Yamaha XJR1300(L) 99 Service Manual Download Page 65

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3-7

MEASURED

CLEARANCE

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

VALVE CLEARANCE (cold):

0.11

0.15 mm

Example: Installed is 250

Measured clearance is 0.23 mm

Replace 250 pad with 260 pad

Pad number: (example)
Pad No. 250 = 2.50 mm
Pad No. 260 = 2.60 mm

Always install pad with number down.

VALVE CLEARANCE (cold):

0.16

0.20 mm

Example: Instaled is 250

Measured clearance is 0.32 mm

Replace 250 pad with 265 pad

Pad number: (example)
Pad No. 250 = 2.50 mm
Pad No. 265 = 2.65 mm

Always install pad with number down.

STANDARD CLEARANCE

ADJUSTING THE VALVE CLEARANCE

CHK

ADJ

INTAKE

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.00

0.05

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310

0.06

0.10

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315

0.11

0.15

0.16

0.20

205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.21

0.25

210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.26

0.30

215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.31

0.35

220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.36

0.40

225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.41

0.45

230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.46

0.50

235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.51

0.55

240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.56

0.60

245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.61

0.65

250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.66

0.70

255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.71

0.75

260 265 270 275 280 285 290 295 300 305 310 315 320

0.76

0.80

265 270 275 280 285 290 295 300 305 310 315 320

0.81

0.85

270 275 280 285 290 295 300 305 310 315 320

0.86

0.90

275 280 285 290 295 300 305 310 315 320

0.91

0.95

280 285 290 295 300 305 310 315 320

0.96

1.00

285 290 295 300 305 310 315 320

1.01

1.05

290 295 300 305 310 315 320

1.06

1.10

295 300 305 310 315 320

1.11

1.15

300 305 310 315 320

1.16

1.20

305 310 315 320

1.21

1.25

310 315 320

1.26

1.30

315 320

1.31

1.35

320

EXHAUST

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.00

0.05

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305

0.06

0.10

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310

0.11

0.15

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315

0.16

0.20

0.21

0.25

205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.26

0.30

210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.31

0.35

215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.36

0.40

220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.41

0.45

225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.46

0.50

230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.51

0.55

235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.56

0.60

240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.61

0.65

245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.66

0.70

250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.71

0.75

255 260 265 270 275 280 285 290 295 300 305 310 315 320

0.76

0.80

260 265 270 275 280 285 290 295 300 305 310 315 320

0.81

0.85

265 270 275 280 285 290 295 300 305 310 315 320

0.86

0.90

270 275 280 285 290 295 300 305 310 315 320

0.91

0.95

275 280 285 290 295 300 305 310 315 320

0.96

1.00

280 285 290 295 300 305 310 315 320

1.01

1.05

285 290 295 300 305 310 315 320

1.06

1.10

290 295 300 305 310 315 320

1.11

1.15

295 300 305 310 315 320

1.16

1.20

300 305 310 315 320

1.21

1.25

305 310 315 320

1.26

1.30

310 315 320

1.31

1.35

315 320

1.36

1.40

320

Summary of Contents for XJR1300(L) 99

Page 1: ......

Page 2: ......

Page 3: ...R1300 L 99 SERVICE MANUAL 1998 by Yamaha Motor Co Ltd 1st Edition August 1998 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly...

Page 4: ...d is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Autho rized yamaha dealers and wil...

Page 5: ...e top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify par...

Page 6: ...Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 E...

Page 7: ...SPEC ENG CARB CHAS ELEC CHK ADJ TRBL SHTG GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETORS CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 EAS0001...

Page 8: ......

Page 9: ...TION NUMBER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEA...

Page 10: ...GEN INFO...

Page 11: ...CYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER For E The vehicle identification number 1 is stamped into the right side of the steering head EAS00018 MODEL CODE The model code label 1 is...

Page 12: ...all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EA...

Page 13: ...rks or numbers are vis ible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not...

Page 14: ...ns Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that...

Page 15: ...ng nut 90890 01304 Piston pin puller This tool is used to remove the piston pins 90890 01312 Fuel level gauge This tool is used to measure the fuel level in the float chamber 90890 01367 90890 01374 F...

Page 16: ...are used to rebore remove and install the valve guide 90890 04019 Valve spring compressor This tool is used to remove or install the valve assemblies 90890 03153 90890 03124 Oil pressure gauge Oil pr...

Page 17: ...No Tool name Function Illustration 90890 06754 Ignition checker This tool is used to check the ignition sys tem components 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur face...

Page 18: ...GEN INFO...

Page 19: ...ONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 CONVERSION TABLE 2 20 GENERAL TIGHTENING TORQUES 2 20 LUBRICATION POINT AND GRADE OF LUBRICANT 2 21 ENGINE 2 21 CHASSIS 2...

Page 20: ...SPEC...

Page 21: ...gine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure STD Starting system Lubrication system Air cooled 4 stroke DOHC Forward inclined parallel 4 cylinder 1250...

Page 22: ...33 21 1 571 31 24 1 292 29 26 1 115 Chassis Frame type Caster angle Trail Double cradle 25 5 100 mm Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 120 70ZR17 58W 180 55ZR1...

Page 23: ...ing Gas oil damper Wheel travel Front wheel travel Rear wheel travel 130 mm 110 mm Electrical Ignition system Generator system Battery type Battery capacity T C I Digital A C generator GT14B 4 12 V 12...

Page 24: ...01 mm 0 05 mm 0 05 mm 79 1 mm Camshaft Drive method Cam cap inside diameter Camshaft outside diameter Shaft to cap clearance Cam dimensions Chain drive Center 25 000 25 021 mm 24 967 24 980 mm 0 020...

Page 25: ...A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem outside diameter IN EX Guide inside diameter IN EX Stem to guide clearance IN EX Stem runout limit 28 9 29 1 m...

Page 26: ...gth IN EX Set length valve closed IN EX Compressed pressure installed IN EX Tilt limit IN EX Direction of winding top view IN EX Clockwise Clockwise 41 1 mm 41 1 mm 34 8 mm 34 8 mm 130 4 154 0 N 13 3...

Page 27: ...End gap installed Side clearance installed Oil ring Taper 1 2 3 0 mm 0 35 0 50 mm 0 03 0 07 mm 0 75 mm 0 1 mm Dimensions B T End gap installed Side clearance 2 5 2 9 mm 0 2 0 5 mm 0 050 0 155 mm Conne...

Page 28: ...n axle deflection limit Drive axle deflection limit 0 06 mm 0 06 mm Shifter Shifter type Guide bar bending limit Guide bar 0 1 mm Carburetor I D mark Main jet M J Main air jet M A J Jet needle J N Nee...

Page 29: ...rance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure hot Pressure check location Paper type Trochoid type 0 12 0 17 mm 0 03 0 08 mm 0 03 0 08 mm 180 220 kPa...

Page 30: ...cover Crankcase cover right Clutch cover Drive sprocket cover Clutch release cylinder Crankcase Bolt Screw Cap nut Bolt Stud bolt Nut Nut Nut Bolt Bolt Bolt Bolt Plug Screw Bolt Bolt Union bolt Bolt...

Page 31: ...clutch idle gear shaft Stopper lever Side plate Shift arm Shift lod A C generator Oil level sensor Rotor Bolt Bolt Plug Bolt Bolt Screw Bolt Nut Bolt Bolt Nut Screw Screw Bolt Screw Bolt Nut Bolt Bol...

Page 32: ...2 12 SPEC MAINTENANCE SPECIFICATIONS Tightening sequence Cylinder head Crankcase...

Page 33: ...re feed Splashed Generator shaft Clutch Transmission Ex camshaft Lifter IN camshaft Lifter Timing chain area Piston Cylinder Connecting rod bearing Crankshaft bearings Main gallery Oil filter Relief v...

Page 34: ...3 mm 83 130 mm No 538 cm3 137 mm Fork oil 10W or equivalent 395 mm Rear suspension Shock absorber travel Spring free length Fitting length Spring rate K1 K2 Stroke K1 K2 88 mm 210 mm 190 mm 20 6 N mm...

Page 35: ...e diameter Caliper cylinder inside diameter Brake fluid type 14 mm 30 2 mm and 27 mm DOT 4 Rear disc brake Type Disc outside diameter thickness Disc deflection limit Pad thickness Single 267 5 mm 5 5...

Page 36: ...Seat lock Fuel sender Side cover and frame Tail light Rear fender and frame Rear fender cover and cover Rear fender cover and frame Grab bar Ignitor Rear turn signal light and rear fender Bolt Nut Nut...

Page 37: ...Rear brake hose Rear brake caliper and bleed screw Rear brake disc and hub Screw Bolt Bolt Bolt Nut Screw Bolt Bolt Bolt Screw Bolt Nut and Bolt Bolt Bolt Bolt Union bolt Nut and bolt Nut Nut Bolt Nut...

Page 38: ...14 3 k Spark plug cap Type Resistance Resin type 10 k Charging system Type Model manufacturer Normal output Rotor coil resistance Stator coil resistance Brush overall length Spring force A C generato...

Page 39: ...Flasher frequency Full transistor type FE246BH DENSO No 75 95 cyl min Oil level switch Model manufacturer 5G2 DENSO Fuel gauge Model manufacturer Sender unit resistance full empty 4 KG NIPPON SEIKI 4...

Page 40: ...P liq Miscella neous kg mm kg cm2 Centigrade 55 997 14 2234 9 5 C 32 lb in psi lb in2 Fahrenheit F EAS00029 GENERAL TIGHTENING TORQUES This chart specifies tightening torques for stan dard fasteners w...

Page 41: ...journal Valve stem IN EX Valve stem end IN EX Valve lifter Oil pump rotor inner outer housing Oil strainer assembly Starter idle gear inner surface Starter wheel gear inner surface Starter clutch out...

Page 42: ...right Rear wheel oil seal left right Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface Tube guide throttle grip inner surface Brake leve...

Page 43: ...2 23 1 Camshaft intake 2 Camshaft exhaust 3 Main gallery 4 Oil strainer 5 Oil pump 6 Main axle 7 Crankshaft SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS...

Page 44: ...2 24 1 Oil cooler 2 Starter clutch 3 Main axle 4 Drive axle 5 Oil pump 6 Oil pan 7 Relief valve 8 Main gallery SPEC LUBRICATION DIAGRAMS...

Page 45: ...2 25 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter SPEC LUBRICATION DIAGRAMS...

Page 46: ...en the wireharness with the steel clamp on the frame 9 Throttle position sensor 10 Ignition coil lead 2 3 11 Throttle cable 12 Engine ground lead 13 Air ventilation hose 14 Rear brake switch 15 Starti...

Page 47: ...and through the hole of plastic panel and then fasten the throttle cables with it Make sure that the end of band inside of motorcycle H Fasten the wireharness to the frame with a plastic band Make sur...

Page 48: ...side cover bracket and fasten them with a plastic band at front of the bracket M Align the white paint marks of the fuel tank drain hose fuel tank breather hose and air filter case drain hose N Touch...

Page 49: ...stic panel and then fasten the clutch hose with it Make sure that the end of band inside of motorcycle B To headlight lower hole C Route the wireharness and start er cable through the guide D Connect...

Page 50: ...r cover AC generator and starter motor to the right side of motorcycle L Fasten the clutch hose with steel clamp on the frame M Clamp the gromet on the clutch hose with wire holder on the frame SPEC C...

Page 51: ...le 14 Seat lock 15 Battery positive lead 16 Fuse box 17 Starter relay connector 18 Flasher relay 19 Oil light relay 20 Igniter unit 21 Fuel sender connector 22 Starter cable 23 Ignition coil 1 4 SPEC...

Page 52: ...positive lead connector on the groove of the battery with the battery rubber band H Position the starter motor cable at 45 degree out side of the mo torcycle I Position the wireharness tail light lea...

Page 53: ...nal light leads left and right with steel clamp on the frame make sure that the end of clamp forward O Route the rear turn signal light leads left and right through the each holes of the rear fender P...

Page 54: ...To front brake master cylinder A Route the throttle cables through the guide on the headlight stay B Route the meter leads main switch lead into the upper hole of the headlight body C Route the handle...

Page 55: ...top per I Route the handlebar switch lead right and front turn signal light lead right into the right under hole of the headlight stay J Fasten the handlebar switch lead right and front brake hose wit...

Page 56: ...SPEC...

Page 57: ...CLEANING THE AIR FILTER ELEMENT 3 22 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 3 23 CHECKING THE FUEL AND VACUUM HOSES 3 23 CHECKING THE CRANKCASE BREATHER HOSE 3 24 CHECKING THE EXHAUST SY...

Page 58: ...ND 3 40 LUBRICATING THE CENTERSTAND 3 40 LUBRICATING THE REAR SUSPENSION 3 40 ELECTRICAL SYSTEM 3 41 CHECKING AND CHARGING THE BATTERY 3 41 CHECKING THE FUSES 3 46 REPLACING THE HEADLIGHT BULB 3 48 AD...

Page 59: ...necessary Fuel filter Check condition Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter Replace Brake Check operation fluid leakage See NOTE Correct if necessary C...

Page 60: ...eplacement 1 When disassembling the master cylinder caliper cylinder or clutch release cylinder replace the brake fluid Normally check the brake fluid level and add the fluid as required 2 On the inne...

Page 61: ...tank Seat Side cover left Side cover right Fuel hose Fuel tank Fuel sender lead Drain hose Grab bar Rear fender cover 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Disconnect the fuel pipe...

Page 62: ...valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Sseat Sside covers Sfuel tank Refer to SEAT SIDE COVER AND FUEL TANK 2 Remov...

Page 63: ...from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve clearance in the following sequence Valve cl...

Page 64: ...er with a small screwdriver and a pair of twee zers Make a note of the position of each valve pad and valve pad number so they can be installed in the correct place f Select the proper valve pad from...

Page 65: ...300 305 310 315 320 0 86 0 90 275 280 285 290 295 300 305 310 315 320 0 91 0 95 280 285 290 295 300 305 310 315 320 0 96 1 00 285 290 295 300 305 310 315 320 1 01 1 05 290 295 300 305 310 315 320 1 0...

Page 66: ...clearance must be measured again and the above steps should be repeated if the measurement is still incorrect i Install the new valve pad with the numbered side facing down j Remove the tappet adjust...

Page 67: ...Install Svacuum gauge 1 Sengine tachometer 2 to the spark plug lead of cyl 1 Vacuum gauge 90890 03094 Engine tachometer 90890 03113 4 Start the engine and let it warm up for several minutes 5 Check Se...

Page 68: ...Pa 10 mm Hg 0 4 in Hg 7 Check Sengine idling speed Out of specification Adjust 8 Stop the engine and remove the measuring equipment 9 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE C...

Page 69: ...he throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is in creased Direction Engine idling speed is de creased 5 Adjust Sthrot...

Page 70: ...ained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased e Tighten the locknuts If the specified throttle cable free play cannot be obtained on the carbure...

Page 71: ...4 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color 5 Clean spark plug with a spark plug cleaner or wir...

Page 72: ...he pickup coil a is within the fir ing range b on th timing plate Incorrect firing range Check the ignition system The ignition timing is not adjustable 4 Remove engine tachometer timing light 5 Insta...

Page 73: ...linder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again SRefer to the following table Compress...

Page 74: ...m 1 8 mSkg 8 Connect Sspark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface SPlace the motorcycle on a suitable stand SMake sure that the motorcycle is uprigh...

Page 75: ...S00075 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Sengine oil filler cap Sengine oil d...

Page 76: ...L PRESSURE 1 Check Sengine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off When the en...

Page 77: ...viscosity too high 6 Install Smain gallery bolt Main gallery bolt 12 Nm 1 2 mSkg EAS00082 ADJUSTING THE CLUTCH LEVER 1 Adjust Sclutch lever position distance a from the handlebar grip to the clutch le...

Page 78: ...f clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance SWhen refilling be careful that water does not enter the...

Page 79: ...recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir di aphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose i...

Page 80: ...ent Damage Replace 5 Install Sair filter element Sair filter case cover along with the gasket Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of...

Page 81: ...TANK 2 Check Scarburetor joint 1 Sintake manifold 2 Cracks damage Replace Refer to CARBURETOR in chapter 6 3 Install Sfuel tank Sside cover Sseat Refer to SEAT SIDE COVER AND FUEL TANK EAS00096 CHECKI...

Page 82: ...S00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes mufflers and gaskets 1 Check Sexhaust pipe 1 Smuffler 2 Cracks damage Replace Sgasket 3 4 5 Exhaust gas...

Page 83: ...After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the ad justing dial EAS00110 ADJUSTING THE REAR BRAKE 1 Check Sbrake pedal...

Page 84: ...dal position make sure that there is no brake drag 3 Adjust Srear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00115 CHECKING THE BRAKE FLUID LEVEL 1 Stand the motorcycle on a...

Page 85: ...2 Check Sfront brake pad Srear brake pad Brake pad almost worn to the wear indicator line 1 Replace the brake pads as a set Refer to REPLACING THE FRONT BRAKE PADS and REPLACING THE REAR BRAKE PADS i...

Page 86: ...ake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Shydraulic brake system a Add the recommended brake fluid to the proper level...

Page 87: ...he angle a should be approximately 90_ Incorrect Adjust 2 Adjust Sshift pedal position a Loosen both locknuts 2 b Turn the shift rod 3 in direction a or b to obtain the correct shift pedal position Di...

Page 88: ...ain slack a Out of specification Adjust Drive chain slack 20 30 mm 4 Adjust Sdrive chain slack a Loosen the tensionbar bolt b Loosen the wheel axle nut 1 c Loosen both locknuts 2 d Turn both adjusting...

Page 89: ...ed prop erly it will wear out rapidly Therefore the drive chain should be serviced especially when the motorcycle is used in dusty areas This motorcycle has a drive chain with small rubber O rings 1 b...

Page 90: ...alling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check Ssteering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness or bind...

Page 91: ...ue wrench at a right angle to the ring nut wrench Ring nut wrench 90890 01403 Lower ring nut initial tightening torque 52 Nm 5 2 mSkg c Loosen the lower ring nut 4 completely then tighten it to specif...

Page 92: ...ll Shandle crown Steering stem nut 110 Nm 11 0 mSkg Upper bracket pinch bolt 30 Nm 3 0 mSkg 12 Install Shandlebar 13 Install Supper handlebar holder Handlebar holder bolt 23 Nm 2 3 mSkg EAS00149 CHECK...

Page 93: ...rely support the motorcycle so that there is no danger of it falling over Spring preload SGrooves are provided to indicate the ad justment position SNever go beyond the maximum or mini mum adjustment...

Page 94: ...shock absorber assemblies evenly Uneven adjustment can result in poor handling and loss of sta bility Spring preload Never go beyond the maximum or minimum adjustment positions 1 Adjust Sspring prelo...

Page 95: ...ider passenger and ac cessories and the anticipated riding speed SOperation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with...

Page 96: ...ire and a new tube as a set STo avoid pinching the tube make sure that the wheel rim band and tube are centered in the wheel groove SPatching a punctured tube is not recom mended If it is absolutely n...

Page 97: ...face until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done For tires with a direction of rotation mark 1 SInstall th...

Page 98: ...suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the p...

Page 99: ...electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SSKIN Wash with water SEYES Flush with water for 15 minutes and get immediate medical atte...

Page 100: ...battery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive terminal Tester negative lead battery negative terminal SThe charge state of a...

Page 101: ...parks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the...

Page 102: ...ce the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am perage readjust the voltage to obtain the sta...

Page 103: ...he battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes...

Page 104: ...Sbattery terminals Dirt Clean with a wire brush Loose connection Connect properly 10 Lubricate Sbattery terminals Recommended lubricant Dielectric grease 11 Install Sseat EAS00181 CHECKING THE FUSES...

Page 105: ...he fuse immediately blows again check the electrical circuit Fuses Amperage rating Quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 15 A 1 Ignition fuse 7 5 A 1 Reserve 30 A 1 15...

Page 106: ...extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touc...

Page 107: ...ll Sheadlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Sheadlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight bea...

Page 108: ...CHK ADJ...

Page 109: ...INGS 4 18 REMOVING THE VALVES 4 19 CHECKING THE VALVES AND VALVE GUIDES 4 20 CHECKING THE VALVE SEATS 4 22 CHECKING THE VALVE SPRINGS 4 23 CHECKING THE VALVE LIFTERS 4 24 INSTALLING THE VALVES 4 24 CY...

Page 110: ...ECKING THE STOPPER LEVER 4 57 INSTALLING THE SHIFT SHAFT 4 57 TIMING PLATE AND PICKUP COIL 4 59 OIL PAN 4 60 REMOVING THE OIL PAN 4 61 CHECKING THE RELIEF VALVE 4 61 CHECKING THE OIL DELIVERY PIPES 4...

Page 111: ...G THE CONNECTING RODS 4 79 INSTALLING THE CRANKSHAFT 4 81 TRANSMISSION 4 82 SHIFT CAM AND SHIFT FORK 4 85 CHECKING THE SHIFT FORK 4 86 CHECKING THE SHIFT DRUM ASSEMBLY 4 86 CHECKING THE TRANSMISSION 4...

Page 112: ...ENG...

Page 113: ...aust chamber Exhaust chamber bracket Oil cooler Air duct left right 6 4 4 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT SIDE COVER AND FUEL TANK in Chapter 3 Refer to CARBURETOR in...

Page 114: ...ound lead Crankcase breather hose 2 1 1 For installation reverse the removal pro cedure Disconnect ground lead NOTE 9 10 11 12 Nm 1 2 m kg 20 Nm 2 0 m kg 25 Nm 2 5 m kg 25 Nm 2 5 m kg 20 Nm 2 0 m kg 1...

Page 115: ...erator lead A C generator Clutch release cylinder comp Shift arm Drive sprocket cover Dowel pins Gasket Nut 1 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Refer to INSTALLING THE ENGINE Di...

Page 116: ...E Order Job Part Q ty Remarks 12 13 14 Lock washer Drive sprocket Drive chain 1 1 1 For installation reverse the removal procedure 25 Nm 2 5 m kg 10 Nm 1 0 m kg 85 Nm 8 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0...

Page 117: ...gine bracket rear lower Engine 1 1 2 1 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure Place a suitable stand under the frame and engine NOTE Refer to INSTALL...

Page 118: ...8 Nm 4 8 m kg Bolt 3 55 Nm 5 5 m kg Bolt 4 30 Nm 3 0 m kg Bolt 5 64 Nm 6 4 m kg Nut 6 64 Nm 6 4 m kg 2 Install shift arm 1 Align the punch mark b in the shift shaft with the punched mark a on the shif...

Page 119: ...d covers Seat fuel tank Bolts Air duct left right Plug cap Cylinder head cover Gasket 2 1 1 4 1 1 Remove the parts in the order listed Refer to SEAT SIDE COVER AND FUEL TANK For installation reverse t...

Page 120: ...y Timing chain guide exhaust side Camshaft caps Dowel pins Camshaft intake Camshaft exhaust Camshaft sprockets 4 1 1 1 1 1 8 16 1 1 2 Remove the parts in the order listed For installation reverse the...

Page 121: ...om each other 2 Remove timing chain guide top side 1 3 Loosen camshaft sprocket bolts 4 Loosen cap bolt 2 5 Remove timing chain tensioner To prevent the timing chain from falling into the crankcase fa...

Page 122: ...clear ance Out of specification Measure the camshaft journal diameter Camshaft journal to camshaft cap clearance 0 020 0 054 mm a Install the camshaft into the cylinder head without the dowel pins and...

Page 123: ...kets and timing chain guides 1 Check camshaft sprocket Damage wear Replace the camshaft sprockets and the timing chain as a set 2 Check timing chain guide exhaust side timing chain guide top side Dama...

Page 124: ...tallation Damage or improper valve timing will result b Fit the timing chain onto both camshaft sprockets and install the camshafts Install the exhaust camshaft 1 first then the intake camshaft 2 Inst...

Page 125: ...afety wire from the timing chain 3 Install timing chain tensioner Installation steps a Remove the tensioner cap bolt 1 washer 2 and springs 3 b Release the timing chain tensioner one way cam 4 and pus...

Page 126: ...with the stationary pointer b Check if both the camshaft timing punch marks a are aligning with the camshaft cap hole b 5 Tighten Bolts cam sprockets Be sure to tighten the camshaft sprocket bolts to...

Page 127: ...1 2 2 4 Remove the parts in the order listed Refer to CAMSHAFTS For installation reverse the removal procedure NOTE Refer to REMOVING INSTALLING THE CYLINDER HEAD Remove the engine mount front and mo...

Page 128: ...osits with a rounded scraper Do not use a sharp instrument to avoid damag ing or scratching spark plug threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpag...

Page 129: ...nstall cylinder head washers copper washers cylinder head nuts Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts in the proper tightening sequence as shown an...

Page 130: ...ters Valve cotters Upper springs seats Valve springs outer Valve springs inner Intake valves Exhaust valves Lower spring seats Oil seals 16 16 32 16 16 16 8 8 16 16 Remove the parts in the order liste...

Page 131: ...f the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat...

Page 132: ...procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of sp...

Page 133: ...guide remover reamer installer 5 5 mm 90890 04016 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or...

Page 134: ...ve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and val...

Page 135: ...e be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the...

Page 136: ...ter spring 130 4 154 0 N 13 3 15 7 kg at 34 8 mm 3 Measure Svalve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake and exhaust inner spring 2 5_ 1 7 mm Intake and e...

Page 137: ...ve cotters by compressing the valve spring with the valve spring compressor 2 Valve spring compressor 90890 04019 4 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a s...

Page 138: ...er head Cylinder block Dowel pins Gasket Piston pin clips Piston pins Pistons Oil ring sets Remove the parts in the order listed Refer to CYLINDER HEAD For installation removal procedure Refer to REMO...

Page 139: ...crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the p...

Page 140: ...on replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 2 0 mm from the bottom edge of the piston Piston size P Standard 78 970...

Page 141: ...side clearance Top ring 0 045 0 080 mm Limit 0 1 mm 2nd ring 0 03 0 07 mm Limit 0 1 mm 2 Install piston ring into the cylinder Level the piston ring in the cylinder with the pis ton crown as shown a 3...

Page 142: ...e lo cated on the upper side of the rings The piston rings that have an R mark must be installed into the 2nd ring groove 2 Install piston 1 piston pin 2 piston pin clip New 3 Apply engine oil onto th...

Page 143: ...ended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A forward 6 Install cylinder block Install pistons 2 an...

Page 144: ...s 1 2 3 Removing the clutch cover Engine oil Clutch cover Gasket Dowel pins 1 1 2 Remove the parts in the order listed Drain For installation reverse the removal procedure 10 Nm 1 0 m kg New ENG CLUTC...

Page 145: ...e plate Clutch push rod short Ball Clutch push rod long O ring Friction plates Clutch plates Friction plates Clutch boss nut Lock washer 1 1 1 1 1 1 1 1 1 6 6 1 1 Remove the parts in the order listed...

Page 146: ...s Stopper ring Clutch plate Clutch spring plate Clutch spring plate seat Friction plates narrow Thrust washer Spacer Bearing Clutch housing 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal pro...

Page 147: ...3 thrust washer 4 spacer 5 bearing 6 clutch housing 7 Insert two 6 mm bolts 8 into the spacer and then remove the spacer by pulling on the bolts EAS00280 CHECKING THE FRICTION PLATES The following pr...

Page 148: ...ess gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit Less than 0 1 mm CHECKING THE CLUTCH SPRING 1 Check Clutch spring Damage Replace as a set 2 Measure Clutc...

Page 149: ...on the clutch housing dogs will cause er ratic clutch operation 2 Check bearing Damage wear Replace the clutch hous ing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wea...

Page 150: ...2 Measure long clutch push rod bending limit Out of specification Replace the long clutch push rod Long clutch push rod bending limit 0 3 mm INSTALLING THE CLUTCH 1 Install clutch housing 1 Engage th...

Page 151: ...r 90890 04086 Clutch boss nut 70 Nm 7 0 m kg 4 Bend the lock washer tab along a flat side of the nut 5 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Re...

Page 152: ...tall the stopper ring onto the groove around the clutch boss with both ends of the ring fitted in the hole a on the boss c Install the other 6 clutch plates and the 6 fric tion plates of wide contact...

Page 153: ...lutch lever holder Clutch master cylinder 1 1 1 1 2 1 1 1 Remove the parts in the order listed Before removing the clutch master cylin der drain the clutch fluid from the entire clutch system For inst...

Page 154: ...Remarks Disassembling the clutch master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedur...

Page 155: ...rts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with wa...

Page 156: ...as they will cause the piston seals to swell and distort Whenever a clutch master cylinder is dis assembled replace the piston seals Recommended clutch fluid Brake fluid DOT 4 EAS00310 INSTALLING THE...

Page 157: ...ill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance When refilling be careful that w...

Page 158: ...m level mark a Add the recommended clutch fluid to the proper lev el Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 7 Check clutch lever operation Soft or spongy feeling Bleed the clutch system...

Page 159: ...1 1 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH RELEASE CYLINDER Before removing the clutch releace cylin der drain the clutch fluid from the entire clutch system NOTE For ins...

Page 160: ...g the clutch release cylinder Clutch release cylinder Piston seal Clutch release cylinder piston Piston seal Spring 1 1 1 1 1 Disassembly the parts in the order listed Refer to DISASSEMBLING THE CLUTC...

Page 161: ...cylinder Never try to pry out the clutch release cylin der piston b Remove the clutch release cylinder piston seals EAS00314 CHECKING THE CLUTCH RELEASE CYL INDER Recommended clutch component p repla...

Page 162: ...d DOT 4 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is...

Page 163: ...Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 4 Check clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper lev el Refer to CHECKING THE CLUTCH...

Page 164: ...sher Oil buffer plate Circlip Oil pump driven gear Washer Oil pump Dowel pin Collar O ring 1 1 1 1 1 1 1 1 1 1 3 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH Refer to INSTALLING...

Page 165: ...sing Inner rotor Outer rotor Pin Dowel pin Oil pump housing Inner rotor Outer rotor Pin Oil pump shaft Oil pump cover 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed Refer to ASSEMBLIN...

Page 166: ...ng clearance B oil pump housing to inner rotor and outer rotor clearance C Outer of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip cle...

Page 167: ...otor 5 pin 6 oil pump housing 7 screw Oil pump housing screw 10 Nm 1 0 m kg When installing the inner rotor align the pin 3 in the oil pump shaft with the groove on the inner rotor 4 3 Check oil pump...

Page 168: ...r Circlip Washer Shift shaft Washer Shift lever spring Bolt Stopper lever Stopper lever spring 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to OIL PUMP Refer to ENGINE Refer to INSTALLIN...

Page 169: ...heck stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 shift shaft lever 3 Hook t...

Page 170: ...4 58 ENG SHIFT SHAFT NOTE Lubricate the oil seal lips with lithium soap base grease Hook the end of the shift lever spring onto the shift lever spring stopper 4...

Page 171: ...fuel tank Pickup coil read Timing plate cover Gasket Pickup coil Timing plate Dowel pin Pickup base 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 4...

Page 172: ...Dowel pin Gasket Relief valve O ring Relief valve O ring Oil strainer Oil strainer housing Gasket 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to REMOVING INSTAL...

Page 173: ...365 CHECKING THE RELIEF VALVE 1 Check relief valve body 1 relief valve 2 spring 3 Cover 4 Damage wear Replace the defective part s circlip 5 EAS00367 CHECKING THE OIL DELIVERY PIPES The following proc...

Page 174: ...l oil strainer cover 1 relief valve 2 The arrow a on the oil strainer cover must point towards the front of the engine EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket New oil pan 1 oil lev...

Page 175: ...Spring rod Chain guide Cover 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS Refer to CYLINDER HEAD Refer to CYLINDERS AND PISTONS Refer to CLUTCH Refer to OIL PUMP Re...

Page 176: ...6 Bearing cover Crankcase lower Dowel pin 1 1 2 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE For installation reverse the removal pro cedure 24 Nm 2 4 m kg 35 Nm 3 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0...

Page 177: ...sequence 2 Place the engine upside down 3 Remove Slower crankcase A Upper crankcase l M10 bolts M8 bolts M6 bolts Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por t...

Page 178: ...he recommended lubricant Recommended lubricant Engine oil 2 Apply sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Do not allow any sealant to come into contact with the oil...

Page 179: ...d by hand SCarefully position the shift forks so that they mesh smoothly with the transmission gears SMesh shift fork center with the 2nd pinion gear 3 on the main axle 7 Install Slower crankcase bolt...

Page 180: ...seal Nozzle Generator shaft Bearing Starter clutch drive gear Starter clutch gear Collar Circlip Starter clutch roller Stopper plate 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer...

Page 181: ...4 69 ENG STARTER CLUTCH Order Job Part Q ty Remarks 13 14 15 Idle gear shaft Starter clutch idle gear Bearing 1 1 1 For installation reverse the removal pro cedure 7 Nm 0 7 m kg 10 Nm 1 0 m kg New...

Page 182: ...peration a Install the starter clutch gear 4 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the start er clutch dri...

Page 183: ...l passages 3 Dirt obstruction Wash the generator shaft and then blow out the oil passages with com pressed air bearing 4 Rough movement Replace INSTALLING THE STARTER CLUTCH ROLL ER 1 Install circlip...

Page 184: ...HY VO chain Crankshaft journal bearings HY VO chain guide 1 1 1 1 1 10 1 Remove the parts in the order listed Refer to CRANKCASE Refer to STARTER CLUTCH Refer to REMOVING INSTALLING THE CRANKSHAFT ASS...

Page 185: ...Connecting rod bolt Coonecting rod Connecting rod cap Connecting rod bearing 8 8 4 4 8 Remove the parts in the order listed For installation reverse the removal procedur Refer to REMOVING INSTALLING T...

Page 186: ...HAFT AND CON NECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Crankshaft runout Less than 0 02 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces beari...

Page 187: ...e Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves SAlign the projections a of the cra...

Page 188: ...example if the crankcase J1 and crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is Bearing size for J1 J1 crankcase J1 crankshaft web 6 2 4 green CRANKSHAFT JOURNAL...

Page 189: ...Assemble the connecting rod halves Do not move the connecting rod or crankshaft until the clearance measurement has been completed Apply molybdenum disulfide grease onto the bolts threads and nuts se...

Page 190: ...big end bearings 6 Select big end bearings P1 X P4 The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 X P...

Page 191: ...01 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace EAS004...

Page 192: ...haft Make sure that the characters b on both the connecting rod and connecting rod cap are aligned 4 Align bolt heads 1 with the connecting rod caps 5 Tighten connecting rod nuts Connecting rod nuts 3...

Page 193: ...haft jour nal upper bearings with the notches b in the crankcase Be sure to install each crankshaft journal up per bearing in its original place 2 Install HY VO chain 1 timing chain 2 onto the cranksh...

Page 194: ...embly and shift forks Crankcase Main axle assembly Oil seal Bearing Drive axle assembly Collar O ring Oil seal Circlip Bearing 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE...

Page 195: ...ion Washer 1st wheel gear Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear collar Washer 5th wheel gear Circlip Washer 2nd wheel gear collar Drive axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disass...

Page 196: ...t Q ty Remarks 2nd pinion gear 5th pinion gear collar Washer 3rd pinion gear Circlip Washer 4th pinion gear Main axle 1st pinion gear 1 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 1...

Page 197: ...and shift fork Crankcase Shif fork quide bar Shift fork L Shift fork C Shift fork R Stopper plate Shift drum 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE For installation rever...

Page 198: ...pt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS00422 CHECKING THE SHIF...

Page 199: ...pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check transmission gear...

Page 200: ...that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase The drive axle bearing pin 5 must face to wards the rear of the crankcase and the main axle bearing pin 6...

Page 201: ...NG THE CARBURETORS 5 4 ASSEMBLING THE CARBURETORS 5 5 INSTALLING THE CARBURETORS 5 7 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 5 8 CHECKING THE FUE...

Page 202: ...CARB...

Page 203: ...r filter joint screws Bolts Air filter case Throttle position sensor lead Starter cable Throttle cables Carburetors 1 1 1 4 4 3 1 1 1 2 1 Remove the parts in the order listed Refer to SEAT SIDE COVER...

Page 204: ...le stop screw set Carburetors Throttle cable bracket Starter plunger set Vacuum chamber cover Piston valve spring Piston valve Jet needle Pilot air jet Pilot screw 1 4 1 1 1 4 1 1 1 1 1 1 1 1 Disassem...

Page 205: ...17 18 19 20 Float chamber Float chamber gasket Float pin Float Needle valve ass y Pilot jet Main jet Needle jet 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to ASSEMBLING THE C...

Page 206: ...and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat...

Page 207: ...ed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 13 Check fuel feed hoses fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses w...

Page 208: ...ing it c If the float height is not within specification inspect the needle valve seat and needle valve d If either the needle valve seat or needle valve is worn replace them both e If both the needle...

Page 209: ...chapter 3 EAS00497 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level below the line on the float chamber 3 5 4 5 mm a Stand the motorcycle on a level...

Page 210: ...n the tachometer Refer to the adjustment procedure below 1 Check Sthrottle position sensor a Disconnect the throttle position sensor cou pler b Remove the throttle position sensor from the carburetor...

Page 211: ...er switches to the throttle position sensor adjustment mode d Loosen the throttle position sensor screws 1 e Adjust the throttle position sensor angle ac cording to the following table The angle of th...

Page 212: ...G THE FUEL COCK OPERATION After installing the fuel cock check its opera tion 1 Check that the fuel cock lever is positioned to ON or R 2 Place a container under the end of the fuel hose 3 Check fuel...

Page 213: ...REAR BRAKES 6 14 FRONT BRAKE PADS 6 14 REAR BRAKE PADS 6 15 REPLACING THE FRONT BRAKE PADS 6 16 REPLACING THE REAR BRAKE PADS 6 18 FRONT BRAKE MASTER CYLINDER 6 20 REAR BRAKE MASTER CYLINDER 6 22 DIS...

Page 214: ...STALLING THE HANDLEBAR 6 54 STEERING HEAD 6 57 LOWER BRACKET 6 57 REMOVING THE LOWER BRACKET 6 59 CHECKING THE STEERING HEAD 6 59 INSTALLING THE STEERING HEAD 6 60 REAR SHOCK ABSORBER SWINGARM AND DRI...

Page 215: ...t Collar Brake disc left right 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated NOTE Refer to REMOVING INSTALLING...

Page 216: ...ty Remarks Disassembling the front wheel Oil seal Bearing Spacer Bearing 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 CHAS FRONT WHEEL AND...

Page 217: ...t squeeze the brake lever when removing the brake calipers 4 Loosen pinch bolt front wheel axle 1 front wheel axle 2 5 Elevate front wheel Place the motorcycle on a suitable stand so that the front wh...

Page 218: ...2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not...

Page 219: ...he brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit minimum Front 4 5 mm Rear 4 5 mm 4 Ad...

Page 220: ...n a crisscross pattern 3 Install speedometer gear unit Make sure that the speedometer gear unit and the wheel hub are installed with the two projec tions a meshed into the two slots b respec tively 4...

Page 221: ...e discs installed 1 Remove balancing weight s Place the front wheel on a suitable balancing stand 2 Find front wheel s heavy spot a Spin the front wheel b When the front wheel stops put an X1 mark at...

Page 222: ...the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced...

Page 223: ...Rear wheel 2 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated NOTE Refer to REMOVING INSTALLING THE REAR WHEEL For installat...

Page 224: ...Collar Brake disc Clutch hub Collar Rear wheel sprocket Clutch dampers Oil seal Bearing 1 1 1 1 1 5 1 1 Remove the parts in the order listed For installation the removal procedure 20 Nm 2 0 m kg 60 N...

Page 225: ...evated 2 Loosen adjusting bolt 1 locknut 2 3 Remove wheel axle nut 3 wheel axle 4 rear wheel right collar 5 Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS00565...

Page 226: ...1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprock et b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Remove the self locki...

Page 227: ...t Lithium soap base grease 2 Tighten wheel axle nut Wheel axle nut 150 Nm 15 0 m kg EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balanc...

Page 228: ...ont brake pads Clip Pad pin Pad support Brake pad 4 2 2 4 Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS For installation reverse the removal procedure CHAS FRONT AND REA...

Page 229: ...pads Caliper Cover Clip Pad pin Pad spring Brake pad Caliper shim 1 1 2 2 1 2 2 Remove the parts in the order listed Refer to REPLACING THE REAR BRAKE PADS For installation reverse the removal proced...

Page 230: ...ean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can c...

Page 231: ...e pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake ca...

Page 232: ...r spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnec...

Page 233: ...screw Bleed screw 6 Nm 0 6 m kg d Install new brake pad shims onto the new brake pads e Install new brake pads and a new brake pad spring The longer tangs a on the brake pad spring must point in the...

Page 234: ...bolt Copper washers Brake hose Master cylinder bracket Master cylinder 1 2 1 1 2 1 1 1 Remove the parts in the order listed Drain Refer to DISASSEMBLING ASSEM BLING AND INSTALLING THE REAR BRAKE MASTE...

Page 235: ...er Job Part Q ty Remarks Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse th...

Page 236: ...Clip reservoir hose Cotter pin copper washer Pin Master cylinder ass y Reservoir tank 2 1 1 1 2 1 2 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to DISASSEMBLING ASSEM BLING THE REAR...

Page 237: ...er Job Part Q ty Remarks Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the...

Page 238: ...he brake switch 3 Remove union bolt 3 copper washers 4 brake hose 5 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLIN...

Page 239: ...e master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace C Front D Rear 3 Check front brake master cylinder rese...

Page 240: ...end of the brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt Brake master cylinder bolt 10 Nm 1 0 m kg 2 Install copper washers New...

Page 241: ...perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage p...

Page 242: ...d reservoir Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the sa...

Page 243: ...mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pe...

Page 244: ...washers Brake hoses Caliper ass y 2 4 2 2 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CAL...

Page 245: ...llowing procedure applies to both of the front brake calipers Clips Pad pin Pad spring Brake pads shims Caliper pistons Bleed screw Dust seals Piston seals 2 1 1 2 2 4 1 4 4 Disassembly the parts in t...

Page 246: ...opper washers Brake hose Caliper ass y 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE...

Page 247: ...ad pins Pad support Brake pads shims Caliper pistons Dust seals Piston seals Bleed screws 1 2 2 1 2 2 2 2 2 2 Disassembly the parts in the order listed For assembly reverse the disassembly procedure R...

Page 248: ...the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood...

Page 249: ...and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the...

Page 250: ...Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow o...

Page 251: ...0 m kg Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touch...

Page 252: ...er does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore alwa...

Page 253: ...l and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt...

Page 254: ...nce When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage...

Page 255: ...ket Cap bolts Bolts lower bracket Front fork left right 2 1 2 2 4 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS For installation reverse the removal procedure Refer to...

Page 256: ...k Cap bolts O rings Plates Spacers Spring seats Fork springs Dust seals Oil seal clips Oil seals Seal spacers Outer tube bushings Bolts damper rod Gaskets 2 2 2 2 2 2 2 2 2 2 2 2 2 Disassembly the par...

Page 257: ...15 16 17 18 19 Inner tubes Inner tube bushings Oil flow stoppers Damper rods Damper rod springs Outer tubes 2 2 2 2 2 2 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLIN...

Page 258: ...motorcycle on a suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts su...

Page 259: ...30 mm 90890 01327 T Handle 90890 01326 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the...

Page 260: ...r the specified limit Replace Spring free length limit 395 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper 2 Damage Repla...

Page 261: ...eal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod 1 Allow the damper rod to slide slowly down the inner tube 2 until it protrudes f...

Page 262: ...890 01367 Adapter 90890 01374 Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its lips Apply fork oil onto the outer surfac...

Page 263: ...ave an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 After filling up slowly pump the fork...

Page 264: ...nstall front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the upper bracket 2 Tighten lower bracket pinch bolt 1 cap...

Page 265: ...rip end right Throttle grip Master cylinder bracket Master cylinder clutch Handlebar switch left Starter lever Starter cable Grip end left 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order lis...

Page 266: ...grip Collar Upper handlebar holders Handlebar 1 1 2 1 Referto REMOVINGTHEHANDLEBAR 26 Nm 2 6 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg 23 Nm 2 3 m kg Refer to INSTALLING THE HANDLEBAR For ins...

Page 267: ...cable housing pull back the rubber cover 2 3 Remove handlebar grip left 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECK...

Page 268: ...torcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 1 upper handlebar holders 2 Upper handlebar holder bolt 23 Nm 2 3 m kg Fir...

Page 269: ...ylinder clutch 1 master cylinder bracket 2 Align the mating surfaces of the master cylinder with the punch mark a on the handlebar 6 Install throttle grip 1 throttle cable housing 2 throttle cables 3...

Page 270: ...lebar There should be 1 3 mm of clearance b be tween the throttle grip and the right grip end 8 Install master cylinder ass y front brake 9 Adjust throttle cable free play Refer to ADJUSTING THE THROT...

Page 271: ...ower bracket Rubber seal Bearing cover Bearing 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT FORK Refer to HANDLEBAR Refer to REMOVING...

Page 272: ...b Part Q ty Remarks 11 12 13 Bearing Dust seal Lower handlebar holders 1 1 2 For installation reverse the removal procedure 110 Nm 11 0 m kg 40 Nm 4 0 m kg 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg CHAS S...

Page 273: ...lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 90890 01268 Ring nut wrench 90890 01403 Securely support...

Page 274: ...enever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubr...

Page 275: ...et Pivot shaft Swingarm Drive chain guide Dust covers Washers Bush 1 1 2 1 1 1 1 1 2 2 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKEDISC AND REAR WHEEL SPROCKET Refer to ENGINE in c...

Page 276: ...Remarks 11 12 Bearings Drive chain 2 1 For installation reverse the removal procedure 23 Nm 2 3 m kg 125 Nm 12 5 m kg 7 Nm 0 7 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg 7 Nm 0 7 m kg CHAS REAR SHOCK ABSORBER...

Page 277: ...en the rear shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive ga...

Page 278: ...old the swingarm so that it does not drop down 3 Check swingarm side play swingarm vertical movement a Check the tightening torque of the pivot shaft nut Pivot shaft nut 125 Nm 12 5 m kg b Check the s...

Page 279: ...ssembly spring 2 Damage wear Replace the rear shock ab sorber assembly gas cylinder 3 Damage gas leaks Replace bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Repla...

Page 280: ...rement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosine an...

Page 281: ...e chain and make sure that the battery breather hose is proper ly routed away from the drive chain and be low the swingarm 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant s...

Page 282: ...CHAS...

Page 283: ...UIT DIAGRAM 7 8 TROUBLESHOOTING 7 9 ELECTRIC STARTING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 7 14 TROUBLESHOOTING 7 15 STARTER MOTOR 7 19 CHARGING SYSTEM 7 22 CIRCUI...

Page 284: ...ELEC...

Page 285: ...l switch Horns Ignition coils Main switch Fuel sender Starter relay Starting circuit cutoff relay Battery Oil level relay Flasher relay Ignitior unit Neutral switch Sidestand switch 1 2 3 4 5 6 7 8 9...

Page 286: ...ecking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to th...

Page 287: ...eck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected P...

Page 288: ...use Side stand switch Neutral switch Oil level switch 1 for Europe 2 for AUS Horn switch Clutch switch Dimmer switch Pass switch Turn signal switch Main switch Front brake switch Engine stop switch 1...

Page 289: ...hown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed fro...

Page 290: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continui...

Page 291: ...tester No continuity Replace Pocket tester 90890 03112 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into t...

Page 292: ...12 14 15 18 Main fuse Battery Main switch Ignition fuse Ignitor unit Ignition coils Spark plugs Pickup coil Neutral switch Sidestand switch Engine stop switch ELEC IGNITION SYSTEM EAS00735 IGNITION SY...

Page 293: ...SPARK PLUGS in chapter 3 Standard spark plug DPR 8EA 9 NGK X24EPR U9 DENSO Spark plug gap 0 8 X 0 9 mm SIs the spark plug in good condition is it of the correct type and its gap within specification Y...

Page 294: ...rom the spark plug SConnect the pocket tester 1k to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 k at 20_C SIs the spark plug cap OK YES Replace the...

Page 295: ...istance EAS00749 SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EAS00750 SCheck the engine stop switch for con...

Page 296: ...ion system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects NO Replace the ignitor unit YES 13 Wiring Properly connect or repair the ignition s...

Page 297: ...y Starter relay Main switch Ignition fuse Starter motor Starting circuit cutoff relay Neutral switch Sidestand switch Start switch Engine stop switch Clutch switch 38 ELEC ELECTRIC STARTING SYSTEM EAS...

Page 298: ...relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When...

Page 299: ...NO EAS00758 1 3 2 WARNING SA wire that is used as a jumper lead must have at least the same capacity of the battery lead otherwise the jumper lead may burn SThis check is likely to produce sparks the...

Page 300: ...te 5 Diode Disconnect the starting circuit cutoff relay from the coupler Connect the pocket tester 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay f...

Page 301: ...WITCHES Is the neutral switch OK YES Replace the neutral switch NO 9 Neutral switch EAS00752 Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK YES Rep...

Page 302: ...n nected and without defects NO The starting system circuit is OK YES 13 Wiring Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES Replace the right handle...

Page 303: ...e starter motor Starter motor front cover Washer set Starter motor rear cover washer set Brush holder brush Armature assembly Starter motor yoke 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order liste...

Page 304: ...hacksaw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commut...

Page 305: ...N 0 780 X 1 021 kg 7 Check gear teeth Damage wear Replace the gear 8 Check oil seal Damage wear Replace the defective part s EAS00772 Assembling The Starter Motor 1 Install brush holder 1 Align the t...

Page 306: ...7 22 CHARGING SYSTEM ELEC 1 2 3 5 Generator Main fuse Battery Main switch EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM...

Page 307: ...cket tester DC 20 V to the battery as shown Charging voltage 14 V at 5 000 r min Tester positive probe battery positive terminal Tester negative probe battery negative terminal SStart the engine and l...

Page 308: ...oil assembly OK YES Replace the stator coil assembly NO Tester positive probe white Tester negative probe black 1 2 SMeasure the stator coil assembly resis tances Tester positive probe white Tester ne...

Page 309: ...the mian switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 7 Main switch EAS00779 SCheck the wiring connections of the entire charging system...

Page 310: ...Brush holder Regulator Rectifier cover Rectifier Rear cover Rotor assembly Bearing cover Bearing Bearing Stator assembly 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order list For assembly rev...

Page 311: ...6 Main fuse Battery Main switch Lights switch Meter light High beam indicator light Pass switch Dimmer switch Headlight fuse Auxiliary light Tail brake light Headlight 47 LIGHTING SYSTEM ELEC EAS00780...

Page 312: ...switch OK YES Replace the main switch NO 3 Main switch EAS00783 SCheck the lights switch for continuity Refer to CHECKING THE SWITCHES SIs the lights switch OK YES The lights switch is faulty Replace...

Page 313: ...onnect or repair the lighting system s wiring NO 7 Wiring Check the condition of each of the light ing system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Check the headlight bulb and socket for...

Page 314: ...main switch to the headlight cou pler is faulty and must be repaired NO YES 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown Tester positive probe blue...

Page 315: ...3 4 The auxiliary light fails to come on for Eu rope 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the aux...

Page 316: ...Horn Flasher relay Oil level switch Fuel gauge 30 Fuel sender 31 Neutral indicator light 33 Turn signal indicator 34 Turn signal indicator 35 Oil level warning light 36 Turn signal switch 39 Horn swi...

Page 317: ...y OK NO EAS00795 4 Wiring SCheck the entire signaling system s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair...

Page 318: ...to ON Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connector at the black terminal as shown Tester positive probe black Tester negative probe ground 1 Set the main sw...

Page 319: ...ke light switch OK YES 2 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired NO This circuit is OK Set the main switch to ON Pull in the brake le...

Page 320: ...cation 1 4 Voltage Connect the tester DC 20 V to the flasher relay coupler wire harness side as shown The flasher relay is faulty and must be re placed NO YES 1 Set the main switch to ON Set the turn...

Page 321: ...turn signal light con nector wire harness side Is the voltage within specification 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWI...

Page 322: ...bulb and socket Check the oil level warnig light bulb and sock et for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the oil level warnig light bulb and socket OK YES Replace the oil lev...

Page 323: ...asure the voltage 12 V of brown and black red at the meter assembly coupler SIs the voltage within specification YES The wiring circuit from the main switch to the meter assem bly coupler is faulty an...

Page 324: ...o the me ter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe black 1 2 YES The wiring circuit from the main switch to the meter assem bly coupler is fault...

Page 325: ...the tachome ter when the main switch is set to ON irrespective of whether the engine is running or not The engine is not operated condition code at 2 000 r min Circuit Defect s System response Condit...

Page 326: ...r 6 Is the throttle position sensor OK YES Replace the throttle position sensor Replace the ignitor unit NOTE 13 Throttle position sensor 9 Ignitor unit EAS00835 TROUBLESHOOTING The tachometer starts...

Page 327: ...nect the starting circuit cutoff relay from the coupler Connect the pocket tester 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay for continuity as...

Page 328: ...the relay unit NO When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed Are the tester readings correct YES Replace the ignitor unit NOTE SELF DI...

Page 329: ...R 8 2 FAULTY CLUTCH 8 3 CLUTCH SLIPS 8 3 CLUTCH DRAGS 8 3 OVERHEATING 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 CHASSIS 8 3 ELECTRICAL SYSTEMS 8 3 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT FORK LEGS 8 4 LEAKING...

Page 330: ...TRBL SHTG...

Page 331: ...Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose vacuum hose Carburetors Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged flo...

Page 332: ...park plug cap Ignition coils Broken or shorted primary or secondary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty ignition unit Faulty pickup coil EAS00848 POOR MEDIUM AND...

Page 333: ...te Swollen friction plate Bent clutch pull rod Damaged clutch boss Burnt primary driven gear bushing Damaged clutch release cylinder Match marks not aligned Engine oil Incorrect oil level Incorrect oi...

Page 334: ...mper rod Incorrect oil viscosity Incorrect oil level EAS00862 UNSTABLE HANDLING Handlebar Bent or incorrectly installed right handlebar Bent or incorrectly installed left handlebar Steering head compo...

Page 335: ...BULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty tu...

Page 336: ...TRBL SHTG...

Page 337: ...13 TPS throttle position sensor 14 Neutral switch 15 Sidestand switch 16 Oil level relay 17 Start switch 18 Engine stop switch 19 Front brake switch 20 Handlebar switches right 21 Lights switch 22 Fu...

Page 338: ...Spark plug 12 Pickup coil 13 TPS throttle position sensor 14 Neutral switch 15 Sidestand switch 16 Oil level relay 17 Start switch 18 Engine stop switch 19 Front brake switch 20 Handlebar switches ri...

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Yamaha XJR1300(L) 99, Service Manual

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