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Yamaha XV1600A1999, Service Manual

The Yamaha XV1600A1999 Service Manual is a comprehensive and essential resource for owners of this powerful motorcycle model. Packed with detailed instructions, diagrams, and maintenance tips, this manual is available for download for free at manualshive.com, ensuring easy access to all the necessary information needed to keep your Yamaha XV1600A1999 running smoothly.

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2-35

CABLE ROUTING

SPEC

V Clamp the pickup coil lead.

W Clamp the starter lead side stand switch lead 

horn lead with a band and then cut of the end. 
Locate the end of band outside.

X Clamp the fuel pump lead to the engine stay with

a band and cut the end of band.

Y Clamp the fuel pump lead.
Z Set the brake pipe and see the white mark.

Summary of Contents for XV1600A1999

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Page 3: ...1600A L SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First Edition December 1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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

Page 5: ... the top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number ...

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

Page 7: ...AL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETION CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 5 CARB 6 CHAS 4 ELEC 7 TRBL SHTG 8 CHK ADJ TABLE OF CONTENTS ...

Page 8: ......

Page 9: ...N NUMBER 1 1 MODEL CODE 1 1 FEATURES 1 2 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 10: ...E GEN INFO ...

Page 11: ...RCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 12: ... running in 5th gear and sends the information out as an electrical signal to the igni tor unit Self diagnosis device This model is equipped with a self diagnosis de vice that has four functions The engine trouble indicator light will come on or flash if trouble occurs in an engine monitoring circuit Circuit Indicator lights Number of flashes Throttle position sensor Engine trouble indicator light...

Page 13: ...he push rods move the rocker arms and lower the exhaust valves which compress the cylinder When the cylinder is compressed pressure is released immediately resulting in smoother engine starting capabilities and smoother crankshaft revolutions 1 Decompression solenoid 2 Decompression solenoid rod 3 Decompression connector 4 Decompression lever 5 Decompression push rod 6 Decompression cam 7 Pin 8 Sp...

Page 14: ... rods 5 toward the camshaft side 3 The decompression cam 6 is pushed in the direction indicated by the arrow and then the pin 7 raises the projection of the decom pression cam 4 When the camshaft is rotated by the selftim ing motor the exhaust valve lifters 8 are lifted by the pin just before top dead center TDC and the exhaust valve push rod 9 and valve rocker arms are operated Thus open ing the ...

Page 15: ... along with the valve lifter body 8 and pushes up the push rods causing the valve to be lifted 3 As the camshaft continues to rotate the valve lifter moves back down to its original position where it remains while the cam heel passes When a positive valve clearance is caused by either heat expansion of the cylinder head or engine oil leaking from the valve lifter during stage 2 the plunger which n...

Page 16: ... all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and ap pearance b...

Page 17: ...s marks or numbers are vis ible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circ...

Page 18: ...tains Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick...

Page 19: ...326 Damper rod holder 90890 01294 T handle Damper rod holder These tools are used to hold the cartridge cylinder when loosening or tightening the cartridge cylinder bolt 90890 01312 Fuel level gauge This tool is used to measure the fuel level in the float chamber 90890 03141 Timing light This tool is used to check the ignition timing 90890 03170 Belt tention gauge This tool is used to measure the ...

Page 20: ...hen removing or installing the clutch boss nut 90890 01701 Sheave holder This tool is used to hold the generator rotor when removing or installing the 90890 01701 rotor when removing or installing the generator rotor bolt generator shaft bolt or pickup coil rotor bolt 90890 01304 Piston pin puller set This tool is used to remove the piston pins 90890 03009 Micrometer 75 100 mm This tool is used to...

Page 21: ...lter wrench This tool is needed to loosen or tighten the oil filter cartridge 90890 03113 Engine tachometer This tool is used to check engine speed 90890 85505 Yamaha bond No 1215 This sealant is used to seal two mating surfaces e g crank case mating surfaces 90890 03153 Oil pressure gauge This tool is used to measure the engine oil pressure 90890 04095 Plane bearing installer remover This tool is...

Page 22: ...GEN INFO ...

Page 23: ...G TORQUES 2 18 GENERAL TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE OIL LUBRICATION CHART 2 25 ENGINE OIL FLOW DIAGRAMS 2 26 TRANSFER GEAR OIL FLOW DIAGRAMS 2 30 CABLE ROUTING 2 32 ...

Page 24: ...E SPEC ...

Page 25: ... length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 500 mm 980 mm 1 140 mm 710 mm 1 685 mm 145 mm 3 200 mm Weight Wet with oil and a full fuel tank Dry without oil and fuel Maximum load total of cargo rider passenger and accessories 332 kg 307 kg 196 kg ...

Page 26: ...in Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular unleaded gasoline 20 L 3 5 L Engine oil Lubrication system Recommended oil Dry sump SAE20W40SE or SAE10W30SE Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve opening pressure 5 0 L 3 7 L 4 1 L 60 kPa 0 6 kg cm2 at 900 r min 600 k...

Page 27: ... oil pump housing clearance Trochoid 0 07 0 12 mm 0 03 0 08 mm 0 17 mm 0 16 mm Starting system type Electric starter Spark plugs Model Manufacturer Quantity Spark plug gap DPR7EA 9 X22EPR U9 NGK DENSO 4 0 8 0 9 mm Cylinder heads Max warpage 0 10 mm Camshafts Drive system Crankcase hole inside diameter Camshaft cover hole inside diameter Camshaft journal diameter crankcase side Camshaft journal dia...

Page 28: ... Rocker arms Rocker arm shafts Rocker arm inside diameter Rocker arm shaft outside diameter Rocker arm to rocker arm shaftclea rance 15 000 15 018 mm 14 981 14 991 mm 0 009 0 037 mm 15 036 mm 14 97 mm 0 08 mm Valves valve seats valve guides Valve clearance cold Intake Exhaust Valve dimensions 0 0 04 mm 0 0 04 mm Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat widt...

Page 29: ... mm 5 975 5 990 mm 5 960 5 975 mm 6 000 6 012 mm 6 000 6 012 mm 0 010 0 037 mm 0 025 0 052 mm 0 4 mm 0 4 mm 5 945 mm 5 920 mm 6 05 mm 6 05 mm 0 08 mm 0 1 mm 0 01 mm Valve seat width Intake Exhaust 0 9 1 1 mm 0 9 1 1 mm Valve springs Inner springs Free length Intake Exhaust Installed length valve closed Intake Exhaust Compressed spring force installed Intake Exhaust 38 26 mm 38 26 mm 29 0 mm 29 0 m...

Page 30: ...er clockwise 2 5_ 2 4 mm 2 5_ 2 4 mm SSS SSS Outer springs Free length Intake Exhaust Installed length valve closed Intake Exhaust Compressed spring force installed Intake Exhaust Spring tilt 43 25 mm 43 25 mm 31 0 mm 31 0 mm 139 161 N 13 9 16 1 kg 139 161 N 13 9 16 1 kg 41 26 mm 41 26 mm SSS SSS SSS SSS Intake Exhaust SSS SSS 2 5_ 2 4 mm 2 5_ 2 4 mm ...

Page 31: ...0156 0 0420 mm VALVE PUSH RODS Valve push rod length Valve push rod runout 293 45 293 95 mm 0 3 mm CYLINDERS Bore Max taper Max out of round 95 000 95 010 mm 0 05 mm 0 05 mm PISTONS Piston to cylinder clearance Diameter D 0 025 0 050 mm 94 960 94 975 mm 0 15 mm Height H Piston pin bore in the piston Diameter Offset Piston pins Outside diameter Piston pin to piston pin bore clearance 5 mm 22 004 22...

Page 32: ... T End gap installed Ring side clearance Oil ring Taper 1 2 3 8 mm 0 30 045 mm 0 03 0 07 mm 0 8 mm 0 12 mm Dimensions B T End gap installed 2 5 3 4 mm 0 2 0 7 mm Connecting rods Crankshaft pin to big end bearing clearance Bearing color code Connecting rod length 0 037 0 074 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 191 95 192 05 mm Crankshaft Width A Max runout C Big end side clearance D 132 8 13...

Page 33: ... Clutch springs Free length Spring quantity Min length Wet multiple disc Rack and pinion pull rod type Cable operation Left hand operation 10 15 mm 2 9 3 1 mm 9 2 2 2 4 mm 8 7 mm 1 2 8 mm 0 2 mm 6 5 mm Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4rd gear 5th gea...

Page 34: ...l manufacturer quantity Throttle cable free play at the flange of the throttle grip ID mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot air jet P A J1 Pilot air jet P A J2 Pilot outlet P O Pilot jet P J Bypass 1 B P1 Bypass 2 B P2 Bypass 3 B P3 Pilot screw turns out P S Valve seat size V S Starter jet 1 G S 1 Starter jet 2 G S 2 Throttle valve size TH V Fuel level F L fuel ...

Page 35: ... Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Spoke wheel 16 Mt 3 50 Steel 110 mm SSS SSS SSS SSS SSS SSS 1 mm 0 5 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 90 kg 90 kg Maximum load High speed riding Min tire tread depth With tube 130 90 16 67H D404FL DUNLOP G703F BRIDGESTONE 250 kPa 2 5 kg cm2 250 kPa 2 5 kg cm2...

Page 36: ...e play lever end Recommended fluid Brake discs Diameter thickness Min thickness Max deflection Brake pad lining thickness Dual disc brake Right hand operation 2 5 mm DOT 4 298 5 mm 6 0 mm 4 5 mm 0 1 mm 0 5 mm Master cylinder inside diameter Caliper cylinder inside diameter 15 8 mm 30 1 mm and 33 3 mm Rear brake Brake type Operation Brake pedal position from the top of the brake pedal to the bottom...

Page 37: ...nner tube fully compressed and without the fork spring Inner tube outer diameter Telescopic fork Coil spring oil damper 140 mm 571 mm 6 8 N mm 0 7 kg mm 0 140 mm No Yamaha fork oil 5WT 554 cm3 110 mm 43 mm 566 mm Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate K1 Spring stroke K1 Optional spring a...

Page 38: ...2 14 CHASSIS SPECIFICATIONS SPEC Item Standard Limit Drive belt Model manufacturer Drive belt slack on a sidestand Drive belt slack on a suitable stand UBD 0568 7 5 13 mm 14 21 mm ...

Page 39: ...SS SSS Throttle position sensor standard resistance 4 0 6 0 kΩ SSS Charging system System type Model manufacturer Nominal output Stator coil resistance color AC magneto F4T363 MITSUBISHI 14 V 21 A at 5 000 r min 0 45 0 55 Ω at 20_C w w SSS SSS SSS SSS Voltage regulator Regulator type Model No load regulated voltage color Semiconductor short circuit SH650D 11 14 1 14 9 V SSS SSS SSS Rectifier Model...

Page 40: ...mm SSS Starter relay Model manufacturer Amperage Coil resistance MS5F 411 JIDECO 180 A 4 18 4 62 Ω SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Plane type YF 12 NIKKO 1 3 A SSS SSS SSS Turn signal relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE246BH DENSO Yes 75 95 cycles min 21 W 2 3 4 W SSS SSS S...

Page 41: ...ATIONS SPEC Item Standard Limit Fuses amperage quantity Main fuse Headlight fuse Signaling system fuse Ignition fuse Carburetor heater Backup fuse odometer Reserve 30 A 1 15 A 1 10 A 1 15 A 1 10 A 1 5 A 1 30 A 15 A 10 A 5 A 1 ...

Page 42: ...mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 CONVERSION TABLE TIGHTENING TORQUES SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMP mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO I...

Page 43: ...buretor joint clamp Air filter case Air filter case clamp Exhaust pipe Muffler Muffler clamp Crankcase cylinder head Crankcase cylinder head Crankcase transfer gear case Pickup coil Pickup coil lead holder Stator coil assembly Stator coil assembly Starter clutch Nut Nut Stud bolt Nut Bolt Bolt Nut Bolt Bolt Nut Union bolt Union bolt Bolt Screw Bolt Screw Nut Bolt Bolt Stub bolt Stub bolt Stub bolt...

Page 44: ...ut Shift shaft spring stopper Stopper lever Neutral switch Bolt Bolt Bolt Bolt Nut Bolt Bolt Nut Bolt Nut Screw Bolt Bolt Nut Bolt Bolt Bolt Bolt Screw M12 M8 M12 M6 M20 M6 M6 M8 M22 M8 M8 M6 M6 M6 M8 M22 M8 M6 M8 M8 M6 M6 1 1 1 4 1 6 1 1 1 4 1 1 2 5 7 1 2 1 2 1 1 2 160 28 115 10 70 8 10 18 85 30 30 8 7 10 30 85 30 10 12 22 10 7 16 0 2 8 11 5 1 0 7 0 0 8 1 0 1 8 8 5 3 0 3 0 0 8 0 7 1 0 3 0 8 5 3 0...

Page 45: ... Relay arm and connecting rod Relay arm and rear shock absorber Relay shock absorber connecting rod and frame Drive belt case upper and swingarm Drive belt case lower and swingarm Mud guard and swingarm Fuel petcock and fuel tank Fuel sender and fuel tank Fuel tank rear and frame Meter cover and fuel tank Side cover and frame Starter relay and battery positive lead Starter relay and starter motor ...

Page 46: ...el axle pinch bolt Rear wheel axle nut Front brake caliper Rear brake caliper Brake disc and wheel Caliper bleed screw Driven sprocket and rear wheel clutch hub Rear brake caliper bracket and swin garm M8 M6 M10 M8 M8 M18 M8 M18 M10 M10 M8 M8 M12 M10 23 4 30 16 16 78 19 150 40 40 23 6 95 48 2 3 0 4 3 0 1 6 1 6 7 8 1 9 15 0 4 0 4 0 2 3 0 6 9 5 4 8 1 First tighten the ring nut to approximately 52 Nm...

Page 47: ...rod end balls Valve stems intake and exhaust Valve stem ends intake and exhaust Valve lifters Oil pump rotors inner and outer and oil pump housing Oil strainer Starter clutch idle gear inner surface Starter clutch idle gear shaft Starter clutch roller and starter clutch gear outer surface Clutch pull rod Pressure plate bearing Transmission gears wheel and pinion Shift drum Shift forks and shift fo...

Page 48: ...wheel oil seal right and left Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal Front footrest pivot Sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt contact surface Clutch lever pivot bolt contact surface Swingarm pivot shaft Swingarm pivot bearing Swingarm pivot oil seal Relay arm bearing inner Rear shock absorber be...

Page 49: ...ting rod Crank pin Crankshaft journal right Camshaft lobe faces Camshaft journal camshaft cover side Crankshaft journal camshaft cover side Starter clutch Generator shaft journal right Generator shaft journal left Clutch Main axle sears Oil pump drive gear Main axle Bypass valve Oil filter cartridge Drive axle gears Drive axle Oil pump Check ball Relief valve Oil tank Rotor 2 Oil strainer Rotor 1 ...

Page 50: ...2 26 ENGINE OIL FLOW DIAGRAMS SPEC 1 Oil tank 2 Oil strainer 3 Dipstick 4 Oil delivery pipe 5 Push rod 6 Oil filter cartridge 7 Engine oil drain bolt oil tank ENGINE OIL FLOW DIAGRAMS ...

Page 51: ...2 27 ENGINE OIL FLOW DIAGRAMS SPEC 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft ...

Page 52: ...2 28 ENGINE OIL FLOW DIAGRAMS SPEC 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt engine ...

Page 53: ...2 29 ENGINE OIL FLOW DIAGRAMS SPEC 1 Main axle 2 Drive axle 3 Engine oil pump 4 Oil strainer A To oil tank B From oil tank C To oil filter cartridge ...

Page 54: ...2 30 TRANSFER GEAR OIL FLOW DIAGRAMS SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle drive shaft 2 Transfer gear oil pump ...

Page 55: ...2 31 TRANSFER GEAR OIL FLOW DIAGRAMS SPEC 1 Transfer gear oil pump 2 Middle driven shaft ...

Page 56: ...itch lead in front of the rectifier regulator bracket E Clamp the rear brake light switch lead to the rectifier regulator lead with a plastic band and cut the end of band EB206000 CABLE ROUTING 1 Throttle cable 2 Clutch cable 3 Left handlebar switch lead 4 Rectifier regulator lead 5 To engine 6 To rear brake light switch 7 Rear brake light switch lead 8 Front brake hose 9 Right handlebar switch le...

Page 57: ...sub wireharness 3 Seat lock cable 4 A I S vacuum hose 5 High tension code 6 To fuel sender 7 0_ 45_ 8 Battery negative lead 9 Starter relay 10 Thermo switch assembly 11 Fuel tank breather hose 12 Starter lead 13 Sidestand switch lead 14 Horn lead 15 Clutch cable 16 Headlight bracket 17 Front brake light switch lead 18 Rectifire regulator lead 19 High tension code 20 To air cut valve assembly 21 Ca...

Page 58: ...nsor lead decompression solelnoid lead pick up coil lead neutral switch lead stator coil lead sidestand switch lead and horn lead to the frame F Route the seat lock cable on the wire harness G Through the seat lock cable on the wireharness H Clamp the wireharness seat lock cable to the frame and the end of clamp is downward Dont clamp the fuel sender lead I The coupler under the wireharness J Clam...

Page 59: ... starter lead side stand switch lead horn lead with a band and then cut of the end Locate the end of band outside X Clamp the fuel pump lead to the engine stay with a band and cut the end of band Y Clamp the fuel pump lead Z Set the brake pipe and see the white mark ...

Page 60: ...5 Stator coil lead 26 To neutral switch 27 To speed sensor 28 To fuel tank 29 To wireharness 1 Battery negative lead 2 High tension code 2 3 Main switch lead 4 Fuel tank breather hose 5 Meter lead 6 Right handlebar switch lead 7 Throttle cable 8 Front brake hose 9 Flasher lead 10 High tension code 3 11 High tension code 4 12 Rear brake light switch lead 13 To stator coil 14 To decompression soleno...

Page 61: ... dounward through the terminal along the body forward the lower side I Clamp the starter lead and horn lead A Dont clamp the hoses B Clamp the fuel tank breather hose and oil tank breather hose C Clamp the throttle cable and fuel tank breather hose D Clamp the throttle cable E Locate the slit to downward F Connect the coupler on the clamp ...

Page 62: ... High tension code 1 16 Wireharness 17 Ignition coil lead 18 High tension code 3 1 Stay 2 Front brake hose 3 Throttle cable 4 Left handlebar switch lead 5 Fuel tank breather hose 6 Meter lead 7 Throttle cable 8 Fuel sender lead 9 Seat lock cable 10 A I S vacuum hose CABLE ROUTING SPEC ...

Page 63: ...front flasher lead into the inside of headlight from through hole of headlight A Clamp the wireharness B Position the white tape on the wireharness with the hole on battery box as shown C Fix the wireharness negative lead coupler to battery band D Set the wireharness regative lead protecter between coupler and clamp E Route the sterter lead between battery box and stay CABLE ROUTING SPEC ...

Page 64: ...SPEC ...

Page 65: ... 25 CHANGING THE TRANSFER GEAR OIL 3 26 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 27 CLEANING THE AIR FILTER ELEMENT 3 28 CHECKING THE CARBURETOR JOINT 3 29 CHECKING THE FUEL HOSES AND FUEL FILTER 3 29 CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE 3 30 CHECKING THE EXHAUST SYSTEM 3 30 CHASSIS 3 31 ADJUSTING THE FRONT BRAKE 3 31 ADJUSTING THE REAR BRAKE 3 32 CHECKING TH...

Page 66: ...THE CABLES 3 48 LUBRICATING THE LEVERS AND PEDALS 3 49 LUBRICATING THE SIDESTAND 3 49 LUBRICATING THE REAR SUSPENSION 3 49 ELECTRICAL SYSTEM 3 50 CHECKING AND CHARGING THE BATTERY 3 50 CHECKING THE FUSES 3 55 REPLACING THE HEADLIGHT BULB 3 57 ADJUSTING THE HEADLIGHT BEAM 3 58 INSTRUMENT FUNCTIONS 3 60 INDICATOR LIGHTS 3 60 COMBINATION METER 3 60 ...

Page 67: ... filter Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout spoke tightness and for damage Tight...

Page 68: ...ing speed and starter operation S Adjust if necessary 22 Engine oil S Check oil level and vehicle for oil leakage S Correct if necessary S Change Warm engine before draining 23 Engine oil filter cartridge S Replace 24 Transfer case oil S Check for leakage S Replace oil at initial 1 000 km and thereafter every 24 000 km or 24 months whichever comes first Since these items require special tools data...

Page 69: ...4 Removing the seats and side covers Rider seat Passenger seat Left side cover Right side cover 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure SEATS AND SIDE COVERS CHK ADJ SEATS AND SIDE COVERS ...

Page 70: ...el tank breather hose Fuel hose Fuel sender coupler Fuel tank 2 1 1 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS Disconnect Disconnect Before disconnecting the fuel hose set the fuel cock to OFF Disconnect For installation reverse the removal procedure NOTE FUEL TANK CHK ADJ EAS00040 FUEL TANK ...

Page 71: ...e Vacuum chamber breather hose air filter case to solenoid valve hose Cylinder head breather hose Air filter case 1 1 1 Remove the parts in the order listed Disconnect Disconnect For installation reverse the removal pro cedure AIR FILTER CASE CHK ADJ AIR FILTER CASE ...

Page 72: ...ew and bring the valve clear ance a to within specification Check if the valve clearance b on the adjusting screw 2 side is within specification B If clearance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or a...

Page 73: ...NCE CHK ADJ 4 Remove shift rod 1 5 Remove rider footrest left bolts 1 6 Remove engine left side cover 1 7 Remove timing mark accessing screw 1 crankshaft end cover 2 8 Remove decompression solenoid cover 1 camshaft sprocket cover 2 ...

Page 74: ...shaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown If the marks are not aligned turn the crank shaft counter clockwise 360 degrees and re check step b d Measure the valve clearance with a thick ness gauge Piston 2 TDC front cylinder a Turn the crankshaft counterclockwise from the piston 1 TDC by 405 degrees b When piston 2 is at TDC on the compres sion stoke align...

Page 75: ...alve clear ance is decreased Valve clear ance is increased d Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion Locknut 20 Nm 2 0 m kg e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 11 Install all removed parts For inst...

Page 76: ...seat Refer to SEATS AND SIDE COVERS 3 Remove fuel tank bolt 1 4 Lift up the fuel tank end 5 Remove fuel pump stay bolts 2 When remove the fuel pump stay don t dis connect other hoses 6 Install inductive tachometer 1 onto the spark plug lead of cylinder 1 Engine tachometer 90890 03113 7 Measure engine idling speed Out of specification Adjust Engine idling speed 850 950 r min 8 Adjust engine idling ...

Page 77: ...throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is increased Direction Engine idling speed is decreased 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 4 8 mm ...

Page 78: ...n Adjust Throttle cable free play at the flange of the throttle grip 4 8 mm 2 Adjust throttle cable free play When the throttle is opened the accelerator cable 1 is pulled Carburetor side a Remove the rider seat and fuel tank Refer to SEATS AND SIDE COVERS and FUEL TANK b Loosen the locknut 2 on the decelerator cable c Turn the adjusting nut 3 in direction a or b to take up any slack on the decele...

Page 79: ...uel tank and rider seat Refer to FUEL TANK and SEATS AND SIDE COV ERS Handlebar side a Loosen the locknut 6 b Turn the adjusting nut 7 in direction c or d until the specified throttle cable free play is obtained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased c Tighten the locknut After adjusting the throttle cable free play start the engine and turn...

Page 80: ...facturer DPR7EA 9 NGK X22EPR U9 DENSO 5 Check electrodes 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean spark plug with a spark plug cleaner or wire brush 7 Measure spark plug gap a with a wire gauge Out of specification Regap Spark plug gap 0 8 0 9 mm 8 Install spark plug Before installing the spark plug clean the...

Page 81: ...iming check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Remove rider seat Refer to SEATS AND SIDE COVERS 2 Remove fuel tank bolt 1 3 Lift up the fuel tank end 4 Remove shift rod 1 5 Remove rider footrest left bolts 1 6 Remove engine left side cover 1 ...

Page 82: ...ngine warm it up for several min utes and then let it run at the specified en gine idling speed Engine idling speed 850 950 r min b Check that the pointer a is within the re quired firing range b on the pickup coil rotor Incorrect firing range Check the ignition system The ignition timing is not adjustable 10 Install all removed parts For installation reverse the removal procedure Note the followi...

Page 83: ... to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove rider seat fuel tank Refer to SEATS AND SIDE COVERS and FUEL TANK 4 Remove camshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFT ERS decompression solenoid Refer to CAMSHAFTS 5 Install camshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 6 Disconne...

Page 84: ... the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug leads before cranking the engine The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm2 c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and ...

Page 85: ...ket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 13 Install Sdecompression solenoid Refer to CAMSHAFTS Scamshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 14 Install Sfuel tank Srider seat Refer to FUEL TANK and SEATS AND SIDE COVERS EAS00071 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface SPlace the motorcycle on a suitable stand SMake sure ...

Page 86: ...ed oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade Non Friction modified ACEA standard G4 or G5 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oi...

Page 87: ...k 2 engine oil drain bolt engine 3 4 Drain engine oil completely from the oil tank and crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench 90890 01426 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil Make sure the O ring 3 is positioned...

Page 88: ...he recom mended engine oil Quantity Total amount 5 0 L Periodic oil replacement 3 7 L With oil filter cartridge replacement 4 1 L Pour the engine oil in several stages First pour in 2 5 L of oil and then start the en gine and rev it 3 to 5 times Stop the engine and then pour in the remainder of the specified amount When starting the engine make sure the dip stick is securely fitted into the oil ta...

Page 89: ...el Refer to CHECKING THE ENGINE OIL LEVEL 14 Check engine oil pressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer...

Page 90: ... engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Soil gallery bolt 1 The engine muffler and engine oil are ex tremely hot 4 Install Soil pressure gauge 1 Oil pressure gauge 90890 03153 5 Measure Sengine oil pressure at the following conditions Engine oil pressure 40 80 kPa ...

Page 91: ...tion Leaking oil passage Faulty oil filter Oil viscosity too high 6 Install oil gallery bolt CHECKING THE TRANSFER GEAR OIL LEVEL 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand Make sure the motorcycle is upright 2 Remove checking bolt 1 3 Check transfer gear oil level The transfer gear oil level should be up to the brim 1 of the hole Below the brim Add the reco...

Page 92: ...ansfer gear oil drain bolt 2 Remove straight plug 1 transfer gear oil drain bolt 2 3 Drain transfer gear oil completely from the transfer gear case 4 Check transfer gear oil drain bolt gasket Damage Replace 5 Install transfer gear oil drain bolt 6 Fill transfer gear case with the specified amount of the recom mended transfer gear oil Quantity Total amount 0 4 L 7 Install straight plug 8 Check tran...

Page 93: ...pecified clutch cable free play is ob tained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased d Tighten the locknut If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side e Pull the boot 1 in Engine side a Loosen the locknut 4 b Turn the adjusting bolt 5 in direction c or d un...

Page 94: ...ge Replace 5 Install air filter element air filter case cover Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor turning leading to poor en gine performance and possible overheat ing When installing the air filter element...

Page 95: ...stall carburetor assembly Refer to CARBURETOR in chapter 6 EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses 1 Remove fuel pump cover 1 2 Check fuel hose 1 Cracks damage Replace fuel filter 2 Contaminants damage Replace Drain and flush the fuel tank if abrasive dam age to any components of the fuel line is evi dent The arrow mark on the fuel ...

Page 96: ...racks damage Replace Loose connection Connect properly Make sure the crankcase breather hose is routed correctly 3 Install fuel tank rider seat Refer to FUEL TANK and SEATS AND SIDE COVERS EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes mufflers and gaskets 1 Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 2 ...

Page 97: ...is obtained Direction Brake lever free play is in creased Direction Brake lever free play is de creased c Tighten the locknut A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in los...

Page 98: ...s lowered After adjusting the brake pedal position check that the end c of the adjusting bolt is visible through the hole d c Tighten the locknut 1 to specification Locknut 18 Nm 1 8 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will co...

Page 99: ...ause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and co...

Page 100: ... chapter 4 Brake pad wear limit a 0 5 mm EAS00118 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to REPLACING THE REAR BRAKE PADS in chapter 4 Brake pad wear limit a 0 5 mm EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake ligh...

Page 101: ...sting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction Brake light comes on soon er Direction Brake light comes on later EAS00129 CHECKING THE BRAKE HOSE 1 Check brake hose Cracks damage wear Replace 2 Check brake hose clamp Loose Tighten the clamp bolt 3 Hold the motorcycle upright and apply the front or rear brake several times 4 Check brake hose Brake f...

Page 102: ... or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure whe...

Page 103: ...the pres sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0 6 m kg k Fill the brake fluid reservoir to the prop...

Page 104: ...in direction b or c to obtain the correct shift pedal position Direction Installed shift rod length in creases Direction Installed shift rod length de creases c Tighten both locknuts d Make sure the installed shift rod length is within specification ADJUSTING THE DRIVE BELT SLACK A drive belt that is too tight will overload the engine and other vital parts and one that is too loose can skip and da...

Page 105: ...est point 3 Measure drive belt slack a Out of specification Adjust Drive belt slack On a sidestand 7 5 13 mm at 4 5 kg On a suitable stand 14 21 mm at 4 5 kg Belt tension gauge 90890 03170 The level marks of the level window on the low er drive belt cover are in units of 5 mm 0 20 in Use them as a standard for measuring the drive belt slack Measure the drive belt slack when the drive belt has been...

Page 106: ... belt slack is increased To maintain the proper wheel alignment adjust both sides evenly e Tighten both locknuts to specification Locknut 32 Nm 3 2 m kg f Tighten the wheel axle nut to specification Wheel axle nut 150 Nm 15 0 m kg g Tighten the brake caliper bracket bolt to specification Brake caliper bracket bolt 40 Nm 4 0 m kg EAS00146 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the motorc...

Page 107: ...sher upper bracket 3 6 Adjust steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 Set the torque wrench at a right angle to the ring nut wrench Ring nut wrench 90890 01443 Lower ring nut initial tightening torque 52 Nm 5 2 m kg c Loosen the lower ring nut completely then ti...

Page 108: ...3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 Make sure the lock washer tabs sit correctly in the ring nut slots 7 Install upper bracket washer steering stem nut 8 Tighten upper bracket pinch bolt 9 Install met...

Page 109: ... movement Repair Refer to FRONT FORK in chapter 4 ADJUSTING THE REAR SHOCK ABSORB ER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over Spring preload Never go beyond the maximum or minimum adjustment positions 1 Adjust spring preload Adjust the spring preload with the special wrench and extension bar included in the own er s tool kit a Loosen the locknut 1 b Tu...

Page 110: ...applies to both of the tires 1 Measure tire pressure Out of specification Regulate The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded motorcyc...

Page 111: ...l of cargo rider passenger and accesso ries It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal inju...

Page 112: ...less wheel Tube or tubeless tire After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufactur er and of the same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Front tire Manufacturer Size ...

Page 113: ...has been repaired or replaced be sure to tighten the tire air valve stem locknut 4 to specification For tires with a direction of rotation mark 5 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 6 with the valve installation point Tire air valve stem locknut 1 5 Nm 0 15 m kg EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all ...

Page 114: ...g procedure applies to all of the cable sheaths and cables Damaged cable sheaths may cause the cable to corrode and interfere with its move ment Replace damaged cable sheaths and cables as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Rough movement Lubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drop...

Page 115: ...s of the levers and pedals Recommended lubricant Lithium soap base grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfid...

Page 116: ... electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention This is a sealed battery Never remove the sealing caps...

Page 117: ... lead 1 then the positive battery lead 2 3 Remove battery band battery 4 Measure battery charge a Connect a pocket tester to the battery termi nals Positive tester probe positive battery terminal Negative tester probe negative battery terminal The charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive battery ter minal is disconnected N...

Page 118: ...ce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate...

Page 119: ...place the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am perage readjust the voltage to obtain the standard charging amper age Leave the battery unused for more than 30 minutes before measur ing its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Rep...

Page 120: ...tage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is re quired Under 12 0 V Replace the battery NOTE Set the charging time to a maximum of 20 hours YES NO Constant amperage chargers are not ...

Page 121: ... wire brush Loose connection Connect properly 9 Lubricate battery terminals Recommended lubricant Dielectric grease 10 Install rider seat Refer to SEATS AND SIDE COVERS EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove left side cover Refer to SEATS AND SIDE COVERS 2 ...

Page 122: ...fuse immediately blows again check the electrical circuit Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 15 A 1 Ignition fuse 15 A 1 Signaling sys tem fuse 10 A 1 Carburetor heater fuse 10 A 1 Backup fuse 5 A 1 Reserve fuse 30 A 1 Reserve fuse 15 A 1 Reserve fuse 10 A 1 Reserve fuse 5 A 1 Never use a fuse with an amperage other than that specified Improvising or using a fuse with the wrong amp...

Page 123: ...0182 REPLACING THE HEADLIGHT BULB 1 Remove screws 1 headlight lens unit 2 2 Disconnect head light coupler 1 3 Remove headlight bulb holder cover 2 4 Detach headlight bulb holder 1 5 Remove headlight bulb 2 Since the headlight bulb gets extremely hot keep flammable products and your hands away from he bulb until it has cooled down ...

Page 124: ...fe of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach headlight bulb holder 8 Install headlight bulb holder cover 9 Connect headlight coupler 10 Install headlight lens unit screws EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjustin...

Page 125: ...USTING THE HEADLIGHT BEAM CHK ADJ a b 2 Adjust headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction Headlight beam moves to the right Direction Headlight beam moves to the left ...

Page 126: ...e fuel cock to RES Then fill the tank at the first opportunity Engine trouble indicator light This indicator light will come on or flash if trouble occurs in a monitoring circuit In such a case take the motorcycle to a Yamaha dealer to have the self diagnostic systems checked COMBINATION METER 1 Combination meter 2 Clock 3 Odometer trip meter 4 Mode button 5 Set button This combination meter is eq...

Page 127: ... 4 400 r min Setting the clock This clock always shows the time regardless of the main switch position 1 Turn the main switch to ON 2 Press both left and right buttons simulta neously until both hours and minutes flash 1 3 Push the left button and the hour display will flash 2 4 Push the right button to change the hours 3 5 Push the left button and the minute display will flash 4 6 Push the right ...

Page 128: ...CHK ADJ ...

Page 129: ...ONT WHEEL 4 7 INSTALLING THE FRONT WHEEL 4 7 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 9 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 4 11 REMOVING THE REAR WHEEL 4 16 CHECKING THE REAR WHEEL 4 16 CHECKING THE REAR WHEEL DRIVE HUB 4 17 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 17 ASSEMBLING THE REAR WHEEL 4 18 INSTALLING THE REAR WHEEL 4 18 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 21 ...

Page 130: ... 4 59 DISASSEMBLING THE FRONT FORK LEGS 4 59 CHECKING THE FRONT FORK LEGS 4 60 ASSEMBLING THE FRONT FORK LEGS 4 61 INSTALLING THE FRONT FORK LEGS 4 64 HANDLEBAR 4 67 REMOVING THE HANDLEBAR 4 69 CHECKING THE HANDLEBAR 4 69 INSTALLING THE HANDLEBAR 4 69 STEERING HEAD 4 73 REMOVING THE LOWER BRACKET 4 75 CHECKING THE STEERING HEAD 4 75 INSTALLING THE STEERING HEAD 4 76 REAR SHOCK ABSORBER AND SWINGAR...

Page 131: ...ke disc cover left Brake disc cover right with weight Brake disc left and right 2 2 1 1 1 2 1 1 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen For installation reverse the removal procedure NOTE 78 Nm 7 8 m kg 40 Nm 4 0 m kg 20 Nm 2 0 m kg 23 Nm 2 3 m kg 23 Nm 2 3 m kg FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRON...

Page 132: ...E DISCS CHAS Order Job Part Q ty Remarks Disassembling the front wheel Oil seal left and right Wheel bearing left and right Spacer 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 ...

Page 133: ...rake caliper right brake caliper Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00523 DISASSEMBLING THE FRONT WHEEL 1 Remove oil seals wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel plac...

Page 134: ... tire front wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 3 Check spokes Bends damage Replace Loose Tighten Refer to CHECKING AND TIGHTENING THE SPOKES in chapter 3 4 Measure radial wheel runout 1 lateral wheel runout 2 Over the specified limits Replace Maximum radial wheel runout 1 0 mm Maximum lateral wheel runout 0 5 mm 5 Check collars Damage wear Re...

Page 135: ...he oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearings puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made only with the outer race 6 Use a socket 7...

Page 136: ...e front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm below the edge of the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace ...

Page 137: ...in specification replace the brake disc EAS00539 ASSEMBLING THE FRONT WHEEL 1 Install wheel bearings oil seals New Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal EAS00544 IN...

Page 138: ... of the brake disc bolts Tighten the brake disc in stages and in a criss cross pattern 3 Install collars front wheel front wheel axle 4 Tighten front wheel axle 1 wheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smooth ly 5 Install brake calipers Make sure the brake hose is routed properly 6 Install refl...

Page 139: ...front wheel stops put an X1 mark at the bottom of the wheel d Turn the front wheel 90_ so that the X1 mark is positioned as shown e Release the front wheel f When the wheel stops put an X2 mark at the bottom of the wheel g Repeat steps b through f several times until all the marks come to rest at the same spot h The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust S...

Page 140: ... posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 141: ...re harness Rear fender assembly 1 1 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS in chapter 3 Disconnect For installation reverse the removal procedure 30 Nm 3 0 m kg 25 Nm 2 5 m kg 88 Nm 8 8 m kg 48 Nm 4 8 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00550 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 142: ...nd right Wheel axle nut Right adjusting plate Left adjusting plate Rear wheel axle 1 1 1 2 2 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen NOTE 32 Nm 3 2 m kg 10 Nm 1 0 m kg 150 Nm 15 0 m kg 48 Nm 4 8 m kg 40 Nm 4 0 m kg 32 Nm 3 2 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00550 ...

Page 143: ...r wheel Collar left and right Brake caliper bracket 1 2 1 For installation reverse the removal procedure 32 Nm 3 2 m kg 10 Nm 1 0 m kg 150 Nm 15 0 m kg 48 Nm 4 8 m kg 40 Nm 4 0 m kg 32 Nm 3 2 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS ...

Page 144: ...ar wheel sprocket Oil seal Collar Circlip Bearing Collar Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel 1 1 1 1 1 1 1 1 1 6 1 Remove the parts in the order listed For installation reverse the removal procedure 23 Nm 2 3 m kg 95 Nm 9 5 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00556 ...

Page 145: ...emarks Disassembling the rear wheel Oil seal Bearing Spacer Bearing 1 1 1 4 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00560 ...

Page 146: ...able stand so that the rear wheel is elevated 2 Remove brake caliper Do not depress the brake pedal when removing the brake caliper 3 Remove rear wheel Push the rear wheel forward and remove the drive belt from the rear wheel sprocket EAS0056 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL BRAKE DISCS 2 Check tire rear wheel Damage wear Replace R...

Page 147: ...mage Replace rear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket Surface plating has come off Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprock et 2 Replace rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especi...

Page 148: ...ts in stages and in a crisscross pattern ASSEMBLING THE REAR WHEEL 1 Install bearings spacer bearing oil seal New Refer to FRONT WHEEL AND BRAKE DISCS EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate oil seal lips Recommended lubricant Lithium soap base grease 2 Install rear wheel drive hub dampers 1 3 Install rear wheel drive hub assembly 1 ...

Page 149: ...TITE 648 to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 6 Install brake caliper bracket 1 washer brake caliper bracket bolt 2 Temporarily tighten the brake caliper bracket bolt 7 Install collars rear wheel adjusting plates rear wheel axle washer wheel axle nut Temporarily tighten the wheel axle nut 8 Adjust drive belt slack Refer to ADJUST...

Page 150: ...g 88 Nm 8 8 m kg 48 Nm 4 8 m kg 9 Tighten wheel axle nut brake caliper bracket bolt 10 Install brake caliper 1 11 Install upper drive belt cover 1 12 Install muffler 13 Tighten muffler mounting bolt 1 Clamp bolt 2 14 Install rear fender assembly 15 Tighten nut 1 bolts 2 16 Connect tail brake light and turn signal light sub wire harness coupler 3 ...

Page 151: ... in chapter 3 EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance Refer to FRONT WHEEL AND BRAKE DISCS ...

Page 152: ...e caliper Brake pad Brake pad shim Brake pad spring Brake pad spring 1 2 1 2 1 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers For installation reverse the removal procedure 27 Nm 2 7 m kg FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 153: ...r bolt Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad 2 1 2 2 1 2 Remove the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET For installation reverse the removal procedure 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS ...

Page 154: ...r new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention EAS00580 REPLACING THE FRONT BRAKE PA...

Page 155: ...e pads brake pad springs Always install new brake pads brake pad shim and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install a new brake pad s...

Page 156: ...ove any excess grease 6 Install brake caliper brake caliper retaining blots brake hose holder bolt 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 157: ...pad cover 2 2 Remove brake pad clips 1 brake pad pins 2 brake pad spring 3 3 Remove brake pads 1 4 Measure brake pad thickness a Out of specification Replace the brake pads as a set Minimum brake thickness 0 5 mm 5 Install brake pads brake pad spring Always install new brake pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the ...

Page 158: ...ring The arrow a on the brake pad spring must point in the direction of disc rotation 6 Install brake pad pins brake pad clips brake pad cover brake caliper 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer...

Page 159: ... master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake level Brake level spring Front brake light switch connector Union bolt Brake hose Copper washer 1 1 1 1 2 1 2 1 1 2 Remove the parts in the order listed Drain Disconnect Disconnect 10 Nm 1 0 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER ...

Page 160: ...b Part Q ty Remarks 11 12 13 Brake master cylinder holder Brake master cylinder Front brake light switch 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS ...

Page 161: ...embling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS EAS00585 ...

Page 162: ... fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt Copper washer Brake hose Rear brake light switch 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Disconnect Disconnect 23 Nm 2 3 m kg 48 Nm 4 8 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 163: ...Part Q ty Remarks 11 12 13 14 Left footrest assembly Cotter pin Pin Brake master cylinder 1 1 1 1 For installation reverse the removal procedure 23 Nm 2 3 m kg 48 Nm 4 8 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS ...

Page 164: ...embling the rear brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS EAS00587 ...

Page 165: ... brake system 1 Remove union bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MAS TER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose ...

Page 166: ...uid delivery passages brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace A Front B Rear 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake master cylin...

Page 167: ...ted with clean or new brake fluid Never use solvents on internal brake com ponents Recommended brake fluid DOT 4 1 Install brake master cylinder kit 1 circlip 2 New dust boot 3 2 Install front brake light switch 1 3 Install brake master cylinder brake master cylinder holder 1 Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with ...

Page 168: ...g the brake hose tighten the union bolt as shown Turn the handlebar to the left and to the right to make sure the brake hose does not touch oth er parts e g wire harness cables leads Correct if necessary 5 Install brake lever spring 1 brake lever 2 6 Connect front brake light switch connectors 1 7 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recomm...

Page 169: ... the boil ing point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately 8 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 9 Install brake master cylinder diaphragm brake master cylinder diaphragm holder brake master cylinder cap rear view mirror 10 Check brake flui...

Page 170: ... MASTER CYLINDER 1 Install brake master cylinder kit 1 circlip 2 New dust boot 3 2 Install brake master cylinder 1 3 Install left footrest assembly 1 4 Install rear brake light switch 1 5 Install copper washers New brake hose union bolt Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING ...

Page 171: ...Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point o...

Page 172: ...id reservoir cover 10 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 11 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest 100 mm 12 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BR...

Page 173: ...washer Brake hose Retaining bolt Brake caliper bolt Brake caliper 1 1 1 2 1 2 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Loosen For installation reverse the removal procedure 40 Nm 4 0 m kg 27 Nm 2 7 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS ...

Page 174: ...d Brake pads spring Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw 2 1 2 2 2 1 2 4 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 6 Nm 0 6 m kg FRONT AND REAR BRAKES CHAS EAS00615 ...

Page 175: ...bolt Copper washer Brake hose Brake caliper bolt Brake caliper 1 2 1 2 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Drain For installation reverse the removal procedure 30 Nm 3 0 m kg 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER ...

Page 176: ...ver Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 1 2 2 1 2 4 8 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 6 Nm 0 6 m kg FRONT AND REAR BRAKES CHAS EAS00617 ...

Page 177: ...er and pump out the brake fluid carefully 2 Remove brake caliper pistons brake caliper piston seals a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake ...

Page 178: ... the brake hose joint opening a to force out the left side pis tons from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston seals d Repeat the previous steps to force out the right side piston from the brake caliper EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pa...

Page 179: ...ages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper piston seals A Front B Rear 2 Check brake caliper brackets 1 Cracks damage Replace A Front B Rear EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers Before installation all internal brake com ponen...

Page 180: ...er piston seals Recommended brake fluid DOT 4 1 Install bleed screw brake caliper piston seals 1 New brake caliper pistons 2 2 Install brake pad spring 1 brake pad springs 2 brake pads 3 Install the brake pad with the attached brake pad shim on t he brake caliper piston side 3 Install brake caliper bracket 1 retaining bolts 2 Temporarily tighten the retaining bolts 4 Install brake caliper 1 brake ...

Page 181: ... fluid Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the...

Page 182: ... operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Wheneve...

Page 183: ...s 3 The arrow a on the brake pad spring must point in the direction of disc rotation 3 Install brake pad cover 4 Install brake caliper 1 brake caliper bolts 2 5 Install copper washers New brake hose union bolt Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper make sure the brake pipe touches the ...

Page 184: ...ance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 7 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 8 Check brake fluid level...

Page 185: ...r bracket Upper fork cover Upper fork cover spacer Upper fork cover washer 1 1 4 1 1 1 1 1 1 Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to FRONT WHEEL AND BRAKE DISCS Refer to FUEL TANK in chapter 3 Loosen 130 Nm 13 0 m kg 10 Nm 1 0 m kg 23 Nm 2 3 m kg 23 Nm 2 3 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg FRONT FORK CHAS EAS00647 FRONT FORK ...

Page 186: ...ower bracket pinch bolt Front fork legs Bolt Brake hose guide Lower fork cover 2 1 3 1 1 Loosen For installation reverse the removal procedure 130 Nm 13 0 m kg 10 Nm 1 0 m kg 23 Nm 2 3 m kg 23 Nm 2 3 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg FRONT FORK CHAS ...

Page 187: ...t seal Oil seal clip Cartridge cylinder bolt Copper washer Cartridge cylinder Rebound spring Inner tube 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed The following procedure applies to both of the front fork legs 10 1 2 3 4 5 6 7 8 9 23 Nm 2 3 m kg 20 Nm 2 0 m kg FRONT FORK CHAS EAS00648 ...

Page 188: ... Q ty Remarks Oil seal Seal spacer Outer tube busing Inner tube busing Oil flow stopper Outer tube 1 1 1 1 1 1 For assembly reverse the disassembly procedure 11 12 13 14 15 16 23 Nm 2 3 m kg 20 Nm 2 0 m kg FRONT FORK CHAS ...

Page 189: ... motorcycle on a suitable stand so that the front wheel is elevated 2 Loosen lower bracket pinch bolts 1 Before loosening the lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove dust seal 1 oil seal clip 2 with a flat head screwdriver Do not scratch the inner ...

Page 190: ...aws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner tube into the outer tube during the above procedure as the oil flow stopper will be damaged EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both o...

Page 191: ...eck cap bolt O ring Damage wear Replace EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability When assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust s...

Page 192: ...3 Lubricate inner tube s outer surface Recommended lubricant Yamaha fork and shock oil 5WT or equivalent 4 Install outer tube onto the inner tube copper washer New cartridge cylinder bolt 5 Tighten cartridge cylinder bolt 1 Apply the locking agent LOCTITE 204 to the threads of the cartridge cylinder bolt While holding the cartridge cylinder with the damper rod holder 2 and T handle 3 tighten the c...

Page 193: ...sure the numbered side of the oil seal faces up Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation 8 Install oil seal clip 1 Adjust the oil seal clip so that it fits into the oute...

Page 194: ...hile filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 11 Install fork spring cap bolt Before installing the cap bolt lubricate its O ring with grease Temporarily tighten the cap bolt EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install lower fork cover 1 brake h...

Page 195: ...g stem nut Make sure the inner fork tube is flush with the top of the upper bracket 4 Tighten lower bracket pinch bolt 1 cap bolt Make sure the brake hoses are routed prop erly 5 Remove steering stem nut upper bracket 6 Install upper fork washer 1 upper fork spacer 2 upper fork cover 3 7 Install upper bracket 1 steering stem nut 2 ...

Page 196: ...4 66 E FRONT FORK CHAS 10 Nm 1 0 m kg 23 Nm 2 3 m kg 8 Tighten upper bracket pinch bolts 1 9 Install brake hose holder front fender 10 Install front wheel Refer to FRONT WHEEL AND BRAKE DISCS ...

Page 197: ...ight switch connector Brake master cylinder holder Brake master cylinder Right handlebar switch Throttle cable holder Throttle cable Throttle grip Clutch switch connector 2 4 2 1 1 1 1 2 1 1 Remove the parts in the order listed Disconnect Disconnect Disconnect 23 Nm 2 3 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg HANDLEBAR CHAS EAS00664 HANDLEBAR ...

Page 198: ... 16 17 18 Left handlebar switch Handlebar grip Clutch cable Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder 1 1 1 1 1 2 1 2 Disconnect For installation reverse the removal procedure 23 Nm 2 3 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg ...

Page 199: ... handlebar EAS00668 CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Install washers lower handlebar holders 1 cable guide 2 Temporarily tighten the nuts 3 2 Install handlebar upper handlebar holders First tighten the bolts on the front side of the handlebar hold...

Page 200: ...wer handlebar holders 3 Tighten lower handlebar holder nuts 4 Install clutch lever Align the slit of clutch lever holder with the punch mark a on the handlebar 5 Install clutch cable Lubricate the end of the clutch cable with a thin coat of lithium soap base grease 6 Install left handlebar switch Align the end a of the left handlebar switch with the punch mark b on the handlebar 7 Connect clutch s...

Page 201: ... rag Do not touch the handlebar grip until the rubber adhesive has fully dried 9 Install throttle grip 10 Connect throttle cable 11 Install right handlebar switch Align the projection a on the right handlebar switch with the hole b in the handlebar 12 Install brake master cylinder brake master cylinder holder Install the brake master cylinder holder with the UP mark facing up Align the end of the ...

Page 202: ...amp rear view mirrors 15 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 15 mm 16 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 4 8 mm ...

Page 203: ...e headlight body Headlight body Headlight bracket Chrome turn signal light bracket cover Turn signal light bracket assembly 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to FRONT FORK Refer to FRONT WHEEL AND BRAKE DISCS Refer to HANDLEBAR 52 Nm 5 2 m kg 1st 3 Nm 0 3 m kg 2nd 7 Nm 0 7 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 130 Nm 13 0 m kg STEERING HEAD CHA...

Page 204: ...nt Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Upper bearing Lower bearing Bearing outer race 1 1 1 1 1 1 1 1 1 2 For installation reverse the removal procedure 52 Nm 5 2 m kg 1st 3 Nm 0 3 m kg 2nd 7 Nm 0 7 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 130 Nm 13 0 m kg ...

Page 205: ... ring nut 1 with the special tool 2 Ring nut wrench 90890 01443 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosene 2 Check bearings bearing races Damage pitting Replace 3 Replace bearings bearing races a Remove the bearing races from the steering head pipe with a long ro...

Page 206: ...d be damaged Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install upper bearing lower bea...

Page 207: ...her 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 4 Install brake hose joint 1 5 Install turn signal light bracket assembly 1 chrome turn signal light bracket cover 2 6 Install headlight bracket 1 7 Install headlight body 1 8 Connect leads in the headlight body 9 Install headlight lens unit ...

Page 208: ...NG HEAD CHAS 10 Install upper bracket steering stem nut front fork legs Refer to FRONT FORK 11 Install handlebar Refer to HANDLEBAR front fork legs Refer to FRONT FORK meter assembly Refer to FUEL TANK in chapter 3 ...

Page 209: ...t cover Self locking nut Bolt shock absorber connecting arm frame Cover left and right Pivot shaft nut washer 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 158 mm 7 Nm 0 7 m kg 59 Nm 5 9 m kg 7 Nm 0 7 m kg 125 Nm 12 5 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM ...

Page 210: ...t Q ty Remarks 9 10 Pivot shaft Rear shock absorber and swingarm assembly 1 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 59 Nm 5 9 m kg 7 Nm 0 7 m kg 125 Nm 12 5 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS ...

Page 211: ... locking nut washer bolt Connecting arm O ring Rear shock absorber Spacer O ring Self locking nut washer bolt Relay arm Spacer oil seal bearing Spacer bearing 1 1 1 1 1 1 2 4 1 1 2 1 1 1 1 1 2 1 1 2 Remove the parts in the order listed Bolt 53 mm Bolt 124 mm Bolt 77 mm 40 Nm 4 0 m kg 59 Nm 5 9 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS ...

Page 212: ...art Q ty Remarks 11 12 13 14 15 16 Spacer bearing Swingarm Dust cover Washer Spacer Bearing 1 1 1 2 2 1 2 For installation reverse the removal procedure 40 Nm 4 0 m kg 59 Nm 5 9 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS ...

Page 213: ...t can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping perfor mance EAS00689 DISPOSING OF A REAR SHOCK ABSORB ER AND GAS CYLINDER Gas pressure must be released before dispos ing of a rear shock absorber and gas cylinder To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole throu...

Page 214: ...mov ing the swingarm from side to side c If the swingarm free play is out of specifica tion check the spaces bearings washers and dust covers Swingarm free play at the end of the swingarm 0 mm d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust covers EAS00696 CHEC...

Page 215: ...Replace bolts Bends damage wear Replace CHECKING THE REPLAY ARM AN CON NECTING ARM 1 Check relay arm 1 connecting arm 2 Damage wear Replace bearings oil seals Damage pitting Replace spacers Damage scratches Replace CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot sha...

Page 216: ...t Kerosine 4 Check dust covers spacer oil seals Damage wear Replace bearings Damage pitting Replace EAS00711 INSTALLING THE REAR SHOCK ABSORB ER AND SWINGARM 1 Lubricate bearings spacers dust covers O rings pivot shaft Recommended lubricant Molybdenum disulfide grease 2 Install bearings spacer 1 washers 2 dust covers 3 ...

Page 217: ...S 59 Nm 5 9 m kg 59 Nm 5 9 m kg 3 Install bearings oil seals 1 spacers 2 4 Install relay arm 1 onto the swingarm 5 Install O rings 1 spacer 2 6 Install connecting arms 1 onto the rear shock absorber 7 install connecting arms 1 onto the relay arm ...

Page 218: ...lay arm 9 Install rear shock absorber and swingarm assem bly pivot shaft washer pivot shaft nut covers 10 Install bolt shock absorber connecting arm frame 1 When installing the bolt shock absorber con necting arm frame hold the swing arm so that it does not drop down 11 Install lower drive belt cover 1 12 Install mud guard 1 ...

Page 219: ...ABSORBER AND SWINGARM CHAS 13 Install locknut 1 adjusting bolt 2 14 Install rear wheel Rear to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET 15 Adjust drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK in chapter 3 ...

Page 220: ...r Dowel pin Slider Drive belt Drive sprocket nut Lock washer Drive sprocket 1 1 2 2 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Refer to REAR SHOCK ABSORBER AND SWINGARM For installation reverse the removal procedure 53 Nm 5 3 m kg 30 Nm 3 0 m kg 10 Nm 1 0 m kg 85 Nm 8 5 m kg DRIVE BELT AND DRIVE SPROCKET CHAS DRIVE BELT AND DRIVE SPROCKET ...

Page 221: ... pedal so the drive sprocket does not move CHECKING THE DRIVE BELT 1 Clean drive belt a Wipe the drive belt with a clean cloth b Put the drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check drive belt To protect the installation drive be...

Page 222: ...sher 2 New drive sprocket nut 3 2 Install drive belt Install the drive belt facing the same way it was removed 3 Install rear shock absorber and swingarm assem bly Refer to REAR SHOCK ABSORBER AND SWINGARM rear wheel Refer to REAR WHEEL BRAKE DISC AND SWINGARM 4 Tighten drive sprocket nut When tightening the drive sprocket nut press down on the brake pedal so the drive sprocket does not move 5 Ben...

Page 223: ...4 93 E DRIVE BELT AND DRIVE SPROCKET CHAS 10 Nm 1 0 m kg 53 Nm 5 3 m kg 30 Nm 3 0 m kg 6 Install dowel pins 1 sliders 2 7 Install drive sprocket cover 1 drive sprocket cover bracket 2 bolts M10 bolts M8 ...

Page 224: ...E CHAS ...

Page 225: ...E ENG CONTENTS ENGINE ENGINE 5 1 INSTALLING THE ENGINE 5 8 ...

Page 226: ...IDE COVER 5 27 CAMSHAFTS 5 29 REMOVING THE CAMSHAFTS 5 31 CHECKING THE CAMSHAFTS 5 32 CHECKING THE DECOMPRESSION SYSTEM 5 34 CHECKING THE OIL DELIVERY PIPE 5 35 INSTALLING THE CAMSHAFTS 5 35 CYLINDER HEADS 5 39 REMOVING THE CYLINDER HEADS 5 41 CHECKING THE CYLINDER HEADS 5 41 CHECKING THE OIL DELIVERY PIPE 5 42 INSTALLING THE CYLINDER HEADS 5 42 VALVES AND VALVE SPRINGS 5 44 REMOVING THE VALVES 5 ...

Page 227: ...LEVER 5 75 INSTALLING THE STOPPER LEVER AND SHIFT SHAFT 5 75 GENERATOR AND STARTER CLUTCH 5 77 REMOVING THE GENERATOR 5 80 CHECKING THE STARTER CLUTCH 5 80 INSTALLING THE GENERATOR 5 81 TRANSFER GEAR CASE 5 85 REMOVING THE BATTERY 5 91 REMOVING THE MIDDLE DRIVEN SHAFT 5 91 CHECKING THE MIDDLE DRIVE 5 91 CHECKING THE OIL STRAINER 5 92 CHECKING THE OIL PUMP 5 92 CHECKING THE OIL PIPE 5 93 ASSEMBLING...

Page 228: ...3 CRANKSHAFT AND CONNECTING RODS 5 114 REMOVING THE CRANKSHAFT 5 115 REMOVING THE CONNECTING RODS 5 115 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 115 INSTALLING THE CONNECTING RODS 5 119 INSTALLING THE CRANKSHAFT 5 121 TRANSMISSION 5 122 CHECKING THE SHIFT FORKS 5 125 CHECKING THE SHIFT DRUM ASSEMBLY 5 125 CHECKING THE TRANSMISSION 5 126 INSTALLING THE TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIF...

Page 229: ...the muffler and exhaust pipes Muffler Front exhaust pipe Rear exhaust pipe Gasket 1 1 1 2 Remove the parts in the order listed For installation reverse the removal procedure 30 Nm 3 0 m kg 20 Nm 2 0 m kg 25 Nm 2 5 m kg ENGINE ENG EAS00188 ENGINE ENGINE ...

Page 230: ...r carburetor joint Air induction system parts Starter motor Refer to SEATS AND SIDE COVERS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Refer to CARBURETOR in chapter 6 Refer to AIR INDUCTION SYSTEM in chapter 6 Refer to STARTER MOTOR in chapter 7 40 Nm 4 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 70 Nm 7 0 m kg ...

Page 231: ...otrest right Oil filter bolt Oil filter bracket Horn Oil delivery pipe Brake hose holder 1 1 1 1 1 Drain Drain Refer to TRANSFER GEAR CASE Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Refer to GENERATOR AND STARTER CLUTCH For installation reverse the removal procedure 40 Nm 4 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 70 Nm 7 0 m kg ENGINE ENG ...

Page 232: ...parks plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Charcoal canister hose carburetor to charcoal canister Plastic clamp Stator coil coupler Decompression solenoid coupler Pickup coil coupler 4 1 1 1 1 1 1 2 1 Disconnect the parts in the order listed ENGINE ENG ...

Page 233: ...E 5 5 ENGINE ENG Order Job Part Q ty Remarks 10 11 12 Neutral switch over Neutral switch Speed sensor 1 1 1 For connecting reverse the disconnection procedure ...

Page 234: ...e bracket bolt Horn bracket Front engine bracket Self locking nut Upper rear mounting bolt Rear engine bracket bolt 4 1 4 1 2 2 1 2 Remove the parts in the order listed Place a suitable stand under the frame and engine NOTE 48 Nm 4 8 m kg 88 Nm 8 8 m kg 88 Nm 8 8 m kg 88 Nm 8 8 m kg 48 Nm 4 8 m kg ENGINE ENG EAS00191 ENGINE ...

Page 235: ...ear engine bracket Lower front mounting bolt Lower rear mounting bolt Engine 2 1 1 1 Refer to INSTALLING THE ENGINE For installation reverse the removal procedure 48 Nm 4 8 m kg 88 Nm 8 8 m kg 88 Nm 8 8 m kg 88 Nm 8 8 m kg 48 Nm 4 8 m kg ENGINE ENG ...

Page 236: ... engine bracket bolts 4 upper rear mounting bolt 5 self locking nuts 6 front engine brackets 7 horn bracket 8 front engine bracket bolts 9 upper front mounting bolt 10 self locking nuts 11 Do not fully tighten the bolts and nuts 2 Tighten front engine bracket bolts 9 self locking nut 6 self locking nuts 11 3 Install speed sensor 1 4 Install neutral switch 1 neutral switch cover 2 ...

Page 237: ...ssion solenoid coupler stator coil coupler 6 Install plastic clamp 1 7 Connect charcoal canister hose carburetor to char coal canister 1 8 Connect clutch cable 1 9 Connect oil tank breather hose 1 cylinder head breather hose 2 spark plug caps 3 Refer to CABLE ROUTING in chapter 2 10 Install brake hose holder 1 joint bolt 2 oil delivery pipe 3 bolts 4 ...

Page 238: ...AND STARTER CLUTCH rider footrest left Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS transfer gear case Refer to TRANSFER GEAR CASE 13 Fill transfer gear case with the specified amount of the recom mended transfer gear oil Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 14 Install oil filter cartridge 15 Fill oil tank with the specified amount of the recom mended engine oil Refer to CHANGI...

Page 239: ...YSTEM in chapter 6 carburetor joint carburetor Refer to CARBURETOR in chapter 6 air filter case Refer to AIR FILTER CASE in chapter 3 fuel tank Refer to FUEL TANK in chapter 3 side covers rider seat Refer to SEATS AND SIDE COVERS in chapter 3 17 Install gaskets exhaust pipes Finger tighten the exhaust pipe nuts 18 Install muffler bolts 1 19 Tighten exhaust pipe nuts clamp bolts 1 ...

Page 240: ...ster hose Rider footrest left Engine left side cover Timing mark accessing screw Crankshaft end cover 4 4 1 2 1 1 1 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVER FUEL TANK and AIR FILTER CASE in chapter 3 Drain Disconnect Disconnect 10 Nm 1 0 m kg 18 Nm 1 8 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg ROCKER ARMS PUSH RODS AND VALVE LIFTERS ENG ROCKER ARMS PUSH RODS AND...

Page 241: ...ion solenoid cover Camshaft sprocket cover Camshaft sprocket cover gasket Dowel pin 1 1 1 2 For installation reverse the removal procedure 10 Nm 1 0 m kg 18 Nm 1 8 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg ROCKER ARMS PUSH RODS AND VALVE LIFTERS ENG ...

Page 242: ... 8 9 10 Removing cylinder head covers Cylinder head breather hose Oil tank breather hose Bolt Bolt Bolt Bolt Rear cylinder head cover Front cylinder head cover Cylinder head cover gasket Dowel pin 1 1 4 4 4 12 1 1 2 4 Remove the parts in the order listed 65 mm 35 mm 50 mm 25 mm 10 Nm 1 0 m kg ...

Page 243: ...ALVE LIFTERS ENG Order Job Part Q ty Remarks 11 12 13 14 Rear cylinder head cover spacer Front cylinder head cover spacer Cylinder head cover spacer gasket Dowel pin 1 1 2 4 For installation reverse the removal procedure 10 Nm 1 0 m kg ...

Page 244: ...e push rods and rocker arms Push rod Rear rocker arm base Front rocker arm base Rocker arm base gasket Dowel pin Rocker arm shaft Rocker arm 1 Rocker arm 2 Locknut Adjusting screw 4 1 1 2 4 4 2 2 2 2 Remove the parts in the order listed For installation reverse the removal procedure 10 Nm 1 0 m kg 20 Nm 2 0 m kg ...

Page 245: ... rod cover Oil seal O ring Throttle stop screw Throttle stop screw holder Rear valve lifter case cover Front valve lifter case cover Rear valve lifter case Front valve lifter case Valve lifter 2 4 4 1 1 1 1 1 1 4 Remove the parts in the order listed Unhook For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg ...

Page 246: ... rotor cover c Check the camshaft drive gear mark c posi tion and camshaft driven gear mark d posi tion as shown If the marks are not aligned turn the crank shaft counterclockwise 360 degrees and re check step b 2 Remove rocker arm bases with the rocker arms 3 Remove valve lifters Make a note of the position of each valve lifter so that they can be installed in the correct place Do not lay the rem...

Page 247: ...place Rocker arm inside diameter 15 000 15 018 mm 4 Measure rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diameter 14 981 14 991 mm 5 Calculate rocker arm to rocker arm shaft clearance Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm Replace the defective part s Rocker arm to ro...

Page 248: ...end Bends damage Replace 2 Measure push rod runout Out of specification Replace Push rod runout 0 3 mm CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check valve lifter Blue discoloration excessive wear pit ting scratches Replace or check the lu brication system 2 Check valve lifter case 1 Damage wear Replace the valve lifter case O ring 2 Damage wear Replace the O ring ...

Page 249: ...Replace Valve lifter case inside diameter 22 990 23 010 mm 5 Calculate valve lifter to valve lifter case clearance Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm Replace the defective part s Valve lifter to valve lifter case clearance 0 0156 0 042 mm BLEEDING THE VALVE LIFTER The valve lifter must be bled in the following conditions replacing parts oil...

Page 250: ...e sure to reinstall the valve lifter to its origi nal position c Start the engine and warm it up d Stop the engine e Remove the camshaft sprocket cover f Rotate the camshaft and align it to top dead center TDC of piston 1 If the spark plugs are removed the crankshaft can be rotated smoothly Be careful as the engine will get hot g When piston 1 is at TDC mark the position of the camshaft driven gea...

Page 251: ... the camshaft drive gear when bleeding the valve lifters and then bleed the valve lifters i Leave the valve lifters and camshaft drive gear aligned for five minutes j If a number of valve lifters are to be bled re peat steps h and i above CHECKING THE PUSH ROD COVERS 1 Check push rod cover 1 Cracks damage Replace oil seal 2 O ring 3 Damage wear Replace the oil seal and O ring as a set INSTALLING T...

Page 252: ...r case covers 1 throttle stop screw holder 2 4 Hook throttle stop screw 3 5 Install O rings 1 oil seals 2 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin ders 1 Install rocker arms 1 rocker arm shafts 2 onto rocker arm base The thread hole a of the rocker arm shaft must face to the outside ...

Page 253: ...stall the push rods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right side of the motorcycle A Rear cylinder B Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter Lubricate the push rod end balls to the engine oil c Install the rocker arm base bolts Tighten the rocker arm base bolts in stages and...

Page 254: ...re applies to both cylin ders 1 Install dowel pins 1 cylinder head cover spacer gasket 2 New 2 Install cylinder head cover spacer 1 3 Install dowel pins 1 cylinder head cover gasket 2 New 4 Install cylinder head cover 1 Bolts 2 25 mm Bolts 3 35 mm Bolts 4 50 mm Bolts 5 65 mm 5 Connect oil tank breather hose 1 cylinder head breather hose 2 ...

Page 255: ...FT SIDE COVER 1 Install dowel pins 1 camshaft sprocket cover gasket 2 New 2 Install camshaft sprocket cover 1 decompression solenoid cover 2 3 Install crankshaft end cover 1 timing mark accessing screw 2 4 Install engine left side cover 1 5 Install rider footrest left 1 6 Connect charcoal canister hoses ...

Page 256: ... in chapter 2 A Forward 10 Fill oil tank with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 11 Install air filter case fuel tank rider seat Refer to AIR FILTER CASE FUEL TANK and SEATS AND SIDE COVERS in chapter 3 12 Adjust installed shift rod length Refer to ADJUSTING THE SHIFT PEDAL in chapter 3 ...

Page 257: ...ession solenoid Long decompression push rod Short decompression push rod Camshaft drive gear Straight key Camshaft driven gear Straight key Oil delivery pipe 1 1 1 1 1 1 1 1 Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Refer to ENGINE 92 mm 78 mm 7 Nm 0 7 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg 30 Nm 3 0 m kg 52 Nm 5 2 m kg CAMSHAFTS ...

Page 258: ... 14 Camshaft cover Camshaft cover gasket Dowel pin Front cylinder camshaft end cover Front cylinder camshaft Rear cylinder camshaft 1 1 1 1 1 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg 30 Nm 3 0 m kg 52 Nm 5 2 m kg ...

Page 259: ...opper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gears 3 Remove front cylinder camshaft end cover camshaft drive gear 1 camshaft driven gear 2 straight keys Cover the crankcase hole with a clean reg 3 to prevent the straight keys from falling into the crankcase 4 Remove oil d...

Page 260: ...nimum camshaft lobe dimen sions Intake lobe a 36 494 mm b 31 850 mm Exhaust lobe a 36 454 mm b 31 850 mm 3 Measure camshaft journal diameter crankcase side a Out of specification Replace the cam shaft Camshaft journal diameter crankcase side 24 937 24 950 mm 4 Measure camshaft journal diameter camshaft cover side b Out of specification Replace the cam shaft Camshaft journal diameter camshaft cover...

Page 261: ...rankcase clearance Out of specification Replace the defective part s Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter Camshaft to crankcase clearance 0 050 0 084 mm 8 Calculate camshaft to camshaft cover clearance Out of specification Replace the defective part s Calculate the clearance by subtracting the cam...

Page 262: ...rt s CHECKING THE DECOMPRESSION SYSTEM 1 Check decompression system Check the decompression system while the decompression push rod is installed in the camshaft Check that the decompression pin 1 projects from the camshaft Check that the decompression push rod 2 moves smoothly 2 Check decompression push rods Bends damage Replace ...

Page 263: ... THE CAMSHAFTS 1 Install camshafts to the camshaft cover front cylinder camshaft end cover Lubricate molybdenum disulfide oil onto the camshft journals and lobes Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft 2 Install front cylinder camshaft end cover 1 Finger tighten the place bolts 3 Install dowel pins 1 camshaft cover gasket 2 New ...

Page 264: ...shaft drive gear 1 with the punch mark b on the cam shaft driven gear 2 Insert a cross headed screwdriver into one of the holes in the outer camshft driven gear and rotate the gear until the teeth of both driven gears are aligned The teeth of both camshaft driven gears must be aligned for installation 6 Install washers camshaft drive gear bolt camshaft driven gear nut 7 Tighten camshaft driven gea...

Page 265: ...ve gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear 9 Install short decompression push rod 1 long decompression push rod 2 10 Install decompression solenoid 1 11 Install valve lifter s push rods rocker arms cylinder head covers Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS exhaust pipes muffler Refer to ENGINE ...

Page 266: ...l tank with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 13 Install air filter case fuel tank rider seat Refer to AIR FILTER CASE FUEL TANK and SEATS AND SIDE COVERS in chapter 3 ...

Page 267: ... pipe Reed valve case to front cylinder pipe Gasket Oil delivery pipe Copper washer 1 1 2 1 4 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS FUEL TANK and AIR FILTER CASE in chapter 3 Refer to CARBURETOR in chapter 6 Refer to ENGINE Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Disconnect Disconnect 50 Nm 5 0 m kg 21 Nm 2 1 m kg 18 Nm 1 8 m kg 39 Nm 3 9 m kg CYLINDER HEADS ...

Page 268: ...s 6 7 8 9 10 Copper washer Rear cylinder head Front cylinder head Cylinder head gasket Dowel pin 2 1 1 2 4 For installation reverse the removal procedure 50 Nm 5 0 m kg 21 Nm 2 1 m kg 18 Nm 1 8 m kg 39 Nm 3 9 m kg CYLINDER HEADS ENG ...

Page 269: ...all of the cyl inder heads 1 Eliminate combustion chamber carbon deposits with a rounded scraper Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Maximum cylinder head warpage 0 10 mm a Place a straightedge 1 and a thickn...

Page 270: ...al times CHECKING THE OIL DELIVERY PIPE 1 Check oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with com pressed air EAS00232 INSTALLING THE CYLINDER HEADS 1 Install dowel pins 1 gasket 2 New 2 Install cylinder heads washers cylinder head nuts M12 1 4 cylinder head nuts M10 5 6 Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening...

Page 271: ...skets reed valve case to front cylinder pipe 1 reed valve case to rear cylinder pipe 2 5 Install rocker arms cylinder head covers Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS muffler exhaust pipes Refer to ENGINE carburetor Refer to CARBURETOR in chapter 6 air filter case fuel tank rider seat Refer to AIR FILTER CASE FUEL TANK and SEATS AND SIDE COVERS in chapter 3 ...

Page 272: ...eat Outer valve spring Inner valve spring Intake valve Exhaust valve Valve oil seal Lower spring seat 4 4 4 4 2 2 4 4 Remove the parts in the order listed The following procedure applies to both cylinders Refer to CYLINDER HEADS For installation reverse the removal pro cedure VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS ...

Page 273: ...age at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 2 Remove valve cotters Remove the valve cotters by compressiong the valve springs with the valve spring compressor 1 Valve spring compressor 90890 ...

Page 274: ...nd valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification Replace the valve guide Valve stem to valve guide clea rance Intake 0 010 0 037 mm Limit 0 08 mm Exhaust 0 025 0 052 mm Limit 0 1 mm 2 Replace Svalve guide To ease valve guide removal and installation and to maintain the correct...

Page 275: ...ide clearance After replacing the valve guide reface the valve seat Valve guide remover 6 mm 90890 04064 Valve guide installer 6 mm 90890 04065 Valve guide reamer 6 mm 90890 04066 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Mea...

Page 276: ...pplies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head Valve seat width Intake 0 9 1 1 mm Limit 2 0 mm Exhaust 0 9 1 1 mm Limit 2 0 mm a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve ...

Page 277: ...he lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your h...

Page 278: ...ion j Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spring Valve spring free length intake and exhaust Inner valve spring 38 26 mm Limit 36 26 mm Outer valve spr...

Page 279: ...3 7 3 kg at 29 0 mm Intake and exhaust outer valve spring 13 9 16 1 kg at 31 0 mm 3 Measure valve spring tilt a Out of specification Replace the valve spring Maximum valve spring tilt Intake and exhaust inner valve spring 2 4 mm Intake and exhaust outer valve spring 2 4 mm EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr valve stem...

Page 280: ... seat 6 into the cylinder head Install the valve springs with the larger pitch a facing up b Smaller pitch 4 Install valve cotters Install the valve cotters by compressing the valve springs with the valve spring compressor 1 Valve spring compressor 90890 04019 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive fo...

Page 281: ...inder heads Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 2 2 4 4 2 2 2 2 2 Remove the parts in the order listed Refer to CYLINDER HEAD For installation reverse the removal pro cedure CYLINDERS AND PISTONS ENG EAS00251 CYLINDERS AND PISTONS ...

Page 282: ...on mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller set 90890 01304 2 Remove top ring 2nd ring oil ring When removing a piston ring open the end gap with your fingers and lift the other side o...

Page 283: ... 05 mm C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 b If out of specification replace the cylinder and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer Micrometer 90890 03009 a 5 mm from the bottom edge of the piston Piston size P Standard 94 960 94 975 mm d If out of specification replace the...

Page 284: ...ore measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 03 0 08 mm Limit 0 12 mm 2nd ring 0 03 0 07 mm Limit 0 12 mm 2 Install piston ring into the cylinder Level the piston ring in the cylinder with the pis ton crown a 10 mm 3 Measure piston ring end gap Out of specification Replace the piston ...

Page 285: ...ton pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 21 991 22 000 mm Limit 21 971 mm 3 Measure piston pin bore diameter in the piston b Our of specification Replace the piston pin Piston pin bore diameter in the piston 22 0...

Page 286: ... INDERS The following procedure applies to all of the pis tons and cylinders 1 Install top ring 2nd ring lower oil ring rail upper oil ring rail oil ring expander Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install piston 1 piston pin 2 piston pin clip 3 New Apply engine oil onto the piston pin Make sure the arrow mark a on the piston faces towards the...

Page 287: ...cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Front of the motorcycle 6 Install cylinder 1 While compressing the piston rings with one hand install the cylinder with the other hand ...

Page 288: ...ch cable Pull lever Pull lever spring Pickup coil coupler Shift arm Clutch cable holder Clutch cover 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS in chapter 3 Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Drain Disconnect Disconnect 10 Nm 1 0 m kg 10 Nm 1 0 m kg CLUTCH ENG EAS00273 CLUTCH ...

Page 289: ...E 5 61 CLUTCH ENG Order Job Part Q ty Remarks 8 9 Clutch cover gasket Dowel pin 1 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg ...

Page 290: ...ull lever shaft and pickup coil Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Pickup coil lead holder Pickup coil 1 1 1 1 2 3 3 1 Remove the parts in the order listed For installation reverse the removal procedure 7 Nm 0 7 m kg CLUTCH ENG ...

Page 291: ...ring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Clutch plate Lock washer Wire circlip Clutch plate Friction plate Clutch damper spring 1 1 1 1 1 7 6 1 1 1 1 1 Remove the parts in the order listed Refer to GENERATOR 70 Nm 7 0 m kg 115 Nm 11 5 m kg 8 Nm 0 8 m kg EAS00274 ...

Page 292: ...3 Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 115 Nm 11 5 m kg 8 Nm 0 8 m kg ...

Page 293: ... clutch boss nut 1 While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut Clutch holding tool 90890 04086 4 Remove clutch boss nut 1 lock washer 2 clutch boss assembly 3 There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch ch...

Page 294: ...s a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm Limit 2 8 mm EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface pla...

Page 295: ...using dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check bearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Che...

Page 296: ...DRIVE 1 Check primary drive gear 1 primary driven gear 2 Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Re place the primary drive gear and clutch hous ing as a set INSTALLING THE PICKUP COIL AND PULL LEVER SHAFT 1 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 2 Install pickup coil pickup coil lead holder Ap...

Page 297: ...RIVE GEAR 1 Install straight key 1 primary drive gear 2 pickup coil rotor 3 spacer 4 pickup coil rotor bolt 5 The timing marks on the pickup coil rotor must face outside Apply locking agent LOCTITE to the threads of the pickup coil rotor bolt While holding the generator rotor 6 with the sheave holder 7 tighten the pickup coil rotor bolt Sheave holder 90890 01701 2 Bend the lock washer tab along a ...

Page 298: ...ven gear teeth and primary drive gear teeth mesh correctly Make sure that the oil pump drive gear teeth and oil pump driven gear teeth mesh correctly 3 Install clutch boss assembly 1 If the wire circlip 2 has been removed care fully install a new one Install the clutch damper spring 3 with the OUTSIDE mark facing out 4 Install clutch boss 1 lock washer New clutch boss nut 2 While holding the clutc...

Page 299: ... Recommended lubricant Engine oil 7 Install friction plates clutch plates First install a friction plate and then alternate between a clutch plate and a friction plate Align the two embossed mark a on the clutch housing with the two semicircular slots b in the friction plates 8 Install pressure plate 1 Align the punch mark a in the pressure plate with the punch mark b in the clutch boss ...

Page 300: ...h spring plate retainer bolts in stages and in a crisscross pattern 10 Install dowel pins 1 clutch cover gasket 2 New 11 Install clutch cover 1 clutch cable holder 2 Tighten the clutch cover bolts in stages and in a crisscross pattern 12 Connect pickup coil coupler Refer to CABLE ROUTING in chapter 2 13 Install shift arm 1 Align the mark a in the shift shaft with the slot in the shift arm ...

Page 301: ...lutch cable holder to 31 8 mm 15 Connect clutch cable 1 16 Fill oil tank with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 17 Install engine left side cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS left side cover Refer to SEATS AND SIDE COVERS in chapter 3 18 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in...

Page 302: ...Engine oil Clutch housing Circlip Shift shaft spring Shift shaft Shift shaft spring stopper Lock washer Stopper lever Stopper lever spring 2 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to CLUTCH For installation reverse the removal procedure 22 Nm 2 2 m kg 10 Nm 1 0 m kg EAS00327 SHIFT SHAFT ...

Page 303: ...LING THE STOPPER LEVEL AND SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 Apply locking agent LOCTITE to the threads of stopper lever bolt Install the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install lock washer 1 New shift shaft spring stopper 2 Apply locking agent LOCTITE to the t...

Page 304: ...OTE 4 Install shift shaft spring circlips shift shaft 1 Install the end of the shift shaft spring onto the shift shaft spring stopper 2 5 Install clutch housing Refer to CLUTCH 6 Fill oil tank Refer to CHANGING THE ENGINE OIL ...

Page 305: ...ch coupler Rider footrest right Stator coil assembly coupler Decompression solenoid coupler Oil delivery pipe Generator cover Generator cover gasket Dowel pin 1 1 1 1 2 1 1 1 2 Remove the parts in the order listed Refer to SEATS AND SIDERS and FUEL TANK in chapter 3 Refer to ENGINE Drain Disconnect Disconnect Disconnect 7 Nm 0 7 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg EAS0...

Page 306: ...TER CLUTCH ENG Order Job Part Q ty Remarks 10 11 Stator coil assembly lead holder Stator coil assembly 1 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg ...

Page 307: ... rotor and starter clutch Starter clutch idle gear shaft 2 Starter clutch idle gear shaft 1 Starter clutch idle gear 2 Starter clutch idle gear 1 Generator rotor Starter clutch gear 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 160 Nm 16 0 m kg EAS00343 ...

Page 308: ...or rotor bolt Sheave holder 90890 01701 3 Remove generator rotor 1 with the rotor puller 2 Rotor puller 90890 01081 EAS00348 CHECKING THE STARTER CLUTCH 1 Check starter clutch idle gears 1 starter clutch gear 2 Chips pitting roughness wear Replace the defective part s 2 Check starter clutch operation a Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch b When tur...

Page 309: ... 1 Install starter clutch gear 1 generator rotor 2 washer generator rotor bolt 3 Clean the tapered portion of the crankshaft and the generator rotor hub 2 Tighten generator rotor bolt 1 While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Sheave holder 90890 01701 3 Install starter clutch idle gear 1 1 starter clutch idle gear 2 2 starter clutch idle gear s...

Page 310: ...the stator coil assembly lead grommet Yamaha bond No 1215 90890 85505 5 Install stator coil assembly 1 stator coil assembly lead holder Apply locking agent LOCTITE to the threads of the stator coil assembly bolts 6 Install dowel pins 1 generator cover gasket 2 New 7 Install generator cover 1 8 Install oil delivery pipe joint 1 bolts 2 oil delivery pipe 3 ...

Page 311: ...CABLE ROUTING in chapter 2 10 Install rider footrest right 1 11 Connect rear brake light switch coupler 1 Refer to CABLE ROUTING in chapter 2 12 Install plastic locking tie 1 Fasten the rear brake light switch lead and wire harness 13 Fill oil tank with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 ...

Page 312: ...5 84 E GENERATOR AND STARTER CLUTCH ENG 14 Install exhaust pipes muffler Refer to ENGINE 15 Install fuel tank left side cover rider seat Refer to FUEL TANK and SEATS AND SIDE COVERS in chapter 3 ...

Page 313: ...ider covers Negative battery lead Positive battery lead Tool kit holder Tool kit Battery holder Battery Plastic bracket Ignitor unit coupler Ignitor unit holder 1 1 1 1 1 1 1 3 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS in chapter 3 Disconnect Disconnect 10 Nm 1 0 m kg TRANSFER GEAR CASE ...

Page 314: ...r Job Part Q ty Remarks 10 11 12 13 14 15 Ignitor unit Battery box Relay unit coupler Turn signal relay coupler Plastic clamp Relay bracket 1 1 1 1 1 1 Disconnect Disconnect For installation reverse the removal procedure 10 Nm 1 0 m kg ...

Page 315: ...pes Engine oil Oil tank breather hose Dipstick Dipstick joint Oil pipe 1 Oil pipe 2 Oil tank cover Oil tank cover gasket Dowel pin Oil strainer 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to ENGINE Drain Disconnect For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg 43 Nm 4 3 m kg ...

Page 316: ... pin Transfer gear oil pump Transfer gear oil pump gasket Transfer gear case cover Transfer gear case cover gasket Dowel pin Oil strainer 1 2 1 2 1 1 1 1 2 1 Remove the parts in the order listed Drain Refer to DRIVE BELT AND DRIVE SPROCKET in chapter 4 10 Nm 1 0 m kg 10 Nm 1 0 m kg 18 Nm 1 8 m kg 85 Nm 8 5 m kg 30 Nm 3 0 m kg 8 Nm 0 8 m kg 24 Nm 2 4 m kg 30 Nm 3 0 m kg 30 Nm 3 0 m kg ...

Page 317: ...imary chain Middle drive gear Middle driven shaft Transfer gear case Spacer Dowel pin Oil seal Bearing 1 1 1 1 1 1 2 1 2 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg 18 Nm 1 8 m kg 85 Nm 8 5 m kg 30 Nm 3 0 m kg 8 Nm 0 8 m kg 24 Nm 2 4 m kg 30 Nm 3 0 m kg 30 Nm 3 0 m kg ...

Page 318: ...ssembling the transfer gear case oil pump Oil pump cover Pin Pin Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing 1 2 1 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 7 Nm 0 7 m kg ...

Page 319: ...ocket 1 Straighten the lock washer tab 2 Loosen middle drive gear nut 1 When loosening the middle drive gear nut press down on the brake pedal so the middle drive gear does not move 3 Remove primary chain 1 middle drive gear 2 middle driven shaft 3 Remove the primary chain middle drive gear and middle driven shaft at the same time CHECKING THE MIDDLE DRIVE 1 Check middle drive gear 1 middle driven...

Page 320: ...an with engine oil CHECKING THE OIL PUMP 1 Check oil pump housing 1 oil pump cover 2 Cracks damage wear Replace the de fective part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clearance b Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 07 0 12 mm Outer rotor to oil pump ho...

Page 321: ...ate inner rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install oil pump housing 1 oil pump outer rotor 2 oil pump inner rotor 3 oil pump shaft 4 pin 5 When installing the oil pump shaft align the pin in the oil pump shaft with the groove in the oil pump inner rotor Align the arrow a on the pump outer rotor with the arrow b on the oil pump inner...

Page 322: ...TALLING THE TRANSFER GEAR CASE 1 Install bearings oil seal 2 Install middle driven shaft 1 middle drive gear 2 primary chain 3 into the transfer gear case O ring spacer drive sprocket nut 4 Install the middle driven shaft middle drive gear and primary chain at the same time Temporarily install the drive sprocket nut onto the middle driven shaft 3 Install oil strainer 1 dowel pins 2 transfer gear c...

Page 323: ...ransfer gear case assembly 1 While installing the middle drive gear 2 onto the drive axle install the transfer gear case as sembly onto the engine Align the splines on the middle gear with the splines on the drive axle 7 Install transfer gear case bolts 1 Nut 2 8 Install lock washer New middle drive gear nut 1 9 Bend the lock washer tab along a flat side of the nut ...

Page 324: ... drive sprocket nut 11 Install transfer gear oil pump gasket New transfer gear oil pump 1 Apply locking agent LOCTITE only to the threads of the transfer gear oil pump bolts M6 25 mm bolts 2 12 Install dowel pins 1 13 Install cover 1 cover bolts M8 2 cover bolts M6 3 14 Install dowel pins 1 ...

Page 325: ... Refer to DRIVE BELT AND DRIVE SPROCKET in chapter 4 17 Fill transfer gear case with the specified amount of the recom mended transfer gear oil Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 INSTALLING THE OIL TANK COVER 1 Install dowel pins 1 oil tank cover gasket 2 New oil strainer 3 2 Install oil tank cover 1 ...

Page 326: ...n the dipstick joint bolt 4 Connect oil tank breather hose 3 5 Install oil pipes 1 INSTALLING THE BATTERY 1 Install relay bracket 1 plastic clamp 2 2 Connect turn signal relay coupler relay unit coupler 3 Install battery box 4 Install ignitor unit 1 ignitor unit holder 2 5 Connect ignitor unit couplers ...

Page 327: ...nstall Negative battery lead 1 to the dipstick joint 8 Install battery 1 battery holder 2 tool kit 3 tool kit holder 4 9 Connect battery leads to the battery terminals First connect the positive battery lead 5 then the negative battery lead 6 10 Check battery terminals ...

Page 328: ...over Oil delivery pipe Engine oil pump driven gear stopper 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS Refer to CYLINDERS AND PISTONS Refer to SHIFT SHAFT Refer to GENERATOR AND STARTER CLUTCH 10 Nm 1 0 m kg 20 Nm 2 0 m kg 43 Nm 4 3 m kg 10 Nm 1 0 m kg 28 Nm 2 8 m kg 10 Nm 1 0 m kg CRANKCASE ENG CRANKCASE ...

Page 329: ...y Remarks 4 5 6 7 8 Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase 1 1 2 1 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 20 Nm 2 0 m kg 43 Nm 4 3 m kg 10 Nm 1 0 m kg 28 Nm 2 8 m kg 10 Nm 1 0 m kg ...

Page 330: ...arks 1 2 3 Removing the buffle plate and bearings Crankshaft Transmission Buffle plate Oil seal Bearing 1 1 4 Remove the parts in the order listed Refer to CRANKSHAFT Refer to TRANSMISSION Installation reverse the removal procedure 10 Nm 1 0 m kg ...

Page 331: ...me in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical or der refer to the numbers in the illustration A Right crankcase B Left crankcase M8 100 mm bolts 1 2 M8 80 mm bolts 3 M6 105 mm bolts 21 M6 85 mm bolts 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 3 Turn shift drum segment Turn the s...

Page 332: ...make sure the crankcase halves separate evenly EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00401 CHECKING THE BEARINGS AND OIL SEAL 1 Check bearings Clean and lubricate the bea...

Page 333: ...ctive part s EAS00416 ASSEMBLING THE CRANKCASE 1 Apply sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Do not allow any sealant to come into contact with the oil gallery 2 Install dowel pins 1 joint pipe 2 3 Install left crankcase onto the right crankcase Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment s tee...

Page 334: ...ion A Left crankcase B Right crankcase M8 100 mm bolts 1 2 M8 80 mm bolts 3 M6 105 mm bolts 21 M6 85 mm bolts 9 13 M6 75 mm bolts 14 15 M6 60 mm bolts 4 7 M6 40 mm bolts 8 10 12 16 20 Bolt 1 3 24 Nm 2 4 m kg Bolt 4 21 10 Nm 1 0 m kg 5 Check crankshaft and transmission operation Rough movement Repair 6 Install engine oil pump driven gear 1 engine oil pump driven gear stopper 2 oil delivery pipe 3 b...

Page 335: ...enerator rotor 2 with the sheave holder 3 tighten the generator shaft bolt Sheave holder 90890 01701 9 Install generator shaft end cover 1 10 Install shift shaft clutch Refer to SHIFT SHAFT and CLUTCH pistons cylinders Refer to CYLINDERS AND PISTONS camshaft Refer to CAMSHAFTS cylinder head Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 11 Install engine Refer to ENGINE ...

Page 336: ...ng the engine oil pump Crankcase Oil strainer Engine oil pump assembly 1 1 Remove the parts in the order listed Separate Refer to CRANKCASE Installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg ENGINE OIL PUMP ENG ENGINE OIL PUMP ...

Page 337: ...pump Spring retainer Spring Relief valve Oil pump housing cover 1 Pin Spring Ball Oil pump outer rotor 1 Oil pump inner rotor 1 Pin 1 1 1 1 2 1 1 1 1 1 Remove the parts in the order listed 1 2 3 4 5 6 7 8 9 10 Nm 1 0 m kg 2 Nm 0 2 m kg 2 Nm 0 2 m kg ENGINE OIL PUMP ENG ...

Page 338: ...rks Oil pump housing cover 2 Pin Oil pump shaft Pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil seal Oil pump housing 1 2 1 1 1 1 2 1 For assembly reverse the disassembly procedure 11 12 13 14 15 16 17 18 10 Nm 1 0 m kg 2 Nm 0 2 m kg 2 Nm 0 2 m kg ...

Page 339: ...n Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 0 12 mm Outer rotor to oil pump housing clearance feed pump 0 03 0 08 mm Outer rotor to oil pump housing clearance scavenging pump 0 06 0 11 mm 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS00365 CHECKING THE RELIEF VALVE 1 Check relie...

Page 340: ...gine oil EAS00374 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install oil pump housing 1 oil seals 2 oil pump outer rotor 2 3 oil pump inner rotor 2 4 pin 5 oil pump shaft 6 pins 7 oil pump housing cover 2 8 pin 9 oil pump inner rotor 1 10 oil pump inner rotor 1 11 ball 12 spring 13 pins 14 oil pump ho...

Page 341: ...ner rotor align the pin in the oil pump shaft with the groove in the inner ro tor 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 The arrow a on the oil strainer cover must point towards the rear of the engine ...

Page 342: ...ankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing 1 1 2 2 2 2 Remove the parts in the order listed Separate Refer to CRANKCASE Installation reverse the removal procedure 38 5 Nm 3 85 m kg CRANKSHAFT AND CONNECTING RODS ENG CRANKSHAFT AND CONNECTING RODS ...

Page 343: ...RODS 1 Remove connecting rod caps 1 connecting rods big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place EAS00398 CHECKING THE CRANKSHAFT AND CON NECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Maximum crankshaft runout 0 04 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surf...

Page 344: ...earings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves Do not mov...

Page 345: ... TIGHTENING until the specified torque is reached If the tightening is inter rupted between 3 3 and 4 0 m kg loosen the connecting rod bolts to less than 3 3 m kg and start again Refer to INSTALLING THE CONNECTING RODS Connecting rod bolt 38 5 Nm 3 85 m kg f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS g Measure the compressed Plastigauge width e on each cra...

Page 346: ...in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 2 re spectively then the bearing size for P1 is P1 connecting rod P1 crank shaft web 6 2 4 green BIG END BEARING COLOR CODE 1 blue 2 black 3 brown 4 green 5 yellow 5 Measure crankshaft journal diameter a Out of specification Replace the crank shaft Crankshaft journal diameter 49 968 49 9...

Page 347: ...culate crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft and crankshaft journal bearings as a set Calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside diameter Crankshaft journal to crankshaft Journal bearing clearance 0 030 0 062 mm INSTALLING THE CONNECTING RODS 1 Lubricate bolt thr...

Page 348: ...in its original place Make sure the projection c on the connecting rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten connecting rod bolt 1 When tightening the connecting rod bolts be sure to use an F type torque wrench Without pausing tighten the connecting rod bolts to the specified torque Apply c...

Page 349: ... INSTALLING THE CRANKSHAFT 1 Install generator shaft 1 2 Install crankshaft Make sure that the generator shaft drive gear teeth and generator shaft driven gear teeth mesh correctly Align the right connecting rod with the front cyl inder sleeve hole ...

Page 350: ...ansmission Crankcase Shift fork guide bar Shift fork L Shift fork R Shift fork C Shift drum assembly Drive axle assembly Main axle assembly Spacer 2 1 1 1 1 1 1 1 Remove the parts in the order listed Separate Refer to CRANKCASE For installation reverse the removal procedure TRANSMISSION ENG TRANSMISSION ...

Page 351: ...in axle assembly Circrip Washer 5th pinion gear 2nd 3rd pinion gear Circlip Washer 4th pinion gear Main axle 1st pinion gear 1 1 1 1 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 TRANSMISSION ENG ...

Page 352: ...5th wheel gear Circlip Washer 2nd wheel gear Circlip Washer 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 11 12 TRANSMISSION ENG ...

Page 353: ...bar on a flat surface Bends Replace Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement along the shift fork guide bar Rough movement Replace the shift fork s and shift fork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum assembly shift drum segment 1 Damage wear Replace the shift ...

Page 354: ...ck transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips Bend...

Page 355: ...ift fork R shift fork C shift fork L shift fork guide bars The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 3 Check transmission Rough movement Repair Oil each gear shaft and bearing thoroughly ...

Page 356: ...E ENG ...

Page 357: ... 8 INSTALLING THE CARBURETOR JOINT 6 12 INSTALLING THE CARBURETOR 6 12 MEASURING AND ADJUSTING THE FUEL LEVEL 6 14 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 15 CHECKING THE FUEL PUMP 6 19 CHECKING THE FUEL COCK 6 19 CHECKING THE FUEL COCK OPERATION 6 20 AIR INDICATION SYSTEM 6 21 AIR INJECTION 6 21 AIR CUTOFF VALVE 6 21 ...

Page 358: ...E CARB CHECKING THE AIR INDUCTION SYSTEM 6 26 INSTALLING THE AIR INDUCTION SYSTEM 6 26 ...

Page 359: ...se carburetor to solenoid valve hose Throttle cable Fuel hose Throttle position sensor Starter cable Starter plunger 1 1 1 2 1 1 1 1 Remove the parts in the order listed Refer to SEATS AND SIDE COVERS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE in chapter 3 Drain Loosen Unhook Disconnect Disconnect Disconnect 48 Nm 4 8 m kg 12 Nm 1 2 m kg CARBURETOR CARB EASS0480 CARBURET...

Page 360: ...canister hose carburetor to charcoal canister Carburetor heater connector Carburetor Fuel pump bracket assembly with fuel pump Vacuum hose Carburetor joint 1 2 1 1 1 1 Disconnect Disconnect Disconnect For installation reverse the removal procedure 48 Nm 4 8 m kg 12 Nm 1 2 m kg ...

Page 361: ...w Vacuum chamber air vent hose Fuel strainer Throttle cable holder Throttle position sensor bracket Carburetor heater Coasting enricher cover Coasting enricher spring Coasting enricher 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed 1 2 3 4 5 6 7 8 9 CARBURETOR CARB EAS00483 ...

Page 362: ...uum chamber cover Piston valve spring Jet needle holder Jet needle kit Piston valve Float chamber Float chamber rubber gasket Drain bolt Accelerator plunger Float pivot pin 1 1 1 1 1 1 1 1 1 1 10 11 12 13 14 15 16 17 18 19 CARBURETOR CARB ...

Page 363: ...marks Float Needle valve Needle valve seat Main jet Spacer Needle jet Pilot jet Starter jet Pilot air jet Pilot screw 1 1 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 20 21 22 23 24 25 26 27 28 29 CARBURETOR CARB ...

Page 364: ...carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket 1 Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check O ring 3 Damage wear Replace the needle v...

Page 365: ... 10 Check jet needle kit 1 main jet 2 needle jet 3 pilot jet 4 starter jet 5 pilot screw 6 pilot air jet 7 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 12 Check starter plunger 1 starter plunger spring 2 Bends cracks damage ...

Page 366: ...Bends cracks damage Replace O ring 3 Damage wear Replace 15 Check fuel hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air CHECKING THE CARBURETOR JOINT 1 Check carburetor joint 1 Cracks damage Replace O rings 2 Damage wear Replace the O ring EAS0048887 ASSEMBLING THE CARBURETOR Before assembling the carburetor wash all of the parts in a petroleum based solvent...

Page 367: ...ot air jet 1 2 Install pilot screw 1 Pilot screw setting 2 1 2 turns out 3 Install starter jet 1 pilot jet 2 4 Install needle jet 1 Align the slot a on the needle jet with the pro jection b on the carburetor body 5 Install spacer 1 main jet 2 ...

Page 368: ...at 1 7 Install needle valve float 1 float pin 2 8 Install accelerator plunger 1 drain bolt 2 float chamber rubber gasket 3 9 Install float chamber 1 10 Install piston valve 1 jet needle kit jet needle holder piston valve spring vacuum chamber cover 2 ...

Page 369: ...the recess in the carburetor body 11 Install coasting enricher 1 coasting enricher spring coasting enricher cover 2 Align the tab a on the coasting enricher with the recess b in the carburetor body 12 Install terminal 1 washer carburetor heater 2 Use Heat Sinker when installing carburetor heater 13 Install throttle position sensor bracket 1 throttle cable holder 2 vacuum chamber air vent hose 3 fu...

Page 370: ...THE CARBURETOR 1 Connect carburetor heater connectors 1 charcoal canister hose carburetor to char coal canister 2 2 Install starter plunger 3 Connect starter cable 1 4 Install throttle position sensor 1 Align the slot a of the throttle position sensor with the projection b of the throttle lever shaft For the correct installation refer to CHECK ING AND ADJUSTING THE THROTTLE POSITION SENSOR ...

Page 371: ...ect throttle cables 1 7 Connect float chamber breather hose carburetor to solenoid valve 1 8 Hook throttle stop screw 1 9 Install carburetor Align the projection a of the carburetor with slot of the carburetor joint 10 Tighten carburetor joint clamp screw 1 ...

Page 372: ...BLE FREE PLAY in chapter 3 EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level fuel level above the float chamber mating surface 4 0 5 0 mm a Stand the motorcycle on a level surface b Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c Install the fuel level gauge 1 onto the fuel drain pipe 2 Fue...

Page 373: ...E THROTTLE POSITION SENSOR Before adjusting the throttle position sensor the engine idling speed should be properly ad justed 1 Check Sthrottle position sensor installed on the carburetor a Disconnect the throttle position sensor cou pler from the wire harness b Connect the pocket tester Ω 1k to the throttle position sensor coupler Positive tester probe blue terminal 1 Negative tester probe black ...

Page 374: ...he read ings from closed to wide open throttle may dif fer slightly from those specified Out of specification or the resistance changes abruptly Go to step 2 below Throttle position sensor resistance 520 900 Ω 4 0 6 0 kΩ at 20_C yellow black 2 Check Sthrottle position sensor removed from the carburetor a Disconnect the throttle position sensor cou pler from the wire harness b Remove the throttle p...

Page 375: ...ester probe black terminal 2 f While slowly opening the throttle check that the throttle position sensor resistance is with in the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the throttle position sensor Check mainly that the resistance changes grad ually when turning the throttle since the read ings ...

Page 376: ...ximum resistance 0 13 0 15 Example If the maximum resistance 5 kΩ then the throttle position sensor s maximum resistance when the throttle is fully closed should be 5 kΩ 0 13 0 15 650 750 Ω Lift the carburetor assembly slightly out of the intake manifolds Loosen the throttle position sensor screws 4 Connect the pocket tester Ω 100 to the throttle position sensor Positive tester probe yellow termin...

Page 377: ...mp is OK Fuel does not flow Replace the fuel pump e Stop the engine and check if the fuel stops flowing from the fuel hose 2 Fuel stops flowing Fuel pump is OK Fuel flows Replace the fuel pump EAS00505 CHECKING THE FUEL COCK 1 Drain fuel for the fuel tank 2 Disconnect fuel hose from the fuel cock 3 Remove fuel cock 1 4 Check fuel cock Cracks damage wear Replace 5 Check fuel cock strainer 1 with co...

Page 378: ...ing the fuel cock check its operation 1 Set the fuel cock to OFF 2 Disconnect fuel hose from fuel cock 3 Check fuel cock operation a Place a container under the end of the fuel cock b Check that the fuel cock lever is turned to ON or RES Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock 4 Connect fuel hose ...

Page 379: ... diaphragm Normally the air cutoff valve is open to allow fresh air to flow into the exhaust port During sudden deceleration the butterfly valve sud denly closes negative pressure is generated and the air cutoff valve is closed in order to pre vent after burning Additionally at high engine speeds and when the pressure decreases the air cutoff valve au tomatically closes to guard against a loss of ...

Page 380: ...N SYSTEM CARB A To the carburetor joint B To the front cylinder head C To the rear cylinder head D To the air cut valve 1 Reed valve 2 Air cut valve 3 Air cleaner 4 Carburetor joint EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 381: ...e case to rear cylinder head hose Reed valve case to rear cylinder head pipe Reed valve case to rear cylinder head hose Reed valve case to rear cylinder head hose Gasket Rectifier regulator coupler Rectifier regulator Air filter bracket 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to FUEL TANK in chapter 3 Disconnect ...

Page 382: ... 13 14 15 16 17 18 19 20 Air filter Air filter cover Air filter hose Air cut valve to air filter hose Plastic locking tie Vacuum hose Bracket Air cut valve holder Air cut valve Air cut valve to reed valve cover hose Reed valve cover Reed valve cover 1 1 1 1 1 1 1 1 1 1 1 1 ...

Page 383: ...6 25 E Order Job Part Q ty Remarks 21 22 23 Reed valve base Reed valve stopper Reed valve 1 2 2 For installation reverse the removal procedure AIR INDUCTION SYSTEM CARB ...

Page 384: ...place 2 Check fibre reed 1 fibre reed stopper reed valve seat Cracks damage Replace the reed valve 3 Measure fibre reed bending a Out of specification Replace the reed valve Maximum fibre reed bending 0 4 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace INSTALLING THE AIR INDUCTION SYSTEM 1 Install reed valves 1 reed valve stoppers 2 reed valve base 3 ...

Page 385: ...reed valve cover bracket 2 3 Install air cut valve to reed valve cover hose 1 air cut valve 2 air cut valve holder 3 4 Install bracket with the air cut valve and reed valve 5 Install vacuum hose 1 plastic locking tie 2 6 Install air cut valve to air filter hose 1 ...

Page 386: ...racket 1 9 Install air filter case assembly 1 10 Install rectifier regulator 1 11 Connect rectifier regulator coupler 2 12 Install gaskets reed valve case to front cylinder head pipe 1 reed valve case to front cylinder head hose reed valve case to rear cylinder head pipe 2 reed valve case to rear cylinder head hose ...

Page 387: ...6 29 E AIR INDUCTION SYSTEM CARB 13 Install fuel tank Refer to FUEL TANK in chapter 3 ...

Page 388: ...E CARB ...

Page 389: ... ELECTRICAL COMPONENTS AND COUPLERS 7 2 SWITCHES 7 6 CHECKING SWITCH CONTINUITY 7 6 CHECKING THE SWITCHES 7 7 CHECKING THE BULBS AND BULB SOCKETS 7 9 TYPES OF BULBS 7 9 CHECKING THE CONDITION OF THE BULBS 7 9 CHECKING THE CONDITION OF THE BULB SOCKETS 7 11 CHECKING THE LEDs 7 11 ...

Page 390: ... 7 27 CHARGING SYSTEM 7 28 CIRCUIT DIAGRAM 7 28 TROUBLESHOOTING 7 29 LIGHTING SYSTEM 7 31 CIRCUIT DIAGRAM 7 31 TROUBLESHOOTING 7 32 CHECKING THE LIGHTING SYSTEM 7 33 SIGNALING SYSTEM 7 36 CIRCUIT DIAGRAM 7 36 TROUBLESHOOTING 7 38 CHECKING THE SIGNALING SYSTEM 7 39 FUEL PUMP SYSTEM 7 45 CIRCUIT DIAGRAM 7 45 FUEL PUMP CIRCUIT OPERATION 7 46 TROUBLESHOOTING 7 47 CHECKING THE FUEL PUMP 7 49 CARBURETOR...

Page 391: ...19 Sidestand switch 20 Pickup coil 21 Startor coil assembly 22 Rear brake light switch 23 Rectifier regulator ESA00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Wire harness 2 Main switch 3 Front brake light switch 4 Ignition coils 5 Throttle position sensor 6 Clutch switch 7 Decompression solenoid 8 Relay unit 9 Turn signal relay 10 Ignitor unit ...

Page 392: ...ND COUPLERS ELEC ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Right handlebar switch coupler left handlebar switch couplers and front turn signal connectors 2 Headlight coupler 1 Tail brake light connectors and rear turn signal connectors ...

Page 393: ...bly couplers 5 Carburetor heater sub wire har ness coupler 6 Throttle position sensor coupler 7 Fuel sender coupler 8 Spark plug cap 2 9 Spark plug cap 1 10 Fuel pump 11 Fuel pump coupler 1 Rear brake light switch lead 2 Rectifier regulator 3 Rectifier regulator coupler 4 Starter motor 5 Starter motor lead 6 Horn coupler 7 Horn 8 Pickup coil 9 Side stand switch ...

Page 394: ...ickup coil coupler speed sensor coupler neutral switch connector and side stand switch coupler 3 Battery negative load 4 Battery positive lead 5 Battery 6 Ignitor unit 7 Tail brake light and rear turn signal light sub wire harness coupler 8 Starter relay 9 Main fuse 10 Starter relay coupler 11 Thermo switch 12 Thermo switch coupler ...

Page 395: ...3 Ignition coil rear cylinder 4 Main switch coupler 5 Main switch 6 Solenoid valve coupler 7 Solenoid valve 8 Spark plug cap 4 9 Rear brake light switch 1 Diode 2 Turn signal relay 3 Relay unit 4 Stator coil 5 Decompression solenoid 6 Neutral switch 7 Speed sensor 8 Relay unit coupler 9 Turn signal relay coupler ...

Page 396: ... pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustrati...

Page 397: ...Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 398: ... switch 2 Dimmer switch 3 Horn switch 4 Turn signal switch 5 Clutch switch 6 Light switch 7 Engine stop switch 8 Start switch 9 Front brake light switch 10 Main switch 11 Fuse 12 Rear brake light switch 13 Sidestand switch 14 Neutral switch ...

Page 399: ...shown in the illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder which must be detached before removing the bulb The ma jority of these bulbs can be removed from their respective socket by turning them coun terclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wi...

Page 400: ... life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to termin...

Page 401: ...ket for continuity If any of the readings indicate no continuity replace the bulb socket CHECKING THE LEDs The following procedure applies to all of the LEDs 1 Check LED for proper operation a Disconnect the meter assembly coupler me ter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minals as shown A wire that is used as a jumper lead must hav...

Page 402: ...arness positive lead Wireharness negative lead Main fuse Relay unit Ignitor unit Ignition coil Spark plug Pickup coil Neutral switch Engine stop switch Ignition fuse 56 Diode 34 35 Sidestand switch 3 4 Main switch Battery EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 403: ... battery EB802403 IGNITION SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EB802011 EB802401 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark ...

Page 404: ...e spark plug cap from the spark plug Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20 C Is the spark plug cap OK YES Replace the spark plug cap NO EB802409 Tester positive probe spark plug lead Tester negative probe spark plug lead 1 1 2 a 2 6 Ignition coil resistance The following procedure applies to all of ...

Page 405: ...ckup coil resistance EB802411 SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EB802412 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES Replace the right handlebar switch NO 9 Engine stop switch EB802413 SCheck the neutral switch for continuity Refer...

Page 406: ...e sky blue Tester negative probe blue yellow 1 2 1 2 Tester positive probe blue yellow Tester negative probe sky blue Continu ity No conti nuity NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the tester readings correct YES NO Replace the relay unit EAS00754 14 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIA...

Page 407: ...harness negative lead Main fuse Starter relay Starter motor Relay unit Ignitor unit Decompression Neutral switch Clutch switch Start switch Engine stop switch Ignition fuse 52 56 Sidestand switch 35 34 Diode 3 4 Main switch Battery 20 solenoid EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 408: ...m operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the en gine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER ...

Page 409: ...flammable gas or fluid is in the vicinity SDoes the starter motor turn NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EB803020 EB802401 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 starter motor 4 relay unit starti...

Page 410: ...elay unit diode Disconnect the relay unit from the coupler Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the diode for continuity as follows YES Replace the relay unit NO Tester positive probe sky blue Tester negative probe black yellow 1 2 Continuity NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the t...

Page 411: ...bar switch NO 8 Engine stop switch EB802413 Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES Replace the neutral switch NO 9 Neutral switch EB802414 Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK YES Replace the side stand switch NO 10 Sidestand switch 1 Tester positive probe red Tester negative...

Page 412: ...tinuity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES Replace the clutch switch NO 12 Clutch switch EB803406 Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES Replace the right handlebar switch NO 13 Start switch FAS00754 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected ...

Page 413: ...Job Part Q ty Remarks 1 2 Removing the starter motor Starter motor lead Starter motor assembly 1 1 Remove the parts in the order listed For installation reverse the removal procedure 5 Nm 0 5 m kg 7 Nm 0 7 m kg EB803500 STARTER MOTOR ...

Page 414: ...Oil seal Bearing Washer set Starter motor front cover Washer set O ring Armature assembly Brush seat along with the brushes Brush holder along with the brushes Starter motor yoke 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 10 2 3 4 5 6 7 8 9 11 12 13 14 1 7 Nm 0 7 m kg EB803501 ...

Page 415: ...cksaw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper op eration of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 03112 Armature assembly Commutator resistance ...

Page 416: ... Replace the brush springs as a set Brush spring force 7 65 10 01 Nm 765 1 001 gf 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s EB803701 ASSEMBLING THE STARTER MOTOR 1 Install starter motor yoke 1 bush holder 2 2 Install brush seat 1 Align the tab a on the brush seat with the slot b in the starter motor rear cover ...

Page 417: ...eal lock washer 1 5 Install O rings 1 New starter motor rear cover 2 starter motor front cover 3 bolts Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers 6 Install starter motor gear 1 circlip 2 INSTALLING THE STARTER MOTOR 1 Install starter motor 1 2 Connect starter lead 2 ...

Page 418: ...7 28 E CHARGING SYSTEM ELEC Generator Rectifier regulator Battery Wireharness positive lead Wireharness negative lead Main fuse 1 2 4 5 6 7 EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 419: ...ery positive terminal Tester negative probe battery negative terminal SStart the engine and let it run at approximate ly 5 000 r min SMeasure the charging voltage NOTE YES NO Replace the fuse 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK EB804010 EB802401 TROUBLESHOOTING The battery is not being charged Check 1 main fuse 2 battery 3 ...

Page 420: ...il resistance 0 45 0 55 Ω at 20_C SIn the stator coil assembly OK YES Replace the stator coil assembly NO Tester positive probe White Tester negative probe white 1 2 SMeasure the startor coil assembly resis tances Tester positive probe white Tester negative probe white 1 3 5 Wiring NO Properly connect or repair the charging system s wiring YES EB804404 SCheck the wiring connections of the entire c...

Page 421: ...ireharness negative lead Meter light 27 Dimmer switch 38 PASS switch 37 Auxiliary light 46 Light switch 38 Tail brake light 54 Headlight fuse 57 High beam indicator light 28 Main fuse 7 Headlight 47 6 LIGHTING SYSTEM ELEC EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 422: ... The lights switch is faulty Replace the right handlebar switch LIGHTING SYSTEM ELEC NOTE YES NO 1 Main and headlight fuses Check the main and headlight fuses for con tinuity Refer to CHECKING THE FUSES in chap ter 3 Are the main and headlight fuses OK Replace the fuse s EB805010 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight posi tion light or met...

Page 423: ...lb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Is the high beam indicator light bulb and socket OK EB805401 CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indicator light fail to come on When the dimmer switch is set to When the dimmer switch is set to Headlight coupler A B YES NO 6 Pass switch Check the pass switch for continuity Refer to CHECKING THE SW...

Page 424: ...ome on NO YES Replace the meter light bulb socket or both 1 Meter light bulb and socket Check the meter light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the meter light bulb and socket OK Headlight Tester positive probe yellow or green Tester negative probe black High beam indicator light Tester positive probe yellow Tester negative probe black 1 2 3 4 5 2 4 Me...

Page 425: ...cket tester DC 20 V to the tail brake light connectors wire harness side as shown The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired This circuit is OK Tester positive probe blue red Tester negative probe black Set the main switch to ON Measure the voltage 12 V of blue on the fail brake light coupler wire harness side Is the voltage within specif...

Page 426: ...7 36 E SIGNALING SYSTEM ELEC EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 427: ...or light 25 Speed meter assembly speed meter combination meter and fuel level meter 29 Turn signal indicator light 30 Fuel sender 32 Flasher relay 33 Horn 39 Horn switch 41 Turn signal switch 42 Front flasher light left 43 Front flasher light right 44 Rear flasher light left 45 Rear flasher light right 48 Rear brake light switch 50 Front brake light switch 54 Tail brake light 55 Signaling system f...

Page 428: ...heck the condition of each of the signal ing system s circuits Refer to CHECK ING THE SIGNAL ING SYSTEM SIGNALING SYSTEM ELEC NOTE YES NO 1 Main signaling system and backup fuses Check the main and signaling system fuses for continuity Refer to CHECKING AND CHARGING THE FUSES in chapter 3 Are the main signaling system and backup fuses OK Replace the fuse s EB806010 TROUBLESHOOTING Any of the follo...

Page 429: ...ler as shown YES NO 2 Voltage Connect the pocket tester DC 20 V to the horn coupler as shown The wiring circuit from the main switch to the horn connector is faulty and must be repaired Tester positive probe black white Tester negative probe ground Set the main switch to ON Push the horn switch Measure the voltage 12 V of brown on the horn coupler Is the voltage within specification Tester positiv...

Page 430: ... SOCKETS Are the turn signal light bulb and socket OK YES NO 2 Brake light switches Check the brake light switches for continuity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch Tester positive probe yellow Tester negative probe black YES NO Replace the turn sig nal light bulb socket or both 1 3 Voltage Connect the pocket tester DC 20 V to the tail brake ...

Page 431: ...y coupler is faulty and must be re paired Tester positive probe brown white Tester negative probe ground 1 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler as shown 6 Voltage Connect the pocket tester DC 20 V to the turn signal light connectors wire harness side or the meter assembly coupler as shown Tester positive probe brown Tester negative probe ground 1 Set the mai...

Page 432: ...HE BULBS AND BULB SOCKETS Is the neutral indicator light bulb and socket OK Replace the neutral indicator light bulb socket or both 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Tester positive probe brown Tester negative probe sky blue Set the main switch to ON Measure the voltage 12 V of brown and sky blue at the meter assembly coupler Is the voltage within s...

Page 433: ...ght fails to come on 1 Engine trouble indicator LED Check the LED of the engine indicator light Refer to CHECKING THE BULBS AND BULB SOCKETS 1 2 YES NO The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired Replace the meter assembly 1 Fuel level indicator light LED Check the LED of the fuel level indicator light Refer to CHECKING THE BULBS AND BULB ...

Page 434: ...44 E YES NO 2 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness Replace the ignitor unit SIGNALING SYSTEM ELEC EAS00843 ...

Page 435: ...Battery 4 Wireharness positive lead 5 Wireharness negative lead Fuel pump 12 Ignitor unit 14 6 Engine stop switch 52 Ignition fuse 56 Main fuse 7 Relay unti 11 FUEL PUMP SYSTEM ELEC EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 436: ...in fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump FUEL PUMP SYSTEM ELEC EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump ...

Page 437: ...CKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch FUEL PUMP SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses Check the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 Are the main and ignition fuses OK Replace the fuse s EB808020 TROUBLESHOOTING The fuel pump fails to operate Check 1 main and ignition fuses 2 battery 3 main switch...

Page 438: ... Relay unit fuel pump relay Disconnect the relay unit from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the relay unit terminals as shown Tester positive probe black blue Tester negative probe black 1 2 Measure the fuel pump resistance Fuel pump resistance 1 6 2 2 Ω at 20 C Is the fuel pump OK Battery positive terminal red black Battery negative terminal blue red 1 2 Tester posit...

Page 439: ...ill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Turn the fuel cock to ON or RES d Connect the battery 12 V to the fuel pump coupler as sh...

Page 440: ...Carburetor heater 60 Carburetor heater graund 61 Main switch 3 Battery 4 Wireharness positive lead 5 Main fuse 7 Carburetor heater fuse 58 Thermo switch 59 CARBURETOR HEATING SYSTEM ELEC EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM ...

Page 441: ...thermometer in the water Slowly heat the water than let it cool to the specified temperature as indicated in the table Check the thermo switch for continuity at the temperatures indicated in the table 1 2 4 3 CARBURETOR HEATING SYSTEM ELEC NOTE YES NO 1 Main and carburetor heater fuses Check the main and carburetor heater fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 Are the main ...

Page 442: ...itch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Does the thermo switch operate properly Carburetor heater resistance 12 V 30 W 6 10 Ω at 20 C Tester positive probe carburetor heater terminal Tester negative probe carburetor heater body 1 2 Is the carburetor heater OK Measure carburetor heater resistance WARNING Test step Water temp...

Page 443: ...ating sys tem s wiring Refer to CIRCUIT DIAGRAM Is the carburetor heating system s wiring properly connected and without defects Properly connect or repair the carburetor heating system s wir ing This circuit is OK CARBURETOR HEATING SYSTEM ELEC EAS00754 ...

Page 444: ...pulse Disconnected Short circuit The engine speed limiter sets in approximately 4 400 rpm The engine trouble indicator light displays the condition code Blinks in patterns of 4 Lights up Decompres sion solenoid Disconnected Short circuit Over heated solenoid Disconnected the thermistor in solenoid Short circuit the thermistor in solenoid The decompression solenoid does not move The starter motor d...

Page 445: ...le indicator light 2 Fuel level indicator light 1 Indicator lights check 1 4 seconds 2 Light off 3 seconds 3 Condition code First fault code 3 throttle position sensor 4 Condition code Next fault code 4 speed sensor 5 Light on 0 5 seconds 6 Light off 0 5 seconds A Light on B Light off C Main switch is turned on D Repetition ...

Page 446: ...ottle position sensor Replace the ignitor unit SELF DIAGNOSIS ELEC NOTE 13 Throttle position sensor 14 Ignitor unit EB812010 TROUBLESHOOTING The engine trouble indicator light or the fuel level level indicator light starts to blink display the self diagnosis se quence Check 1 throttle position sensor 2 speed sensor 3 decompression solenoid 4 fuel level meter Before troubleshooting remove the follo...

Page 447: ...GNOSIS ELEC YES NO 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM In the wire harness OK Replace the speed sensor BAD Repair or replace the wire harness Replace the ignitor unit 2 Speed sensor CIRCUIT DIAGRAM EAS00843 ...

Page 448: ...er negative probe green 1 2 Measure the decompression solenoid resis tance Decompression solenoid resistance thermistor 68 75 78 75 Ω at 25 C The resistance value for the thermistor changes when the temperature changes therefore measure the decompression sole noid resistance at the specified temperature Connect the pocket tester Ω 1 to the de compression solenoid coupler as shown YES NO Repair or ...

Page 449: ...l sender OK Check the decompression solenoid for con tinuity Is the decompression solenoid OK YES NO Replace the decom pression solenoid EB812040 4 Fuel level meter CIRCUIT DIAGRAM Replace the ignitor unit Tester positive probe green Tester negative probe black blue 2 Fuel sender Disconnect the fuel sender coupler from the wire harness Drain the fuel from the fuel tank and remove the fuel sender f...

Page 450: ...7 60 YES NO 3 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace or replace the wire harness Replace the meter assembly SELF DIAGNOSIS ELEC EAS00843 ...

Page 451: ...UM AND HIGH SPEED PERFORMANCE 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 FAULTY GEAR SHIGTING 8 3 SHIFTING IS DIFFICULT 8 3 SHIFT PEDAL DOES NOT MOVE 8 3 JUMPS OUT OF GEAR 8 3 FAULTY CLUTCH 8 3 CLUTCH SLIPS 8 3 CLUTCH DRAGS 8 3 OVERHEA TING 8 4 ENGINE 8 4 FUEL SYSTEM 8 4 CHASSIS 8 4 ELECTRICAL SYSTEMS 8 4 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT FORK LEGS 8 4 LEAKING OIL 8 4 MALFUNCTION 8 4 UNSTABLE HANDLNG ...

Page 452: ...DOES NOT LIGHT 8 5 HEADLIGHT BULB BURNT OUT 8 5 TAIL BRAKE LIGHT DOES NOT LIGHT 8 5 TAIL BRAKE LIGHT BULB BURNT OUT 8 5 TURN SIGNAL DOES NOT LIGHT 8 5 TURN SIGNAL BLINKS SLOWLY 8 5 TURN SIGNAL REMAINS LIT 8 5 TURN SIGNAL BLINKS QUICKLY 8 5 HORN DOES NOT SOUND 8 5 ...

Page 453: ...ubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING PROBLEMS ENGINE Cylinders and cylinder heads See page 5 39 to 5 43 and 5 53 to 5 59 Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damage...

Page 454: ...ged ignition coil Ignition system See page 7 12 to 7 16 Faulty ignitor unit Faulty pickup coil ELECTRICAL SYSTEMS Battery See page 3 51 to 3 56 Faulty battery Discharged battery Fuses See page 3 56 to 3 58 Blown damaged or incorrect fuse Incorrectly installed fuse Spark plugs See page 3 14 to 3 15 Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode ...

Page 455: ...ine oil See page 3 20 to 3 21 Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter See page 3 7 and 3 29 Clogged air filter element EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft See page 5 74 to 5 76 Incorrectly adjusted shift r...

Page 456: ...l Incorrect oil viscosity Inferior oil quality FUEL SYSTEM Carburetor See page 6 1 to 6 20 Incorrect main jet setting Incorrect fuel level Damaged or loose carburetor joint Ait filter See page 3 7 and 3 29 Clogged air filter element EAS00857 POOR BRAKING PERFORMANCE See page 3 34 to 3 38 and 4 22 to 4 54 Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake ...

Page 457: ...arness EAS00864 UNSTABLE HANDLING Handleber See page 4 67 to 4 72 Bent or incorrectly installed handlebar Steering head components See page 3 41 to 3 43 and 4 73 to 4 78 Incorrectly installed upper bracket Incorrectly installed lower bracket incor rectly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork legs See page 3 43 to 3 44 and 4 55 to 4 66 Uneven oil leve...

Page 458: ...TRBL SHTG ...

Page 459: ...XV1600A WIRING DIAGRAM for EUR ...

Page 460: ...XV1600AL WIRING DIAGRAM for AUS ...

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