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Yamaha VMX12H, Supplementary Service Manual


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HYDRAULIC CLUTCH

3.

Inspect:

Replace.

Wear

Replace.

seal

CLUTCH REASSE

M

B

LY

internal parts should be cleaned in new 

Internal parts should be lubricated with brake

brake fluid only.

fluid when installed. 

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

Summary of Contents for VMX12H

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 MA...

Page 4: ...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 c...

Page 5: ...echanic 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...

Page 6: ...ecifications 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 lubric...

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 OVER...

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 m...

Page 9: ...e 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 prov...

Page 10: ...et 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 p...

Page 11: ...output Brush overall length Limit Commutator diameter Wear Iimit Mica undercut Starter switch Model manufacturer Amperage rating Coil winding resistance Thermostatic switch Model manufacturer Constan...

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 oi...

Page 13: ...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...

Page 14: ...ication 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...

Page 15: ...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 bea...

Page 16: ...num 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...

Page 17: ...g 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 connec...

Page 18: ...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 Plastig...

Page 19: ...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...

Page 20: ...RVICE 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 p...

Page 21: ...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...

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 V...

Page 25: ...el 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 str...

Page 26: ...cwith an easy to read handy reference thatcontainscomprehensiveexplanationsofalldisassembly repair assembly andinspections A set of particularly important procedure is placedbetweena line of asterisks...

Page 27: ...leshooting 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 explo...

Page 28: ...E 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...

Page 29: ...mber 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 si...

Page 30: ...ent 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 SERVI...

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...

Page 32: ...te 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...

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 Ty...

Page 34: ...AKE 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 rot...

Page 35: ...il 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...

Page 36: ...r 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...

Page 37: ...ap 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...

Page 38: ...ner 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 p...

Page 39: ...ethe 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 co...

Page 40: ...OCTITE 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 weig...

Page 41: ...mp 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...

Page 42: ...lts 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...

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: ...nition 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 c...

Page 46: ...ontrol 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...

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 sen...

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 Corpor...

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 th...

Page 52: ...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 explo...

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...

Page 54: ...CIFICATIONS 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 0...

Page 55: ...ne 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...

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

Page 57: ...LIT 1...

Page 58: ...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 i...

Page 59: ...n 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 regar...

Page 60: ...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 o...

Page 61: ...ng 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...

Page 62: ...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 6...

Page 63: ...m 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...

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

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

Page 66: ...VMX 12 NC SERVICE MANUAL Edition December 1984 2nd Printing September 1985 JEM B 171 ALL RIGHTS RESERVED BY MOTOR CORPORATION U S A CYPRESS CALIFORNIA 90630 LIT 11616 04 67...

Page 67: ...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 ma...

Page 68: ...ppendices 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 ind...

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 exact...

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

Page 71: ...NGINE 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...

Page 72: ...dentification 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 au...

Page 73: ...ents 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 s...

Page 74: ...LS 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 tec...

Page 75: ...ed 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...

Page 76: ...ver 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 nee...

Page 77: ...oosen 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 A...

Page 78: ...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 gaug...

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...

Page 80: ...ol 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...

Page 81: ...emove 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 instrum...

Page 82: ...L 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...

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: ...y 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 CONTR...

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...

Page 86: ...dometer 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 o...

Page 87: ...rical 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 pl...

Page 88: ...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...

Page 89: ...on 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 Adjust...

Page 90: ...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 P...

Page 91: ...ENT 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 p...

Page 92: ...ith 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...

Page 93: ...r 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 I...

Page 94: ...ZATION 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 SYNCHR...

Page 95: ...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...

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 adjus...

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...

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...

Page 99: ...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...

Page 100: ...he 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 l...

Page 101: ...essthan 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...

Page 102: ...ired 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 Re...

Page 103: ...L 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 part...

Page 104: ...h 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...

Page 105: ...stem 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...

Page 106: ...ttle 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 Yamah...

Page 107: ...ep 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...

Page 108: ...ap 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 fron...

Page 109: ...ndard 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...

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 step...

Page 111: ...at 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...

Page 112: ...sconnect 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...

Page 113: ...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...

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 wh...

Page 115: ...se 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 hi...

Page 116: ...estribute 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...

Page 117: ...AL 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...

Page 118: ...s 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...

Page 119: ...ttery 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...

Page 120: ...mal 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 pl...

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 Ins...

Page 122: ...5A 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 t...

Page 123: ...UMP 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 CRANK...

Page 124: ...CASE 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 CAMSH...

Page 125: ...n 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...

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 j...

Page 127: ...nnect 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 h...

Page 128: ...ST 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...

Page 129: ...emove 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 D...

Page 130: ...haust 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 rea...

Page 131: ...r 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 t...

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 statio...

Page 133: ...t 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 R...

Page 134: ...ear 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...

Page 135: ...eel 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...

Page 136: ...il 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 clutc...

Page 137: ...lutch 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 p...

Page 138: ...SASSEMBLY 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...

Page 139: ...ASSEMBLY 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 29...

Page 140: ...ankcase 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 CRANK...

Page 141: ...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 bear...

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...

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 D...

Page 144: ...ve 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 Replaceei...

Page 145: ...ve 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...

Page 146: ...t 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 dt...

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...

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...

Page 149: ...ps 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 Th...

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 Mol...

Page 151: ...t 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 gh...

Page 152: ...utside 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 Di...

Page 153: ...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...

Page 154: ...earance 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...

Page 155: ...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...

Page 156: ...ion 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 opera...

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...

Page 158: ...ction 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...

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 spr...

Page 160: ...lace 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 sur...

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 car...

Page 162: ...ubricate 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...

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 j...

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...

Page 165: ...ent 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...

Page 166: ...s 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...

Page 167: ...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 I...

Page 168: ...IDDLE 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 4...

Page 169: ...aringretainer 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 joi...

Page 170: ...lace 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 Sele...

Page 171: ...refore 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...

Page 172: ...r 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...

Page 173: ...epeat 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 B...

Page 174: ...s 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...

Page 175: ...rfaces 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 thread...

Page 176: ...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...

Page 177: ...ly 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 Beari...

Page 178: ...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...

Page 179: ...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 le...

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: ...ve 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...

Page 183: ...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 su...

Page 184: ...tion 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 stam...

Page 185: ...ins 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 alignedsotha...

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 cra...

Page 187: ...ainaxle 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 Y...

Page 188: ...ainoil 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 arro...

Page 189: ...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 Breath...

Page 190: ...s 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 fr...

Page 191: ...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...

Page 192: ...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 repositi...

Page 193: ...essure 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 crisscro...

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...

Page 195: ...rd 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 stage...

Page 196: ...INDER 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...

Page 197: ...ckets 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...

Page 198: ...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 chai...

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 tim...

Page 200: ...ead 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...

Page 201: ...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...

Page 202: ...ylinder 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...

Page 203: ...ng 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 5...

Page 204: ...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...

Page 205: ...APTER 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 sec...

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

Page 207: ...D 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...

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 hou...

Page 209: ...ick 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 t...

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 oolan...

Page 211: ...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...

Page 212: ...ove 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 BEARI...

Page 213: ...areful 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...

Page 214: ...eal 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 scratche...

Page 215: ...lowing inspection steps Thermostatic valve inspectionsteps thermostatic valve in a vessel or reliable thermometer in water water slowly thermometer while stirring water water continuaII Thermometer Wa...

Page 216: ...e 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...

Page 217: ...t 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...

Page 218: ...s 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 thro...

Page 219: ...he 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 condu...

Page 220: ...spect 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...

Page 221: ...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...

Page 222: ...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...

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...

Page 224: ...ASSEMBLY 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...

Page 225: ...crews 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...

Page 226: ...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 ov...

Page 227: ...leum 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...

Page 228: ...ect 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...

Page 229: ...agm 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...

Page 230: ...ly 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 abo...

Page 231: ...retor 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 thro...

Page 232: ...just 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 Fi...

Page 233: ...alve 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 t...

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...

Page 235: ...n 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...

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 I...

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: ...SSEMBLY MASTER CYLINDER DISASSEMBLY BRAKE INSPECTION AND BRAKE REASSEMBLY AIR BLEEDING BRAKE DISC INSTALLATION HYDRAULIC CLUTCH CLUTCH RELEASE DISASSEMBLY MASTER CYLINDER DISASSEMBLY CLUTCH INSPECTION...

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: ...ne 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...

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 af...

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 fro...

Page 244: ...er 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 bol...

Page 245: ...EAR 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: ...e 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...

Page 247: ...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 Pi...

Page 248: ...ONT 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...

Page 249: ...d 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...

Page 250: ...ove 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...

Page 251: ...ner 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 rem...

Page 252: ...D 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...

Page 253: ...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...

Page 254: ...ng 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 Drai...

Page 255: ...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 Dus...

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 pas...

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 p...

Page 258: ...rvoir 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...

Page 259: ...ocedure 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 m...

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: ...e 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 befo...

Page 262: ...uid 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...

Page 263: ...lutch 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 Hos...

Page 264: ...rakefluid 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 th...

Page 265: ...st 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...

Page 266: ...amper 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...

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 steeringcrow...

Page 268: ...linder 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...

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...

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 th...

Page 271: ...64 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 Retainin...

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 Tig...

Page 273: ...st 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...

Page 274: ...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...

Page 275: ...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 bra...

Page 276: ...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...

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...

Page 278: ...g 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 sl...

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: ...ar 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 Repla...

Page 281: ...MENT 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 sho...

Page 282: ...WINGARM 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: ...ollars 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 s...

Page 284: ...r 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 Damag...

Page 285: ...teps 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...

Page 286: ...aring 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 Dr...

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 su...

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...

Page 289: ...n 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 motorc...

Page 290: ...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 b...

Page 291: ...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 limi...

Page 292: ...ar 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...

Page 293: ...24 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...

Page 294: ...pling 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 retai...

Page 295: ...al 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 N...

Page 296: ...ts 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...

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...

Page 298: ...t 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...

Page 299: ...mbly 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 11...

Page 300: ...ring 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...

Page 301: ...g 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...

Page 302: ...7 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...

Page 303: ...RMOMETER 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 T...

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

Page 305: ...vo 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...

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: ...tarter 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 BAT...

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

Page 309: ...arting 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...

Page 310: ...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 e...

Page 311: ...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 al...

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...

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: ...asure 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 t...

Page 315: ...shes 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...

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 specificati...

Page 317: ...ff 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...

Page 318: ...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...

Page 319: ...lue 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 specific...

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 sw...

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 se...

Page 324: ...ent 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 rever...

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

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

Page 327: ...ring 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 ENGIN...

Page 328: ...ture 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 0...

Page 329: ...e 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 Ora...

Page 330: ...attery 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...

Page 331: ...e 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 Measur...

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...

Page 333: ...move 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 Inst...

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

Page 335: ...iagram 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 Starte...

Page 336: ...e 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...

Page 337: ...YSTEM 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...

Page 338: ...illight 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...

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...

Page 342: ...attery 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 Fault...

Page 343: ...t 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 specific...

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 determ...

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 Blac...

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 LIGHT...

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...

Page 350: ...05 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...

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...

Page 352: ...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 co...

Page 353: ...st 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 No...

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

Page 355: ...ws 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 F...

Page 356: ...on 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 FUE...

Page 357: ...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 Troubleshoo...

Page 358: ...ump 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...

Page 359: ...eshooting 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...

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 flo...

Page 361: ...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...

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

Page 363: ...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 uni...

Page 364: ...ion 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...

Page 365: ...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 con...

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: ...e 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 ope...

Page 368: ...bl 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...

Page 369: ...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 Rep...

Page 370: ...NS 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 INF...

Page 371: ...r 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 i...

Page 372: ...pe 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...

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...

Page 374: ...X 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...

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 3...

Page 376: ...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...

Page 377: ...l 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 Abov...

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

Page 379: ...t 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...

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...

Page 381: ...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 Spec...

Page 382: ...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...

Page 383: ...aster 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...

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...

Page 385: ...rging 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 ge...

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 Pl...

Page 387: ...ing 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...

Page 388: ...ss 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...

Page 389: ...23 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...

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: ...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 Pas...

Page 396: ...utral 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 le...

Page 397: ...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...

Page 398: ...gative 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 wireharne...

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: ...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...

Page 403: ...m...

Page 404: ...ly 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 get...

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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