Yamaha XV16AL Service Manual Download Page 159

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4 - 37

CHAS

FRONT AND REAR BRAKES

5. Check:

• brake hoses
• brake fluid reservoir hose

Cracks/damage/wear

→

Replace.

EAS00598

ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER

WARNING

• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.

• Never use solvents on internal brake

components.

1. Install:

• brake master cylinder kit

• circlip

• dust boot

Recommended brake fluid

DOT 4

New

2. Install:

• front brake light switch

3. Install:

• brake master cylinder
• brake master cylinder holder

NOTE:

• Install the brake master cylinder holder

with the “UP” mark facing up.

• Align the end of the brake master cylinder

holder with the punch mark

in the han-

dlebar.

• First, tighten the upper bolt, then the

lower bolt.

10 Nm (1.0 m · kg, 7.2 ft · lb)

Summary of Contents for XV16AL

Page 1: ...SERVICEMANUAL LIT 11616 12 56 4WM 28197 E0 XV16AL XV16ALC XV16ATL XV16ATLC ...

Page 2: ...o provide the customer with the most satis faction from his vehicle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifica tions and significant changes in specifications or procedures will be forwarded to all autho rized Yamaha dealers and will appear in future editions of this manual where applicable Thi...

Page 3: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub sec tion 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 indi cat...

Page 4: ...ant B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrica tion points G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap base grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the following M Apply lockin...

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

Page 6: ...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 1 ...

Page 7: ...CYCLE 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 1 ...

Page 8: ...n 5th gear and sends the information out as an electrical signal to the ignitor unit Self diagnosis device This model is equipped with a self diagno sis device that has four functions The engine trouble indicator light will come on or flash if trouble occurs in an engine monitoring circuit Refer to SELF DIAGNOSIS in chapter 7 Circuit Indicator lights Num ber of flashes Throttle position sensor Eng...

Page 9: ...h the 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 start ing capabilities and smoother crankshaft revolutions 1Decompression solenoid 2Decompression solenoid rod 3Decompression connector 4Decompression lever 5Decompression push rod 6Decompression cam 7Pin 8Spring...

Page 10: ...n rods 5 toward the cam shaft 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 decompression cam 4 When the camshaft is rotated by the self timing 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 oper ated Thus opening the...

Page 11: ...ifter body 8 and pushes up the push rod causing the valve to be lifted 3 As the camshaft continues to rotate the valve lifter moves back down to its original posi tion 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 no longer receives press...

Page 12: ...all of the parts and place them in trays in the order of disassembly This will speed up assem bly and allow 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 replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but ...

Page 13: ...numbers are visible When installing oil seals lubri cate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1Oil seal ACHTUNG CAUTION Do not spin bearings with compressed air because this will damage the bearing sur faces 1Bearing EAS00025 CIRCLIPS Before reassembly check all circlips care fully and replace damaged or distorted cir...

Page 14: ...nd disconnect several times 3 Check all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure all connections are tight 5 Check continuity with the pocket tester NOTE If there is no continuity clean the termi nals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revi...

Page 15: ...M 01326 Damper rod holder YM 1300 1 T handle Damper rod holder These tools are used to hold the cartridge cylinder when loosening or tightening the cartridge cylinder bolt YM 01312 A Fuel level gauge This tool is used to measure the fuel level in the float chamber YM 33277 A Timing light This tool is used to check the ignition tim ing YM 03170 Belt tension gauge This tool is used to measure the dr...

Page 16: ...g or installing the clutch boss nut YS 01880 Sheave holder This tool is used to hold the generator rotor when removing or installing the gen erator rotor bolt generator shaft bolt or pickup coil rotor bolt YU 01304 Piston pin puller This tool is used to remove the piston pins YU 03009 Micrometer 75 100 mm This tool is used to measure the piston skirt diameter YU 03017 Cylinder bore gauge 50 100 mm...

Page 17: ...n the steering stem ring nuts YU 38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge YU 8036 A Inductive tachometer This tool is used to check engine speed ACC 11001 05 01 Quick Gasket This sealant is used to seal two mating surfaces e g crankcase mating sur faces 90890 03153 Oil pressure gauge This tool is used to measure the engine oil pressure Tool No Tool ...

Page 18: ...8 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 2 ...

Page 19: ...00 mm 59 1 in XV16AT Seat height 710 mm 28 0 in Wheelbase 1 685 mm 66 3 in Minimum ground clearance 145 mm 5 71 in Minimum turning radius 3 200 mm 126 in Weight Wet with oil and a full fuel tank 332 kg 732 lb XV16A 347 kg 765 lb XV16AT Dry without oil and fuel 307 kg 678 lb XV16A 322 kg 710 lb XV16AT Maximum load total of cargo rider passenger and accessories 196 kg 432 lb XV16A 181 kg 399 lb XV16...

Page 20: ... L 17 6 Imp qt 21 1 US qt Reserve only 3 5 L 3 08 Imp qt 3 70 US qt Engine oil Lubrication system Dry sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 40 F 5 C or above Non Friction modiﬁed Quantity Total amount 5 0 L 4 4 Imp qt 5 3 US qt Without oil filter cartridge replacement 3 7 L 3 3 Imp qt 3 9 US qt With oil filter cartridge replace ment 4 1 L 3 6 Imp qt 4 3 US qt Oil pre...

Page 21: ...learance 0 03 0 08 mm 0 001 0 003 in 0 16 mm 0 006 in Starting system type Electric starter Spark plugs Model Manufacturer Quantity DPR7EA 9 X22EPR U9 NGK DENSO 4 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder heads Max warpage 0 10 mm 0 004 in Camshafts Drive system Gear drive Crankcase hole inside diameter 25 000 25 021 mm 0 9843 0 9851 in Camshaft cover hole inside diam eter 28 000 28 021 mm...

Page 22: ... diameter 14 981 14 991 mm 0 5898 0 5902 in 14 97 mm 0 5894 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in 0 08 mm 0 003 in Valves valve seats valve guides Valve clearance cold Intake 0 0 04 mm 0 0 0016 in Exhaust 0 0 04 mm 0 0 0016 in Valve dimensions Valve head diameter A Intake 33 9 34 1 mm 1 3346 1 3425 in Exhaust 27 9 28 1 mm 1 0984 1 1063 in Valve face width B In...

Page 23: ...5 mm 0 2382 in Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in 0 1 mm 0 004 in Valve stem runout 0 01 mm 0 0004 in Valve seat width Intake 0 9 1 1 mm 0 035 0 043 in Exhaust 0 9 1 1 mm 0 035 0 043 in Valve springs Inner springs Free length Intake 38 26 mm 1 51 in 36 26 mm 1 43 in Exhaust 38 26 mm 1 51 in 36 26 mm ...

Page 24: ...gs Free length Intake 43 25 mm 1 70 in 41 26 mm 1 62 in Exhaust 43 25 mm 1 70 in 41 26 mm 1 62 in Installed length valve closed Intake 31 0 mm 1 22 in Exhaust 31 0 mm 1 22 in Compressed spring force installed Intake 139 161 N 13 9 16 1 kgf 30 6 35 5 lb Exhaust 139 161 N 13 9 16 1 kgf 30 6 35 5 lb Spring tilt Intake 2 5 2 4 mm 2 5 0 094 in Exhaust 2 5 2 4 mm 2 5 0 094 in Item Standard Limit 2 ...

Page 25: ...od runout 0 3 mm 0 012 in Cylinders Bore 95 000 95 010 mm 3 7402 3 7406 in Max taper 0 05 mm 0 0016 in Max out of round 0 05 mm 0 0016 in Pistons Piston to cylinder clearance 0 025 0 050 mm 0 001 0 002 in 0 15 mm 0 006 in Diameter D 94 960 94 975 mm 3 7386 3 7392 in Height H 5 mm 0 20 in Piston pin bore in the piston Diameter 22 004 22 015 mm 0 8663 0 8667 in 22 045 mm 0 8679 in Offset 1 0 mm 0 04...

Page 26: ... mm 0 031 in Ring side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 in Oil ring Dimensions B T 2 5 3 4 mm 0 098 0 134 in End gap installed 0 2 0 7 mm 0 008 0 028 in Connecting rods Crankshaft pin to big end bearing clearance 0 037 0 074 mm 0 0015 0 0029 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Connecting rod length 191 95 192 05 mm 7 557 7 561 in Crankshaft Width A 1...

Page 27: ...9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Plate quantity 9 Clutch plates Thickness 2 2 2 4 mm 0 087 0 094 in Plate quantity 8 Max warpage 0 2 mm 0 008 in Clutch springs Free length 7 mm 0 276 in Spring quantity 1 Min length 6 5 mm 0 256 in Transmission Transmission type Constant mesh 5 speed Primary reduction system Spur gear Primary reduction ratio 72 47 1 532 Secondary reduction system Belt drive ...

Page 28: ...etor Model manufacturer quantity BSR40 MIKUNI 1 Throttle cable free play at the ﬂange of the throttle grip 3 5 mm 0 12 0 20 in ID mark 4WM1 00 4WM2 10 for California Main jet 165 Main air jet 60 Jet needle 6HDC26 Needle jet X 2 Pilot air jet 100 Pilot outlet 1 0 XV16A 1 1 XV16AT Pilot jet 35 Bypass 1 0 9 Bypass 2 1 0 Bypass 3 0 9 Pilot screw turns out 2 1 2 Valve seat size 2 0 Starter jet 1 57 5 S...

Page 29: ... Wheel type Spoke wheel Rim Size 16 MT3 50 Material Steel Wheel travel 110 mm 4 33 in Wheel runout Max radial wheel runout 1 mm 0 04 in Max lateral wheel runout 0 5 mm 0 02 in Front tire Tire type With tube Size 130 90 16 67H Model manufacturer D404FL DUNLOP G703F BRIDGESTONE Tire pressure cold 0 90 kg 0 198 lb 250 kPa 2 5 kg cm2 36 psi 90 kg 198 lb Maximum load 250 kPa 2 5 kg cm2 36 psi High spee...

Page 30: ...0 20 in Recommended ﬂuid DOT 4 Brake discs Diameter thickness 298 5 mm 11 7 0 20 in Min thickness 4 5 mm 0 18 in Max deflection 0 1 mm 0 004 in Brake pad lining thickness 6 0 mm 0 24 in 0 5 mm 0 02 in Master cylinder inside diameter 15 8 mm 0 62 in Caliper cylinder inside diameter 30 1 mm 1 19 in and 33 3 mm 1 31 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal...

Page 31: ...leg 554 cm3 19 5 Imp oz 18 7 US oz Level from the top of the inner tube with the inner tube fully compressed and without the fork spring 110 mm 4 33 in Inner tube outer diameter 43 mm 1 69 in Rear suspension Suspension type Swingarm link suspension Rear shock absorber assembly type Coil spring gas oil damper Rear shock absorber assembly travel 50 mm 1 97 in Spring Free length 187 mm 7 36 in 182 mm...

Page 32: ...SSIS SPECIFICATIONS SPEC 2 14 Drive belt Model manufacturer UBD 0568 Drive belt slack on a sidestand 7 5 13 mm 0 30 0 51 in Drive belt slack on a suitable stand 14 21 mm 0 55 0 83 in Item Standard Limit 2 ...

Page 33: ...g caps Material Resin Resistance 10 kΩ Throttle position sensor standard resistance 4 0 6 0 kΩ Charging system System type AC magneto Model manufacturer F4T363 MITSUBISHI Nominal output 14 V 21 A at 5 000 r min Stator coil resistance 0 45 0 55 Ω at 20 C 68 F Voltage regulator Regulator type Semiconductor short circuit Model SH650D 11 No load regulated voltage 14 1 14 9 V Rectiﬁer Model SH650D 11 R...

Page 34: ...rcut 0 7 mm 0 03 in Starter relay Model manufacturer MS5F 411 JIDECO Amperage 100 A Coil resistance 4 18 4 62 Ω Horn Horn type Eddy Model manufacturer quantity YP 12 NIKKO 2 Max amperage 2 A Turn signal relay Relay type Semi transistor Model manufacturer FB257H DENSO Self cancelling device built in Yes Turn signal blinking frequency 75 95 cycles min Wattage 27 W 2 3 4 W 21 23 W 2 3 4 W Fuel sender...

Page 35: ... 2 17 Fuses amperage quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 10 A 1 Ignition fuse 15 A 1 Carburetor heater fuse 10 A 1 Backup fuse odometer 5 A 1 Reserve fuse 30 A 15 A 10 A 5 A 1 Item Standard Limit 2 ...

Page 36: ...multi fas tener assemblies in a crisscross pattern and progressive stages until the specified tight ening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Width across flats B Thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30...

Page 37: ... LT Oil delivery pipe generator cover to crankcase Nut M20 1 40 4 0 29 Joint bolt M16 1 40 4 0 29 Oil delivery pipe cylinder head to crankcase Union bolt M10 2 21 2 1 15 Oil delivery pipe cylinder head to crankcase Union bolt M8 1 18 1 8 13 Carburetor joint Bolt M6 4 12 1 2 8 7 Carburetor joint clamp Screw M4 1 3 0 3 2 2 Air filter case Bolt M6 3 7 0 7 5 1 Air filter case clamp Screw M4 1 3 0 3 2 ...

Page 38: ...0 1 0 7 2 Transfer gear oil drain bolt M8 1 18 1 8 13 Middle drive gear Nut M22 1 85 8 5 61 Use a lock washer Transfer gear case Bolt M8 4 30 3 0 22 Transfer gear case Nut M8 1 30 3 0 22 Transfer gear oil checking bolt M6 1 8 0 8 5 8 Transfer gear oil pump cover Screw M6 2 7 0 7 5 1 LT Transfer gear oil pump Bolt M6 5 10 1 0 7 2 LT Drive pulley case Bolt M8 7 30 3 0 22 Drive pulley Nut M22 1 85 8 ...

Page 39: ... 30 3 0 22 Muffler stay and frame M8 26 2 6 19 Muffler stay and muffler M10 30 3 0 22 Ignition coil M6 7 0 7 5 1 Swingarm pivot shaft M18 125 12 5 90 Relay arm and swingarm M12 59 5 9 43 Relay arm and connecting rod M12 59 5 9 43 Relay arm and rear shock absorber M10 40 4 0 29 Rear shock absorber connecting rod and frame M12 59 5 9 43 Drive belt case upper and swingarm M6 10 1 0 7 2 Drive belt cas...

Page 40: ...rest bracket and rear brake bracket M8 16 1 6 11 Footrest bracket and shift rod bracket M8 16 1 6 11 Front wheel axle M18 78 7 8 56 Front wheel axle pinch bolt M8 19 1 9 13 Rear wheel axle nut M18 150 15 0 110 Front brake caliper M10 40 4 0 29 Rear brake caliper M10 40 4 0 29 Brake disc and wheel M8 23 2 3 17 LT Caliper bleed screw M8 6 0 6 4 3 Driven pulley and rear wheel clutch hub M12 95 9 5 68...

Page 41: ... M Valve stem ends intake and exhaust E Valve lifters E Oil pump rotors inner and outer and oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Starter clutch idle gear shaft E Starter clutch roller and starter clutch gear outer surface E Clutch pull rod M Pressure plate bearing E Transmission gears wheel and pinion M Shift drum E Shift forks and shift fork guide bars E Shif...

Page 42: ...Rear wheel drive hub mating surface LS Rear brake pedal shaft LS Shift pedal LS Front footrest pivot LS Sidestand sliding surface LS Tube guide throttle grip inner surface LS Brake lever pivot bolt contact surface LS Clutch lever pivot bolt contact surface LS Swingarm pivot shaft M Swingarm pivot bearing M Swingarm pivot oil seal M Relay arm bearing inner M Rear shock absorber bearing inner M Conn...

Page 43: ...SPEC 2 25 ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2 ...

Page 44: ...2 26 SPEC ENGINE OIL FLOW DIAGRAMS 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 2 ...

Page 45: ...2 27 SPEC 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft ENGINE OIL FLOW DIAGRAMS 2 ...

Page 46: ...2 28 SPEC 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt engine ENGINE OIL FLOW DIAGRAMS 2 ...

Page 47: ...2 29 SPEC 1 Main axle 2 Drive axle 3 Engine oil pump 4 Oil strainer Å To oil tank ı From oil tank Ç To oil filter cartridge ENGINE OIL FLOW DIAGRAMS 2 ...

Page 48: ...SPEC 2 30 TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump TRANSFER GEAR OIL FLOW DIAGRAMS 2 ...

Page 49: ...SPEC 2 31 1 Transfer gear oil pump 2 Middle driven shaft TRANSFER GEAR OIL FLOW DIAGRAMS 2 ...

Page 50: ...rake hose 3 Clutch cable 4 Left handlebar switch lead 5 Vacuum hose air induction system 6 Rear brake light switch lead 7 Rectifier regulator Å Route the rear brake light switch lead in front of the rectifier regulator bracket on the frame CABLE ROUTING 2 ...

Page 51: ...lead C Throttle position sensor lead D Horn lead E Sidestand switch lead F Sidestand switch Å Fasten the wire harness fuel sender lead wire harness side and seat lock cable with a plastic locking tie ı To the speed sensor neutral switch stator coil and decompres sion solenoid Ç Fasten the throttle position sensor lead carburetor heater lead and fuel pump lead with a plastic locking tie to the engi...

Page 52: ...witch coupler 7 Meter assembly couplers 8 Right handlebar switch lead 9 Fuel tank breather hose 0 Spark plug cap 4 A Spark plug cap 2 B Sidestand switch coupler C Pickup coil lead D Horn leads E Starter motor lead F Sidestand switch lead G Decompression solenoid lead H Stator coil lead I Rollover valve CABLE ROUTING 2 ...

Page 53: ... the decompression solenoid Î To the fuel tank To the wire harness Ï Fasten the starter motor lead stator coil lead decompression solenoid lead pickup coil lead speed sensor lead and neutral switch lead with a plastic clamp and then insert the clamp into the frame Ì To the starter relay Ó To the decompression solenoid È To the speed sensor CABLE ROUTING 2 ...

Page 54: ...nder lead 9 Vacuum hose air induction system 0 Solenoid valve lead California only A Spark plug lead 4 B Spark plug lead 2 C Spark plug lead 1 D Spark plug lead 3 Å Fasten the wire harness with a plastic clamp and then insert the clamp into the relay bracket ı Position the white tape on the wire harness with the hole on battery box as shown Ç To the main switch Î To the meter assembly CABLE ROUTIN...

Page 55: ... Fuel tank breather hose 3 Charcoal canister to carburetor hose 4 Charcoal canister 5 Charcoal canister to rollover valve hose 6 Rollover valve 7 Solenoid valve coupler 8 Solenoid valve 9 Solenoid valve to air filter case hose 0 Solenoid valve to carburetor hose CABLE ROUTING 2 ...

Page 56: ...ION TIMING 3 16 MEASURING THE COMPRESSION PRESSURE 3 18 CHECKING THE ENGINE OIL LEVEL 3 20 CHANGING THE ENGINE OIL 3 22 MEASURING THE ENGINE OIL PRESSURE 3 25 CHECKING THE TRANSFER GEAR OIL LEVEL 3 26 CHANGING THE TRANSFER GEAR OIL 3 27 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 28 CLEANING THE AIR FILTER ELEMENT 3 29 CHECKING THE CARBURETOR JOINT 3 30 CHECKING THE FUEL HOSES AND FUEL FILTER 3 30 CHEC...

Page 57: ...ING THE FRONT FORK 3 43 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 44 CHECKING THE TIRES 3 45 CHECKING AND TIGHTENING THE SPOKES 3 48 CHECKING AND LUBRICATING THE CABLES 3 49 LUBRICATING THE LEVERS AND PEDALS 3 50 LUBRICATING THE SIDESTAND 3 50 LUBRICATING THE REAR SUSPENSION 3 50 ELECTRICAL SYSTEM 3 51 CHECKING AND CHARGING THE BATTERY 3 51 CHECKING THE FUSES 3 56 REPLACING THE HEADLIGHT BULB 3...

Page 58: ... page 3 14 Check condition Adjust gap and clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system See page 3 31 Check breather hose for cracks or damage Replace if necessary 4 Fuel line See page 3 30 Check fuel hose for cracks or dam age Replace if necessary 5 Fuel filter See page 3 30 Replace initial 20 0...

Page 59: ... 25 000 km Medium weight wheel bearing grease Repack 10 Brake Clutch lever pivot shaft See page 3 50 Apply chain lube lightly Yamaha chain and cable lube or SAE 10W30 motor oil 11 Brake pedal and shift pedal shaft See page 3 50 Lubricate Apply chain lube lightly Yamaha chain and cable lube or SAE 10W30 motor oil 12 Sidestand pivot See page 3 50 Check operation and lubricate Apply chain lube lightl...

Page 60: ... AND SIDE COVERS Order Job Part Q ty Remarks Removing the seats and side covers Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 3 Left side cover 1 4 Right side cover 1 For installation reverse the removal procedure 3 ...

Page 61: ...16AT ACCESSORY PARTS Order Job Part Q ty Remarks Accessory parts removal front Remove the parts in the order listed 1 Front windshield 1 2 Chrome flasher bracket cover 1 3 Windshield stay 2 For installation reverse the removal procedure 3 ...

Page 62: ...arts removal rear Remove the parts in the order listed 1 Emblem 1 2 Backrest holder 1 3 Backrest 1 4 Backrest stay 1 5 Saddlebag 2 6 Passenger footrest 2 7 Saddlebag stay 2 8 Grip 2 For installation reverse the removal procedure XV16AT ACCESSORY PARTS 3 ...

Page 63: ...the order listed Rider seat Refer to SEATS AND SIDE COVERS 1 Meter assembly 2 Meter assembly coupler 2 Disconnect 3 Fuel tank breather hose 1 4 Fuel hose Disconnect 5 Fuel sender coupler 1 Disconnect 6 Fuel tank 1 For installation reverse the removal procedure NOTE Before disconnecting the fuel hose set the fuel cock to OFF 3 ...

Page 64: ...the air filter case Remove the parts in the order listed 1 Vacuum chamber breather hose air filter case to solenoid valve hose 1 Disconnect 2 Cylinder head breather hose 1 Disconnect 3 Air filter case 1 For installation reverse the removal procedure AIR FILTER CASE 3 ...

Page 65: ...specification Check if the valve clearance b on the adjusting screw 2 side is within specification ıIf 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 tempera ture When the valve clearance is to be mea sured or adjusted the piston must be at top dead center...

Page 66: ...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 ADJUSTING THE VALVE CLEARANCE 3 ...

Page 67: ...not aligned turn the crankshaft counterclockwise 360 degrees and recheck step b d Measure the valve clearance with a thick ness gauge Valve clearance cold Intake valve 0 0 04 mm 0 0 0016 in Exhaust valve 0 0 04 mm 0 0 0016 in 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 com pression stoke align the TDC mark...

Page 68: ...still out of speci fication repeat all of the valve clearance adjustment steps until the specified clearance is obtained 11 Install all removed parts NOTE For installation reverse the removal proce dure Note the following points Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 12 Adjust installed shift rod length Refer to ADJUSTING THE SHIFT PEDAL Adjusting screw side Slip side Direct...

Page 69: ... minutes 2 Remove rider seat Refer to SEATS AND SIDE COVERS 3 Remove fuel tank bolt 1 4 Lift up the fuel tank end 5 Install inductive tachometer 1 onto the spark plug lead of cylinder 1 6 Measure engine idling speed Out of specification Adjust 7 Adjust engine idling speed a Turn the throttle stop screw 1 in direc tion a or b until the specified engine idling speed is obtained Inductive tachometer ...

Page 70: ...ing speed should be adjusted 1 Measure throttle cable free play a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 4 8 mm 0 16 0 31 in 2 Adjust throttle cable free play NOTE 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 ...

Page 71: ...ed Direction b Throttle cable free play is decreased 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 c Tighten the locknut WARNING WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling ...

Page 72: ... 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 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug ...

Page 73: ...ming 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 3 ...

Page 74: ... it up for several minutes and then let it run at the speci fied engine idling speed b Check that the pointer a is within the required firing range b on the pickup coil rotor Incorrect firing range Check the igni tion system NOTE The ignition timing is not adjustable Engine idling speed 850 950 r min 10 Install all removed parts NOTE For installation reverse the removal proce dure Note the followi...

Page 75: ...G THE VALVE CLEARANCE 2 Start the engine warm it up for several minutes 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 LIFTERS decompression solenoid Refer to CAMSHAFTS 5 Install camshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 6 Disconnect spark plug c...

Page 76: ...rking ground all spark plug leads before cranking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 14 psi c If the compression pressure is above the maximum specification check the cylin der head valve surfaces and piston crown for carbon deposits d Carbon deposits Eliminate e If the compression pressure is below the minimum specification ...

Page 77: ...VERS EAS00071 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure the motorcycle is upright 2 Start the engine and warm it up by run ning the engine or letting the engine run at idle for 15 minutes until the engine oil inside of the oil tank has reached a tem perature of 60 C 140 F and then turn it off Compression pressure...

Page 78: ...fore checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick in when insect ing the oil level ACHTUNG CAUTION Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase NOTE API Service SE SF and SG type or equiva...

Page 79: ... drain bolt engine 3 4 Drain engine oil completely from the oil tank and crank case 5 If the oil filter cartridge is also to be replaced perform the following proce dure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring 3 of the new oil fil ter cartridge with a thin coat of engine oil ACHTUNG CAUTION Make sure the O ring 3 is positioned cor rectly in the groove...

Page 80: ... and then pour in the remainder of the specified amount ACHTUNG CAUTION When starting the engine make sure the dipstick is securely fitted into the oil tank 9 Fill when the engine is disassembled crankcase and oil tank T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb Quantity Total amount 5 0 L 4 4 lmp qt 5 3 US qt Periodic oil replacement 3 7 L 3 3 lmp qt 3 9 US qt With oil filter cartridge repla...

Page 81: ...o 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 engine oil starts to seep from the oil gal lery 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 fil ter cartridge and the oil pump for dam age or leakage Refer to ENGI...

Page 82: ...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 oil gallery bolt 1 WARNING WARNING The engine muffler and engine oil are extremely hot 4 Install oil pressure gauge 1 5 Measure engine oil pressure at the following conditions Oil pressure gauge 90890 03153 Engine oil pressure 0 4 0 8 kPa 0 004 0 ...

Page 83: ...n Leaking oil pas sage Faulty oil filter Oil viscosity too high T R 20 Nm 2 0 m kg 14 ft lb CHECKING THE TRANSFER GEAR OIL LEVEL 1 Stand the motorcycle on a level surface NOTE 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 ...

Page 84: ...olt 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 T R 18 Nm 1 8 m kg 13 ft lb 6 Fill transfer gear case with the specified amount of the recom mended transfer gear oil Quantity Total amount 0 4 L 0 35 Imp qt 0 42 US qt 7 Instal...

Page 85: ...he specified clutch cable free play is obtained d Tighten the locknut NOTE 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 until the specified clutch cable free play is obtained c Tighten the locknut Direction...

Page 86: ...stall air filter element air filter case cover ACHTUNG CAUTION Never operate the engine without the air filter 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 tuning leading to poor engine performance and possible overheating NOTE When installing the air filter eleme...

Page 87: ... 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 NOTE Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident The arrow mark on the fuel fi...

Page 88: ...nnection Connect properly ACHTUNG CAUTION 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 exhaust pipes mufflers and gaskets 1 Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 2 Measure tighte...

Page 89: ... 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 loss of control and possibly an accident Therefore check and if neces sary bleed the brake system ACHTUNG CAUTION After adjusting the brake lever free play make sure there ...

Page 90: ... WARNING WARNING 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 consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system ACHTUNG CAUTIO...

Page 91: ...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 performance 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 ACHTUNG CAUTION Brake fluid may damage painted surfaces and ...

Page 92: ...ke pad wear limit a 0 5 mm 0 02 in 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 0 02 in EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear bra...

Page 93: ... nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b 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 flu...

Page 94: ... or brake fluid reservoir to overflow When bleeding the hydraulic brake sys tem make sure there is always enough brake fluid before applying the brake Ignoring this precaution could allow air to enter the hydraulic brake system consid erably lengthening the bleeding proce dure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure w...

Page 95: ...w 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 k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING WARNING After bleeding the hydraulic brake system check the brak...

Page 96: ...en both locknuts d Make sure the installed shift rod length is within specification Installed shift rod length 374 4 378 4 mm 14 74 14 90 in Direction b Installed shift rod length increases Direction c Installed shift rod length decreases ADJUSTING THE DRIVE BELT SLACK ACHTUNG CAUTION A drive belt that is too tight will overload the engine and other vital parts and one that is too loose can skip a...

Page 97: ...t slack a Out of specification Adjust NOTE The level marks of the level window on the lower 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 pushed with 4 5 kg 10 lbs of pressure using a belt tension gauge 1 4 Adjust drive belt slack NOTE Place the motorcycle on the suitable stand so th...

Page 98: ...tion f Tighten the wheel axle nut to specification g Tighten the brake caliper bracket bolt to specification EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the motorcycle on a level surface WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated Direction a Drive belt ...

Page 99: ...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 NOTE Set the torque wrench at a right angle to the ring nut wrench c Loosen the lower ring nut completely then tighten it to specification WARNING WARNING Do not overtighten the lower ring nut Ring nut wrench YU 33975 T R Lower ring nut initial tightening torque ...

Page 100: ... nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE 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 meter assembly Refer to FUEL TANK T R 130 Nm 13 0 m kg 94 ft ...

Page 101: ...ORK in chapter 4 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over Spring preload ACHTUNG CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload NOTE Adjust the spring preload with the special wrench and extension bar included in the owner s tool kit a Loosen the locknut 1 b...

Page 102: ...re applies to both of the tires 1 Measure tire pressure Out of specification Regulate WARNING WARNING 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 accessories and the anticipated riding speed Operation of an o...

Page 103: ... load 250 kPa 2 5 kgf cm2 36 psi 250 kPa 2 5 kgf cm2 36 psi 90 kg maxi mum load 250 kPa 2 5 kgf cm2 36 psi 280 kPa 2 8 kgf cm2 40 psi High speed riding 250 kPa 2 5 kgf cm2 36 psi 280 kPa 2 8 kgf cm2 40 psi 2 Check tire surfaces Damage wear Replace the tire 1Tire tread depth 2Side wall 3Wear indicator WARNING WARNING Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire f...

Page 104: ...d below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning han dling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Å ı Front tire Rear tire Manufacture...

Page 105: ...red or replaced be sure to tighten the tire air valve stem locknut 4 to specification NOTE 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 installa tion point T R Tire air valve stem locknut 1 5 Nm 0 5 m kg 1 1 ft Ib EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to...

Page 106: ...e applies to all of the cable sheaths and cables WARNING WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement Replace damaged cable sheaths and cables as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitabl...

Page 107: ... of the levers and ped als 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 108: ...yte 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 because ...

Page 109: ... 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 ter minals NOTE The charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive battery terminal is disconnected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V b Check the c...

Page 110: ... reduce the chance of sparks do not plug in the battery charger until the bat tery 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 termi nals and that they are not shorted A cor roded battery charger lead clip may...

Page 111: ...3 54 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger 3 ...

Page 112: ...3 55 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger 3 ...

Page 113: ...sh Loose connection Connect properly 9 Lubricate battery terminals 10 Install rider seat Refer to SEATS AND SIDE COVERS Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses ACHTUNG CAUTION 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 CO...

Page 114: ...diately blows again check the electrical circuit WARNING WARNING Never use a fuse with an amperage other than that specified Improvising or using a fuse with the wrong amperage may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire Item Amperage Q ty Main fuse 30A 1 Headlight fuse 15A 1 Ignition fuse 15A 1 Signalin...

Page 115: ...G THE HEADLIGHT BULB 1 Remove screws 1 headlight lens unit 2 2 Disconnect headlight coupler 1 3 Remove headlight bulb holder cover 2 4 Detach headlight bulb holder 1 5 Remove headlight bulb 2 WARNING WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 3 ...

Page 116: ...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 New EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting ...

Page 117: ...ADJ ADJUSTING THE HEADLIGHT BEAM 2 Adjust headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left 3 ...

Page 118: ...ck 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 diagnos tic systems checked COMBINATION METER 1Combination meter 2Clock 3Odometer trip meter 4Mode button 5Set button This combination meter is equipped with a...

Page 119: ...4 400 r min Setting the clock This clock always shows the time regard less 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 dis play will flash 4 6 Push the right...

Page 120: ...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 PULLEY 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 PULLEY 4 17 ASSEMBLING THE REAR WHEEL 4 18 INSTALLING THE REAR WHEEL 4 18 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 21 4 ...

Page 121: ...LING THE REAR BRAKE CALIPER 4 52 FRONT FORK 4 55 REMOVING THE FRONT FORK LEGS 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 STEERIN...

Page 122: ...CHAS DRIVE BELT AND DRIVE PULLEY 4 90 REMOVING THE DRIVE BELT AND DRIVE PULLEY 4 91 CHECKING THE DRIVE BELT 4 91 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 92 4 ...

Page 123: ...ed 1 Reflector left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 1 Loosen 4 Front wheel axle 1 5 Front wheel 1 6 Collar left and right 2 7 Brake disc cover left 1 8 Brake disc cover right with weight 1 9 Brake disc left and right 2 For installation reverse the removal procedure NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated 4 ...

Page 124: ...BRAKE DISCS Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassembly procedure 4 ...

Page 125: ...right brake caliper NOTE Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel NOTE 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 NOTE To prevent damaging the wheel pl...

Page 126: ... 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 0 04 in Maximum lateral wheel runout 0 5 mm 0 02 in 5 Check collars Dam...

Page 127: ... screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a general bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassem bly ACHTUNG CAUTION Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made only with the outer race 6 NOTE Use a socket 7 that ...

Page 128: ... 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 0 05 in below the edge of the brake disc Maximum brake disc deflection Front 0 15 mm 0 006 in Rear 0 15 mm 0 006 in 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Repla...

Page 129: ...Nm 2 3 m kg 17 ft lb LOCTITE EAS00539 ASSEMBLING THE FRONT WHEEL 1 Install wheel bearings oil seals Install the new wheel bearings and oil seals in the reverse order of disassem bly ACHTUNG CAUTION Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal New ...

Page 130: ...ft lb 3 Install collars front wheel front wheel axle 4 Tighten front wheel axle 1 wheel axle pinch bolt 2 ACHTUNG CAUTION Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly T R 78 Nm 7 8 m kg 56 ft lb T R 20 Nm 2 0 m kg 14 ft lb 5 Install brake calipers WARNING WARNING Make sure the brake hose is routed prop erly 6 Insta...

Page 131: ...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 front wh...

Page 132: ...position 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 sta tionary at all of the positions rebalance it 4 ...

Page 133: ...er Job Part Q ty Remarks Removing the rear fender and muf fler Remove the parts in the order listed Rider seat Refer to SEATS AND SIDE COVERS in chapter 3 1 Muffler 1 2 Tail brake light and turn signal light sub wire harness 1 Disconnect 3 Rear fender assembly 1 For installation reverse the removal procedure 4 ...

Page 134: ...e order listed 1 Upper drive belt cover 1 2 Brake caliper 1 3 Brake caliper bracket bolt 1 4 Locknut left and right 2 Loosen 5 Adjusting bolt left and right 2 Loosen 6 Wheel axle nut 1 7 Right adjusting plate 1 8 Left adjusting plate 1 9 Rear wheel axle 1 NOTE Place the motorcycle on a suitable stand so that the rear wheel is ele vated 4 ...

Page 135: ...4 13 CHAS Order Job Part Q ty Remarks 10 Rear wheel 1 11 Collar left and right 2 12 Brake caliper bracket 1 For installation reverse the removal procedure REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 4 ...

Page 136: ...he brake disc and rear wheel pulley Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel pulley 1 3 Oil seal 1 4 Collar 1 5 Circlip 1 6 Bearing 1 7 Collar 1 8 Bearing 1 9 Rear wheel drive hub 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 For installation reverse the removal procedure 4 ...

Page 137: ... DISC AND REAR WHEEL PULLEY EAS00560 Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Oil seal 1 2 Bearing 1 3 Spacer 1 4 Bearing 4 For assembly reverse the disassembly procedure 4 ...

Page 138: ...d so that the rear wheel is elevated 2 Remove brake caliper NOTE Do not depress the brake pedal when removing the brake caliper 3 Remove rear wheel NOTE Push the rear wheel forward and remove the drive belt from the rear wheel pulley EAS00566 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL AND BRAKE DISCS 2 Check tire rear wheel Damage wear Repla...

Page 139: ...cks damage Replace rear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1 Check rear wheel pulley Surface plating has come off Replace the rear wheel pulley Bent teeth Replace the rear wheel pul ley 2 Replace rear wheel pulley a Remove the self locking nuts and the rear wheel pulley b Clean the rear wheel drive hub with a clean cloth especially t...

Page 140: ...ley self locking nut 95 Nm 9 5 m kg 68 ft lb ASSEMBLING THE REAR WHEEL 1 Install bearings spacer bearing oil seal Refer to FRONT WHEEL AND BRAKE DISCS New 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 4 ...

Page 141: ...8 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 NOTE Temporarily tighten the brake caliper bracket bolt 7 Install collars rear wheel adjusting plates rear wheel axle washer wheel axle nut NOTE Temporarily tighten the wheel axle nut 8 Adjust drive belt slack Refer to ADJ...

Page 142: ...belt cover 1 T R 10 Nm 1 0 m kg 7 2 ft lb 12 Install muffler 13 Tighten muffler mounting bolt 1 Clamp bolt 2 T R 30 Nm 3 0 m kg 22 ft lb T R 25 Nm 2 5 m kg 18 ft lb 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 T R 88 Nm 8 8 m kg 64 ft lb T R 48 Nm 4 8 m kg 35 ft lb REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 4...

Page 143: ...pter 3 EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE 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 4 ...

Page 144: ...ng the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake hose holder bolt 1 2 Retaining bolt 2 3 Brake caliper 1 4 Brake pad 2 5 Brake pad shim 1 6 Brake pad spring 2 7 Brake pad spring 1 For installation reverse the removal procedure 4 ...

Page 145: ...moving the rear brake pads Remove the parts in the order listed Muffler Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 1 Brake caliper bolt 2 2 Brake pad cover 1 3 Brake pad clip 2 4 Brake pad pin 2 5 Brake pad spring 1 6 Brake pad 2 For installation reverse the removal procedure 4 ...

Page 146: ...new brake fluid for cleaning 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 immediate medical attention EAS00580 REPLACING THE FRONT BRAKE PADS T...

Page 147: ...ings NOTE Always install new brake pads brake pad shim and a new brake pad springs 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 cali per with your finger c Tighten the bleed screw d Install a new brake pad shim onto the new brake pad that is on t...

Page 148: ...ing bolts brake hose holder bolt Recommended lubricant Lithium soap base grease T R 27 Nm 2 7 m kg 19 ft lb 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 chapte...

Page 149: ... 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 pad thickness 0 5 mm 0 02 in 5 Install brake pads brake pad spring NOTE 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 ...

Page 150: ...the direction of disc rotation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb 6 Install brake pad pins brake pad clips brake pad cover brake caliper T R 40 Nm 4 0 m kg 29 ft lb 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...

Page 151: ...ts in the order listed Brake fluid Drain 1 Rear view mirror 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir dia phragm holder 1 4 Brake master cylinder reservoir dia phragm 1 5 Brake lever 2 6 Brake lever spring 1 7 Front brake light switch connector 2 Disconnect 8 Union bolt 1 9 Brake hose 1 Disconnect 10 Copper washer 2 4 ...

Page 152: ...4 30 CHAS FRONT AND REAR BRAKES Order Job Part Q ty Remarks 11 Brake master cylinder holder 1 12 Brake master cylinder 1 13 Front brake light switch 1 For installation reverse the removal procedure 4 ...

Page 153: ...Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure 4 ...

Page 154: ...the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Rear brake light switch 1 Disconnect 4 ...

Page 155: ...4 33 CHAS FRONT AND REAR BRAKES Order Job Part Q ty Remarks 11 Left footrest assembly 1 12 Cotter pin 1 13 Pin 1 14 Brake master cylinder 1 For installation reverse the removal procedure 4 ...

Page 156: ... Order Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure 4 ...

Page 157: ...tem 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE 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 MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 4 ...

Page 158: ...passages brake master cylinder body Obstruction Blow out with com pressed air ÅFront ıRear Å ı 2 Check brake master cylinder kit 1 Damage scratches wear Replace ÅFront ıRear Å ı 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 cylinder rese...

Page 159: ...ake fluid Never use solvents on internal brake components 1 Install brake master cylinder kit 1 circlip 2 dust boot 3 Recommended brake fluid DOT 4 New 2 Install front brake light switch 1 3 Install brake master cylinder brake master cylinder holder 1 NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a in ...

Page 160: ...en the union bolt as shown Turn the handlebar to the left and to the right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary New T R 30 Nm 3 0 m kg 22 ft lb 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 flu...

Page 161: ...point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake 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 br...

Page 162: ...New 2 Install brake master cylinder 1 T R 23 Nm 2 3 m kg 17 ft lb 3 Install left footrest assembly 1 T R 48 Nm 4 8 m kg 35 ft lb 4 Install rear brake light switch 1 5 Install copper washers brake hose union bolt WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING New T R 30 Nm 3 0 m kg 22 ft lb 4 ...

Page 163: ...r 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 performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the...

Page 164: ...servoir 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 3 9 in 12 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR ...

Page 165: ...emove the parts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Reflector 1 2 Brake hose holder bolt 1 3 Union bolt 1 4 Copper washer 2 5 Brake hose 1 6 Retaining bolt 2 Loosen 7 Brake caliper bolt 2 8 Brake caliper 1 For installation reverse the removal procedure 4 ...

Page 166: ... in the order listed The following procedure applies to both of the front brake calipers 1 Retaining bolt 2 2 Brake caliper 1 3 Brake caliper bracket 2 4 Brake pad 2 5 Brake pad spring 2 6 Brake pad spring 1 7 Brake caliper piston 2 8 Brake caliper piston seal 4 9 Bleed screw 1 For assembly reverse the disassembly procedure 4 ...

Page 167: ...s Removing the rear brake caliper Remove the parts in the order listed Muffler Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper bolt 2 5 Brake caliper 1 For installation reverse the removal procedure 4 ...

Page 168: ...mbling the rear brake caliper Remove the parts in the order listed 1 Brake pad cover 1 2 Brake pad clip 2 3 Brake pad pin 2 4 Brake pad spring 1 5 Brake pad 2 6 Brake caliper piston 4 7 Brake caliper piston seal 8 8 Bleed screw 1 For assembly reverse the disassembly procedure 4 ...

Page 169: ...e brake fluid care fully 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 WARNING WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pistons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake ca...

Page 170: ...ose joint opening a to force out the left side pistons from the brake caliper WARNING WARNING 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 replace ment schedule Brak...

Page 171: ...tion Blow out with com pressed air WARNING WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals ÅFront ıRear Å ı 2 Check brake caliper brackets 1 Cracks damage Replace ÅFront ıRear Å ı EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers WARNING WARNING Before installation all internal brake com...

Page 172: ...ll bleed screw brake caliper piston seals 1 brake caliper pistons 2 New 2 Install brake pad spring 1 brake pad springs 2 brake pads 3 NOTE Install the brake pad with the attached brake pad shim on the brake caliper piston side 3 Install brake caliper bracket 1 retaining bolts 2 NOTE Temporarily tighten the retaining bolts 4 Install brake caliper 1 brake caliper bolts 2 5 Tighten retaining bolts 3 ...

Page 173: ...NING WARNING 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 performance When refilling be careful that water does not enter the brake master cylinder re...

Page 174: ...ft 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 WARNING WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whene...

Page 175: ... of disc rotation 3 Install brake pad cover 4 Install brake caliper 1 brake caliper bolts 2 T R 40 Nm 4 0 m kg 29 ft lb 5 Install copper washers brake hose union bolt WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the brake hose onto the brake caliper make sure the brake pipe touches the projection a...

Page 176: ...r does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION 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 Below the minimum level...

Page 177: ...procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Meter assembly Refer to FUEL TANK in chapter 3 1 Front fender 1 2 Brake hose holder 1 3 Upper bracket pinch bolt 4 Loosen 4 Cap bolt 1 5 Steering stem nut 1 6 Upper bracket 1 7 Upper fork cover 1 8 Upper fork cover spacer 1 9 Upper fork cover washer 1 4 ...

Page 178: ...6 CHAS Order Job Part Q ty Remarks 10 Lower bracket pinch bolt 2 Loosen 11 Front fork leg 1 12 Bolt 3 13 Brake hose guide 1 14 Lower fork cover 1 For installation reverse the removal procedure FRONT FORK 4 ...

Page 179: ...ork leg Remove the parts in the order listed The following procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Fork spring 1 4 Dust seal 1 5 Oil seal clip 1 6 Cartridge cylinder bolt 1 7 Copper washer 1 8 Cartridge cylinder 1 9 Rebound spring 1 0 Inner tube 1 4 ...

Page 180: ...8 CHAS Order Job Part Q ty Remarks A Oil seal 1 B Seal spacer 1 C Outer tube bushing 1 D Inner tube bushing 1 E Oil flow stopper 1 F Outer tube 1 For assembly reverse the disassembly procedure FRONT FORK 4 ...

Page 181: ... stand so that the front wheel is elevated 2 Loosen lower bracket pinch bolts 1 WARNING WARNING 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 ACHTUNG CAUTION Do not scratch the...

Page 182: ...be from the outer tube by pulling the inner tube forcefully but carefully ACHTUNG CAUTION 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 of the front ...

Page 183: ...ring Damage wear Replace EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING WARNING 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 NOTE When assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal ...

Page 184: ... s outer surface 4 Install outer tube onto the inner tube copper washer cartridge cylinder bolt Recommended lubricant Yamaha fork and shock oil 5WT or equivalent New 5 Tighten cartridge cylinder bolt 1 NOTE 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 cartridge cylinder...

Page 185: ...d side of the oil seal faces up NOTE 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 New 8 Install oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer ...

Page 186: ... each front fork leg 554 L 488 lmp qt 589 US qt Front fork leg oil level a from the top of the inner tube with the inner tube fully com pressed and without the fork spring 110 mm 4 33 in Recommended oil Yamaha fork and shock oil 5WT or equivalent EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install lower fork cover 1 brake hose guide 2 bo...

Page 187: ... 94 ft lb 4 Tighten lower bracket pinch bolt 1 cap bolt WARNING WARNING Make sure the brake hoses are routed prop erly 5 Remove steering stem nut upper bracket T R 20 Nm 2 0 m kg 14 ft lb T R 23 Nm 2 3 m kg 17 ft lb 6 Install upper fork washer 1 upper fork spacer 2 upper fork cover 3 7 Install upper bracket 1 steering stem nut 2 T R 130 Nm 13 0 m kg 94 ft lb 4 ...

Page 188: ...S FRONT FORK 8 Tighten upper bracket pinch bolts 1 T R 10 Nm 1 0 m kg 7 2 ft lb 9 Install brake hose holder front fender T R 23 Nm 2 3 m kg 17 ft lb 10 Install front wheel Refer to FRONT WHEEL AND BRAKE DISCS 4 ...

Page 189: ...rder listed 1 Rear view mirror left and right 2 2 Plastic clamp 4 3 Front brake light switch connector 2 Disconnect 4 Brake master cylinder holder 1 5 Brake master cylinder 1 6 Right handlebar switch 1 7 Throttle cable holder 1 8 Throttle cable 2 Disconnect 9 Throttle grip 1 10 Clutch switch connector 1 Disconnect 4 ...

Page 190: ...marks 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 15 Cable guide 1 16 Upper handlebar holder 2 17 Handlebar 1 18 Lower handlebar holder 2 For installation reverse the removal procedure 4 ...

Page 191: ...ck handlebar Bends cracks damage Replace WARNING WARNING Do not attempt to straighten a bent han dlebar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Install washers lower handlebar holders 1 cable guide 2 NOTE Temporarily tighten the nuts 3 2 Install handlebar upper handlebar holders ACHTUNG CAUTION First tighten the bolts on the front side of the handlebar holder then on ...

Page 192: ...handlebar holder nuts T R 40 Nm 4 0 m kg 29 ft lb 4 Install clutch lever NOTE Align the slit of clutch lever holder with the punch mark a on the handlebar 5 Install clutch cable NOTE Lubricate the end of the clutch cable with a thin coat of lithium soap base grease 6 Install left handlebar switch NOTE Align the end a of the left handlebar switch with the punch mark b on the handlebar 7 Connect clu...

Page 193: ... grip until the rubber adhesive has fully dried 9 Install throttle grip 10 Connect throttle cable 11 Install right handlebar switch NOTE Align the projection a on the right handle bar switch with the hole b in the handlebar 12 Install brake master cylinder brake master cylinder holder NOTE Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinde...

Page 194: ...irrors 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 0 39 0 59 in 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 0 16 0 31 in 4 ...

Page 195: ...n chapter 3 Front fork legs fork covers Refer to FRONT FORK Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Handlebar handlebar holders Refer to HANDLEBAR 1 Steering stem nut 1 2 Upper bracket 1 3 Headlight lens unit 1 4 Lead in the headlight body 1 5 Headlight body 1 6 Headlight bracket 1 7 Chrome turn signal light bracket cover 1 8 Turn signal light bracket assembly 1 4 ...

Page 196: ...rks 9 Brake hose joint 1 10 Lock washer 1 11 Upper ring nut 1 12 Rubber washer 1 13 Lower ring nut 1 14 Lower bracket 1 15 Bearing cover 1 16 Upper bearing 1 17 Lower bearing 1 18 Bearing outer race 2 For installation reverse the removal procedure 4 ...

Page 197: ...G Securely support the lower bracket so that there is no danger of it falling Ring nut wrench YU 33975 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 rod 1 and hammer b Remove the bearing r...

Page 198: ...s and bearing races as a set Whenever the steering head is disassem bled 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 bearing bearing races bearing cover lower...

Page 199: ... AND ADJUSTING THE STEERING HEAD in chapter 3 4 Install brake hose joint 1 T R 7 Nm 0 7 m kg 5 1 ft lb 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 4 ...

Page 200: ...ERING HEAD 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 4 ...

Page 201: ... Remove the parts in the order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 1 Adjusting bolt 1 2 Locknut 1 3 Mud guard 1 4 Lower drive belt cover 1 5 Horn coupler 1 Disconnect 6 Horn 1 7 Self locking nut 1 8 Bolt shock absorber connecting arm frame 1 R 158 mm 6 22 in 9 Cover left and right 2 10 Pivot shaft nut washer 1 1 4 ...

Page 202: ...4 80 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job Part Q ty Remarks 11 Pivot shaft 1 12 Rear shock absorber and swingarm assembly 1 For installation reverse the removal procedure 4 ...

Page 203: ...n the order listed 1 Self locking nut washer bolt 1 1 1 Bolt R 53 mm 2 19 in 2 Self locking nut washer bolt 1 1 1 Bolt R 124 mm 4 88 in 3 Connecting arm 2 4 O ring 4 5 Rear shock absorber 1 6 Spacer O ring 1 2 7 Self locking nut washer bolt 1 1 1 Bolt R 77 mm 3 03 in 8 Relay arm 1 9 Spacer oil seal bearing 1 2 1 10 Spacer bearing 1 2 4 ...

Page 204: ...2 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job Part Q ty Remarks 11 Spacer bearing 1 1 12 Swingarm 1 13 Dust cover 2 14 Washer 2 15 Spacer 1 16 Bearing 2 For installation reverse the removal procedure 4 ...

Page 205: ...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 per formance EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER Gas pressure must be released before dis posing of a rear shock absorber and gas cyl inder To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the gas cylinder at a poin...

Page 206: ...swingarm free play is out of specifi cation check the spacers bearings washers and dust covers d Check the swingarm vertical movement ı 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 T R Pivot shaft nut 125 Nm 12 5 m kg 90 ft lb Swingarm free play at the end of the swingarm Zero mm Zero in EAS...

Page 207: ...ends damage wear Replace CHECKING THE RELAY ARM AND CONNECTING ARM 1 Check relay arm 1 connecting arms 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 WARNING WARNING Do not attempt to straighten a bent pivot sh...

Page 208: ... Kerosine 4 Check dust covers spacer oil seals Damage wear Replace bearings Damage pitting Replace EAS00711 INSTALLING THE REAR SHOCK ABSORBER 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 4 ...

Page 209: ...rings oil seals 1 spacers 2 4 Install relay arm 1 onto the swingarm T R 59 Nm 5 9 m kg 43 ft lb 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 T R 59 Nm 5 9 m kg 43 ft lb 4 ...

Page 210: ...rber and swingarm assembly pivot shaft washer pivot shaft nut covers T R 125 Nm 12 5 m kg 90 ft lb 10 Install bolt shock absorber connecting arm frame 1 NOTE When installing the bolt shock absorber connecting arm frame hold the swingarm so that it does not drop down 11 Install horn 1 12 Connect horn coupler 2 13 Install lower drive belt cover 1 4 ...

Page 211: ... AND SWINGARM 14 Install mud guard 1 15 Install locknut 1 adjusting bolt 2 16 Install rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 17 Adjust drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK in chapter 3 4 ...

Page 212: ...e order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY Rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM 1 Drive pulley cover bracket 1 2 Drive pulley cover 1 3 Slider 2 4 Dowel pin 2 5 Drive belt 1 6 Drive pulley nut 1 7 Lock washer 1 8 Drive pulley 1 For installation reverse the removal procedure 4 ...

Page 213: ...the drive pulley 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 detergent 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 ACHTUNG CAUTION To protect the drive belt from da...

Page 214: ...ive belt ACHTUNG CAUTION Install the drive belt facing the same way it was removed 3 Install rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM rear wheel Refer to REAR WHEEL BRAKE DISC AND SWINGARM 4 Tighten drive pulley nut NOTE When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move 5 Bend the lock washer tab along a ...

Page 215: ...ELT AND DRIVE PULLEY 6 Install dowel pins 1 sliders 2 7 Install drive pulley cover 1 drive pulley cover bracket 2 bolts M10 bolts M8 T R 10 Nm 1 0 m kg 7 2 ft lb T R 53 Nm 5 3 m kg 38 ft lb T R 30 Nm 3 0 m kg 22 ft lb 4 ...

Page 216: ...ENG CONTENTS ENGINE ENGINE 5 1 INSTALLING THE ENGINE 5 8 5 ...

Page 217: ...E 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 45...

Page 218: ...VER 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 T...

Page 219: ...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 SHIFT ...

Page 220: ...NE ENGINE Order Job Part Q ty Remarks Removing the muffler and exhaust pipes Remove the parts in the order listed 1 Muffler 1 2 Front exhaust pipe 1 3 Rear exhaust pipe 1 4 Gasket 2 For installation reverse the removal procedure 5 ...

Page 221: ...o SEATS AND SIDE COVERS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Carburetor carburetor joint Refer to CARBURETOR in chapter 6 Air induction system parts Refer to AIR INDUCTION SYSTEM in chapter 6 Starter motor Refer to STARTER MOTOR in chap ter 7 5 ...

Page 222: ... case Refer to TRANSFER GEAR CASE Rider footrest left Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Rider footrest right Refer to GENERATOR AND STARTER CLUTCH 1 Oil filter bolt 1 2 Oil filter bracket 1 3 Horn 2 4 Oil delivery pipe 1 5 Brake hose holder 1 For installation reverse the removal procedure ENGINE 5 ...

Page 223: ...rts in the order listed 1 Spark plug caps 4 2 Cylinder head breather hose 1 3 Oil tank breather hose 1 4 Clutch cable 1 5 Charcoal canister hose carburetor to charcoal canister 1 6 Plastic clamp 1 7 Stator coil coupler 1 8 Decompression solenoid coupler 2 9 Pickup coil coupler 1 ENGINE 5 ...

Page 224: ...5 5 ENG Order Job Part Q ty Remarks 10 Neutral switch cover 1 11 Neutral switch 1 12 Speed sensor 1 For connecting reverse the disconnec tion procedure ENGINE 5 ...

Page 225: ...the parts in the order listed 1 Self locking nut 4 2 Upper front mounting bolt 1 3 Front engine bracket bolt 4 4 Horn bracket 1 5 Front engine bracket 2 6 Self locking nut 2 7 Upper rear mounting bolt 1 8 Rear engine bracket bolt 2 NOTE Place a suitable stand under the frame and engine 5 ...

Page 226: ...rder Job Part Q ty Remarks 9 Rear engine bracket 2 10 Lower front mounting bolt 1 11 Lower rear mounting bolt 1 12 Engine 1 Refer to INSTALLING THE ENGINE For installation reverse the removal procedure ENGINE 5 ...

Page 227: ... front engine brackets 7 horn bracket 8 front engine bracket bolts 9 upper front mounting bolt 0 self locking nuts A NOTE Do not fully tighten the bolts and nuts 2 Tighten front engine bracket bolts 9 self locking nut 6 self locking nuts A T R 48 Nm 4 8 m kg 35 ft lb T R 48 Nm 4 8 m kg 35 ft lb T R 88 Nm 8 8 m kg 64 ft lb 3 Install speed sensor 1 4 Install neutral switch 1 neutral switch cover 2 5...

Page 228: ...Connect charcoal canister hose carburetor to charcoal canister 1 8 Connect clutch cable 1 9 Connect oil tank breather hose 1 cylinder head breather hose 2 spark plug caps 3 NOTE Refer to CABLE ROUTING in chapter 2 10 Install brake hose holder 1 joint bolt 2 oil delivery pipe 3 bolts 4 T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 ...

Page 229: ...footrest right Refer to GENERATOR AND STARTER CLUTCH rider footrest left Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS transfer gear case Refer to TRANSFER GEAR CASE 15 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 16 Install oil filter cartridge 17 Fill oil tank with the specified amount of the recom...

Page 230: ...apter 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 19 Install gaskets exhaust pipes NOTE Finger tighten the exhaust pipe nuts 20 Install muffler bolts 1 T R 30 Nm 3 0 m kg 22 ft lb 21 Tighten exhaust pipe nuts clamp bolts 1 T R 20 Nm 2 0 m kg 14 ft lb T R 25 Nm 2 5 m kg 18 ft lb ...

Page 231: ...cover Remove the parts in the order listed Rider seat fuel tank air filter case Refer to SEATS AND SIDE COVER FUEL TANK and AIR FILTER CASE in chapter 3 Engine oil Drain 1 Spark plug cap 4 Disconnect 2 Spark plug 4 3 Shift rod 1 4 Charcoal canister hose 2 Disconnect 5 Rider footrest left 1 6 Engine left side cover 1 7 Timing mark accessing screw 1 8 Crankshaft end cover 1 5 ...

Page 232: ... Part Q ty Remarks 9 Decompression solenoid cover 1 10 Camshaft sprocket cover 1 11 Camshaft sprocket cover gasket 1 12 Dowel pin 2 For installation reverse the removal procedure ROCKER ARMS PUSH RODS AND VALVE LIFTERS 5 ...

Page 233: ...rs Remove the parts in the order listed 1 Cylinder head breather hose 1 2 Oil tank breather hose 1 3 Bolt 4 R 65 mm 2 56 in 4 Bolt 4 R 35 mm 1 38 in 5 Bolt 4 R 50 mm 1 97 in 6 Bolt 12 R 25 mm 0 98 in 7 Rear cylinder head cover 1 8 Front cylinder head cover 1 9 Cylinder head cover gasket 2 10 Dowel pin 4 5 ...

Page 234: ...RODS AND VALVE LIFTERS Order Job Part Q ty Remarks 11 Rear cylinder head cover spacer 1 12 Front cylinder head cover spacer 1 13 Cylinder head cover spacer gasket 2 14 Dowel pin 4 For installation reverse the removal procedure 5 ...

Page 235: ...ods and rocker arms Remove the parts in the order listed 1 Push rod 4 2 Rear rocker arm base 1 3 Front rocker arm base 1 4 Rocker arm base gasket 2 5 Dowel pin 4 6 Rocker arm shaft 4 7 Rocker arm 1 2 8 Rocker arm 2 2 9 Locknut 2 10 Adjusting screw 2 For installation reverse the removal procedure 5 ...

Page 236: ...arts in the order listed 1 Push rod cover 2 2 Oil seal 4 3 O ring 4 4 Throttle stop screw 1 Unhook 5 Throttle stop screw holder 1 6 Rear valve lifter case cover 1 7 Front valve lifter case cover 1 8 Rear valve lifter case 1 9 Front valve lifter case 1 10 Valve lifter 4 For installation reverse the removal procedure 5 ...

Page 237: ...ck the camshaft drive gear mark c position and camshaft driven gear mark d position as shown If the marks are not aligned turn the crankshaft counterclockwise 360 degrees and recheck step b 2 Remove rocker arm bases with the rocker arms 3 Remove valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the cor rect place ACHTUNG CAUTION Do not lay the rem...

Page 238: ...0 15 018 mm 0 5906 0 5913 in 4 Measure rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diame ter 14 981 14 991 mm 0 5898 0 5902 in 5 Calculate rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the defective part s Rocker...

Page 239: ...nds damage Replace 2 Measure push rod runout Out of specification Replace Push rod runout 0 3 mm 0 012 in CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check valve lifter Blue discoloration excessive wear pit ting scratches Replace or check the lubrication system 2 Check valve lifter case 1 Damage wear Replace the valve lifter case O ring 2 Damage wear Replace the O ring 5 ...

Page 240: ...ifter case inside diameter 22 990 23 010 mm 0 9051 0 9059 in 5 Calculate valve lifter to valve lifter case clearance NOTE Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm 0 0028 in Replace the defective part s Valve lifter to valve lifter case clearance 0 0156 0 042 mm 0 0006 0 0017 in BLEEDING A VALVE LIFTER A valve lifter must be bled in the following ...

Page 241: ...driven gear aligns with the punch mark on the camshaft drive gear as shown This is the condi tion in which piston 1 is at top dead center TDC NOTE The crankshaft can be rotated smoothly when the spark plugs are removed WARNING WARNING Be careful since the engine is hot g With piston 1 at TDC count the indi cated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown ...

Page 242: ...s aligned for five minutes to allow the valve lifter to bleed j If necessary repeat steps h and i to bleed other valve lifters 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 THE VALVE LIFTERS AND PUSH ROD COVERS 1 Install valve lifter cases front and rear valve lifters NOTE Install the ...

Page 243: ...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 cylinders 1 Install rocker arms 1 rocker arm shafts 2 onto rocker arm base NOTE The thread hole a of the rocker arm shaft must face to the outside 5 ...

Page 244: ...h rods between the rocker arms and valve lifters as shown The illustration is viewed from the right side of the motorcycle ÅRear cylinder ıFront cylinder 1Intake side rocker arm 2Exhaust side rocker arm 3Intake valve lifter 4Exhaust valve lifter Lubricate the push rod end balls with engine oil c Install the rocker arm base bolts NOTE Tighten the rocker arm base bolts in stages and in a crisscross ...

Page 245: ...cover spacer gasket 2 New 2 Install cylinder head cover spacer 1 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install dowel pins 1 cylinder head cover gasket 2 New 4 Install cylinder head cover 1 Bolts 2 R 25 mm 0 98 in Bolts 3 R 35 mm 1 38 in Bolts 4 R 50 mm 1 97 in Bolts 5 R 65 mm 2 56 in T R 10 Nm 1 0 m kg 7 2 ft lb 5 Connect oil tank breather hose 1 cylinder head breather hose 2 5 ...

Page 246: ... 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 5 ...

Page 247: ...n chapter 2 ÅForward 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 5 ...

Page 248: ... ROCKER ARMS PUSH RODS AND VALVE LIFTERS Muffler exhaust pipes Refer to ENGINE 1 Decompression solenoid 1 2 Long decompression push rod 1 92 mm 3 6 in 3 Short decompression push rod 1 78 mm 3 1 in 4 Camshaft drive gear 1 5 Straight key 1 6 Camshaft driven gear 1 7 Straight key 1 8 Oil delivery pipe 1 5 ...

Page 249: ...Job Part Q ty Remarks 9 Camshaft cover 1 10 Camshaft cover gasket 1 11 Dowel pin 1 12 Front cylinder camshaft end cover 1 13 Front cylinder camshaft 1 14 Rear cylinder camshaft 1 For installation reverse the removal procedure 5 ...

Page 250: ...r 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 NOTE Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase 4 Remove oil deliver...

Page 251: ...4 mm 1 4368 in b 31 850 mm 1 2539 in Exhaust cam a 36 454 mm 1 4352 in b 31 850 mm 1 2539 in 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 0 9818 0 9823 in 4 Measure camshaft journal diameter camshaft cover side b Out of specification Replace the cam shaft Camshaft journal diameter camshaft ...

Page 252: ...earance Out of specification Replace the defec tive part s NOTE Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter 8 Calculate camshaft to camshaft cover clearance Out of specification Replace the defec tive part s NOTE Calculate the clearance by subtracting the camshaft journal diameter camshaft cover side fro...

Page 253: ...HECKING THE DECOMPRESSION SYSTEM 1 Check decompression system NOTE 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 5 ...

Page 254: ... 1 Install camshafts to the camshaft cover front cylinder camshaft end cover NOTE Apply molybdenum disulfide oil onto the camshaft journals and cam lobes Align the punch mark a on the rear cylin der camshaft with the punch mark b on the front cylinder camshaft 2 Install front cylinder camshaft end cover 1 NOTE Finger tighten the end cover bolts 3 Install dowel pins 1 camshaft cover gasket 2 New 5 ...

Page 255: ...punch mark b on the camshaft driven gear 2 Insert a cross headed screwdriver into one of the holes in the outer camshaft 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 gear nut 1 NOTE Place a folded ...

Page 256: ...riven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear T R 30 Nm 3 0 m kg 22 ft lb 9 Install short decompression push rod 1 long decompression push rod 2 10 Install decompression solenoid 1 11 Install valve lifters push rods rocker arms cylinder head covers Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS exhaust pipes muffler Refer to ENGINE 5 ...

Page 257: ... 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 5 ...

Page 258: ...SIDE COVERS FUEL TANK and AIR FILTER CASE in chapter 3 Carburetor carburetor joint Refer to CARBURETOR in chapter 6 Muffler exhaust pipes Refer to ENGINE Rocker arms push rod cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 1 Reed valve case to rear cylinder pipe 1 Disconnect 2 Reed valve case to front cylinder pipe 1 Disconnect 3 Gasket 2 4 Oil delivery pipe 1 5 Copper washer 4 5 ...

Page 259: ...40 ENG CYLINDER HEADS Order Job Part Q ty Remarks 6 Copper washer 2 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 For installation reverse the removal procedure 5 ...

Page 260: ...linder head 1 Eliminate combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damaging 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 cyl inder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure th...

Page 261: ... oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with compressed 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 NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two s...

Page 262: ...4 Install gaskets 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 5 ...

Page 263: ...ve the parts in the order listed The following procedure applies to both cylinders Cylinder head Refer to CYLINDER HEADS 1 Valve cotter 4 2 Upper spring seat 4 3 Outer valve spring 4 4 Inner valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve oil seal 4 8 Lower spring seat 4 For installation reverse the removal procedure 5 ...

Page 264: ... 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 NOTE There should be no leakage at the valve seat 1 2 Remove valve cotters NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor 1 Valve spring compressor YM 0401...

Page 265: ...em to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0006 0 0020 in Limit 0 1 mm 0 004 in 2 Replace valve guide NOTE To ease valve guide removal and installa tion and ...

Page 266: ...OTE After replacing the valve guide reface the valve seat Valve guide remover 6 mm YM 4064 A Valve guide installer 6 mm YM 04065 A Valve guide reamer 6 mm YM 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 Measure valve margi...

Page 267: ... 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 cylin der head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a ...

Page 268: ...e 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 NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth between you...

Page 269: ...valve seat width again If the valve seat width is out of specifica tion 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 1 51 in Limit 36 26 mm 1 43 in Outer valve spri...

Page 270: ...t 1 14 in Intake and exhaust outer valve spring 13 9 16 1 kg at 31 0 mm 30 6 35 5 lb at 1 22 in 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 0 094 in Intake and exhaust outer valve spring 2 4 mm 0 094 in EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and relate...

Page 271: ...lve springs with the larger pitch a facing up bSmaller pitch New 4 Install valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring com pressor 1 Valve spring compressor YM 04019 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ACHTUNG CAUTION Hitting the valve tip with excessive force could damage the va...

Page 272: ... Removing the cylinders and pistons Remove the parts in the order listed Cylinder heads Refer to CYLINDER HEAD 1 Cylinder 2 2 Cylinder gasket 2 3 Dowel pin 4 4 Piston pin clip 4 5 Piston pin 2 6 Piston 2 7 Top ring 2 8 2nd ring 2 9 Oil ring 2 For installation reverse the removal procedure 5 ...

Page 273: ...tion mark on each piston crown Before removing the piston pin deburr the piston pin clip groove and the piston 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 YU 01304 2 Remove top ring 2nd ring oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the...

Page 274: ...rometer a5 mm 0 20 in from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clear ance with the following formula Cylinder bore gauge YU 03017 Cylinder bore C 95 000 95 010 mm 3 7402 3 7406 in Maximum taper T 0 05 mm 0 0016 in Out of round R 0 05 mm 0 0016 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D...

Page 275: ... 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 0 0012 0 0031 in Limit 0 12 mm 0 0047 in 2nd ring 0 03 0 07 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2 Install piston ring into the cylinder NOTE Level the piston ring in the cylinder with the piston crown a 10 mm 0 39 in 3 Measure piston ring end gap Out...

Page 276: ...piston pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrica tion system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8661 in Limit 21 971 mm 0 8650 in 3 Measure piston pin bore diameter in the piston b Out of specification Replace the piston pin Piston pin bo...

Page 277: ... CYLINDERS The following procedure applies to all of the pistons and cylinders 1 Install top ring 2nd ring lower oil ring rail upper oil ring rail oil ring expander NOTE 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 NOTE Apply engine oil onto the piston pin Make sure the arrow mark a on the pis ton faces to...

Page 278: ...inder with the recommended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps aTop ring bLower oil ring rail cUpper oil ring rail d2nd ring ÅFront of the motorcycle 6 Install cylinder 1 NOTE While compressing the piston rings with one hand install the cylinder with the other hand 5 ...

Page 279: ...er listed Left side cover Refer to SEATS AND SIDE COVERS in chapter 3 Engine left side cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Engine oil Drain 1 Clutch cable 1 Disconnect 2 Pull lever 1 3 Pull lever spring 1 4 Pickup coil coupler 1 Disconnect 5 Shift arm 1 6 Clutch cable holder 1 7 Clutch cover 1 5 ...

Page 280: ...5 61 ENG CLUTCH Order Job Part Q ty Remarks 8 Clutch cover gasket 1 9 Dowel pin 1 For installation reverse the removal procedure 5 ...

Page 281: ...he pull lever shaft and pickup coil Remove the parts in the order listed Pull lever 1 Pull lever spring 1 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 2 4 Bearing 3 5 Pickup coil lead holder 3 6 Pickup coil 1 For installation reverse the removal procedure 5 ...

Page 282: ...r listed Generator rotor cover Refer to GENERATOR 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 7 7 Clutch plate 6 8 Lock washer 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 1 12 Clutch damper spring 1 5 ...

Page 283: ...damper spring seat 1 14 Clutch boss 1 15 Thrust washer 1 16 Clutch housing 1 17 Circlip 1 18 Oil pump drive gear 1 19 Dowel pin 1 20 Spacer 1 21 Pickup coil rotor 1 22 Primary drive gear 1 23 Straight key 1 For installation reverse the removal procedure 5 ...

Page 284: ... nut 1 NOTE While holding the clutch boss 2 with the universal clutch holder 3 loosen the clutch boss nut 4 Remove clutch boss nut 1 lock washer 2 clutch boss assembly 3 NOTE 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 chattering Universal clutch holder YM...

Page 285: ... plate thickness Out of specification Replace the fric tion plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 8 mm 0 110 in 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...

Page 286: ...or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause erratic 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 NOTE Pitting on the clutch boss splines will cause erratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check ...

Page 287: ...riven gear 2 Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Replace the primary drive gear and clutch housing as a set INSTALLING THE PICKUP COIL AND PULL LEVER SHAFT 1 Apply sealant onto the pickup coil lead grommet Quick Gasket ACC 11001 05 01 2 Install pickup coil pickup coil lead holder NOTE Apply locking agent LOCTITE to the threads of ...

Page 288: ...y drive gear 2 pickup coil rotor 3 spacer 4 pickup coil rotor bolt 5 ACHTUNG CAUTION The timing marks on the pickup coil rotor must face outside NOTE 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 2 Bend the lock washer tab along a flat side of the nut Sheave holder YS 01880 T ...

Page 289: ...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 NOTE If the wire circlip 2 has been removed carefully install a new one Install the clutch damper spring 3 with the OUTSIDE mark facing out 4 Install clutch boss 1 lock washer clutch boss nut 2 NOTE While holding the clutch boss with the uni versal c...

Page 290: ... lubricant Engine oil 7 Install friction plates clutch plates NOTE First install a friction plate and then alter nate 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 NOTE Align the punch mark a on the pressure plate with the punch mark b on the clutch boss 5 ...

Page 291: ... kg 5 8 ft lb 10 Install dowel pins 1 clutch cover gasket 2 New 11 Install clutch cover 1 clutch cable holder 2 NOTE Tighten the clutch cover bolts in stages and in a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb 12 Connect pickup coil coupler NOTE Refer to CABLE ROUTING in chapter 2 13 Install shift arm 1 NOTE Align the mark a in the shift shaft with the slot in the shift arm T R 10 Nm 1 0 m kg...

Page 292: ...cable holder to 31 8 mm 1 25 in 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 ...

Page 293: ...t and stop per lever Remove the parts in the order listed Engine oil Drain Clutch housing Refer to CLUTCH 1 Circlip 2 2 Shift shaft spring 1 3 Shift shaft 1 4 Shift shaft spring stopper 1 5 Lock washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation reverse the removal procedure 5 ...

Page 294: ... SHAFT 1 Install stopper lever 1 stopper lever spring 2 NOTE 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 segment assembly 2 Install lock washer 1 shift shaft spring stopper 2 NOTE Apply locking agent LOCTITE to the threads of shift shaft sprin...

Page 295: ...nstall shift shaft spring circlips shift shaft 1 NOTE 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 5 ...

Page 296: ...over fuel tank Refer to SEATS AND SIDE COVERS and FUEL TANK in chapter 3 Muffler exhaust pipes Refer to ENGINE Engine oil Drain 1 Plastic locking tie 1 2 Rear brake light switch coupler 1 Disconnect 3 Rider footrest right 1 4 Stator coil assembly coupler 1 Disconnect 5 Decompression solenoid coupler 2 Disconnect 6 Oil delivery pipe 1 7 Generator cover 1 8 Generator cover gasket 1 9 Dowel pin 2 5 ...

Page 297: ...5 78 ENG GENERATOR AND STARTER CLUTCH Order Job Part Q ty Remarks 10 Stator coil assembly lead holder 1 11 Stator coil assembly 1 For installation reverse the removal procedure 5 ...

Page 298: ...the generator rotor Remove the parts in the order listed 1 Starter clutch idle gear shaft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Starter clutch gear 1 For installation reverse the removal procedure 5 ...

Page 299: ...or rotor bolt Sheave holder YS 01880 3 Remove generator rotor 1 with the rotor puller 2 Rotor puller YM 01080 A 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 turning...

Page 300: ...nerator rotor 2 washer generator rotor bolt 3 NOTE Clean the tapered portion of the crankshaft and the generator rotor hub 2 Tighten generator rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Sheave holder YS 01880 T R 160 Nm 16 0 m kg 115 ft lb 3 Install starter clutch idle gear 1 1 starter clutch idle gear 2 2 starter clutch idle gea...

Page 301: ...OTE Apply locking agent LOCTITE to the threads of the stator coil assembly bolts T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 6 Install dowel pins 1 generator cover gasket 2 New 7 Install generator cover 1 T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install oil delivery pipe joint 1 bolts 2 oil delivery pipe 3 T R 40 Nm 4 0 m kg 29 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 40 Nm 4 0 m kg 29 ft lb 5 ...

Page 302: ...tall rider footrest right 1 T R 48 Nm 4 8 m kg 35 ft lb 11 Connect rear brake light switch coupler 1 NOTE Refer to CABLE ROUTING in chapter 2 12 Install plastic locking tie 1 NOTE 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 5 ...

Page 303: ...5 84 ENG GENERATOR AND STARTER CLUTCH 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 5 ...

Page 304: ...e the parts in the order listed Rider seat side covers Refer to SEATS AND SIDE COVERS in chapter 3 1 Negative battery lead 1 2 Positive battery lead 1 Disconnect 3 Tool kit holder 1 4 Tool kit 1 5 Battery holder 1 6 Battery 1 7 Plastic bracket 1 8 Ignitor unit coupler 3 Disconnect 9 Ignitor unit holder 1 5 ...

Page 305: ...E Order Job Part Q ty Remarks 10 Ignitor unit 1 11 Battery box 1 12 Relay unit coupler 1 Disconnect 13 Turn signal relay coupler 1 Disconnect 14 Plastic clamp 1 15 Relay bracket 1 For installation reverse the removal procedure 5 ...

Page 306: ...s in the order listed Muffler exhaust pipes Refer to ENGINE Engine oil Drain 1 Oil tank breather hose 1 Disconnect 2 Dipstick 1 3 Dipstick joint 1 4 Oil pipe 1 1 5 Oil pipe 2 1 6 Oil tank cover 1 7 Oil tank cover gasket 1 8 Dowel pin 2 9 Oil strainer 1 For installation reverse the removal procedure 5 ...

Page 307: ...er listed Transfer gear oil Drain Drive pulley Refer to DRIVE BELT AND DRIVE PUL LEY in chapter4 1 Drive pulley case 1 2 Dowel pin 2 3 Cover 1 4 Dowel pin 2 5 Transfer gear oil pump 1 6 Transfer gear oil pump gasket 1 7 Transfer gear case cover 1 8 Transfer gear case cover gasket 1 9 Dowel pin 2 10 Oil strainer 1 5 ...

Page 308: ...r Job Part Q ty Remarks 11 Lock washer 1 12 Primary chain 1 13 Middle drive gear 1 14 Middle driven shaft 1 15 Transfer gear case 1 16 Spacer 1 17 Dowel pin 2 18 Oil seal 1 19 Bearing 2 For installation reverse the removal procedure 5 ...

Page 309: ... Disassembling the transfer gear case oil pump Remove the parts in the order listed 1 Oil pump cover 1 2 Pin 2 3 Pin 1 4 Oil pump shaft 1 5 Oil pump inner rotor 1 6 Oil pump outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure 5 ...

Page 310: ...traighten the lock washer tab 2 Loosen middle drive gear nut 1 NOTE When loosening the middle drive gear nut press down on the brake pedal so the mid dle drive gear does not move 3 Remove primary chain 1 middle drive gear 2 middle driven shaft 3 NOTE 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 driv...

Page 311: ...il CHECKING THE OIL PUMP 1 Check oil pump housing 1 oil pump cover 2 Cracks damage wear Replace the defective part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clear ance b Out of specification Replace the oil pump 1Inner rotor 2Outer rotor 3Oil pump housing Inner rotor to outer rotor tip clearance 0 07 0 12 mm 0 003 0 005 in Outer rotor to oil pump housin...

Page 312: ...r 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 NOTE 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 oil pump outer rotor with the arrow b on the oil pump inne...

Page 313: ...NSTALLING 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 pulley nut 4 NOTE Install the middle driven shaft middle drive gear and primary chain at the same time Temporarily install the drive pulley nut onto the middle driven shaft 3 Install oil strainer 1 dowel pins 2 transfer gea...

Page 314: ...ive gear 2 onto the drive axle install the transfer gear case assembly 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 T R 30 Nm 3 0 m kg 22 ft lb T R 30 Nm 3 0 m kg 22 ft lb 8 Install lock washer middle drive gear nut 1 9 Bend the lock washer tab along a flat side of the nut New T R 85 Nm 8 5 m kg 61 ft lb 5 ...

Page 315: ... oil pump 1 NOTE Apply locking agent LOCTITE only to the threads of the transfer gear oil pump bolts 2 M6 25 mm bolts New T R 10 Nm 1 0 m kg 7 2 ft lb 12 Install dowel pins 1 13 Install cover 1 cover bolts M8 2 cover bolts M6 3 T R 24 Nm 2 4 m kg 17 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 14 Install dowel pins 1 5 ...

Page 316: ...T AND DRIVE PUL LEY 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 oil strainer 3 New 2 Install oil tank cover 1 T R 10 Nm 1 0 m kg 7 2 ft lb 5 ...

Page 317: ...t 4 Connect oil tank breather hose 3 5 Install oil pipes 1 T R 10 Nm 1 0 m kg 7 2 ft lb 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 5 ...

Page 318: ...e 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 ACHTUNG CAUTION First connect the positive battery lead 5 then the negative battery lead 6 10 Check battery terminals 5 ...

Page 319: ...parts in the order listed Engine Refer to ENGINE Camshaft Refer to CAMSHAFTS Piston Refer to CYLINDERS AND PISTONS Shift shaft Refer to SHIFT SHAFT Generator rotor Refer to GENERATOR AND STARTER CLUTCH 1 Generator shaft end cover 1 2 Oil delivery pipe 1 3 Engine oil pump driven gear stopper 1 5 ...

Page 320: ...5 101 ENG CRANKCASE Order Job Part Q ty Remarks 4 Engine oil pump driven gear 1 5 Left crankcase 1 6 Dowel 2 7 Joint pipe 1 8 Right crankcase 1 For installation reverse the removal procedure 5 ...

Page 321: ...y Remarks Removing the baffle plate and bear ings Remove the parts in the order listed Crankshaft Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Baffle plate 1 2 Oil seal 1 3 Bearing 4 Installation reverse the removal proce dure 5 ...

Page 322: ...stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustra tion ÅRight crankcase ıLeft crankcase M8 100 mm bolts 1 2 M8 80 mm bolt 3 M6 105 mm bolt K M6 85 mm bolts 9 C M6 75 mm bolts D E M6 60 mm bolts 4 7 M6 40 mm bolts 8 0 B F J Å ı 3 Turn shift drum segment NOTE Turn the shift drum...

Page 323: ... make sure the crank case 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 com pressed air EAS00401 CHECKING THE BEARINGS AND OIL SEAL 1 Check bearings Clean and lubricate the ...

Page 324: ...s EAS00416 ASSEMBLING THE CRANKCASE 1 Apply sealant onto the crankcase mating surfaces NOTE Do not allow any sealant to come into con tact with the oil gallery 2 Install dowel pins 1 joint pipe 2 Quick Gasket ACC 11001 05 01 3 Install left crankcase onto the right crankcase NOTE Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment s teeth ...

Page 325: ...ase M8 100 mm bolts 1 2 M8 80 mm bolt 3 M6 105 mm bolt K M6 85 mm bolts 9 C M6 75 mm bolts D E M6 60 mm bolts 4 7 M6 40 mm bolts 8 0 B F J 5 Check crankshaft and transmission operation Rough movement Repair T R Bolt 1 3 24 Nm 2 4 m kg 17 ft lb Bolt 4 K 10 Nm 1 0 m kg 7 2 ft lb Å ı 6 Install engine oil pump driven gear 1 engine oil pump driven gear stopper 2 oil delivery pipe 3 bolts 4 T R 10 Nm 1 ...

Page 326: ...he sheave holder 3 tighten the genera tor shaft bolt Sheave holder YS 01880 T R 28 Nm 2 8 m kg 20 ft lb 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 5 ...

Page 327: ... OIL PUMP Order Job Part Q ty Remarks Removing the engine oil pump Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Oil strainer 1 2 Engine oil pump assembly 1 Installation reverse the removal proce dure 5 ...

Page 328: ...Remarks Disassembling the engine oil pump Remove the parts in the order listed 1 Spring retainer 1 2 Spring 1 3 Relief valve 1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Ball 1 8 Oil pump outer rotor 1 1 9 Oil pump inner rotor 1 1 0 Pin 1 5 ...

Page 329: ...Order Job Part Q ty Remarks A Oil pump housing cover 2 1 B Pin 2 C Oil pump shaft 1 D Pin 1 E Oil pump inner rotor 2 1 F Oil pump outer rotor 2 1 G Oil seal 2 H Oil pump housing 1 For assembly reverse the disassembly procedure 5 ...

Page 330: ...p 1Inner rotor 2Outer rotor 3Oil pump housing Inner rotor to outer rotor tip clearance 0 0 12 mm 0 0 005 in Outer rotor to oil pump housing clearance feed pump 0 03 0 08 mm 0 001 0 003 in Outer rotor to oil pump housing clearance scavenging pump 0 06 0 11 mm 0 001 0 004 in 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS00365 CHECKING THE RELIEF VA...

Page 331: ...P 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 0 oil pump outer rotor 1 A ball B spring C pins D oil pump housing cover 1 E relief valve F T R 2 Nm 0 2 m...

Page 332: ...r rotor T R 10 Nm 1 0 m kg 7 2 ft lb 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 T R 10 Nm 1 0 m kg 7 2 ft lb EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer cover must point towards the rear of the engine T R 10 Nm 1 0 m kg 7 2 ft lb 5 ...

Page 333: ...s Removing the crankshaft and con necting rods Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal procedure 5 ...

Page 334: ...nnecting rod caps 1 connecting rods big end bearings NOTE Identify the position of each big end bear ing so that it can be reinstalled in its origi nal place EAS00398 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Maximum crankshaft runout 0 04 mm 0 0016 in 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surf...

Page 335: ...er bearing into the connecting rod and the big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearings with the notches b in the connect ing rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been complet...

Page 336: ...HT ENING until the specified torque is reached If the tightening is interrupted between 3 3 and 4 0 m kg 24 and 29 ft lb loosen the connecting rod bolts to less than 3 3 m kg 24 ft lb and start again Refer to INSTALLING THE CONNECT ING RODS f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS g Measure the compressed Plastigauge width e on each crankshaft pin If t...

Page 337: ...haft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 2 respectively 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 NOTE Measure the diameter of each crankshaft journal ...

Page 338: ...te crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft and crankshaft journal bearings as a set NOTE Calculate the clearance by subtracting the crankshaft journal diameter from the crank shaft journal bearing inside diameter Crankshaft journal to crankshaft journal bearing clearance 0 030 0 062 mm 0 0012 0 0024 in INSTALLING THE CONNECTING RODS 1...

Page 339: ...necting rods face towards the left side of the crankshaft Make sure the characters d on both the connecting rod and connecting rod cap are aligned 4 Tighten connecting rod bolt 1 ACHTUNG CAUTION 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 continuous torque between 3 3 and 4 0 m kg 24 ...

Page 340: ...LLING THE CRANKSHAFT 1 Install generator shaft 1 2 Install crankshaft NOTE 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 cylinder sleeve hole 5 ...

Page 341: ...embly and transmission Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Shift fork guide bar 2 2 Shift fork L 1 3 Shift fork R 1 4 Shift fork C 1 5 Shift drum assembly 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation reverse the removal procedure 5 ...

Page 342: ...sembling the main axle assem bly Remove the parts in the order listed 1 Circrip 1 2 Washer 1 3 5th pinion gear 1 4 2nd 3rd pinion gear 1 5 Circlip 1 6 Washer 1 7 4th pinion gear 1 8 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure 5 ...

Page 343: ...xle assem bly Remove the parts in the order listed 1 5th wheel gear 1 2 Circlip 1 3 Washer 1 4 2nd wheel gear 1 5 Circlip 1 6 Washer 1 7 1st wheel gear 1 8 4th wheel gear 1 9 Circlip 1 0 Washer 1 A 3rd wheel gear 1 B Drive axle 1 For assembly reverse the disassembly procedure 5 ...

Page 344: ...ur face Bends Replace WARNING WARNING 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 s 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 sh...

Page 345: ... 3 Check 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 transmis sion axle assemblies 5 Check transmission gear movement Rough movement Replace the defec tive part s 6 Check circl...

Page 346: ...hift fork C shift fork L shift fork guide bars NOTE 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 NOTE Oil each gear shaft and bearing thor oughly 5 ...

Page 347: ... 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 INDUCTION SYSTEM 6 21 AIR INJECTION 6 21 AIR CUTOFF VALVE 6 21 6 ...

Page 348: ...CARB CHECKING THE AIR INDUCTION SYSTEM 6 26 INSTALLING THE AIR INDUCTION SYSTEM 6 26 6 ...

Page 349: ...uel tank Refer to FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Fuel from the carburetor Drain 1 Carburetor joint clamp screw 1 Loosen 2 Throttle stop screw 1 Unhook 3 Vacuum chamber breather hose carburetor to solenoid valve hose 1 Disconnect 4 Throttle cable 2 Disconnect 5 Fuel hose 1 6 Throttle position sensor 1 7 Starter cable 1 Disconnect 8 Starter plunger 1 6 ...

Page 350: ... carburetor to charcoal canister 1 Disconnect 10 Carburetor heater connector 2 Disconnect 11 Carburetor 1 12 Fuel pump bracket assembly with fuel pump 1 13 Vacuum hose 1 Disconnect 14 Carburetor joint 1 For installation reverse the removal procedure CARBURETOR 6 ...

Page 351: ...etor Remove the parts in the order listed 1 Throttle stop screw 1 2 Vacuum chamber air vent hose 1 3 Fuel strainer 1 4 Throttle cable holder 1 5 Throttle position sensor bracket 1 6 Carburetor heater 1 7 Coasting enricher cover 1 8 Coasting enricher spring 1 9 Coasting enricher 1 6 ...

Page 352: ...arks 0 Vacuum chamber cover 1 A Piston valve spring 1 B Jet needle holder 1 C Jet needle kit 1 D Piston valve 1 E Float chamber 1 F Float chamber rubber gasket 1 G Drain bolt 1 H Accelerator plunger 1 I Float pivot pin 1 CARBURETOR 6 ...

Page 353: ...Job Part Q ty Remarks J Float 1 K Needle valve 1 L Needle valve seat 1 M Main jet 1 N Spacer 1 O Needle jet 1 P Pilot jet 1 Q Starter jet 1 R Pilot air jet 1 For assembly reverse the disassembly procedure CARBURETOR 6 ...

Page 354: ...rburetor 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 val...

Page 355: ...place 10 Check jet needle kit 1 main jet 2 needle jet 3 pilot jet 4 starter jet 5 pilot air jet 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check piston valve movement Insert the piston valve into the carbure tor body and move it up and down Tightness Replace the piston valve 12 Check starter plunger 1 starter plunger spring 2 Bends cracks damage Replace ...

Page 356: ... 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 EAS00487 ASSEMBLING THE CARBURETOR ACHTUNG CAUTION Before assembling the carburetor wash all the parts in a petroleum based sol vent...

Page 357: ...tall pilot air jet 1 2 Install starter jet 1 pilot jet 2 3 Install needle jet 1 NOTE Align the slot a on the needle jet with the projection b on the carburetor body 4 Install spacer 1 main jet 2 5 Install needle valve seat 1 6 ...

Page 358: ...bber gasket 3 8 Install float chamber 1 9 Install piston valve 1 jet needle kit jet needle holder piston valve spring vacuum chamber cover 2 NOTE Install the end of the piston valve spring onto the spring guide on the vacuum chamber cover Align the tab a on the piston valve dia phragm with the recess in the carburetor body 6 ...

Page 359: ...e coasting enricher with the recess b in the carburetor body 11 Install terminal 1 washer carburetor heater 2 NOTE Use Heat Sinker when installing the car buretor heater Heat Sinker T R 2 5 Nm 0 25 m kg 2 0 ft lb 12 Install throttle position sensor bracket 1 throttle cable holder 2 fuel strainer 3 vacuum chamber air vent hose 4 6 ...

Page 360: ... THE CARBURETOR 1 Connect carburetor heater connectors 1 charcoal canister hose carburetor to charcoal canister 2 2 Install starter plunger 3 Connect starter cable 1 4 Install throttle position sensor NOTE Align the slot a of the throttle position sensor with the projection b of the throt tle lever shaft For the correct installation refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 ...

Page 361: ...ottle cables 1 7 Connect float chamber breather hose carburetor to solenoid valve 1 8 Hook throttle stop screw 1 9 Install carburetor NOTE Align the projection a of the carburetor with slot of the carburetor joint 10 Tighten carburetor joint clamp screw 1 6 ...

Page 362: ...tle grip 4 8 mm 0 16 0 31 in EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust 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 d Loosen the fuel drain bolt 3 e Measure the fuel level a Fuel level belo...

Page 363: ... POSITION SENSOR NOTE Before adjusting the throttle position sen sor the engine idling speed should be properly adjusted 1 Check throttle position sensor installed on the carburetor a Disconnect the throttle position sensor coupler from the wire harness b Connect the pocket tester Ω 1k to the throttle position sensor coupler c Measure the maximum throttle position sensor resistance Out of specific...

Page 364: ...pecification or the resistance changes abruptly Go to step 2 below Positive tester probe yellow terminal 3 Negative tester probe black terminal 2 Throttle position sensor resis tance 520 900 Ω 4 0 6 0 kΩ at 20 C 68 F yellow black blue 2 Check throttle position sensor removed from the carburetor a Disconnect the throttle position sensor coupler from the wire harness b Remove the throttle position s...

Page 365: ... change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the throttle position sensor NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those spec ified Maximum throttle position sen sor resistance 4 0 6 0 kΩ at 20 C 68 F blue black blue Positi...

Page 366: ...5 650 750 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 e Adjust the throttle position sensor angle so that the measured resistance is within the specified range After adjusting the throttle position sensor angle tighten the throttle position sensor screws Positive tes...

Page 367: ... check if the fuel stops flowing from the fuel hose 2 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump Fuel stops flowing Fuel pump is OK Fuel flows Replace the fuel pump EAS00505 CHECKING THE FUEL COCK 1 Drain fuel from 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 comp...

Page 368: ...he fuel cock check its oper ation 1 Set the fuel cock to OFF 2 Disconnect fuel hose from the 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 4 Connect fuel hose Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock 6 ...

Page 369: ...piston valve diaphragm Normally the air cutoff valve is open to allow fresh air to flow into the exhaust port During sudden decelera tion the butterfly valve suddenly closes negative pressure is generated and the air cutoff valve is closed in order to prevent after burning Additionally at high engine speeds and when the pressure decreases the air cutoff valve automatically closes to guard against ...

Page 370: ... INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1Reed valve 2Air cut valve 3Air cleaner 4Carburetor joint ÅTo the carburetor joint ıTo the front cylinder head ÇTo the rear cylinder head ÎTo the air cut valve 6 ...

Page 371: ...uel tank Refer to FUEL TANK in chapter 3 1 Reed valve case to rear cylinder head hose 1 2 Reed valve case to rear cylinder head pipe 1 3 Reed valve case to front cylinder head hose 1 4 Reed valve case to front cylinder head hose 1 5 Gasket 2 6 Rectifier regulator coupler 1 Disconnect 7 Rectifier regulator 1 8 Air filter bracket 1 6 ...

Page 372: ... 1 10 Air filter cover 1 11 Air filter hose 1 12 Air cut valve to air filter hose 1 13 Plastic locking tie 1 14 Vacuum hose 1 15 Bracket 1 16 Air cut valve holder 1 17 Air cut valve 1 18 Air cut valve to reed valve cover hose 1 19 Reed valve cover 1 20 Reed valve case 1 6 ...

Page 373: ...6 25 CARB AIR INDUCTION SYSTEM Order Job Part Q ty Remarks 21 Reed valve base 1 22 Reed valve stopper 2 23 Reed valve 2 For installation reverse the removal procedure 6 ...

Page 374: ...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 1Surface plate Maximum fibre reed bending 0 4 mm 0 016 in 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 6 ...

Page 375: ...ed 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 6 ...

Page 376: ...cket 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 6 ...

Page 377: ...6 29 CARB AIR INDUCTION SYSTEM 13 Install fuel tank Refer to FUEL TANK in chapter 3 6 ...

Page 378: ...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 7 ...

Page 379: ... 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 37 CIRCUIT DIAGRAM 7 37 TROUBLESHOOTING 7 39 CHECKING THE SIGNALING SYSTEM 7 40 FUEL PUMP SYSTEM 7 46 CIRCUIT DIAGRAM 7 46 FUEL PUMP CIRCUIT OPERATION 7 47 TROUBLESHOOTING 7 48 CHECKING THE FUEL PUMP 7 50 CARBURETOR H...

Page 380: ... switch 4Ignition coils 5Throttle position sensor 6Clutch switch 7Decompression solenoid 8Relay unit 9Turn signal relay 0Ignitor unit ABattery BStarter relay CMain fuse DThermo switch EFuse box FSpeed sensor GHorns HNeutral switch ISidestand switch JPickup coil KStator coil assembly LRear brake light switch MRectifier regulator 7 ...

Page 381: ...NTS AND COUPLERS 1Right handlebar switch coupler left handlebar switch couplers and front turn signal connectors 2Headlight coupler 1Tail brake light connectors and rear turn signal connectors ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 7 ...

Page 382: ...r assembly couplers 5Carburetor heater sub wire harness coupler 6Throttle position sensor coupler 7Fuel sender coupler 8Spark plug cap 2 9Spark plug cap 1 0Fuel pump AFuel pump coupler 1Rear brake light switch lead 2Rectifier regulator 3Rectifier regulator coupler 4Starter motor 5Starter motor lead 6Horn coupler 7Horn 8Pickup coil 9Sidestand switch 7 ...

Page 383: ...coil coupler speed sensor coupler neutral switch connector and sidestand switch coupler 3Battery negative lead 4Battery positive lead 5Battery 6Ignitor unit 7Tail brake light and rear turn signal light sub wire harness coupler 8Starter relay 9Main fuse 0Starter relay coupler AThermo switch BThermo switch coupler CHorn DHorn coupler 7 ...

Page 384: ...nsor 3Ignition coil rear cylinder 4Main switch coupler 5Main switch 6Solenoid valve coupler 7Solenoid valve 8Spark plug cap 4 9Rear brake light switch 1Diode 2Turn signal relay 3Relay unit 4Stator coil 5Decompression solenoid 6Neutral switch 7Speed sensor 8Relay unit coupler 9Turn signal relay coupler 7 ...

Page 385: ...nge 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 illus tration NOTE indicates a continuity of el...

Page 386: ...heck each switch for damage or wear proper connections and also for continuity between the terminals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch 7 ...

Page 387: ...G THE SWITCHES 1Dimmer switch 2Horn switch 3Turn signal switch 4Clutch switch 5Engine stop switch 6Start switch 7Front brake light switch 8Main switch 9Fuse 0Rear brake light switch ASidestand switch BNeutral switch 7 ...

Page 388: ...hown in the illustration on the left Bulbs A and B are used for the head lights and usually use a bulb holder which must be detached before remov ing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwis...

Page 389: ...e life 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 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to ter minal 1 and the tester ...

Page 390: ...dings indicate no continu ity 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 meter assembly side b Connect two jumper leads 1 from the battery terminals to the respective cou pler terminals as shown WARNING WARNING A wire that is used as a jumper lead must have at least the same c...

Page 391: ...B802001 IGNITION SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 9 Relay unit B Ignitor unit C Ignition coil D Spark plug F Pickup coil G Neutral switch a Engine stop switch i Ignition fuse k Sidestand switch l Diode 7 ...

Page 392: ...O 1 Main and ignition fuses Check the main and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge...

Page 393: ...ps Disconnect the 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 YES NO Spark plug cap resistance 10 kΩ at 20 C 68 F Is the spark plug cap OK Replace the spark plug cap EB802409 6 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil connectors from t...

Page 394: ...K Replace the pickup coil EB802411 YES NO 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EB802412 YES NO 9 Engine stop switch Check the engine stop switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EB802413 YES NO 10 Neutral switch Check the neutral s...

Page 395: ...unit diode Remove 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 fol lows Tester positive probe sky blue 1 Tester negative probe blue yellow 2 Continu ity Tester positive probe blue yellow 2 Tester negative probe sky blue 1 No conti nuity Are the tester readings correct Replace the relay unit NOTE When you switch...

Page 396: ...NG SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 9 Relay unit B Ignitor unit E Decompression solenoid G Neutral switch Y Clutch switch a Engine stop switch b Start switch i Ignition fuse k Sidestand switch l Diode 7 ...

Page 397: ...tor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above con ditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTC...

Page 398: ... fuses Check the main and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EB803...

Page 399: ...unit EB803403 YES NO 5 Relay unit diode Disconnect the relay unit from the cou pler Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the diode for continuity as fol lows Tester positive probe sky blue 1 Tester negative probe black yellow 2 Continu ity Tester positive probe sky blue 1 Tester negative probe blue yellow 3 Tester positive probe black yellow 2 Tester negative pr...

Page 400: ...NO 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EB802412 YES NO 8 Engine stop switch Check the engine stop switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EB802413 YES NO 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING T...

Page 401: ... NO 12 Clutch switch Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK Replace the clutch switch EB803406 YES NO 13 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the right handlebar switch FAS00754 YES NO 14 Wiring Check the entire starting system s wir ing Refer to CIRCUIT DIAGRAM Is the...

Page 402: ...MOTOR EB803500 STARTER MOTOR Order Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed 1 Starter motor lead 1 2 Starter motor assembly 1 For installation reverse the removal procedure 7 ...

Page 403: ...clip 1 2 Starter motor 1 3 Starter motor rear cover 1 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Washer set 1 8 Starter motor front cover 1 9 Washer set 1 0 O ring 2 A Armature assembly 1 B Brush seat along with the brushes 1 C Brush holder along with the brushes 1 D Starter motor yoke 1 For assembly reverse the disassembly procedure 7 ...

Page 404: ...ator NOTE The mica must be undercut to ensure proper operation of the commutator Minimum commutator diameter 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Measure armature assembly resistances commu tator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter mo...

Page 405: ...the brush springs as a set Brush spring force 7 65 10 01 N 765 1 001 gf 27 0 35 3 oz 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 NOTE Align the tab a on the brush seat with the slot b in the starter motor rear cover 7 ...

Page 406: ... cover 3 bolts NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers New T R 7 Nm 0 7 m kg 5 1 ft lb 6 Install starter motor gear 1 circlip 2 INSTALLING THE STARTER MOTOR 1 Install starter motor 1 2 Connect starter lead 2 T R 7 Nm 0 7 m kg 5 1 ft lb T R 5 Nm 0 5 m kg 3 6 ft lb STARTER MOTOR 7 ...

Page 407: ...YSTEM CIRCUIT DIAGRAM 1 2 ON OFF 3 7 5 8 4 6 W W W W W W W W W W W W Br L Br L B B B R R R L Y L Y L B L B Br L L Y L B R R R B R R R R L B B B B B R R R W L B R W W W R G R W BLACK BLACK BLACK 1Generator 2Rectifier regulator 4Battery 5Main fuse 7 ...

Page 408: ...FUSES in chapter 3 Is the main fuse OK Replace the fuse EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EB804400 3 Charging voltage Connect the inductive tachometer to the spark plug lead of cylinder 1 Co...

Page 409: ... positive probe white 1 Tester negative probe white 2 Tester positive probe white 1 Tester negative probe white 3 Measure the stator coil assembly resis tances Stator coil resistance 0 45 0 55 Ω at 20 C 68 F Is the stator coil assembly OK Replace the stator coil assembly EB804404 YES NO 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging sys...

Page 410: ...STEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse O High beam indicator light P Meter light V Dimmer switch Z Front turn signal position light Headlight c Tail brake light h Headlight fuse 7 ...

Page 411: ...t fuses Check the main and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and headlight fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EB...

Page 412: ...adlight bulb and socket Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Is the headlight bulb and socket OK Replace the head light bulb socket or both YES NO 2 High beam indicator light bulb and socket Check the high beam indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Is the high beam indicator light bulb ...

Page 413: ...couplers are faulty and must be repaired EB805411 2 A meter light fails to come on YES NO 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 Replace the meter light bulb socket or both YES NO 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as ...

Page 414: ...ke light coupler is faulty and must be repaired 4 The front turn signal position light fails to come on YES NO 1 Front turn signal position light bulb and socket Check the front turn signal position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the front turn signal position light bulb and socket OK Replace the front turn signal position light bulb socket or...

Page 415: ...7 37 ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 ...

Page 416: ... indicator light MSpeedometer assembly speedometer combination meter and fuel level meter NFuel level indicator light QFuel sender RTurn signal relay SHorn WHorn switch XTurn signal switch ZFront turn signal position light Rear turn signal light _Front brake light switch cTail brake light dRear brake light switch jSignaling system fuse SIGNALING SYSTEM 7 ...

Page 417: ...HARGING THE FUSES in chapter 3 Are the main signaling system and backup fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EB802411 YES NO 3 Main switch Check the main switch for continuity Re...

Page 418: ...pecification The wiring circuit from the main switch to the horn connector is faulty and must be repaired NO YES 3 Horn Disconnect the horn coupler at the horn Connect a jumper lead 1 to the brown terminal in the horn coupler and the horn terminal Connect a jumper lead 2 to the horn ter minal and ground the jumper lead Set the main switch to ON Push the horn switch Does the horn sound The horn is ...

Page 419: ...rake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired EB806413 3 A turn signal light turn signal indicator light or both fail to blink YES NO 1 Turn signal light bulb a...

Page 420: ...and must be repaired 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Tester positive probe brown white 1 Tester negative probe ground YES NO Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V of brown white at the turn signal relay coupler Is the voltage within specification The turn signal relay is faulty and must be replaced ...

Page 421: ...icator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the neutral indicator light bulb and socket OK Replace the neutral indicator light bulb socket or both YES NO YES NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch 3 Voltage Connect the pocket tester DC 20 V to the...

Page 422: ...sure the fuel sender resistance Fuel sender resistance Full position of the float Å 11 13 Ω at 20 C 68 F Empty position of the float ı 140 143 Ω at 20 C 68 F Is the fuel sender OK Replace the fuel sender YES NO 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire har ness side as shown Tester positive probe brown 1 Tester negative probe black 2 Set the main switch to ON M...

Page 423: ...45 ELEC SIGNALING SYSTEM EAS00843 YES NO 2 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the ignitor unit Repair or replace the wire harness 7 ...

Page 424: ...7 46 ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse 9 Relay unit 0 Fuel pump B Ignitor unit a Engine stop switch i Ignition fuse 7 ...

Page 425: ...PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump 1Battery 2Main fuse 3Main switch 4Ignition fuse 5Engine stop switch 6Ignitor unit 7Fuel pump relay 8Fuel pump 7 ...

Page 426: ...ion fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EAS00739 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EAS00749 YES NO 3 Main switc...

Page 427: ...e relay unit EB808400 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump coupler fuel pump side as shown Tester positive probe black blue 1 Tester negative probe black 2 YES NO Measure the fuel pump resistance Fuel pump resistance 1 6 2 2 Ω at 20 C 68 F Is the fuel pump OK Replace the fuel pump EAS00754 YES NO 7 Wiring Check...

Page 428: ... spill 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 container c Turn the fuel cock to ON or RES d Connect the battery 12 V to the fuel pump coupler as ...

Page 429: ...7 51 ELEC CARBURETOR HEATING SYSTEM EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse e Carburetor heater f Thermo switch g Carburetor heater fuse 7 ...

Page 430: ...39 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery EAS00749 YES NO 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EAS00823 4...

Page 431: ... prop erly Replace the thermo switch WARNING WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it YES NO 5 Carburetor heater Remove the carburetor heater from the carburetor Connect the pocket tester to the carbure tor heater as shown Tester positive probe carburetor heater terminal 1 Tester negative probe ca...

Page 432: ...Wiring Check the entire carburetor heating sys tem s wiring Refer to CIRCUIT DIAGRAM Is the carburetor heating system s wir ing properly connected and without defects This circuit is OK Properly connect or repair the carbu retor heating sys tem s wiring 7 ...

Page 433: ...Condition code When engine is stopped When engine is running Throttle posi tion sensor Disconnected Short circuit Locked The ignitor unit stays set to the wide open throttle ignition tim ing The motorcycle can be rid den The engine trouble indicator light displays the condition code Blinks in patterns of 3 Lights up Speed sensor Abnormal pulse Disconnected Short circuit The engine speed limiter se...

Page 434: ...rouble indicator light 2Fuel level indicator light 1Indicator lights check 1 4 seconds 2Light off 3 seconds 3Condition code First fault code 3 throttle position sensor 4Condition code Next fault code 4 speed sensor 5Light on 0 5 second 6Light off 0 5 second ÅLight on ıLight off ÇMain switch is turned on ÎRepetition 7 ...

Page 435: ...nk display the self diagnosis sequence Pocket tester YU 03112 EB812020 1 Throttle position sensor CIRCUIT DIAGRAM AThrottle position sensor BIgnitor unit EAS00843 YES NO 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness EB812401 YES NO 2 Throttle position sensor Check the throttle position sensor for continuity R...

Page 436: ...IT DIAGRAM BIgnitor unit HSpeed sensor EAS00843 YES NO BAD 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the speed sensor Replace the ignitor unit Repair or replace the wire harness 7 ...

Page 437: ... 10 to the decompression solenoid coupler as shown Tester positive probe green 1 Tester negative probe green 2 Measure the decompression solenoid resistance Decompression solenoid resis tance thermistor 68 75 78 75 Ω at 25 C 77 F Connect the pocket tester Ω 1 to the decompression solenoid coupler as shown Tester positive probe black 3 Tester negative probe black 4 Decompression solenoid resistance...

Page 438: ... light Refer to CHECKING THE LEDs Is the fuel level indicator light LED OK Repair the meter assembly YES NO 2 Fuel sender Disconnect the fuel sender coupler from the wire harness Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank Connect the pocket tester Ω 10 to the fuel sender coupler Tester positive probe green 1 Tester negative probe black blue 2 Measure the fuel s...

Page 439: ...61 ELEC SELF DIAGNOSIS EAS00843 YES NO 3 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the meter assembly Replace or replace the wire harness 7 ...

Page 440: ... AND HIGH SPEED PERFORMANCE 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 FAULTY GEAR SHIFTING 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 OVERHEATING 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 HANDLING 8 ...

Page 441: ...ES 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 8 ...

Page 442: ...amaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter See page 3 7 and 3 29 Incorrectly installed air filter Clogged air filter element Crankcase and crankshaft See page 5 100 to 5 107 and 5 114 to 5 121 Incorrectly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank See page 3 6 Empty fuel tank Clogged fuel filter Clogged fuel strainer Clogged fuel tan...

Page 443: ... starter motor Faulty starter relay Faulty starting circuit cutoff relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder heads See page 5 39 to 5 43 and 5 53 to 5 59 Incorrect valve clearance Damaged valve train components Air filter See page 3 7 and 3 29 Clogged air filter element FUEL SYSTEM Carburetor See page 6 1 to 6 20 Faulty starter plunger Loose o...

Page 444: ...transmission gears Incorrectly assembled transmission JUMPS OUT OF GEAR Shift shaft See page 5 74 to 5 76 Incorrect shift pedal position Incorrectly returned stopper lever Shift forks See page 5 122 to 5 127 Worn shift fork Shift drum See page 5 122 to 5 127 Incorrect axial play Worn shift drum groove Transmission See page 5 122 to 5 127 Worn gear dog EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch See...

Page 445: ...ee page 7 12 to 7 16 Faulty ignitor unit 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 caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS00860 FAULTY FRONT FORK LEGS See page 3 43 to 3 4...

Page 446: ...45 HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Incorrectly grounded circuit Poor contacts main or dimmer switch Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier regulator Incorrectly grounded circuit Faulty main switch Faulty dimmer switch Headlight bulb life expired TAIL BRAK...

Page 447: ... Dimmer switch W Horn switch X Turn signal switch Y Clutch switch Z Front turn signal position light Rear turn signal light Headlight Right handlebar switch Front brake light switch a Engine stop switch b Start switch c Tail brake light d Rear brake light switch e Carburetor heater f Thermo switch g Carburetor heater fuse h Headlight fuse i Ignition fuse j Signaling system fuse k Sidestand switch ...

Page 448: ...PRINTED IN U S A YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 449: ...UAL 1998 by Yamaha Motor Corporation U S A First Edition October 1998 All rights reserved Any reproduction or unautho rized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 12 56 ...

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Yamaha XV16AL, Service Manual

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