motor LIGHTS Dimmer switch Clutch switch Headlight Diode HIGH BEAM indicator light Sidestand switch Meter light light Fuse HEAD Ignitor unit Fuse SIGNAL Pick up coil Relay unit FUEL RESERVE switch Starting circuit cut off relay Fuel pump relay Flasher relay Fuel pump Cancellingunit TURN switch TURN indicator light light Flasher light Reed switch Electric fan Spark plug Starter switch FUEL indi...

Page 306: ...ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 TCI unit Pressuresensor Ignition coil Neutral switch gauge Ignition coil Thermostatic switch Thermo unit IGNITION COIL PRIMARY 2 752 10 7 3 ...

Page 307: ...Starter relay Diode Main fuse Main switch Battery Wire harness Rectifier with regulator Sidestand switch Rear brake switch Horn Relay unit Sidestand relay V boost valve control unit Fuel pump relay BATTERY CAPACITY 16AH C SPECIFIC GRAVITY 1 280 7 4 ...

Page 308: ...ELECTRIC STARTING SYSTEM I I ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7 5 ...

Page 309: ...tarting circuit in wiring diagram NOTE For the encircled numbers and color cords see page 7 2 Relay unit Startingcircuit cut off relay Starter switch Main fuse Battery Starter motor Starter Main switch Fuse IGNITION ENGINE STOP switch switch Sidestand switch Sidestand relay 7 6 ...

Page 310: ...y vol t age 12V on t he L W l ead f rom t he st art er rel ay Correct t he bat t ery t erm i nal connect i on I t 12V Connectt he LAN l ead f rom t he st art er rel ay t o t he bat t ery negat i ve t erm i nal use a j um perl ead I f t he st art er rel ay does not cl i ck repl ace t he rel ay The engi ne does notrev sm oot hl y Recharge orrepl ace t he bat t ery 7 7 ...

Page 311: ...t 2 THE STARTER M O TO R DO ES NO T O PE RATE r el ay and st ar t er m ot or e m ai n sw i t c f r am e use a j um per l ead I f t he r el ay uni t cl i cks check t he st ar t er cl ut ch and neut r alswi t ches Repl ace swi t ch es i f necessar y 7 8 ...

Page 312: ... switch is on The starting circuit cut off relay prevents the starter from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is off so current cannot reach the starter motor When one of both of the above conditons have been met however the starting circuit cut off relay is on and the engine can be started by pressing the starter switch WHEN...

Page 313: ...ELECTRIC STARTING SYSTEM STARTER MOTOR TEST O ring Brush holder assembly seal Brush MINIMUM BRUSH LENGTH 5 5 mm 0 22 in COMMUTATOR WEAR LIMIT 7 10 ...

Page 314: ...easure Commutator diameter Out of specification Replace starter motor 3 Measure undercut betweencommutator segments Out of specification Scrape mica to proper valve Use a hacksaw blade that is ground to fit Mica Undercut 0 7 mm 0 028 in NOTE The mica insulation of the commutator must be undercut to ensure proper operation of the mu r 4 Measure coil Replacestarter motor Continuity check Insulation ...

Page 315: ...ushes Damage Replace 7 Measure length Out of specification Replace Minimum Brush Length 5 5 mm 0 22 in 8 springs Compare with new spring Replace Installation 1 Install motor NOTE Align the match marks on the brackets with the match marks on the housing 7 12 ...

Page 316: ... the starter switch and check to see if the starter relay clicks Starter relay clicking Starter relay OK Starter relay not clicking Measure coil resistance 2 Measure relay resistance Out of specification Replace By the following measurement steps Starter relay resistance measurement steps Disconnect the lead and the battery the Pocket Tester leads Red the coil resistance positive lead to the start...

Page 317: ...off relay resistance Use the Pocket Tester Out of specification Replace Starting Circuit Cut off Relay Resist 225 10 at 20 C 4 Check circuit cut off relay contacts Use 12V battery and the PocketTester Out of specification Replace YU 03112 Battery Connected Batterv Disconnected SIDESTAND RELAY TEST 1 Remove cover left Electricalcomponents board relay 7 14 ...

Page 318: ...l ay Bl ue Yel l ow Red W hi t e Bl ack W hi t e Bl ack DI O DE TEST 1 R em ove cover panel Di ode 2 Check cont i nui t y di scont i nui t y D efecti ve el em ent s R epl ace di ode Pocket tester Cont i nui t y Scal e x 1 X Di scont i nui t y Scal e x NO TE The r esul t s 0 or X shoul d be r ever sed accordi ng to the Pocket Tester pol ari ty ...

Page 319: ...Blue switch contact Out of specification Replace switch Blue Ground SIDESTAND SWITCH TEST 1 Remove 2 Disconnect 3 Check cover left 02 pin connector Blue Yellow and Black switch contacts Out of specification Replace switch Sidestand Up Sidestand Down Blue Yellow Black 7 16 ...

Page 320: ...CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7 17 ...

Page 321: ... SYSTEM Afcrementioned circuit diagram shows charging circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 2 AC Magneto Rectifier with regulator Main fuse Battery Main switch 7 18 ...

Page 322: ...CHARG I NG SYSTEM TRO UBLESHO O TI NG Bat t er y vol t age M or e t han 12V t o m easur e t he gener at or vol t age ...

Page 323: ... stator coil and Generator Voltage 14 5 Never disconnect the wires from the battery while the generator is operating otherwise the voltage across the generator terminals will increase and damage the semiconductors BATTERY INSPECTION Refer to CHAPTER 2 BATTERY INSPEC T N section STATOR COIL RESISTANCE TEST 1 Remove 2 Disconnect Side cover left 03 pin conn ector White White and White From Tester 3 C...

Page 324: ...ment Replace rectifier d b White White White Red Black b 0 0 X d X 0 X Regulator Brown Rectifier d C Pocket Tester C 0 X d X I 0 X a e e 0 0 X a X 0 X Continuity NOTE The results 0 or X should be reversed ac cording to the Pocket Tester polarity X Discontinuity Do not overcharge rectifier or damage may result Avoid A short Inverting and battery leads Direct connection of rectifier to battery 7 21 ...

Page 325: ... MEMO 7 22 ...

Page 326: ...IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 7 23 ...

Page 327: ...iring diagram NOTE For the encircled numbers and color codes see page Ignition coil Spark plug Ignition coil Spark plug ignition coil Spark plug Ignition coil Spark plug Main switch Fuse IGNITION ENGINE STOP switch Sidestandrelay Pressure sensor ignitor unit Pick up coil 7 24 ...

Page 328: ...ature 2 Connect Tester 3 Start the engine and increase the spark gap until misfire occurs Test at various between idle and red line Spark plug lead Spark plug Do not run the engine in neutral above 6 000 for more than 1 or 2 seconds Minimum Spark Gap 6 mm 0 24 in Faulty ignition system operation at the mini mum spark gap or smaller Follow thetrouble shooting chart until the source of the problem i...

Page 329: ...se IGNITION 5A and wiring circuit ON Check for voltage 2V on the lead at the TCI unit and ignition coils I No Measurethe pickup coils resistance Pickup coil 1 15 at 20 C 68 Orange Black Orange Gray Orange Wh Orange Replacethe pickup coil assembly I No Check the ignition coils for resistance primary and secondary Primarv 10 at 20 C TCI unit is faulty replacethe unit Secondary 13 2 20 a t 20 C 68 F ...

Page 330: ...battery operated frequent cleaning and adjustment of points Pressure sensor Pickup coil Ignitor unit Advance control Electronic advance circuit Ignition coil x Spark plug x 4 Battery 7 27 OPERATION TCI Unit The TCI functions on the same principle as a conventional DC ignition system with the transistor control box in place of contact breaker points exception of using magnetic pickup coils and a TC...

Page 331: ...ge 12V battery 4 Turn the spark plug gap adjuster and increase the gap to the maximum limit unless misfire occurs first I Minimum Spark Gap 6 mm 0 24 in IGNITION COIL RESISTANCE TEST 1 Connect 2 Measure Tester coil resistance coil resistance Out of specification Replace 1 Primary Coil Resistance 10 at 20 C 68 Secondary Coil Resistance 13 2 20 at 20 C Spark PlugCap 10 10 7 28 ...

Page 332: ... SPARK PLUG IN SPECT N section PRESSURE SENSOR Operation This pressure sensor unit consists of a semi conductor strain gauge and an amplifyingcircuit is sensed by the strain gauge and amplified in the circuit connected with this gauge The amplified pressure signals are then transmitted to the ignition system for the control of ignition timing advance Pressure to the carburetor joint venturiportion...

Page 333: ...emove cover left component board connector hose sensor 2 Disconnect 3 Remove Inspection 1 Connect Tester voltage 2 Measure Out of specification Replace Output voltage Atmospheric pressure Pressure Installation 1 Install sensor Reverse the removal procedure 7 30 ...

Page 334: ...LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 7 31 ...

Page 335: ...diagram shows lighting circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 2 LIGHTS Dimmer switch Headlight HIGH BEAM indicator light Meter lights light Fuse HEAD Starter switch Main fuse Battery Main switch 7 32 ...

Page 336: ...ve fail to operateproceedfurther Low battery voltage indicates either a faulty battery low battery fluid level or a defective charging system Also check fuse condition Replace any open fuses There are individual fuses for various circuits see complete Circuit Diagram NOTE Check each bulb first before performing the following check 7 33 ...

Page 337: ...SYSTEM Headl i ght Troubl eshoot i ng R epl ace Repl ace Check m ai n swi t ch r epl ace i f necessar y Check START swi t ch i fnecessar y n open or poor co Poor gr ound or poor connect i on ofhead l i ghtwi r i ng ...

Page 338: ...aillight Troubleshooting Poor ground or poor connection of taillight wiring TAILLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING I Faulty Replace Check taillight bulb Faulty Check main fuse Replace I I t Novoltaae Check main switch replace if necessary Measure voltage on Blue lead from main Iswitch ON position No voltage 12v 7 35 ...

Page 339: ...MEMO 7 36 ...

Page 340: ...SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 7 37 ...

Page 341: ... numbers and color codes see page 7 2 Horn Flasher relay OIL indicator light TURN switch gauge TURN indicator light NEUTRAL indicator light light Front brake switch Rear brake switch light Battery Fuse SIGNAL Relay assembly HORN switch unit Neutral switch Flasher light Reedswitch Main fuse Main switch 7 38 ...

Page 342: ...battery voltage before proceeding further Check for Battery Defective bulb 12V on Sky Blue lead to neutral switch 12V on Brown lead to indicator light 1 Check voltage Defective components Replace Faulty battery Faulty I Horn 1 Check operation Defective components Replace Brake Light 1 Check light operation Defective components Replace light switch Front and rear brake NEUTRAL Indicator Light light...

Page 343: ...ht 1 Check light operation Refer to SELF CANCELLING FLASHER SYSTEM section O I L LEVEL GAUGE TEST 1 Drain oil level gauge level gauge resistance 2 Remove 3 Measure Use the Pocket Tester Out of specification Replace Oil Level Gauge Resistance Float is down Infinity Float is up Zero ohms Ground 4 Install level gauge 5 Connect Leads 6 Fill Crankcase Refer to CHAPTER 2 ENGINE O I L RE PLACEMENT sectio...

Page 344: ... system turns off the involved in turning or changing lanes Generally the signal will cancel after either 10 seconds or 150 meters 490 feet whichever is greater At very low speed the function is determined turn signal after a period of time or distance by distance at high speed especially when changing speeds the cancelling determination is a combination of both times and distance The determinatio...

Page 345: ... inoperative Faulty Check buIb Replace Left circuit for 12V on Chocolate lead to light Check for ground on Black lead to light Right circuit for 12V on Dark green lead to light Check for ground on Black lead to light i No voltage Correct I I I Measurevoltage at TURN switch as follows lead lead voltage Replace switch I flasher relay fuses SIGNAL IPoor condition No voltage on lead I MAIN main switch...

Page 346: ... Tester on the Ohm x 1 position LIGHTS Dimmer switch TURN switch HORN switch ENGINE STOP switch START switch Lead Color Main Switch HI 0 0 LO 0 0 Lead Color R Br L Switch Position Switch Position LIGHTS Dimmer Switch I Lead Color OFF ON 0 0 TURN Switch Switch Position I I I I I J HORN Switch 7 43 ...

Page 347: ... Switch Position OFF ON SIGNAL SYSTEM I Lead Color RIB 0 START Switch Switch Position Color Code OFF I 7 44 ...

Page 348: ...COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 7 45 ...

Page 349: ... circuit diagram shows cooling circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 2 Temperature meter Thermo unit Fuse SIGNAL Thermostatic switch Electric fan Fuse Main fuse Battery Main switch 7 46 ...

Page 350: ...105 3 C 221 0 37 4 or more I I I Defective I Correct Check the connectors Replace fan motor assembly Fan operative No voltage I Check wiring circuit and correct defective Check battery voltage on Blue leads Fan operative Replace the thermostatic switch I Replace the fan motor assembly 7 47 ...

Page 351: ... s f an m ay cont i nue t o r un unt i l t he engi ne t em per at ur e has cool ed dow n to about 91 C 195 8 THERM OSTATI C SW I TCH COOLANT TEM PERATURE El ect r i c Fan I nspect i on I The f ol l owi ng pr obl em s m ay r equi r e r epai ror repl acem ent of com ponents Fan El ect r i c f an m ot or Ther m ost at i c Sw i t ch I nspect i on 1 R em ove Top cover Cover r i ght Ther m ost at i c sw...

Page 352: ...o 208 4 3 Less than 98 C I 208 4 F I I Test 1 2 Heat up tests Test 3 4 Cool down tests 3 Install switch Thermostatic Switch 15 Nrn 1 5 11 Three Bond After replacing the therrnostaic switch check the coolant level in the radiator and also check for any leakage THERMO UNIT AND THERMOMETER Operation The thermo unit has less resistance at higher temperatures and thus allows more current to pass throug...

Page 353: ...ust be replaced 2 operation By the following inspectionsteps Thermo unit inspectionsteps Immerse thermo unit in water Temperature gauge Thermo unit Pocket Tester Water Check continuity a t indicated Note temperatuers while heatingthe water Malfunction Replace switch Resistance 3 Install nit Thermo unit 15 Nm 1 5 11 Three Bond After replacing the thermo unit check the coolant level in the radiator ...

Page 354: ...FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7 51 ...

Page 355: ...ows fuel pump circuit in wiring diagram NOTE For the encircled numbersand color codes see page 7 2 FUEL indicator light Fuel sender unit Main fuse Battery Main switch Fuse IGNITION ENGINE STOP switch FUEL RESERVE switch Fuel pump relay Fuel pump G I 7 52 ...

Page 356: ...ion Fuel reserve switch in ON position Ignitor unit FUEL indicator light Fuel sender in FULL position Fuel sender in EMPTY position Engine stop switch Main switch To main fuse and battery R W I R G FUEL PUMP 1 START stop switch turned to ON reserveswitch turned to RES For about 5 seconds when carburetor fuel level is low Engineturned on After about 0 1 second STOP I warning indicator light comes o...

Page 357: ...d I O K Less than 11V Check ignitor unit output voltage condition Check fuel pump relay ground lead Orange lead by testing No 1 rear cylinder minimum spark gap Refer to I NO Ignition System Troubleshooting NO I 12v Replace ignitor unit Measure ignitor unit input voltage I Red Whitelead I No voltage Check engine stop main switch main I fuse and battery 1 Faulty and or discharge Replacefaulty parts ...

Page 358: ...pump replace if necessary Stop the engine and turn on the main engine stop switches and measure the fuel pump input voltage lead More than More than Turn the fuel reserve switch to RES and measure the fuel pump input voltage Less than 11V I lead I stop switches main relay input voltage lead lead Check reserve switch replace if necessary Check fuel pump relay ground lead I Replace fuel pump relay I...

Page 359: ...leshooting Chart 3 Fuel pump does not stop after 30 seconds when fuel indicater light onwhile engine isrunning Check fuel pump connections correct if necessary Fuel sender unit resistance Replace 0 9 0 2 at 20 C Check fuel pump relay ground lead I 1 Correct ground lead I Replacefuel pump relay 7 56 ...

Page 360: ... Pump Relay Input Voltage 12v Black FUEL PUMP TEST Operation The diaphragm is pulled left by the plunger allowing fuel to be sucked into the fuel chamber Fuel is pushed out from the pump until carb float chamber is filled with fuel and then the cut off switch cuts off the circuit When the spring pushes the diaphragm further to the end the cut off switch turns on and the solenoid coil pullsthe plun...

Page 361: ...t switch Diaphragm Plunger Solenoid coil Fuel chamber Valve Outlet Inspection 1 Connect 2 Check 2V pump operation Faulty operation Replace 3 Inspect pump Replace FUEL SENDER UNIT TEST 1 Remove cover 2 Measure sender unit resistance Out of specification Replace Green Black 7 58 ...

Page 362: ...V BO O ST SYSTEM V BO O ST SYSTEM CI RCUI T DI AG RAM ...

Page 363: ...t circuit in wiring diagram NOTE For the encircled numbers and color codes see page 7 2 Ignition coil Spark plug Main fuse Battery Main switch Fuse IGNITION ENGINE STOP switch V boost valve control unit Servo motor Ignitor unit Pick up coil 7 60 ...

Page 364: ...tion The butterfly valve begins to open a t approximately 6 000 r min and fully opens at approximately 8 000 r min For example while the 1 cylinder is in the intake stroke the 2 cylinder is in the com bustion storke and consequently the 2 carb is a t rest If the butterfly valve opens in this state an air fuel mixture flows into the 1 cylinder through the 1 and 2 carbs as in the super charger syste...

Page 365: ...t he cont r olcam e Ther ef or e t he ser vo m ot orst ar t s t o oper at e at 5 730 engi ne r m i n but t he val ves begi ne t o open at6 000 r m i n Bat t er y M ai n sw i t ch Fuse V boostval ve cont r oluni t Pot ent i om et er Dr i ve pul l ey Vacancy But t er f l y vl ave Reduct i ongear 1 Servo m ot or l gni t or uni t Val ve angl e i nf or m at i on B M ot ordri ve Revol ut i on i nf or m ...

Page 366: ...Valve opens Valve closed Servo motor starts Main switch ON 1 second Engine starting Increased engine speed Time Initial operation 8 000 rlmin I I I I I I I I 5 730 I 7 63 ...

Page 367: ...ge 0 16V Rechargethe battery I n Check butterfly valves and control cable for mechanical faults Correct any When the main switch is turned on after the control cable is disconnected the servo motor operate one cycle I NO NU Check each couplers lead connections Correct I and fuse Poor condition Check for the servo motor condition Replacethe servo motor Replacethe V boost valve control unit I 7 64 ...

Page 368: ...ubl eshoot i ng Chart 2 W hen t he m ai n sw i t ch i s t urned on t he but t erf l y val ves operat e one cycl e uni tand t he V b I C heck the ignitor and the ignition coil I O K R eplace the V boost valve control unit I ...

Page 369: ...e Potentiometer resistance Use the Pocket Tester Out of specification Replace 7 5 30 at 20 C 68 F SERVO MOTOR TEST 1 Disconnect 2 Connect 3 Check motor coupler Battery motor operation Not operation Replace 7 66 ...

Page 370: ...ONS 8 1 GENERAL SPECIFICATIONS 8 1 MAIWTENANCE FICATIONS 8 3 GENERAL TORQUE SPECIFICATIONS 8 18 DEFINITION OF UNITS 8 18 CONVERSION TABLES 8 19 LUBRICATION DIAGRAMS 8 20 CABLE ROUTING 8 24 CONSUMER INFORMATION 8 32 WIRING DIAGRAM 8 33 ...

Page 371: ...ar Case Total Amount Radiator Capacity Air Filter Fuel Including All routes Tank Capacity Total Reserve 1 F 01 1FK 000101 2 300 mm 90 6 in 795 mm 31 3 in 1 160 mm 45 7 in 765 mm 30 1 in 1 590 mm 62 6 in 145 mm 5 7 in 274 604 I 275 606 2 790 mm 10 in Liquid cooled 4 stroke gasoline DOHC V 4 cylinder 1 198 76 x 66 mm 2 992 x 2 598 in 10 5 1 1 422 4 5 206 psi Electric starter Wep sump 4 cycle oil or ...

Page 372: ...ype Double cradle Caster Angle Trail 119 mm 4 7 in Tu ess Size Size Wear Limit Basic Weight 274 604 Maximum Load 225 496 Cold Tire Pressure FRONT Chassis Tire 11 18 BRIDGESTONE M LOP F17 1 15 1 mm 0 04 in Tire Pressure ColdTire With Oil and Full Fuel Tank 275 606 REAR 235 255 2 6 36 psi 235 275 2 8 40 235 255 2 6 36 psi Up to 90 98 I Load 90 198 225 496 Load High Speed Riding 2 4 34 psi 2 4 34 psi...

Page 373: ... 3 W x 1 3w x 1 3w x 1 3w 4 HIGH BEAM 01L LEVEL TURN FUEL Meter Light MAINTENANCE FICATIONS Engine CyIinder Bore Size Taper Limit Out of Round Limit Model 75 07 76 02 mm 2 956 2 993 in 0 05 mm 0 002 in 0 05 mm 0 002 in 0 03 mm 0 0012 in Camshaft Drive Method Cam Cap Inside Dia Camshaft Outside Dia Shaf Clearance Cam Dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Chain drive Cen...

Page 374: ...EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX 30 6 mm 1 197 1 205 in 24 9 25 1 mm 0 980 0 988 in 3 1 mm in 2 4 mm 0 051 0 095 in 0 9 1 1 mm 0 035 0 043 in 0 9 1 1 mm 0 035 0 043 in 1 4 mm 0 055 in 1 4 mm 0 055 in 1 1 1 5 mm 0 043 0 059 in 1 1 1 5 mm 0 043 0 059 in 0 7 mm 0 028 in 0 7 mm 0 028 in 5 475 5 490 mm 0 2156 0 2161 in 5 475 mm 0 2156 in 5 445 mm 0 214 in 5 420 mm 0 213 in...

Page 375: ... Piston Clearance Piston Size D Measuring Point H Limit H 8 5 VMX 39 65 mm 1 561 in 39 65 mm 1 561 in 37 45 mm 1 474 in 37 45 mm 1 474 in 31 8 mm 1 25 in 31 8 mm 1 25 in 6 29 7 39 13 9 16 3 Ib 6 29 7 39 13 9 16 3 mm 0 067 in mm 0 067 in Left Left 41 10 mm 1 618 in 41 10 mm 1 618 in 38 90 mm 1 531 in 38 90 mm 1 531 in 33 8 1 331 in 33 8 mm 1 331 in 13 3 15 7 29 3 34 6 13 3 15 7 29 3 34 6 mm 0 071 i...

Page 376: ...k Oil Ring Dimensions x End Gap Installed Connecting Rod Oil Clearance Bearing Color Code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Limit 0 03 mm 0 0012 in Big EndSide Clearance D Journal Oil Clearance BearingColor Code 1 Blue 2 Black 3 Brown 4 Green 0 320 0 924 mm 0 0126 0 0364 in 0 020 0 044 mm 0 0008 0 0017 in 5 Yellow 6 Pink 7 Red 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 11 in 2 2 2 4 mm 0 087 0 095...

Page 377: ...el Engine IdlingSpeed Vacuum Pressurea t Idling Speed Vacuum Synchronous Difference VMX Guide Bar 0 025 mm 0 001 in 1FKOO 1JHOO 3 4 Y 0 Preset 0 9 0 8 0 8 0 9 1 5 45 16 1 mm 0 63 0 04 in 950 1 050 Above 170 mm Hg 6 69 in Below 20 mm Hg 0 79 in Hg LubricationSystem Oil Filter Type Oil Pump Type Tip Clearance Limit Side Clearance Limit BypassValve Setting Pressure Relief Valve Operating Pressure Pap...

Page 378: ...FICATIONS Model Lubrication Chart Intake camshaft Cylinder head I I Crankcase TighteningSequence I Lower Case With ...

Page 379: ...ft Drive Middle Gear Backlash Limit Final Gear Backlash Limit Ring Gear Stopper Clearance 363 8 rnrn 14 3 in 240 mm 9 45 in 16 rnrn 0 63 in 73 6 103 0 0 75 1 05 10 7 14 9 psi 0 3 L 0 26 Imp qt 0 32 US 0 2 L 0 18 Imp qt 0 21 US SingIe suction trifugaI pump 31 21 1 476 0 05 0 12 mm 0 002 0 005 in 0 3 mm 0 012 in 0 1 0 2 mrn 0 004 0 008 in 0 3 rnm 0 012 in 0 30 0 60 mm 0 012 0 024 in 8 9 ...

Page 380: ... 0 4 2 9 0 7 5 1 Bolt Nut Bolt Bolt Bolt Flange bolt Flange bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Screw with washer Nut Bolt with washer Bolt Screw Screw Screw Screw Screw Bolt Union bolt Bolt Bolt Flange bolt Union bolt Union bolt Flange bolt Union bolt Flange bolt Bolt Flange bolt Screw Screw Screw Bolt Bolt Nut Bolt Screw Bolt Bolt Bolt Thread Size M6 x 1 0 M12 x 1 25 x 1 25 M6 x 1 0 M8 x 0 ...

Page 381: ...7 0 7 5 1 Screw M6 x 1 0 Bolt M6 x 1 0 11 10 1 0 7 2 Screw M6 x 1 0 2 7 0 7 5 1 Bolt M6 x 1 0 6 10 1 0 7 2 Bolt M6 x 1 0 9 10 1 0 7 2 Bolt M8 x 1 25 1 38 3 8 27 M20 x 1 1 70 7 0 50 Use lock washer Special M6 x 1 0 2 12 1 2 8 7 Bolt M6 x 1 0 6 8 0 8 5 8 Nut M44 x 1 5 1 110 11 80 Stake Bolt M8 x 1 25 3 30 3 0 22 1 4 0 4 2 9 Part Name Thread Size Q ty Remarks Torx screw M8 x 1 25 4 25 2 5 18 Stake Bo...

Page 382: ...9 47 in 217 5 mm in 26 5 2 7 151 0 50 mm 0 1 97 in 56 85 mm 1 97 3 35 in K2 K2 Min Max Rear Suspension Shock Absorber Travel Spring Free Length Fitting Length Spring Rate 19 1 1 95 109 Stroke Optional Spring No Free Play Limit End mm Zeroin Side Zero mm Zeroin Limit K2 K2 Rear Arm Front Wheel wheel Rim Size x 18 Rim Material Aluminum Rim Runout Limit Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in Rear...

Page 383: ...Master Cylinder Inside Diameter Release Cylinder Inside Diameter Brake Fluid Type Brake Lever Free Play Brake Pedal Position Brake Pedal Free Play Brake Lever and Brake Pedal 12 7 mm 0 50 in 42 85 mm 1 69 in DOT 15 87 mm 0 63 in 38 1 mm 1 50 in DOT 2 5 mm 0 08 0 20 in 20 mm 0 8 in Adjustment not permitted Front Fork Rear Shock Absorber Spring Damping seat adjuster Air pressure 39 2 58 8 5 7 8 5 ps...

Page 384: ... 18 Rear Master Cylinder Frame M8 x 1 25 23 2 3 17 Pivot Shaft Left Frame M22 x 1 5 100 10 0 72 Pivot Shaft Right Frame M25 x 1 5 6 0 6 4 3 Pivot Shaft Right Locknut M25 x 1 5 100 10 8 72 Front Fender Fork Brace M6 x 1 0 9 0 9 6 5 Handlebar Upper Holder M8 x 1 25 20 2 0 14 Handlebar Lower Holder MlOx 1 25 40 4 0 29 Engine Bracket Front upper MlOx 1 25 40 4 0 29 Engine Bracket Front Lower MlOx 1 25...

Page 385: ...arging pe A C Generator I Timing Advanced Timing B T D C Advancer Type 15 at 20 C 68 F Orange Black Orange Gray Orange Orange TID ITACHI CM11 61 I I 10 at 20 C 68 F 13 2 20 a t 20 C 68 F A C magneto generator 3 a t 1 000 43 at 9 000 Vacuum and electrical C E n 60 40 20 0 1 2 3 4 5 6 7 8 9 Nominal Output 25A at 5 000 30 a 20 3 10 0 1 2 3 4 5 6 Engine speed 8 15 ...

Page 386: ... 5 mm 0 49 in 5 5 mm 0 22 in 560 680 g 19 7 23 9 28 mm 1 1 in 27 mm 1 06 in 0 7 mm 0 028 in Limit Commutator Starter Relay A 104 1 Amperage Rating 1O O A Coil Winding Resistance 3 552 10 a t 20 C 68 Plain type x 1 Horn Ty ty MaximumAmperage Semi transister type IPPON Self Cancelling Device Yes Flasher Frequency Wattage Self Cancelling Unit PPONDENSO Oil Level Switch Fuel Gauge Sender Unit Resistan...

Page 387: ...ding Resistance Fuel Pump Relay Electric Fan Thermostatic Switch Thermo unit Circuit Breaker ufacturer Amperage for Individual Circuit x Quantity Main Headlight Signal Ignition Reserve T 100 Y1 ISHI 10 at 20 C 68 Yes RON 1 10 at 20 C PPONDENSO IPPON THERMOSTAT Fuse 30A x 1 15A x 1 x 1 1 8 17 ...

Page 388: ...ess otherwise specified torque specifications call for clean dry threads Components should be at room temperature General torque specifications Nm B Bolt 10 mm 12 mm 14mm 17mm 22mm 6 mm 6 0 6 4 3 8 mm 15 1 5 11 30 3 0 22 55 5 5 40 14mm 85 8 5 61 16mm 130 13 0 94 8 18 Unit Read Definition Measure mm millimeter meter Length cm centimeter meter Length kilogram gram Weight N Newton 1 x Force Nm Newton...

Page 389: ...723 0 03527 km m m cm mm 2 352 0 6214 0 6214 3 281 1 094 0 3937 0 03937 cc 0 03382 cc 0 06102 t I iter 2 1134 lit liter 1 057 lit liter 0 2642 56 007 14 2234 Centigrade 9 5 32 US cu in pt US qt US gal psi Fahrenheit Inch t o metric system Known Multiplier Result 0 13826 0 01152 13 831 1 1521 mi ft in in 0 4535 28 352 0 4252 1 609 1 609 0 3048 0 9141 2 54 25 4 cm mm US cu in US US gal US psi Fahren...

Page 390: ...LUBRICATION DIAGRAMS LUBRICATION AGRAMS LUBRICATION DIAGRAM 8 20 ...

Page 391: ...LUBRICATION DIAGRAMS LUBRICATION DIAGRAM 2 8 21 ...

Page 392: ...LUBRICATION AGRAMS LUBRICATION DIAGRAM 8 22 ...

Page 393: ...LUBRICATION DIAGRAMS LUBRICATION DIAGRAM 4 ...

Page 394: ... Headlight body Brake joint Hose guide Wireharness Front flasher light lead Left Clutch hose Speedometer cable Front brake hose light lead Front flasher light lead Right Front brake hose 8 24 ...

Page 395: ...r fan lead Horn lead For speedometer cable Clamp For brake hose 19 Guide For throttle cable Guide For clutch hose Handlebar switch lead Left A Passthe handlebar switch lead inside the clutch hose B Pass the meter lead outside the utch hose C Pass the clutch hose outside the throttle cable D Pass the brake hose outside the speedometer cable E Pass the clutch hose under the throttle cable guide 8 25...

Page 396: ...eutral switch lead Regulater lead Sidestand switch lead lead on frame A C generator lead Band Clamp For clutch hose Clamp Clamp For clutch hose Starter relay Ignition coil Clamp For sidestand switch lead Pass the band through the guide on frame 8 26 ...

Page 397: ...y lead Fuel filter cover lead flasher light lead Left coil lead up coil lead Starter relay lead Starter motor lead switch lead Regulater lead level switch lead Neutral switch lead Battery positive lead fuse pump Fuse box V boost valve control unit Meter lead Clamp the taillight lead and rear flasher light lead Right Clamp the rear flasher light lead Left 8 27 ...

Page 398: ...egative lead reservoir Band Main switch lead switch brake reservoir tank Battery box For battery breather hose For reservoir tank breather hose and Battery breather hose Earth lead A Pass the wireharness outside the main switch stay Pass the earth lead outside the reservoir tank breather hose C Guide For battery breather hose reservoir tank breather hose and rear brake switch lead ...

Page 399: ...CABLE ROUTING Fuel filter bracket Fuel filter Fuel pipe Clamp cover Filler cap Battery band Fuel pump Fuel pipe ...

Page 400: ...CABLE ROUTING Reservoir tank clip Spring clip Filler cover Pipe joint clip Drain hose Band flow hose Over valve Holder Fuel sender Battery breather hose A 8 30 ...

Page 401: ...CABLE ROUTING CANISTER PIPE ROUTING To carburetor To fuel tank TO Canister ...

Page 402: ...r different conditions of loading and with partial failures of the braking system The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions and the information may not be correct under other conditions Descriptionof vehicles to which this table applies motorcycle A Fully Operational Service Brake Load Light Maximum I I I 0 100 200 300 F...

Page 403: ...m ...

Page 404: ...sly prefer a quality product 1 Real 2 Authentic not artificial 3 Yamaha GENUINE A PARTS ACCESSORIES Don t compromise the quality and performance of your Yamaha with off brand alternatives You ll be getting exactly what you re paying ...

Page 405: ...PROTECT YOURINVESTMENT Use Genuine YAMAHA Parts And Accessories LIT 11616 VM 13 YAMAHA MOTOR CORPORATION U S A PRINTED IN U S A ...

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Yamaha Vmax VMX12N, Supplementary Service Manual

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