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Yamaha XT 600 A, Service Manual

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Summary of Contents for XT 600 A

Page 1: ...Yamaha Motor Corporation U S A 1st Edition January 1990 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A PIN L1T 11616 07 43 ...

Page 2: ...ion from his motor cycle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual NOTE ___________________________...

Page 3: ...d in a box preceded by a relevant symbol An encircled numeral indicates a part name and an encircled alphabetical letter data or an alignment mark J the others being indicated by an alphabetical letter in a box A condition of a faulty component will precede an arrow symbol and the course of action re quired the symbol EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly...

Page 4: ...ngine Carburetion Chassis J Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Special tool Tightening j Wear limit clearance j Engine speed n V A Illustrated symbols to in the exploded dia gram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide...

Page 5: ...INDEX GENERAL INFORMATION GEN INFO SPECIFICATIONS jD SPEC PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL ENG CARBURETION CARB c T0 too CHAS CHASSIS ELECTRICAL TROUBLESHOOTING ...

Page 6: ...S 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 4 SPECIAL TOOLS 1 4 FOR TUNE UP 1 4 FOR ENGINE SERVICE 1 5 FOR CHASSIS SERVICE 1 8 FOR ELECTRICAL COMPONENTS 1 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 11 ELECTRICAL 2 15 GENERAL TORQUE SPECIFICATIONS 2 17 DEFINITION OF UNITS 2 17 LUBRICATION POINTS AND LUBRICANT TYPE 2 18 ENGINE 2 18 CHASS...

Page 7: ...EL INSPECTION 3 16 ENGINE OIL REPLACEMENT 3 18 ENG OIL PRESSURE INSPECTION 3 22 CLUTCH ADJUSTMENT 3 23 ENGINE OIL TANK STRAINER CLEANING 3 25 1 AIR FILTER CLEANING 3 27 CARBURETOR JOINT INSPECTION 3 28 CARB FUEL LINE INSPECTION 3 29 CRANKCASE VENTILATION HOSE INSPECTION 3 29 EXHAUST SYSTEM INSPECTION 3 29 CANISTER INSPECTION XT600 EAC ONLY 3 30 CHAS CHASSIS 3 32 FRONT BRAKE ADJUSTMENT 3 32 REAR BR...

Page 8: ...55 CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL 4 1 ENGINE OIL 4 1 SEAT AND FUEL TANK 4 1 BATTERY LEAD 4 1 CARBURETOR 4 2 CLUTCH CABLE 4 2 EXHAUST PI PE 4 2 STARTER MOTOR 4 3 HOSE AND LEAD 4 3 DRIVE CHAIN 4 4 ENGINE PROTECTOR 4 4 ENGINE REMOVAL 4 5 ENGINE DiSASSEMBLy 4 6 CYLINDER HEAD CYLINDER CAMSHAFT AND PISTON 4 6 STARTER IDLE GEAR AND CRANKCASE COVER LEFT 4 9 CLUTCH PRIMARY DRIVE GEAR AND BALANCER...

Page 9: ...HAFT STOPPER LEVER 4 37 STARTER DRIVE 4 38 CRAN KSHAFT 4 39 BALANCER DRIVE GEAR AN D BALANCER GEAR 4 39 CRANKCASE 4 40 BEARING AND OIL SEAL 4 40 ENGINE ASSEMBLY AND ADJUSTMENT 4 41 VALVE 4 42 ROCKER ARM 4 43 CRANKSHAFT AND BALANCER 4 45 TRANSMISSION AND SHIFTER 4 48 OIL STRAINER 4 51 CRANKCASE 4 51 I GEN INFO SPEC R 1 INSP ADJ 1 ENG CARB SHIFT LEVER AND OIL PUMP 4 52 CHAS CAM CHAIN 4 54 1 O g D I ...

Page 10: ...NT 6 5 INSTALLATION 6 6 REAR WHEEL 6 8 REMOVAL 6 9 INSPECTION 6 10 INSTALLATION 6 11 FRONT AND REAR BRAKE 6 13 BRAKE PAD REPLACEM ENT 6 15 CALIPER DISASSEMBLY 6 20 MASTER CYLINDER DISASSEMBLY 6 23 INSPECTION AND REPAIR 6 25 CALIPER ASSEMBLY 6 29 MASTER CYLINDER ASSEMBLY 6 34 FRONT FORK 6 39 REMOVAL 6 40 DISASSEMBLY 6 41 INSPECTION 6 43 ASSEMBLY 6 44 INSTALLATION 6 47 STEERING HEAD AND HANDLEBAR 6 ...

Page 11: ...N MANUAL 7 5 CHECKING SWITCH FOR TERMINAL CONNECTION 7 5 CHECKING OF BULBS FOR HEADLIGHT TAIL BRAKE LIGHT FLASHER LIGHT METER LIGHT ETC 7 8 KINDS OF BULBS 7 8 CHECKING BULB CONDITION 7 8 IGNITION SYSTEM 7 11 CIRCUIT DIAGRAM 7 11 TROUBLESHOOTING 7 13 ELECTRICAL STARTING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 STARTING CIRCUIT OPERATION 7 23 TROUBLESHOOTING 7 24 STARTER MOTOR 7 30 CHARGING SYSTEM 7 35 CIRC...

Page 12: ...ERFORMANCE 8 3 FAULTY GEAR SHIFTING 8 4 HARD SHIFTING 8 4 CHANGE PEDAL DOES NOT MOVE 8 4 JUMP OUT GEAR 8 4 CLUTCH SLIPPING DRAGGING 8 5 CLUTCH SLIPPING 8 5 CLUTCH DRAGGING 8 5 FAULTY BRAKE 8 6 POOR BRAKING EFFECT 8 6 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8 6 OIL LEAKAGE 8 6 MALFUNCTION 8 6 INSTABLE HANDLING 8 7 INSTABLE HANDLING 8 7 FAULTY SIGNAL AND LIGHTING SYSTEM 8 8 HEADLIGHT DARK ...

Page 13: ...OVERHEATING 8 9 OVERHEATING 8 9 XT600EA EAC CIRCUIT DIAGRAM J GEN INFO SPEC ENG J CARS c sG t CHAS ...

Page 14: ...er is used to identify your motorcycle and may be used to register your motorcycle with the licensing au thority in your state ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the right rear section of the engine Starting serial number XT600EA Except for California 3UY 000101 XT600EAC For California 3UY 005101 NOTE ________________________ The first three digit...

Page 15: ...CIAL TOOL 3 When disassembling the motorcycle keep mated parts together This includes gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the motorcycle disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are c...

Page 16: ...sembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates CD and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1 Install the bearing s and oil seal s with their manufacturer s marks or numbers facing out ward In other word...

Page 17: ...per 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 improvised techniques FOR TUNE UP 1 Inductive timing light PI N YM 33277 A G PI N 90890 031 09 This tool is necessary for adjusting ignition timing 2 Fuel levle gauge PI N YM 01312 A PI N 90890 01312 This gauge is used to mea...

Page 18: ...is necessary for adjusting the valve clearance FOR ENGINE SERVICE 1 Universal clutch holder PI N YM 91 042 Q PI N 90890 04086 This tool is used to hold the clutch when remov ing or installing the clutch boss locknut 2 Crankcase separator PIN YU 01135 A PIN 90890 01135 This tool is necessary to separate the crankcase 3 Valve spring compressor PIN YM 04019 PIN 90890 04019 This tool is needed to remo...

Page 19: ... PI N YM 01227 PI N 90890 01227 This tool is used to rebore the new valve guide 6 Valve guide installer 7 mm 0 28in PI N YM 04017 PI N 90890 0401 7 This tool is needed to install the valve guides properly 7 Valve seat cutter set PI N YM 91043 This tool is needed to resurface the valve seat 8 Piston pin puller PI N YU 01304 PI N 90890 01304 This tool is used to remove the piston pin ...

Page 20: ...90 01274 Crankshaft installer bolt PIN 90890 01275 11 Adapter 10 M 14 PI N YM 90069 PI N 90890 04059 This tool is used to install the crankshaft 12 Crank pot spacer PI N YM 91044 P N 90890 04081 Q Spacer P N 90890 01016 This tool is used to install the crankshaft 13 Rotor holder PI N YS 01880 PI N 90890 01701 This tool is used to hold the rotor when remov ing or installing the rotor securing nut ...

Page 21: ...e mating surfaces etc FOR CHASSIS SERVICE 1 T Handle PI N YM 01326 P N 90890 01326 CD Damper rod holder 27 mm 1 06in PI N YM 01388 P N 90890 01388 V This tool is used to loosen and tighten the front fork cylinder holding bolt 2 Front fork seal drive weight PI N YM 33963 PI N 90890 01367 CD Adapter 41 mm 1 61in PI N YM 33968 PI N 90890 01381 V 3 Ring nut wrench PI N YU 33975 CD P N 90890 01403 V Th...

Page 22: ...YU 33260 A D PI N 90890 03021 This instrument is necessary for checking the ig nition system components 2 Pocket tester PI N YU 03112 PI N 90890 03112 This instrument is available for checking the elec trical system 3 Dynamic spark tester R N YM 34487 PI N 90890 03144 This instrument is necessary for checking the ig nition system components ...

Page 23: ...cturer Clutch Type GENERAL SPECIFICATIONS ISPECI p 1 SPECIFICATIONS XT600EA EAC 3UY2 XT600EA 3UY1 XT600EAC JYA3UYEO LA000101 XT600EA JYA3UYCO LA005101 XT600EAC 3UY 000101 XT600EA 3UY 005101 XT600EAC 2 200 mm 87 4 in 820 mm 32 3 in 1 245 mm 49 0 in 855 mm 33 7 in 1 445 mm 56 9 in 235 mm 9 3 in 168 kg 370 Ib 2 200 mm 86 6 in Air cooled 4 stroke SOHC Forward inclined sing le cylinder 595 cm3 95 x 84 ...

Page 24: ...e Pressure cold tire Maximum load 202 kg 445 Ib Cold tire pressure Front Rear Up to 90 kg 198 Ib load 150 kPa 150 kPa 1 5 kg cm2 21 psi 1 5 kg cm2 21 psi 90 kg 198 Ib Maximum load 150 kPa 200 kPa 1 5 kg cm 2 21 psi 2 0 kg cm 2 28 psi Off road riding 125 kPa 125 kPa 1 25 kg cm2 18 psi 1 25 kg cm 2 18 psi High speed riding 150 kPa 150 kPa 1 5 kg cm2 21 psi 1 5 kg cm2 21 psi Load is total weight of c...

Page 25: ...ty 12V 8AH Headlight type Quartz bulb halogen Bulb wattage quantity Headlight 12V 60W 55W 1 pc Tail Brake light 12V 8W 27W 1 pc Flasher light 12V 27W 4 pc Front position light 12V 8W 2 pc Meter light 12V 3 4W 1 pc NEUTRAL indicator light 12V 3 4W 1 pc HIGH BEAM indicator light 12V 3 4W 1 pc TURN indicator light 12V 3 4W 1 pc Over REV indicator light 12V 3 4W 1 pc 2 3 ...

Page 26: ...aust A head diameter 8 face width C seat width 0 margin thickness A B 2 4 XT600EA EAC 0 03 mm 0 0012 in Lines indicate straightedge measurement 94 97 95 02 mm 3 739 3 741 in 95 1 mm 3 744 in 50 mm 1 97 in Chain drive left 22 967 22 980 mm 0 904 0 905 in 0 020 0 054 mm 0 0008 0 0021 in 36 47 36 57 mm 1 436 1 440 in 30 06 30 16 mm 1 183 1 187 in 6 41 mm 0 252 in 36 62 36 72 mm 1 442 1 446 in 30 11 3...

Page 27: ...NS ISPECI jJ 1 XT600EAjEAC 6 975 6 990 mm 0 274 0 275 in 6 955 6 970 mm 0 273 0 274 in 7 000 7 012 mm 0 275 0 276 in 7 000 7 012 mm 0 275 0 276 in 0 010 0 037 mm 0 0004 0 001 in 0 030 0 057 mm 0 001 0 002 in 0 01 mm 0 0004 in 1 1 mm 0 043 in 1 1 mm 0 043 in Inner spring 40 1 mm 1 58 in 40 1 mm 1 58 in 22 7 mm 0 89 in 22 7 mm 0 89 in Clockwise c Outer spring 43 8 mm 1 72 in 43 8 mm 1 72 in 34 2 mm ...

Page 28: ...g 0 02 0 06 mm 0 0008 0 002 in Crankshaft F Crank width A 74 95 75 00 mm 2 950 2 953 in Runout limit C b 0 03 mm 0 0012 in Big end side Clearance 0 0 35 0 65 mm 0 013 0 026 in Small end Free play F Q 0 8 mm 0 031 in Balancer Drive method Gear Clutch Friction plate Thickness 2 72 2 88 mm 0 107 0 113 in Quantity 6 pcs Wear limit 2 6 mm 0 102 in Friction plate Thickness 2 94 3 06 mm 0 116 0 120 in Qu...

Page 29: ...uretor 00 Cut away C A 5 5 Pilot air jet size p A J 1 1 0 Pilot jet P J 48 Enricher air jet size E A J 1 1 1 Pilot screw P S Preset Valve seat size V S dl2 5 Sta rter jet G S 76 Fuel level with special tool F L 6 0 8 0 mm 0 24 0 31 in Float height F H 25 0 27 0 mm 0 98 1 06 in Engine idle speed 1 300 1 400 r min Lubrication systsem Oil filter Type Paper type Oil pump T pe Trochoid type Tip clearan...

Page 30: ...agneto Hexagon nut M14 x 1 5 120 12 0 85 Locknut valve clearance adjuster Hexagon nut M6 x 1 0 14 1 4 10 Cam sprocket Flange bolt M7 x 1 0 20 2 0 14 Cam chain tensioner Hexagon socket head bolt M6 x 1 0 10 1 0 7 2 Flange bolt M16 x 1 0 20 2 0 14 Rocker arm shaft Hexagon socket head bolt M6 x 1 0 10 1 0 7 2 Oil pump Hexagon socet head bolt M6 x 1 0 10 1 0 7 2 Oil strainer Panhead screw M6 x 1 0 7 0...

Page 31: ...r plate bearing a Flat head screw M6 x 1 0 7 0 7 5 1 Pressure plate Flange bolt M6 x 1 0 8 0 8 5 8 Clutch boss Hexagon nut M20 x 1 0 90 9 0 65 Primary drive gear Hexagon nut M20 x 1 0 120 12 0 85 Push lever Panhead screw M8 x 1 0 12 1 2 8 7 Push rod Hexagon nut M6 x 1 0 8 0 8 5 8 Drive sprocket Hexagon bolt M18 x 1 0 110 11 0 80 Stopper plate oil seal Hexagon bolt M6 x 1 0 10 1 0 7 2 Stopper lever...

Page 32: ...MAINTENANCE SPECIFICATIONS ISPECI 9 11 Tightening sequence Cylinder head Crankcase Left hand 2 10 ...

Page 33: ...on Shock absorber travel 71 mm 2 8 in Spring free length 255 mm 10 0 in Fitting length 243 5 mm 9 6 in Spring rate K1 95 N mm 9 5 kg mm 532 ib in Stroke K1 Zero 71 0 mm Zero 2 8 in Optional spring No Enclosed gas pressu re 2 000 kPa 20 kg cm2 284 psi Swingarm Free play limit 1 0 mm 0 039 in at swingarm end Move swingarm end side to side Side clearance 0 4 0 7 mm 0 016 0 027 in at swingarm pivot Fr...

Page 34: ...ype Single Disc outside diameter 220 mm 8 66 in Disc thickness 5 0 mm 0 20 in Pad thickness 6 0 mm 0 24 in Wear limit 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 5 in Caliper cylinder inside diameter 34 9 mm 1 37 in Brake fluid type DOT No 4 Brake lever and pedal Brake lever free play 2 0 5 0 mm 0 08 0 20 in at end of brake lever Brake pedal position 15 mm 0 59 in below top of footres...

Page 35: ...nd frame M10 X 1 25 64 6 4 46 Engine stay upper and engine M10 x 1 25 64 6 4 46 Engine rear and frame M 1Ox 1 25 64 6 4 46 Engine protector and frame M6 x 1 0 10 1 0 7 2 Rear shock absorber Swingarm Pivot shaft M14 x 1 5 85 8 5 61 Swingarm and relay arm M12 x 1 25 59 5 9 43 Relay arm and connecting rod M1 Ox 1 25 32 3 2 23 Connecting rod and frame M1 Ox 1 25 32 3 2 23 Rear shock absorber and frame...

Page 36: ... x 1 0 5 0 5 3 6 License bracket and flap M4 x 0 7 2 0 2 1 4 Rear reflector and stay M5 x O S 4 0 4 2 9 Fuel tank and fuel cock M6 x 1 0 7 0 7 5 1 Fuel tank stay and frame M6 x 1 0 7 0 7 5 1 Helmet holder and frame M6 x 1 0 7 0 7 5 1 Clutch cable and crankcase cover M6 x 1 0 10 1 0 7 2 License bracket and tail lamp M6 x 1 0 7 0 7 5 1 Starter switch and lead M6 x 1 0 3 0 3 2 2 Regulator and frame M...

Page 37: ... speed x 1 000 r min Ignitor Unit model Manufacturer TNDF09 NIPPON DENSO Pickup coil resistance 184 276 D at 20 C 68 F color Green White Blue Yellow Ignition coil Model Manufacturer J0268 NIPPON DENSO Primary coil resistance 3 4 4 6 D at 20 C 68 F Secondary coil resistance 10 4 15 6 kD at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kD at 20 C 68 F Charging system Type A C magneto genera...

Page 38: ...cturer SM 13 MITSUBA Output 0 8 kw Brush overall length 12 mm 0 47 in limit 5 mm 0 20 in Commutator diameter 28 mm 1 10 in limit 27 mm 1 06 in Mica undercut depth 0 7 mm 0 03 in Starter switch Model Manufacturer MS5D 191 HITACHI Amperage rating 100A Horn Type Plane type Quantity 1 pc Model Manufacturer YF 12 NIKKO Maximum amperage 2 5A Flasher relay Type Condenser type Model Manufacturer FZ257SD N...

Page 39: ...call for clean dry threads Components should be at room tem perature A Distance across flats B Outside thred diameter DEFINITION OF UNITS A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm Unit Read Definition mm millimeter 10 3 meter cm centimeter 10 2 meter kg kilogram 103 gram N Newton 1 kg x m sec2 Nm Newton meter Nxm m kg Meter kilogram mxkg Pa Pascal N m2 N mm Newton per millimeter N mm l liter cm3 C...

Page 40: ... 0 Valve stem and valve guide Oil seal valve stem end G Rocker arm shaft and rocker arm 0 Cam and bearing camshaft 10 Rotor and rotor housing oil pump 0 Push rod I Primary driven gear and main axle 0 Sliding gear transmission Ie Free movement gear transmission 8 Shift fork and guide bar 0 Shift cam and bearing shift cam 0 Shift shaft 0 Crankcase mating surfaces Sealant quick gasket Yamaha Bond No ...

Page 41: ...m and thrust cover I iC Pivot shaft swingarm I Bushes rear shock absorber I Bushes relay arm and connecting rod I Bearings relay arm and connecting rod Pivoting points brake pedal and change pedal Bearings steering head Right handlebar end Pivoting points brake lever and clutch lever Clutch cable end Pivoting point sidestand Bushes chain tensioner Grease nipple swingarm Grease nipple relay arm Gre...

Page 42: ...LUBRICATION DIAGRAM Oil tank 2 Oil strainer oil tank 3 Oil strainer engine 4 Oil pump LUBRICATION DIAGRAM ISPECII ll Al Feed rn J Scavenge 2 20 ...

Page 43: ...Oil pump Oil filter Cam shaft Oil delivery pipe Main axle Drive axle Oil hose LUBRICATION DIAGRAM ISPECI jJ 1 IN Feed ffil Scavenge 2 21 A 1 1_ _ rID _ ...

Page 44: ...Oil filter Cam shaft Crank pin Main axle Drive axle Drain bolt LUBRICATION DIAGRAM ISPEC ff Al Feed aJ Scavenge A LI_ _ BJ _ __ 3 ____J 4 ___U_i 2 22 ...

Page 45: ...I Oil pump 2 Oil filter 3 Oil delivery pipe 4 Transmission 5 Oil strainer LUBRICATION DIAGRAM ISPECll fl 6 Feed llil Scavenge A Il _ rID ___ 2 23 ...

Page 46: ...switch the couper underneath the meter lead and pilot box Align the white tape on the wirehar 4 Clamp the wires at the point ness with the Headlightstay where taping will stop near the 9 Brake hose OJ Pass the wireharness between the wireharness 10 Flasher light lead left 11 Main switch lead 1 Clutch switch lead 13 Pilot box lead 14 Brake hose guide 15 Wireharness 16 Clamp 1 Speedometer cable 18 S...

Page 47: ...use Wireharness Ignition coil Cable guide Breather hose guide Rear brake switch lead 2 25 IAl Pass the overflow hose carburetor and air vent hose carburetor bet ween the relayarm and swing arms BJ Fit the hole of the meter cable band to the projection of the outer tube Clamp the brake hose Q Secure the brake hose outside and the meter cable inside with cable guides E Hook throttle cables 1 2 and t...

Page 48: ...r brake switch Reservoir hose guide Reservoir hose Air vent hose Overflow hose 2 26 181 Pass the vacuum hose through the hole on the flap BJ Clamp the horn lead g Pass the reservoir hose through the reservoir hose guide Q Pass the breather hose over the oil hose IE Hook the brake switch spring to the inside of the brake pedal return spring to prevent crossing ...

Page 49: ...CD Ignitor unit Wireharness Clamp 4 Band 5 Flasher light lead left 6 Flasher light lead right 7 Rectifier Regulator CABLE ROUTING ISPECI Pfl 8 Pass the rear flasher light lead through the guide 2 27 ...

Page 50: ...Roll over valve Carburetor Canister Relay arm Hose to atmosphere Connecting rod J Over flow hose Hose to carburetor Grommet Collar AJ Pass the hose to the right hand side of the relay arm and connecting rod rn J Pass the over flow hose through the clamp 2 28 Al 5 6 ...

Page 51: ...hain condition 6 Drive chain Adjust and lubricate chain SAE 30W 50W motor oil Every 500 km 300 mil tholoughly rou Yamaha chain and cable r Control and meter Apply chain lube lube or SAE 1OW30 motor 0 0 0 0 0 0 cable thoroughly oil Rear arm pivot B shaft and rear Apply untile new grease Lithium soap base grease suspention link shows 0 0 0 0 0 pivots Brake Clutch Yamaha chain and cable 9 Apply chain...

Page 52: ...at 2 Remove Side cover left CD Sidecover right NOTE _________________________ When removing the side covers remove the bolt Then pull the front portion of the side cover outward to remove the projection from the grommet Then pull the front portion of the side cover downward then pull for ward to remove from the tail cover 18l Side cover left BJ Side cover right ...

Page 53: ...____________________ When removing the air scoops remove the bolt Then pull the bottom portion of the air scoop outward to remove the projection from the gromm et Then pull the front portion of the air scoop forward then pull forward to remove from the fuel tunk 8 Air scoop left IHI Air scoop right ...

Page 54: ...e bolt Then pull the projections from the grom mets 5 Turn the fuel cock to OFF 6 Disconnect Fuel hose CD NOTE _________________________ Place a rug on the engine to absorb a spilt fuel AWARNING Gasoline is highly flammable Aboid spilling fuel on the hot engine 7 Disconnect Flap Vacuum hose Roll over valve hose XT600EAC 8 Remove Fuel tank ...

Page 55: ... AND COVER 3 5 Except for XT600EAC llil For XT600EAC INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Install Flap Side covers Seat Bolt side cover 7 Nm 0 7 m kg 5 1 ft lb Bolt seat 10 Nm 1 0 m kg 7 2 ft lb ...

Page 56: ... stroke When removing the spark plug and tappet covers use caution to prevent an object from falling into the engine AWARNING Securely support the motorcycle so there is no danger of it falling over 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Remove Bolts ignition coil bracket CD 3 Disconnect Leads ignition coil Plug cap 4 Remove S...

Page 57: ...ecification Adjust Valve clearance cold Intake O 05 O 1 Omm O 002 O 004 in Exhaust O 12 O 17mm O 005 O 007 in 9 Adjust Valve clearance Adjustment steps Loosen the locknut CD Insert a Feeler Gauge between the adjuster end and the valve end Turn the adjuster CD clockwise or counter clockwise with the valve adjusting tool until proper clearance is obtained Valve adjusting tool PI N YM 08035 PI N 9089...

Page 58: ... exhaust Spark plug 11 Connect Leads ignition coil Spark plug cap 12 Install Bolts ignition coil bracket Tappet cover exhaust 12 Nm 1 2 m kg 8 7 ft lb Bolt tappet cover intake 10 Nm 1 0 m kg 7 2 ft lb Spark plug 18 Nm 1 8 m kg 13 ft lb NOTE __________________________ The tappet cover intake should be installed with the arrow mark Q upward 13 Install Fuel tank Cover Air scoops Side covers Seat Refe...

Page 59: ...I N 90890 03113 3 Check eEngine idle speed Out of specification Adjust Engine idle speed 1 300 1 400 rl min 4 Adjust eEngine idle speed Adjustment steps Turn the throttle stop screw Q in or out until specified idle speed is obtained Turn in Idle speed becomes higher Turn out Idle speed becomes lower NOTE ___________________________ After adjusting the engine idle speed the throt tle cable free pla...

Page 60: ... SEAT FUEL TANK AND COVER section 2 Check Throttle cable free play Out of specification Adjust Throttle cable free play 3 5mm 0 12 0 20 in 3 Adjust Throttle cable free play Adjustment steps Loosen the locknuts CD on the throttle cable 1 Turn the adjuster clockwise or counter clockwise until proper free play is obtained If the play is still incorrect after the adjuster is loosened 5mm 0 2 in make a...

Page 61: ...Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Disconnect Spark plug cap 3 Remove Spark plug When removing the spark plug use caution to prevent an object from falling into the engine 4 Inspect Spark plug type Incorrect Replace Standard spark plug DPR8EA 9 N G KI X24EPR U9 N D 5 Inspect Electrode CD Wear Damage Replace Insulator Abnormal color Replace Normal color is a m...

Page 62: ...Spark plug gap DPRSEA 9 X24EPR U9 O S 0 9 mm 0 031 0 035 in 8 Tighten Spark plug Before installing a spark plug clean the gasket and plug surfaces Spark plug 18 Nm 1 8 m kg 13 ft lb NOTE __________________________ Finger tighten the spark plug before torquing to specification 9 Connect Spark plug cap 10 Install Fuel tank Cover Air scoops Side covers Seat Bolt seat 10 Nm 1 0 m kg 7 2 ft lb ...

Page 63: ...ons the oil may spurt out when removing the plug Therefore care should be used when removing 4 Check Ignition timing Checking steps eWarm up the engine and let it at the specified speed Engine speed 1 350 r min e Visually check the stationary pointer CD to verify it is within the required firing range indicated on the flywheel Incorrect firing range Check pickup assembly NOTE _____________________...

Page 64: ...overs Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Check Valve clearance Out of specification Adjust Refer to the VALVE CLEARANCE ADJ USTM ENT section 3 Install Sub tank fuel 4 Start the engine and let it warm up Then stop the engine 5 Remove Spark plug 6 Install Compression gauge CD Adapter Compression gauge P N YU 33223 P N 90890 03081 Adapter PI N YU 3322...

Page 65: ...ure at sea level Standard 1 100 kPa 11 kg cm2 156 psi Minimum 900 kpa 9kg cm2 128 psi Maximum 1 200 kPa 12kg cm2 171 psi If pressure falls below the minimum level 1 Squirt a few drops of oil into the affected cylinder 2 Measure the compression again Compression pressure with oil introduced into cylinder Reading Diagnosis Higher than without Worn or damaged oil pistons Defective ring s Same as with...

Page 66: ...t Ib ENGINE OIL LEVEL INSPECTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage AWARNING Never remove the oil tank cap just after high speed operation The heated oil could spurt out causing danger Wait until the oil cools down to approximately 60 C 140 F 1 Place the motorcycle on a level place 2 Remove Cover fuel tank Refer to the ...

Page 67: ... the oil up to the minimum level Recommended oil SAE 20W40 type SE motor oil or SAE 10W30 type SE motor oil 5 Install Oil tank cap 6 Start the engine and warm up until the oil temperature rises to aporoximately 60 C 140 F When the oil tank is empty never start the engine 7 Idle the engine more than 10 seconds while keeping the motorcycle upright Then stop the engine and add the oil to the maximum ...

Page 68: ...0 C 140 F Engine oil replacement without oil filter 1 Place the motorcycle on a level place 2 Remove Cover fuel tank Refer to the SEAT FUEL TANK AND COVER section 3 Warm up the engine for several minutes then stop the engine Then place a recepta cle under the drain bolt 4 Remove Oil tank cap Drain bolt oil tank CD Drain bolt crankcase 5 Drain Engine oil NOTE _________________________ When the drai...

Page 69: ...bolt crankcase 9 Fill Bolt oil filter cover 10 Nm 1 0m kg 7 2 ft Ib Drain bolt oil tank 18 Nm 1 8 m kg 13 ft Ib Drain bolt crankcase 30 Nm 3 0 m kg 22 ft Ib Oil tank to frame Oil filter Chamber Recommended oil SAE 20W40 type SE SF motor oil or SAE 1OW30 type SE SF motor oil Oil quantity Oil tank 2 7 L 2 4 Imp qt 2 9 US qt Oil filter room 0 06 L 0 05 Imp qt 0 06 US qt Do not allow foreign material ...

Page 70: ...T FUEL TANK AND COVER section 3 Warm up the engine for several minutes then stop the engine Then place a recep tacle under the drain bolts 4 Remove Oil tank cap Drain bolt CD oil tank e Drain bolt CV crankcase 5 Drain Engine oil NOTE __________________________ When the drain bolt CD is removed the oil will not drain directly downward Therefore a receptacle should be placed slightly in front of the...

Page 71: ...lter cover Drain bolt crankcase Drain bolt oil tank 10 Fill Bolt oil filter cover 10 Nm 1 0 m kg 7 2 ft Ib Drain bolt oil tank 18 Nm 1 8 m kg 13 ft Ib Drain bolt crankcase 30 Nm 3 0 m kg 22 ft Ib Oil tank to frame Oil filter chamber Recommended oil SAE 20W40 type SE SF motor oil or SAE 10W30 type SE SF motor oil Oil quantity Oil tank 2 8 L 2 5 Imp qt 3 0 US qtj Oil filter room 0 06 L 0 05 Imp qt 0...

Page 72: ...INSPEC TION section Oil pressure Refer to the OIL PRESSURE INSPEC TION section Oil leaks 13 Install Oil tank cap 3 22 Cover OIL PRESSURE INSPECTION 1 Remove Air bleed screw Q 2 Start the engine and keep it idling for sev eral minutes 3 Inspect Oil condition of the bleed hole Oil flows out Oil pressure is good No oil comes out Oil pressure is bad CAUTION If no oil comes out after a lapse of one min...

Page 73: ...ay is increased Free play is decreased Tighten the locknuts NOTE _________________________ The above procedure provides for maximum cable free play to allow for proper clutch actuating mechanism adjustment Mechanism adjustment 1 Loosen eLocknut CD 2 Tighten eAdjuster 3 Drain eEngine oil Refer to the ENGINE OIL REPLACE MENT section 4 Remove e Rear brake switch CD 5 Disconnect eSpring rear brake swi...

Page 74: ...r ________ Proper push rod free play is essential to avoid excessive clutch slippage 13 Install Crankcase cover right Union bolt Bolt crankcase cover 10 Nm 1 0 mkg 7 2 ft Ib Union bolt engine oil delivery 18 Nm 1 8 m kg 13ft lb 14 Connect Return Spring brake pedal 15 Install Footrest right Bolt footrest 45 Nm 4 5 mkg 32 tHb 16 Connect Spring rear brake switch NOTE __________________________ Hook t...

Page 75: ...nt section ENGINE OIL TANK STRAINER CLEANING Components are firmly fixed in place Attention should be paid when removing them AWARNING Securely support the motorcycle so there is no danger of it falling over 1 Place the motorcycle on a level place 2 Remove Cover fuel tank Refer to the SEAT FUEL TANK AND COVER section 3 Warm up the engine for several minutes then stop the engine Then place a recep ...

Page 76: ...the hose by twisting and pulling down ward 9 Remove Oil strainer CD Gasket 10 Clean Oil strainer Slow out the oil strainer with compressor air 11 Insect Oil hose Gasket oil strainer Gasket drain plug Damage Replace 12 Install Reverse the removal procedure Bolt oil strainer 90Nm 9 0m kg 65ft lb Bolt oil pipe 10Nm 1 Om kg 7 2ft lb Nut engine stay front 64Nm 6 4m kg 46ft lb Bolt engine protector 10Nm...

Page 77: ...se cover CD 2 Remove Air filter element CD Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine damage Additionally operation without the filter element will affect carbu retor tuning with subsequent poor perfor mance and possible engine overheating 3 Clean Air filter element Blowout dust in the element from the...

Page 78: ...ir filter case 6 Install Air filter case cover CD as shown 7 Install Side cover right Seat Bolt seat 10Nm 1 Om kg 7 2ft Ib CARBURETOR JOINT INSPECTION 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SET FUEL TANK AND COVER section 2 Inspect Carburetor joint CD Crack Damage Replace Bolt carburetor joint 10 Nm 1 0 m kg 7 2 ft Ib Screw clamp 2 Nm 0 2 m kg 1 4 ft Ib 3 Insta...

Page 79: ...Install Air scoop left Side cover left Seat Bolt seat 10Nm 1 Om kg 7 2ft lb CRAN KCASE VENTI LATIOr HOSE INSPECTION 1 Inspect Crankcase ventilation hose CD Crack Damage Replace EXHAUST SYSTEM INSPECTION 1 Inspect Exhaust pipe CD Muffler Crack Damage Replace Gasket Exhaust gas leaks Replace Nut exhaust pipe 10 Nm 1 0 m kg 7 2 ft Ib Bolt muffler 40 Nm 4 0 m kg 29 ft Ib Bolt clamp 20 Nm 2 0 m kg 14 f...

Page 80: ...tor Canister removal 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section 2 Remove Filter case cover right CD Breather hose from crankcase Breather hose filtercase NOTE ____________________________ When removing the breather hose filter case take care so that the clamp dose not slide down the hose 3 Disconnect Battery lead NOTE ______________...

Page 81: ...use box J from filter case projection Filter case cover 5 Disconnect Ignitor unit CD 6 Remove Bolts air filter case Joint bands Move airfilter case to the rear of shock absorber as shown so that the canister can be seen Do not pinch ignitor leads when removing air filter case 7 Disconnect Hose to carburetor CD 8 Remove Canister Canister installation Reverse the Removal procedure Note the following...

Page 82: ...djuster in or out until the speci fied free play is obtained Free play is decreased Free play is increased Tighten the locknut Proper lever free play is essential to avoid excessive brake drag REAR BRAKE ADJUSTMENT 1 Check Brake pedal height Out of specification Adjust Brake pedal height 15 mm 0 59 in Below top of footrest 2 Adjust Brake pedal height Adjustment steps Loosen the locknut CD Turn the...

Page 83: ...N 1 Place the motorcycle on a level place NOTE _________________________ Position the motorcycle straight up when i nspecting the brake fluid level When inspecting the front brake fluid level make sure the master cylinder top is horizon tal by turning the handlebars 2 Inspect Brake fluid level Fluid level is under LOWER level line CD Fill up AJ Front Bl Rear Recommended brake fluid Front DOT No 4 ...

Page 84: ...hem ical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock BAKE PAD INSPECTION 1 Activate the brake lever or brake pedal 2 Check Pad thickness Out of specification Replace Wear limit Front 1 0 mm 0 04 in Rear 0 8 mm 0 03 in Refer to the BRAKE PAD RE...

Page 85: ...ld the switch body CD with your hand so that it does not rotate and turn the adjusting nut BRAKE HOSE INSPECTION 1 Inspect e Brake hose Crack Damage Replace Refer to the FRONT AND REAR BRAKE section in the CHAPTER 6 for replace ment I8l Front H Rear AIR BLEEDING AWARNING Bleed the brake system if eThe system has been disassembled e A brake hose has been loosened or removed eThe brake fluid is very...

Page 86: ...t h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal I p I Bleed screw 6 Nm 0 6 m kg 4 3 ft Ib i Repeat steps e to h until all of the air bubbles have been removed from the system NOTE __________________________ If the bleeding is difficult it may be necessary to let the brake fluid system stabilize for a few hours Repeat the bleeding procedure...

Page 87: ... specified limits Remove the cotter pin CD and loosen the axle nut Loosen the bolt caliper bracket Loosen the bolts swingarm end 3 37 Turn the chain puller CD clockwise or coun terclockwise until the specified slack is obtained NOTE __________________________ Turn each chain puller exactly the same amount to maintain correct axle alignment There are marks on each side of swingarm and on each chain...

Page 88: ...e chain with small rubber O rings between the chain plates Steam cleaning high pressure washes and certain solvents can damage these O rings Use only kerosene to clean the drive chain Wipe it dry and thoroughly lubricate it with SAE 30 50W motor oil Do not use any other lubricants on the drive chain They may contain solvents that could damage the O rings Recommended lubricant SAE 30 50 motor oil C...

Page 89: ...y placing a suitable stand under the engine 3 Check Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth Looseness Adjust steering head 4 Adjust Steering head Adjustment steps Loosen the bolt CD steering shaft and bolt handle crown Remove the cover fuel tank Tighten the ring nut using the ring nut wrench Ring nut wrench PI N YU 33975 P N 90890 0...

Page 90: ...ring shaft 72 Nm 7 2 m kg 52 ft lb Bolt handle crown 23 Nm 2 3 m kg 17 ft lb Install the cover fuel tank REAR SHOCK ABSORBER ADJUSTMENT NOTE _________________________ The spring preload of the rear shock absorber can be adjusted to suit rider s preferance weight and the course conditions AWARNING Securely support the motorcycle so there is no danger of it falling over 1 Adjust 3 40 Spring preload ...

Page 91: ...anges 1 mm 0 04 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting Tighten the locknut Locknut 42 Nm 4 2 mokg 30 ftolb Always tighten the locknut against the spring adjuster and torque the locknut to specifica tion TIRE INSPECTION AWARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air...

Page 92: ...than listed could cause tire deflation during extreme high speed riding Always use genuine parts or their equivalent for replacement Be sure to install the valve caps securely as these are important to prevent air pres sure leakage during extreme high speed riding 1 Check Tire pressure Out of specification Adjust Basic weight With oil and full 168 kg 370 Ib fuel tank Maximum load 182 kg 401 Ib Col...

Page 93: ...pth front and rear 0 8 mm 0 03 in CD Tread depth Side wall Wear indicator AWARNING It is dangerous to ride with a worn out tire When a tire tread begins to show lines replace the tire immediately Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement 4 Tighten Valve stem locknut 1 ...

Page 94: ...NING Never attempt even small repairs to the wheel CABLE INSPECTION AND LUBRICATION AWARNING Damaged cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace such cable as soon as possible 1 Inspect Cable sheath Damage Replace 2 Check Cable operation Unsmooth operation Lubricate Recommended lubricant SAE 10W30 motor oil NOTE _________________...

Page 95: ... Lubricate pivoting parts of each lever and pedal Recommended lubricant SAE 10W30 motor oil SIDESTAND LUBRICATION Lubricate the sidestand at pivot points Recommended lubricant SAE 10W30 motor oil SWINGARM AND RELAY ARM LUBRICATION Lubricate the swingarm and relay arms at their pivoting points Light weight lithium soap base grease CD Grease nipple IAl Swingarm BJ Relayarm ...

Page 96: ... normal way thus making it im possible for the battery to operate regularly The charging time charging current and charging voltage for the MF battery is differ ent than general type batteries The MF battery should be charged as in structed in the Charging method Should the battery be overcharged the electrolyte level will lower extremely Therefore use special care when charging the battery Distil...

Page 97: ...ink large quantities of water or milk fol low with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive measures Charge batteries in a well ventilated area keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE When chargi...

Page 98: ..._______________ The state of a discharged MF battery can be checked by measuring open circuit voltage the voltage measured with the positive terminals being disconnected Open circuit voltage Charging time 12 8 v or higher No charging isnecessary 12 7v 11 5v 5 10 hours Less than 11 5 v 15 20 hours Battery condition chart as shown 5 Charging method of MF battery elf it is impossible to set the stand...

Page 99: ...ry to generate heat at the contact area A weak clip spring may cause sparks Before removing the clips from the battery terminals be sure to turn off the power switch of the charger Change in the open circuit voltage of the M F battery after being charged is shown below As shown in the figure the open circuit voltage is stabilized 30 minutes after charging has been completed Therefore to check the ...

Page 100: ...t the charg I ing voltage at 20 25 v Monitor the amperage for 3 5 minutes to check if the stan dard charging current is rea ched lA or more If the current is more than 1 amp adjust the voltage to 16 17 v and continue charging NO Set the timer according to the charging time suitable for the open circuit voltage After 5 minutes adjust the voltage to 16 17 v and continue charging If current does not ...

Page 101: ...an the standard _ 1 1 charging current written on the battery Charge the battery until the battery s charging voltage is 16 volts or more NOTE __________ Set the charging time at 20 hours maximum Check the open circuit voltage after having left the battery for 30 minutes after charging 12 8 v or more Charging is complete 12 7 v or less Recharging is necessary Under 12 v Replace the battery Volt me...

Page 102: ...rated NO 1 charging current of the 1 charger is flowing by checking AM P meter Since the charging current is com tant the charging time varies depending on the battery capacity If rated current is not flowing replace the battery Set the charging time according to the instructions specified for the charger Measure the battery open circuit volt age after having left the battery unused for more than ...

Page 103: ... the terminals apply grease light ly to the terminals 7 Install Battery 8 Connect Battery leads NOTE __________________________ Connect the positive lead first and then con nect the negative lead 9 Install Side cover left Seat Bolt seat 10 Nm 1 0 m Kg 7 2 ft Ib FUSE INSPECTION 1 Remove Seat Side cover left Refer to the SEAT FUEL TANK AND COVER section 2 Remove Fuse CD ...

Page 104: ...fuse IS blown replace it 4 Replace eBlown fuse Blown fuse replacement steps Turn off ignition and the circuit Install a new fuse of proper amperage IrD IFuse 20 ampsx1pc Turn on switches to verify operation of electri cal device If fuse blows immediately again check circuit in question AWARNING Do not use fuses of higher amperage rating than recommended Extensive electrical system damage and fire ...

Page 105: ...uster CD clock To right the wise whill turning adjuster beam counterclockwise at the same time Turn the adjuster clock To left the wise whill turning adjuster beam CD counterclockwise at the same time HEADLIGHT BULB REPLACEMENT 1 Remove Cowling headlight NOTE __________________________ When removing the cowling remove the bolt CD pull out the projections from the gromets to remove the cowling 2 Re...

Page 106: ...new CD Secure the new bulb with the bulb holder Avoid touching glass part of bulb Also keep it free from oil otherwise transparency of glass bulb life and illuminous flux will be adversely affected If oil gets on bulb clean it with a cloth moistened thoroughly with alcohol or lacquer thinner 6 Connect Bulb cover Headlight leads 7 Install Headlight lens unit Cowling headlight Bolt headlight upper 1...

Page 107: ... Shift shaft A C magneto AWARNING Securely support the motorcycle so there is no danger of it falling over ENGINE OIL 1 D ain Engine oil Refer to the ENGINE OIL REPLACEMENT section in the CHAPTER 3 SEAT AND FUEL TANK 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 BATTERY LEAD 1 Disconnect Battery lead NOTE _____________...

Page 108: ...or Refer to the CARBURETOR REMOVAL section in the CHAPTER 5 CLUTCH CABLE 1 Remove Clutch cable CD 2 Disconnect Clutch cable end CD NOTE __________________________ Remove the cable end while pushing it toward holder EXHAUST PIPE 1 Remove Exhaust pipe CD ...

Page 109: ...emove Oil delivery pipe CD 2 Remove Bolt CD oil hose clamp 3 Disconnect Starter motor lead CD Ground lead 4 Remove Starter motor HOSE AN D LEAD 1 Remove Breather hose CD oil tank Breather hose crankcase 2 Remove Oil hose CD inlet Oil hose outlet ...

Page 110: ...d so that it does not interfere with engine removal DRIVE CHAIN 1 Remove Change pedal CD Cover drive sprocket 2 Remove Drive sprocket CD NOTE __________________________ Before removing the nut drive sprocket straighten the lock washer tab Loosen the nut drive sprocket while apply ing the rear brake ENGINE PROTECTOR 1 Remove Engine protector CD ...

Page 111: ... it falling over 1 Place a suitable stand under the engine 2 Remove Engine stay CD upper 3 Remove Engine stay CD front 4 Remove Bolt CD Pivot shaft Engine assembly NOTE _________________________ The engine and swingarm are installed using the same pivot shaft Therefore take care so that the pivot shaft is pulled not entirely out but for enough to set the engine free ...

Page 112: ...he cylinder head cylinder camshaft and piston can be maintained by removing the following parts eSeat eSide covers eAir scoops e Cover fuel tank e Fuel tank eCarburetor e Exhaust pipe 1 Remove eSpark plug CD eTappet cover intake eTappet cover exhaust eCylinder head cover eBlind cap eDowel pin 2 Loosen e Bolt CD chain tensioner 3 Remove eChain tensioner ...

Page 113: ...ankcase cover left NOTE _________________________ Fasten safety wire to the cam chain to pre vent it from falling into the crankcase 5 Remove Chain guide CD 6 Remove Cylinder head NOTE _________________________ Loosen each bolt 1 4 turn and remove them af ter all bolts are loosened ...

Page 114: ..._____________ Before removing piston pin circlip cover crank case with a clean rag to prevent circlip from fail ing into crankcase cavity 10 Remove Piston pin CD Piston NOTE __________________________ Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin groove is deburred and piston pin is still difficult to re move use piston pin puller ...

Page 115: ...GEAR AND CRANKCASE COVER LEFT NOTE _________________________ With the engine mounted the starter idle gear and crankcase cover left can be maintained by removing the following parts Starter motor Drive sprocket cover 1 Remove Cover CD starter idle gear Dowel pin Gasket 2 Remove Starter idle gear 1 CD Bearing Shaft 3 Remove Neutral switch lead CD ...

Page 116: ...ead holder CD Pickup coil Stator coil CLUTCH PRIMARY DRIVE GEAR AND BALANCER GEAR NOTE _________________________ With the engine mounted the clutch primary drive gear and balancer gear can be maintained by removing the following parts Footrest right Union bolt oil delivery pipe 1 Remove Oil filter cover CD Oil filter O ring Crankcase cover right ...

Page 117: ...using Push rod NOTE _________________________ Before loosening the nut jJ clutch boss straighten the lock washer tab Hold the clutch boss to loosen the nut clutch boss by the universal clutch holder Universal clutch holder PIN YM 91042 PIN 90890 04086 3 Remove Primary drive gear CD Plate Balancer drive gear Plate Key Plate washer Plate j Balancer gear Key ...

Page 118: ...holder Rotor holder PI N YS 01880 PI N 90890 01701 Do not allow the rotor holder to touch the projections on the rotor 4 Remove Push lever CD Spring Plain washer NOTE _________________________ Loosen the screw to remove the push lever OIL PUMP AND SHIFT LEVER NOTE __________________________ With t he engine mounted the oil pump and shift lever can be maintained by removing the following parts Foot...

Page 119: ...rclip CD from drive axle Collar Circlip 3 Remove Circlip CD Shift lever Spring Plain washer 4 Remove Stopper lever CD Collar Spring A C MAGNETO AND CAM CHAIN NOTE __________________________ With the engine mounted the A C magneto can be maintained by removing the following parts Seat Side cover left Crankcase cover left ...

Page 120: ..._____________ Hold the rotor to loosen the nut rotor by the rotor holder J Rotor holder PIN YS 01880 PIN 90890 01701 Do not allow the special tool to touch the projections on the rotor NOTE __________________________ Remove the rotor by the rotor puller Rotor puller PI N YU 33270 PI N 90890 01362 2 Remove Chain guide Q Cam chain ...

Page 121: ...890 01135 NOTE __________________________ Fully tighten the tool holding bolts but make sure the tool body is parallel with the case If necessary one screw may be backed out slightly to level tool body CAs pressure is applied alternately tap on the front engine mounting boss transmission shahs and shift cam Then remove the crankcase NOTE __________________________ If the crankcase will not come of...

Page 122: ...t mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force SHIFTER AND TRANSMISSION 1 Remove Guide bar CD Shift cam Shift fork j j 3 Shift fork j j 2 Shift fork j j 1 2 Remove Transmission assembly CD ...

Page 123: ...rating tool Crankcase separating tool PI N YU 01135 A PI N 90890 01135 Fully tighten the tool holding bolts but make sure the tool body is parallel with the case If necessary one screw may be backed out slightly to level tool body OIL STRAINER NOTE _________________________ It is recommended that the oil strainer be replaced whenever the engine is disassembled 1 Remove Oil strainer CD eOil passage...

Page 124: ...wing parts Seat Side covers Air scoops Cover fuel tank Fuel tank Cylinder head cover 1 Remove Plug CD 2 Remove Bolt CD rocker arm shaft 3 Remove Rocker arm shaft Rocker arm NOTE __________________________ Remove the rocker arm shaft by the slide ham mer bolt CD and weight Slide hammer set PIN YU 01083 A Slide hammer bolt PIN 90890 01083 Weight PI N 90890 01084 ...

Page 125: ...ead cover Cylinder head 1 Check Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to the INSPECTION AND REPAIR VALVE SEAT section NOTE _________________________ Before removing the internal parts valve valve spring spring seat etc ofthe cylinder head the valve sealing should be checked Checking steps Supply a clean solvent CD into the intake and exhau...

Page 126: ...Valve Oil seal J NOTE __________________________ Identify each part position very carefully so that it can be reinstalled in its original place NOTE _________________________ Compress the valve spring to remove the valve cotter by the valve spring compressor Valve spring compressor PI N YM 04019 PI N 90890 04019 ...

Page 127: ...k plug threads Valve seat 2 Inspect Cylinder head Scratches Damage Replace 3 Measure Warpage Out of specification Resurface Cylinder head warpage Less than 0 03 mm 0 0012 in 4 Resurface Cylinder head Resurfacement steps Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE _________________________ Rotate the head several times to ...

Page 128: ...____ Heat the cylinder head in an oven to 1aao c 212 F to ease guide removal and installation and to maintain correct interference fit Remove the valve guide using the valve guide remover CD Install the valve guide new using the valve guide installer and valve guide remover CD After installing the valve guide bore the valve guide using the valve guide reamer to obtain proper stem to guide clearanc...

Page 129: ... limit 0 7 mm 0 028 in 5 Check Valve stem end Mushroom shape or diameter larger than rest of stem Replace Runout Out of specification Replace Stem runout limit 0 01 mm 0 0004 in NOTE Always replace the guide if the valve is replaced Always replace the oil seal if the valve is removed VALVE SEAT 1 Clean the valve face and valve seat to remove carbon deposits 2 Inspect Valve seat Pitting Wear Reface...

Page 130: ...ss the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width Wherever the valve seat and valve face made contact bluing will have been removed If the valve seat width is too wide too nar row or seat has not centered the valve seat must be refaced 4 Reface Valve seat Use a 30 45 and 60 valve seat cutter CD Valve seat cutter Pi N YM 91043 When twi...

Page 131: ...ve seat is in the middle of the valve face but too narrow Valve seat cutter set Desired result To achieve a uni Use 45 cutter form valve seat width of 1 0 mm O 039 in la Valve seat is too narrow and right up near valve margin Valve seat cutter set Desired result 30 cutter first To center the seat and to achieve its Use width of 1 0 mm 45 cutter 0 039 in Q Valve seat is too narrow and is located do...

Page 132: ...e Applya molybdenum disulfide oil to the valve stem 1 nstall the valve into the cylinder head Turn the valve until the valve face and valve seat are evenly polished then clean off all compound NOTE __________________________ To obtain the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and re...

Page 133: ...eat width again If the valve seat width is out of specification reface and lap the valve seat VALVE SPRING 1 Measure Valve spring free length Out of specification Replace I Valve spring free length Inner spring Outer spring 40 1 mm 1 58 in 43 8 mm 1 72 in 2 Measure Valve spring installed force Out of specification Replace Installed length Valve spring installed force Inner spring Outer spring 22 7...

Page 134: ... 1 Inspect Cam lobes 0 075 in Pitting Scratches Blue discoloration Replace 2 Measure Cam lobes Out of specification Replace Intake 36 47 36 57 mm 30 06 30 16 mm 1 436 1 440 in 1 183 1 187 in Exhaust 36 62 36 72 mm 30 11 30 21 mm 1 442 1 446 in 1 185 1 189 in ROCKER ARM AND ROCKER ARM SHAFT 1 Inspect Rocker arm shaft Blue discoloration Grooves Replace then inspect lubrication system ...

Page 135: ...Arm to shaft clearance Arm to shaft clearance Rocker arm inside diameter Rocker arm shaft outside diameter Out of specification Replace as a set Arm to shaft clearance 0 009 0 042 mm 0 0003 0 0020 in CAM CHAIN AND CAM SPROCKET 1 Inspect Cam chain Stiff Cracks Replace cam chain and cam sprocket as a set 2 Inspect Cam sprocket Wear Oamage Replace cam sprocket and cam chain as a set CD 114 tooth Corr...

Page 136: ...Measurement steps IFirst steps I Measure the cylinder bore C with a cylinder bore gauge 304 011 CD 50 mm 1 97 in from the cylinder top 4 30 NOTE _________________________ Measure the cylinder bore C in parallel to and at right angles to the crankshaft Then find the average of the measurements Standard Cylinder 94 97 95 02 mm bore C 3 739 3 741 in C X Y 2 Wesr limit 95 1 mm 3 744 in If out of the s...

Page 137: ...0 in Oversize 4 96 0 mm 3 780 in 81f out of the specification replace the piston and piston rings as a set I 3rd steps I Find the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 045 0 065 mm 0 002 0 003 in Limit 0 1 mm 0 004 in If out of the specification rebore or replace the cylinder and repla...

Page 138: ...ring in cylinder NOTE __________________________ Insert a ring into cylinder and push it approxi mately 20 mm 0 8 in into cylinder Push ring with piston crown so that ring will be at a right angle to cylinder bore 20 mm 0 8 in 3 Measure Ring end gap Out of specification Replace NOTE __________________________ You cannot measure end gap on expander spacer of oil control ring If oil control ring rai...

Page 139: ...1 in 3 Measure to Piston pin to piston clearance Out of specification Replace piston Piston pin to piston clearance Bore size piston pin Outside diameter piston pin Piston pin to piston clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 07 mm 0 003 in CLUTCH 1 Inspect Clutch housing dogs Cracks Pitting edges Moderate Deburr Severe Replace clutch housing NOTE _________________________ Pitting on fri...

Page 140: ...l cause erratic operation 4 Measure Friction plate thickness Out of specification Replace as a set Thickness Wear limit Type A 2 94 3 06 mm 2 8mm 2 pes 0 116 O 120in 0 11 in Type 8 2 72 2 88 mm 2 6mrn 6 pes 0 107 O 113in 0 10 in 5 Measure Clutch plate warpage Out of specification Replace as a set Clutch plate warpage limit 0 2 mm 0 008 in 6 Measure Push rod runout Roll the push rod on a V block Ou...

Page 141: ...r rotor V Side clearance between outer rotor and pump housing Ouf of specifications Replace oil pump Oil pump clearance Tip clearance Side clearance 2 Inspect 0 12 mm 0 005 in 0 03 0 08 mm 0 001 0 003 in Oil pump drive gear CD Oil pump driven gear Wear Cracks Damage Replace PRIMARY DRIVE 1 Inspect Primary drive gear teeth CD Primary driven gear teeth Wear Damage Replace both gears Excessive noises...

Page 142: ...oove CD Shift cam segment Wear Damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork and or guide bar 4 Inspect Guide bar Roll the guide bar on a flat surface Bends Replace AWARNING Do not attempt to straighten a bent guide bar 5 Measure Transmission shaft runout Use centering device and dial gauge Out of specification Replace bent shaft Maximum runout 0 08 mm 0 003 in ...

Page 143: ...place Transmission gear reassembling points Press the 2nd wheel gear in the drive axle CD as shown 60 0 mm 2 36 in Press the 2nd pinion gear and 5th pinion gear in the main axle 90 5 mm 3 56 in 8 Inspect Circlip Damage Looseness Bends 4 Replace SHIFT SHAFT AND STOPPER LEVER 1 Inspect Shift shaft Bends Wear Damage 4 Replace 2 Inspect Stopper lever CD Roller turns roughly 4 Replace Bends Damage 4 Re...

Page 144: ...the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replacf It When turning the starter wheel gear r Junter clockwise ill the starter wheel W dr should turn freely If not the starter clutch is fal Y Replace it 2 Inspect Starter idle gear 1 teeth CD Starter idle gear 2 teeth Starter wheel gear teeth Burrs Chips Roughness Wear Replace 3 Inspect Starter wheel g...

Page 145: ... Replace big end bear ing crank pin and or connecting rod Small end free play 0 8 mm 0 031 in Side clearance Out of specification Replace connecting rod Big end side clearance 0 35 0 65 mm O 014 0 026 in Crankshaft reassembling point The crankshaft CD and the crank pin oil passages must be properly interconnected with a tolerance of less than 1 mm 0 04 in BALANCER DRIVE GEAR AND BALANCER GEAR 1 In...

Page 146: ... Check Match marks CD If they are not aligned Align match marks as shown CRANKCASE 1 Inspect Crank halves Bearing seat Damage Replace BEARING AND OIL SEAL 1 Inspect Bearing Roughness Pitting Damage Replace Oil seal lip Damage Wear Replace ...

Page 147: ...pring 2 5 or 1 9 mm 0 075 in 1 10 Nm 11 0 m kg 7 2 7 14 Nm 1 4 m kg 10 ft lb 6 STEM RUNOUT LIMIT 0 01 mm 0 0004 in VALVE SEAT WIDTH 1 0 1 2 mm 10 04 0 05 in 9 Outer spring 10 Valve intake 11 Valve retainer 1 Rocker arm shah exhaust 13 Rocker arm II 4 14 Rocker arm II 3 15 Rocker arm shah exhaust 16 Valve exhaust VALVE CLEARANCE COLD A Intake 0 05 0 1 0 mm 0 002 0 004 in Exhaust 0 12 0 17 mm 0 005 ...

Page 148: ...Install Oil seal CD Valve Valve retainer Inner spring Outer spring Valve retainer NOTE __________________________ Install the inner and outer springs with wider gapped coils facing upwards as shown J Larger pitch Smaller pitch 4 Install Valve cotter CD NOTE __________________________ Compress the valve spring to install the valve cotter by the valve spring compressor Valve spring compressor PIN YM...

Page 149: ... ROCKER ARM 1 Lubricate eEngine oil to the rocker arm shaft 2 Install Rocker arm Rocker arm shaft Bolt CD rocker arm shaft 10 Nm 1 0 mokg 7 2 fto b NOTE _________________________ Numeral is stamped on the rocker arm CD 1 2 3 4 3 Install Plug CD ...

Page 150: ...ank left 3 Connecting rod 4 Bearing Bearing Bearing J Balancer Bearing CRANK WIDTH A 74 95 75 00 mm 2 950 2 953 in RUNOUT LIMIT B 0 03 mm 0 0012 in C SMALL END FREE PLAY 0 8 mm 0 031 in BIG END SIDE CLEARANCE o 0 35 0 65 mm 0 013 0 026 in B6307SH2 C4 120 Nm 12 0 mokg 85 ftolb 4 44 ...

Page 151: ...IN YM 91044 PIN 90890 04081 Spacer PIN 90890 01016 NOTE __________________________ Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the in stalling tool until the crankshaft bottoms against the bearing To protect the crankshaft against scratches or to facilitate the operation of the instal lation Apply the grease to the oi...

Page 152: ...el gear Drive axle 5th wheel gear j 3rd wheel gear 4th wheel gear 1st wheel gear B6305NRX1C3 16 Bearing Bearing 2nd pinion gear 5th pinion gear 3rd pinion gear 4th pinion gear Main axle Bearing MAIN AXLE RUNOUT LIMIT 0 08 mm 0 003 in IclUSE NEW ONE I DRIVE AXLE RUNOUT LIMIT 0 08 mm 0 003 in 14 4 46 ...

Page 153: ...DJUSTMENT IENGI I SHIFTER CD Stopper lever Guide bar Shift fork 3 Shift fork 1 m Shift cam 6 Guide bar 7 Shift fork 2 1 m Shift shaft 1 Shift shaft 2 Oil seal j Shift lever 11 1 m SD12 22 6 110 Nm 1 0 m okg 7 2 ftolb I 4 47 ...

Page 154: ...hift cam Guide bar NOTE _________________________ Each shift fork is identified by a number cast on its side All the numbers should face the left side 3 Install Shift shaft 1 CD Shift shaft 2 NOTE _________________________ Align the punch mark on the change shaft with the punch mark on the shift shaft 4 Check Transmission operation Unsmooth operation Repair ...

Page 155: ...IENGI I ENGINE ASSEMBLY AND ADJUSTMENT OIL STRAINER AND OIL PUMP Oil strainer 2 Oil pump 3 Oil pump gear OIL PUMP TIP CLEARANCE A 0 12 mm 0 005 in SIDE CLEARANCE 0 03 0 08 mm 0 001 0 003 in 4 49 ...

Page 156: ...k plate Crankcase left Crankcase ventilation hose Dowel pin Dowel pin Dowel pin Stopper plate Collar A TIGHTENING SEQUENCE 7 Nm 0 7 m kg 5 1 ft lb 10Nm 1 0m kg 7 2ft lb 20 Nm 2 0 m kg 14 ft lb t t I SEALANT QUICK B GASKET B YAMAHA BOND NO 1215 B 4 50 ENG tit I I ...

Page 157: ...Sealant quick gasket PIN ACC 11 001 01 Yamaha Bond No 1215 PIN 90890 85505 2 Install Dowel pin 3 Fit the left crankcase onto the right case Tap lightly on the case with a soft hammer NOTE _________________________ Turn the shift cam to the position shown in the figure so that it dqes not contact the crankcase when installing the crankcase Before installing and torquing the crankcase holding screws...

Page 158: ... ft lb 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair SHIFT LEVER AND OIL PUMP 1 Install Spring CD Collar Stopper lever Bolt stopper lever 10 Nm 1 0 mokg 7 2 ft lb NOTE _________________________ Set the spring and stopper lever at proper po sition 2 Install Plain washer CD Spring Shift lever Circlip...

Page 159: ...aft 3 Install Circlip CD to drive axle Collar Circlip 4 Apply 4 stroke engine oil to the oil passages in the crankcase Apply a liberal amount of 4 stroke engine oil to the oil pump passages in the crankcase or the engine may be damaged 5 Apply 4 stroke engine oil to the oil passages in the oil pump 6 Install O ring CD Oil pump Oil pump gear Circlip Bolt oil pump 10 Nm 1 0 m kg 7 2 ft lb ...

Page 160: ...ENGINE ASSEMBLY AND ADJUSTMENT ENG CAM CHAIN 1 Install Cam chain CD Chain guide 4 54 ...

Page 161: ...n Piston pin clip PISTON SIZE A 94 915 94 965 mm 3 737 3 739 in D USE NEW ONE 4 55 PISTON RING END GAP Top O 30 O 45mm O 012 O 018in B 2nd O 30 O 45mm O 012 O 018in Oil O 20 O 70mm O 008 O 028in PISTON RING SIDE CLEARANCE C Top 0 04 0 08 mm 0 002 0 003in 2nd 0 03 0 07 mm 0 001 0 003in Oil 0 02 O 06 mm O 008 0 002in CD 5 6 ...

Page 162: ...asket Dowel pin Dowel pin A TIGHTENING SEQUENCE 42 Nm 4 2 m kg 30 ft lb 22 Nm 2 2 m kg 16 ft lb I 3 4 56 BORE SIZE 94 97 95 02mm 3 739 3 741 in B LIMIT 95 1 mm 3 744 in PISTON TO CYLINDER CLEARANCE C 0 045 0 065 mm 0 002 0 003 in LIMIT 0 1 mm 0 004 in 129 Nm 2 9 m kg 21 ft lb 1 ...

Page 163: ...ER HEAD Cylinder head cover Tappet cover intake O ring Tappet cover exhaust O ring Blind cap Cylinder head Valve guide intake valve 9 Valve guide exhaust valve 10 Spark plug 11 Dowel pin 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 4 57 I I I ...

Page 164: ...CAM CHAIN CD Camshaft l Cam sprocket Chain guide Cam chain Chain guide Gasket J Chain tensioner SHAFT TO CAP CLEARANCE A 0 020 0 054 mm 0 0008 0 0021 in CAMSHAFT RUNOUT LIMIT 0 03 mm 0 0012 in 3 J 4 58 r 120 Nm 2 0 m kg 14 h lb 1 20 Nm 2 0 m kg 14 ft lb ...

Page 165: ...____ The arrow on the piston must point to the front of the engine Before installing the piston pin clip cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase AWARNING Always use a new piston pin clip 3 Install Dowel pin CD O ring 4 Install Gasket CD cylinder NOTE ___________________________ Install the gasket cylinder as shown...

Page 166: ...efore installing the cylinder apply a liberal coat ing of 4 stroke engine oil to the piston rings CD Top ring bl Oil ring Lower rail Oil ring Upper rail 2nd ring 6 Install Cylinder CD NOTE ______________ Install the cylinder with one hand while com pressing the piston rings with the other hand Tie the cam chain with a piece of mechanics wire and feed it through the chain opening Bolts 10 Nm 1 0 m ...

Page 167: ...lowest num bered one f Bolt CD and 29 Nm 2 9 m kg 21 ft lb Nut and 22 Nm 2 2 m kg 16 ft lb Bolt j 10 Nm 1 0 m kg 7 2 ft lb 9 Install Chain guide Camshaft Cam sprocket Installing steps Install the camshaft onto the cylinder head as shown compression stroke Rotate the crankshaft counterclockwise direction until the crankcase pointer CD and a dot on the cam chain drive sprocket are aligned ...

Page 168: ...hile pushing the cam chain damper be sure cam sprocket timing marks align with the cylinder head upper surface elf marks are aligned tighten the cam sprocket bolts Bolt cam sprocket 20 Nm 2 0 mokg 14 ftolb elf marks do not align change the meshing piston of sprocket and cam chain 10 Apply eYamaha bond No 1215 CD to the mating surfaces Sealant quick gasket PI N ACC 11 001 01 Yamaha Bond No 1215 PI ...

Page 169: ...e tension rod Install the tensioner with a new gasket into the cylinder Bolt tensioner body 10 Nm 1 0 mokg 7 2 ftolb AWARNING Always use a new gasket Install the spring washer and tensioner cap bolt Tensioner cap bolt 20 Nm 2 0 m okg 14 ftolb 14 Adjust Valve clearance Valve clearance cold Intake O 05 O 1 0 mm O 002 O 004in Exhaust 0 12 0 17 mm 0 005 0 007 in Refer to the VALVE CLEARANCE AD JUSTMEN...

Page 170: ...CD exhaust Tappet cover intake Spark plug Tappet cover exhaust 12 Nm 1 2 m kg 8 7 ft lb Bolt tappet cover intake 10 Nm 1 0 m kg 7 2 ft Ib Spark plug 18 Nm 1 8 m kg 13 ft Ib NOTE _________________________ The intake tappet cover should be installed with the arrow mark upward ...

Page 171: ...ckup coil 3 Stator coil PICKUP COIL RESISTANCE A 184 276Q at 20 C 68 F Green White Blue Yellow 17 Nm 0 7 m kg 5 1 ft lb 1 120Nm 12mokg 85ftolb 17 Nm 0 7 m kg 5 1 ft lb 1 a B 4 65 3 30 Nm 3 0 mokg 22 ftolb STATOR COil RESISTANCE 0 52 0 78 Q at 20 C 68 F White White ...

Page 172: ... the woodruff key is properly seated in the keyway of the crankshaft Apply a light coating of lithium soap base grease to the tapered portion of the crankshaft end 2 Tighten Nut rotor Nut rotor 120 Nm 12 0 mokg 85 ftold NOTE ________ Hold the rotor to tighten the nut rotor by the rotor holder j Rotor holder PIN YS 01880 PIN 90890 01701 CAU1fPN Do not allow the rotor holder to touch the projections...

Page 173: ...1 1 BALANCER GEAR AND PRIMARY DRIVE GEAR Key Balancer gear Plate Lock washer Nut Plate washer Key A USE NEW ONE I60 Nm 6 0 mokg 43 ft lb I 5 10 A USE NEW ONE Plate Balancer drive gear Plate Primary drive gear 120 Nm 12 0 mokg 85 ft lb 4 67 ...

Page 174: ...pes 0 116 0 120 in B 2 72 2 88 mm 6pes 0 107 0 113 in Friction plate type B Clutch boss Thrust washer jJ Clutch housing Push rod Push lever J Primary drive gear Wear limit 2 8 mm 0 110 in 2 6 mm 0 102 in 8 Nm 0 8 m kg 5 8 ft lb 120 Nm 12 0 m kg 85 ft lb 4 68 CLUTCH SPRING MINIMUM B FREE LENGTH 32 6 mm 1 283 in CLUTCH PLATE C WARPAGE LIMIT 0 2 mm 0 008 in PUSH ROD RUNOUT LIMIT 0 2 mm 0 008 in ...

Page 175: ...IL FILTER AND OIL DELIVERY LINE CD Oil filter Oil filter cover Oil hose Oil hose Oil delivery pipe Oil drain bolt 10 Nm 1 0 m kg 7 2 ft lb 15 Nm 0 5 m kg 3 6 ft lb I 10 Nm 1 0 m kg 7 2 ft lb r 18Nm 1 8mo kg 13ft lb 10 Nm 1 0 m kg 7 2 ft lb 4 69 ...

Page 176: ...kg 43 ft lb Nut primary drive gear 120 Nm 12 0 m kg 85 ft lb NOTE __________________________ When installing the drive gear align the punched mark on the drive gear with the punched mark on the balancer gear AWARNING Always use a new lock washer NOTE __________________________ Hold the rotor A C magneto to tighten the nut and by the rotor holder Rotor holder PI N YS 01880 PI N 90890 01701 Do not a...

Page 177: ...e B j Clutch plate Friction plate type A Wave plate Ball jJ Pressure plate Clutch spring Bolt pressure plate Nut clutch boss 90 Nm 9 0 m kg 65 ft lb Bolt pressure plate 8 Nm 0 8 m kg 5 8 ft lb NOTE _________________________ Hold the clutch boss to tighten the nut clutch boss by the universal clutch holder Universal clutch holder PIN YM 91042 PIN 90890 04086 Bend the lock washer tab along the nut f...

Page 178: ...e placed on the inside of the second friction plate Friction Plate Type A Type 8 Quantity 2 pes 6 pes Inside 116 mm 113 mm Diameter 0 14 67 in 14 45 in NOTE _________________________ Align the punched mark on the clutch boss with the arrow mark on the clutch pressure plate 5 Adjust Clutch mechanism free play Refer to the CLUTCH ADJUSTMENT section in the CHAPTER 3 6 Install Dowel pin Gasket Crankca...

Page 179: ...ENGINE ASSEMBLY AND ADJUSTMENT 1 ENG 1 1 STARTER GEAR CD Starter gear Starter idle gear 1 Starter idle gear 2 Starter wheel gear Starter one way 10 Nm 1 0 m kg 7 2 ft lb 120 Nm 12 0 mokg 85 ftolb 4 73 ...

Page 180: ...r coil CD Pickup coil Lead holder Screws stator and pickup coil 7 Nm 0 7 m kg 5 1 ft lb Use LOCTITE Screw lead holder 7 Nm 0 7 m kg 5 1 ft lb 2 Install Shaft CD Searing Starter idle gear 2 3 Install Dowel pin CD Gasket O ring Crankcase cover left Plugs Bolt crankcase cover 10 Nm 1 0 m kg 7 2 ft lb AWARNING Always use a new gasket ...

Page 181: ...starter idle gear Bolts starter idle gear cover 10 Nm 1 0 mokg 7 2 ftolb REMOUNTING ENGINE When remounting the engine reverse the EN GINE REMOVAL procedure Note the following points AWARNING Securely support the motorcycle so there is no danger of it falling over 1 Install Engine Pivot shaft CD NOTE _________________________ Apply the grease to the pivot shaft ...

Page 182: ...ft 85 Nm 8 5 m kg 61 ft lb 2 Install Engine protector CD Bolt engine protector 10 Nm 1 0 m kg 7 2 ft lb 3 Connect Magneto lead 4 Install Spark plug lead CD 5 Install Drive sprocketCD Drive chain Nut drive sprocket 110 Nm 11 0 m kg 80 ft lb NOTE ___________________________ Bend the lock washer tab along the nut flats AWARNING Always use a new lock washer 4 76 ...

Page 183: ... Bolt footrest 45 Nm 4 5 m kg 32ft lb 7 Adjust Drive chain slack 30 40 mm 1 18 1 57 in Refer to the DRIVE CHAIN SLACK AD JUSTMENT section in the CHAPTER 3 8 Install Oil hose CD inlet Oil hose outlet Bolt oil hose 10Nm 1 0 kg 7 2 ft lb 9 Install Starter motor CD Bolts starter motor 10 Nm 1 0 m kg 7 2 ft lb 10 Install Bolt CD oil hose clamp Bolt oil hose clamp 10 Nm 1 0 m kg 7 2 ft lb ...

Page 184: ...e engine oil to the cam shaft upper side and into the oil filter room Apply a liberal amount of 4 stroke engine oil to the oil passage in the crankcase or the engine may be damaged Oil quantity Cam shaft 0 1 L 0 09 Imp qt 0 11 US qt Oil filter room 0 06 L 0 05 Imp qt 0 06 US qt 14 Install Tappet cover exhaust Air bleed screw oil filter cover Bolt tappet cover 10 Nm 1 0 m kg 7 2 ft lb Bolt air blee...

Page 185: ... Adjust Clutch cable f ree play Free play rA l 2 3 mm 0 08 0 12 in Refer to the CLUTCH ADJUSTMENT section in the CHAPTER 3 18 lnstall Carburetor Screw clamp 2 Nm 0 2 m kg 1 4 ftolb Refer to the CARBURETOR INSTALLA TION section in the CHAPTER 5 19 Adjust Throttle cable free play Free play rA l 3 5 mm 0 12 0 20 in Refer to the THROTTLE CABLE FREE PLAY ADJUSTMENT section in the CHAPTER 3 ...

Page 186: ...stall Fuel tank Never start the engine when the oil is drained 23 Apply Engine oil Oil quantity 3 3 L 2 9 Imp qt 3 5 US qt Refer to the ENGINE OIL REPLACE MENT section in the CHAPTER 3 24 Check Engine idle speed Engine idle speed 1 300 1 400 r min Refer to the IDLE SPEED ADJUSTMENT section in the CHAPTER 3 25 Install Cover fuel tank Air scoops Side covers Seat Bolt seat 10 Nm 1 0 m kg 7 2 ft lb ...

Page 187: ...ondary Main nozzle Secondary Piston valve Jet needle set Secondary 2 Nm 0 2 m kg 1 4 ft lb 9 Nm 0 9 mokg 6 5 ftolb 3 Nm 0 3 m kg 2 2 ft lb CARBURETOR ICARBI I CARBURETION SPECIFICATIONS Model XT600EA XT600EAC Carburetor I D mark 3UY1O 3UYOO Main jet M J Primary 130 Secondary 104 Pilot jet P J 48 Jet needle J N Primary 5D93 1 1 Secondary 5X7B 1 1 Pilot screw P S Preset Float heig ht F H 25 0 27 0 m...

Page 188: ...le Primary Valve seat Needle valve Main nozzle Primary Main jet Primary Jet needle Secondary J Main nozzle Secondary Main jet Secondary 5 2 CARBURETOR ICARBI I AJ Primary carburetor ill Secondary carburetor J Air Fuel J Mixture ...

Page 189: ...iaphragm Coasting enricher Starter plunger Throttle stop screw Pilot screw 1 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 2 Loosen Locknut Q 3 Remove Throttle cable 4 Loosen Screw clamp Q NOTE _________________________ Move carburetor joint bands to the rear ...

Page 190: ...lter case CD Air filter case from projection _ Carburetor joint from carburetor by mov ing air filter case to the rear 6 Remove Carburetor DISASSEMBLY 1 Remove Stay plate CD front Stay plate rear 2 Separate Primary carburetor Secondary carburetor ...

Page 191: ...loat pin Float NOTE _________________________ Remove the float pin in the arrow direction 2 Remove Needle valve Valve seat CD Main jet Main nozzle Pilot jet O ring 3 Remove Throttle stop screw CD Stqrter plunger 4 Remove Cover CD coasting enricher Spring Diaphragm 5 5 ...

Page 192: ...emove Top cover CD Gasket Screw connecting arm 6 Remove Throttle lever CD Collar Cable holder 7 Remove Throttle shaft CD Spring 8 Remove Connecting arm CD Jet needle Throttle valve Secondary carburetor 1 Remove Plug CD Main jet l ...

Page 193: ...______________ Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air 2 Inspect Valve seat CD Needle valve Wear Contamination Replace O ring Damage Replace NOTE ________________________ Always replace the needle valve and valve seat as a set 3 Inspect Starter plunger CD Wear Damage Replace Throttle stop screw Damage Replace ...

Page 194: ... eJet needle secondary Bends Wear Replace 6 Inspect eThrottle valve CD primary ePiston valve secondary WearI Damage Replace 7 Check eFree movement Stick Replace Insert the throttle valve and piston valve into the carburetor body and check for free movement IAl Primary carburetor ill Secondary carburetor 8 Inspect eFloat CD Damage Replace ...

Page 195: ...procedures Note the following points Before reassembling wash the all parts with a clean gasoline Secondary carburetor 1 Install Jet needle CD Piston valve NOTE _________________________ Match the tab on the diaphragm to the match ing recess in the secondary carburetor 2 Install Spring CD Top cover Screw top cover 2 Nm 0 2 m kg 1 4 ft lb 3 Install Main jet CD Plug I Main jet 2 Nm 0 2 m kg 1 4 ft l...

Page 196: ...the illustrated position 2 Install Throttle valve 3 Install Spring Throttle shaft NOTE __________________________ Set the spring as shown 4 Install Screw connecting arm NOTE __________________________ Turn the throttle shaft 112 turn clockwise to give preload to the spring and hold it Then install the screw connecting arm Screw connecting arm 2 Nm 0 2 m kg 1 4 ft lb ...

Page 197: ...throttle lever nut Screw cable holder CD 3 Nm 0 3 m kg 2 2 ft Ib 6 Install Top cover CD Screw top cover 2 Nm 0 2 m kg 1 4 ft lb 7 Install Diaphragm CD coasting enricher NOTE _________________________ Match the tab on the diaphragm to the match ing recess in the coasting enricher Spring Cover 8 Install Starter plunger CD Throttle stop screw Starter plunger 6 Nm 0 6 m kg 4 3 ft lb ...

Page 198: ... 27 0 mm 0 98 1 06 in Measurement and adjustment steps Hold the carburetor in an upside down po sition Measure the distance from the mating sur face of the float chamber gasket removed to the top of the float NOTE _________________________ The float arm should be resting on the needle valve but not compressing the needle valve If the float height is not within specification inspect the valve seat ...

Page 199: ... Stay plate rear Screw stay plate 3 Nm 0 3 m kg 2 2 ft lb 15 Adjust Secondary carburetor synchronization Adjustment steps Raise the primary throttle valve CD to a height of 7 0 mm 0 28 in as indicated Turn the synchronizing screw CD in or out so that secondary throttle valve is begun to open Make sure that the secondary valve is opened horizontally when the primary car buretor valve is fully opene...

Page 200: ...2 Install e Carburetor joint to carburetor by moving air filter case forward eAir filter case on to projection CD e Bolts air filter case Bolt air filter case 10Nm 1 0 mokg 7 2 ft lb Screw clamp 2Nm 0 2 mokg 1 4ft lb 3 Install eThrottle cable CD 4 Adjust eThrottle cable free play Refer to the THROTTLE CABLE FREE PLAY ADJUSTMENT section in the CHAPTER 3 Throttle cable free play 3 5 mm 0 12 0 20 in ...

Page 201: ...Level Gauge CD to the float chamber nozzle Fuel level gauge PI N YM 01312 A PI N 90890 01312 4 Loosen the drain screw and warm up the engine for several minutes 5 Measure Fuel level Out of specification Adjust Fuel level 6 0 8 0 mm 0 24 0 31 in Below the carburetor body edge 6 Adjust Fuel level Adjustment steps Remove the carburetor Inspect the valve seat and needle valve If either is worn replace...

Page 202: ...r Oil seal Bearing Collar Front wheel Bearing Gear unit speedometer 10 Damper rubber 158 Nm 5 8 mokg 42 ftolb I 19 Nm 0 9 mokg 6 5 ftolb I 6 1 7 A TIRE SIZE 90 90 21 54S B RIM SIZE 1 85 x 21 RIM RUNOUT LIMIT VERTICAL C 2 0 mm 0 08 in LATERAL 2 0 mm 0 08 in _ 4 9 ...

Page 203: ...heel by placing a suitable stand under the engine 3 Remove Speedometer cable CD Disc cover 4 Loosen Nut CD axle holder 5 Remove Wheel axle Front wheel NOTE _________________________ Do not depress the brake lever when the wheel is off the motorcycle otherwise the brake pads will be forced shut 6 Remove Collar CD Gear unit speedometer AJ Right side ffi Left side 7 Remove Circlip CD Washer Meter clu...

Page 204: ...CTION section in the CHAPTER 3 4 Check Spoke s Bend Damage Replace Loose spoke s Retighten Turn the wheel and tap the spokes with a screw driver NOTE _________________________ A tight spoke will emit a clear ringing tone a 340005 loose spoke will sound flat J HJ 002 6 3 5 Tighten Loose spokes Spoke 2 Nm 0 2 m kg 1 4 ft lb NOTE _________________________ Check the wheel runout after tightening spoke...

Page 205: ...e damper rubber should be installed with the 3TB mark CD outside_ 8 Inspect Wheel bearings CD Bearings allow play in the wheel hub or wheel turns roughly Replace Oil seals Wear Damage Replace Oil seal and wheel bearing replacement steps eClean the outside of the wheel hub e Remove the oil seals CD use a flat head screw driver NOTE __________________________ Place a rag on the outer edge to prevent...

Page 206: ... rim wheel balancer should be adjusted Adjust the wheel balance with brake disk installed 1 Remove Balancing weight 2 Set the wheelan a suitable stand 3 Find Heavy spot Procedure a Spin the wheel and wait for it to rest b Put an Xl mark on the wheel bottom spot c Turn the wheel so that the Xl mark is 90 up d Let the wheel fall and wait for it to rest Put an X2 mark on the wheel bottom spot e Repea...

Page 207: ...90 up Check that t he heavy spot is at rest there If not try another weight until the wheel is balanced 5 Check Wheel balance Checking steps Turn the wheel so that it comes to each point as shown Check that the wheel is at rest at each point If not readjust the wheel balance INSTALLATION Reverse the Removal procedure Note the following points 1 Lubricate Wheel axle CD Bearings Oil seal lip Drive D...

Page 208: ...ith the locating slot on the gear unit assembly 4 Tighten Wheel axle CD Nut axle holder Wheel axle 58 Nm 5 8 mokg 42 ft lb Nut axle holder 9 Nm 0 9 mokg 6 5 ftolb NOTE __________________________ The axle holder should be installed with the arrow mark facing upward First tighten the nuts on the upper side of the axle holder and then tighten the nuts on the lower side Space Make sure that the speedo...

Page 209: ... EBE L R EA R W H E E L lcHASI 1 2 USE NEW ONE D DRIVE CHAIN SLACK 30 40 mm 1 18 1 57 i 6 8 A TIRE SIZE 120 90 17 64S B RIM SIZE MT 2 50 X 17 RIM RUNOUT LIMIT C VERTICAL 2 0 mm 0 08 in LATERAL 2 0 mm 0 08 in B6203RS ...

Page 210: ...aliper protector 4 Remove Bolt CD brake caliper Bolt caliper bracket NOTE _________________________ Do not depress the brake pedal when the wheel is off the motorcycle as tlie brake pads will be forced shut 5 Remove Cotter pin CD Bolt Axle nut Bolt swingarm end 6 Remove Chain pullers CD Wheel axle Caliper bracket Rear wheel NOTE __________________________ Before removing the rear wheel push the wh...

Page 211: ...NSPE CTION section 2 Inspect Tire Wheel Damper rubber Refer to the FRONT WHEEL INSPE CTION section 3 Inspect Spoke s Refer to the FRONT WHEEL INSPE CTION section 4 Measure Wheel runout Refer to the FRONT WHEEL INSPE CTION section 5 Check Oil seals Wheel bearings Refer to the FRONT WHEEL INSPE CTION section 6 Check Wheel balance Refer to the FRONT WHEEL STATIC WHEEL BALANCE ADJUSTMENT sec tion ...

Page 212: ...e on the left side and the R mark on the right side 3 Adjust Drive chain slack Drive chain slack 30 40 mm 1 18 1 57 in Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 4 Tighten Axle nut Bolt swingarm end Bolt caliper bracket Bolt brake caliper Axle nut 90 Nm 9 0 mokg 65 ft lb Bolt swingarm end 3 Nm 0 3 mokg 2 2 ftolb Bolt caliper bracket 45 Nm 4 5 mokg 32 ftolb Bolt brake calipe...

Page 213: ...t after torque tighten ing If the axle nut groove is not aligned with the wheel shaft cotter pin hole align groove to hole by tightening up on the axle nut 5 Install Cotter pin NOTE _________________________ Bend the ends of the cotter pin as illustration AWARNING Always use a new cotter pin ...

Page 214: ...RAKE FLUID TYPE A If DOT 4 is not available DOT 3 can be used B BRAKE PAD WEAR LIMIT 1 0 mm 0 04 in C BRAKE DISC WEAR LIMIT 4 0 mm 0 16 in I D 1 USE NEW ONE I I Piston 9 Piston seal 10 Dust seal II Brake pads I Brake disc Damper rubber 6 Nm 0 6 m kg 4 3 ft lb 26 Nm 2 6 m o kg 19 ft lb 118 Nm 1 8 mokg 13 fto bll 135 Nm 3 5 m kg 25 tt lb I 101 USE NEW ONE 5 13 ...

Page 215: ...KE PAD WEAR LIMIT 0 8 mm 0 03 in C BRAKE DISC WEAR LIMIT 4 5 mm 0 18 in FRONT AND REAR BRAKE ICHASI I Brake caliper Piston Piston seal Dust boot Ring dust boot 15 Shim 1 Brake pads 1 Pad springs 1 Mounting support 19 Brake disc 16 Nm 0 6 m kg 4 3 ft lb I 123 Nm 2 3 mokg 17 ftolb I r 13 5 N m 3 5 m k g 2 5 ft I b 1 18 20 Nm 2 0 m kg 14 ft lb f 19 9 6 14 ...

Page 216: ...ow brake fluid to contact painted sur faces or plastic parts otherwise damage may occur Disconnect any hydraulic connection other wise the entire system must be disassem bly drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE _______________________ It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads AWARNING Secur...

Page 217: ...d Replace the pads as a set if either is found to be worn to the wear limit Wear limit 1 0 mm 0 04 in 4 Lubricate Guide pins CD r d lithium soap base grease 5 Install Caliper bracket CD to caliper body NOTE _________________________ Place the rubber boot securely in the groove of guide pin when installing the caliper body 6 Install Pad spring CD new Brake pad assembly new ...

Page 218: ... new and brake pad assembly new NOTE _________________________ The longer tangs of the pad spring must point in the outside direction 7 Install Retaining bolts 8 Install Bolts caliper body CD 9 Tighten Bolts caliper body CD Retaining bolts Bolt caliper body 35 Nm 3 5 mokg 25 ftolb Retaining bolt 18 Nm 1 8 mokg 13 ftolb 10 Inspect Brake fluid level Refer to the BRAKE FLUID INSPECTION section in the...

Page 219: ...y clockwise 2 Remove Brake pads CD Shim Pad springs NOTE __________________________ Replace the spring if the pad replacement is required Replace the pads as a set if either is found to be worn to the wear limit Wear limit rAl 0 8 mm 0 03 in Replace the pad shim if the pad replacement is required 3 Lubricate Guide pin CD lithium soap base g as 4 Install Pad springs CD Shim rake pads Caliper body ...

Page 220: ...rew Caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the pad shim new to the piston side brake pad Install the pad springs new and brake pads new NOTE __________________________ Be sure to position the pad so that its round side is upward Install the caliper body NOTE ____________________________ Place the rubber boot j securely in the groove of guide pin when installing the caliper body 5 Inst...

Page 221: ...Refer to AIR BLEEDING section in the CHAPTER 3 CALIPER DISASSEMBLY NOTE __________________________ Before disassembling the front brake caliper or rear brake caliper drain the brake system of its brake fluid AWARNING Securely support the motorcycle there is no danger of falling over Front Brake 1 Loosen Union bolt CD NOTE ___________________________ Loosen slightly so that brake fluid does not lea...

Page 222: ...h the standing brake fluid 4 Remove Caliper bracket CD Piston Dust seal Piston seal Remove steps Blow compressed air into the tube joint open ing to force out the piston from the caliper body AWARNING Never try to pry out the piston Cover the piston with a rag Use care so that piston does not cause injury as it is expelled from the cylinder Rear Brake 1 Loosen Union bolt CD NOTE __________________...

Page 223: ... the caliper to catch the standing brake fluid 4 Remove Piston CD Ring dust boot Dust boot Piston seal NOTE __________________________ Remove the piston and then the ring dust boot and dust boot Removal steps Blow compressed air into the tube joint opening to force out the piston from the caliper body AWARNING Never try to pry out the piston Cover the piston with a rag Use care so that piston does...

Page 224: ...drain the brake system of the brake fluid AWARNING Securely support the motorcycle so there is no danger of it falling over 6 23 Front Brake 1 Remove Protecter right CD 2 Remove Brake lever CD Return spring brake lever Brake switch Mirror right 3 Loosen Union bolt CD NOTE __________________________ Loosen slightly so that brake fluid does not leak out ...

Page 225: ..._______ Place a container under the master cylinder to catch the standing brake fluid Rear Brake 1 Remove Seat Side cover right Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 2 Remove Cotter pin CD Plain washer Pin 3 Loosen Union bolt NOTE ______________ Loosen slightly so that brake fluid does not leak out 4 Remove Bolts master cylinder 5 Remove Union bolt Copper washers J NOTE __...

Page 226: ...aphragm NOTE _________________________ Place the container under the reservoir tank to catch the standing brake fluid 9 Disconnect Reservoir tank hose J from reservoir tank INSPECTION AND REPAIR Recommended brake component replacement schedule Brake pads As required Piston seal Every two years dust seal Brake hoses Every four years Brake fluid Replace only when brakes are disassembled AWARNING All...

Page 227: ...st Damage Replace Rubber boots Cracks Wear Damage Replace Oil delivery passage caliper body Blowout with compressed air AWARNING Replace the piston seal and dust boot when ever a caliper is disassembled A Front rnJ Rear 3 Inspect Master cylinder CD Wear Scratches Replace master cylin der assembly Master cylinder body Cracks Damage Replace Oil delivery passage master cylinder body Blowout with comp...

Page 228: ...hragm rear Wear Damage Replace Reservoir tank Cracks Damage Replace AJ Front ill Rear 6 Inspect Brake hoses CD Reservoir hose Cracks Wear Damage Replace AJ Front ill Rear 7 Measure Brake pad thickness Out of specification Replace Pad wear limit Front 1 0 mm 0 04 in Rear 0 8 mm 0 03 in ...

Page 229: ...place Refer to the FRONT WHEEL INSPECTION section A Front ill Rear 9 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Maximum deflection 0 15 mm 0 006 in Brake disc thickness Out of specification Replace Minimum thickness Front 4 0 mm 0 16 in Rear 4 5 mm 0 18 in CD Dial gauge NOTE __________________________ Tighte...

Page 230: ...a caliper is disassembled Front Brake 1 Install Piston seals CD Dust seals Pistons V 1 tj __________ Always was new piston seal and dust seal 2 Install Caliper bracket CD to the caliper body Pad spring Brake pads Retaining bolts Refer to the BRAKE PAD REPLACE MENT section NOTE _____________ Place the rubber boot securely in the groove of guide pin when installing the caliper body 3 Tighten Bolts C...

Page 231: ...er washers 5 Fill Brake fluid Recommended Brake Fluid If DOT 4 is not available DOT 3 can be used CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately AWARNING Use only the d esignated quality brake flued otherwise the rubber seals may deteriorate causing laekage and poor brake performance Refill with the same type of brake fluid mixing fluids m...

Page 232: ...ER 3 8 Install Diaphragm CD Master cylinder cap Screws Screw master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib Rear Brake 1 Install Pistion seal CD Piston Rubber boot Ring dust boot NOTE _________________________ First assemble the piston seal then assemble the piston Stop when this is about half finished and attach the dust boot Then while moving the piston into position attach the rubber boot to the m...

Page 233: ...otector Retaining bolt 23 Nm 2 3 m kg 17 ft Ib NOTE _________________________ Place the rubber boot securely in the groove of guide pin when installing the caliper body 5 Install Copper washers CD Brake hose Union bolt Bolt brake hose clamp Union bolt 26 Nm 2 6 m kg 19 ft Ib CAUTION When installing the brake hose lightly touch the pipe portion of the brake hose with the projections Q on brake cali...

Page 234: ...luids may result in a harmful chem ical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 7 Air bleed Brake system Refer to the AIR BLEEDING section in the CHAPTER 3 8 Inspect Brake fluid level Fluid level is under LOWER level line CD Fill up Refer ...

Page 235: ...used Rear Brake DOT 4 Replace the master cylinder kit whenever a caliper is disassembled Front Brake 1 Install Master cylinder kit CD Circlip Dust boot 2 Install Master cylinder NOTE __________________________ Install the master cylinder holder with the UP mark facing upward Tighten first the upper bolt then the lower bolt Bolt master cylinder bracket 7 Nm 0 7 m kg 5 1 ft lb 3 Install Copper washe...

Page 236: ...id If DOT 4 is not available DOT 3 can be used CAUTION Brake fluid may erobe painted surfaces or plastic parts Always clean up spilled fluid immediately AWARNING Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill withe the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lea...

Page 237: ...r cap Screws Screw master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib Rear Brake 1 Install Reservoir tank CD temporarily 2 Connect Reservoir tank hose to reservoir tank 3 Install e Master cylinder kit CD Adjusting rod Circlip Dust boot 4 Install Copper washers Brake hose Union bolt j temporarily tighten When installing the brake hose lightly touch the pipe portion of the brake hose with the projections o...

Page 238: ...R 2 Always use new copper washers 5 Install Master cylinder Q Bolt master cylinder Bolt master cylinder 20 Nm 2 0 m kg 14 ft Ib 6 Tighten Union bolt Union bolt 26 Nm 2 6 m kg 19 ft lb 7 Connect Reservoir hose to master cylinder 8 Install Pin Plain washer Cotter pin j AWARNING Always use a new cotter pin 9 Fill Brake fluild Recommended brake fluid DOT 4 ...

Page 239: ...rmful chemi cal reaction and lead to poor performace Be careful that water does not enter the master cylinder whem refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 10 Air bleed Brake system Refer to the AIR BLEEDING section in the CHAPTER 3 11 Inspect Brake fluid level Fluid level is under LOWER level line CD Fill up Refer to the BRAKE FLUID INSP...

Page 240: ...ork tube Damper rod Oil lock pieces FORK OIL EACH CAPACITY A 538 em3 18 9 Imp OZ 18 1 US oz GRADE FORK OIL 10W OR EQUIVALENT FRONT FORK ICHASI I FORK SPRING B MINIMUM FREE LENGTH 468 4 mm 18 4 in 23 Nm 2 3 m kg 17 ft lb 30 Nm 3 0 mokg 22 ft lb IC IUSE NEW ONE I 6 39 ...

Page 241: ...place 2 Elevate the front wheel by placing a suitable stand under the engine 3 Remove Front wheel Refer to the FRONT WHEEL RE MOVAL section 4 Remove for left hand front fork Band CD speedometer cable Holder brake hose Bolt brake caliper 5 Loosen Pinch bolt CD handlebar crown Cap bolt Nut lower bracket AWARNING Support the fork before loosening the pinch bolt 6 Remove Front fork s ...

Page 242: ...ve Snap ring CD NOTE __________________________ Use a thin screwdriver and be careful not to scratch the inner fork tube 5 Remove Bolt CD damper rod Washer NOTE _________________________ Hold the damper rod to loosen the bolt damper rod by the T handle and holder T handle YM 01326 90890 01326 Holder 27 mm 1 06 in YM 01388 90890 01388 ...

Page 243: ...the outer tube by forcefully but carefully withdrawing the inner fork tube Ilili0AO tb lfri________ Excessive force will damage the oil seal and or the bushes Damaged oil seal and bushing must be replaced Avoid bottoming the inner tube in the outer tube during the above procedure as the oil lock piece will be damaged 8 Remove Dust seal CD Oil seal CV Washer Slide metal Oil lock pieces Slide bush ...

Page 244: ...fork tube as this may dangerously weaken the tube 2 Measure Fork spring free length Out of specification Replace Fork spring free length 478 0 mm 18 8 in Minimum free length 468 4 mm 18 4 in 3 Inspect Damper rod Q Wear Damage Replace Contamination Blowout all oil passages with compressed air Piston ring Wear Damage Replace 4 Inspect Rebound spring Q Wear Damage Replace ...

Page 245: ...k reassembly be sure to use fol lowing new parts Guide bush Oil seal Dust seal Make sure all components are clean before reassembly 1 Install Damper rod CD Allow the damper rod to slide slowly down the inner fork tube CV until it protrudes from the bottom being careful not to damage the inner fork tube 2 Install Oil lock piece CD to damper rod CV 3 Lubricate Inner fork tube outer surface Fork oil ...

Page 246: ...damper rod 62 Nm 6 2 m kg 45 ft Ib LOCTITE 5 Install Slide metal CD Use the fork seal driver weight and adapter Inner fork tube Outer fork tube Fork seal driver weight YM 33963 90890 01367 Adapter 41 mm 1 61 in YM 33968 90890 01381 6 Install Washer CD Oil seal Use the fork seal driver weight and adapter Fork seal driver weight YM 33963 90890 01367 Adapter 41 mm 1 61 in YM 33968 90890 01381 ...

Page 247: ...CV NOTE _________________________ Fit the snap ring CV correctly in the groove in the outer tube 8 Fill Front fork Each fork 538 cm3 18 9 Imp OZ 18 1 US oz Fork Oil 10W or equivalent After filling slowly pump the fork up and down to distribute oil Oil level 155 mm 6 10 in From the top of inner fork tube fully compressed without spring CD Inner fork tube CV Fork oil 9 Before installing the cap bolt...

Page 248: ... end in such a way that it is flush with the top of the handle crown 2 Tighten Nut Q lower bracket Cap bolt Pinch bolt handlebar crown Nut lower bracket 23 Nm 2 3 m kg 17 ft Ib Cap bolt 30 Nm 3 0 m kg 22 ft Ib Pinch bolt handlebar crown 23 Nm 2 3 m kg 17 ft Ib 3 Install Front wheel Wheel axle 58 Nm 5 8 m kg 42 ft Ib Nut axle holder 9 Nm 0 9 m kg 6 5 ft Ib Bolt brake caliper 35 Nm 3 5 m kg 25 ft Ib...

Page 249: ...peedometer cable Cable holder speedometer cable Headlight stay Ring nut 20 Nm 2 0 m kg 14 tt lb J4J j 6 1 I _ L 1 172 Nm 7 2 m kg 52 ft lb I 13 0 N m 3 0 m k g 22 ft I b I 6 IBlusENEwo i 7 f 9 1 12 3 N m 2 3 m k 9 17 ft I b I I 7 G o 7 N m 0 7 m kg S 1 f t I b 11 Nm 10 1 m 0 7 ft lbll 1 1 z 1 A TIGHTENING STEPS Tighten ring nut 38 Nm 3 8 m kg 27 tt lbl Loosen it one turn Retighten it 6 Nm 0 6 m kg...

Page 250: ...stand under the engine 3 Remove Front wheel Refer to the FRONT WHEEL REMOVAL section Front forks Refer to the FRONT FORK REMOVAL section 4 Remove Bolts CD front fender Front fender Washer 5 Remove Screw CD cowling Cowling Reflector NOTE _________________________ When removing the cowling unhook the snaps on the cowling from the grommets on the headlight stay 6 Remove Headlight lens unit CD 7 Disco...

Page 251: ...witch coupler Main switch coupler Brake switch coupler Clutch switch coupler 9 Remove Speedometer cable CD 10 Remove Headlight stay CD Meter assernbly 11 Remove Protecter right Brake lever Mirror right Sands CD Master cylinder assembly 12 Remove Handlebar switch right CD 13 Loosen Throttle holder assembly ...

Page 252: ...lutch cable 16 Remove eClutch cable 17 Remove eBands CD Handlebar switch left Clutch switch 18 Remove Handlebar CD eThrottle holder assembly 19 Remove Steering shaft bolt CD Handlebar crown Ring nut Bearing cover Bearing upper AWARNING When removing the ring nut support the lower bracket so that it may not fall down ...

Page 253: ... 1 Wash the bearings with a solvent 2 Inspect eBearing CD e Bearing race Pitting Damage Replace as a set Bearing race replacement steps Remove the bearing races using a long rod CD and hammer as shown Remove the bearing race on the steering stem using the floor chisel and the hammer as shown Install the new dust seal and races NOTE __________________________ Always replace bearings races and dust ...

Page 254: ...acement steps Remove the handlebar grip and lever holder Install the lever holder to a new handlebar Apply a light coat of an adhesive for rubber on the leh handlebar end Install the handlebar grip NOTE _________________________ Wipe off excess adhesive with a clean rag AWARNING Leave the handlebar intact until the adhesive becomes dry enough to make the grip and handlebar stuck securely INSTALLAT...

Page 255: ... wrench Ring nut wrench PI N YU 33975 PI N 90890 01403 NOTE __________________________ Set the torque wrench to the ring nut wrench so that they form a right angle Ring nut initial tightening 38 Nm 3 8 m kg 27 ft Ib Loosen the ring nut one turn Retighten the ring nut using the ring nut wrench AWARNING Avoid over tightening Ring nut final tightening 6 Nm 0 6 m kg 4 3 ft Ib 4 Install Handlebar crown...

Page 256: ...__________________ The upper handlebar holder should be installed with the punched mark CD forward A Forward 0 IlgN First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side 6 55 7 Install e Handleber sVvitch right CD NOTE ____________________________ When installing the handlebar switch right make sure its projection fits into the hole as shown ...

Page 257: ...n the lower bolt Bolts master cylinder bracket 7 Nm 0 7 m kg 5 1 ft olb 10 Install Meter assembly CD Headlight stay Bolt meter assembly 7 Nm 0 7 m kg 5 1 ft olb Bolt headlight stay 7 Nm 0 7 mokg 5 1 ftolb 11 Install Speed meter cable 12 Install Front fork Refer to the FRONT FORK INSTALLA TI 0 N section Nut lower bracket 23 Nm 2 3 m kg 17 ft Ib Pinch bolt handlebar crown 23 Nm 2 3 m kg 17 ft Ib 13 ...

Page 258: ...ion in the CHAPTER 2 15 Install Headlight lens unit Cowling Bolt headlight upper 16 Nm 1 6 mokg 12 ftolb Bolt headlight lower 7 Nm 0 7 mokg 5 1 ft lb Bolt cowling 7 Nm 0 7 mokg 5 1 ft lb 16 Install Front wheel Refer to the FRONT WHEEL INSTAL LATION section Wheel axle 58 Nm 5 8 mokg 42 ftolb Nut axle holder 9 Nm 0 9 mokg 6 5 ftolb 17 Adjust Clutch cable free play Refer to the CLUTCH ADJUSTMENT sect...

Page 259: ...NGARM ICHASIAI REAR SHOCK ABSORBER AND SWINGARM CD Rear shock absorber assembly Spring SPRING PRELOAD STANDARD FITTING LENGTH 243 5 mm 9 6 in A MINIMUM LENGTH 4 1 237 5 mm 9 4 in t MAXIMUM LENG H J 248 5 mm 9 8 m r 1 1 r n J 6 58 ...

Page 260: ...REAR SHOCK ABSORBER AND SWINGARM ICHASIAI Swingarm Relay arm Connection rod Chain case Chain protector Chain guide 6 59 17 Nm 0 7 m kg 5 1 ft lb 1 32 Nm 3 2 m kg 23 ft b ...

Page 261: ...is may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Take care not to scratch the contact surface of the piston rod with the cylinder or oil could leak out When scrapping the shock absorber refer to the NOTES ON DISPOSAL section NOTES ON DISPOSAL Shock absorber disposal steps Gas press...

Page 262: ...e on a level place 2 Remove Seat Side covers Air scoops Cover fuel tank Fuel tank Refer to the SEAT FUEL TANK AND COVER section in the CHAPTER 3 3 Elevate the rear wheel by placing a suitable stand under the engine 4 Remove Rear wheel Refer to the REAR WHEEL REMOVAL section 5 Remove Chain case CD 6 Pull up the rubber cover CD 7 Remove Cotter pin Washer Shaft ...

Page 263: ...D 9 Remove Rubber cover CD Washer from rear shock absorber 10 Remove Bolt CD connecting rod 11 Remove Bolt CD hose clamp 12 Check Swingarm free play Inspection steps eCheck the tightening torque of the pivot shaft swingarm securing nut CD Nut pivot shaft 85 Nm 8 5 m kg 61 ft Ib ...

Page 264: ...e check the inner collar bearing washer and thrust cover Side play at end of swingarm Limit 1 0 mm 0 04 in eCheck the swingarm vertical movement ill by moving it up and down If vertical movement is tight binding or rough check the innercollar bearing washer and thrust cover 13 Remove eChain guide CD 14 Remove e Pivot shaft eSwingarm ...

Page 265: ...rod relay arm Connecting rod Thrust cover J relay arm Collar relay arm Rubber cap Nut relay arm swingarm Relay arm Thrust cover relay arm Collar relay arm Thrust cover swingarm Collar swingarm INSPECTION 1 Inspect Shock absorber Oil leaks Damage Replace 2 Inspect Swingarm Bends Cracks Damage Replace 3 Inspect Relay arm CD Connecting rod Bends Cracks Damage Replace ...

Page 266: ...Damage Replace Bearing Pitting Damage Replace 5 Inspect Chain guide CD Chain protector roller Chain protector Wear Damage Replace NOTE _________________________ When replacing the bearing and bush of swin garm pivot install new bearing CD and bush as shown 4 mm 0 16 in 8 mm 0 32 in 8 mm 0 32 in 4 mm 0 16 in SIDE CLEARANCE ADJUSTMENT 1 Measure Engine mounting boss width ...

Page 267: ...2 pcs 3 Measure Pivot width 4 Measure Washer thickness Out of specification Replace Washer thickness 1 90 2 00 mm 0 075 0 079 in 5 Calculate Swingarm side clearance Out of specification Adjust side clear ance using shim By using formula given below Side clearance x 2 x 2 Side clearance at swingarm pivot 0 4 0 7 mm 0 016 0 028 in Limit O 3mm O 012in ...

Page 268: ...m 8 22 in 1 9 mm 0 075 in Side clearance 63 6 74 9 x 2 208 8 1 9 x 2 0 8 mm 0 03 in Then install the one shim Shim thickness 6 0 3 mm 0 012 in INSTALLATION Reverse the REMOVAL procedure Note the following points 1 Lubricate Bearing Bushing Thrust cover inside Collar Pivot shah Bolt relay arm swingarm Bolt connecting rod relay arm Bolt connecting rod frame Shah shock absorber r rllithium soap base ...

Page 269: ...59 Nm 5 9 m kg 43 ft Ib Nut relay arm connecting rod 32 Nm 3 2 m kg 23 ft Ib Bolt chain protector 7 Nm 0 7 m kg 5 1 ft lb 3 Tighten Nut CD pivot shaft Nut CD pivot shaft 85 Nm 8 5 m kg 61 ft Ib 4 Tighten Bolt CD chain guide Bolt CD chain guide 7 Nm 0 7 m kg 5 1 ft Ib 5 Tighten Nut CD connecting rod frame Nut CD connecting rod frame 32 Nm 3 2 m kg 23 ft Ib ...

Page 270: ...cover NOTE __________________________ Bend the ends of the cotter pin AWARNING Always use a new cotter pin 8 Tighten Screw Q chain case Screw Q chain case 4 Nm 0 4 m kg 2 9 ft Ib 9 Install Rear wheel Refer to the REAR WHEEL INSTALLA TION section 10 Adjust Drive chain slack Drive chain slack 30 40 mm 1 18 1 57 in Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 ...

Page 271: ...2 2 ft Ib Bolt caliper bracket 45 Nm 4 5 m kg 32 ft Ib Bolt brake caliper 35 Nm 3 5 m kg 25 ft Ib Refer to the REAR WHEEL INSTALLA TION section in the CHAPTER 6 12 Install Cotter pin NOTE ___________________________ Bend the ends of the cotter pin as illustration AWARNING Always use a new cotter pin 13 Install Fuel tank Cover fuel tank Air scoops Side covers Seat Bolt seat 10 Nm 1 0 m kg 7 2 ft Ib...

Page 272: ...I I DRIVE CHAIN AND SPROCKET Clutch hub 2 Collar 3 Driven sprocket 4 Bearing Oil seal 6 Collar 7 Drive chain 8 Drive sprocket DR1VE CHAIN SLACK A 30 40 mm 1 18 1 57in B6203RS 162 Nm 6 2 mokg 45 ftolb 1 110 Nm 11 0 makg 80 ftatb 6 71 ...

Page 273: ...over drive sprocket 3 Remove Drive sprocket CD NOTE __________________________ Before removing the nut drive sprocket straighten the lock washer tab Loosen the nut drive sprocket while apply ing the rear brake 4 Elevate the rear wheel by placing a suitable stand under the engine o AWJ RNING Securely support the motorcycle so there is no danger of it falling over 5 Remove Rear wheel Driven sprocket...

Page 274: ...make the chain tense by finger 1a link length is a measurement between the insides of the CD and lJ rollers as shown Two or three different 1a link lengths should be measured 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain This motorcycle has a drive chain with small rubber O rings CD between the chain plates...

Page 275: ...nt SAE 30 50 motor oil 5 Inspect Drive chain Stiff Clean and lublicate or replace 6 Inspect Drive sprocket Driven sprocket More than 1 4 teeth CD wear Replace sprocket Bent teeth Replace sprocket Correct 3 Roller 4 Sprocket Driven sprocket replacement steps Straighten the lock washer tabs and remove the driven sprocket Install a new driven sprocket and lock washers AWARNING Always use new lock was...

Page 276: ...ove the oil seals CD using a flat head screw driver NOTE _________________________ Place a rag on the outer edge to prevent damage Remove the bearing using a general bear ing puller Install the new bearing and oil seal by revers ing the previous steps NOTE __________________________ Use a socket that matches the outside diameter of the race of the bearing and oil seal Jlf aiu igl jI ________ Do no...

Page 277: ... Nut pivot shaft 85 Nm 8 5 m kg 61 ft Ib Nut frame connecting rod 32 Nm 3 2 m kg 23 ft Ib 2 Install Rear wheel Refer to the REAR WHEEL INSTALLA TION section 3 Install Drive sprocket Nut drive sprocket 110 Nm 11 0 m kg 80 ft Ib AWARNING Always use a new lock washer NOTE __________________________ Tighten the nut drive sprocket while apply ing the rear brake After tightening the nut bend the lock wa...

Page 278: ... nut 90 Nm 9 0 m kg 65 ft lb Bolt swingarm end 3 Nm 0 3 m kg 2 2 ft lb Bolt caliper bracket 45 Nm 4 5 m kg 32 ft lb Bolt brake caliper 35 Nm 3 5 m kg 25 ft lb Refer to the REAR WHEEL INSTALLATION section 6 Install Cotter pin NOTE _________________________ Bend the ends of the cotter pin as illastration AWARNING Always use a new cotter pin 7 Install Cover drive sprocket Change pedal Bolt cover 10 N...

Page 279: ...L XT600EA EAC CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 0 0 T B r RNJ RNJ RO WQ c L1Y W fl GNJ W B 4 R W Gy I OFF RUN 0 0 RNJ 0 fnj J _J iW B I r nO j t B Y O r B W 1 t I ___ Sb 1 r B W L Gy Br Br Br Br h p o BrNJ Br _ l P B ON G Y HI LO L Y B B J L 7 1 ...

Page 280: ... left Front flasher position light left Horn COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green L Blue 0 Orange P Pink R Red Sb Sky blue W White HORN switch Front brake switch Rear brake switch Tail brake light LIGHTS dimmer switch Meter light Headlight HIGH BEAM indicator light START switch Starter relay Starter motor Battery Fuse ENGINE STOP switch Starting circuit cut off relay Gy G...

Page 281: ...Ignition coil Rectifier Regulator Battery Ignitor unit 7 Fuse Diode 9 Starter relay 10 Starting circuite cut off relay 7 3 IGNITION COIL PRIMARY COIL RESISTANCE 3 4 4 S Q at 20 C SS F SECONDARY COIL RESISTANCE 10 4 15 Sk Q at 20 C SS F BATTERY CAPACITY 12V SAH SPECIFIC GRAVITY 1 320 ...

Page 282: ... Rear brake switch 2 Horn 3 Neutral switch 4 Sidestand switch 5 Flasher relay 7 Nm 0 7 m kg 5 1 ft lb 2 20 Nm 2 0 m kg 14 ft lb ELECTRICAL COMPONENTS IELECI iii I 5 7 4 ...

Page 283: ... top line indicates the colors of leads connected with the terminals in the switch component Q D indicates the terminals between which there is a continuity of electricity i e a closed circuit at the respective switch posi tions In this chart R and Br and L W and L R are continuous with the ON switch position B and B W is continuous with the OFF switch position B and B W is continuous with the LOC...

Page 284: ... color combination for continuity a closed cir cuit In this example the continuity is as follows R and Br and L W and L R are continu ous with the ON switch position B and B W is continuous with the OFF switch position B and B W is continuous with the LOCK switch position B and B W and R and L R are continu ous with the P switch position Please note that there is no continuity an open circuit at a...

Page 285: ...on and there must be no continuity the tester indicating 00 at OFF LOCK or P There is something wrong between R and Br if there is no continuity at the ON position or if the re is some continuity either at the OFF or LOCK or P NOTE __________________________ Check the switch for continuity several times 5 Next go on to checking of the continuity between B and B W L W and L R and R and L R at the r...

Page 286: ...__________________________ Bulbs of the and type uses a bulb holder Remove the bulb holder before removing the bulb itself Most of the bulb holders for this type can be removed by turning them coun terclockwise Most of the bulbs of and type can be removed from the bulb sockets by pushing and turning them counterclockwise Bulbs of the type can be removed from the bulb sockets by simply pulling them...

Page 287: ...connecting the tester lead to the CD terminal and the tester lead to the terminal Then check the continuity between the CD and terminals by connect ing the tester lead still to the CD terminal and the tester lead to the terminal If the tester shows 00 in either case replace the bulb 3 Check the bulb socket by installing a proven bulb to it As in the checking of bulbs connect the pocket tester lead...

Page 288: ...CHECKING OF BULBS IElECIIiiiI 7 10 ...

Page 289: ...i I IGNITION SYSTEM CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 0 fO 1 7 B r R W R W OFF RUN 0 0 R w Gy R W 0 BMI B r l Y o J t B Y o__B W 1 t t Sb B W Br Br __ L Br h ON G Y L Gy Br p Br W P B Ch D9 l Ch WD9 l B L B B L J L 4 7 11 ...

Page 290: ... circuit in the circuit diagram NOTE ___________________________________________________________ For the color codes see page 7 2 Main switch Pickup coil Ignitor Ignition coil Spark plug Clutch switch Diode Neutral switch Sidestand switch Battery Fuse ENGINE STOP switch Starting circuit cut off relay 5 7 12 ...

Page 291: ...Seat 2 Side cover left and right 3 Air scoop left and right 4 Cover fuel tank 5 Fuel tank 6 Cowling headlight Use the following special tools in this troubleshooting Dynamic spark tester 1 Fuse PI N YM 34487 PI N 90890 03144 Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION section in the CHAPTER 3 CONTINUITY 2 Battery Check the ...

Page 292: ...31 0 035 in CORRECT 4 Ignition spark gap Disconnect the spark plug cap from spark plug Connect the dynamic spark tester CD as shown Spark plug cap Spark plug Turn the main switch to ON Check the ignition spark gap Start engine and increase spark gap until misfire occurs Minimum spark gap 6 0 mm 0 24 in IGNITION SYSTEM IELEel iiiI INCORRECT I Repair or replace spark plug MEETS SPECIFICATION Ignitio...

Page 293: ...ON 6 Ignition coil resistance Disconnect the ignition coil leads Orange and Black from the wire harness Connect the pocket tester Q x 1 to the ignition coil Tester lead EEl terminal Tester lead e terminal G J I Check the primary coil for specificated resistance Primary coil resistance 3 4 4 6Q at 20 C 68 F EEl terminal e terminal IGNITION SYSTEM IELECI iii I OUT OF SPECIFICATION t Spark plug cap i...

Page 294: ... 8 terminal n BOTH MEET SPECIFICATIONS 7 Main switch Disconnect the main switch coupler from the wire harness Connect the pocket tester Qxl to the main switch term inal Check the switch component for the conti nuity between Red CD and Brown l Refer to the CHECKING OF SWITCHES section CORRECT IGNITION SYSTEM IELECI iIiiiiIl OUT OF SPECIFICATION 1 Ignition coil is faulty replace it INCORRECT l Main ...

Page 295: ...HECKING OF SWITCHES section CORRECT 9 Sidestand switch Disconnect the sidestand switch coupler from the wire harness Connect the pocket tester Q x 1 to the sidestand switch terminal Check the switch component for the conti nuity between Black CD and Black Refer to the CHECKING OF SWITCHES section CORRECT IGNITION SYSTEM IElEel1ii I 7 17 INCORRECT ENGINE STOP switch is faulty replace handlebar swit...

Page 296: ... CHECKING OF SWITCHES section CORRECT 11 Clutch switch Disconnect the clutch switch coupler from the wire harness Connect the pocket tester Qx1 to the clutch switch lead Check the switch component for the conti nuity between Black CD and Black Yellow Refer to the CHECKING OF SWITCHES section CORRECT IGNITION SYSTEM IELECIIiiI INCORRECT 1 Neutral switch is faulty replace it INCORRECT 1 Clutch switc...

Page 297: ...D terminal Tester lead Green White termi nal I I n Check the pickup coil for specified resistance Pickup coil resistance 184 276 Q at 20 C 68 F Blue Yellow Green White OUT OF SPECIFICATION i Pickup coil is faulty replace it MEET SPECIFICATION 13 Wiring connection Check the entire ignition system for connec tions Refer to the WIRING DIAGRAM section CORRECT Ignitor unit is faulty Replace the ignitor...

Page 298: ...IGNITION SYSTEM IHEel iii I 7 20 ...

Page 299: ...TING SYSTEM IElECI iii I ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM CD R Br L ON OFF LOCK P 1 Br RO WO LN W E GIW W B Gv J B c nO j B Y o BIW r RIW RIW OFF RUN 0 f O I R W 1 1 __ _Sb f l BIW L Gy Br Br p Br P B L 7 21 ...

Page 300: ...rcuit in the circuit diagram NOTE _____________________________________________________________ For the color codes see page 7 2 Main switch Clutch switch Diode Neutral switch Sidestand switch START switch Starter relay Starter motor Battery Fuse ENGINE STOP switch Starting circuit cut off relay 7 22 ...

Page 301: ...ch is closed 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 open so current cannot reach the starter motor When one of both of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch...

Page 302: ... Side cover left and right 3 Air scoop left and right 4 Cover fuel tank 5 Fuel tank 6 Cowling headlight Use the following special tool in this troubleshooting Pocket tester PI N YU 03112 PI N 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION section in the CHAPTER 3 CONTINUITY 2 Battery Check the battery condit...

Page 303: ...sing the jumper lead CD as shown Battery terminal Red White terminal Frame Blue White terminal Check the starter motor operation OPERATIVE 7 25 AWARNING A wire for the jumper lead must have the equivalent capacity as that of the battery lead or more otherwise it may cause the jumper lead to be burned This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinit...

Page 304: ...the CHECKING OF SWITCHES section CORRECT 6 ENGINE STOP switch Disconnect the handlebar switch right lead coupler from the wire harness Connect the pocket tester Qx1 to the engine stop switch terminal Check the switch component for the conti nuity between Red White CD and Red White Refer to the CHECKING OF SWITCHES section R W R W 7 26 INCORRECT 1 Main switch is faulty replace it INCORRECT 1 ENGINE...

Page 305: ...ty between Black CD and Black Refer to the CHECKING OF SWITCHES section B B CORRECT 8 Neutral switch Disconnect the neutral switch coupler from the wire harness Connect the pocket tester Q x 1 to the neutral switch lead Check the s itch component for the conti nuity between Sky blue CD and ground Refer to the CHECKING OF SWITCHES section INCORRECT Sidestand switch is faulty replace it INCORRECT 1 ...

Page 306: ...rcuit cut off relay relay assembly Connect the pocket tester DC20V to the starting circuit cut off relay coupler termi nals Battery terminal Red White CD terminal Battery terminal Sky blue terminal Tester lead Red Yellow terminal Tester lead Ground Turn the main switch to ON Check for voltage 1 2V on the Red White and Red Yellow leads at the star ting circuit cut off relay coupler terminals n MEET...

Page 307: ...bar switch terminal Check the START switch component for the continuity between Blue White CD and Black Refer to the CHECKING OF SWITCHES section L W B Free CORRECT 12 Wiring connection Check the entire ignition system for connec tions Refer to the WIRING DIAGRAM section INCORRECT 1 START switch is faulty replace handlebar switch right POOR CONNECTION 1 Correct ...

Page 308: ...ator 4 O ring 4 ELECTRICAL STARTING SYSTEM IElECI iii I BRUSH LENGTH LIMIT A 5 mm 0 20 in COMMUTATOR WEAR LIMIT B 27 mm 1 06 in C MICA UNDERCUT 0 7 mm 0 027 in ARMATURE COIL RESiSTANCE D oQ at 20 C 68 F 2 CD 7 Nm 0 7 m kg 5 1 ft lb 7 30 ...

Page 309: ...AL section in the CHAPTER 4 Disassembly 1 Remove Circlip CD Drive gear 2 Remove Bolts CD Shim Washer Shim Brush Armature Yoke j Inspection and Repair 1 Inspect Commutator Dirty Clean it with 600 grit sand paper 2 Measure Commutator diameter Out of specification Replace starter motor Commutator wear limit 27 mm 1 06 in ...

Page 310: ...mutator 4 Inspect eArmature coil insulation continuity Defects s Replace starter motor Armature coil inspecting steps eConnect the Pocket Tester for continuity check CD and insulation check eMeasure the armature resistances Armature coil resistance Continuity check CD oQ at 20 C 68 F Insulation check More than 1M Q at 20 C 68 F elf the resistance is incorrect replace the starter motor 5 Measure ii...

Page 311: ...following points 1 Install eBrush seat NOTE __________________________ Align the projection CD on the brush seat with the slot on the housing 2 Install eYoke CD eHousing cover NOTE __________________________ Align the match marks on the yoke with the match marks on the housings 3 Install eBolts CD Bolt yoke assembly 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 312: ...iiii I 7 34 Installation 1 Install Starter motor NOTE _________________________ Apply a lightly grease to the O ring CD Bolt starter motor 10 Nm 1 0 m kg 7 2 ft Ib Refer to the ENGINE OVERHAUL ENGINE INSTALLATION section in the CHAPTER 4 ...

Page 313: ...Q R Br L ON 10fO 0 OFF LOCK P 10f 1 L Br I R W R W OFF RUN 0 ro CHARGING SYSTEM IElEel iii I t R W Gy J J 4 j I B Y B W It l 1 Sb f l B W L Gy Br Br I t I HI LO Y Br h ON G Y L Br Br o p Br W P B Ch 0 9 I Ch W 0 9 l B L B B L J L 7 35 ...

Page 314: ...I Aforementioned circuit diagram shows charging circuit in the circuit diagram NOTE _____________________________________________________________ For the color codes see page 7 2 Rectifier regulator A C magneto Battery Fuse 7 36 ...

Page 315: ...his troubleshooting Inductive tachometer 1 Fuse PIN YU OS036 A PIN 90S90 03113 Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION section in the CHAPTER 3 CONTINUITY 2 Battery Check the battery condition Refer to the BATIERY INSPECTION sec tion in the CHAPTER 3 Voltage 12 S V or higher at 20 C 6S F CORRECT 7 37 Pocket tester PIN Y...

Page 316: ... charging voltage Charging voltage 14 0V at 5 000 r min NOTE Use a full charged battery 4 Stator coil resistance OUT OF SPECIFICATION CHARGING SYSTEM IELEel iiiI MEETS SPECIFICATION I ICharging circuit is good Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Q x 1 to the stator coil leads Stator coil 1 Tester lead White lead CD Tester lead White lead Stator coil 2...

Page 317: ...2 0 78n at 20 C S8 F CHARGING SYSTEM IELEeIiii I OUT OF SPECIFICATION 1 Stator coil is faulty replace it n BOTH RESISTANCES MEET SPECIFICATIONS 5 Wiring connection Check the entire charging system for connec tions Refer to the WIRING DIAGRAM section CORRECT RectifierIregulator is faulty replace it POOR CONNECTION I Correct 7 39 ...

Page 318: ...CHARGING SYSTEM IHEel iiiii I 7 40 ...

Page 319: ... Br ON OFF LOCK P 10I I Br L 0 L RIW RIW OFF RUN 0 1 0 R LIGHTING SYSTEM IHEel iii I RO WO LIY W Gffl W B r Rffl L iJ j Gy I __ _ _ B Y o_Bffl R C 4_ Sb Bffl Br Br _ J I HI LO Y L ON G Y L Gy Br p P B Ch 09 l Ch W 0 9 l B L B B L J L 7 41 ...

Page 320: ...uit diagram shows lighting circuit NOTE _____________________________________________________________ For color codes see page 7 2 CD Main switch Tail brake light LIGHTS dimmer switch Meter light Headlight HIGH BEAM indicator light Battery Fuse 7 42 ...

Page 321: ... headlight 4 Headlight lens unit 5 Tail cover Use the following special tool in this troubleshooting Pocket tester P N YU 03112 P N 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION in the CHAPTER 3 CONTINUITY 2 Battery Check the battery condition Refer to the BATIERY INSPECTION sec tion in the CHAPTER 3 Voltag...

Page 322: ... switch Disconnect the handlebar switch left cou ple from the wireharness Connect the pocket tester Q x 1 to the handlebar switch left terminal Check the switch component for the conti nuity between Brown CD and Green and Brown CD and Yellow Refer to the CHECKING OF SWITCHES section 2 3 y Br G HI 101 0 LO 10fO G Br WCh m P B Br y Og X CORRECT LIGHTING SYSTEM IHEel iii I INCORRECT 1 IMain switch is...

Page 323: ...M __IElECI iii 1 5 Wiring connection Check the entire lighting system for con nections Refer to the WIRING DIAGRAM section CORRECT Check condition of each circuit for lighting system Refer to LIGHTING SYSTEM CHECK sec tion POOR CONNECTION ICorrect 7 45 ...

Page 324: ...tester DC20V to the headlight and HIGH BEAM indicator light couplers Head light Tester lead Green CD or Yellow lead Tester lead Black lead HIGH BEAM indicator light A B Tester lead Yellow lead Tester lead Black lead DC20V When LIGHT dimmer switch is HI position rnJ When LIGHT dimmer switch is La position NOCONTINUITY 1 IReplace bulb and or bu b s o ck e t OUT OF SPECIFICATION 7 46 1 Wiring circuit...

Page 325: ...or continu ity Refer to the CHECKING OF BULBS sec tion CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket coupler Tester lead Blue CD terminal Tester lead Black terminal DI B L DC20vt4 I l r I I NOCONTINUITY l IReplace bulb and or bu_lb so_c_k_e_t_ ______ I Turn the main switch to ON OUT OF SPECIFICATION Check for voltage 12V on the Blue lead at the bulb socket connector n MEE...

Page 326: ...bulb socket connector Tester lead Blue CD terminal Tester lead Black terminal eTurn the main switch to ON Check for voltage 1 2V on the Blue lead at the bulb socket connector n MEETS LIGHTING SYSTEM IElEel iiiii I NOCONTINUITY 1 IBulb and or bulb socket are faulty replace OUT OF SPECIFICATION 1 SPECIFICATION 12V Wiring circuit from main switch to bulb socket connector is faulty repair ThiS circuit...

Page 327: ...ector Tester lead Blue CD terminal Tester lead Black terminal B B LJ D 0 II DC20V I o Turn the main switch to ON Check for voltage 12V on the Blue lead at the bulb socket connector n MEETS LIGHTING SYSTEM IELEel1ii I NOCONTINUITY l IReplace bulb and or bu_lb_s_oc_k_e_t_ ___ OUT OF SPECIFICATION SPECIFICATION 12V Wiring circuit from main switch to bulb socket connector is faulty repair IThis circui...

Page 328: ...LIGHTING SYSTEM IHEel iii I 7 50 ...

Page 329: ...CK P 10I I B r L ro L L R W R W OFF RUN 0 f R SIGNAL SYSTEM IELEel iiiI Rtl WO y E iJR y BIW I 0 I 1 R I B Y o_BIW t R I I T r Sb 1 B w L Sb Gy Br Br HI LO y b B B J J iQ 8r h X ON GIY L Br P PIB B L N R Br o Br W Ch 09 I Ch W 0 9 l B L B B L ll l L 7 51 ...

Page 330: ...es see page 7 2 Main switch Ignitor NEUTRAL indicator light Neutral switch REV indicator light Flasher relay TU RN switch TURN indicator light 1 Front flasher position light r ight j Rear flasher light right l Rear flasher light left Front flasher positio 1 light left Horn HORN switch Front brake switch Rear brake switch Tail brake light Battery Fuse 7 52 ...

Page 331: ...ht 5 Tail cover 3 Cowling headlight Use the following special tool in this troubleshooting Pocket tester P N YU 03112 P N 90890 03112 1 Fuse Remove the fuse Connect the pocket tester Q x 1 to the fuse Check the fuse for continuity Refer to the FUSE INSPECTION in the CHAPTER 3 CONTINUITY 2 Battery Check the battery condition Refer to the BATTERY INSPECTION sec tion in the CHAPTER 3 Voltage 12 8 v o...

Page 332: ...between Red CD and Brown 2 Refer to the CHECKING OF SWITCHES section CORRECT 4 Wiring connection Check the entire signal system for connec tions Refer to the WIRING DIAGRAM section CORRECT Check condition of each circuit for signal system Refer to SIGNAL SYSTEM CHECK section SIGNAL SYSTEM IELECIIii I INCORRECT l IMain switch is faulty replace it POOR CONNECTION l ICorrect 7 54 ...

Page 333: ...Refer to the CHECKING OF SWITCHES section CORRECT 2 Voltage Connect the pocket tester DC20V to the horn lead Tester lead Brown CD lead Tester lead Frame ground Turn the main switch to ON Check for voltage 12V on the Brown lead at the horn terminal n MEETS SIGNAL SYSTEM IHEel iii I INCORRECT l HORN switch is faulty replace handlebar switch left OUT OF SPECIFICATION l Wiring circuit from main switch...

Page 334: ...T SOUNDED eConnect the pocket tester DC20V to the horn at the Pink terminal Tester lead Pink CD lead Tester lead Frame ground eTurn the main switch to ON eCheck for voltage 1 2V on the Pink lead at the horn terminal SIGNAL SYSTEM IELEel iiIi I HORN IS SOUNDED IHorn is good OUT OF SPECIFICATION l IHorn is faulty replace it n MEETS SPECIFICATION 12V IAdjust or replace horn I 7 56 ...

Page 335: ...ct the pocket tester Q x 1 to the brake switch terminal Check the switch component for the conti nuity between Green Yellow CD and Brown or Black and Black Refer to the CHECKING OF SWITCHES section ON Pull in OFF Free ON Step down OFF Free B B 00 Front brake switch lID Rear brake switch CORRECT Br GIY I I SIGNAL SYSTEM IHEel iiiii I NOCONTINUITY 1 IReplace bulb and or bulb socket INCORRECT 1 IBrak...

Page 336: ...et connector is faulty repair SPECIFICATION 12V IThis circuit is good I 3 Flasher light and or TURN indicator light do not blink 1 Bulb and bulb socket Check the bulb and bulb socket for continu ity Refer to the CHECKING OF BULBS sec tion CONTINUITY 2 TU RN switch Disconnect the handlebar switch left cou pler from the wireharness Connect the pocket tester Q x 1 to the handlebar switch left leads C...

Page 337: ...round Turn the main switch to ON Check for voltage 12V on the Brown lead at the flasher relay terminal n MEETS SIGNAL SYSTEM IELECIIiiiI INCORRECT i TURN switch is faulty replace handlebar switch left OUT OF SPECIFICATION l Wiring circuit from main switch to flasher relay connector is faulty repair SPECIFICATION 12V 7 59 ...

Page 338: ...he Brown White lead at the flasher relay terminal n MEETS SPECIFICATION 12V 5 Voltage Connect the handlebar switch left coupler to the wireharness Connect the pocket tester DC20V to the bulb socket connector At flasher light left Tester lead Chocolate CD lead Tester lead Frame ground At flasher light right Tester lead Dark Green lead Tester lead Frame ground Q n g D B Ch B D9 f k 10 I OUT OF SPECI...

Page 339: ... BULBS sec tion CONTINUITY 2 Neutral switch Disconnect the neutral switch lead from the wireharness Connect the pocket tester Q x 1 to the neutral switch leads Check the switch component for the conti nuity between Sky blue Q and Ground Refer to the CHECKING OF SWITCHES section Sb CORRECT 3 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Brown Q terminal Tester lea...

Page 340: ...V Wiring circuit from main switch to bulb socket connector is faulty repair 4 Neutral switch lead Disconnect the neutral switch lead and bulb socket connector from the wireharness Connect the pocket tester Q X 1 to the Sky blue neutral switch lead CD wirehar ness side and bulb socket terminal J Br Sb 2 CONTINUITY IThis circuit is good NOCONTINUITY 7 62 l Wiring circuit from bulb socket to neutral ...

Page 341: ...parts STARTING FAILURE HARD STARTING FUEL SYSTEM PROBABLE CAUSE Fuel tank l Empty Clogged fuel filter Clogged fuel tank cap air passage Deteriorated fuel or fuel containing water or foreign material Fuel cock Clogged fuel hose L Clogged fuel filter Carburetor Deteriorated fuel fuel containing water or foreign material Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Groove ...

Page 342: ...h Faulty sidestand switch Faulty clutch switch Starter motor Faulty starter motor l_Faulty starter relay Faulty circuit cut off relay relay unit Faulty starter clutch COMPRESSION SYSTEM PROBABLE CAUSE Cylinder and cylinder head l Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket Worn damaged or seized cylinder Piston and piston rings L Improperly i...

Page 343: ...magneto Faulty ignition coil Valve train Improperly adjusted valve clearance POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURE HARD STARTING FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM and Valve train PROBABLE CAUSE Carburetor Deteriorated fuel fuel containing water or foreign material Sucked in air Deformed float Diaphragm malfunction Gro...

Page 344: ... plate Swollen friction plate Broken clutch boss Engine oil r High oil level L Improper quality high viscosity Deterioration CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE Shift shaft Bent shift shaft Shift cam and shift fork Lr Groove jammed with impurities Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear L Jammed impurities Incorrectly assembled transmission JUMP OUT ...

Page 345: ...ABLE CAUSE Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate L Incorrectly assembled clutch Engine oil Low oil level L Improper quality low viscosity Deterioration CLUTCH DRAGGING Refer to the HARD SHIFTING 8 5 ...

Page 346: ...d Improper brake fluid level FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LEAKAGE PROBABLE CAUSE L r Bent damaged or rusty inner tube Damaged or cracked outer tube Damaged oil seal lip Improperly installed oil seal Improper oil level too much Loose damper rod holding bolt Broken cap bolt O ring Loose drain bolt Damaged drain bolt gasket MALFUNCTION PROBABLE CAUSE L r Bent deformed or dama...

Page 347: ...e Front forks rL Uneven oil levels on both sides Broken spring Twisted front forks Tires L Uneven tire pressures on both sides I ncorrect tire pressure Unevenly worn tires Wheels l Incorrect wheel balance Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel run out Frame Twisted L Damaged head pipe Improperly installed bearing race Swingarm Worn bearing or bush Bent or damaged Rea...

Page 348: ... switch Bulb life expired PROBABLE CAUSE L _ _ _ _ _ _ _ _ _ _ _ _ _ Improper bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and or LIGHTS switch Bulb life expired FLASHER DOES NOT LIGHT PROBABLE CAUSE L _ _ _ _ _ _ _ _ _ _ _ _ _ Improperly grounded Discharged battery Faulty TURN switch Faulty flasher relay Broken wireharness Loosely connected coupler Bulb burnt out...

Page 349: ...BLE CAUSE L _ _ _ _ _ _ _ _ _ _ _ _ _ Faulty battery Faulty main and or HORN switch Improperly adjusted horn Faulty horn Broken wireharnes OVERHEATING OVERHEATING PROBABLE CAUSE Ignition system Lr Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system T Improper carburetor main jet l improper setting Improperly adjusted fuel level Clogged air filter element Compress...

Page 350: ...ight 8 8 r H I 0 D 0 J 1 I N S T I UW ry t 1 r Starter Flasher LIGHT HORN position light Irightl START switch Ne tral St rter relay switch motor relay dimmer sWitch ENGINE STOP Front flasher position light leftl COLOR CODE B Black Horn Br Brown Ch Chocolate Dg Dark green G Green L o P R Sb W switch TURN switch switch Blue Orange Pink Red Sky blue White Gy Gray Y Yellow B W Black White B Y Black ye...

Page 351: ...YAIVIAHA MOTOR CO LTD IWATA JAPAN PRINTED IN U S A ...

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