Yamaha XVS650 Service Manual Download Page 207

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Summary of Contents for XVS650

Page 1: ...H XVS650 LIT 11616 XV OO ...

Page 2: ...YAMAHA lIT 11616 11 16 5BN 28197 EO ...

Page 3: ...Yamaha Motor Corporation U S A First edition August 1997 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LlT 11616 11 16 ...

Page 4: ...odifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol me...

Page 5: ...mber that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks The meanings of the symbol marks are given on the next page 4 A job instruction chart J accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the step by step fo...

Page 6: ...are used to identify the specifications appearing in the text Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit clearance Engine speed n V A Illustrated symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight Iithiu...

Page 7: ...EBOO4000 CHAPTER TITLES GENERAL INFORMATION I D 1 I SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING SPEC o ...

Page 8: ...INGS 1 2 LOCK WASHERS PLATES AND COITER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION DIAGRAMS 2 23 CABLE ROUTIN...

Page 9: ...SPECTION 3 21 FUEL LINE INSPECTION 3 21 BREATHER HOSE INSPECTION 3 22 EXHAUST SYSTEM INSPECTION 3 22 CHASSIS 3 23 FRONT BRAKE ADJUSTMENT 3 23 REAR BRAKE ADJUSTMENT 3 24 BRAKE FLUID LEVEL INSPECTION 3 25 BRAKE PAD INSPECTION 3 26 BRAKE SHOE INSPECTION 3 26 BRAKE LIGHT SWITCH ADJUSTMENT 3 26 BRAKE HOSE INSPECTION 3 27 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 3 27 SHIFT PEDAL ADJUSTMENT 3 28 FINAL GEAR OI...

Page 10: ...ROCKER ARM AND CAMSHAFT REMOVAL 4 18 ROCKER ARM AND CAMSHAFT INSPECTION 4 18 ROCKER ARM AND CAMSHAFT INSTALLATION 4 19 VALVES AND VALVE SPRINGS 4 21 VALVE AND VALVE SPRING REMOVAL 4 22 VALVE AND VALVE SPRING INSPECTION 4 22 VALVE AND VALVE SPRING INSTALLATION 4 26 CYLINDERS AND PISTONS 4 28 PISTON REMOVAL 4 29 CYLINDER AND PISTON INSPECTION 4 29 PISTON RING INSPECTION 4 31 PISTON PIN INSPECTION 4 ...

Page 11: ...STALLATION 4 62 CRANKCASE ASSEMBLY 4 63 TRANSMISSION 4 65 SHIFT FORK INSPECTION 4 66 SHIFT CAM INSPECTION 4 66 TRANSMISSION INSPECTION 4 66 TRANSMISSION INSTALLATION 4 68 MIDDLE GEAR 4 69 MIDDLE DRIVEN PINION GEAR 4 69 MIDDLE DRIVE PINION GEAR 4 71 MIDDLE DRIVEN PINION GEAR REMOVAL 4 72 MIDDLE DRIVE PINION GEAR REMOVAL 4 73 MIDDLE GEAR INSPECTION 4 74 MIDDLE DRIVE PINION GEAR INSTALLATION 4 74 MID...

Page 12: ...TMENT 6 29 FRONT WHEEL AND BRAKE DISC 6 1 FRONT WHEEL DiSASSEMBLy 6 3 FRONT WHEEL INSPECTION 6 3 BRAKE DISK INSPECTION 6 4 FRONT WHEEL ASSEMBLY 6 5 FRONT WHEEL INSTALLATION 6 5 FRONT WHEEL STATIC BALANCE ADJUSTMENT 6 6 FRONT BRAKE 6 8 FRONT BRAKE PADS 6 8 BRAKE PAD REPLACEMENT 6 9 MASTER CYLINDER 6 11 MASTER CYLINDER INSPECTION 6 13 MASTER CYLINDER ASSEMBLy 6 13 MASTER CYLINDER INSTALLATION 6 14 F...

Page 13: ... BACKLASH MEASUREMENT 6 57 FINAL GEAR BACKLASH ADJUSTMENT 6 58 DRIVE SHAFT 6 59 FINAL GEAR 6 60 FINAL DRIVE GEAR DISASSEMBLY 6 61 FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY 6 61 FINAL DRIVE RING GEAR POSITIONING 6 63 DElVE SHAFT INSPECTION 6 67 FINAL GEAR CASE INSTALLATION 6 67 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS 7 1 SWITCH INSPECTION 7 2 SWITCH INSPECTION 7 2 INSPECTING A SWITCH SHO...

Page 14: ... PUMP SYSTEM 7 38 CIRCUIT DIAGRAM 7 38 FUEL PUMP CIRCUIT OPERATION 7 39 TROUBLESHOOTING 7 40 FUEL PUMP TEST 7 43 CARBURETOR HEATER SYSTEM 7 44 CIRCUIT DIAGRAM 7 44 TROUBLESHOOTING 7 45 SELF DIAGNOSIS 7 49 TROUBLESHOOTING 7 50 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE HARD STARTING 8 FUEL SYSTEM 8 1 ELECTRICAL SYSTEM 8 1 COMPRESSION SYSTEM 8 2 POOR IDLE SPEED PERFORMANCE 8 2 POOR IDLE SPEED PERFOR...

Page 15: ...BRAKE 8 4 POOR BRAKING EFFECT 8 4 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION 8 4 MALFUNCTION 8 4 OIL LEAKAGE 8 4 UNSTABLE HANDLING 8 5 UNSTABLE HANDLING 8 5 FAULTY LIGHTING AND SIGNAL SYSTEMS 8 5 HEADLIGHT DOES NOT LIGHT 8 5 BULB BURNT OUT 8 5 FLASHER DOES NOT LIGHT 8 5 FLASHER BLINKS SLOWLY 8 5 FLASHER REMAINS LIT 8 5 FLASHER BLINKS QUiCKLy 8 5 HORN DOES NOT SOUND 8 5 XVS650AK C WIRING DIA...

Page 16: ...TORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is 0 stamped into the right side of the steering head MODEL LABEL The model label CD is affixed to the frame This information will be needed to order spare parts 1 1 ...

Page 17: ...hine disassembly clean all 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 ES101010 REPLACEMENT PARTS 1 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 func tion ...

Page 18: ... When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liber ally when installing if appropriate D Oil seal 300 003 Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces D Bearing 300 002 EB101050 CIRCLIPS 1 Check all circlips carefully before reas sembly Always replace piston pin clips after one use Re...

Page 19: ... several times 3 Check Connector leads Looseness Bend up the pin CD and con nect the terminals 4 Connect Connector terminals NOTE _ The two terminals click together 5 Check Continuity using a pocket tester NOTE _ If there is no continuity clean the termi nals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revital izer available at most part stores Ch...

Page 20: ... name I How to use Slide hammer bolt weight These tools are used to remove the rocker arm shaft Final gear backlash band This tool is needed when measuring final gear backlash Piston pin puller This tool is used to remove the pis ton pin Illustration YM 01312 A 90890 01312 T handle YM 01326 90890 01326 Holder YM 01388 90890 01388 Puller YU 33270 90890 01362 Adapter YM 33282 90890 04089 Weight YM 3...

Page 21: ... holder This tool is needed to hold the rotor when removing or installing the rotor bolt Compression gauge set These tools are needed to measure engine compression Vacuum gauge This gauge is needed for carburetor synchronization Pocket tester This instrument is needed for check ing the electrical system Engine tachometer This tool is needed for observing engine rpm Timing light This tool is necess...

Page 22: ...iddle driven shaft bearing driver Plain bearing installer I remover These tools are needed when remov ing or installing the main journal bearing Universal joint holder This tool is needed when removing or installing the driven pinion gear nut Middle gear backlash tool This tool is needed for the gear back lash adjustment Clutch holding tool This tool is needed to hold the cl utch when removing or ...

Page 23: ...__________I I I ...

Page 24: ... Fuel Type Fuel tank capacity Fuel reserve amount Standard XVS650 5BN1 For USA 5BN2 For California 5BN3 For Canada 2 450 mm 96 5 in 930 mm 36 6 in 1 135 mm 44 7 in 710 mm 28 0 in 1 625 mm 64 0 in 145 mni 57 1 in 3 400 mm 133 9 in 243 kg 535 7 Ib Air cooled 4 stroke SOHC V type 2 cylinder 0 649 cm3 81 x 63 mm 3 19 x 2 48 in 9 1 1 000 kPa 10 kg cm2 14 1 psi at 300 rlmin Electric starter Wet sump Yam...

Page 25: ...58 4th 28 24 1 167 5th 29 30 0 967 Chassis Frame type Double cradle Caster angle 35 Trail 145 mm 5 71 in Tire Type With tube Size front 130 90 1667S rear 170 80 15M C 77S Manufacturer front BRIDGESTONE DUNLOP rear BRIDGESTONE DUNLOP Type front G703 D404F rear G702 D404 Maximum load except motorcycle 200 kg 441 Ib Tire pressure cold tire 0 90 kg 0 1981b load front 225 kPa 2 25 kg cm2 32 6 psi rear ...

Page 26: ... travel 140 mm 5 5 in Rear wheel travel 98 mm 3 9 in Electrical Ignition system T C 1 digital Generator system A C magneto Battery type GT12B 4 Battery capacity 12 V 10 AH Headlight type Quartz bulb halogen Bulb wattage x quantity Headlight 12 V60W 55 W Tail brake light 12V8W 27W Turn signal 12 V 27 Wx 4 Licence light 12 V 5 W xl Meter light 12V1 7Wx1 Neutral indicator light 12V1 7Wx1 High beam in...

Page 27: ... diameter Camshaft outside diameter Shaft to cap clearance Cam dimensions A Chain drive left right 28 000 28 021 mm 1 1024 1 1032 in 27 96 27 98 mm 1 1008 1 1016 in 0 020 0 061 mm 0 0008 0 0024 in Intake I A 39 733 mm 1 5643 in 39 63 mm 1 5602 in liB 32 217 mm 1 2683 in 32 12 mm 1 2647 in IIC 7 733 mm O 3044 in Exhaust II A 39 772 mm 1 5658 in 39 67 mm 1 5619 in II B 32 302 mm 1 2717 in 32 20 mm 1...

Page 28: ...idth Margin Thickness II A head diameter IN 36 9 37 1 mm 1 4528 N 1 4606 in EX 31 9 32 1 mm 1 2559 1 2638 in B face width IN 2 3 mm 0 09 in EX 2 3 mm 0 09 in _ flC seat width IN 1 0 1 2 mm 0 039 0 047 in 1 8mm 0 07 in EX 1 0 1 2 mm 0 039 0 047 in 1 8mm 0 07 in IJD margin thickness IN 1 0 1 4 mm 0 039 0 055 in 0 8mm 0 03 in EX 1 0 1 4 mm 0 039 0 055 in 0 8mm 0 03 in Stem outside diameter IN 6 975 6...

Page 29: ...ed IN EX Compressed pressure IN installed 37 1 mm 1 46 in 37 1 mm 1 46 in 21 8 25 6 kg 48 06 56 44 Ib Tilt limit Direction of winding top view EX IN EX IN EX 21 8 25 6 kg 48 06 56 44 Ib 2 5 j1 9mm 0 075 in 2 5 j1 9mm 0 075 in Counter clockwise Counter clockwise Piston Piston to cylinder clearance Piston size 110 H Measuring point I H Oversize 2nd Oversize 4th Piston off set 0 035 0 055 mm 0 0014 0...

Page 30: ...earance Color code corresponding size Crankshaft c Big end side clearance 0 Big end radial clearance liE Journal oil clearance Plain 1 2 x 3 2 mm 0 047 x 0 126 in 0 15 0 30 mm 0 006 0 012 in 0 03 0 07 mm 0 012 0 003 in Taper 1 5 x 3 6 mm 0 059 0 142 in 0 30 0 45 mm 0 012 0 018 in 0 02 0 06 mm 0 0008 0 0024 in 2 5 x 3 1 mm 0 098 x 0 122 in 0 2 0 7 mm 0 008 x 0 028 in 0 026 0 050 mm 0 001 0 002 in C...

Page 31: ...Drive axle deflection limit 0 06 mm 0 002 in Shifter Shifter type Guide bar _ Carburetor I D mark 5BN 00 5BN1 5BN3 5BN 10 5BN2 Main jet M J 90 Main air jet M A J 50 Jet needle J N 4CT3 1 Needle jet N J 0 4 Pilot air jet P A J 1 100 Pilot outlet P O 0 85 Pilot jet P J 20 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 2 1 2 Valve seat size V S 1 0 Starter jet G S 1 17 5 Sta...

Page 32: ... 0 005 in 0 2mm 0 008 in Side clearance 0 03 0 08 mm 0 001 0 003 in 0 15 mm 0 006 in Relief valve operating pressure 440 540 kPa 4 5 5 5 kg cm2 63 8 78 3 psi Oil pressure hot 10 kPa 0 1 kg cm2 1 5 psi at 1 200 r min Pressure check location Hie UNION BOLT Shaft drive Middle gear backlash 0 05 0 10 mm 0 002 0 004 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in 2 9 ...

Page 33: ...m Lubrication chart Pressure feed Splashed MAINTENANCE SPECIFICATIONS ISPECI a I Standard Rocker arm shaft Middle gear housing Starter clutch Main axle Drive axle n J Relief valve L 1 vl Oil strainer 2 10 ...

Page 34: ...MAINTENANCE SPECIFICATIONS ISPECI 0 1 Cylinder head tightening sequence Crankcase tightening sequence Left crankcase 2 11 Right crankcase ...

Page 35: ... 2 55 5 5 39 8 Timing chain tensioner Bolt M6 4 12 1 2 8 7 Timing chain guide Bolt M6 4 10 1 0 7 2 Oil pump Bolt M6 3 7 0 7 5 1 Oil strainer cover Bolt M6 3 10 1 0 7 2 Oil filter cover Bolt M6 5 10 1 0 7 2 Carburetor joint Bolt M6 4 12 1 2 8 7 Air filter case stay Bolt M6 2 12 1 2 8 7 Air filter case assembly Bolt M6 2 12 1 2 8 7 Exhaust pipe joint rear and cyl Nut M8 2 20 2 0 14 5 inder head Exha...

Page 36: ... M8 1 12 1 2 8 7 Middle drive pinion gear Nut M20 1 120 12 0 86 8 Stake Bearing retainer middle driven M65 1 110 11 0 79 6 shaft Yoke middle driven shaft Nut M14 1 90 9 0 65 1 f Bearing housing middle drive Bolt M8 4 25 2 5 18 1 shaft Shift lever stopper Bolt M8 1 22 2 2 15 9 f Use lock washer Shift pedal link Bolt M6 1 10 1 0 7 2 Shift pedal adjuster Nut M6 2 7 0 7 5 1 1 of 2 has LH thread Stator...

Page 37: ... mm 3 74 in Oil grade Fork oil lOW or equivalent Rear suspension Shock absorber travel 42 mm 1 65 in Spring free length 179 5 mm 7 07 in 165 mm 6 5 in Fitting length 165 5 mm 6 52 in Spring rate K1 137 N mm 13 7 kg mm 6 52 Ib in Stroke K1 0 42 mm 0 1 65 in Optional spring No Swingarm Free play limit end _ 1 mm 0 04 in side 1mm 0 04 in Front wheel Type Spoke wheel Rim size 16 x MT3 00 Rim material ...

Page 38: ...nder inside diameter 33 3 mm 1 31 in Brake fluid type DOT 4 Rear brake Type Leading trailing _ _ Brake drum inside diameter 200 mm 7 87 in 201 mm 7 9 in Lining thickness 4 mm 0 16 in 2mm 0 08 in Shoe spring free length 68 mm 2 68 in Brake lever brake pedal Brake lever free play at pivot 1 2 mm 0 04 0 08 in Brake lever free play at lever end 10 15 mm 0 39 0 59 in Brake pedal position 85 m 3 35 in B...

Page 39: ...0 3 0 21 7 Stay and engine front upper M10 40 4 0 28 9 Stay and engine front lower M10 40 4 0 28 9 Frame and engine rear upper M10 40 4 0 28 9 Frame and engine rear lower M12 74 7 4 53 5 Regulator stay and frame M6 13 1 3 9 4 Regulator and regulator stay M6 7 0 7 5 1 Muffler stay and frame M8 30 3 0 21 7 Rear shock absorber and swingarm M12 62 6 2 44 8 Rear shock absorber and frame M12 62 6 2 44 8...

Page 40: ...r wheel axle nut M14 97 9 7 70 2 Tension bar and swingarm M8 20 2 0 14 5 Tension bar and brake shoe plate M8 20 2 0 14 5 Brake cam shaft lever M6 10 1 0 7 2 Clutch hub and damper M10 62 6 2 44 8 Final gear case housing cover M10 18 1 8 13 0 Bearing housing final gear case M8 23 2 3 16 6 Bearing housing final gear case M10 23 2 3 16 6 f 1 Bearing retainer final drive pinion gear M65 115 11 5 83 2 L...

Page 41: ...em Type A C magneto Model manufacturer F4T459 MITSUBISHI Nominal output 14 V 20 A at 5 000 rlmin Stator coil resistance I color 0 50 0 620 at 20 C White White Voltage regulator Type Semi conductor short circuit type Modell manufacturer SH650D l1 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier Model manufacturer SH650D ll SHINDENGEN Capacity 18A Withstand voltage 200V Battery Specific gr...

Page 42: ... Full transistor type Model manufacturer FE257BH I DENSO Self cancelling device Yes Flasher frequency 75 95 cycle min Wattage 27 Wx2 3 4W Fuel pump relay Modell manufacturer G8R 30Y I OMRON Circuit breaker Type Fuse Amperage for individual circuit MAIN 30 Ax 1 HEAD LIGHT 15 Ax 1 SIGNALS 10 Ax 1 IGNITION 10 Ax 1 Reserve 30 Ax 1 Reserve 15 A x 1 Reserve 10 Ax 1 2 19 ...

Page 43: ...d warpage tighten mUlti fastener assemblies in a criss cross fashion in progressive stages until the specified torque is reached Unless oth erwise specified torque specifications require clean dry threads Components should be at room temperature IA L A Distance between flats B Outside thread diameter A 8 General torque specifications nut bolt m k Nm 10mm 6mm 6 0 6 4 3 12mm 8mm 15 1 5 11 14mm 10mm ...

Page 44: ...t pin Crankshaft journal big end Piston surface Piston pin Camshaft cam lobe journal Rocker arm shaft Valve stem IN EX G Valve stem end IN EX Oil pump rotor inner outer housing Idle gear surface Starter idle gear Starter idle gear shaft Middle drive gear Primary driven gear Push rod 1 Transmission gear wheel pinion G Shift cam Shift fork guide bar Shift shaft assembly Valve spring intake Push rod ...

Page 45: ... lip Front wheel oil seal lip right left Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand boft sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt contact surface Clutch lever pivot bolt contact surface Rear shock absorber lower oil seal lip Swingarm pivot bearing inner surface Swingarm pivot oil seal lip 2 22 ...

Page 46: ...LUBRICATION DIAGRAMS ISPECI U I EB205000 LUBRICATION DIAGRAMS CD Rocker arm intake Rocker arm exhaust Camshaft Drain bolt Oil strainer Push lever j Push rod 1 Oil pump 2 23 ...

Page 47: ...LUBRICATION DIAGRAMS ISPECI g I CD Rocker arm shaft intake Rocker arm shaft exhaust Camshaft Drive axle Relief valve Oil pump j Oil filter Crankshaft 2 24 ...

Page 48: ...CD Crankshaft Oil filter Oil pump LUBRICATION DIAGRAMS ISPECI I 2 ...

Page 49: ...G Camshaft Rocker arm Starter idle gear LUBRICATION DIAGRAMS ISPECI U I Drive axle Main axle 2 26 ...

Page 50: ...r hose Speedometer cable Speedometer Speedometer light leads j Rectifier regulator Rear brake switch lead Sidestand switch lead CABLE ROUTING ISPECI I Horn jJ Headlight lead Right handlebar switch lead Spark plug lead Fuel hose Main switch lead Fuel pump lead Main switch Fuel pump A B ...

Page 51: ...ank breather hose through the fuel tank hole o h CABLE ROUTING ISPECI I J Connect the rear brake switch coupler in front of the roll over valve stay f To the speedometer light leads Pass the right handlebar switch lead and head light lead over the other harness and leads 8 Pass the clutch cable through the cable guide rn Fasten the sidestand switch lead and rectifier regulator lead with a plastic ...

Page 52: ...rectifier regulator f Pass the rear brake switch lead between the frame and rectifier regulator Do not pinch the rear brake switch lead CABLE ROUTING ISPECI U I QJ Fasten the rear brake switch lead and rectifier regulator lead with a plastic locking tie lB Place the couplers behind the steering head Pass the speedometer cable through the holder I Pass the fuel tank breather hose through the holder...

Page 53: ...attery positive lead Spark plug lead Starter cable J Right handlebar switch lead Brake hose Throttle cables Thermo switch lead Flasher light relay CABLE ROUTING ISPECI U I Pass the tail brake light lead between the frame bracket and battery box 1m Fasten the tail brake light lead with a battery band Do not pinch the harness and tail brake light lead f9 To the ignition coil Qj The end of the plasti...

Page 54: ...Fasten the spark plug lead with a metal clamp Q Pass the ignition coil lead inside of the starter cable CABLE ROUTING ISPECIU I IKl Fasten the fuse box lead with a plastic locking tie J Fasten the battery positive lead with a bat tery box clamp M The carburetor heater relay should not touch the wire harness fD Fasten the wire harness with a plastic locking tie Q From the engine fJ Pass the starter...

Page 55: ...nd j Pass the wire harness between the frame and battery box Q Place the end of the plastic locking tie as shown rID 3 4 CABLE ROUTING ISPECI I lYJ Fasten the starter cable with a plastic locking tie Inside the motorcycle 00 Pass the fuel tank breather hose through the holder YJ Fasten the fuel tank breather hose with a metal clamp Pass the speedometer cable through the front side guide Fasten the...

Page 56: ...hrough the frame hole Fasten the wire harness with a plastic band at the point where the tape is located rn The wire harness and leads should not touch the rear shock absorber ID To the starter relay ID 3 4 CABLE ROUTING ISPECI a I fi To the flasher light relay rnTo the rear fender OJ To the battery negative lead kJ Pass the ignitor unit leads through the battery box hole A A ...

Page 57: ...ad Pickup coil lead A C magneto lead Thermo switch lead Fuel tank breather hose Frame Wire harness Air filter case AJ Pass the throttle cables through the cable guide rnJ Pass the brake hose in front of the upper bracket g Pass the left handlebar switch lead over the right handlebar switch lead QJ Pass the clutch cable through the cable guide Fasten the handlebar switch leads with a plastic band F...

Page 58: ...lead under the ignition coil lead thermo switch lead and throttle position sensor TPS lead lMJ From the engine CABLE ROUTING SPECI u I lliJ 20 mm 0 79 in Q Pass the thermo switch lead inside of the silencer breather hose E Place the end of the plastic locking tie as shown Q Inside the motorcycle B Fasten the wire harness with a plastic locking tie lliJ Pass the wire harness between the air filter ...

Page 59: ...l pump Rollover valve Ignition coil CABLE ROUTING ISPECI 0 1 To the rollover valve To the engine g From the fuel cock Q Position the hose clip tabs downward ID From the fuel tank E The longer stem on the rollover valve faces up lQ The tabs on both hose clips should face in the same direction 2 36 ...

Page 60: ...gnition coil CABLE ROUTING ISPECI 0 1 Position the spark plug lead in front of the fuel tank I Pass the fuel tank breather hose through the hose guide g Pass the fuel hose through the hose guide Q Fasten the fuel hose To the engine III Position the hose clip tabs inward Position the hose clip tabs downward F 2 37 ...

Page 61: ... Hose canister atmosphere FOR CALIFORNIA oJ M M CABLE ROUTING ISPECI I Position this under clamp Both and 1m Install clamp so that opening faces upward g Install pipe with diagonal cut facing downward QJ Install clip with knob pointing inward Install this so that opening faces outward WPosition this under clamp Place in front of L 2 38 ...

Page 62: ...nth 7 months 13 months 19 months 2Smonths 31 month 1 Valve clearance Check and adjust valve clearance J J J J when engine is cold Check condition Adjust gap and clean 2 Spark plugs Replace at 13 000 km or 13 months Replace J Replace and thereafter every 12 000 km or 12 months 3 Crankcase ventiIa Check ventilation hose for cracks or J J j j j tion system damage Replace if necessary 4 Fuel line Chec...

Page 63: ...essary 9 Tares Check tire tread wear and for dam j j age Replace if necessary 10 Wheel bearings Check bearings for looseness or j oJ j oJ damage Replace if necessary Check swing arm pivot for play 11 Swing arm Correct if necessary oJ Moderately repack every 24 000 km Repack 15 200 mi or 24 months 2 Check bearing play and steering for smooth operation 12 Steering bearings Correct if necessary j j R...

Page 64: ...le from the 7 000 km 4 400 mi or 7 months every 6 000 km 3 800 mil or 6 month interval Brake fluid replacement 1 When disassembling the master cylinder or caliper cylinder replace the brake fluid Nor mally check the brake fluid level and add fluid as required 2 0n the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four ...

Page 65: ...move the parts in the order below 1 Fuel hose 1 NOTE Set the fuel cock to OFF before dis connecting the fuel hose 2 Meter assembly 1 3 Meter lead couper 2 4 Speedometer cable 1 NOTE Disconnect the speedometer cable from the front wheel side first 5 Starter knob bracket 1 6 Fuel tank assembly 1 7 Passenger seat 1 8 Seat bracket 1 9 Rider s seat 1 For installation reverse the removal procedure 3 4 ...

Page 66: ...d or adjusted the piston must be at Top Dead Center T D C on the compres sion stroke 1 Remove Meter assembly Fuel tank Refer to FUELTANK AND SEATS 2 Remove Carburetor assembly Refer to CARBURETOR in CHAPTER 5 3 Disconnect Spark plug caps 4 Remove Spark plugs 5 Remove Ignition coil Q 6 Remove Cylinder head covers Refer to ENGINE REMOVAL Cylinder head cover brackets Refer to CYLINDER HEADS 7 Remove ...

Page 67: ...0 005 0 007 in Measuring steps Turn the crankshaft clockwise with a wrench Align the camshaft sprocket mark with the stationary pointer 6 on the cylinder head When the mark is aligned with the pointer the piston is at Top Dead Center TDC A d B d 3 6 Check the front rear cylinder timing mark on the rotor If necessary turn the crankshaft to align the timing mark with the pointer on the AC magneto co...

Page 68: ... is obtained Turning in valve clearance is decreased Turning out valve clearance is increased Hold the adjuster to prevent it from mov ing and tighten the locknut Locknut 14 Nm 1 4 m kg 10 It Ib Measure the valve clearance again If the clearance is still incorrect repeat all the clearance adjustment steps until the specified clearance is obtained 12 1nstall All removed parts NOTE _ Install all rem...

Page 69: ...the valve clearance should be properly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level surface NOTE _ Place the motorcycle on a suitable stand 2 Remove Vacuum plugs CD 3 Attach Vacuum gauge CD Engine tachometer to the 1 spark plug lead Vacuum gauge YU 08030 A 90890 03094 Engine tachometer YU 08036 A 90890 03113 4 Start the engine and let it warm up for several ...

Page 70: ...and check the synchronization again Vacuum pressure at idle speed 29 0 kPa 220 mm Hg 8 7 in Hg NOTE _ The difference between the two carburetors should not exceed 1 33 kPa 10 mm Hg 0 39 in Hg 7 Check Engine idling speed Out of specification Adjust 8 Stop the engine and detach the measur ing equipment 9 Adjust Throttle cable free play Refer to THROTTLE CABLE ADJUST MENT Free play throttle cable 4 6...

Page 71: ...ne tachometer YU 08036 A 90890 03113 1 Start the engine and let it warm up for several minutes 2 Attach Engine tachometer to the 1 spark plug lead 3 Check Engine idling speed Out of specification 7 Adjust Engine idling speed 1 150 1 250 r min 4 Adjust Engine idling speed Adjustment steps Turn the throttie stop screw cD in or out until the specified idling speed is obtained idling speed is increase...

Page 72: ...ting the throttle cable free play the engine idling speed and carbure tor synchronization should be adjusted properly 1 Check Throttle cable free play Out of specification Adjust Free play throttle cable 4 6 mm 0 16 0 24 in At throttle grip flange 2 Remove Rider s seat Fuel tank Refer to FUEL TANK AND SEATS 3 Adjust Throttle cable free play Adjustment steps NOTE _ When the motorcycle is accelerati...

Page 73: ...nut A WARNING Additional step Loosen the locknut Turn the adjuster in or out until the specified free play is obtained free play is decreased free play is increased Turning out Turning in After adjusting turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change 4 1nstall Fuel tank Rider s seat Refer to FUEL TANK AND SEATS EB303040 SPARK P...

Page 74: ...k plug cleaner or wire brush 5 Measure Spark plug gap with a wire gauge Out of specification Adjust gap Spark plug gap 0 8 0 9 mm 0 031 0 035 in 6 1nstall Spark plug 18 Nm 1 8 m kg 13 ft Ib NOTE _ Before installing a spark plug clean the gasket surface and the plug surface EB3030S1 IGNITION TIMING CHECK NOTE _ Prior to checking the ignition timing check all electrical connections related to the ig...

Page 75: ...6 A 90890 03113 3 Check Ignition timing Checking steps Start the engine and let it warm up for several minutes Let the engine run at the specified speed Engine idling speed V t 1 150 1 250 r min Check that the stationary pointer is within the firing range 6 on the rotor Incorrect firing range Check the ignition system NOTE _ Ignition timing is not adjustable 4 1nstall Timing plug CD 3 14 ...

Page 76: ...ark plug caps Spark plugs Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 6 Measure Compression pressure If it exceeds the maximum pressure allowed Inspect the cylinder head valve surfaces and piston crown for car bon deposits If it is below the minimum pressure 7 Squirt a few drops of oil ...

Page 77: ...inimum 1 000 kPa 10 kg cm2 142 2 psi Maximum 1 200 kPa 12 kg cm2 170 6 psi Measurement steps Crank the engine with the throttle wide open until the reading on the compres sion gauge stabilizes A WARNING To prevent sparking ground all spark plug leads before cranking the engine Repeat the previous steps for the other cylinders NOTE _ The difference in compression pressure between the highest and lo...

Page 78: ... F or higher Yamalube 4 20W40 or SAE 20W40 type SE motor oil At 15 C SOOF or lower ID Yamalube 4 10W30 or SAE 10W30 type SE motor oil Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase NOTE _ Recommended engine oil classification API Service liSE IISF type or equivalent e g SF SE IIS...

Page 79: ... oil filter is to be replaced during this procedure remove the following parts and reinstall them afterwards Replacement steps Remove the oil filter element cover G and oil filter element Check the a ring If cracked or dam aged replace them with new one Install the oil filter element and oil filter element cover Oil filter cover 10 Nm 1 0 m kg 7 2 ft Ib 5 1nstall Gasket Drain bolt 43 Nm 4 3 m kg 3...

Page 80: ...oil leaks Oil level 9 Check Oil pressure Checking steps Slightly loosen the oil gallery bolt CD Start the engine and keep it idling until oil starts to seep from the oil gallery bolt If no oil comes out after one minute turn the engine off so that it will not seize Check the oil passages oil filter and oil pump for damage or leakage Refer to INSPECTION AND REPAIR in CHAPTER 4 Start the engine afte...

Page 81: ... play is obtained free play is decreased free play is increased Turning out Turning in Tighten the locknuts Handlebar end Engine end 2 EB303120 AIR FILTER CLEANING 1 Remove Air filter case cover CD 2 Remove Air filter element 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 ...

Page 82: ...filter element Air filter case cover NOTE _ When installing the element in its case make sure its sealing surface matches the sealing surface of the filter case so that no air can leak out EB303130 CARBURETOR JOINT INSPECTION 1 lnspect Carburetor joints CD Cracks damage t Replace Refer to IJCARBURETOR in CHAPTER 5 EB303140 FUEL LINE INSPECTION 1 lnspect Fuel hose Cracks damage t Replace Fuel filte...

Page 83: ...ear cylinder Refer to IIENGINE REMOVAL in CHAP TER 4 2 1nspection Breather hose D Cracks damage Replace Loose connection Connect properly l jlj 1111_ l 1 _ Make sure that the crankcase breather hose is routed correctly EB303160 EXHAUST SYSTEM INSPECTION 1 lnspect Exhaust pipe front CD Exhaust pipe joint rear Muffler assembly lower Muffler assembly upper Cracks damage 1 Replace Gaskets Exhaust gas ...

Page 84: ...er free play is decreased Turning out brake lever free play is increased Tighten the locknut After adjusting the front brake lever free play make sure that there is no brake drag A WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleeding the brake system before the motorcycle is operated Air in the brake system wi...

Page 85: ...lay is obtained Adjustment steps Loosen the locknut CD Turn the adjuster in or out until the specified pedal height is obtained Tighten the locknut 4 Adjust Brake pedal free play 2 Adjust Brake pedal height EB304012 REAR BRAKE ADJUSTMENT 1 Check Brake pedal height Out of specification Adjust Turning in brake pedal height is decreased Turning out brake pedal height is increased 3 Check Brake pedal ...

Page 86: ...4 NOTE _ For a correct reading of the brake fluid level make sure the top of the handlebar brake fluid reservoir is horizontal Brake fluid may corrode painted surfaces or plastic parts Always clean up any spilt fluid immediately A WARNING Use only the designated brake fluid Other fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of fluid M...

Page 87: ... Replace the brake shoes as a set Refer to REAR WHEEL AND REAR BRAKE in CHAPTER 6 EB304050 BRAKE LIGHT SWITCH ADJUSTMENT NOTE _ The brake light switch is operated by move ment of the brake pedal Adjustment is correct when the brake light comes on just before the braking effect starts 1 Check Brake light operation timing Incorrect Adjust 2 Adjust Brake light operation timing Adjustment steps Hold t...

Page 88: ...tem whenever the system is disassembled a brake hose is loosened or removed the brake fluid level is very low brake operation is faulty If the brake system is not properly bled a loss of braking performance may occur 1 Bleed Brake system Air bleeding steps a Fill the reservoir with the proper brake fluid b lnstall the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c...

Page 89: ... precaution could allow air to enter the brake system lengthening the bleeding procedure con siderably j Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft Ib NOTE _ If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the brake system have dis appeared k Fill the brake fluid reservoir to the proper ...

Page 90: ...on a level surface NOTE _ When inspecting the final gear oil level make sure the motorcycle is upright Place the motorcycle on a suitable stand 2 Remove Oil filler bolt CD 3 lnspect Oil level Oil level should be to the bottom brim 1 of the hole Oil level is too low Add oil to the proper level Recommended oil SAE 80 API GL 4 Hypoid gear oil If necessary an SAE 80W90 hypoid gear oil may be used for ...

Page 91: ... case I I O tntitv Refer to IiFINAL GEAR OIL LEVEL INSPEC TION 5 lnstall Oil filler bolt 23 Nm 2 3 m kg 17 ft Jb EB304130 STEERING HEAD INSPECTION A WARNING Securely support the motorcycle so that there is no danger of it falling over 1 Stand the motorcycle on a level surface NOTE _ Place the motorcycle on a suitable stand 2 Elevate the front wheel by placing a suit able stand under the engine 3 C...

Page 92: ... _ Set the torque wrench at a right angle to the ring nut wrench Adjustment steps Remove the lock washer CD the upper ring nut and the rubber washer Loosen the lower ring nut Tighten the lower ring nut using the ring nut wrench 6 Adjust Steering head Loosen the lower ring nut completely then tighten it to specification A WARNING Do not overtighten the ring nut Lower ring nut final tightening 18 Nm...

Page 93: ...l their slots are aligned Install the lock washer CD NOTE _ Make sure the lock washer tabs sit correctly in the ring nut slots 7 1nstall Upper bracket Steering stem nut 11 0 N m 1 1 0 m k g 1 9 6 ft lb Front fork pinch bolts upper 20 N m 2 o m kg 1 4 5 ft Ib q EB304140 FRONT FORK INSPECTION A WARNING Securely support the motorcycle so that there is no danger of 4t falling over 1 Stand the motorcyc...

Page 94: ... extension bar included in the owner s tool kit to adjust the spring preload Adjustment steps Turn the adjuster CD in or out Selecting a Spring preload is softer lower number Selecting a Spring preload is harder higher number Adjustment numbers Standard number 3 Minimum number 1 Maximum number 7 Never turn the adjuster beyond the maxi mum or minimum adjustment number E6304170 TIRE INSPECTION 1 Mea...

Page 95: ...eration of an overloaded motorcycle could cause tire damage an accident or injury Basic weight With oil and 243 kg 535 7 Ib full fuel tank Maximum 200 kg 440 9 Ib load Cold tire Front Rear pressure Up to 90 kg 225 kPa 225kPa 2 25 kgf cm2 2 25 kgf cm2 198Ib load 32 6 psi 32 6 psi 90 kg 198 Ib 225 kPa 250 kPa maximum 2 25 kgf cm2 2 50 kgf cm2 load 32 6 psi 36 3psi High speed 225 kPa 250 kPa 2 25 kgf...

Page 96: ... below have been approved by Yamaha Motor Co ltd for this model No guaran tee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle The front and rear tires should always be by the same manufac turer and of the same design FRONT TIRE Manufacturer Size Type BRIDGESTONE 130 90 1667S G703 DUNLOP 130 90 16678 D404F REAR TIRE...

Page 97: ...t to make any repairs to the wheels EB304190 SPOKE INSPECTION AND TIGHTENING 2 1nspect Spokes CD Bending damage 4 Replace Loose spoke 4 Retighten 3 Tighten Spokes Spoke wrench NOTE _ Be sure to tighten the spokes before and after break in Nipple 3 Nm 0 3 m kg 2 2 ft Ib EB304200 CABLE INSPECTION AND LUBRICATION A WARNING Damaged cable sheaths may cause corro sion and interfere with cable movements ...

Page 98: ...icant t Engine oil NOTE _ Hold the cable end upright and pour a few drops of lubricant into the cable sheath EB304210 LEVER AND PEDAL LUBRICATION Lubricate the pivoting points on the levers and pedals Recommended lubricant t lithium soap base grease EB304220 SIDESTAND LUBRICATION Lubricate the pivoting point and the contact surfaces on the sidestand Recommended lubricant t Lithium soap base grease...

Page 99: ...e different from those of general type bat teries The MF battery should be charged as explained in CHARGING METHOD If the battery is overcharged the electro lyte level will drop considerably There fore take special care when charging the battery A WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid ...

Page 100: ...o IIFUEL TANK AND SEATS Battery cover CD 2 Disconnect Battery leads First disconnect the negative lead CD then disconnect the positive lead 2 3 Remove Battery band Battery Volt meter 4 Check Battery condition Battery condition checking steps Connect a digital voltmeter to the battery terminals Tester lead 7 battery terminal Tester lead 7 battery terminal NOTE _ The charge state of an MF battery ca...

Page 101: ...after charging is shown below As shown in the figure the open circuit voltage stabilizes about 30 min utes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage SATTERV INSPECTION II g 1 1 Check the condition of the battery using the following charts Example Open circuit voltage 12 QV Charging time 6 5 hours Charge conditi...

Page 102: ...ed NO Adjust the voltage so that current is at standard charging level Set the timer according to the charging time suitable for the open circuit voltage Refer to Battery condition checki ng steps YES Monitor the amperage for 3 5 minutes to check if the standard charging current is reached NO If the current does not exceed standard charging current after 5 minutes replace the battery In case that ...

Page 103: ...arge the battery until the battery s charging voltage is 15 V NOTE _ Set the charging time at 20 hours maximum NO This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Charger Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required U...

Page 104: ...ery Battery band 7 Connect Battery leads First connect the positive lead CD then connect the negative lead 8 1nstall Rider s seat Refer to FUEL TANK AND SEATS EB305010 FUSE INSPECTION When checking or replacing the fuse always turn off the main switch Other wise a short circuit may occur 1 Remove Battery cover 2 lnspect Fuses Inspection steps Connect the pocket tester and check the fuse for contin...

Page 105: ...rical devices elf the fuse blows again immediately check the electrical circuit Description Current rating Quantity Main 30A 1 Headlight 15A 1 Carburetor 15A 1 heater Signals 10A 1 Ignition 10A 1 Reserve 30A 1 Reserve 15A Reserve lOA 1 A WARNING Never use a fuse with a rating other than that specified Never use other materials in place of a fuse An improper fuse may cause extensive damage to the e...

Page 106: ...ntally Turn the adjuster in or out Turning in headlight beam to the left Turning out headlight beam to the right EB30S030 HEADLIGHT BULB REPLACEMENT 1 Remove Headlight lens unit 2 Disconnect Leads in headlight body CD 3 Remove Bulb cover 4 Unhook Bulb holder CD 5 Remove Bulb A WARNING Since the bulb may be hot keep flammable products and your hands away from it Do not touch the bulb until it has c...

Page 107: ...e the trans parency of the glass life of the bulb and the luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alco hol or lacquer thinner 7 Hook up Bulb holder a lnstall Bulb cover 9 Connect Leads in headlight body 10 lnstall Headlight lens unit 3 46 ...

Page 108: ... ty Remarks Remove the parts in the order below Stand the motorcycle on a level sur face A WARNING Securely support the motorcycle so there is no danger of it falling over 1 2 3 4 Muffler assembly upper Muffler assembly lower Exhaust pipe gasket Brake pedal link 1 1 1 1 Refer to IIBRAKE PEDAL INSTALLA TION 5 Rear brake switch 6 Brake pedal footrest right 7 Exhaust pipe 8 Exhaust pipe gasket 1 1 1 ...

Page 109: ...m kg 18 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib ENGINE REMOVAL ENG 20 Nm 2 0 m kg 14 5 ft Ib Order Job name Part name Q ty Remarks 9 Battery cover 1 10 Side cover right 1 For installation reverse the removal procedure 4 2 ...

Page 110: ...n the order below Fuel tank Refer to IIFUEL TANK AND SEATSfI in CHAPTER 3 Carburetor assembly Refer to CARBURETORfI in CHAPTER 5 1 Battery leads 2 Disconnect NOTE Firstf disconnect the negative leadf then disconnect the positive lead 2 Starter motor assembly 1 3 Spark plug cap 1 4 Ignition coil cylinder 1 side 1 5 Baffle cover 1 6 Upper cylinder head cover rear 1 7 Lower cylinder head cover rear 1...

Page 111: ...4 ENGINE REMOVAL ENG 5 Nm 0 5 m kg 3 6 ft Ib 7 Order Job name Part name Q ty Remarks 9 Lower cylinder head cover front 1 10 Cover 1 11 AIS ass y 1 For installation reverse the removal procedure 4 4 ...

Page 112: ...cover left 1 2 Middle gear case cover 1 3 Sidestand assembly 1 4 Shift pedal footrest left 1 1 5 Clutch cable 1 6 Neutral switch lead 1 7 Crankcase cover Ieft gasket 1 1 8 Dowel pins 2 9 Rectifier regulator 1 Remove the parts in the order below Drain Refer to IJENGINE OIL REPLACE MENT in CHAPTER 3 Do not remove the bolts Refer to SHIFT PEDAL INSTALLA TION For installation reverse the removal proce...

Page 113: ...he parts in the order below Place a suitable stand under the frame and engine A WARNING Securely support the motorcycle so there is no danger of it falling over 1 Engine stay front upper left 1 2 Engine stay front upper right 1 3 Cable holder 1 4 Engine stay front lower left 1 5 Engine stay front lower right 1 6 Engine mounting bolt rear upper 1 L 75mm 2 95 in left 7 Engine mounting bolt rear uppe...

Page 114: ... 53 5 ft Ib Order Job name Part name Q ty Remarks 8 Engine mounting bolt rear lower 1 L 150mm 5 9 in 9 Rubber boot 1 10 Engine assembly 1 NOTE Remove the engine assembly from the right side of the motorcycle 11 Canister bracket 1 For California 12 Canister ass y 1 For installation reverse the removal procedure 4 7 ...

Page 115: ...D 10 N m 1 0 m kg 7 2 ft b NOTE _ Align the punch mark on the shift rod with the slot on the shift pedal link BRAKE PEDAL INSTALLATION 1 Connect Brake pedal link CD 10 N m 1 0 m kg 7 2 ft b NOTE _ Align the punch mark on the brake rod with the slot 6 on the brake pedal link 4 8 ...

Page 116: ...y Refer to IIENGINE REMOVAL 1 Cylinder head cover brackets 2 2 Tappet cover exhaust O ring 1 1 3 Tappet cover intake O ring 1 1 4 Camshaft sprocket cover O ring 1 1 5 Baffle plate O ring only rear cylin 1 1 der head 6 Timing chain tensioner gasket 1 1 7 Camshaft sprocket plate only rear 1 Refur uCYUNDERHEADREMOVAU cylinder head INSTALLATION 8 Camshaft sprocket 1 9 Exhaust pipe joint rear gasket 1 ...

Page 117: ...5 3 ft b 10 Nm 1 0 m kg 7 2 ft Ib 20 Nm 2 0 m kg 14 4 ft Ib 20 Nm 2 0 m kg 14 4 ft Ib 55 Nm 5 5 m kg 39 8 it Ib Order Job name Part name O ty Remarks 12 Dowel pins 2 13 Cylinder head gasket 1 For installation reverse the removal procedure 4 10 ...

Page 118: ...ligned with the stationary pointer on the cylin der head The rear piston is at TDC on the compres sion stroke when there is clearance at both of the rocker arms If there is no clearance then turn the crankshaft clock wise one full turn Check that the rear piston is at TDC in the compression stroke 2 Loosen Bolt camshaft sprocket CD NOTE _ Use the sheave holder to hold the rotor Sheave holder YS 01...

Page 119: ...kcase cover Oeft when the front piston is at TOC on the compression stroke When the III mark is aligned with the station ary pointer the punch mark on the cam shaft sprocket should be aligned with the stationary pointer on the cylinder head The front piston is at TOC on the compres sion stroke when there is clearance at both of the rocker arms If there is no clearance then turn the crankshaft cloc...

Page 120: ...rpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE _ To ensure an even surface rotate the cylin der head several times CYLINDER HEADS 4 1nspect Camshaft sprockets Wear damage 7 Replace the camshaft sprockets and the timing chain as a set 1 4 tooth Correct G Roller Sprocke...

Page 121: ...1nstall Camshaft sprocket Installation steps Turn the crankshaft clockwise Align the T mark with the stationary pointer 6 on the crankcase cover left Install the camshaft sprocket with the tim ing mark facing out Turn the camshaft just enough to remove any slack from the exhaust side of the tim ing chain Insert your finger into the hole and timing chain tensioner hole and push the timing chain gui...

Page 122: ...e a new gasket Install the spring washer and cap bolt J J Cap bolt timing chain tensioner e 20 Nm 2 0 m kg 14 4 ft Ib 4 lnstall Camshaft sprocket plate CD Bolt camshaft sprocket 55 N m 5 5 m kg 39 S ft Ib l NOTE _ Be sure the projection on the camshaft sprocket plate is aligned with the hole in the sprocket Use the sheave holder to hold the rotor Sheave holder YS 01880 90890 01701 5 Check Alignmen...

Page 123: ...ise 290 Align the I mark with the stationary pointer EV on the crankcase cover left Install the camshaft sprocket with the tim ing mark facing out Turn the camshaft just enough to remove any slack from the intake side of the tim ing chain Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward While pushing the timing chain guide be sure that the tim...

Page 124: ...nd camshaft removal Remove the parts in the order below Cylinder heads Refer to CYLINDER HEAD 1 Lock washer 1 2 Stopper plate 1 3 Union bolt gasket 2 2 4 Rocker arm shafts 2 5 Rocker arms 2 Refer to ROCKER ARM AND CAM 6 Camshaft bushing 1 SHAFT REMOVAL INSTALLATION 7 Camshaft dowel pin 1 1 8 Locknuts 2 9 Valve adjusters 2 For installation reverse the removal procedure 4 17 ...

Page 125: ...ushing CD Camshaft NOTE _ Screw a 10 mm bolt into the threaded end of the camshaft and pullout the cam shaft ROCKER ARM AND CAMSHAFT INSPECTION 1 1nspect Camshaft bushings Damage wear 1 Replace 2 1nspect Camshaft lobes CD Valve adjusters Blue discoloration pitting scratches 1 Replace 3 Measure Camshaft lobe length and width 6 Out of specification 1 Replace Camshaft lobe limit Intake 39 63 mm 1 56 ...

Page 126: ...ide diameter 14 000 N 14 018 mm 0 5512 IY 0 5519 in Measure the outside diameter fi of the rocker arm shafts Out of specification 7 Replace Rocker arm outside diameter 13 980 N 13 991 mm 0 5504 0 5508 in Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Clearance greater than 0 08 mm 7 Replace the defective part s Rocker arm to shaft s...

Page 127: ...ar cylinder head and the NO 2 camshaft J is installed in the front cylinder head 3 Apply Engine oil onto the rocker arm shafts 4 1nstall Rocker arms CD Rocker arm shafts intake and exhaust NOTE _ The thread hole of the rocker arm shafts must face to the outside After installation make sure that the thread hole of the rocker arm shaft is positioned correctly as shown in the illus tration 4 20 ...

Page 128: ...efer to CYLINDER HEADS Rocker arms and camshafts Refer to ROCKER ARMS AND CAM SHAFT 1 VaIve cotters 4 Refer to IIVALVE AND VALVE SPRING REMOVAlJlNSTALLATION 2 Valve spring retainers 2 3 Valve springs 2 4 Valve intake 1 i Refer to IIVALVE AND VALVE SPRING 5 Valve exhaust 1 INSTALLATION 6 Valve stem seals 2 7 Valve spring seats 2 For installation reverse the removal procedure 4 21 ...

Page 129: ... 2 Remove Valve cotters NOTE Attach a valve spring compressor CD between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor YM 04019 90890 04019 a VALVE AND VALVE SPRING INSPECTION 1 Measure Stem to guide clearance Stem to guide clearance valve guide inside diameter valve stem diameter 6 Out of specification Replace the valve guide Clearance stem to...

Page 130: ...e guide using a valve guide reamer to obtain proper stem to guide clearance Valve guide remover installer 7 0 mm 0 28 in Remover YM 01225 A Reamer YM 0127 Installer YM 04017 90890 04018 302 013 VALVESANDVALVESPRINGS IENG I I 2 Replace Valve guide 3 lnspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace OIJ___ 11 4 Measure M...

Page 131: ...lve seat width Out of specification 7 Reface the valve seat Valve seat width Intake 1 0 1 2 mm 0 039 0 047 in limit 1 8 mm 0 071 in Exhaust 1 0 1 2 mm 0 039 0 047 in limit 1 8 mm 0 071 in Measurement steps Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the ...

Page 132: ...eat are evenly polished then clean off all of the compound NOTE _ For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem to...

Page 133: ...spring force 21 8 25 6 kg at 37 1 mm 48 1 56 4 Ib at 1 46 in 302 006 302 028 302 050 12 Measure Spring tilt Out of specification 7 Replace Spring tilt limit 2 5 1 9 mm 0 074 in VALVE AND VALVE SPRING INSTALLATION 1 Apply Molybdenum disulfide oil onto the valve stem and valve stem seal 2 lnstall Valve spring seats Valve stem seals _ Valves Valve springs Valve spring retainers NOTE _ Install the val...

Page 134: ...g with a valve spring compressor CD install the valve cotters Valve spring compressor YM 04019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood lllj l lllIlllj llj l _ Hitting the valve tip with excessive force could damage the valve 4 27 ...

Page 135: ...Refer to CYLINDER HEADS 1 Timing chain guide 1 The up mark should face towards the cylinder head 2 Cylinder O ring 1 1 Refer to CYLINDER AND PISTON INSTALLATION 3 O ring collar 1 1 4 Dowel pins 2 5 Cylinder gasket 1 6 Piston pin clips 2 7 Piston pin 1 Refer to PISTON REMOVAlJCYLlN 8 Piston 1 DER AND PISTON INSTALLATION 9 Piston ring set 1 For installation reverse the removal procedure 4 28 ...

Page 136: ...on head for reference during reinstallation Before removing each piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and the pis ton pin is still difficult to remove use the piston pin puller CYLINDERS AND PISTONS ENG CYLINDER AND PISTON INSPECTION 1 1nspect Cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston 2 Measure Pis...

Page 137: ... piston skirt diameter lip with a micrometer 6 mm from the piston bottom edge Piston size P Standard 80 92 80 97 mm 3 186 3 188 in If out of specification replace the piston and the piston rings as a set 3rd step Use the following formula to calculate the piston to cylinder clearance Piston to cylinder clearance Cylinder bore C Piston skirt diameter IIp Clearance piston to cylinder 0 035 0 055 rom...

Page 138: ...m 0 0008 0 0024 in Limit 0 12 mm 0 0047 in 307 027 2 Position Piston ring into the cylinder NOTE _ Using the piston crown push the ring into the cylinder so that the ring will be at a right angle to the cylinder bore 40 mm 1 57 in 3 Measure End gap Out of specification 7 Replace NOTE _ You cannot measure the end gap on the expander spacer of the oil ring If the oil ring rails show excessive gap re...

Page 139: ...e the piston pin to piston clear ance using the following formula Piston pin to piston clearance Bore size piston pins 6 Outside diameter piston pins Outside diameter piston pin 19 995 20 000 mm 0 1872 0 7874 in If out of specification replace the piston Clearance piston pin to piston 0 004 0 020 mm 0 00016 0 0008 in Measurement steps Measure the piston pin outside diameter If out of specification...

Page 140: ...2nd ring Oil ring Offset the piston ring end gaps as shown Top ring end Oil ring end lower Oil ring end upper Q 2nd ring end 3 1nstall Piston CD Piston pin Piston pin clips _ NOTE _ Apply engine oil onto the piston pin pis ton ring and piston Be sure that the piston is positioned cor rectly as shown in the illustration EX mark 4 Lubricate Piston Piston rings Cylinder NOTE _ Apply a liberal coating...

Page 141: ... O ring 4 Oil filter 5 Crankcase cover right O ty Remarks Remove the parts in the order below Stand the motorcycle on a level surface A WARNING Securely support the motorcycle so there is no danger of it falling over Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to ENGINE REMOVAL 1 1 L 70mmx1 65mmx1 25mmx3 2 76 in x 0 065 in x 0 049 in x 3 1 1 1 L 65 mm x 1 55 mm x 1 45 mm x 4 30 mm x 4 2 56...

Page 142: ...CLUTCH 7m For installation _ l p ro cedu reo I reverse the removal 4 35 ...

Page 143: ...Refer to OIL PUMP Clutch springs 5 2 Pressure plate 1 3 Push plate push rod 1 1 1 Refer to CLUTCH INSTALLATION 4 Ball 1 5 Friction plates 6 6 Clutch plates 5 7 Nut locknut 1 1 Refer to CLUTCH REMOVAL INSTAL LATION 8 Clutch boss 1 9 Thrust washer 10 Nut primary drive gear Refer to PRIMARY DRIVE GEAR REMOVAl INSTALLATION 11 Clutch housing 1 12 Push rod 2 1 Refer to INSTALLATION ...

Page 144: ...CLUTCH ENG Order Job name Part name Q ty Remarks 13 Lock washer 1 14 Claw washer 1 15 Drive gear oil pump 1 16 Primary drive gear 1 17 Straight key 1 For installation reverse the removal procedure ...

Page 145: ...n the teeth of the primary drive gear and primary driven gear to lock them CLUTCH REMOVAL 1 Straighten Lock washer tab 2 Loosen Nut clutch boss D NOTE _ Loosen the nut clutch boss D while hold ing the clutch boss with the clutch hold ing tool 311 000 Thickness friction plate 2 9 3 1 mm 0 114 0 122 in Wear limit 2 6 mm 0 102 in 311 002 3 tnspect Clutch plate Damage 7 Replace the clutch plates as a ...

Page 146: ...gs as a set Free length clutch spring 39 5 mm 1 555 in Wear limit 38 5 mm 1 516 in 4 39 9 lnspect Dogs on the clutch housing Pitting wear damage Deburr or replace Clutch housing bearing Wear damage Replace the clutch hous ing NOTE _ Pitting on the clutch housing dogs will cause erratic operation 10 lnspect Clutch boss splines Pitting wear damage Replace the clutch boss NOTE _ Pitting on the clutch...

Page 147: ...e primary drive gear and primary driven gear to lock them 2 Bend Lock washer tab along a flat side of the nut CLUTCH INSTALLATION 1 lnstall Lock washer CD _ Nut clutch boss 70 N m 7 0 m k g 5 0 6 ft lb JI NOTE _ Tighten the nut clutch boss while hold ing the clutch boss with a clutch holding tool Clutch holding tool YM 91042 90890 04086 2 Bend Lock washer tab along a flat side of the nut 3 1nstaII...

Page 148: ...o 8 m k g 5 8 ft I b NOTE _ Tighten the pressure plate bolts in stages using a crisscross pattern 6 Check Push lever position Push the push lever assembly in the direc tion of the arrow and make sure that the match marks are aligned Match marks not aligned Adjust Match mark on the push lever assembly 6 Match mark on the crankcase 7 Adjust Push lever position Adjustment steps Loosen the nut CD Turn...

Page 149: ...GINE OIL REPLACE MENT in CHAPTER 3 Clutch assembly Refer to CLUTCH Crankcase cover left Refer to ENGINE REMOVAL Circlip 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Stopper lever 1 Refer to IISHIFT SHAFT INSTALLA 6 Torsion spring stopper lever 1 TION 7 Washer 1 8 Circlip 1 9 Torsion spring shift shaft 1 For installation reverse the removal procedure ...

Page 150: ...lace Bends damage t Replace 3 Jnspect Torsion spring shift shaft CD Torsion spring stopper lever Wear damage t Replace SHIFT SHAFT INSTALLATION 1 lnstall Shift shaft CD Torsion spring shift shaft Washer Stopper lever Torsion spring stopper lever Washer NOTE _ Hook the spring end on the stopper lever and the crankcase boss Mesh the stopper lever J with the shift cam stopper 4 43 ...

Page 151: ..._____________S_H_IF_T_S_H_A_R_I GI I 2 1nstall Shift lever NOTE _ Insert the shift arm G between the pins on the shift cam segment 4 44 ...

Page 152: ...der Job name Part name Q ty Remarks Oil pump removal Remove the parts in the order below Crankcase cover right Refer to CLUTCH 1 Circlip 1 2 Driven gear oil pump 1 3 Oil pump assembly 1 4 O rings collar 2 1 For installation reverse the removal procedure ...

Page 153: ...rks Oil pump disassembly Disassembly the parts in the order below CD Spring retainer 1 Spring 1 Relief valve 1 Oil pump cover 1 Pin 1 Shaft 1 J Inner rotor 1 Outer rotor 1 Dowel pins 2 Oil pump housing 1 For assembly reverse the disassembly procedure 4 46 ...

Page 154: ...ance between the inner rotor CD and the outer rotor Side clearance fi between the outer rotor and the pump housing Out of specification Replace the oil pump assembly lip clearance 0 12 mm 0 005 in Limit 0 2 mm 0 008 in Side clearance 0 03 0 08 mm 0 001 0 003 in Limit 0 15 mm 0 006 in 3 Check Oil pump operation Unsmooth operation Replace ...

Page 155: ...7 Nm 0 7 m kg 5 1 ft Ib Order Job name Part name Q ty Remarks Stator removal Remove the parts in the order below Engine oil Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Crankcase cover left Refer to uCLUTCH Rider s seat Refer to FUEL TANK AND SEATS in CHAPTER 3 1 Stator coil 1 2 Pickup coil 1 For installation reverse the removal procedure 4 48 ...

Page 156: ... AC magneto and starter clutch Remove the parts in the order below removal 1 Shaft 1 2 Starter idler gear 1 3 Bolts 3 4 Rotor 1 J eferto HAC MAGNETO REMOVAU INSTALLATION 5 Woodruff key 1 6 Starter wheel gear 1 rRefer to 11 AC MAGNETO INSTALLA 7 Washer 1 TION 8 Starter clutch assembly 1 For installation reverse the removal procedure 4 49 ...

Page 157: ...f key Remove the rotor and the woodruff key NOTE _ When installing the flywheel puller remove three of the starter clutch bolts Remove the rotor by pushing back the rotor the flywheel puller and the adapter Install the flywheel puller bolts and tighten the center bolt making sure that the tool body stays parallel to the rotor If necessary one holding bolt may be backed out slightly for realignment...

Page 158: ...clockwise the starter clutch and the starter wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the starter wheel gear counterclockwise 6 the starter wheel gear should turn freely If not the starter clutch is faulty Replace it AC MAGNETO INSTALLATION 1 1nstall Washer CD Starter wheel gear Woodruff key Rotor NOTE _ Clean the tapered portion of the crank shaft a...

Page 159: ...n Bolt rotor CD 80 Nm 8 0 m kg 57 9 ft Ib I Bolts starter clutch 20 N m 2 0 m kg 14 4 ft lb q NOTE _ Tighten the rotor bolt CD and starter clutch bolts while holding the magneto rotor with a sheave holder Sheave holder YS 01880 90890 01701 4 52 ...

Page 160: ...ve the parts in the order below Engine assembly Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEADS Cylinder and piston Refer to IICYLINDERS AND PISTONS Clutch assembly Refer to IICLUTCH Shift shaft Refer to SHIFT SHAFT Oil pump assembly Refer to 1I0lL PUMP AC magneto and starter clutch Refer to AC MAGNETO AND STARTER CLUTCH Middle drive pinion gear Refer to MIDDLE GEAR 1 Timing chain gu...

Page 161: ...m kg 7 2 It Ib 24 Nm 2 4 m kg 17 4 ft Ib 1 24 Nm 2 4 m kg 17 4 ft Ib 6 x 10Nm 1 0 m g 7 2ft IJ Order Job name Part name Q ty Remarks 6 O rings 2 7 Oil strainer 1 8 Crankcase right 1 Refer to I CRANKCASE SEPARATION ASSEMBLY 9 Dowel pins 3 10 O ring 1 For assembly reverse the separation procedure 4 54 ...

Page 162: ... Crankshaft and connecting rod Remove the parts in the order below removal 1 Crankshaft assembly 1 2 Main journal bearings 2 3 Nuts connecting rod caps 4 4 Connecting rod bolts 4 Refer to CRAN KSHAFT REMOVAL INSTALLATION 5 Connecting rods 2 6 Connecting rod caps 2 7 Plain bearings 4 For installation reverse the removal procedure 4 55 ...

Page 163: ...the shift cam to the position shown in the figure so that it does not contact the crankcase when separating the crankcase 8J Right crankcase ID Left crankcase Remove the right crankcase NOTE _ For this removal slits in the crankcase can be use as shown Use a soft hammer to tap on one side of the crankcase Tap only on reinforced por tions of the crankcase Do not tap on the crankcase mating surfaces...

Page 164: ...necting rod caps G Connecting rod Plain bearings NOTE _ Identify the position of each bearing very carefully so that it can be reinstalled in its original place CRANKSHAFT INSPECTION 1 Thoroughly wash the crankcase halves in mild solvent 2 ThoroughJy clean all the gasket mating surfaces and crankcase mating surfaces 3 lnspect Crankcase Cracks damage Replace Oil delivery passages Blockage Blowout t...

Page 165: ...t engine damage they must be installed in their original posi tions Clean the bearings crank pins and bear ing portions of the connecting rods Install the upper half of the bearing into the connecting rod and the lower half of b the bearing into the connecting rod cap NOTE _ Align the projection of the bearing with the notch 6 of the connecting rod and its cap Put a piece of Plastigauge CD on the ...

Page 166: ...ghtening is interrupted between 3 0 and 3 6 m kg loosen the nut to less than 3 0 m kg and start again Remove the connecting rods and bear ings On each crank pin measure the width of the compressed Plastigauge 1 If the oil clearance is out of specification select a replacement bearing 8 Select Crank pin bearing P NOTE _ The numbers CD indicate crankshaft jour nal sizes are stamped on the crankweb a...

Page 167: ...al bearing the smaller value is used Clean the surface of main journal and journal bearings Check the bearing surface If the bearing surface is worn or scratched the bearings should be replace NOTE _ If either of the right or left journal bearing is worn or scratched both bearings should be replaced as a set Measure the outside diameter of each main journal at two places If it is out of specificat...

Page 168: ...ove the main journal bearings out of crankcase Clean the bearing seat in the crankcase where the bearing is fitted Measure the diameter of the bearing seat at two places NOTE _ If the diameter of the bearing seat in the crankcase exceeds 49 02 mm the crankcase should be replaced with a new one The new crankcase includes new journal bear ings The each inside diameter of bearing is normally 45 000 4...

Page 169: ...Align the projection on the bearing with the projection 6 and stat on the special tools 3 CRANKSHAFT AND CONNECTING RODS ENG ti CRANKSHAFT INSTALLATION 1 Attach Main journal bearings CD I 3 lnstall Connecting rod bearings CD NOTE _ Align the projection of the bearings with the notches 6 in the connecting rod cap Install each bearing in its original place 309 6 4 lnstall Connecting rods CD NOTE _ T...

Page 170: ...type torque wrench Without pausing tighten to full torque specification Apply continuous torque between 3 0 and 3 6 m kg Once you reach 3 0 m kg DO NOT STOP TIGHTEN ING until final torque is reached If the tightening is interrupted between 3 0 and 3 6 m kg loosen the nut to less than 3 0 m kg and start again 7 1nstall Crankshaft CD NOTE _ Align the left connecting rod with the rear cylinder sleeve...

Page 171: ...nstalling the crankcase 3 Tighten Crankcase bolts follow the proper tightening sequence NOTE _ The numbers embossed on the crankcase indicate the crankcase tightening sequence J M8 4 Nm 2 4 m kg 17 4ft Ib I G M6 O N m 1 0 m kg 7 2 ft lb 1 NOTE _ Lubricate the bolt threads with engine oil Tighten the bolts in increasing numerical order M6x45mm CD M6x55mm M6x95mm M8x60mm M8x80mm J M8x 100mm 4 64 ...

Page 172: ...nkcase separation Refer to II CRANKSHAFT 1 Guide bar 1 1 2 Guide bar 2 1 3 Shift fork 2 IIC 1 4 Shift fork 3 uR 1 Refer to IITRANSMISSION INSTALLA 5 Shift fork 1 ilL 1 TION 6 Shift cam 1 7 Main axle assembly 1 8 Drive axle assembly 1 9 Bearing retainer 2 10 Bearings 4 11 Shim 1 For installation reverse the removal procedure 4 65 ...

Page 173: ...ar 3 Check Shift fork movement on the guide bar Unsmooth operation 7 Replace the shift fork and the guide bar 319 001 4 66 SHIFT CAM INSPECTION 1 1nspect Shift cam grooves Scratches wear damage 7 Replace Shift cam segment CD Wear damage 7 Replace Shift cam bearing Pitting damage 7 Replace TRANSMISSION INSPECTION 1 Measure Axle runout Use a centering device and a dial gauge Out of specification 7 R...

Page 174: ...eplace 2 103 103 2 mm 3 Check Proper pinion gear engagement each gear to its counter part Incorrect 7 Reassemble Gear movement Roughness 7 Replace Transmission gear reassembling point Press the 2nd pinion gear CD into the 1st pinion gear main axle 4 1nspect Circlip Bends looseness damage 7 Replace 5 1nspect Bearings Unsmooth 7 Replace 4 67 ...

Page 175: ...ork 3 IIR Shift fork 1 L Guide bar 1 Guide bar 2 NOTE _ The number stamped into the shift fork must always face towards the right side of the crankcase Be sure that the shift fork guide pin is properly seated in the shift drum groove 4 Check Shift operation Unsmooth operation Repair NOTE _ Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neut...

Page 176: ...ion gear removal Remove the parts in the order below Engine assembly Refer to IIENGINE REMOVAL 1 Bolts 4 2 Shim 1 3 Circlips 4 4 Bearings 4 5 Yoke 1 6 Nut 1 7 Yoke 1 Refer to IIMIDDLE DRIVEN PINION 8 Collar 1 GEAR REMOVAl INSTALLATION 9 Bearing housing O ring 1 1 10 Spring retainers 2 11 Spring seat 1 12 Damper spring 1 13 Damper cam 1 4 69 ...

Page 177: ...9 0 m kg 65 1 it Ib Order Job name Part name Q ty Remarks 14 Middle driven pinion gear 1 r efer to IIMIDDLE DRIVEN PINION 15 Middle driven shaft 1 GEAR REMOVALJINSTALLATION For installation reverse the removal procedure 4 70 ...

Page 178: ...rive pinion gear removal Remove the parts in the order below 1 Middle gear cover O ring 1 1 2 Nut 1 efer to MIDDLE DRIVE PINION 3 Middle drive pinion gear 1 GEAR REMOVALJINSTALLATION 4 Screw gasket 1 1 5 Push lever axle 1 6 Torsion spring 1 7 Washer 1 8 Oil seal 1 For installation reverse the removal procedure 4 71 ...

Page 179: ...g housing assembly CD 2 Loosen Nut middle driven shaft CD NOTE _ Use the universal joint holder to hold the yoke Universal joint holder VM 04062 90890 04062 Removal steps Clean the outside of the middle driven shaft Place the middle driven shaft assembly onto a hydraulic press Never directly press the shaft end with a hydraulic press this will result in damage to the shaft thread Install the suita...

Page 180: ...earing retainer wrench 5 Remove Bearing retainer CD Bearing The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise Remove the bearing retainer and bearing MIDDLE DRIVE PINION GEAR REMOVAL 1 Loosen Nut middle drive pinion gear CD NOTE _ Flatten the punched position of the mid dle drive pinion gear nut using the drift punch Put the engine in 1st and...

Page 181: ...dle gear as a set 4 Inspect Bearing Pitting damage Replace the bearing housing assembly O rings Damage Replace 5 Check Universal joint movement Roughness Replace the universal joint Sheave holder YS 01880 90890 01701 NOTE _ Tighten the nut middle drive pinion gear while holding the rotor with the sheave holder To lock the threads stake them with a cen ter punch MIDDLE DRIVE PINION GEAR INSTALLATIO...

Page 182: ...E Use a socket CD that matches the diameter of the outer bearing race and the oil seal Do not contact the bearing center race or balls Contact should be made only with the outer race 3 lnstall Bearing retainer CD Install steps Attach the folded rag Secure the bearing housing edge in the vise Attach the bearing retainer wrench Bearing retainer wrench YM 04057 90890 04057 Tighten the bearing retaine...

Page 183: ... a hydraulic press this will result in damage to the shaft thread Install the hand made tool CD to protect the bearing and bearing housing from damage Install the wood piece e g on the shaft end to protect the thread from damage Press the wood piece and secure the mid dle driven shaft assembly 5 Tighten Nut middle driven pinion gear CD 90 Nm 9 0 m kg 65 1 ft Ib I NOTE Use the universai joint holde...

Page 184: ...r ing 8 Using a suitable socket press each bear ing into the hole on yoke NOTE _ The bearings must be inserted far enough into the cross joint so that the circlips can be installed 9 lnstall Circlips into the groove of each bearing 10 lnstall Middle driven pinion gear assembly NOTE _ Just finger tighten the bolts at this stage NOTE _ When installing the shims make sure that the tabs are positioned...

Page 185: ...ve gear by using shims CD with their respective thickness calcu lated from information marked on crank case bearing housing and drive gear end CD Shim thickness II A To find shim thickness itA use following formula Middle drive pinion gear shim thickness II A 6 Where a numeral usually a decimal num ber on the middle drive pinion gear is either added to or subtracted from II 44 6 a numeral usually ...

Page 186: ...ied in the following thick ness Middle drive pinion gear shim Thickness mm 0 20 0 30 0 40 Middle gear backlash tool YM 33222 90890 04080 GEAR BACKLASH ADJUSTMENT 1 1nstall Middle gear backlash tool CD NOTE _ This tool will prevent the drive axle from turning 2 1nstall Bolts driven gear bearing housing NOTE _ Just finger tighten the bolts at this stage Clearance between the crankcase and the driven...

Page 187: ...Under or same specification Incorrect Check for faulty parts and or reassemble the bearing housing Backlash gear 0 05 0 10 mm 0 002 0 004 in Do not hammer the universal joint or the collapsible collar of the driven pinion gear may be distorted This will result in a change in the standard spinning torque requiring replacement of the collapsible collar and reassembly of the driven gear assembly NOTE...

Page 188: ...e bolts so that the crankcase bearing housing clear ance is about 2 mm and repeat all previous steps 7 Repeat steps 4 and 5 until the correct gear backlash is achieved Backlash gear 0 05 0 10 mm 0 002 0 004 in 8 Measure Crankcase bearing housing clearance Use a feeler gauge 9 Select Shim s Selection steps For example the clearance between the crankcase and the bearing housing is 0 46 mm 0 018 in T...

Page 189: ... Shims are supplied in the following thickM nesses Middle drive pinion gear shim 4 M 82 Thickness mm 0 10 0 15 0 20 10 Tighten Bolts driven gear bearing housing CD 25 Nm 2 5 m kg 18 1 It Ib I 11 Measure Gear backlash ...

Page 190: ... CHAPTER 3 1 Air filter case assembly 1 2 Air duct 1 3 Cylinder head breather hose 1 Disconnect 4 Throttle position sensor lead 1 5 Thermo switch lead 1 6 Fuel hose 1 7 Carburetor assembly 1 8 Starter cable 1 NOTE 9 Throttle cables 2 After removing the carburetor assem bly remove the starter cable and throttle cables 10 Cover 1 For installation reverse the removal procedure 5 1 ...

Page 191: ...mble the parts in the order below CD Carburetor heater lead 1 Carburetor heaters 1 2 12V 15W Carburetor heaters 2 2 12V 30W Float chamber 1 Float 1 Needle valve set 1 j Main jet 1 Jet holder 1 Pilot jet 1 Jet needle set 1 f Refer to CARBURETOR ASSEMBLY Needle jet 1 Starter plunger set 1 5 2 ...

Page 192: ...y Remarks Diaphragm set 1 Refer to CARBURETOR ASSEMBLY Throttle position sensor 1 Refer to THROTTLE POSITION SEN SOR TPS INSPECTION AND ADJUST MENT Pilot screw 1 Refer to CARBURETOR ASSEMBLY Main air jet 1 For assembly reverse the disassembly procedure 5 3 ...

Page 193: ...ontamination t Clean Cleaning steps Wash the carburetor in a petroleum based solvent Do not use any caustic carbure tor cleaning solution Blowout all of the passages and jets with compressed air 2 1nspect Float Damage t Replace 3 1nspect Needle valve CD Valve seat V O ring Contamination wear damage t Replace as a set 4 tnspect Piston valve D Scratches wear damage t Replace Rubber diaphragm V Tears...

Page 194: ...ew j Starter plunger Bends wear damage Replace Blockage Blowout the jets with com pressed air 7 Check Free movement Insert the throttle valve into the carbure tor body and check for free movement Sticks tight Replace 8Jnspect Joints fuel Q Joints air vent hose vacuum chamber Joints carburetor breather hose Cracks damage Replace CARBURETOR ASSEMBLY Before reassembling wash all of the parts in a cle...

Page 195: ...stall Pilot screw CD Pilot screw turns out 2 1 2 3 1nstall Jet needle NOTE _ Align the projection on the plastic stop per with the hole 6 in the piston valve 4 1nstall Diaphragm CD NOTE _ Match the tab on the diaphragm to the recess in the carburetor body 3 5 6 5 1nstall Diaphragm CD Compression spring Cover NOTE _ Match the tab on the diaphragm to the recess in the carburetor body ...

Page 196: ...ust Fuel level 7 5 8 5 mm 0 3 0 33 in below the float chamber line Fuel level gauge YM 01312 A 90890 01312 Loosen the drain screw ev e Hold the gauge vertically next to the float chamber line 6 Measure the fuel level with the gauge If the fuel level is incorrect adjust it Remove the carburetor assembly Inspect the valve seat and needle valve elf either is worn replace them both If both are fine ad...

Page 197: ...pocket tester Q x 1k to the TPS connector Tester lead Black terminal CD Tester lead 7 Blue terminal Check the TPS resistanee TPS resistance NR N 4 0 6 0 kQ at 20 C Black Blue Out of specification 7 Replace the TPS Connect the pocket tester Q x 1k to the TPS connector Tester lead 7 Yellow terminal Tester lead 7 Black terminal CD While slowly turning the throttle check the TPS resistance c J11 TPS r...

Page 198: ...t or left Stop turn ing the sensor body when the specified resistance is indicated on the tester Resistance when the throttle is closed Resistance IIR x 0 13 0 15 Example If R 5 kQ 5 x 0 13 0 15 0 65 0 75 The specified resistance when the throttle is closed is 650 750 Q Tighten the TPS mounting screws Detach the pocket tester leads and con nect the TPS connector ...

Page 199: ...g the unburned exhaust gases is approximately 600 to 700 C VIEW 2 FLOW During normal operation the valve is open lAl From the air fiiter ID To the reed valve To the carburetor joint AIR CUT OFF VALVE The air cut off valve is operated by intake gas pressure through the diaphragm Nor mally this valve is opened in order to allow fresh air to flow into the exhaust port When the throttle is rapidly clo...

Page 200: ... head rID To the rear cylinder head AIR INDUCTION SYSTEM AIS ICARBI i11 fJ A A AIR INDUCTION SYSTEM INSPECTION 1 fnspect Hose connections Poor connections 7 Properly connect Hoses Reed vaIves Air cut off valve Air filter Cracks damage 7 Replace Clogged 7 Clean 5 11 ...

Page 201: ......

Page 202: ...s Remove the parts in the order below Stand the motorcycle on a level sur face A WARNING 1 2 3 4 5 6 7 Speedometer cable Front wheel axle pinch bolt Front wheel axle Front wheel assembly Collar Speedometer gear unit Brake disc Securely support the motorcycle so there is no danger of it falling over 1 Disconnect 1 Loosen 1 1 Refer to FRONT WHEEL INSTALLA 1 TION 1 1 For installation reverse the remo...

Page 203: ... ty Remarks Front wheel disassembly Disassemble the parts in the order below G Oil seals 1 Clutch retainer 1 Speedometer clutch 1 Oil seal Bearing 1 Refer to FRONT WHEEL DISASSEM Collar 1 BLY ASSEMBLY J Bearing 1 For assembly reverse the disassembly procedure 6 2 ...

Page 204: ...e bearings using a standard bearing puller 2 FRONT WHEEL INSPECTION 1 1nspect Front wheel axle by rolling it on a flat surface Bent Replace A WARNING Do not attempt to straighten a bent axle 2 1nspect Front tire Refer to TIRE INSPECTION in CHAPTER 3 Front wheel Refer to WHEEL INSPECTION in CHAP TER 3 3 Check Spokes Bends damage Replace Loose spokes Retighten Turn the wheel and tap the spokes with ...

Page 205: ...eel bearings Bearings allow free play in the wheel hub or the wheel does not turn smoothly Replace Oil seals Wear damage 7 Replace Measuring point 2 mm 0 08 in Brake disc thickness Out of specification 7 Replace BRAKE DISK INSPECTION 1 1nspect Brake disc Galling damage 7 Replace 2 Measure Brake disc deflection Out of specification 7 Inspect the wheel runout If wheel runout is within the limits rep...

Page 206: ...ter race FRONT WHEEL INSTALLATION 1 1nstall Brake disc CD 23 Nm 2 3 m kg 16 6 ft Ib I NOTE _ Apply LOCTITE to the th reads of the brake disc bolts Tighten the brake disc bolts in stages using a crisscross pattern 2 1nstall Speedometer gear unit CD NOTE _ Be sure that two projections inside the wheel hub mesh with the two slots 6 in the gear unit assembly 3 Tighten Front wheel Front wheel axle r 59...

Page 207: ... wheel s bottom spot c Turn the wheel so that the Xl mark is 90 up d Release the wheel and wait for it to rest Put an X2 mark on the wheel s bottom spot e Repeat steps b c and d several times until all the marks come to the same spot f This spot is the wheel s heavy spot If X 340 014 340 016 6 6 4 Adjust Front wheel static balance Adjusting steps Install a balancing weight CD onto the rim exactly ...

Page 208: ... DISC ICHASI I 5 Check Front wheel static balance x Checking steps Turn the wheel so that it comes to each point as shown Check that the wheel is at rest at each point If not readjust the front wheel 340 017 static balance _ ...

Page 209: ...2 1 23 Nm 2 3 m kg 16 6 It Ib Order Job name Part name Q ty Remarks Front brake pad removal Remove the parts in the order below 1 Retaining bolt 1 2 Brake caliper 1 Refer to II BRAKE PAD REPLACE 3 Brake pads 2 MENT 4 Pad spring 1 For installation reverse the removal procedure 6 8 ...

Page 210: ...ire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE _ It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove Bolt caliper support bolt CD Move the direction brake caliper to the arrow mark 2 Remove Brake pads CD NOTE _ Install new brake pad springs when the brake pads have to be re...

Page 211: ...b Install new brake pads and a new brake pad spring nstall the brake caliper and retaining bolt Bolt brake caliper 40 Nm 4 0 m kg 28 9 ft Ib Retaining bolt 23 Nm 2 3 m kg 16 6 ft Ib 4 lnspect Brake fluid level Refer to BRAKE FLUID INSPECTION in CHAPTER 3 LOWER level line 5 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to JI AIR BLEEDING HYDRAULIC BRAKE SYSTEMV in ...

Page 212: ...linder removal Remove the parts in the order below Brake fluid Drain 1 Rear view mirror right 1 2 Brake lever compression spring 1 1 3 Front brake switch 1 4 Union bolt 1 5 Copper washers 2 6 Brake hose 1 Refer to MASTER CYLINDER INSTALLATION 7 Master cylinder bracket 1 8 Master cylinder 1 For installation reverse the removal procedure 6 11 ...

Page 213: ...Part name Q ty Remarks Master cylinder disassembly Disassemble the parts in the order below CD Dust boot 1 Circlip 1 Refer to MASTER CYLINDER Master cylinder cup kit 1 ASSEMBLY Spring 1 For assembly reverse the disassembly procedure 6 12 ...

Page 214: ...t Master cylinder cup kit CD Scratches wear damage 7 Replace as a set 3 1nspect Diaphragm Wea r damage 7 Replace 4 lnspect Brake hose Cracks wear damage 7 Replace EB702060 MASTER CYLINDER ASSEMBLY All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid V DOT 4 Whenever a master cylinder is disassem bled replace the piston...

Page 215: ... tighten the upper bolt then tighten the lower bolt 2 1nstall Copper washers CD _ Brake hose Union bolt 30 Nm 3 0 m kg 21 7 ft Ibl I NOTE _ Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary A WARNING Proper brake hose routing ...

Page 216: ...the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed Brake system Refer to II AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 1nspect Brake fl...

Page 217: ...ame Part name Q ty Remarks Front brake caliper removal Remove the parts in the order below Brake fluid Drain 1 Brake hose holder 1 2 Union bolts 1 3 Copper washers 2 4 Brake hose 1 Refer to IJCALIPER INSTALLATION 5 Retaining bolt 1 6 Brake caliper assembly 1 For installation reverse the removal procedure 6 16 ...

Page 218: ... caliper disassembly Disassemble the parts in the order below Brake pads Refer to uFRONT BRAKE PADS CD Pad spring 1 Brake caliper pistons 2 Dust seals 2 Referto CALIPER DISASSEMBLY ASSEMBLY Caliper piston seals 2 Bleed screw 1 For assembly reverse the disassembly procedure 6 17 ...

Page 219: ...Remove the caliper piston seals EB702040 CALIPER INSPECTION Recommended brake component replacement schedule Brake pads As required Piston seals dust Every two years seals Brake hoses Every two years Replace when Brake fluid brakes are disas sembled A WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 1 ...

Page 220: ...nal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid U 00T4 Replace the caliper piston seals whenever a brake caliper is disassembled 1 1nstall Caliper piston seats CD Dust seals 2 1nstall Brake caliper pistons CD CALIPER INSTALLATION 1 lnstall Brake caliper CD Retaining bolt 3 N m 2 3 m kg 1 6 6 ft lb q Brake hose Copper washe...

Page 221: ...NING Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling po...

Page 222: ...0 m kg 14 4 ft Ib 25 Nm 2 5 m kg 18 1 ft Ib Order Job name Part name Q ty Remarks Muffler and rear brake rod removal Remove the parts in the order below 1 Muffler 1 2 Adjuster 1 3 Pin 1 4 Compression spring 1 5 Cotter pin 1 6 Nut plate washer 1 1 7 Bolt 1 8 Tension bar 1 For installation reverse the removal procedure 6 21 ...

Page 223: ...r below Stand the motorcycle on a level sur face A WARNING 1 2 3 Final gear oil Bolts Rear axle nut washer Rear wheel assembly 4 1 1 1 6 22 Securely support the motorcycle so there is no danger of it falling over Drain Refer to IIFINAL GEAR OIL REPLACE MENT in CHAPTER 3 Refer to REAR WHEEL REMOVAL INSTALLATION For installation reverse the removal procedure ...

Page 224: ... name Part name Q ty Remarks Rear wheel disassembly Disassemble the parts in the order below CD Lock washers 2 Clutch hub 1 Dampers 6 O rings 2 Bearing 1 Spacer collar 1 1 Refer to REAR WHEEL DISASSEM BLY ASSEMBLY j Bearing 1 For assembly reverse the disassembly procedure 6 23 ...

Page 225: ...b name Part name Q ty Remarks Rear brake disassembly Disassemble the parts in the order below CD Brake shoes 2 Tension springs 2 Bolt 1 Camshaft lever 1 Refer to REAR BRAKE ASSEMBLY Wear indicator 1 Camshaft 1 j Washer 1 For assembly reverse the disassembly procedure 6 24 ...

Page 226: ...ar axle nut CD 4 Remove Rear wheel assembly NOTE _ Remove the rear wheel assembly rear wheel axle and drive shaft by pulling back on the rear wheel assembly REAR WHEEL DISASSEMBLY 1 Remove Bearings G Remove the bearings using a standard bearing puller V REAR WHEEL INSPECTION 1 1nspect Rear wheel axle Refer to ilFRONT WHEEL Rear tire Refer to TIRE INSPECTION in CHAPTER 3 Rear wheel Refer to WHEEL I...

Page 227: ...Refer to IIFRONT WHEELII REAR BRAKE INSPECTION 1 tnspect Brake lining surface Glazed areas 7 Polish Use coarse sandpaper NOTE _ Wipe the polished areas with a cloth NOTE _ Replace the brake shoes as a set if either is found to be worn to the wear limit 2 Measure Brake lining thickness Out of specification 7 Replace G Measuring points Brake lining thickness 4 0 mm 0 16 in Wear limit 2 0 mm 0 08 in ...

Page 228: ...aked in lacquer thinner or solvent Scratches Use an emery cloth polish lightly and evenly 5 1nspect Camshaft face Wear 7 Replace REAR WHEEL ASSEMBLY 1 1nstall Spacer Collar Bearings Installation steps Install the new bearings by reversing the removaI steps NOTE _ Use a socket CD that matches the diameter of the outer bearing race and the oil seal Do not contact the bearing center race or balls Con...

Page 229: ...G After installing the spring and brake shoes take care not to damage the spring REAR WHEEL INSTALLATION 1 1nstall Rear wheel assembly NOTE _ Make sure that the splines of the clutch hub fit correctly into the final gear case 2 1nstall Rear wheel axle Washer Rea r wheel axle nut r 92 N m 9 2 m kg 6 6 5 ft Ib l j Bolt 90 Nm 9 0 m kg 65 1 ft Ib I 3 Adjust Brake pedal free play Refer to REAR BRAKE AD...

Page 230: ...EL STATIC BALANCE ADJUSTMENT NOTE _ After replacing the tire and or wheel the static wheel balance should be adjusted Adjust the static wheel balance with the rear brake disc and hub installed 1 Adjust Rear wheel static balance Refer to FRONT WHEEL 6 29 ...

Page 231: ...rt name Q ty Remarks Front fork removal Remove the parts in the order below Front wheel Refer to FRONT WHEEL 1 Brake hose holder 1 2 Brake caliper assembly 1 3 Front fender 1 4 Upper bracket bolts 2 ILoosen 5 Cap bolts 2 Refer to FRONT FORK INSTALLA 6 Lower bracket bolts 2 TION 7 Steering stem nut 1 8 Upper bracket with handle 1 6 30 ...

Page 232: ...m 11 0 m kg 72 ft Ib 23 Nm 2 3 m kg 16 6 ft Ib Order Job name Part name Q ty Remarks 9 Upper fork covers 2 10 Upper fork cover spacers 2 11 Upper fork cover washers 2 12 Front forks 2 13 Lower fork covers 2 For installation reverse the removal procedure 6 31 ...

Page 233: ... fork disassembly Disassemble the parts in the order below G Cap bolt 1 O ring 1 Spacer colla r 1 Refer to FRONT FORK ASSEMBLY Spring seat 1 Fork spring 1 Dust seal 1 j Retaining clip 1 Damper rod bolt 1 Refer to FRONT FORK DISASSEM Gasket 1 BLY ASSEMBLYII Damper rod rebound spring 1 1 Oil seal 1 6 32 ...

Page 234: ...16 6 ft Ib I Order Job name Part name Q ty Remarks Seal spacer 1 Slide metal 1 Inner tube piston metal 1 1 Refer to FRONT FORK ASSEMBLY Oil lock piece 1 Outer tube 1 For assembly reverse the disassembly procedure 6 33 ...

Page 235: ...der YM 01388 90890 01388 3 Remove Damper rod Rebound spring 4 Remove Inner tube Removal steps Hold the fork leg horizontally Securely clamp the caliper mounting boss of the outer tube in a vise with soft jaws Separate the inner tube from the outer tube by pulling forcefully but carefully on the inner tube Excessive force will damage the oil seal and or the slide metal A damaged oil seal and metal ...

Page 236: ...cified limit Replace Fork spring free length limit 332 5 mm 13 1 in 342 018 3 1nspect Damper rod CD Wear damage Replace Contamination 7 Blowout all of the oil passages with compressed air Oil lock piece Damage Replace 4 1nspect a ring cap bolt Wear damage Replace FRONT FORK ASSEMBLY NOTE _ When reassembling the front fork replace the following parts Piston metal Slide metal Oil seal Dust seal Befo...

Page 237: ...tube outer surface Recommended lubricant U Yamaha fork oil10WT or equiv alent 3 1nstaII Inner tube CD to outer tube 4 1nstall GasketG _ Damper rod bolt 5 Tighten Damper rod bolt G 30 N m 3 o m k9 2 1 7 ft Ib I NOTE __ _ Apply LOCTITE to the th reads of the damper rod holder Tighten the damper rod bolt while holding the damper rod with a T handle and a damper rod holder T handle VM 01326 90890 0132...

Page 238: ...nstall Oil seal CD _ Use the fork seal driver weight and the adapter Fork seal driver weight YM 01326 90890 01367 Adapter YM 01388 90890 01381 Make sure that the numbered side of the oil seal faces up 8 lnstall Retaining clip CD NOTE _ Adjust the retaining clip so that it fits into the outer tube groove 9 1nstall Dust seal CD Use the fork seal driver weight Fork seal driver weight YM 33963 90890 0...

Page 239: ...an upright position 11 1nstaII Fork spring CD Spring seat Spacer collar O ring Cap bolt NOTE _ Before installing the cap bolt apply grease to the O ring Temporarily tighten the cap bolt FRONT FORK INSTALLATION 1 1nstall Lower fork covers D Front forks Temporarily tighten the lower bracket pinch bolts 2 lnstall Upper bracket Steering stem nut 11 O N m 1 1 O m k g 7 9 6 ft lb H NOTE _ When aligning ...

Page 240: ...kg 17 ft Ib 4 Remove Steering stem nut Upper bracket 5 1nstall Upper fork cover washers CD Upper fork cover spacers Upper fork covers 6 1nstall Upper bracket CD Steering stem nut r 1 1 ON m 1 1 0 m kg 79 6 ft lb Jf 7 Tighten Front fork pinch bolts upper 23 Nm 2 3 m kg 17 ft Ib 8 1nstall Front fender CD Brake hose holders ...

Page 241: ... A WARNING Securely support the motorcycle so that there is no danger of it falling over 1 2 3 4 5 6 7 8 9 10 Plastic locking ties Clutch cable Clutch switch lead Handlebar switch left Grip left Clutch lever assembly Master cylinder bracket Master cylinder assembly Handlebar switch right Throttle cables 6 40 4 1 1 1 1 1 1 1 1 2 Refer to HANDLEBAR INSTALLA TION Refer to I HANDLEBAR INSTALLA TION ...

Page 242: ...Nm 2 0 m kg 4 4 it Ib Order Job name Part name Q ty Remarks 11 Throttle grip assembly 1 12 Cable guide 1 13 Handlebar holder upper 2 Refer to HANDLEBAR INSTALLA 14 Handlebar 1 TION 15 Handlebar holder lower 2 For installation reverse the removal procedure 6 41 ...

Page 243: ...ght coat of rubber adhesive on the end of the handlebar elnstall the handlebar grip NOTE _ Wipe off excess adhesive with a clean rag A WARNING Do not touch the grip until the adhesive has set HANDLEBAR INSTALLATION 1 lnstall Washers Handlebar holder lower CD Cable guide NOTE _ Temporarily tighten the nuts 2 lnstall Handlebar Handlebar holder upper 23 N m 2 3 m k g 1 6 6 ft lb I NOTE _ The upper ha...

Page 244: ...ng it all the way to the left and then to the right If there is any contact with the fuel tank adjust the handlebar position 3 Tighten Nut lower handlebar holder 1r 20 N m 2 O m kg t 14 4 11 lb JI 4 1nstal1 Throttle cables Q Throttle grip assembly NOTE _ Align the projection on the handlebar switch right with the hole in the han dlebar 5 1nstall Master cylinder front brake Refer to MASTER CYLINDER...

Page 245: ...1 7 1nstaII Handlebar switch left CD NOTE _ Align the matching surface of the handlebar switch left with the punch mark on the handlebar a Adjust Throttle cable free play Refer to THROTTLE CABLE ADJUST MENT in CHAPTER 3 6 44 ...

Page 246: ... level sur face A WARNING 1 2 3 4 5 6 7 8 9 Front forks Handlebar Headlight lens unit Leads in the headlight body Front fork cover Front flasher light left right Flasher bracket cover Headlight body Upper bracket Lock washer Upper ring nut Securely support the motorcycle so that there is no danger of it falling over Refer to FRONT FORK Refer to HANDLEBAR 1 Disconnect 1 1 1 1 1 1 1 1 6 45 ...

Page 247: ... Nm 1 8 m kg 13 0 ft Ib Order Job name Part name Q ty Remarks 10 Rubber washer 1 11 Lower ring nut 1 Refer to STEERING HEAD REMOVAL INSTALLATiON 12 Bearing cover 1 13 Lower bracket 1 14 Bearing upper 1 15 Rubber seal 1 16 Bearing lower 1 For installation reverse the removal procedure 6 46 ...

Page 248: ...eer ing head pipe using a long rod CD and a hammer as shown Remove the bearing race on the lower bracket using a floor chisel and a ham mer as shown Install the new rubber seal and races 354 007 6 47 NOTE _ Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal If the bearing race is not fitted squarely the steering head pipe coul...

Page 249: ...d swingarm removal Seats 3 Remove the parts in the order below Stand the motorcycle on a level sur face A WARNING Securely support the motorcycle so there is no danger of it falling over Refer to FUEL TANK AND SEATS in CHAPTER 3 1 2 Rear wheel Final gear case Muffler assembly Battery cover Side cover right Side cover left Tool box cover 6 48 Refer to REAR WHEEL Refer to IIENGINE REMOVAL in CHAPTER...

Page 250: ... Remarks 3 Toolbox 1 4 Bolt nut rear shock absorber 1 1 upper 5 Pivot shaft nut 1 Loosen 6 Pivot shaft right 1 JRefer to SWINGARM INSTALLA 7 Pivot shaft left 1 TION 8 Swingarm 1 9 Rear shock absorber 1 Refer to REAR SHOCK ABSORBER INSTALLATI0 N 10 Collars 2 11 Rubber boot 1 12 Bushing 1 13 Collars 2 14 Oil seals 2 15 Bearings 2 For installation reverse the removal procedure 6 49 ...

Page 251: ...orm or damage the cylinder in any way Cylinder damage will result in poor damping performance NOTES ON DISPOSAL Shock absorber disposal steps Gas pressure must be released before dis posing of the shock absorber To do so drill a 2 3 mm hole through the cylinder wall as shown A WARNING Wear eye protection to prevent eye dam age from escaping gas and or metal chips REAR SHOCK ABSORBER INSPECTION 1 1...

Page 252: ... kg 72 3 ft Ib LOCTITE Tightening steps Tighten the pivot shaft left D to specifi cation SWINGARM INSTALLATION 1 1nstall Swingarm Pivot shaft left D Pivot shaft right Pivot shaft nut Tighten the pivot shaft nut to specifica tion Pivot shaft nut 100 Nm 10 m kg 72 3 ft Ib REAR SHOCK ABSORBER INSTALLATION 1 1nstall Rear shock absorber D 62 N m 6 2 m k 9 4 4 8 ft Ib I NOTE _ Install the rear shock abs...

Page 253: ...ck the swingarm side play by mov ing the swingarm from side to side If side play is noticeable check the inner collar bearing washer and thrust cover Side play at swingarm end Zero mm Check the swingarm vertical movement ffi by moving it up and down If vertical movement is not smooth or if there is binding check the inner collar bearing washer and thrust cover 2 1nspect Swingarm Cracks bends damag...

Page 254: ... drive component or area 3 A locked up condition of the shaft drive mechanism or no power transmitted from the engine to the rear wheel Possible causes A Bearing damage B lmproper gear lash C Damaged gear teeth D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Smali foreign objects lodged between moving parts NOTE _ Causes A Band C may be extremely difficult to diagno...

Page 255: ...is extremely destruc tive to the gear teeth If a test ride follow ing reassembly indicates this condition stop riding immediately to minimize gear damage c A slight clunk evident at low speed operation This noise must be distin guished from normal motorcycle opera tion Diagnosis Possible broken gear teeth A WARNING Stop riding immediately if broken gear teeth are suspected This condition could res...

Page 256: ...distance necessary to locate the leak Leakage Inspect the component hous ing gasket and or seal for damage Damage Replace the component CD Oil seal O ring Forward IAI Middle gear rnJ Final gear NOTE An apparent oil leak on a new or nearly new motorcycle may result from the application of a rust preventive coating or excessive seal lubrication Always clean the motorcycle and recheck the suspected l...

Page 257: ...vate and spin the front wheel Feel for wheel bearing damage YES _ _ _ NO Check the rear wheel Feel for bearing damage NO Rear wheel bearings and shaft drive bearings are probably not damaged Repeat the test or remove the individual components YES Remove the rear wheel Check for wheel bearing damage YES Replace the rear wheel bearing Refer to IIREAR WHEELII NO IRemove the drive shaft components ...

Page 258: ...ng gear NOTE _ Do not overtighten the bolt just finger tighten it Position mark Final gear backlash band YM 01231 90890 01231 5 Attach Final gear backlash band CD Dial gauge NOTE _ Measure the final gear backlash at four positions Rotate the final drive shaft 90 each time 6 Measure Final gear backlash Gently rotate the final drive gear coupling from engagement to engagement Over the specified limi...

Page 259: ...hims and thrust washer Reducing the shim gear backlash is thickness increased Increasing the shim gear backlash is thickness decreased elf it is necessary to increase the final gear backlash by more than 0 1 mm Reduce the thrust washer thickness by 0 1 mm for every 0 1 mm increase of ring gear shim thickness elf it is necessary to reduce the final gear backlash by more than 0 1 mm Increase the thr...

Page 260: ...e parts in the order below Stand the motorcycle on a level sur face A WARNING 1 2 3 4 Rear wheel assembly Collar Drive shaft assembly Final drive pinion gear assembly Final gear assembly Securely support the motorcycle so there is no danger of it falling over Refer to REAR WHEEL 1 1 1 Refer to FINAL DRIVE GEAR DISAS SEMBLY 1 For installation reverse the removal procedure 6 59 ...

Page 261: ...emble the parts in the order below Q Bolts bearing housing 2 NOTE Bolt bearing housing 6 Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them Bearing housing O ring 1 1 Ring gear 1 Thrust washer 1 Shim s 1 For assembly reverse the disassembly procedure ...

Page 262: ...hammer lightly tap on the final drive shaft end Removal of the final drive shaft should only be performed if gear replacement is neces sary A WARNING Always use new bearings and races EB707033 FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY 1 Remove Guide collar CD Oil seal Roller bearing Use a suitable press tool and an appro priate support for the final gear case 2 1nspect Final drive rolter b...

Page 263: ...al of the final drive shaft roller bearing is a difficult procedure and is rarely necessary 4 1nstall Final drive roller bearing new Installation steps Heat the final gear case to 150 cC 302 F Install the roller bearing outer races using the proper adapter Install the inner race onto the drive shaft 5 1nstall Guide collar CD Oil seal _ Roller bearing outer race To install the above components into...

Page 264: ...ive gear end CD Final drive gear shim thickness II A Ring gear shim thickness 8 Thrust washer c To find the final drive gear shim thickness A use the following formula Final drive geaf shim thickness A Where a numeral usually a decimal number on the final drive pinion gear is either added to or subtracted from 80 a numeral on the final drive gear case O e 79 50 Example is 80 01 If the final gear c...

Page 265: ...m 0 02 in final drive gear shim To find the ring gear shim thickness B use the following formula Ring gear shim thickness B CD Where a numeral on the final gear case Le 45 55 C a numeral on the bearing housing I e 1 35 a numeral usually a decimalnumber on the inside of the ring gear either added to or subtracted from 35 40 CD the ring gear bearing thickness consid ered constant Ring gear bearing t...

Page 266: ...edths Rounded value 0 1 2 3 4 0 5 6 7 8 9 10 2 1nstall Shims proper size as calculated FinaI drive shaft assembly Bearing retainer final drive shaft 115 Nm 11 5 m kg 83 2 ft Ib I Use a bearing retainer wrench The final drive shaft bearing retainer has left hand threads Turn the retainer coun terclockwise to tighten it Bearing retainer wrench YM 04050 90890 04050 3 Adjust Gear backlash Refer to FIN...

Page 267: ...ing gear Remove the ring gear assembly Measure the ring gear thrust washer clearance and the width of the flattened Plastigauge CD If the clearance is correct install the ring gear assembly If out of specification select the correct th rust washer Ring gear thrust washer selection steps Using the following chart select the suit able thrust washer Ring gear thrust washer clear ance 0 1 0 2 mm 0 004...

Page 268: ...7040 DElVE SHAFT INSPECTION 1 1nspect Drive shaft splines Wear damage 7 Replace l FINAL GEAR CASE INSTALLATION 1 Apply Sealant onto the mating surface of both final gear case halves Yamaha Bond No 1215 ACC 1100 15 01 90890 85505 6 67 ...

Page 269: ...ICHASIAI ...

Page 270: ... at 20 C 68 F ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS CD Thermo switch Starter relay Main switch Igniter unit Ignition coil Flasher relay Fuse Neutral switch Carburetor heater relay Rear brake switch Relay unit Side stand switch j Battery Rectifier regulator Headlight relay Horn 7 1 ...

Page 271: ...ew times when checking it INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switchl handlebar switchl engine stop switch tight switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position 0 0 indi cates the terminals with continuity The example c...

Page 272: ...I I I Lf f Rffl Br RIB B G Y L I I I I I I I 1 I I I I I I I __ __ l 1 __ 0 I I I I B OFF I ON I I I I 1 1 I I 1 _ _ _ r I I lrn I 1 19 r n 1 4 I I I V I 1 I I I I 1_ _ J I 1 I 1 I l _J t l I I I Y 1 I I I I I II I 1 _ J I l J BWEI Og y Ch G n SlY l Y 1 T I j I 1 a I I cr m 6 b I _ _ J _ I I I I I I I I I I I I I I I I I I I I D Y r b BIY I II I 11 I II I I I I I _ __ l B OFF ON 1 I j 1 I J I I I ...

Page 273: ...Clutch switch Horn switch Dimmer switch Turn switch Main switch Front brake switch SWITCH INSPECTION IELECI0 I j Engine stop switch Start switch Fuse Rear brake switch Sidestand switch Neutral switch 7 4 ...

Page 274: ...in switch Battery Fuse Relay unit Sidestand switch Ignition unit Ignition coil Sparkplug Pickup coil Neutral switch Ignition fuse Engine stop switch n _m C 2 c _8 i 00 2 Ci en m s C 2 3 o 2 en al I m s m m n D ...

Page 275: ... Use the following special tool s for trou bleshooting EB802011 1 Fuses main and ignition Refer to IISWITCH INSPECTION CONTINUITY EB802012 2 Battery Check the battery condition Refer to II BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 7 6 8 Main switch 9 Engine stop switch 10 Neutral switch 11 Sidestand switch 12 Relay unit diode 13 Wiring connection the ...

Page 276: ...plug cap Turn the main switch to liON Check the ignition spark gap Crank the engine by pushing the starter switch and increase the spark gap until a misfire occurs Minimum spark gap 6 0 mm 0 24 in OUTOF SPECIFICATION OR NO SPARK EB802015 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester 0 x 1k to the spark plug cap IGNITION SYSTEM IELECI0 I Standard spark plug DPR7EAw...

Page 277: ...ter 0 x 1 to the ignition coil Check if the primary coil has the speci fied resistance Primary coil resistance 3 8 N 4 6 0 at 20 C 68 F Connect the pocket tester 0 x 1k to the ignition coil Check if the secondary coil has the spec ified resistance Secondary coil resistance 10 1 N 15 1 kO at 20 C 68 F n BOTH MEET V SPECIFICATION Tester lead 7 Red Black terminal Tester lead 7 Orange Gray terminal 37...

Page 278: ...up coil resistance 182 222 0 at 20 C 68 F Gray Black n MEETS V SPECIFICATION 8 Main switch Refer to SWITCH INSPECTION CORRECT 9 Engine stop switch Refer to iiSWITCH INSPECTION CORRECT 10 Neutral switch Refer to IiSWITCH INSPECTIONiI CORRECT 11 Sidestand switch Refer to IiSWITCH INSPECTIONiI CORRECT OUT OF SPECIFICATION l IReplace the pickup coil INCORRECT IReplace main switch INCORRECT IReplace ha...

Page 279: ...Tester lead 7 Sky blue D tinuity NOTE When you switch the 1 _ and leads of the digital pocket tester the readings in the above chart will be reversed CORRECT EB80201D 13 Wiring connection Check the connections of the entire igni tion system Refer to CIRCUIT DIAGRAM CORRECT IReplace the ignitor unit IGNITION SYSTEM IELECIC 11 INCORRECT IReplace the relay unit POOR CONNECTION l IProperly connect the...

Page 280: ...h Battery Main fuse Starter relay j Starter motor Relay unit Sidestand switch Neutral switch Clutch switch Ignition fuse Engine stop switch Start switch mm 1 c m 4 c D a n at 2 C t t I 3 m a n t Z C t m 3 m r m n o ...

Page 281: ...h is closed The starting circuit cut off relay prevents the starter from operating when neither of these conditions have been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by pressing the starter switc...

Page 282: ...the entire starting system NOTE _ Remove the following part s before trou bleshooting 1 Battery cover 2 Rider s seat 3 Fuel tank 4 Steering head side covers Use the following special tool s for trou bleshooting Pocket tester VU 03112 90890 03112 EB802011 1 Fuses main and ignition Refer to IJSWITCH INSPECTION J CONTINUITY NO CONTINUITY IReplace the fuse s Clean the battery terminals Recharge or rep...

Page 283: ...y to produce sparks so be sure that no flammable gas or fluid is in the vicinity DOES NOT MOVE IRepair or replace the starter motor MOVES EB803023 14 Relay unit starting circuit cut off relay Remove the relay unit from the wire har ness Connect the pocket tester 0 x 1 and battery 12 V to the relay unit terminals Battery terminal Red Black terminal CD Battery terminal BlacklYellow terminal Tester l...

Page 284: ...BlueNellow No Con Tester lead Sky blue CD tinuity NOTE When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed CORRECT EB803024 6 Starter relay Remove the starter relay from the wire harness Connect the pocket tester 0 x 1 and battery 12 V to the starter relay termi nals Battery tenninal Red Whitetenninal CD Battery terminal Blue terminal Tester ...

Page 285: ...tch switch Refer to SWITCH INSPECTION J CORRECT 12 Start switch Refer to IISWITCH INSPECTION ti J CORRECT EB803028 13 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM IReplace main switCh INCORRECT IReplace handlebar switch right INCORRECT IReplace neutral switch INCORRECT IReplace sidestand switch INCORRECT IReplace clutch switch INCORRECT IReplace ha...

Page 286: ...E ASSEMBLY in CHAPTER 4 1 Starter motor O ring 1 1 2 Starter motor lead 1 Starter motor disassembly Disassemble the parts in the order below CD Front bracket 1 Washer kit 1 Refer to IlSTARTER MOTOR ASSEM Rear bracket 2 BLY Shims 1 Brush seat Brush 1 1 1 NOTE Be sure to remove the installation nut on brush 1 first Armature coil 1 For assembly reverse the disassembly procedure 7 17 ...

Page 287: ... grounded to fit the commutator Mica undercut 0 7 mm 0 03 in NOTE The mica insulation of the commutator must be undercut to ensure proper opera tion of the commutator 4 1nspect Armature coil resistances insulation con tinuity Defects Replace the starter motor Inspection steps Connect the pocket tester for the continu ity G and insulation checks Measure the armature coil resistances Armature coil c...

Page 288: ...RTING SYSTEM IELECIc 11 5 Measure Brush length Out of specification Replace 7 1nspect Bearing Roughness Replace Oil seal Bushing Wear damage Replace EBa03036 STARTER MOTOR ASSEMBLY Reverse the Removal procedure Note the following points 1 1nstall Brush seat CD NOTE _ Align the projection on the brush seat with the slot on the housing 2 lnstall Shims CD Armature coil ...

Page 289: ...4 ELECTRIC STARTING SYSTEM IELECI0 I 3 1nstall Gasket CD Yoke Washer kit Brackets NOTE _ Align the match marks on the yoke with the match marks fi on the brackets 7 20 ...

Page 290: ...EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM CHARGING SYSTEM IELEC I0 I D AC magneto stator coil Rectifier regulator w Battery f i Main fuse 7 21 ...

Page 291: ...ne tachometer YU 08036 A 90890 03113 Pocket tester YU 03112 90890 03112 1 Fuses main Refer to SWITCH INSPECTION CONTINUITY EB802012 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT E8804011 3 Charging voltage Connect the engine tachometer to the spark plug lead 1 Connect the pocket tester DC 20 V to the battery ...

Page 292: ...ite terminal Tester lead 7 White terminal Q Tester lead 7 White terminal Measure the stator coil resistance ijj Stator coil resistance 0 50 Y 0 62 Q at 20 C 68 F n BOTH MEET V SPECIFICATION EB80401S 5 Wiring connections Check the connections of the entire charging system Refer to I CIRCUIT DIAGRAM CORRECT IReplace the rectifier regulator CHARGING SYSTEM IELECIL JI MEETS SPECIFICATION i IThe chargi...

Page 293: ...r es 3 2 C t 3 iTI1 m n D1 HiSll c cl i 22 Ci at 3 t ri Main switch _ Battery m i Main fuse Meter light High beam indicator light Headlight Q Dimmer switch Tail brake light Headlight fuse I N ...

Page 294: ...shooting 1 Battery cover 2 Rider1 s seat 3 Fuel tank 4 Steering head side covers 5 Headlight lens unit 6 Tail brake light unit Use the following special tool s for trou bleshooting EBB02011 Pocket tester YU 03112 90890 03112 1 Fuses main and head light Refer to IISWITCH INSPECTION CONTINUITY EBB02012 2 Battery Check the battery condition Refer to BATTERY INSPECTIONII in CHAPTER 3 Open circuit volt...

Page 295: ...onnections of the entire lighting system Refer to WIRING DIAGRAM CORRECT Check the condition of each of the lighting system s circuits Refer to LIGHTING SYSTEM CHECK LIGHTING SYSTEM IELECI0 I INCORRECT IReplace main switch INCORRECT Dimmer switch is faulty replace handle bar switch left POOR CONNECTION IProperly connect the lighting system 7 26 ...

Page 296: ...v T ffi I 7 1 3 Turn the main switch to liON Turn the dimmer switch to LO or iiHI Check the voltage 12 V of the IIGreen and ilYeliow leads on the bulb socket connector n MEETS V SPECIFICATION IThis circuit is not faulty LIGHTING SYSTEM IELECI0 I NO CONTINUITY IReplace the bulb an IIor bulb socket Headlight Tester lead 7 Yellowtenninal CDor Green tenninal Tester lead 7 Black terminal High beam indi...

Page 297: ...EETS V SPECIFICATION IThis circuit is not faulty EB805022 3 1f the taillight fails to come on 1 Bulb and bulb socket Check the bulb and bulb socket for conti nuity CONTINUITY 2 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Blue terminal CD Tester lead 7 Black terminal LIGHTING SYSTEM IELECI0 I NO CONTINUITY IReplace the bulb and or bulb socket 2 OUT OF SPECIFIC...

Page 298: ...e 12 V of the blue lead on the bulb socket connector n MEETS V SPECIFICATION IThis circuit is not faulty LIGHTING SYSTEM IELECI0 I OUT OF SPECIFICATION J The wiring circuit from the main switch to the bulb socket connector is faulty repair it 7 29 ...

Page 299: ...EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM SIGNAL SYSTEM IELECIe JI 7 30 ...

Page 300: ...ht Neutral ignitor light High beam indicator light Rear turn signal R Rear turn signal l Front turn signal R Front turn signal L Turn switch l Horn switch Flasher relay Horn Rear brake switch Tail brake light Front brake switch Right handlebar switch 7 31 SIGNAL SYSTEM IELECI0 I ...

Page 301: ...ery cover 2 Rider s seat 3 Fuel tank 4 Steering head side covers 5 Headlight lens unit 6 Tail brake light unit Use the following special tool s for trou bleshooting Pocket tester YU 03112 90890 03112 EB802011 1 Fuses main and signals Refer to SWITCH INSPECTION CONTINUITY EB802012 2 Battery Check the battery condition Refer to BATIERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 2...

Page 302: ...eck the connections of the entire sig nal system Refer to IICIRCUIT DIAGRAM CORRECT Check the condition of each of the signal system s circuits Refer to IISIGNAL SYSTEM CHECK SIGNAL SYSTEM IELEe I0 I INCORRECT IReplace main switch POOR CONNECTION IProperly connect the signal system 7 33 ...

Page 303: ...n MEETS V SPECIFICATION 3 Voltage Connect the pocket tester DC 20 V to the horn at the Pink terminal Tester lead Pink lead D Tester lead 7 Frame ground Turn the main switch to ON Check the voltage 12 V of the IIPink lead at the horn terminal n MEETS V SPECIFICATION IAdjust or replace the horn SIGNAL SYSTEM IELECI0 I NO CONTINUITY IReplace the handlebar switch left OUT OF SPECIFICATION l The wiring...

Page 304: ... the Yellow lead on the bulb socket connector n MEETS V SPECIFICATION IThis circuit is not faulty EB806023 3 lf the turn signal and or turn indicator light fails to blink 1 Turn switch Refer to SWITCH INSPECTION CORRECT 2 Voltage SIGNAL SYSTEM IELECIell INCORRECT IReplace brake switch OUT OF SPECIFICATION J The wiring circuit from the main switch to the bulb socket connector is faulty repair it IN...

Page 305: ...rame ground EEfj Turn the main switch to liON Check the voltage 12 V on the Brown White CD lead at the flasher relay termi nal n MEETS V SPECIFICATION OUT OF SPECIFICATION The flasher relay is faulty replace it 4 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Flasher light lID Turn indicator light At the flasher light left Tester lead Chocolate lead CD Tester lead Frame gro...

Page 306: ...Y 2 Voltage Connect the pocket tester DC 20 V to the buIb socket coupler Tester lead Brown terminal CD Tester lead SkyIblue ground Turn the main switch to liON Check the voltage 12 V n MEETS V SPECIFICATION IThis circuit is not faulty SIGNAL SYSTEM IELECI 11 OUT OF SPECIFICATION The wiring circuit from the turn switch to the bulb socket connector is faulty repair it NO CONTINUITY IReplace the neut...

Page 307: ...E8808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM FUEL PUMP SYSTEM IELEC IP I 7 38 ...

Page 308: ...uel pump circuit consists of the fuel pump relay fuel pump engine stop switch and ignitor unit The ignitor unit includes the control unit for the fuel pump D Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit j Fuel pump relay Fuel pump 1 t 7 39 ...

Page 309: ... Use the following special tooHs for trou bleshooting EB802011 1 Fuses main and ignition Refer to SWITCH INSPECTION CONTINUITY EB802012 2 Battery Check the battery condition Refer to uBATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C l68 F CORRECT 5 Relay unit fuel pump relay 6 Fuel pump 7 Wiring connections the entire fuel sys tem Pocket tester VU 031 12 90890 03112 NO C...

Page 310: ...rminal t Blue Red terminal Tester lead t Red Black terminal CD Tester lead t Blue Black terminal Check the fuel pump relay for continuity CONTINUITY EBS08021 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester 0 x 1 to the fuel pump coupler terminals Tester lead Blue Black terminal CD Tester lead t Black terminal FUEL PUMP SYSTEM IELECI0 I INCORR...

Page 311: ...MEET V SPECIFICATION eBS08022 7 Wiring connections Check the connections of the entire fuel pump system Refer to uCIRCUIT DIAGRAM 1 CORRECT IReplace the ignitor unit FUEL PUMP SYSTEM IELECI0 I OUT OF SPECIFICATION J IReplace the fuel pump POOR CONNECTION J IProperly connect the fuel pump system 7 42 ...

Page 312: ...o accidentally spill some wipe it up imme diately with dry rags If gasoline touches the engine when the engine is still hot there is a danger of combustion Make sure that the engine is completely cool before performing the following test 1 Check Fuel pump operation Checking steps Fill up the fuel tank Put the end of the fuel hose into an open container Connect the battery 12 V to the fuel pump cou...

Page 313: ... D I m m a tJ n tJ a t tllJ m e 3 a m d D I m D tJ tJ I m s m m n Main switch Battery Main fuse Neutral switch 8 Carburetor heater J 4 Carburetor heater relay Thermo switch Carburetor heater fuse r fu ilf li _ 11 l __ f flo flo ...

Page 314: ...g part s before trou bleshooting 1 Battery cover 2 Rider s seat 3 Fuel tank 4 Steering head side covers Use the following special tool s for trou bleshooting EBS02011 Pocket tester YU 03112 90890 03112 1 Fuses main and carburetor heater Refer to IJSWITCH INSPECTION CONTINUITY EB802012 2 Battery Check the battery condition Refer to BATIERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more...

Page 315: ...harness Connect the pocket tester 0 x 1 and battery 12 V to the carburetor heater relay terminaIs Battery terminal Brown Yellow terminal CD Battery terminal Sky blue terminal Tester lead Brown Black terminal Tester lead Black Yellow terminal Check the carburetor heater relay for no continuity NO CONTINUITY INCORRECT IReplace main switch INCORRECT IReplace neutral switch CONTINUITY IReplace carbure...

Page 316: ...uity Note the temperatures while heating the water with the temperature gauge Test step Water temperature Good condition 1 Less than 23 3 C 0 73 4 5 4 F 2 More than 23 3 C x 73 4 5 4 F 3 More than 12 4 C x 53 6 7 2 F 4 Less than 12 4 C 0 53 6 7 2 F Test 1 2 Heat up test Test 3 4 Cool down test 0 Continuity X No continuity If condition is not good replace the thermo switch J CORRECT 7 Carburetor he...

Page 317: ... heater resistance 12V15W 6 12 Q at 20 C 68 F 12V30W 6 10 Q at 20 C 68 F CORRECT 1 Wiring connection Check the connections of the carburetor heater system Refer to CIRCUIT DIAGRAM INCORRECT IReplace carburetor heater POOR CONNECTION l Properly connect the carburetor heater system ...

Page 318: ... if there is a malfunction it comes on for 1 4 seconds goes off and then begins flashing However it is on while the engine is running Display condition code Item Condition Response When When engine is engine is stationary running Throttle position sen Disconnected Enables the motorcycle to Blinks in Light on sor TPS Short circuit run so that the ignition Locked timing is fixed when the throttle is...

Page 319: ...T DIAGRAM Throttle position sensor TPS Ignitor unit 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM CONTINUllY 2 TPS Pocket tester VU 03112 90890 03112 NO CONTINUITY IRepair or replace the wire harness Check the TPS for continuity Refer to THROTTLE POSITION SEN SOR TPS INSPECTION AND ADJUST MENT in CHAPTER 5 n GOOD V CONDITION IReplace the ignitor unit BAD CONDITION I...

Page 320: ...t range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body Full transistor system Faulty ignitor unit Faulty pickup coil 8 1 Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Worn needle valve Improperly sealed varve seat Improperly adjusted fuel level Improperly set pilot je...

Page 321: ...ew Improper throttle cable free play Flooded carburetor Piston and piston ring Improperly installed piston ring Worn fatigued or broken piston ring Seized piston ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft Electrical system Faulty battery Faulty spark plug Faulty ignitor unit Faulty pickup coil Faulty ignition coil Valve train Improperly adj...

Page 322: ...G CLUTCH SLIPPING Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate clutch plate Incorrectly assembled clutch CLUTCH DRAGGING Clutch Warped pressure plate Unevenly tensioned clutch springs Bent push rod Broken clutch boss Burnt primary driven gear bushing Bent clutch plate Swollen friction plate Match marks not aligned 8 3 Transmission Seized tr...

Page 323: ...mproper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Drum brake Worn brake shoe Worn or rusty brake drum Improper brake free play adjustment Improper brake cam lever position Improper brake shoe position Fatigue fauIty return spring Oily or greasy brake shoe brake drum Broken brake rod EB907000 FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION MALFUNCTION Bent deformed or...

Page 324: ...ing head tube Improperly installed bearing race 8909000 FAULTY LIGHTING AND SIGNAL SYSTEMS HEADLIGHT DOES NOT LIGHT BULB BURNT OUT Improper bulb Improper bulb Too many electric accessories Faulty battery Hard charging broken stator coil wire Faulty rectifier regulator faulty rectifier regulator Improperly grounded Incorrect connection Faulty main and or lights switch Improperly grounded Bulb life ...

Page 325: ...ater relay Thermo switch 9 Carburetor heater fuse Headlight fuse Signal system fuse Ignition fuse Front brake switch Engine stop switch Start switch Right handlebar switch 1 GV1 _ I G I a 8iL mfu B 71tJ I I W CD Q T T 1t 4 n n _ _ n i J t J 4 1 6 11 1 9 ilfi I W 1 9fll n T r n tRI __ STOP miOj BlACK t f t t ILP n i n 1 I I n t t il _ _j i ill ritiI l J J n 1 n_ UH _ _ n _ _ 4J L E R 1m nnn 1 _ u u...

Page 326: ......

Page 327: ...YAMAHA YAMAHA MOTOR CO LTD Printed in USA ...

Page 328: ...YAMAHA LIT 11616 11 21 5FB 28197 EO ...

Page 329: ...ary Service Manual together with the following manual XVS650AK C SERVICE MANUAL LlT 11616 11 16 5BN 28197 EO XVS650K C SUPPLEMENTARY SERVICE MANUAL 1997 by Yamaha Motor Corporation U S A First edition December 1997 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A PIN LlT 11616 11 21 ...

Page 330: ...provide the customer with the most satisfaction from his motorcycle 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 NOT...

Page 331: ...tion of jobs and notes is presented in an easy to read way by the use of symbol marks The meanings of the symbol marks are given on the next page 4 Dimension figures and the number of parts j are given for bolts and screws that have a required tightening torque 5 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 6 For jobs requiri...

Page 332: ...re used to identify the specifications appearing in the text Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit clearance Engine speed Q V A Illustrated symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium...

Page 333: ...CIFICATIONS 2 MAINTENANCE SPECIFICATIONS 3 CHASSIS 3 CABLE ROUTING 4 PERIODIC INSPECTION AND ADJUSTMENTS 13 FUEL TANK AND SEATS 13 HEAD LIGHT BEAM ADJUSTMENT 14 HEAD LIGHT BULB REPLACEMENT 14 CHASSIS 16 FRONT FORK 16 FRONT FORK DiSASSEMBLy 19 FRONT FORK INSPECTION 20 FRONT FORK ASSEMBLy 20 FRONT FORK INSTALLATION 23 STEERING HEAD 24 ...

Page 334: ...MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the right side of the steering head MODEL LABEL The model label CD is affixed to the frame This information will be needed to order spare parts 1 ...

Page 335: ...g 501 Ib Chassis Frame type Double cradle Caster angle 35 Trail 153 mm 6 02 in Tire Type With tube Size front 100 90 19 57S rear 170 80 15M C 77S Manufacturer front BRIDGESTONE DUNLOP rear BRIDGESTONE DUNLOP Type front L309 F24 rear G546 K555 Maximum load except motorcycle 180 kg 397 Ib Tire pressure cold tire 0 90 kg 0 1981b load front 200 kPa 2 0 kg cm2 29 psi rear 225 kPa 2 25 kg cm2 32 6 psi 9...

Page 336: ... 168 5 mm 6 63 in 165mm 6 5 in Fitting length 160 5 mm 6 32 in Spring rate K1 186 N mm 18 6 kg mm 1041 6Ib in Stroke K1 o 37 mm 0 1 46 in Optional spring No Front wheel Type Spoke wheel Rim size 19 x MT2 50 Rim material Steel Rim runout limit radial 1 0 mm 0 04 in 2mm 0 08 in lateral 0 5 mm 0 02 in 2mm 0 08 in Front brake Type Single disk _ Disc outside diameter x thickness 298 x 5 mm 11 73 x 0 2 ...

Page 337: ... tank breather hose Speedometer cable Speedometer j Speedometer light leads Vacuum chamber air vent hose Rectifier regulator l Sidestand switch lead Rear brake switch lead Horn Headlight lead Right handlebar switch lead Main switch Main switch lead Fuel pump lead Fuel hose 4 Spark plug lead Fuel pump o ...

Page 338: ...witch lead with a plastic locking tie CABLE ROUTING ISPECI 0 1 Pass the speedometer cable speedometer light leads and fuel tank breather hose through the fuel tank hole 8 To the speedometer light leads en Pass the right handlebar switch lead and head light lead over the other harness and leads QJ Pass the clutch cable through the cable guide 00 Fasten the sidestand switch lead and rectifier regula...

Page 339: ...e holder ID To the rectifier regulator lJ Pass the rear brake switch lead between the frame and rectifier regulator Do not pinch the rear brake switch lead CABLE ROUTING ISPECI U I Q1 Fasten the rear brake switch lead with a plastic locking tie 2 To the speedometer light leads Pass the fuel tank breather hose and vacuum chamber air vent hose through the holder 00 Pass the speedometer cable through...

Page 340: ...h lead Pickup coil lead A C magneto lead Battery negative lead Starter motor lead Battery cover Battery Wire harness Starting circuit cut off relay o Fuel tank breather hose Speedometer cable 7 Ignitor unit Pass the tail brake light lead between the frame bracket and battery box Position the mud guard the between the edge of the frame bracket and the tail brake light lead Fasten the dimmer switch ...

Page 341: ... tie 8J Pass the right handlebar switch lead behind the upper bracket ITl Fasten the brake hose grommet with a brake hose holder depending on model type CABLE ROUTING ISPECI 1 Q Fasten the brake hose with a brake hose holder KJ Pass the left handlebar switch lead under the main switch l J Fasten the spark plug lead with a metal clamp lMl Pass the ignition coil lead inside of the starter cable lED ...

Page 342: ...tery negative lead Q Fasten the pickup coil lead A C magneto lead neutral switch lead and starter motor lead with CABLE ROUTING ISPECIU I a plastic locking tie 2 Fasten the battery negative lead starter motor lead and wire harness with a plastic locking tie IWl Fasten the wire harness with a clamp 00 Fasten the battery negative lead and tail brake light lead with a clamp YJ Pass the wire harness b...

Page 343: ...The wire harness and leads should not touch the rear shock absorber CABLE ROUTING ISPECI U I IAJ Fasten the wire harness and leads with a plastic locking tie IAK1 Pass the plastic band through the frame hole Fasten the wire harness with a plastic band at the point where the tape is located lAD Fasten the wire harness and leads with a plastic locking tie l Ml Fasten the wire harness and leads with ...

Page 344: ...Pass the starter cable between the ignition coil and spark plug lead Speedometer ca ble Neutral switch lead Pickup coil lead A C magneto lead Thermo switch lead Fuel tank breather hose Wire harness Throttle position sensor TPS lead Frame Air filter case CD Front flasher light right Throttle cables Brake hose Right handlebar switch lead Clutch cable Left handlebar switch lead j Front flasher light ...

Page 345: ...o switch lead inside of the silencer breather hose CABLE ROUTING ISPECI I ill Fasten the wire harness and throttle position sensor TPS lead with a plastic locking tie Q Inside the motorcycle f Route the wire harness and throttle position sensor TPS lead so they run along the bottom of the frame tube Q Place the end of the plastic locking tie as shown ill Fasten the wire harness with a plastic lock...

Page 346: ...nd seats removal Remove the parts in the order below 1 Fuel hose 1 NOTE Set the fuel cock to OFF before dis connecting the fuel hose 2 Meter assembly 1 3 Meter lead couper 2 4 Speedometer cable 1 NOTE Disconnect the speedometer cable from the front wheel side first 5 Starter knob bracket 1 6 Fuel tank assembly 1 7 Passenger seat 1 8 Seat bracket 1 9 Rider s seat 1 For installation reverse the remo...

Page 347: ...ontally Turn the adjuster in or out Turning in headlight beam to the left Turning out headlight beam to the right EB305030 HEADLIGHT BULB REPLACEMENT 1 Remove Headlight lens unit 2 Disconnect Leads in headlight body CD 3 Remove Bulb cover 4 Unhook Bulb holder CD 5 Remove Bulb A WARNING Since the bulb may be hot keep flammable products and your hands away from it Do not touch the bulb until it has ...

Page 348: ...wise the trans parency of the glass life of the bulb and the luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alco hol or lacquer thinner 7 Hook up Bulb holder 8 1nstall Bulb cover 9 Connect Leads in headlight body 10 lnstall Headlight lens unit 15 ...

Page 349: ... 10 Nm 1 0 m kg 7 2 It Ib I I I I I I I I I 1 2 Order Job name Part name Q ty Remarks Front fork removal Remove the parts in the order below Front wheel Refer to IIFRONT WHEEL 1 Brake hose holder 1 2 Brake caliper assembly 1 3 Front fender 1 4 Front flasher light holder nuts 2 5 Upper bracket boIts 2 6 Cap bolts 2 Loosen Refer to IIFRONT FORK INSTALLA 7 Lower bracket bolts 2 TION 8 Front forks 2 F...

Page 350: ...ont fork disassembly Disassemble the parts in the order below CD Cap bolt 1 O ring 1 Spacer collar 1 r Refer to IIFRONT FORK ASSEMBLV Spring seat 1 Fork spring 1 Dust sear 1 j Retaining clip 1 Damper rod bolt 1 Refer to IIFRONT FORK DISASSEM Gasket 1 BLY ASSEMBLV Damper rod rebound spring 1 1 Oil seal 1 17 ...

Page 351: ...5 30 N m 3 O m kg t 21 7 ft Ib H Order Job name Part name Q ty Remarks Seal spacer 1 Slide metal 1 Inner tube piston metal 1 1 Refer to FRONT FORK ASSEMBLY Oil lock piece 1 Outer tube 1 For assembly reverse the disassembly procedure 18 ...

Page 352: ...der YM 01388 90890 01388 3 Remove Damper rod Rebound spring 4 Remove Inner tube Removal steps Hold the fork leg horizontally Securely clamp the caliper mounting boss of the outer tube in a vise with soft jaws Separate the inner tube from the outer tube by pulling forcefully but carefully on the inner tube Excessive force will damage the oil seal and or the slide metal A damaged oil seal and metal ...

Page 353: ... Replace 342 018 Fork spring free length limit 284 mm 11 18 in 3 1nspect Damper rod CD Wear damage Replace Contamination Blowout all of the oil passages with compressed air Oil lock piece Damage 7 Replace 4 1nspect O ring cap bolt Wear damage 7 Replace FRONT FORK ASSEMBlV NOTE _ When reassembling the front fork replace the following parts Piston metal Slide metal Oil seal Dust seal Before reassemb...

Page 354: ...e outer surface Recommended lubricant U Yamaha fork oil10WT or equiv alent 3 1nstall Inner tube CD to outer tube 4 1nstall Gasket CD _ Damper rod bolt 5 Tighten Damper rod bolt CD ril 30 N m 3 O m k g 2 1 7 ft lb lq NOTE __ _ Apply LOCTITE to the threads of the damper rod holder Tighten the damper rod bolt while holding the damper rod with a T handle and a damper rod holder T handle YM 01326 90890...

Page 355: ... 1nstall Oil seal j Use the fork seal driver weight and the adapter Fork seal driver weight YM 01326 90890 01367 Adapter YM 01388 90890 01381 Make sure that the numbered side of the oil seal faces up a lnstall Retaining clip j NOTE _ Adjust the retaining clip so that it fits into the outer tube groove 9 lnstall Dust seaI j Use the fork seal driver weight Fork seal driver weight YM 33963 90890 0136...

Page 356: ...ng NOTE _ Hold the fork in an upright position 11 lnstall Fork spring CD Spring seat Spacer collar O ring Cap bolt NOTE _ Before installing the cap bolt apply grease to the O ring Temporarily tighten the cap bolt FRONT FORK INSTALLATION 1 tnstall Front forks CD NOTE _ Make sure that the inner tube end is flush with the top of the upper bracket 2 Tighten Lower bracket bolts CD O N m 3 0 m k g 2 1 7...

Page 357: ...racket 6 Lock washer 7 Upper ring nut STEERING HEAD ICHASI I 1st 52 Nm 5 2 m kg 37 6 ft Ib 2nd 18 Nm 1 8 m kg 13 0 ft Ib 110 Nm 11 0 m kg 79 6ft Ib 5 O ty Remarks Remove the parts in the order below Stand the motorcycle on a level sur face A WARNING Securely support the motorcycle so that there is no danger of it falling over Refer to IIFRONT FORK Refer to IJHANDLEBAR 1 Disconnect 1 1 1 1 1 1 24 ...

Page 358: ...0 Nm 11 0 m kg 79 6 It Ib 5 Order Job name Part name Q ty Remarks 8 Rubber washer 1 9 Lower ring nut 1 Refer to JlSTEER1NG HEAD REMOVAL INSTALLATION 10 Bearing cover 1 1 Lower bracket 1 12 Bearing upper 1 13 Rubber seal 1 14 Bearing lower 1 For installation reverse the removal procedure 25 ...

Page 359: ...YAMAHA YAMAHA MOTOR CO LTD Printed in USA ...

Page 360: ...PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories 1111111111111111111 L1T 11616 XV OO YAMAHA MOTOR CORPORATION U S A PRINTED IN U S A ...

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Yamaha XVS650, Service Manual

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