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Yamaha XVZ13TF 1999, Service Manual

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Yamaha XVZ13TF 1999 Service Manual Download Page 402

8-4

1

Dimmer switch

2

Horn switch

3

Turn signal switch

4

Pass switch

5

Clutch switch

6

Main switch

7

Front brake switch

8

Gruise control switch

9

“CANCEL”  switch

10

Engine stop switch

11

Start switch

12

Emargency stop switch

13

Side stand switch

14

Neutral switch

15

Rear brake switch

16

Oil level switch

for OCE

SWITCH INSPECTION

ELEC

Summary of Contents for XVZ13TF 1999

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Page 3: ...Z13TF L SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First edition January 1999 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...icy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed eral environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where a...

Page 5: ...spections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspection and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 N...

Page 6: ...rical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel bearin...

Page 7: ...CIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS ...

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ... 1 2 CRUISE CONTROL 1 2 DIGITAL SPEEDOMETER 1 4 AUDIO SYSTEM 1 5 IMPORTANT INFORMATION 1 13 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 13 REPLACEMENT PARTS 1 13 GASKETS OIL SEALS AND O RINGS 1 13 LOCK WASHERS PLATES AND COTTER PINS 1 14 BEARINGS AND OIL SEALS 1 14 CIRCLIPS 1 14 CHECKING THE CONNECTIONS 1 15 SPECIAL TOOLS 1 16 ...

Page 11: ...GEN INFO ...

Page 12: ...OTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head EAS00018 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...ctions 1 CRUISE switch Push this switch to ON when the cruise control system is preset The ON indicator light will come on Once the switch is released it will return to the center Hold position To cancel the cruise control system push the switch to OFF or main switch to the OFF position 2 ON indicator light This indicator light comes on when the cruise control systems preset when ON is selected by...

Page 14: ...ximately 1 6 km h 5 If the control switch is held in the ACC or DEC position longer than 0 5 seconds the speed can be successively increased or decreased slowly 6 The cruise control will be deactivated if the front or rear brake is applied or if the clutch is disengaged or if the CANCEL switch is pushed 7 After canceling the speed is returned to the one set before the cancellation by pushing the c...

Page 15: ...es in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F 2 Resetting a meter To reset a trip odometer to 0 0 select it by pushing the SELECT button and push the RESET button To reset the fuel reserve trip meter select it by pushing the SELECT button and push the RESET button The display will return to prior mode ODO TRIP 1 or TRIP 2 If you do not reset the fuel reserve trip meter manually it will...

Page 16: ...ECT button and the minute digits will start flashing d Push the RESET button to set the minutes e Push the SELECT button to start the clock After setting the clock be sure to push the SELECT button before turning the main switch to OFF otherwise the clock will not be set AUDIO SYSTEM 1 POWERING ON OFF THE AUDIO SYS TEM Turning on off the audio system Turn the main switch to the ACC or ON posi tion...

Page 17: ...he up down switch 1 for less than one second The APC auto program control indicator will ap pear in the display Push the witch once for each song to be skipped Pushing the switch in direction n will search in the forward direction Pushing the switch in direction o will search in the reserve direction When searching in the forward direction the num ber of song that are being skipped will appear i e...

Page 18: ...tor will appear Dolby noise reduction The Dolby noise reduction can be turned on or off by pushing the EJECT button for at least two seconds When the noise reduction is on the BNR indi cator appears in the display Ejecting the cassette tape Push the EJECT button to eject the tape from the cassette dack Blank skipping When there is a blank portion on the cassette tape the BLS indicator light will c...

Page 19: ...ld it for as least 1 second The tuner will automatically stop at the first sta tion that has a strong enough radio wave Manually turning When a radio wave is too weak to be picked up automatically it can be selected manually as follows Push the SELECT button until RADIO sta tion appears Push the up down switch 1 for less than 1 se cond in either direction and the ferequency will change in 0 1 MHz ...

Page 20: ...is found push the up down switch for less than one second to select the channel number to be set for that station d Push the SELECT button to programing the channels in memory e Repeat this procedure for the remaining sta tions desived to be preset in memory Programing preset stations in memory auto matically Setting up to 6 channels can be made by the fol lowing procedure Stations will be startin...

Page 21: ...SIC SETTINGS AUDIO system The following settings can be made in the audio system Selecting output between speakers and a head set assembly Controlling bass level Controlling treble level Controlling fader balance between the front and the rear speakers Controlling intercom volume level Changing auto volume level Setting procedure The following setting procedures apply to the audio system auxiliary...

Page 22: ...ingthe treble level a To control the treble level push the SE LECT button until the TREB indicator ap pears b Push the up down switch 1 in either direc tion to change the level The treble level can be set from 6 to 6 Controlling the fader balance between front and rear speakers a To control the fader push the SELECT but ton until the FAD indicator appears b Push the up down switch 1 in either dire...

Page 23: ...ystem a To control the level for the auto volume con trol system push the SELECT button untill the AV indicator appears b Push the up down switch 1 in either direc tion to change the volume level The auto volume control rate of compensa tion can be adjusted from 0 to 5 ...

Page 24: ...ly clean all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all re placements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and ap...

Page 25: ...rs are vis ible When installing oil seals apply a light coat of lithium soap base grease onto the oil seal lips Oil bearings liberally when instal ling if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS 1 Before reassembly check all circlips careful ly and replace damaged or distorted circlips Always repl...

Page 26: ...Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with a pocket tester Pocket tester YU 03112 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a...

Page 27: ...lustration YM 33961 90890 04105 Tappet adjusting tool This tool is needed to rotate the camshaft for access to the valve lift er and valve pad YU 08030 A 90890 03094 Vacuum gauge This gauge is needed for carburetor synchronization YU 08036 A 90890 03113 Engine tachometer This tool is needed for observing en gine rpm YU 33277 A 90890 03141 Timing light This tool is necessary for checking ignition t...

Page 28: ...0890 04064 Valve guide remover 6 0 mm This tool is needed to remove and install the valve guide YM 04065 A 90890 04065 Vale guide installer 6 0 mm This tool is needed to install the valve guide YM 04066 90890 04066 Valve guide reamer 6 0 mm This tool is needed to rebore the new valve guide YM 91042 90890 04085 Universal clutch holder This tool is needed to hold the clutch when removing or installi...

Page 29: ...ressor This tool is needed when removing or installing the damper spring YM 33222 Middle drive gear holder This tool is needed to remove and install the middle drive pinion gear This tool is also used for the gear backlash adjustment 90890 04080 Middle drive gear holder This tool is needed for the gear backlash adjustment YM 04054 90890 04054 Offset wrench 55 mm This tool is needed when removing o...

Page 30: ...ools are needed to loosen and tighten the damper rod holding bolt Weight YM 33963 90890 01367 Adapter YM 8020 90890 01374 Fork seal driver weight adapter These tools are needed when instal ling the slide metal oil seal and dust seal into the fork YM 01230 90890 01230 Final gear backlash band This tool is needed when measuring final gear backlash YM 01229 90890 01229 Coupling gear middle shaft tool...

Page 31: ...GEN INFO ...

Page 32: ...SPEC 2 ...

Page 33: ...FICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 AUDIO SYSTEM SPECIFICATIONS 2 21 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 24 COOLING SYSTEM DIAGRAMS 2 25 LUBRICATION DIAGRAMS 2 26 CABLE ROUTING 2 30 ...

Page 34: ...SPEC ...

Page 35: ...ement Bore stroke Compression ratio Compression pressure STD Starting system Liquid cooled 4 stroke DOHC V type 4 cylinder 1 294 cm3 79 66 mm 10 1 1 520 kPa 15 2 kg cm2 15 2 bar at 175 r min Electric starter Lubrication system Wet sump Oil type or grade Engine oil Yamalube 4 20W40 or SAE20W40 type SE motor oil Yamalube 4 10W30 or SAE10W30 type SE motor oil Final gear oil Engine oil Periodic oil ch...

Page 36: ...960 22 28 0 786 Chassis Frame type Caster angle Trail Double cradle 29 10 152 mm Tire Type Size front rear Tubeless 150 80B16 71H 150 90B15M C 74H Manufacturer front rear Type front rear BRIDGESTONE DUNLOP BRIDGESTONE DUNLOP G705 D404F G702 D404 Tire pressure cold tire 0 X 90 kg load front rear 90 X 190 kg load front rear 250 kPa 2 50 kg cm2 2 50 bar 250 kPa 2 50 kg cm2 2 50 bar 250 kPa 2 50 kg cm...

Page 37: ...ight Auxiliary light Tail brake light Front flasher light Rear flasher light License light Indicator light Neutral indicator light Turn indicator light High beam indicator light Fuel level indicator light Oil level indicator light Engine overheat indicator light Engine trouble indicator light Over drive indicator light SET indicator light RES indicator light ON indicator light 12 V 60 W 55 W 1 12 ...

Page 38: ...16 mm 40 mm SSS SSS Out of round limit SSS 0 05 mm Camshaft Drive method Cam cap inside diameter Camshaft outside diameter Shaft to cap clearance Cam dimensions Chain drive Center 25 000 X 25 021 mm 24 967 X 24 980 mm 0 020 X 0 054 mm SSS SSS SSS SSS Intake A B Exhaust A B 35 75 X 35 85 mm 27 95 X 28 05 mm 35 75 X 35 85 mm 27 95 X 28 05 mm 35 65 mm 27 85 mm 35 65 mm 27 85 mm ...

Page 39: ...sions 0 11 X 0 15 mm 0 16 X 0 20 mm A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem outside diameter IN EX Guide inside diameter IN EX Stem to guide clearance IN EX 28 9 X 29 1 mm 23 9 X 24 1 mm 1 3 X 3 2 mm 1 6 X 2 9 mm 0 9 X 1 1 mm 0 9 X 1 1 mm 0 8 X 1 2 mm 0 8 X 1 2 mm 5 975 X 5 990 mm 5 960 X 5 975 mm 6 000 X 6 012 mm 6 000 X 6 012 mm 0 010 X 0 037 mm ...

Page 40: ...37 kg SSS SSS 35 3 mm 35 3 mm SSS SSS SSS SSS 2 5_ 1 6 mm 2 5_ 1 6 mm Direction of winding IN top view EX Counter clockwise Counter clockwise SSS SSS Valve spring Outer Free length IN EX Set length valve closed IN EX Compressed pressure IN installed EX Tilt limit IN EX 39 45 mm 39 45 mm 33 8 mm 33 8 mm 10 1 X 11 9 kg 10 1 X 11 9 kg SSS SSS 37 25 mm 37 25 mm SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 1 7 mm ...

Page 41: ...eter 4 mm 0 mm 19 004 X 19 015 mm 18 991 X 19 000 mm SSS SSS 19 045 mm 18 975 mm Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed Barrel 3 1 1 0 mm 0 20 X 0 35 mm 0 03 X 0 07 mm SSS SSS 0 55 mm 0 12 mm 2nd ring Type Dimensions B T End gap installed Side clearance Oil ring Taper 3 1 1 2 mm 0 35 X 0 50 mm 0 02 X 0 06 mm SSS SSS 0 8 mm 0 12 mm Dimensions B T End ga...

Page 42: ...learance Color code corresponding size 0 021 X 0 039 mm 0 020 X 0 038 mm Blue Black Brown Green Yellow Pink Red SSS 0 1 mm SSS Ballancer Ballancer drive method Gear Clutch Friction plate thickness Quantity Friction plate wear limit Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Clutch rele...

Page 43: ... 4 120 110 5DL41 54 P 0 85 1 1 15 0 8 0 8 0 8 1 5 35 0 5 110 17 mm 950 X 1 050 r min 36 kPa 270 mmHg SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Fuel pump Type Model manufacturer Consumption amperage max Output pressure Electrical type 4NK MITSUBISHI 1 A 15 X 20 kPa 0 2 kg cm2 0 2 bar SSS SSS SSS SSS Lubrication system Oil filter type Oil pump type Inner rotor to outer ...

Page 44: ...pressure Reservoir tank capacity From low to full level Water pump Type Reduction ratio 257 4 mm 360 mm 27 mm 95 X 125 kPa 0 95 X 1 25 kg cm2 0 95 X 1 25 bar 0 84 L 0 25 L Single suction centrifugal pump 31 21 1 476 SSS SSS SSS SSS SSS SSS SSS SSS Shaft drive Middle gear backlash Final gear backlash 0 05 X 0 12 mm 0 1 X 0 2 mm SSS SSS ...

Page 45: ...2 11 MAINTENANCE SPECIFICATIONS SPEC Item Standard Crankcase tightening sequence ...

Page 46: ...ase Middle gear bearing retainer Main axle bearing retainer Crankcase cover plate Bolt Plug Stand bolt Nut Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Plug Bolt Bolt Bolt Union bolt Bolt Plug Bolt Screw Union bolt Union bolt Union bolt Bolt Bolt Screw Screw Screw Screw Bolt Bolt Nut Stud bolt Plug Bolt Screw Screw Screw M6 1 0 M18 1 5 M8 1 25 M12 1 25 M10 1 25 M6 1 0 M6 1 0 M8 0 75 M12 1 25 M7 1 0 M8 1...

Page 47: ...tch Oil level switch Thermo unit Thermo switch Ignition coil assembly Ignitor unit assembly Bolt Bolt Bolt Nut Bolt Screw Union bolt Nut Nut Bolt Torx Screw Screw Bolt Bolt Screw Bolt Nut Nut Bolt Bolt Stud bolt Stud bolt Nut Nut Bolt Plug Plug Screw Bolt Screw Bolt Bolt Nut M12 1 25 M8 1 25 M6 1 0 M20 1 0 M6 1 0 M8 1 25 M10 1 25 M44 1 5 M16 1 5 M8 1 25 M6 1 0 M5 0 8 M6 1 0 M8 1 25 M6 1 0 M6 1 0 M...

Page 48: ...S 568 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS Rear suspension Shock absorber travel Spring free length Fitting length Spring rate K1 Stroke K1 Optional spring Enclosed gas air pressure STD Min X Max 45 mm 186 5 mm 165 5 mm 147 N mm 14 7 kg mm 0 X 45 mm No 0 kPa 0 kgf cm2 0 bar 0 X 400 kPa 0 X 4 0 kgf cm2 0 X 4 0 bar SSS 181 5 mm SSS SSS SSS SSS SSS SSS Swingarm Free play limit end side SSS SSS 0 mm...

Page 49: ...fluid type 15 87 mm 30 1 mm 33 3 mm DOT 4 SSS SSS SSS SSS Rear disc brake Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Single 320 7 mm 7 5 mm 7 5 mm SSS SSS 0 5 mm 0 5 mm Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type 12 7 mm 33 9 mm 30 2 mm DOT 4 SSS SSS SSS SSS Brake lever brake pedal Brake lever ...

Page 50: ...ngarm pivot shaft left Swingarm pivot shaft right Swingarm pivot shaft locknut right Relay arm and frame Relay arm and connecting rod Connecting rod and swingarm Rear shock absorber and frame Rear shock absorber and connecting rod Fuel petcock and fuel tank Fuel sender and fuel tank Fuel tank front and frame Fuel tank rear and frame Fuel pump bracket and bridge plate Cover and fuel tank Rider seat...

Page 51: ... rear brake hose Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Front wheel axle Front wheel axle pinch bolt Rear wheel axle nut Front brake caliper Rear brake caliper Brake disc and wheel Caliper bleed screw M8 M8 M12 M10 M8 M8 M10 M10 M6 M10 M8 M8 M18 M8 M18 M10 M10 M8 M8 23 30 122 52 23 23 30 26 4 30 23 23 78 19 150 40 40 23 6 2 3 3 0 12 2 5 2 2 3 2 3 3 0 2 6 0 4...

Page 52: ...ing resistance Secondary winding resistance F6T541 MITSUBISHI 6 mm 3 57 X 4 83 Ω at 20_C 10 71 X 14 49 kΩ at 20_C SSS SSS SSS SSS Spark plug cap Type Resistance Resin type 10 kΩ SSS SSS Charging system Type Model manufacturer Nominal output Stator coil resistance color A C magneto generator F4T655 MITSUBISHI 14 V 29 A at 5 000 r min 0 279 X 0 341 Ω at 20_C White White SSS SSS SSS SSS Rectifier reg...

Page 53: ...uantity Model manufacturer Maximum amperage Plane type for EUR Eddy type for OCE 2 YF 12 NIKKO for EUR YFM 12 NIKKO for OCE 3 A for EUR 4 A for OCE SSS SSS SSS SSS SSS SSS SSS Flasher relay Type Model manufacturer Self cancelling device Flasher frequency Wattage Full transistor type FE246BH DENSO No 75 X 95 cycle min 21 W 2 3 4 SSS SSS SSS SSS SSS Oil level switch Model manufacturer 4XY DENSO SSS ...

Page 54: ... 4XY MITSUBISHI SSS Vacume pump 4XY MITSUBISHI SSS Circuit breaker Type Amperage for individual circuit MAIN HEAD SIGNAL IGNITION FAN Back up odometer Cruse control Carburetor Audio DC outlet Reserve Reserve Reserve Reserve Fuse 30 A 1 15 A 1 15 A 1 10 A 1 10 A 1 10 A 1 10 A 1 10 A 1 10 A 1 5 A 2 10 A 2 15 A 1 30 A 1 5 A 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 55: ...te Frequency AM FM 531 X 1 602 KHz 87 5 X 108 MHz 450 KHz 10 7 MHz Bass Treb 10dB 100 HZ 10dB 10KHz Amplifier Output Power Auto Vol Range Output Impedance Speaker Headset 14W x 4 SP 1W x 2 HS 5 steps 4 Ω 8 Ω X 16 Ω Deck Circuit System Tape Speed Taper 4 track 2 channel Stereo for reproduction 4 75 cm sec Normal and Metal ...

Page 56: ...s are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A nut B bolt General torque specifications nut bolt Nm m kg ft lb 10 mm 6 mm 6 ...

Page 57: ...on pin Camshaft cam lobe journal Timing chain tensioner Valve stem IN EX Valve stem end IN EX Valve lifter Water pump impeller shaft Oil pump rotor inner outer housing Oil strainer assembly Idle gear surface Starter idle gear Starter idle gear shaft Starter clutch outer roller Push rod ball Pressure plate bearing Transmission gear wheel pinion Shift cam Shift fork guide bar Shift shaft assembly Sh...

Page 58: ... left Rear wheel oil seal Clutch hub fitting area Rear brake pedal shaft Shift pedal Front footrest pivot Rear footrest pivot Sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt contact surface Clutch lever bolt contact surface Swingarm pivot shaft Swingarm pivot bearing Swingarm pivot oil seal Relay arm bearing inner Rear shock absorber bearing inner Connecting...

Page 59: ...2 25 COOLING SYSTEM DIAGRAMS SPEC A To coolant reservoir tank EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostatic valve housing 3 Radiator hose 4 Radiator 5 Water pump ...

Page 60: ...RAMS SPEC 10 Main axle 11 Drive axle EAS00034 LUBRICATION DIAGRAMS 1 Camshaft intake 2 Camshaft exhaust 3 Water pump impeller shaft 4 Water pump drive gear 5 Main gallery 6 Oil filter 7 Crankshaft 8 Oil strainer 9 Oil pump ...

Page 61: ...2 27 LUBRICATION DIAGRAMS SPEC 1 Camshaft 2 Main gallery 3 Crankshaft 4 Oil level switch ...

Page 62: ...2 28 1 Main axle 2 Drive axle 3 Middle driven pinion gear 4 Middle drive pinion gear LUBRICATION DIAGRAMS SPEC ...

Page 63: ...2 29 1 Crankshaft 2 Oil pipe 3 Oil filter 4 Water pump drive gear 5 Oil strainer 6 Oil pump LUBRICATION DIAGRAMS SPEC ...

Page 64: ...plete A Fasten the wire harness with a plastic clamp B To rear brake switch C Position the vacuum hose as shown D To regulator E Fasten the wire harness with a plastic clamp F Fasten the side stand switch lead fan motor lead and noise filter lead with a plastic clamp G Align the projection downward H Fasten teh side stand switch lead fan motor lead and noise filter lead with a plastic clamp EAS000...

Page 65: ...asten the side stand switch lead fan motor lead and noise filter lead with a plastic clamp L Route the side stand switch lead fan motor lead and noise filter lead inside the pipe Make sure that the leads are not come out of the pipe M Fasten the cruise control cable and wire harness with a plastic clamp N Route the cruise control cable and wire har ness outside of the steel clamp CABLE ROUTING SPE...

Page 66: ... Handlebar switch lead left 18 Handlebar switch lead right 19 Front brake switch lead 20 Wire harness sub lead right 21 Ground lead 22 Headlight harness 23 Meter lead 24 Antenna lead with cover 25 Handlebar switch lead right 26 Front brake switch lead 1 Antenna lead with cover 2 Auxiliary terminal 3 CD code 4 Meter lead 5 Hazard relay 6 DC outlet lead 7 Speaker lead 8 Hazard relay lead 9 Antenna l...

Page 67: ...eadlight harness Q Put the plug for CD cord under the cassette deck A To the CRUISE switch B Connect the couplers with same color C Fasten the headlight harness and handlebar switch left and right lead with a plastic clamp D Fasten the turn signal lead with a plastic clamp E To the turn signal light F To headlight G Fasten the audio coupler and headlight harness with a plastic clamp H Fasten the m...

Page 68: ...amp the head light harness right Route the head light harness so that DIN cable set comes upper side T For installing the stay do not catch the throttle cable U Put it under the cassette deck sideways Not clamped V At the white tape on the antenna lead attach a plastic clamp CABLE ROUTING SPEC ...

Page 69: ...o the left under cowling G To the fan motor H To the right under cowling I Fasten the ignition coil lead with a plastic clamp with the end towards the under side of the motorcycle 1 Brake hose 2 Clutch hose 3 Handlebar switch lead left 4 Remote controller lead 5 Throttle cable 6 Handlebar switch lead right 7 Wire harness assembly CABLE ROUTING SPEC ...

Page 70: ...uretor G To the wire harness H Fasten the starter lead with a plastic clamp with the end towards the front side of the motorcycle I Align the white mark on the wire harness with the plastic clamp with the end towards the front side of the motor cycle 1 Wire harness 2 Starter lead 3 Brake hose 4 Battery negative lead 5 Wire harness CABLE ROUTING SPEC ...

Page 71: ...drain hose K Front the air cleaner L From the coolant reservoir tank M From the engine N To the horn O Fasten the wire harness with a plastic clamp with the end towards the front side of the motor cycle P To the relay CABLE ROUTING SPEC ...

Page 72: ...ess sub lead with a plastic clamp G To the upper cowling H Fasten the audio lead CD lead option and ground lead with a plastic clamp I Fasten the ground lead and engine stop switch lead J To the under cowling K Insert the hose through the metal clilp L To the AIS 1 Plastic clamp 2 Emergency stop switch 3 Bolt ground 4 Platic clamp 5 Bolt ground 6 Carburetor heater relay 7 Flasher relay 8 Thermo sw...

Page 73: ... end of clamp to the rear side of the motorcycle N Position the end of clamp to the rear side of the motorcycle O To the engine P Clamp the horn lead white mark and ground lead Q Route the battery negative lead between the wire harness and pipe R To the AIS S Fasten the wire harness flasher relay and ther mo switch lead with a plastic clamp T Fasten the wire harness with a plastic clamp U To the r...

Page 74: ...e cable holder G Route the wire harness with the frame guide T bar H Fasten the speed sensor lead and wire harness I Align the marking tape on the head set lead CD cord option antenna lead and CB cord and fasten them tail lead and DC outlet lead with a plastic clamp J Position the lead wires on the rear fender as shown K Clamp the speed sensor lead in the clip on the rear arms 1 Front remote contr...

Page 75: ... the wire harness behind the igniter unit P From coolant reservoir tank Q From air cleaner case R From engine S Route the hoses on the left side of the engine leads T Fasten the starter lead pick up lead AC magneto lead neutral switch lead ignition coil sub lead and oil level gauge lead with a plastic clamp U From fuel tank V Make sure that the sidestand switch lead has no loosening CABLE ROUTING ...

Page 76: ... F Fasten the wire harness sub lead throttle cable head set lead and clutch hose with a plastic clamp G Insert the wire harness into the air induction box guide and hold it with clamp H Fasten the fuel hose on the carburetor with a plastic clamp I Position the throttle cables do not outside of the carburetors J To plastic clamp on the cross pipe K To wire harness assembly L Fasten the clutch hose ...

Page 77: ...main switch lead and ignition coil 4 lead with a plastic clamp E Be sure not to squeeze each leads 17 Tail brake light lead 18 Head set lead 19 CD cord option 20 Antenna lead 21 Plastic clamp 1 Fuel tank breather hose 2 Bracket 3 Head set lead 4 CD code option 5 Antenna lead 6 Ground lead 7 Wire harness 8 Plastic clamp 9 CD cord option 10 DC outlet 11 Screw 12 Fuel sender lead 13 Plastic clamp 14 ...

Page 78: ...he main harness V Fasten the handlebar switch lead left clutch hose and remote controler lead with a plastic clamp F Positon the clip end at upper G Route the AIS hose through the clip H Route the tail brake light lead through the hole in the cover at the back of the frame I After routing the leads fasten them with clamp J Fix the connector with a clamp as shwon K Route the wireharness between bra...

Page 79: ...CHK ADJ 3 ...

Page 80: ...ING THE ENGINE OIL PRESSURE 3 24 CHECKING THE CLUTCH FLUID LEVEL 3 26 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3 27 CLEANING THE AIR FILTER ELEMENT 3 28 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 3 29 CHECKING THE FUEL HOSES AND FUEL FILTER 3 30 CHECKING THE CRANKCASE BREATHER HOSE 3 31 CHECKING THE EXHAUST SYSTEM 3 31 CHECKING THE COOLANT LEVEL 3 31 CHECKING THE COOLING SYSTEM 3 32 CHANGING ...

Page 81: ...LS 3 48 CHECKING AND LUBRICATING THE CABLES 3 49 LUBRICATING THE LEVERS AND PEDALS 3 49 LUBRICATING THE SIDESTAND 3 49 LUBRICATING THE REAR SUSPENSION 3 49 ELECTRICAL SYSTEM 3 50 CHECKING AND CHARGING THE BATTERY 3 50 CHECKING THE FUSES 3 55 REPLACING THE HEADLIGHT BULB 3 57 ADJUSTING THE HEADLIGHT BEAM 3 58 ...

Page 82: ...l and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout and for damage Rebalance or replace if necessary 10 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if nec...

Page 83: ... 24 Final gear oil S Check oil level and vehicle for oil leakage S Change oil at initial 1 000 km and thereafter every 24 000 km or 24 months whichever comes first Since these items require special tools data and technical skills they should be serviced by a Yama ha dealer D The air filter needs more frequent service if you are riding in unusually wet or dusty areas D Hydraulic brake and clutch sy...

Page 84: ...ont cowling chrome cover Wind shield Front cowling Headlight unit MCU lead speedometer lead headlight lead Front pannel 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE FRONT COWLING COVER Disconnect For installation reverse the removal procedure FRONT COWLING ...

Page 85: ...owling cover 2 c Then push the center portion of the cover 3 inward and lift the entire cover upward INSTALLING THE FRONT COWLING COVER 1 Install front cowling cover a First insert each side of the cowling cover 1 into the cowling b While pushing the center portion of the cowl ing cover 2 inward push downward to install c Tighten the bolts 3 ...

Page 86: ...S CHK ADJ Order Job Part Q ty Remarks 1 2 Removing the rider and passenger seats Rider seat Passenger seat 1 1 Remove the parts in the order listed For installation reverse the removal procedure EB302001 RIDER AND PASSENGER SEATS ...

Page 87: ... breather hose Fuel sender lead coupler Fuel hose Fuel tank 1 1 1 1 1 Remove the parts in the order listed Refer to RIDER AND PASSENGER SEATS Disconnect Disconnect Before disconnecting the hose turn the fuel cock OFF For installation reverse the removal procedure NOTE 7 Nm 0 7m kg 16 Nm 1 6m kg EB302002 FUEL TANK ...

Page 88: ...Antenna Antenna trunk wire harness lead Trunk Saddlebags 1 1 1 1 1 2 Remove the parts in the order listed Disconnect For installation reverse the removal procedure 6 5 Nm 0 65 m kg 7 5 Nm 0 75 m kg 12 Nm 1 2 m kg 6 5 Nm 0 65 m kg 2 5 Nm 0 25 m kg SADDLEBAGS CHK ADJ SADDLEBAGS ...

Page 89: ...er TDC on the compression stroke 1 Remove rider seat fuel tank Refer to RIDER AND PASSENGER SEATS and FUEL TANK air induction box carburetor assembly Refer to CARBURETOR in CHAPTER 6 cylinder head stay under cowling 2 Drain coolant Refer to CHANGING THE COOLANT 3 Disconnect spark plug leads coolant hose 1 4 Remove chrome cylinder head covers 2 5 Remove spark plugs cylinder head cover 1 6 Measure v...

Page 90: ... record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 3 2 4 A Front d For each cylinder starting with cylinder 1 at TDC turn the crankshaft counterclockwise as specified in the following table B Degrees that the crankshaft is turned counter clockwise C Cylinder D Combustion cycle 3 Cylinder 180_ 2 Cylinder 430_ 4 Cylinder ...

Page 91: ...osition of each valve pad and valve pad number so they can be installed in the correct place e Select the proper valve pad from the follow ing table Valve pad thickness range Available valve pads No 200 320 2 00 3 20 mm 25 thickness in 0 05 mm increments The thickness of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter not the camshaft Since valve pad...

Page 92: ...90 295 300 305 310 315 320 0 86 0 90 275 280 285 290 295 300 305 310 315 320 0 91 0 95 280 285 290 295 300 305 310 315 320 0 96 1 00 285 290 295 300 305 310 315 320 1 01 1 05 290 295 300 305 310 315 320 1 06 1 10 295 300 305 310 315 320 1 11 1 15 300 305 310 315 320 1 16 1 20 305 310 315 320 1 21 1 25 310 315 320 1 26 1 30 315 320 1 31 1 35 320 EXHAUST 200 205 210 215 220 225 230 235 240 245 250 2...

Page 93: ... valve pad number is only an approxi mation The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect h Install the new valve pad with the numbered side facing down i Remove the tappet adjusting tool j Measure the valve clearance again k If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment ...

Page 94: ...ve vacuum plugs 3 Install adapters vacuum gauge 1 engine tachometer 2 to the spark plug lead of cyl 1 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 minutes 5 Check engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 950 1 050 r min 6 Adjust carburetor synchron...

Page 95: ... carburetor 3 by turning the synchronizing screw 3 in ei ther direction until both gauges read the same Vacuum pressure at engine idling speed 37 kPa 280 mmHg The difference in vacuum pressure between two carburetors should not exceed 1 33 kPa 10 0 mmHg 7 Check engine idling speed Out of specification Adjust 8 Stop the engine and remove the measuring equipment 9 Adjust throttle cable free play Ref...

Page 96: ... 08036 A 90890 03113 3 Check engine idling speed Out of specification I Adjust 4 Adjust engine idling speed Engine idling speed 950 1 050 r min a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is increased Direction Engine idling speed is decreased 5 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE...

Page 97: ...throttle cable Direction Throttle cable free play is increased Direction Throttle cable free play is decreased d Tighten the lock nut 1 e Turn the adjusting nut 4 in direction c or d to take up any slack on the cruise control cable Direction Cruise control cable free play is increased Direction Cruise control cable free play is decreased Cruise control cable free play 1 2mm f Tighten the lock nut ...

Page 98: ...eck throttle grip movement Stroke the cruise control wire when throttle grip movement 5 Install fuel tank rider seat Refer to FUEL TANK and RIDER AND PASSENGER SEATS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Disconnect spark plug cap 2 Remove spark plug Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with co...

Page 99: ...Before installing the spark plug clean the spark plug and gasket surface 8 Connect spark plug cap EAS00064 CHECKING THE IGNITION TIMING Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure that all connections are tight and free of corrosion 1 Remove timing plug 1 2 Install timing light 1 engine tachometer 2 to the spark plug lead of cyl 1 Timi...

Page 100: ...generator rotor Incorrect firing range Check the ignition system The ignition timing is not adjustable 4 Remove timing light engine tachometer 5 Install timing plug 1 EAS00065 MEASURING THE COMPRESSION PRES SURE The following procedure applies to all of the cyl inders Insufficient compression pressure will result in a loss of performance 1 Check valve clearance Out of specification Adjust Refer to...

Page 101: ...he cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again Refer to the following table Compression pressure with oil applied in the cylinder Reading Diagnosis Higher than without oil Piston wear or damage Repair Same as without oil Piston ring s valves cylinder head gasket or piston possibl...

Page 102: ...ween cylinders should not exceed 100 kPa 7 Install spark plug 8 Connect spark plug cap EAS00071 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Check engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b Below the minimum level mark Add t...

Page 103: ...rt the engine warm it up for several min utes and then turn it off 4 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled EAS00073 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove engine oil filler cap 1 engine oil drain bolt 2 4 ...

Page 104: ...d correctly in the groove of the oil filter car tridge c Tighten the new oil filter cartridge 1 to speci fication with an oil filter wrench 2 Oil filter cartridge 17 Nm 1 7 m kg 6 Check engine oil drain bolt gasket Damage Replace 7 Install engine oil drain bolt 8 Fill crankcase with the specified amount of the recom mended engine oil Quantity Total amount 4 3 L Without oil filter cartridge re plac...

Page 105: ...heck the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to CHECKING THE OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification Oil gallery bolt 5 Nm 0 5 m kg EAS00077 MEASURING THE ENGINE OIL PRESSURE 1 Check engine oil level Below the minimum level mark ...

Page 106: ...easure Sengine oil pressure at the following conditions Engine oil pressure 250 350 kPa 2 5 3 5 kg cm2 2 5 3 5 bar Engine speed Approx 5 000 r min Engine oil temperature 100_C Out of specification Adjust Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter ...

Page 107: ...ls to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the clutch fluid and could cause vapor lock Clut...

Page 108: ...epeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Remove left rear cylinder side cover 1 2 Bleed hydraulic clutch system a Add the recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir di aphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly squeeze the...

Page 109: ...tch system check the clutch operation EAS00086 CLEANING THE AIR FILTER ELEMENT 1 Remove under cover 1 2 Remove air filter case 1 3 Remove air filter case cover 4 Remove air filter element 5 Clean air filter element Apply compressed air to the inner surface of the air filter element 6 Check air filter element Damage Replace ...

Page 110: ...ect the carburetor tuning leading to poor en gine performance and possible overheat ing Make sure that the air filter element is properly installed in the air filter case Make sure that the air filter is installed with its mesh side facing towards the rear of the mo torcycle 8 Install air filter case 9 Connect breather hoses EAS00095 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The followin...

Page 111: ...SSENGER SEATS and FUEL TANK 2 Remove left side cover right side cover 3 Remove rear inner cover 4 Check fuel hose 1 Cracks damage Replace fuel filter 2 Damage dirt Replace Drain and flush the fuel tank if abrasive dam age to any components of the fuel line is evi dent The arrow mark a on the fuel filter should face to the side of the fuel pump 3 5 Install rear inner cover 6 Install left side cover...

Page 112: ...reather hose is routed correctly EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes mufflers and gaskets 1 Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 2 Check tightening torque Exhaust pipe nut 4 20 Nm 2 0 m kg Exhaust pipe bolt 5 25 Nm 2 5 m kg Muffler and muffler bracket bolt 6 30 Nm 3 0 m kg Muffler bolt ...

Page 113: ...ation of the coolant Use only distilled water Soft water may be used if distilled water is not available 4 Start the engine warm it up for several min utes and then turn it off 5 Check coolant level Before checking the coolant level wait a few minutes until it settles 6 Install side cover right EAS00104 CHECKING THE COOLING SYSTEM 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK under co...

Page 114: ... not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly rotate the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his sing sound has stopped press do...

Page 115: ...eaded hole and pull on the spark plug 8 Drain coolant from the engine and radiator 9 Check rubber washer 1 coolant drain bolt radiator 2 copper washer 3 coolant drain bolt water pump 4 Damage Replace 10 Install drain plugs cylinders coolant drain bolt radiator coolant drain bolt water pump 11 Fill cooling system with the specified amount of the recom mended coolant Recommended antifreeze High qual...

Page 116: ...clothes quick ly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water Soft water may be used if distilled wat...

Page 117: ...CKING THE COOLANT LEV EL Before checking the coolant level wait a few minutes until it settles 17 Install rear inner cover right side cover left side cover 18 Install fuel tank rider seat Refer to FUEL TANK and RIDER AND PASSENGER SEATS 19 Start the engine and let it warm up for sever al minutes 20 Turn off the engine and inspect the coolant level Refer to CHECKING THE COOLANT LEV EL Before inspec...

Page 118: ...l is lowered After adjusting the brake pedal height check that the adjuster end b is in the cen ter of the projections a c Tighten the locknut 1 to specification Locknut 26 Nm 2 6 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consi...

Page 119: ...rate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage...

Page 120: ...rake pedal less than 3 8 mm 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later When o...

Page 121: ...KE SYS TEM Bleed the hydraulic brake system whenever the system was disassembled a brake hose was loosened or removed the brake fluid level is very low brake operation is faulty Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before ap...

Page 122: ... g Loosen the bleed screw This will release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0 6 m kg k ...

Page 123: ...rcycle is upright 2 Remove final drive housing oil filler bolt 1 3 Check final drive oil level The final drive oil level should be to the bot tom brim 2 of the filler hole Below the bottom brim Add the recom mended final drive oil to the proper level Recommended final drive oil SAE 80 hypoid gear oil graded GL 4 GL 5 or GL 6 or multi purpose SAE 80W 90 hypoid gear oil 4 Install final drive housing...

Page 124: ...NG AND ADJUSTING THE STEER ING HEAD 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head 3 Remove front cowling Refer...

Page 125: ... overtighten the lower ring nut Lower ring nut final tightening torque 3 Nm 0 3 m kg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and inspect the upper and lower bearings Refer to STEERING HEAD AND HAN DLEBAR in CHAPTER 7 e Install the rubber washer 6 f Install the upper ring nut 7 g Fing...

Page 126: ...lace oil seal Oil leakage Replace 3 Hold the motorcycle upright and apply the front brake 4 Check operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Repair Refer to FRONT FORK in CHAPTER 7 EAS00156 ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over 1...

Page 127: ...passenger and ac cessories and the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and full fuel tank 394 kg Maximum load 190 kg Cold tire pressure Front tire Rear tire Up to 90 kg load 250 kPa 2 50 kgf cm2 2 50 bar 250 kPa 2 50 kgf cm2 2 50 bar 90 kg maximum load 250 kPa 2 50 kgf cm...

Page 128: ... is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufactur er and...

Page 129: ...re has been repaired or replaced be sure to tighten the tire valve stem lock nut 1 to specification For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Tire valve stem locknut 1 6 Nm 0 16 m kg EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Ch...

Page 130: ...th operation Lubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Engine oil EAS00172 LUBRICATING THE SIDESTAND L...

Page 131: ...electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion This is a sealed battery Never remove the sealing caps...

Page 132: ... negative lead 1 then the positive lead 2 3 Remove battery 4 Check battery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive terminal Tester negative lead battery negative terminal The charge state of a MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary wh...

Page 133: ...m the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery ter minal and that they are not shorted A cor rected ...

Page 134: ...ard charging current after 5 minutes re place the battery In case that charging requires more than 5 hours it is advisable to check he charging current after a lapse of 5 hours If there is any charge in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charg...

Page 135: ...f battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charging is com plete 12 7 V or less Recharging is re quired Under 12 0 V Replace the battery NOTE Set the charging time at 20 hours maximum YES NO CHECKING AND CHARGING THE BATTERY CHK ADJ Cha...

Page 136: ...ead 2 9 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 10 Lubricate battery terminals Recommended lubricant Dielectric grease 11 Install rider seat Refer to RIDER AND PASSENGER SEAT EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Re...

Page 137: ...lectrical circuit is operational d If the fuse immediately blows again check the electrical circuit Fuses Amperage rating Quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 15 A 1 Ignition fuse 10 A 1 Digital clock fuse 10 A 1 Radiator fan fuse 10 A 1 Reserve fuse 30 A 15 A 10A 5 A 1 1 2 1 Never use a fuse with an amperage rating other than that specified Improvising or us ing a...

Page 138: ...ts extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install headlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb...

Page 139: ...headlight bulb holder 8 Install bulb cover 9 Connect headlight leads 10 Install headlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting knob 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered ...

Page 140: ...ENG 4 ...

Page 141: ...REMOVING THE VALVES 4 27 CHECKING THE VALVES AND VALVE GUIDES 4 28 CHECKING THE VALVE SEATS 4 30 CHECKING THE VALVE SPRINGS 4 32 CHECKING THE VALVE LIFTERS 4 32 INSTALLING THE VALVES 4 33 CLUTCH 4 35 CLUTCH MASTER CYLINDER 4 35 CHECKING THE CLUTCH MASTER CYLINDER 4 37 ASSEMBLYNG THE CLUTCH MASTER CYLINDER 4 38 INSTALLING THE CLUTCH MASTER CYLINDER 4 38 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 4 4...

Page 142: ...PES 4 66 CHECKING THE OIL STRAINER 4 66 INSTALLING THE OIL GALLERY PIPES 4 66 ASSEMBLING THE OIL PUMP 4 67 INSTALLING THE OIL PUMP 4 67 INSTALLING THE OIL STRAINER 4 68 INSTALLING THE OIL PAN 4 68 CRANKCASE 4 69 DISASSEMBLING THE CRANKCASE 4 72 CHECKING THE CRANKCASE 4 73 ASSEMBLING THE CRANKCASE 4 74 CRANKSHAFT 4 77 REMOVING THE CRANKSHAFT ASSEMBLY 4 78 CHECKING THE CRANKSHAFT 4 78 CHECKING THE B...

Page 143: ...THE TRANSMISSION 4 103 MIDDLE GEAE 4 104 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 4 106 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 107 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 4 107 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 108 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 4 108 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 4 109 ALIGNING THE MIDDLE GEAR 4 111 ADJUSTING THE MIDDLE GEAR BAC...

Page 144: ...ENG ...

Page 145: ...d Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Drain Refer to CHARGING THE ENGINE OIL in CHAPTER 3 Drain Refer to CHARGING THE COOLANT in CHAPTER 3 Drain Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3 WARNING 64 Nm 6 4 m kg ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL LEADS CABLES AND HOSES ...

Page 146: ...Hoses coolant Side covers left and right Rear inner cover Plastic shroud Under covers Air cleaner box 2 1 2 4 2 2 1 1 2 2 Disconnect First disconnect the negative lead then the positive lead Disconnect Disconnect Disconnect For connecting reverse the disconnection procedure NOTE 64 Nm 6 4 m kg ENGINE REMOVAL ENG ...

Page 147: ...diator Engine guards and horn left and right Starter lead AIS pipe Reed valve Air cutoff valve Air cleaner 1 2 1 2 1 1 1 Remove the parts in the order listed Refer to RADIATOR in CHAPTER 5 For EUR For installation reverse the removal procedure ENGINE REMOVAL ENG RADIATOR AND AIS ...

Page 148: ...pper gaskets Shift pedal link Clutch release cylinder AIS pipe 4 2 4 4 1 1 2 Remove the parts in the order listed Disconnect Refer to CLUTCH RELEASE CYLINDER For installation reverse the removal procedure Refer to CARBURETORS in CHAPTER 6 30 Nm 3 0 m kg 20 Nm 2 0 m kg 25 Nm 2 5 m kg 30 Nm 3 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg ENGINE REMOVAL ENG MUFFLERS AND EXHAUSTS ...

Page 149: ...d Spring rear brake switch Reservoir tank rear brake Brake pedal assembly 2 1 1 1 1 1 Remove the parts in the order listed Disconnect For OCE For OCE Disconnect Refer to FRONT AND REAR BRAKES in CHAPTER 7 For installation reverse the removal procedure 52 Nm 5 2 m kg ENGINE REMOVAL ENG HORN AND BRAKE PEDAL ...

Page 150: ...upper Bolts down tube Down tube right side 2 1 1 1 6 4 4 1 Remove the parts in the order listed Place a suitable stand under the frame and engine Securely support the motorcycle so there is no danger of it falling over Disconnect NOTE WARNING 78 Nm 7 8 m kg 40 Nm 4 0 m kg 40 Nm 4 0 m kg 45 Nm 4 5 m kg Disconnect Refer to INSTALLING THE ENGINE M10 30 4 M10 70 6 M10 70 4 M12 75 ENGINE REMOVAL ENG EN...

Page 151: ...assembly 1 2 1 Remove the engine assembly from the right side of the motorcycle For installation reverse the removal procedure NOTE Refer to INSTALLING THE ENGINE 78 Nm 7 8 m kg 40 Nm 4 0 m kg 40 Nm 4 0 m kg 45 Nm 4 5 m kg M10 30 4 M10 70 6 M10 70 4 M12 75 ENGINE REMOVAL ENG ...

Page 152: ... 6 Do not fully tighten the bolts 3 Tighten the bolts in the following order 1 Bolts rear 1 78 Nm 7 8 m kg 2 Down tube right 2 45 Nm 4 5 m kg 3 Engine bracket 3 40 Nm 4 0 m kg 4 Bolts front lower 4 40 Nm 4 0 m kg 5 Bolts front upper 5 40 Nm 4 0 m kg 6 Bolts cylinder head stay 6 64 Nm 6 4 m kg 4 Install shift arm 1 Align the punch mark a in the shift shaft with the slot b in the shift arm Align the...

Page 153: ...vel surface Securely support the motorcycle so there is no danger of it falling over Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3 Refer to CLEANING THE AIR FILTER in CHAPTER 3 Refer to CARBURETORS in CHATER 6 Drain Refer to CHANGING THE COOLANT in CHAPTER 3 WARNING 18 Nm 1 8 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg M6 23 16 M6 30 4 M6 14 12 CAMSHAFTS ENG CAMSHAFTS CYLINDE...

Page 154: ...rome cylinder head covers Spark plugs Bolts cylinder head covers Cylinder head covers Gaskets cylinder head covers 4 2 8 4 16 2 2 Disconnect Disconnect For installation reverse the removal procedure 18 Nm 1 8 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg M6 23 16 M6 30 4 M6 14 12 CAMSHAFTS ENG ...

Page 155: ...and rubber Bolts camshaft sprockets Camshaft caps Camshafts intake and exhaust Camshaft sprockets 1 1 2 2 2 4 8 16 4 4 Remove the parts in the order listed Refer to CYLINDER HEAD COVERS For installation reverse the removal procedure 10 Nm 1 0 m kg 20 Nm 2 0 m kg 7 Nm 0 7 m kg 12 Nm 1 2 m kg 20 Nm 2 0 m kg M6 28 M6 20 4 M6 12 2 M7 12 8 M6 40 32 Refer to REMOVING INSTALLING THE CAMSHAFTS CAMSHAFTS E...

Page 156: ...e 1 timing plug 2 3 Align and I marks on the generator rotor with the stationary pointer on the crankcase cover a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the and I marks a with the stationary pointer b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 4 Loosen cap bolt 1 5 Remove timing chain t...

Page 157: ...ts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in When loosening the camshaft cap bolts make sure that the camshaft lobes do not touch the valve lifters 9 Remove intake camshaft exhaust camshaft To prevent the timing chain from falling into the crankcase fasten it with a wire to it 10 Remove camshaft sprockets ...

Page 158: ...0_ i e 360_ plus an addi tional 70_ 2 Align S mark with the stationary pointer EB401401 CHECKING THE CAMSHAFTS 1 Check Scamshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Scamshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake a 35 65 mm b 27 85 mm Exhaust a 35 65 mm b 27 85 mm 3 Measure Scamshaft runout Out...

Page 159: ...stall the dowel pins and camshaft caps Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Camshaft cap bolt 10 Nm 1 0 m kg d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure camshaft journal diameter a Out o...

Page 160: ...shaft sprockets and the respective tim ing chain as a set 3 Check timing chain guide exhaust side timing chain guide intake side timing chain guide top side Damage wear Replace the defective part s EAS00211 CHECKING THE TIMING CHAIN TENSION ERS The following procedure applies to both of the timing chain tensioners 1 Check timing chain tensioner Cracks damage Replace 2 Check one way cam operation R...

Page 161: ... chain tensioner Then install the front cylinder cam shafts and related parts Rear cylinder 1 Install intake camshaft exhaust camshaft Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing a Install the camshaft sprockets onto the cam shafts Refer to the camshaft sprocket installation steps below Make sure that the REAR marks a on the camshaft sprockets ...

Page 162: ...all hole in the camshaft is aligned with the camshaft cap mark e Apply engine oil onto the threads of the cam shaft cap bolts f Tighten the camshaft cap bolts The camshaft caps are numbered from right to left First tighten intake and exhaust camshaft cap bolts 3 1 and finally 4 Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out The camshaft cap bol...

Page 163: ...in onto the exhaust cam shaft sprocket f Install the exhaust camshaft sprocket with the REAR mark facing out and then finger tighten the camshaft sprocket bolts Align the EX mark hole in the exhaust cam shaft sprocket with the thread hole in the cam shaft g Turn the exhaust camshaft so that the mark o small hole on the camshaft is aligned with the mark on the camshaft cap h To remove the timing ch...

Page 164: ...n tensioner bolt 12 Nm 1 2 m kg d Install the spring 3 washer 2 and cap bolt 1 Cap bolt 20 Nm 2 0 m kg 4 Turn crankshaft several turns counterclockwise 5 Check TDC mark a Make sure that the TDC mark on the genera tor rotor is aligned with the crankcase edge b camshaft timing punch mark c o small hole Make sure hat the punch marks in the cam shafts are aligned with the marks d on the camshaft caps ...

Page 165: ...side 3 Stiming chain guide exhaust side 4 8 Lubricate Stiming chain Scamshaft sprockets Scamshafts Svalve pads Recommended lubricant Engine oil Front cylinder When installing the front cylinder camshafts re peat the rear cylinder camshaft installation pro cedure However note the following points 1 Install Sexhaust camshaft Sintake camshaft a From the and I marks turn the crank shaft counterclockwi...

Page 166: ...Install intake camshaft sprocket exhaust camshaft sprocket onto the camshafts a Align the mark a on the generator rotor with the crankcase edge b b Install the camshaft sprocket with the FRONT mark facing out and then finger tighten the camshaft sprocket bolts c Turn the intake and exhaust camshafts and align the camshaft timing marks c o big hole with the camshaft cap marks d 3 Measure valve clea...

Page 167: ...delivery pipes Cylinder heads Timing chain dampers Gaskets cylinder heads Dowel pins 2 2 2 2 2 2 4 Remove the parts in the order listed Refer to ENGINE REMOVAL For installation reverse the removal procedure Refer to CAMSHAFTS Refer to INSTALLING THE CYLINDER HEADS 30 Nm 3 0 m kg 30 Nm 3 0 m kg 30 Nm 3 0 m kg M10 28 M8 22 2 CYLINDER HEADS ENG CYLINDER HEADS ...

Page 168: ...damper Damage wear Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 03 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cylin der head as follows d Place a 400 X 600 grit wet sandpaper on the surface plate and resurface the cylinder...

Page 169: ...ith a wire Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern Install the timing chain guide intake side into the timing chain guide slot in the cylinder head Front cylinder When installing the front cylinder head repeat the rear cylinder head installation procedure However note the following points 1 Install cylinders nuts ...

Page 170: ...ing retainers Valve springs inner outer Valves intake exhaust Valve spring seats Oil seals Valve guides 16 16 32 16 16 16 8 8 16 16 16 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to CAMSHAFTS Refer to CYLINDER HEADS For installation reverse the removal procedure Refer to REMOVING INSTALLING THE VALVES VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS ...

Page 171: ...lifter and valve pad so that they can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 3 Remove valve cotters 1 Remove the valve co...

Page 172: ...g procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a X Valve stem diameter b Out of specification Replace the valve guide Valve stem to valve guide clearance Intake 0 010 X 0 037 mm Limit 0 08 mm Exhaust 0 025 X 0 052 mm Limit 0 1 mm 2 Replace Svalve guide To ease valve guide remov...

Page 173: ...btain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover 6 0 mm YM 4064 A 90890 04064 Valve guide installer 6 0 mm YM 04065 A 90890 04065 Valve guide reamer 6 0 mm YM 04066 90890 04066 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape...

Page 174: ...re applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head Valve seat width Intake 0 9 X 1 1 mm Limit 1 4 mm Exhaust 0 9 X 1 1 mm Limit 1 4 mm a Apply Mechanic s blueing dye Dykem b onto the valve face b Install th...

Page 175: ...inder head d Turn the valve unit the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hand e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound f...

Page 176: ...EX 37 3 mm Limit 35 3 mm outer IN EX 39 45 mm Limit 37 25 mm 2 Measure compressed spring force a Out of specification Replace the valve spring b Installed length Compressed spring force installed inner IN EX 4 57 5 37 kg outer IN EX 10 1 11 9 kg 3 Measure valve spring tilt a Out of specification Replace the valve spring Spring tilt limit inner IN EX 2 5 1 6 mm outer IN EX 2 5 1 7 mm EAS00242 CHECK...

Page 177: ...ubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve 1 lower spring seat 2 oil seal 3 New valve spring 4 upper spring seat 5 into the cylinder head Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install valve cotters 1 Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compresso...

Page 178: ...a soft face hammer Hitting the valve tip with excessive force could damage the valve 6 Install valve lifter 1 valve pad 2 Apply molybdenum disulfide oil onto the valve lifter and valve pad The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 179: ... bolt Copper washers Clutch hose Master cylinder Clutch switch 1 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Disconnect For installation reverse the removal procedure NOTE Before removing the master cylinder drain the clutch fluid from the entire clutch system Refer to INSTALLING THE CLUTCH MASTER CYLINDER 30 Nm 3 0 m kg 10 Nm 1 0 m kg CLUTCH ENG CLUTCH CLUTCH MASTER CYLINDER ...

Page 180: ...lutch master cylinder Master cylinder cap Holder diaphragm Diaphragm Push rod Dust boot Circlip Washer Master cylinder kit 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 CLUTCH ENG ...

Page 181: ...arts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00308 CHECKING THE CLUTCH MASTER CYL INDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every ...

Page 182: ...d and lubricated with clean or new clutch fluid Never use solvents on internal clutch com ponents as they will cause the piston seals to swell and distort Whenever a clutch master cylinder is dis assembled replace the piston seals Recommended clutch fluid Brake fluid DOT 4 EAS00310 INSTALLING THE CLUTCH MASTER CYL INDER 1 Install clutch master cylinder 1 Install the clutch lever holder with the UP...

Page 183: ...ster cylinder reservoir with the specified amount of the recom mended clutch fluid Recommended clutch fluid Brake fluid DOT 4 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical react...

Page 184: ...hat the top of the reser voir is horizontal 5 Bleed clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in CHAPTER 3 6 Check clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in CHAPTER 3 7 Check clutch lever operation Soft spongy feeling Bleed the clutch sys tem Refer to BLEEDING THE HYDRAULIC CL...

Page 185: ...lease cylinder 1 2 1 2 1 Remove the parts in the order listed Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Refer to STARTER CLUTCH AND GENERATOR For installation reverse the removal procedure NOTE Before removing the clutch release cylinder or the master cylinder drain the clutch fluid from the entire clutch system 12 Nm 1 2 m kg Refer to INSTALLING THE CLUTCH RELEASE CYLINDER 25 Nm 2 5 m kg CLUT...

Page 186: ... Oil seal Piston release cylinder Spring Piston seal Air bleed screw 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure Never attempt to pry out the piston 1 CAUTION 2 3 4 5 6 Nm 0 6 m kg Refer to DISASSEMBLING THE CLUTCH RELEASE CYLINDER ...

Page 187: ...e piston is expelled from the clutch release cylinder Never try to pry out the clutch release cylin der piston b Remove the clutch release cylinder piston seals EAS00314 CHECKING THE CLUTCH RELEASE CYL INDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every two years Clutch fluid Every two years and whenever the clutch is disassembled 2 Check clutch r...

Page 188: ... fluid DOT 4 Replace the piston seal and oil seal when ever the clutch release and master cylinder are disassembled 1 Install piston seal 1 New spring 2 piston release cylinder 3 oil seal 4 New EAS00315 INSTALLING THE CLUTCH RELEASE CYL INDER 1 Install copper washers New clutch hose 1 union bolt 2 Proper clutch hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING W...

Page 189: ...t enter the reservoir Water will signifi cantly lower the boiling point of the clutch fluid and could cause vapor lock Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately In order to ensure a correct reading of the clutch fluid level make sure that the top of the reser voir is horizontal 3 Bleed clutch system Refer to BLEEDING THE ...

Page 190: ...l pins 2 1 1 1 2 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Refer to ENGINE REMOVAL Disconnect for OCE For OCE Refer to INSTALLING THE CLUTCH For installation reverse the removal procedure WARNING 10 Nm 1 0 m kg CLUTCH ENG CLUTCH COVER ...

Page 191: ...essure plate Push rod 2 O ring Ball Friction plates Clutch plates Nut Lock washer Clutch boss Retaining wire Clutch plate 1 1 1 1 1 1 1 7 6 1 1 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg M6 25 6 Refer to INSTALLING THE CLUTCH Refer to INSTALLING THE CLUTCH CLUCH ENG CLUTCH ...

Page 192: ...6 17 18 19 20 21 22 Friction plate Spring plate Washer Clutch housing Push rod 1 Circlip Oil pump drive gear Dowel pins 1 1 1 1 1 1 1 2 For installation reverse the removal procedure Refer to INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg M6 25 6 ...

Page 193: ... nut Universal clutch holder YM 91042 90890 04086 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm Limit ...

Page 194: ... Less than 0 2 mm EAS00283 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate 1 Damage Replace clutch spring 2 clutch spring plate seat 3 EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation EAS00285 CHECKING THE CLUTCH BOSS ...

Page 195: ... INSTALLING THE CLUTCH 1 Install clutch spring plate 1 friction plate 2 clutch plate 3 wire circlip New 4 Install the clutch spring plate with the OUT SIDE mark facing towards the clutch cover 2 Tighten clutch boss nut 1 While holding the clutch boss 2 with the univer sal clutch holder 3 tighten the clutch boss nut Universal clutch holder YM 91042 90890 04086 3 Bend the lock washer tab along a fla...

Page 196: ...lates with the two punch marks b in the clutch housing 6 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Recommended lubricant Lithium soap base grease 7 Install long clutch push rod 1 ball 2 short clutch push rod 3 along with a new O ring 4 8 Install pressure plate 1 Align the punch mark a in the clutch boss with the punch mark b in the pressure plat...

Page 197: ... spring plate seat 1 clutch spring plate 2 clutch spring plate retainer 3 clutch spring plate bolts 4 Tighten the clutch spring plate bolts in stages and in a crisscross pattern 10 Install clutch cover 1 Tighten the clutch cover bolts in stages and in a crisscross pattern ...

Page 198: ...ver Gasket Dowel pins Shift pedal link 1 1 2 1 Remove the parts in the order listed Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Refer to ENGINE REMOVAL Loosen the bolts in a crisscross pattern Disconnect For installation reverse the removal procedure NOTE 10 Nm 1 0 m kg 10 Nm 1 0 m kg M6 20 M6 35 3 M6 45 3 SHIFT SHAFT ENG SHIFT SHAFT SHIFT ARM ...

Page 199: ...ft and stopper lever B Shift shaft assembly Circlip Washer Torsion spring Stopper lever Return spring 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 10 Nm 1 0 m kg M6 18 Refer to INSTALLING THE SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER ...

Page 200: ...0330 CHECKING THE STOPPER LEVER 1 Check stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever EAS00333 INSTALLING THE SHIFT SHAFT 1 Install stopper lever spring 1 stopper lever 2 2 Install shift shaft Install the stopper lever spring and stopper le ver as shown Hook the end of the shift lever spring onto the shift lever spring stopper 1 ...

Page 201: ... Dowel pins Pickup coil lead stator coil lead Cable holder Pickup coil 1 1 1 2 1 1 1 1 Remove the parts in the order listed Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Refer to ENGINE REMOVAL Refer to SHIFT SHAFT Refer to CRANKCASE COVER LEFT SIDE Remove from the cable clamp 52 Nm 5 2 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg M6 30 3 M10 32 2 M6 45 7 M6 60 4 STARTER CLUTCH AND GENERATOR ENG STARTER CLUT...

Page 202: ...b Part Q ty Remarks 8 9 Plate stater coil Stater coil 1 1 For installation reverse the removal procedure 52 Nm 5 2 m kg 7 Nm 0 7 m kg 10 Nm 1 0 m kg M6 30 3 M10 32 2 M6 45 7 M6 60 4 STARTER CLUTCH AND GENERATOR ENG ...

Page 203: ...lutch assembly Starter motor lead Starter motor 2 3 1 1 1 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE GENERATOR Disconnect For installation reverse the removal procedure Refer to INSTALLING THE GENERATOR 10 Nm 1 0 m kg 24 Nm 2 4 m kg 130 Nm 13 0 m kg M6 25 M6 55 M8 25 6 M12 48 STARTER CLUTCH AND GENERATOR ENG STARTER CLUTCH AND GENERATOR ...

Page 204: ...er YS 01880 90890 01701 2 Remove generator rotor 1 with the flywheel puller set 2 woodruff key Flywheel puller set YU 33270 90890 01362 Adopter YM 33282 90890 04089 EAS00350 CHECKING THE STARTER CLUTCH 1 Check starter clutch rollers 1 Damage wear Replace 2 Check starter clutch idler gear 1 starter clutch drive gear 2 starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Che...

Page 205: ... B it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced EAS00354 INSTALLING THE GENERATOR 1 Install starter wheel gear 1 woodruff key 2 generator rotor 3 washer 4 pin 5 generator rotor bolt 6 Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key ...

Page 206: ...et tabs Oil pipe Oil gallery pipe Oil filter 1 1 1 2 1 1 1 2 1 2 1 1 1 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to CLUTCH Refer to REMOVING INSTALLING THE OIL PAN Refer to INSTALLING THE OIL PUMP Straighten For installation reverse the removal procedure 24 Nm 2 4 m kg M8 95 10 Nm 1 0 m kg M6 25 3 10 Nm 1 0 m kg M6 30 12 10 Nm 1 0 m kg M6 16 12 Nm 1 2 m kg M6 12 17 Nm 1 7 ...

Page 207: ...Oil strainer housing Gasket Circlip Driven gear oil pump Gear housing Spring Relief valve Inner rotor Shaft Pin Outer rotor 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to ASSEMBLING THE OIL PUMP 1 10 2 3 4 5 6 7 8 9 11 12 OIL PAN AND OIL PUMP ENG ...

Page 208: ...4 64 Order Job Part Q ty Remarks Dowel pins Oil pump housing 2 1 For assembly reverse the disassembly procedure Refer to ASSEMBLING THE OIL PUMP 13 14 OIL PAN AND OIL PUMP ENG ...

Page 209: ... damage wear Replace the de fective part s 2 Measure inner rotor to outer rotor tip clearance A outer rotor to oil pump housing clearance B oil pump housing to inner rotor and outer rotor clearance C Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 X 0 12 mm Limit 0 17 mm Outer rotor to oil pump housing clearance 0 ...

Page 210: ...The following procedure applies to all of the oil gallery pipes 1 Check oil gallery pipe 1 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 oil strainer housing 2 Damage Replace Contaminants Clean with engine oil INSTALLING THE OIL GALLERY PIPES 1 Install oil gallery pipe 1 oil pipe 2 Always use new O rings 2 Bend bracket t...

Page 211: ... 2 Install oil pump shaft 1 to the oil pump cover 2 pin 3 inner rotor 4 outer rotor 5 pin 6 oil pump housing screw When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a on the in ner rotor 4 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 After tightening the bolts make sure that the oil pump turns sm...

Page 212: ...er cover 2 relief valve The arrow a on the oil strainer cover must point towards the rear of the engine EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket New oil pan 1 oil level switch 2 engine oil drain bolt Always use new copper washers Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch s O ring with en gine oil ...

Page 213: ... oil pump assembly Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to CYLINDER HEADS Refer to WATER PUMP in CHAPTER 5 Refer to CLUTCH Refer to SHIFT SHAFT AND STOPPER LEVER Refer to CLUTCH RELEASE CYLINDER Refer to STARTER CLUTCH AND GENERATOR Refer to OIL PAN AND OIL PUMP 25 Nm 2 5 m kg M8 21 4 30 Nm 3 0 m kg M8 30 3 7 Nm 0 7 m kg M6 13 3 CRANKCASE ENG CRANKCASE ...

Page 214: ...earing Middle driven gear assembly Shims Crankcase upper Crankcase lower 1 2 1 2 4 1 1 For installation reverse the removal procedure Refer to ASSEMBLING THE CRANKCASE Refer to DISASSEMBLING ASSEMBLING THE CRANKCASE 25 Nm 2 5 m kg M8 21 4 30 Nm 3 0 m kg M8 30 3 7 Nm 0 7 m kg M6 13 3 CRANKCASE ENG ...

Page 215: ...rain plugs cylinders Oil pipe Bracket timing chain damper Circlip Oil pump drive shaft Idler gear oil pump 1 1 2 1 4 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 10 Nm 1 0 m kg M6 16 4 10 Nm 1 0 m kg M6 40 6 18 Nm 1 8 m kg M8 22 24 Nm 2 4 m kg M8 25 CRANKCASE ENG ...

Page 216: ...lustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence 2 Remove upper crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly 3 Remove dowel pins O ring 4 Remove crankshaft journal l...

Page 217: ...n Blow out with compressed air 4 Check crankcase breather cover 1 crankcase breather spacer 2 Cracks damage Replace oil pipe crankcase breather 3 Blockage Blow out the passages with compressed air 5 Check drain plugs cylinders 1 Cracks wear damage Replace 6 Check oil pipe 1 Blockage Blow out the passages with compressed air union bolt 2 Blockage Blow out the passages with compressed air 7 Check id...

Page 218: ... 1 SIdler gear oil pump 2 Scirclip 3 New 2 Install Sbracket timing chain damper 1 Soil pipe 2 Apply LOCTITER to the bracket bolt 3 Install Sdrain plugs cylinders 2 4 Install Soil pipe 1 Srubber gaskets 2 New Scrankcase breather spacer 3 Scrankcase breather cover 4 Always use new O rings 5 Install Scrankcase breather assembly 4 ...

Page 219: ...within 2 X 3 mm of the crankshaft journal bearings 8 Install upper crankcase 1 onto the lower crankcase 2 Before tightening the crankcase bolts make sure that the transmission gears shift cor rectly when the shift drum assembly is turned by hand 9 Install final drive assembly Refer to MIDDLE GEAR The arrow on the final drive assembly must point towards the upper crankcase 10 Install middle driven ...

Page 220: ...8 and 30 SInstall the cable holder on bolts 22 and 32 SInstall the washers on bolts 2 and 4 X 8 A Upper crankcase B Lower crankcase M10 bolt 40 Nm 4 0 mSkg M8 bolt 24 Nm 2 4 mSkg M6 bolt 12 Nm 1 2 mSkg 12 Install Smiddle driven shaft bearing housing retain ers 1 Smain axle bearing retainer 2 Always use new screws SApply LOCTITER on to the retainer screws SAfter tightening the middle driven shaft b...

Page 221: ...ase separation Balancer shaft Balancer shaft bearings Crankshaft Timing chains Main journal bearings 1 4 1 2 8 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CRANKSHAFT CRANKSHAFT ENG CRANKSHAFT ...

Page 222: ...ear Replace the crankshaft 3 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 020 X 0 038 mm Limit 0 1 mm Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine d...

Page 223: ...rankshaft journal Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings 3 into the lower crankcase and assemble the crankcase halves Align the projections a of the crankshaft jour nal lower bearings with the notches b in the crankcase Do not move the crankshaft until the clearance measurement has been completed ...

Page 224: ... 22 and 32 Install the washers on bolts 2 and 4 X 8 A Upper crankcase B Lower crankcase M 10 bolt 40 Nm 4 0 m kg M 8 bolt 24 Nm 2 4 m kg M 6 bolt 12 Nm 1 2 m kg g Remove the lower crankcase and the crank shaft journal lower bearings h Measure the compressed Plastigauge width c on each crankshaft journal If the clearance is out of specification select replacement crankshaft journal bearings ...

Page 225: ...nal bearing sizes J1 X J4 refer to the bearings shown in the crankshaft illustration If J1 X J4 are the same use the same size for all of the bearings For example if the crankcase J and crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is Bearing size for J1 J1 crankcase J1 crankshaft web 6 2 4 green CRANKSHAFT JOURNAL BEARING COLOR CODE 1 blue 2 black 3 brown 4 gre...

Page 226: ...ear Replace the balancer shaft 3 Measure balancer shaft journal to balancer shaft jour nal bearing clearance Out of specification Replace the balancer shaft journal bearings Balancer shaft journal to balan cer shaft bearing clearance 0 020 X 0 048 mm Do not interchange the balancer shaft bear ings To obtain the correct balancer shaft jour nal to balancer shaft journal bearing clear ance and preven...

Page 227: ...f the balancer shaft journal upper bearings with the notches b in the crankcase d Put a piece of Plastigauge 1 on each ba lancer shaft journal Do not put the Plastigauge over the oil hole in the balancer shaft journal e Install the balancer shaft journal lower bear ings 1 into the lower crankcase and as semble the crankcase halves Align the projections a of the balancer shaft journal lower bearing...

Page 228: ...nd 32 Install the washers on bolts 2 and 4 8 A Upper crankcase B Lower crankcase M 10 bolt 40 Nm 4 0 m kg M 8 bolt 24 Nm 2 4 m kg M 6 bolt 12 Nm 1 2 m kg g Remove the lower crankcase and the ba lancer shaft journal lower bearings h Measure the compressed Plastigauge width c on each balancer shaft journal If the clearance is out of specification select re placement balancer shaft journal bearings ...

Page 229: ...nal bearing sizes P1 P2 refer to the bearings shown in the ba lancer shaft illustration If P1 P2 are the same use the same size for all of the bearings For example if the crankcase P1 and balancer weight P1 numbers are 6 and 2 respective ly then the bearing size for P1 is Bearing size for P1 P1 crankcase P1 balancer weight 6 2 4 green BALANCER SHAFT JOURNAL BEARING COLOR CODE 1 blue 2 black 3 brow...

Page 230: ...nstall each crankshaft journal up per bearing in its original place 2 Install timing chain 1 onto the crankshaft sprocket crankshaft assembly 2 Pass the timing chain through the timing chain cavity To prevent the timing chain from falling into the crankcase fasten it with a wire EAS00410 INSTALLING THE BALANCER SHAFT 1 Install balancer shaft Align the punch mark a in the balancer shaft drive gear ...

Page 231: ...g rods pistons Piston pin clips Piston pins Pistons Piston rings 8 4 8 4 4 8 4 4 12 Remove th parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CONNECTING RODS AND PISTONS Refer to INSTALLING THE PISTONS AND CONNECTING RODS 36 Nm 3 6 m kg CONNECTING RODS AND PISTONS ENG CONNECTING RODS AND PISTONS ...

Page 232: ...oving the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crank case For reference during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove i...

Page 233: ...l scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge a 40 mm from the top of the cylinder Measure cylinder bore C by taking side to side and front to back measurements of the cyl inder Then find the average of the measure ments b If out of specification rebore or rep...

Page 234: ...arance with the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 055 0 069 mm Limit 0 15 mm f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS00264 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a...

Page 235: ... piston ring end gap Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 20 0 35 mm Limit 0 55 mm 2nd ring 0 35 0 50 mm Limit 0 8 mm Oil ring 0 3 0 9 mm Piston ring oversize Top and 2nd piston rings The size of the top and 2nd oversize piston rin...

Page 236: ...k pison pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 18 991 19 000 mm 3 Calculate piston pin to piston clearance Out of specification Replace the piston pin Piston pin to piston clearance Piston pin bore size b Piston pin outside diameter a...

Page 237: ...he connecting rods b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge on the crank shaft pin d Assemble the connecting rod halves Do not move the connecting rod or crankshaft until the cleara...

Page 238: ...HE CONNECTING RODS Connecting rod nut 36 Nm 3 6 m kg f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS g Measure the compressed Plastigauge width 1 on the crankshaft pin If the clearance is out of specification select replacement big end bearings 2 Select big end bearings P1 P2 The numbers A stamped into the crankshaft web and the numbers 1 on the connecting ro...

Page 239: ...il ring rail 3 upper oil ring rail 4 oil ring expander 5 Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 2 Install piston 1 piston pin 2 piston pin clip New 3 Apply engine oil onto the piston pin 4 Y mark 5 EX exhaust side 6 IN intake side 7 Projection 3 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil ...

Page 240: ... each bearing in its original place 6 Install Piston ring compressor 1 Piston ring compressor YM 8037 90890 05158 7 Install connecting rod and piston assembly The stamped Y mark 1 on the No 2 and No 4 connecting rods should face towards the right side of the crankcase The stamped Y mark 1 on the No 1 and No 3 connecting rods should face towards the left side of the crankcase A Top view 2 Front 3 Y...

Page 241: ...olt threads and nut surfaces The projection 1 on the connecting rod cap should face toward the crankshaft web When tightening the nuts be sure to use an F type torque wrench Without pausing tighten to full torque specification Apply continuous torque be tween 3 0 and 3 6 m kg Once you reach 3 0 m kg DO NOT STOP TIGHTENING until fi nal torque is reached If the tightening is in terrupted between 3 0...

Page 242: ...ng Oil seal Bearing circlips Guide bars Shift forks Neutral switch Shift cam retainer Shift cam 1 1 1 1 2 2 3 1 1 1 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure Refer to INSTALLING THE SHIFT FORKS 7 Nm 0 7 m kg M6 13 3 M5 9 3 4 Nm 0 4 m kg Refer to INSTALLING THE TRANSMISSION TRANSMISSION ENG TRANSMISSION ...

Page 243: ...rive pinion gear assembly Circlip Bearing 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle Plug 2nd wheel gear Washer Circlip 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to MIDDLE GEAR 1 10 2 3 4 5 6 7 8 9 11 12 TRANSMISSION ENG ...

Page 244: ...ring Circlip Bearing Main axle 4th pinion gear Washer Circlip 2nd 3rd pinion gear 5th pinion gear Washer Circlip Bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the disassembly procedure 13 14 15 16 17 18 19 20 21 22 23 24 25 TRANSMISSION ENG ...

Page 245: ...S00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shi...

Page 246: ...mit 0 08 mm 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Drive axle runout limit 0 08 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective whe...

Page 247: ...iner 2 SApply LOCTITER 648 to the shift cam retain er screws SRotate the shift cam to the neutral position 3 Install Sneutral switch 1 Apply grease to the neutral switch Always use a new O ring EAS00428 INSTALLING THE TRANSMISSION 1 Install Smain axle assembly 1 Sdrive axle assembly 2 SMake sure that the bearing circlips 3 are in serted into the grooves in the lower crankcase SThe bearing pin 4 ar...

Page 248: ...ing Shims O ring Bearing Collapsible collar Spacer Bearing Middle drive shaft Retainer 1 1 1 1 1 2 1 1 1 1 1 1 1 Remove the parts in the ordr listed Refer to CRANKCASE Refer to TRANSMISSION Refer to DISASSEMBLING ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 90 Nm 9 0 m kg 110 Nm 11 0 m kg 30 Nm 3 0 m kg Refer to DISASSEMBLING ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY MIDDLE GEAE ENG MIDDLE GEAE ...

Page 249: ... Middle drive pinion gear Damper cam Damper spring Spring seat Bearing Nut Bearing 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING THE MDDLE DRIVE SHAFT ASSEMBLY 90 Nm 9 0 m kg 110 Nm 11 0 m kg 30 Nm 3 0 m kg MIDDLE GEAR ENG ...

Page 250: ...the spring re tainers Damper spring compressor YM 33286 90890 04090 2 Straighten the stake 3 Remove middle drive shaft nut 1 bearing 2 middle drive shaft 3 a Secure the middle drive shaft holder in a vice b Loosen the middle drive shaft nut with the middle drive shaft nut wrench 4 Middle drive shaft nut wrench YM 04054 90890 04054 c Remove the middle drive shaft nut and bear ing ...

Page 251: ...driven yoke as shown press the bearing into the pipe It may be necessary to lightly tap the universal joint driven yoke with a center punch d Repeat the above steps to remove the oppo site side s bearing e Separate the universal joint yokes 2 Loosen middle driven shaft nut While holding the universal joint driven yoke with the universal joint holder 1 loosen the middle driven shaft nut Universal j...

Page 252: ...ck bearings Damage pitting Replace the middle drive shaft bearing housing assembly 3 Check O ring oil seal Damage Replace the defective part s 4 Check universal joint movement Rough movement Replace the universal joint EAS00441 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Tighten middle drive shaft nut Lock the threads on the middle drive shaft nut by staking them with a center punch 1 ...

Page 253: ...s procedure for the first time be sure to have at least one extra collaps ible collar on hand SIf there is insufficient preload on the bearings the middle driven shaft can move slightly al lowing oil to leak past the seal In addition to torquing the middle driven shaft nut to specifi cation you must also check the spinning torque bearing preload 1 Install Sbearing outer race into the middle driven...

Page 254: ...h enough tighten the middle driven shaft nut slightly and check the spinning torque again Re peat these steps until the proper spinning torque is obtained If the spinning torque specification is ex ceeded remove the middle driven shaft as sembly install a new collapsible collar and repeat steps 1 3 Middle driven gear spinning torque 0 4 0 5 Nm 0 04 0 05 m kg 4 Install universal joint driven yoke c...

Page 255: ...ings If a needle is out of place the yoke will not go all the way onto the bearings 6 Press each bearing into the universal joint driven yoke assembly with a socket of the proper size The bearings must be inserted far enough into the universal joint driven yoke assembly so that circlips can be installed ALIGNING THE MIDDLE GEAR 1 Select middle drive gear shim s Select the proper middle drive gear ...

Page 256: ...Therefore T A B 43 06 42 45 0 61 mm c Then calculated shim thickness is 0 61 mm Shims can only be selected in 0 05 mm incre ments therefore round off to the hundredths digit of the calculated thickness and select the appropriate shim s with the following chart Hundredths digit Rounded value 0 1 2 0 3 4 5 6 5 7 8 9 10 d Using the above example the calculated shim thickness of 0 61 mm is rounded off...

Page 257: ...hin specification as stated below Then repeat all of the previous steps Tighten the middle driven shaft bearing hous ing bolts carefully one thread turn at a time only Push in the middle driven shaft bearing housing and then tighten the bolts to specifica tion Clearance between the crankcase and the middle driven shaft bearing housing should be approximately 2 mm 0 08 in when measured with a thick...

Page 258: ...r ing housing is 0 42 mm Therefore the chart instructs you to round off the 2 to 0 Thus you should use one 0 40 mm shim Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Shims are supplied in the following thicknesses 8 Loosen Smiddle driven shaft bearing housing bolts 9 Install Sshim s R 10 Tighten Smiddle driven shaft bearing housing bolts 11 Measure Smiddle gear backlash Out of specification ...

Page 259: ...COOL 5 ...

Page 260: ...HE RADIATOR 5 3 THERMOSTAT 5 5 THERMOSTAT HOUSING 5 6 CHECKING THE THERMOSTAT 5 7 ASSEMBLING THE THERMOSTAT 5 7 INSTALLING THE THERMOSTAT 5 8 WATER PUMP 5 9 DISASSEMBLING THE WATER PUMP 5 11 CHECKING THE WATER PUMP 5 11 ASSEMBLING THE WATER PUMP 5 13 INSTALLING THE WATER PUMP 5 14 ...

Page 261: ...COOL ...

Page 262: ...r and lower Thermo unit lead Fan lead Radiator Fan motor 2 2 2 1 1 1 1 Remove the parts in the order listed Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3 Refer to CHANGING THE COOLANT in CHAPTER 3 Loosen Disconnect Disconnect For installation reverse the removal procedure 2 Nm 0 2 m kg 7 Nm 0 7 m kg M6 12 3 M6 40 2 RADIATOR COOL COOLING SYSTEM RADIATOR ...

Page 263: ...age Replace 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 95 X 125 kPa 0 95 X 1 25kgf cm2 0 95 X 1 25 bar a Install the radiator cap tester 1 to the radia tor cap Radiator cap tester YU 24460 01 90890 01325 b Apply the specified pressure for ten seconds and make sure that there is no drop in pres sure 4 Check radiator fa...

Page 264: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 265: ...e right Thermostatic hose clamp lower Thermo switch lead Thermostat 1 2 1 2 1 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in CHAPTER 3 Refer to CHANGING THE COOLANT in CHAPTER 3 Refer to CLEANING THE AIR FILTER in CHAPTER 3 Refer to REMOVING THE RADIATOR Disconnect Loosen Disconnect 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg THERMOSTAT COOL THERMOSTAT ...

Page 266: ...5 5 THERMOSTAT COOL Order Job Part Q ty Remarks 7 Radiator cap pipe 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg ...

Page 267: ...ng cover O ring housing cover Thermostatic valve Thermo switch Thermostat housing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 23 Nm 2 3 m kg 10 Nm 1 0 m kg Refer to ASSEMBLING THE THERMOSTAT THERMOSTAT COOL THERMOSTAT HOUSING ...

Page 268: ...the thermostat valve after keep the water around 95 _C in 5 X 6 minuts 1 Thermometer 2 Water 3 Thermostat 4 Container A Closes B Opens SDo not put the thermostat directly to the bottom of the container 4 SIf the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Sthermostat housing cover 1 Sthermostat housing 2 Cracks dama...

Page 269: ... or subjected to a strong impact EAS00466 INSTALLING THE THERMOSTAT 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 270: ...ing Water pump inlet pipe O ring Water pump housing Gasket Dowel pins 1 2 1 1 1 1 1 1 2 Remove the parts in the order listed Refer to CHANGING THE COOLANT in CHAPTER 3 Loosen For installation reverse the removal procedure M6 25 4 M6 30 2 M6 80 3 M6 14 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg Refer to INSTALLING THE WATER PUMP WATER PUMP COOL WATER PUMP ...

Page 271: ... Gear stopper pin Circlip Impeller Bearing Oil seal Water pump seal Damper rubber Slip ring 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to DISASSEMBLING ASSEMBLING THE WATER PUMP For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 Refer to ASSEMLING THE WATER PUMP ...

Page 272: ...ter pump seal 1 Tap out the water pump seal from the inside of the water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00474 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 2 Check impeller 1 rubber damper 2 rubber damper holder 3 Cracks damage wear Replace ...

Page 273: ...Check water pump seal 1 oil seal 2 Cracks damage wear Replace 4 Check bearing Roughness Replace 5 Check water pump driven gear Pitting wear Replace 7 Check water pump inlet pipe radiator outlet hose Cracks damage wear Replace ...

Page 274: ...e rubber damper and rub ber damper holder are flush with the impel ler Tilt limit 0 15 mm 1 Straightedge 2 Impeller 3 Install water pump seal 1 New Never lubricate the water pump seal surface with oil or grease Install the water pump seal from the special tools Before installing the water pump seal apply Yamaha bond No 1215 to the water pump housing 2 Mechanical seal installer 3 90890 04078 Middle...

Page 275: ...ide of the bearing with the number faces up Gently tap the bearing into place until it is flush with the water pump housing 5 Install impeller 1 circlip 2 6 Install key water pump driven gear Align the slot a in the water pump driven gear with the pin b 7 Install circlip 1 EAS00478 INSTALLING THE WATER PUMP 1 Install water pump housing 1 Always use a new gascket ...

Page 276: ...ump inlet pipe 2 apply a thin coat of lithium soap base grease onto the O rings 3 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 4 Check cooling system Leaks Repair or replace the faulty part 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 277: ...COOL ...

Page 278: ...CARB 6 ...

Page 279: ...MEASURING AND ADJUSTING THE FUEL LEVEL 6 10 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 11 CHECKING THE FUEL PUMP 6 14 CHECKING THE FUEL COCK 6 15 CHECKING THE FUEL COCK OPERATION 6 15 AIR INDUCTION SYSTEM 6 16 AIR INJECTION 6 16 AIR CUT OFF VALVE 6 16 AIR INDUCTION SYSTEM DIAGRAMS 6 17 CHECKING THE AIR INDUCTION SYSTEM 6 18 ...

Page 280: ...CARB ...

Page 281: ... lead Carburetour heater lead Throttle cables Air vent hoses Clamps carburetor joints Carburetor assembly 1 1 2 1 1 2 2 4 1 Remove the parts in the order listed Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3 Disconnect Disconnect Disconnect Disconnect Loosen For installation reverse the removal procedure CARBURETORS CARB CARBURETORS CARBURETORS ...

Page 282: ...the carburetors Choke knob Choke knob bracket Choke lever TPS Throttle stop screw Bracket Connecting bolt Bracket Carburetor heater Bracket Fuel feed pipe Breather hose Synchronization rod Bracket 1 2 2 1 1 1 4 1 4 1 2 1 1 1 Remove the parts in the order listed CARBURETORS CARB ...

Page 283: ...6 3 Order Job Part Q ty Remarks 15 16 Bracket Carburetors 1 4 For assembly reverse the disassembly procedure CARBURETORS CARB ...

Page 284: ...chment cover Spring Diaphragm Vacuum chamber cover Spring Vacuum piston Plastic screw Spring Plastic bushing 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The remaining steps should be followed for all four of the carburetors NOTE Refer to ASSEMBLING THE CARBURETORS 1 10 2 3 4 5 6 7 8 9 11 12 CARBURETORS CARB ...

Page 285: ...amber cover Gasket Float pin Float Needle valve Holding screw valve seat Valve seat Main jet Main jet holder Pilot jet Needle jet 1 1 1 1 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 13 14 15 16 17 18 19 20 21 22 23 24 CARBURETORS CARB ...

Page 286: ...lvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket 1 Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check O ring 3 Dam...

Page 287: ...0 Check jet needle kit 1 needle jet 2 main jet 3 pilot jet 4 pilot screw 5 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 12 Check fuel feed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with comp...

Page 288: ... following procedure applies to both of the carburetors Before assembling the carburetors wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install piston valve holder 2 Install needle jet 1 pilot jet main jet Align the slot a on the needle jet with the pro jection b on the carburetor body 3 Measure float height a Out of specification Adjust Float height 8 0 9 0 mm ...

Page 289: ... both e If both the needle valve seat and needle valve are fine adjust the float height by bend ing the float tang 1 f Check the float height again 4 Install coasting enricher diaphragm 1 coasting enricher spring 2 coasting enricher cover 3 Align the tab a on the coasting enricher dia phragm with the recess b in the carburetor body 5 Install piston valve piston valve spring vacuum chamber cover 1 ...

Page 290: ...play at the flange of the throttle grip 4 6 mm Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in CHAPTER 3 EAS00495 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level above the edge of body b 13 0 14 0 mm a Stand the motorcycle on a level surface b Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c Ins...

Page 291: ...ure the fuel level again g Repeat steps a to f until the fuel level is within specification EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR Before adjusting the throttle position sensor the engine idling speed should be properly ad justed 1 Check Sthrottle position sensor with it installed on the carburetor a Disconnect the throttle position sensor cou pler b Connect the pocket tester...

Page 292: ...he carburetor a Disconnect the throttle position sensor cou pler b Remove the throttle position sensor from the carburetor c Connect the pocket tester Ω 1 k to the throttle position sensor Tester positive lead Blue 1 Tester negative lead Black 2 d Check the throttle position sensor maximum resistance Out of specification Replace the throttle position sensor Throttle position sensor maximum resista...

Page 293: ...ance when the throttle is fully closed Throttle position sensor maximum resistance throttle is fully closed Maximum resistance 0 13 0 15 Example If the maximum resistance 5 kΩ then the throttle position sensor s maximum resistance when the throttle is fully closed should be 5 kΩ 0 13 0 15 650 750 Ω e Lift the carburetor assembly slightly out of the intake manifolds f Loosen the throttle position s...

Page 294: ... OK Fuel does not flow Replace the fuel pump c Stop the engine and check if the fuel stops flowing from the fuel hose 1 Fuel stops flowing Fuel pump is OK Fuel flows Replace the fuel pump Gasoline and its vapors are highly flam mable and explosive Therefore keep gas oline away from fire sparks or open flames e g welding equipment lighted ciga rettes Failure to check for gasoline leaks may re sult ...

Page 295: ...NG THE FUEL COCK OPERATION After installing the fuel cock check its operation 1 Check that the fuel cock lever is positioned to ON or RES 2 Place a container under the end of the fuel hose 3 Check fuel cock operation a Suck on the end of the vacuum hose Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock ...

Page 296: ...required temperature for burning the un burned exhaust gases is approximately 600_ to 700_C AIR CUT OFF VALVE The air cut off valve is operated by intake gas pressure through the diaphragm Normally this valve is opened in order to allow fresh air to flow into the exhaust port When the throttle is rapidly closed negative pressure is generated and the valve closes in order to prevent after burning V...

Page 297: ...r 1 B To cylinder 2 C To cylinder 3 D To cylinder 4 E To carburetor joint 2 F To carburetor joint 4 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Carburetor joint cylinder 2 5 Carburetor joint cylinder 4 EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 298: ... INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1 Check hoses Loose connection Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check air cutoff valve Cracks damage Replace ...

Page 299: ...CHAS 7 ...

Page 300: ...AKE PADS 7 18 REPLACING THE REAR BRAKE PADS 7 20 FRONT BRAKE MASTER CYLINDER 7 23 REAR BRAKE MASTER CYLINDER 7 25 REMOVING THE FRONT BRAKE MASTER CYLINDER 7 28 REMOVING THE REAR BRAKE MASTER CYLINDER 7 28 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 7 29 INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 30 INSTALLING THE REAR BRAKE MASTER CYLINDER 7 32 FRONT BRAKE CALIPERS 7 34 REAR BRAKE CALIPER...

Page 301: ... SWINGARM 7 70 REMOVING THE SWINGARM 7 72 CHECKING THE SWINGARM 7 72 INSTALLING THE SWINGARM 7 73 SHAFT DRIVE 7 74 SHAFT DRIVE 7 74 TROUBLESHOOTING 7 74 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 7 77 FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 7 78 FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 7 78 MEASURING THE RING GEAR BACKLASH 7 79 ADJUSTING THE RING GEAR BACKLASH...

Page 302: ...CHAS CHECKING THE DRIVE SHAFT 7 91 INSTALLING THE DRIVE SHAFT 7 91 ...

Page 303: ...CHAS ...

Page 304: ...el surface Securely support the motorcycle so there is no danger of it falling over Do not depress the brake lever when the wheel is off of the motorcycle as the brake pads will be forced shut Loosen Elevate the front wheel Place a suitable stand under the engine NOTE WARNING 78 Nm 7 8 m kg 23 Nm 2 3 m kg 19 Nm 1 9 m kg 23 Nm 2 3 m kg 25 Nm 2 5 m kg M8 25 6 M8 25 6 40 Nm 4 0 m kg FRONT WHEEL AND B...

Page 305: ...ake discs Brake disc cover right with weight 2 1 2 1 For installation reverse the removal procedure Refer to INSTALLING THE FRONT WHEEL 78 Nm 7 8 m kg 23 Nm 2 3 m kg 19 Nm 1 9 m kg 23 Nm 2 3 m kg 25 Nm 2 5 m kg M8 25 6 M8 25 6 40 Nm 4 0 m kg FRONT WHEEL AND BRAKE DISCS CHAS ...

Page 306: ... ty Remarks Disassembling the front wheel Oil seals Bearings Spacer 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 3 2 FRONT WHEEL AND BRAKE DISCS CHAS EAS00518 FRONT WHEEL ...

Page 307: ...d 2 Loosen front wheel axle 1 3 Remove brake caliper brake caliper bracket Do not squeeze the brake lever when removing the brake calipers 4 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check ti...

Page 308: ...place wheel bearings New oil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings with a general bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Use a socket 1 that matches the d...

Page 309: ...ont brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge 1 at a right angle against the brake disc surface e Measure the deflection 2 X 3 mm b below the edge of the brake disc 3 Measure brake disc thickness a Measure the brake disc thickness at a few different locations Out of specification Repl...

Page 310: ... INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs 1 Lubricate wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2 Install brake disc 1 brake disc cover 2 Apply LOCTITE 648 to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 3 Tighten wheel axle 1 wheel axle pinch bolt 2 Before tightening the w...

Page 311: ...pot a Spin the front wheel b When the front wheel stops put an X mark at the bottom of the wheel c Turn the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps b through d several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the ...

Page 312: ... heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Sfront wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 313: ... assembly 1 1 2 2 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to RIDER AND PASSENGER SEATS in CHAPTER 3 Refer to SADDLEBAGS in CHAPTER3 Disconnect For installation reverse the removal procedure WARNING 48 Nm 4 8 m kg 48 Nm 4 8 m kg 23 Nm 2 3 m kg REAR WHEEL AND BRAKE DISC CHAS EAS00551...

Page 314: ... cover right Exhaust pipe Rear brake caliper Pinch bolt Rear wheel axle nut Washer 1 1 1 1 1 1 1 1 Remove the parts in the order listed Do not depress the brake pedal when removing the rear brake caliper Loosen NOTE 150 Nm 1 5 m kg 23 Nm 2 3 m kg 40 Nm 4 0 m kg 40 Nm 4 0 m kg REAR WHEEL AND BRAKE DISC CHAS EAS00560 REAR WHEEL AND BRAKE DISC ...

Page 315: ...wheel Collar Brake disc 1 1 1 1 1 1 Elevate the rear wheel Place a suitable stand under the engine Move the wheel to the right to separate it from the final gear case For installation reverse the removal procedure NOTE 150 Nm 1 5 m kg 40Nm 4 0m kg 23 Nm 2 3 m kg 40Nm 4 0m kg REAR WHEEL AND BRAKE DISC CHAS ...

Page 316: ...r wheel Oil seal Bearing Collar Oil seal Bearing Circlip Clutch hub Hub dust seal Damper O ring 1 1 1 1 1 1 1 1 6 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 10 REAR WHEEL AND BRAKE DISC CHAS ...

Page 317: ...pedal when removing the brake caliper 3 Loosen pinch bolt 1 4 Remove wheel axle nut 2 washer wheel axle 3 Move the rear wheel to the right to separate it from the final drive housing 5 Remove rear wheel EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL AND BRAKE DISCS 2 Check tire rear wheel Damage wear Replace Refer to CHECKING THE TIRES ...

Page 318: ...WHEEL 1 Lubricate wheel axle wheel bearings oil seal lips Recommended lubricant Lithium soap base grease 2 Tighten wheel axle nut pinch bolt brake caliper bolts EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust r...

Page 319: ...ake caliper retaining bolts Brake caliper Brake pads 2 1 2 Remove the parts in the order listed For installation reverse the removal procedure 25 Nm 2 5 m kg Refer to REPLACING THE FRONT BRAKE PADS FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 320: ...caliper 1 2 2 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure NOTE Refer to REPLACING THE REAR BRAKE PADS When the brake pads have to be replaced install a new brake pad spring Replace the brake pads as a set if either is found to be worn to the wear limit 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS REAR BRAKE PADS ...

Page 321: ...ents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00582 REPLACING THE...

Page 322: ...ake pads brake pads Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install new brake pad shims onto ...

Page 323: ...BRAKE FLUID LEVEL in CHAPTER 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake pad cover 1 brake caliper 2 2 Remove brake pad clips 1 brake pad pi...

Page 324: ... install new brake pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg e Install new brake pads and a new brake pad spring The arrow mark a of the b...

Page 325: ...r bolt 40 Nm 4 0 m kg 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 326: ...aster cylinder Front brake switch 1 1 1 1 2 1 1 1 Remove the parts in the order below Before removing the master cylinder drain the brake fluid from the entire brake system For installation reverse the removal procedure NOTE 10 Nm 1 0 m kg 30 Nm 3 0 m kg New Refer to REMOVING INSTALLING THE FRONT BRAKE MASTER CYLINDER FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER ...

Page 327: ...master cylinder Master cylinder cap Holder diaphragm Master cylinder diaphragm Dust boot Circlip Master cylinder kit 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 FRONT AND REAR BRAKES CHAS EAS00585 ...

Page 328: ...linder Cotter pin Washer 1 1 1 1 1 1 1 Remove the parts in the order listed Before removing the master cylinder drain the brake fluid from the entire brake system Disconnect Disconnect NOTE 52 Nm 5 2 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg New Refer to REMOVING INSTALLING THE REAR BRAKE MASTER CYLINDER FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 329: ...arks 8 9 10 11 Clevis pin Reservoir hose Reservoir tank cover Reservoir tank 1 1 1 1 Unhook from the clamps For installation reverse the removal procedure 52 Nm 5 2 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg New FRONT AND REAR BRAKES CHAS ...

Page 330: ...er cylinder Dust boot Circlip Brake pedal push rod Master cylinder kit Cap reservoir tank Diaphragm Reservoir tank 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 FRONT AND REAR BRAKES CHAS EAS00587 ...

Page 331: ... switch 1 2 Remove union bolt 1 copper washers 2 brake hoses 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove brake pedal assembly 1 2 Remove joint bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end ...

Page 332: ...id delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace A Front B Rear 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake master cyli...

Page 333: ... brake fluid DOT 4 1 Install brake master cylinder 1 Install the brake master cylinder holder with the UP mark facing up Align the end of the brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt 2 Install copper washers 1 New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer t...

Page 334: ...e perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 Check brake fluid level ...

Page 335: ...ce Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore...

Page 336: ...st brake pedal position a Refer to ADJUSTING THE REAR BRAKE in CHAPTER 3 Brake pedal position below the top of the rider footrest 100 mm 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in CHAPTER 3 ...

Page 337: ...e the parts in the order listed Before removing the brake caliper drain the brake fluid from the entire brake system For installation reverse the removal procedure NOTE NOTE 30 Nm 3 0 m kg Refer to INSTALLING THE FRONT BRAKE CALIPERS Put the brake hose end into a container and pump out the brake fluid carefully 40 Nm 4 0 m kg 25 Nm 2 5 m kg FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS ...

Page 338: ... brake caliper Air bleed screw Caliper pistons Caliper piston seals 1 8 4 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 6 Nm 0 6 m kg Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS FRONT AND REAR BRAKES CHAS ...

Page 339: ...order listed Before removing the master cylinder drain the brake fluid from the entire brake system For installation reverse the removal procedure NOTE NOTE Refer to INSTALLING THE REAR BRAKE CALIPER Put the brake hose end into a container and pump out the brake fluid carefully 30 Nm 3 0 m kg 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER ...

Page 340: ...ake pads Air bleed screw Caliper pistons Caliper piston seals 1 2 1 4 8 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 Nm 0 6 m kg Refer to REAR BRAKE PADS Refer to DISASSEMBLING THE REAR BRAKE CALIPER FRONT AND REAR BRAKES CHAS EAS00617 ...

Page 341: ... brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the one brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper Never try to pry out the brake caliper pistons c Remove the brake caliper piston seals d Repeat the previous steps to force out the other...

Page 342: ...brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood 3 b Blow compressed air into the brake hose joint opening a to force out the left side pis tons from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston seals d Repeat the previous steps to force out the right side pistons from th...

Page 343: ...whenever the brake is disassembled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper piston seals A Front B ...

Page 344: ...ke com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper bracket brake caliper 1 temporarily copper washers New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installin...

Page 345: ...luid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid ...

Page 346: ...Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING Wh...

Page 347: ...of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt br...

Page 348: ...7 45 FRONT AND REAR BRAKES CHAS 7 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 349: ...Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to FRONT AND REAR BRAKES Refer to FRONT WHEEL Refer to FRONT COWLING in CHAPTER 3 Refer to HANDLEBAR WARNING 20 Nm 2 0 m kg 10 Nm 1 0 m kg FRONT FORK CHAS EAS00647 FRONT FORK ...

Page 350: ...fork cover washers Front fork pinch bolts lower Front fork legs Brake hose guides Lower fork covers 1 2 2 2 4 2 2 2 Refer to CHECKING THE STEERING HEAD in CHAPTER 3 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS Loosen 20 Nm 2 0 m kg 10 Nm 1 0 m kg FRONT FORK CHAS ...

Page 351: ...Damper rod rebound spring Inner tube Oil seal Seal spacer 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed 1 2 3 4 5 6 7 8 9 10 23 Nm 2 3 m kg 20 Nm 2 0 m kg Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS Drain the fork oil Pump the fork tube several times to remove the fork oil FRONT FORK CHAS EAS00648 ...

Page 352: ... Outer tube bushing Inner tube bushing Oil flow stopper Outer tube 1 1 1 1 For assembly reverse the disassembly procedure 11 12 13 14 23 Nm 2 3 m kg 20 Nm 2 0 m kg Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS FRONT FORK CHAS ...

Page 353: ...acket Refer to STEERING HEAD 3 Loosen lower bracket pinch bolt 1 Before loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove front fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove dust seal 1 oil seal clip 2 with a flat head screwdriver Do not scratch the inner tube 2 Remove damper rod bolt ...

Page 354: ...e inner tube into the outer tube during the above procedure as the oil flow stopper will be damaged EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Over the specified lim...

Page 355: ...ORK LEGS The following procedure applies to both of the front fork legs Make sure that the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability When assembling the front fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the...

Page 356: ...90 01326 4 Install outer tube bushing 1 with the fork seal driver weight 2 and adapt er 3 Fork seal driver weight YM 33963 90890 01367 Adapter YM 8020 90890 01374 5 Install washer oil seal 1 with the fork seal driver weight and adapter Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its lips Apply fork oil onto the outer ...

Page 357: ...L Front fork leg oil level from the top of the inner tube with the inner tube fully compressed and without the fork spring 117 mm Recommended oil Yamaha fork and shock oil 5W or equivalent While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 9 Install spring 1 cap bolt 2 Install the spring with the smaller pitch facing...

Page 358: ...hten the lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Install upper bracket Temporarily tighten the steering stem nut 3 Tighten lower bracket pich bolt 4 remove upper bracket 5 Install upper fork cover 1 upper bracket 2 6 Tighten cap bolt 3 Make sure that the brake hoses are routed properly 7 Adjust spring preload Refer ADJUSTING THE ...

Page 359: ...rottle grip 4 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to FRONT AND REAR BRAKES WARNING 28 Nm 2 8 m kg 10 Nm 1 0 m kg 32 Nm 3 2 m kg Refer to INSTALLING THE HANDLEBAR M6 25 M8 25 4 HANDLEBAR CHAS EAS00664 HANDLEBAR ...

Page 360: ...ndlebar switches left Grip left Handlebar bracket upper Handlebar Handlebar bracket lower 1 1 1 1 2 1 2 Refer to CLUTCH in CHAPTER 4 Disconnect For installation reverse the removal procedure Refer to INSTALLING THE HANDLEBAR 23 Nm 2 3 m kg 10 Nm 1 0 m kg 35 Nm 3 5 m kg M6 25 M8 25 4 HANDLEBAR CHAS ...

Page 361: ...ndlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken it 3 Install handlebar grip a Apply a light c...

Page 362: ...urely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 1 upper handlebar holders 2 First tighten the bolts on the front side of the handlebar holder then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position Align the match marks a on the handlebar with the upper surface...

Page 363: ...le grip 7 Carburetor 8 Cruise control actuator 4 Install right handlebar switch Align the pins a on the right handlebar switch with the holes b in the handlebar 5 Install left handlebar switch Align the mating surfaces of the left handlebar switch with the punch mark a on the handlebar 6 Install brake master cylinder Refer to FRONT AND REAR BRAKES 7 Adjust throttle cable free play cruise control c...

Page 364: ...ove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to RIDER AND PASSENGER SEATS and FUEL TANK in CHAPTER 3 Refer to HANDLEBAR Refer FRONT COWLING in CHAPTER 3 Refer to FRONT FORK Disconnect WARNING 130 Nm 13 0 m kg 52 Nm 5 2 m kg 3 Nm 0 3 m kg 1st 2nd STEERING HEAD CHAS EAS00676 STEERING HEAD...

Page 365: ... bracket Lock washer Upper ring nut Rubber washer Lower ring nut Bearing cover Bearing upper Bearing races Lower bracket Bearing lower Rubber seal 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 For installation reverse the removal procedure Refer to REMOVING THE LOWER BRAKET INSTALLING THE STEERING HAND 130 Nm 13 0 m kg 52 Nm 5 2 m kg 3 Nm 0 3 m kg 1st 2nd STEERING HEAD CHAS ...

Page 366: ... ring nut 2 Hold the lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 90890 01268 Ring nut wrench YU 33975 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearing Recommended cleaning solvent Kerosine 2 Check bearing 1 bea...

Page 367: ...roperly the steering head pipe could be damage Always replace the bearing balls and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base gre...

Page 368: ...NG HEAD CHAS NOTE NOTE 3 Install upper bracket steering stem nut Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK Temporarily tighten the upper and lower bracket pinch bolts ...

Page 369: ...onnecting arm swingarm 1 1 1 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to REAR WHEEL AND BRAKE DISC Refer to ENGIEN REMOVAL in CHAPTER 4 Refer to REAR SHOCK ABSORBER ASSEMBLY WARNING 59 Nm 5 9 m kg 48 Nm 4 8 m kg 50 Nm 5 0 m kg 50 Nm 5 0 m kg REAR SHOCK ABSORBER ASSEMBLY CHAS EAS...

Page 370: ...Part Q ty Remarks 6 7 8 Connecting arms Bolt relay arm frame Relay arm 2 1 1 For installation reverse the removal procedure 59 Nm 5 9 m kg 48 Nm 4 8 m kg 50 Nm 5 0 m kg 50 Nm 5 0 m kg REAR SHOCK ABSORBER ASSEMBLY CHAS ...

Page 371: ...over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear shock absorber assembly EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1 Check rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly bushings Damage wear Replace bolts Bends damage wear Replace 2 Check relay arm Cracks damage Replace 3 Check connecting arms Cr...

Page 372: ...ant Molybdenum disulfide grease 2 Install rear shock absorber assembly Rear shock absorber assembly upper nut 1 59 Nm 5 9 m kg Rear shock absorber assembly lower nut 2 50 Nm 5 0 m kg Relay arm to frame nut 3 50 Nm 5 0 m kg When installing the rear shock absorber as sembly lift up the swingarm Install the connecting arm front bolt from the right ...

Page 373: ...eedometer sensor leads 1 1 1 3 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to REAR WHEEL AND BRAKE DISC Refer to REAR SHOCK ABSORBER ASSEMBLY Unhook from the cable guide WARNING 100 Nm 10 0 m kg 42 Nm 4 2 m kg 16 Nm 1 6 m kg 4 SWINGARM CHAS EAS00701 SWINGARM SWINGARM ...

Page 374: ...er Job Part Q ty Remarks 6 7 Pivot shafts right and left Swingarm 2 1 For installation reverse the removal procedure Refer to REMOVING THE SWINGARM 100 Nm 10 0 m kg 42 Nm 4 2 m kg 16 Nm 1 6 m kg 4 SWINGARM CHAS ...

Page 375: ...ot bolts and locknut Locknut 100 Nm 10 0 m kg Left pivot bolt 100 Nm 10 0 m kg Right pivot bolt 7 Nm 0 7 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers and bearings Swingarm side play at the end of the swingarm 0 mm d Check the swingarm vertical movement B by moving the swingarm up and down If sw...

Page 376: ... Check spacers 1 oil seals 2 bearings 3 universal joint boot 4 Damage wear Replace EAS00712 INSTALLING THE SWINGARM 1 Lubricate drive shaft splines Recommended lubricant Lithium soap base grease 2 Lubricate bearings spacers oil seals Recommended lubricant Molybdenum disulfide grease ...

Page 377: ...ne or a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mecha nism or no power transmitted from the engine to the rear wheel A Bearing damage B Improper gear lash C Damaged gear teeth D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Small foreign objects lodged between moving parts Causes A B and C may be extremely difficult to d...

Page 378: ...sufficient gear lash is extremely destruc tive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimize gear dam age c A slight clunk evident at low speed opera tion This noise must be distinguished from normal motorcycle operation Diagnosis Possible broken gear teeth Stop riding immediately if broken gear teeth are suspected This condition...

Page 379: ...ce the wheel bearing Refer to FRONT WHEEL AND BRAKE DISCS Rear wheel bearings and shaft drive bearings are probably not damaged Repeat the test or remove and check the components Remove the rear wheel Is the wheel bearing damaged Replace the rear wheel bearing Refer to REAR WHEEL AND BRAKE DISCS Remove and check the drive shaft compo nents SHAFT DRIVE CHAS EAS00716 Troubleshooting chart When cause...

Page 380: ... normal 3 Check shaft drive housing for oil leaks a Thoroughly clean the entire motorcycle and then completely dry it b Apply a leak locating compound or dry pow der spray to the shaft drive c Test ride the motorcycle long enough to lo cate a leak Oil leak Repair or replace the faulty part s 1 Oil seal 2 O ring 3 Forward What may appear to be an oil leak on a new or fairly new motorcycle may resul...

Page 381: ...ive shaft 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Refer to REAR WHEEL AND BRAKE DISC For installation reverse the removal procedure WARNING 42 Nm 4 2 m kg FINAL DRIVE ASSEMBLY AND DRIVE SHAFT CHAS EAS00718 FINAL DRIVE ASSEMBLY AND DRIVE SHAFT ...

Page 382: ...ation Adjust Ring gear backlash 0 1 X 0 2 mm a Install a bolt 1 of the specified size into the final drive oil filler hole b Finger tighten the bolt until it stops the ring gear from moving Do not overtighten the bolt c Install the special tool 2 and dial gauge 3 Final gear backlash band YM 01230 90890 01230 3 Dial gauge plunger contact point d Gently rotate the gear coupling from engage ment to e...

Page 383: ...cross pattern loosen each nut 1 4 of a turn After all of the nuts are fully loos ened remove them and the bolts 2 Remove Sring gear bearing housing 1 Remove the ring gear bearing housing off the final gear case by using a flat head screw driver at grooves a SDo not use a driver at any other part than SDo not damage the joint surface of the final gear case 3 Remove Sfinal gear housing rim 1 Sring g...

Page 384: ...ust washer thickness by 0 2 mm for every 0 2 mm decrease of ring gear shim thick ness EAS00721 MEASURING THE RING GEAR TO STOP PER BOLT CLEARANCE 1 Remove ring gear bearing housing along with the ring gear Refer to ADJUSTING THE RING GEAR BACKLASH 2 Measure ring gear to stopper bolt clearance a Out of specification Adjust Ring gear to stopper bolt clearance 0 3 X 0 6 mm 1 Ring gear 2 Stopper bolt ...

Page 385: ...t shims thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 2 Install stopper bolt shim s 1 stopper bolt 2 ring gear 3 4 Ring gear bearing housing Apply LOCTITE onto the stopper bolt 3 Measure ring gear to stopper bolt clearance If the ring gear to stopper bolt clearance is out of specification repeat the above procedure ...

Page 386: ...ft 1 1 1 1 1 1 Disassemble the parts in the order listed Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them NOTE Refer to DISASSEMBLING THE FINAL DRIVE ASSEMBLY ALIGHING THE FINAL DRIVE PINION GEAR AND RING GEAR 1 2 3 4 5 6 7 8 9 23 Nm 2 3 m kg 40 Nm 4 0 m kg 9 Nm 0 9 m kg 42 Nm 4 2 m kg 110 Nm 11 0 m kg 23 Nm 2 3 m kg 110 Nm 11 0 m kg FINAL...

Page 387: ...oller bearing Ring gear stopper Shim s 1 1 1 Refer to REMOVING AND INSTALLING THE RING GEAR BEARINGS For assembly reverse the disassembly procedure 10 11 12 13 14 23 Nm 2 3 m kg 40 Nm 4 0 m kg 9 Nm 0 9 m kg 42 Nm 4 2 m kg 110 Nm 11 0 m kg 23 Nm 2 3 m kg 110 Nm 11 0 m kg FINAL DRIVE CHAS ...

Page 388: ...locking nut gear coupling with the special tool 1 Final drive shaft holder YM 01229 90890 01229 3 Remove bearing retainer with the special tool 1 Final drive shaft bearing retainer wrench YM 04050 90890 04050 The bearing retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove final drive pinion gear Always use new bearings The final drive pinion gear should only b...

Page 389: ... to approximately 150_C b Remove the bearing outer races with an ap propriately shaped punch 2 c Remove the inner race from the final drive pinion gear The removal of the final drive pinion gear bear ing is a difficult procedure and is rarely neces sary 4 Install Sbearing New 1 a Heat the final gear case to approximately 150_C b Install the bearing outer races with a socket or appropriate tool tha...

Page 390: ...ny of the following parts are replaced final drive housing any bearing 1 Select final drive pinion gear shim s 1 ring gear shim s 2 a Position the final drive pinion gear and the ring gear with shims 1 and 2 Calculate the respective thicknesses from information marked on the final drive housing and the drive pinion gear 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b To find fina...

Page 391: ... only available in 0 10 mm increments round off to the hundredths digit Hundredths Rounded value 0 1 2 3 4 0 5 6 7 8 9 10 In the example above the calculated final drive pinion gear shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Ring gear shim thickne...

Page 392: ...ess is 0 51 mm Shim sizes are supplied in the following thick nesses Since the ring gear shims are only available in 0 10 mm increments round off the hundredths digit Hundredths Rounded value 0 1 2 3 4 0 5 6 7 8 9 10 In the example above the calculated ring gear shim thickness is 0 51 mm The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm ring gear shim 2 Install shims as...

Page 393: ...ing along with the ring gear b Place four pieces of Plastigauge between the original thrust washer and the ring gear c Install the ring gear bearing housing and tighten the bolts and nuts to specification Ring gear housing bolt 40 Nm 4 0 m kg Ring gear bearing housing nut 23 Nm 2 3 m kg Do not turn the final drive pinion gear and ring gear while measuring the ring gear to thrust washer clearance w...

Page 394: ... thrust washer clearance is within the specified limits Ring gear to thrust washer clearance 0 1 X 0 2 mm EAS00727 CHECKING THE DRIVE SHAFT 1 Check drive shaft splines Damage wear Replace the drive shaft EAS00728 INSTALLING THE DRIVE SHAFT 1 Lubricate drive shaft splines Recommended lubricant Molybdenum disulfide grease 2 Apply sealant onto both final drive housing mating sur faces Quickgasket ACC...

Page 395: ...VE CHAS NOTE 42 Nm 4 2 m kg 4 Install drive shaft Align the drive shaft splines with the driven yoke to the universal joint 5 Tighten final bearing housing nuts 6 Install rear wheel Refer to REAR WHEEL AND BRAKE DISC ...

Page 396: ...ELEC 8 ...

Page 397: ...8 13 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8 14 TROUBLESHOOTING 8 15 STARTER MOTOR 8 18 CHECKING THE STARTER MOTOR 8 20 ASSEMBLING THE STARTER MOTOR 8 21 INSTALLATION 8 22 CHARGING SYSTEM 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 24 LIGHTING SYSTEM 8 26 CIRCUIT DIAGRAM 8 26 TROUBLESHOOTING 8 27 CHECKING THE LIGHTING SYSTEM 8 28 SIGNAL SYSTEM 8 30 CIRCUIT DIAGRAM 8 30 TROUBLESHOOTING 8 32 COOL...

Page 398: ...RATION 8 53 CRUISE CONTROL SYSTEM 8 62 CIRCUIT DIAGRAM 8 62 CRUISE CONTROL CIRCUIT OPERATION 8 64 CRUISE CONTROL SYSTEM COMPONENTS 8 65 TROUBLE SHOOTING 8 66 SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL SYSTEM 8 72 SELF DIAGNOSIS 8 75 TROUBLESHOOTING 8 77 FUEL METER 8 80 TROUBLESHOOTING 8 82 SET RES INDICATOR LIGHT 8 84 TROUBLESHOOTING 8 86 ...

Page 399: ... unit 9 Battery 10 Fuse main 11 Starter relay 12 Speed sensor 13 Neutral switch 14 Oil level switch 15 Pickup coil 16 Sidestand switch 17 Rear brake switch 18 Flasher relay 19 Starting circuit cut off relay 20 Rectifier regulator 21 Horn 2 22 Fan motor 23 Thermo switch 24 Main switch 25 Brake light relay blue 26 Cruise control relay white EAS00729 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 400: ...pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustratio...

Page 401: ... stop switch 14 Side stand switch 15 Neutral switch 16 Rear brake switch 17 Oil level switch for EUR SWITCH INSPECTION ELEC EAS00731 SWITCH CONTINUITY INSPECTION Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity...

Page 402: ...ch 5 Clutch switch 6 Main switch 7 Front brake switch 8 Gruise control switch 9 CANCEL switch 10 Engine stop switch 11 Start switch 12 Emargency stop switch 13 Side stand switch 14 Neutral switch 15 Rear brake switch 16 Oil level switch for OCE SWITCH INSPECTION ELEC ...

Page 403: ...shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their re spective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise ...

Page 404: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 405: ... tester No continuity Replace Pocket tester 90890 03112 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb soc...

Page 406: ...ain switch 5 Battery 6 Fuse main 13 Ignitor 14 Ignition coil 15 Spark plug 23 Engine stop switch 25 Fuse ignition 28 Pick up coil 65 Neutral switch IGNITION SYSTEM ELEC DAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 407: ...GNITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 Main and ignition fuses 2 Battery 3 Spark plugs 4 Ignition spark gap 5 Spark plug cap resistan...

Page 408: ...ies to all of the spark plug caps SRemove the spark plug cap SConnect the pocket tester Ω 1k range to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20_C SIs the spark plug cap OK Replace the spark plug cap 6 Ignition coil resistance SThe following procedure applies to all of the ignition coils SDisconnect the ignition coil leads from the wire...

Page 409: ...y Refer to CHECKING THE SWITCHES SIs the engine stop switch OK 10 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK Replace the neutral switch 1 2 1 2 EAS00753 12 Starting circuit cut off relay diode SDisconnect the starting circuit cut off relay coupler from the wire harness SConnect the pocket tester Ω 1 to the starting circuit cut o...

Page 410: ...ire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects Properly connect or repair the ignition system s wiring Replace the ignitor unit IGNITION SYSTEM ELEC EAS00754 ...

Page 411: ...elay 8 Starter motor 10 Starting circuit cutoff relay 11 Diode 23 Engine stop switch 24 Start switch 25 Fuse ignition 26 Side stand switch 49 Clutch switch 65 Neutral switch ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 412: ...e neutral relay prevents the starter motor from operating when neither of these conditions has been met In this instance the neutral relay is open so current cannot reach the starter mo tor When at least one of the above conditions has been met the neutral relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE...

Page 413: ... OK NO YES SClean the battery terminals SRecharge or re place the battery ELECTRIC STARTING SYSTEM ELEC NOTE SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 1 Main and ignition fuses SAre the main and ignition fuses OK NO YES Replace the fuse s EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 Main and ignition fuses 2 Battery 3 Starter mo...

Page 414: ...top switch OK EAS00751 NO YES Replace the neutral switch 8 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Disconnect the starting circuit cut off relay coupler from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the starting circuit cut off relay coupler as shown 4 Starting circuit cut off relay EAS00759 Battery p...

Page 415: ...GRAM Is the starting system s wiring properly con nected and without defects The starting system circuit is OK Properly connect or repair the starting system s wiring NO EAS00763 YES Replace the clutch switch 10 Clutch switch Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK EAS00752 NO YES Replace the side stand switch 9 Sidestand switch Check the sides...

Page 416: ...assembly Starter motor lead Starter motor O ring 1 1 1 Remove the parts in the order listed Refer to REMOVING THE ENGINE in CHAPTER 4 For installation reverse the removal procedure 10 Nm 1 0 m kg M6 25 1 M6 55 1 7 Nm 0 7 m kg M5 110 2 ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR ...

Page 417: ...ear bracket Washer kit Brush seat Brush 1 Armature coil 1 1 2 1 1 1 1 Disassemble the parts in the order listed Be sure to remove the installation nut on brush 1 first For assembly reverse the disassembly procedure NOTE 1 2 3 4 5 6 Refer to ASSEMBLING THE STARTER MOTOR 10 Nm 1 0 m kg M6 25 1 M6 55 1 7 Nm 0 7 m kg M5 110 2 ...

Page 418: ...e commutator Mica insulation undercut 0 7 mm The mica insulation of the commutator must be undercut to ensure proper operation of the commutator 4 Measure Sarmature coil resistances continuity and in sulation Out of specification Replace the starter motor a Check the continuity resistance 1 and mica insulation resistances 2 with a pocket tes ter Pocket tester YU 03112 90890 03112 b Measure the arm...

Page 419: ...a set Brush spring force 570 X 920 N 7 Check gear teeth Damage wear Replace the gear 8 Check bearing 1 oil seal 2 bushing 3 Damage wear Replace the defective part s EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 Align the tab a on the brush seat with the slot b in the rear cover 2 Install washers 1 armature coil 2 o ring 3 rear bracket 4 To prevent damaging the brushes during instal ...

Page 420: ...0 Nm 1 0 m kg 3 Install o ring 1 New washers 2 front bracket 3 o ring 4 New Align the match marks a on the yoke with the match marks b on the brackets 4 Install bolts 1 INSTALLATION 1 Install starter motor Refer to AC MAGNETO AND STARTER CLUTCH in CHAPTER 4 ...

Page 421: ...8 23 1 AC magneto 3 Rectifire reguretor 5 Battery 6 Fuse main CHARGING SYSTEM ELEC YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 422: ...n CHAPTER 3 SAre the fuses OK NO YES Replace the fuse s EAS00739 NO YES SClean the battery terminals SRecharge or re place the battery 2 Battery Open circuit voltage 12 8 V or more at 20_C SIs the battery OK Tester positive probe white Tester negative probe white 1 2 3 1 EAS00776 4 Stator coil resistance SRemove the generator cover SConnect the pocket tester Ω 1 to the sta tor coils as shown Teste...

Page 423: ...coil resistances Stator coil resistance 0 279 X 0 341 Ω at 20_C SIs the stator coil OK NO YES Replace the stator coil assembly EAS00779 5 Wiring SCheck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly connected and without defects CHARGING SYSTEM ELEC ...

Page 424: ...light 75 Tail brake light 77 Headlight 78 Front turn signallight left 79 Front turn signallight right 4 Main switch 5 Battery 6 Fuse main 20 Light switch 34 Fuse headlight 45 Dimmer switch LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 425: ...STEM ELEC NOTE SCheck the main and headlight fuses for con tinuity Refer to CHECKING THE FUSES in CHAPTER 3 EAS00738 YES NO YES NO WAS00739 1 Main and headlight fuses SAre the main and headlight fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20_C SIs the battery OK SClean the battery termin...

Page 426: ...lb and socket for continuity Are the headlight bulb and socket OK Headlight Tester positive probe yellow or green Tester negative probe black High beam indicator light Tester positive probe yellow Tester negative probe black 1 2 3 4 5 2 Voltage Connect the pocket tester 20 V DC to the headlight and high beam indicator light cou plers as shown A B When the dimmer switch is set to When the dimmer sw...

Page 427: ... voltage 12 V of blue red yellow on the tail brake light coupler tail brake light side Is the voltage within specification The wiring circuit from the main switch to the tail brake light coupler tail brake light side is faulty and must be repaired 1 This circuit is OK Set the main switch to ON Measure the voltage 12 V of blue on the meter light coupler wire harness side Is the voltage within speci...

Page 428: ...8 30 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 429: ...ht relay 40 Rear brake switch 41 Horn 2 42 Horn 1 43 Flasher relay 46 Horn switch 47 Turn signal switch 52 Oil level indicator light 54 Over drive indicator light 55 Neutral indicater light 56 Fuel level indicator light 59 Turn indicator light left 60 Turn indicator light right 65 Neutral switch 68 Fuel sender unit 75 Tail brake light 77 Front turn signal light left 78 Front turn signal light righ...

Page 430: ...L SYSTEM ELEC NOTE EAS00738 1 Main signal and ignition fuses SCheck the main signal and ignition fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the main signal and ignition fuses OK YES NO Replace the fuse s EAS00739 2 Battery SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20_C SIs the battery OK YES NO SCle...

Page 431: ... brake light fails to come on YES Set the main switch to ON Measure the voltage 12 V of pink at the horn terminal Is the voltage within specification Replace the horn 1 Tail brake light bulb and socket Check the tail brake light bulb and socket for continuity Are the tail brake light bulb and socket OK Replace the tail brake light bulb socket or both 2 Brake switch Check the brake switch for conti...

Page 432: ...ircuit is OK 1 2 1 2 Turn signal switch Check the turn signal switch for continuity Refer to CHECKING THE SWITCHES Is the turn signal switch OK NO YES Replace the left han dlebar switch 1 Tester positive probe brown Tester negative probe ground YES NO Set the main switch to ON Measure the voltage 12 V of brown at the flasher relay coupler wire harness side Is the voltage within specification The w...

Page 433: ...eutral indicator light fails to come on NO YES The flasher relay is faulty and must be replaced 5 Voltage rear Connect the pocket tester 20 V DC to the turn signal light connector wire harness side as shown NO YES The wiring circuit from the turn signal switch to the turn sig nal light connector wire harness side is faulty and must be repaired This circuit is OK Left turn signal light Tester posit...

Page 434: ...r both 1 2 Tester positive terminal black red Tester negative terminal brack white YES NO SDrain the engine oil and remove the engine oil level switch from the oil pan SCheck the engine oil level switch for conti nuity Refer to CHECKING THE SWITCHES SIs the engine oil level switch OK Replace the engine oil level switch 3 Engine oil level switch 2 Starting circuit cut off relay SDisconnect the star...

Page 435: ...ave continuity NO YES Replace the fuel lev el indicator light bulb socket of both Set the main switch to ON Measure the voltage 12 V Is the voltage within specification This circuit is OK EAS00803 6 The fuel level indicator light fails to come on 1 Tester positive probe green white Tester negative probe ground YES NO NO YES Set the main switch to ON Measure the voltage 12 V Is the voltage within s...

Page 436: ...he wiring circuit from the main switch to the meter light cou pler wire harness side and meter light coupler to over drive switch are faulty and must be repaired This circuit is OK 7 The over drive indicator light fails to come on 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES NO Replace the neutral switch Connect the pocket tes...

Page 437: ...n switch 5 Battery 6 Fuse main 30 Thermo switch 31 Noise filter 32 Fan motor 33 Fues fan motor 35 Fuse signal 53 Engine overheat indica tor light 67 Thermo unit COOLING SYSTEM ELEC COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 438: ... radiator fan mo tor fuses for continuity Refert to CHECKING THE FUSES in CHAPTER 3 1 Main signal and radiator fan motor fuses SAre the main turn signal and radiator fan motor fuses OK YES NO Replace the fuse s EAS00739 2 Battery Open circuit voltage 12 8 V or more at 20_C EAS00808 TROUBLESHOOTING SThe radiator fan motor fails to turn SThe engine overheat indicator light fails to come on when the ...

Page 439: ...thermo switch operate properly as described above YES NO Replace the thermo switch SDoes the rediator fan motor turn EAS00811 5 Thermo switch SRemove the thermo switch from the thermo stat housing SConnect the pocket tester Ω 1 to the thermo switch as shown 1 2 3 SHandle the thermo switch with special care SNever subject the thermo switch to strong shocks If the thermo switch is dropped replace it...

Page 440: ...is circuit is OK Temperature sender resistance 80_C 47 53 Ω 100_C 26 30 Ω SHandle the temperature sender with special care SNever subject the temperature sender to strong shocks If the temperature sender is dropped replace it WARNING 7 Thermo unit SRemove the thermo unit sender from the ra diator SConnect the pocket tester Ω 10 to the thermo unit as shown SImmerse the temperature sender in a con t...

Page 441: ...8 43 4 Main switch 5 Battery 6 Fuse main 10 Starting circuit cutoff relay 12 Fuel pump 13 Ignitor 23 Engine stop switch 25 Fuse ignition FUEL PUMP SYSTEM ELEC FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 442: ...el 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 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump ...

Page 443: ... Tester negative probe blue black 1 2 3 4 Replace the starting circuit cut off relay FUEL PUMP SYSTEM ELEC If the fuel pump fails to operate NOTE EAS00738 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 Open circuit voltage 12 8 V or more at 20_C SIs the battery OK SAre the main and ignition fuses OK EAS00739 2 Battery SCheck th...

Page 444: ...ue black Tester negative probe black Replace the fuel pump SMeasure the fuel pump resistance 1 2 SIs the fuel pump OK Fuel pump resistance 4 30 Ω at 20_C EAS00817 7 Wiring SCheck the entire fuel pump system s wiring Refer to CIRCUIT DIAGRAM SIs the fuel system s wiring properly con nected and without defects YES NO Properly connect or repair the fuel sys tem s wiring Replace the ignitor unit EAS00...

Page 445: ...way from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is not a fire may occur Therefore make sure that the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Connect ...

Page 446: ... Main switch 5 Battery 6 Fuse main 36 Fuse carburetor heater 37 Carburetor heater relay 39 Thermo switch 65 Neutral switch 70 Carburetor heater 1 71 Carburetor heater 2 72 Carburetor heater 3 73 Carburetor heater 4 CABURETOR HEATING SYSTEM ...

Page 447: ...ral switch EAS00751 EAS00822 CARBURETOR HEATING SYSTEM ELEC NOTE SCheck the main and carbretor heater fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 1 Main and carbretor heater fuses SAre the main and carbretor heater fuses OK YES NO Replace the fuse s EAS00739 SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 2 Battery YES NO SClean the battery terminal...

Page 448: ...or heating elements 6 Thermo switch SRemove the thermo switch from the thermo switch plate SConnect the pocket tester to the Ω 1 to the thermo switch as shown Tester positive probe black white Tester negative probe black yellow 1 2 YES NO Replace the thermo switch SDoes the thermo switch operated properly COOL DOWN A B SCheck the thermo switch for continuity at the temperatures indicated below 20_...

Page 449: ...8 51 4 Main switch 5 Battery 6 Fuse main 17 Fuse back up AUDIO SYSTEM ELEC AUDIO SYSTEM ...

Page 450: ... 52 AUDIO SYSTEM ELEC 80 Fuse audio 81 MCU 82 Speaker front 83 Speaker front 84 Speaker rear 85 Rear remoto controller 86 Fuse front DC outlet 87 Fuse rear DC outlet 88 DC outlet front 89 DC outlet rear ...

Page 451: ... 19 CD changer option The audio system circuit con sists of the front rear remote controllers front rear speakers tape deck and main control unit MCU 1 Battery 2 Fuse main 3 Main switch 4 Fuse back up 5 Fuse audio 6 Main control unit 7 Front remoto controller 8 Rear remoto controller 9 Front speakers 10 Rear speakers AUDIO SYSTEM ELEC AUDIO SYSTEM CIRCUIT OPERATION ...

Page 452: ... the coupler as shown and pull it out straight If the coupler is twisted when disconnect ing the inner pins may be damaged INSTALL 1 Connect Front remote control coupler to the main control unit Tape deck coupler to the main control unit When connecting a coupler be sure to align projection 1 with indent 2 and push in ward straightly If the coupler is twisted when connecting the inner pins may be ...

Page 453: ...ing 5 Wiring connections Check the wiring blue green of MCU front remote controller 1 2 Front remote Controller Display AUDIO SYSTEM ELEC NOTE Check the main back up and audio fuse for continuity Refer to CHECKING THE FUSES in CHAPTER 3 1 Fuse Is the main back up and audio fuse OK YES NO Replace the fuses 2 Ground lead Check the ground lead Check the wiring Check the ground Is the ground lead OK Y...

Page 454: ...g connections Check the wiring of MCU antenna Is the MCU antenna wiring properly con nected and without defected NO YES Replace the MCU Correct the MCU antenna wiring 3 Casset deck does not sound 1 Casset deck Check the cassette deck operation Is the cassette deck moved NO YES Replace the cassette deck 2 Wiring connections Is the MCU cassette deck 13P wiring properly connected and without defected...

Page 455: ...eaker resistance Speaker resistance 3 4 X 4 6 Ω at 20_C SIs the speaker resistance within specifica tion YES NO Replace the speaker 1 2 2 2 2 1 1 1 AUDIO SYSTEM ELEC NOTE YES NO Set up the FADE switch SChange the out put mode HS SP 2 Front or rear speaker does not sound 1 FADE switch S FADE switch set up near front or rear S FADE switch set up OK Replace the MCU Speaker does not sound Check 1 Out ...

Page 456: ... MCU 18P connector Is the MCU 18P connector OK YES NO Correct the MCU 18P connector Replace the MCU Change the out put mode SP HS 2 Front head set does not sound 1 Wiring connections Left Tester positive prove 3 Tester negative prove 2 Right Tester positive prove 5 Tester negative prove 2 AUDIO SYSTEM ELEC NOTE Headset does not sound Check 1 Out put mode 2 Front head set 3 Rear head set 4 Wiring c...

Page 457: ...set does not sound 1 Rear remote controller volume Check the rear remote controller volume out put level Is the rear remote controller volume out put level OK YES NO Adjust the rear re mote controller vol ume out put level Check the head set wiring for continuity YES NO Correct the head set wiring 2 Wiring connections Check the wiring of head set Connect the pocket tester Ω 1 to the head set as sh...

Page 458: ...not used 1 Intercom volume out put level YES NO Adjust the Intercom volume out put level Check the head set wiring Connect the pocket tester Ω 1 to the head set wiring as shown 2 Wiring connections Left Tester positive prove 3 Tester negative prove 2 Right Tester positive prove 5 Tester negative prove 2 Check the head set wiring for continuity Is the head set wiring OK YES NO Correct the head set ...

Page 459: ...re audio system Before troubleshooting remove the follow ing part s 1 Front cowling 2 Trunk NOTE Is the MCU front remote controller 13P wiring properly connected and without de fected YES NO Correct the MCU front remote control ler 13P wiring 1 Wiring connections Check the MCU front remote controller 13P wiring blue Repalce MCU or front remoto control ler AUDIO SYSTEM ELEC NOTE Front remote contro...

Page 460: ...8 62 CRUISE CONTROL SYSTEM ELEC CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM ...

Page 461: ...CANCEL switch 35 Fuse signal 38 Brake light relay 40 Rear brake switch 49 Clutch switch 57 Speedometer Fuel meter 62 Cruise control light MAIN 63 Cruise control light SET 64 Cruise control light RES 66 Speed sensor 75 Tail brake light 90 Cruise control unit 91 Vacuum pump 92 Fuse cruise control 93 CRUISE switch 94 Cruise control relay ...

Page 462: ...ake switch 18 Rear brake light switch 19 Front brake light switch 20 Brake lamp relay 21 Brake light 22 To ignition coil 23 Speed sensor 24 Speedometer CRUISE CONTROL CIRCUIT OPERATION 1 Battery 2 Main fuse 3 Main switch 4 Signal fuse 5 Cruise control fuse 6 CRUISE switch 7 Cruise contrl relay 8 ON indicator light 9 SET indicator light 10 RES indicator light ...

Page 463: ...SE switch 20 Ignition coil 7 Front brake switch 8 Cruise control switch cancel switch 9 Clutch switch 10 Cruise control unit 11 Rear brake switch 12 Vacuum pump 13 Vacuum autuator 14 Throttle cable joint 1 Speed sensor 2 Battery 3 Fuse 4 Main switch 5 Fuse 6 Indicators CRUISE CONTROL SYSTEM COMPONENTS ...

Page 464: ...switch Tester positive prove red blue Tester negative prove brown red or yellow black SIs the CRUISE switch OK Replace the CRUISE switch 1 2 3 SCheck the control fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the control fuses OK YES NO Replace the fuse s 1 Main signal and cruise control fuses EAS00738 CRUISE CONTROL SYSTEM ELEC NOTE EAS00781 TROUBLESHOOTING Check 1 main signal...

Page 465: ... repaired This circuit is OK 2 1 Disconnect the relay from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the relay unit terminal as shown YES NO Replace the relay unit 5 Cruise control relay Battery positive terminal yellow red Battery negative terminal black Tester positive prove brown red Tester negative prove yellow red Does the cruise control relay have continu ity between bro...

Page 466: ...S indicator light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the SET RES indicator light bulb and socket OK YES NO Replace the SET RES indicator light bulb socket or both Connect the pocket tester DC 20 V to the SET RES indicator light couplers wire harness side as shown YES NO 2 Voltage SET indicator light Tester positive probe yellow black Tester negative pro...

Page 467: ...n a Engine warning light is flashing Fault code 4 Refer to SELF DIAGNOSIS b SET and or RES indicator light is flash ing Fault code 4 Refer to SELF DIAGNOSIS Is the speed sensor OK NO Faulty YES Normal Replace the cruise control unit 2 Speed sensor Disconnect the right handlebar switch cou pler from the wire harness Check the CANCEL switch for continuity YES NO 1 CANCEL switch Tester positive prove...

Page 468: ...m actuator Is the actuator diaphram staying 2 Throttle cable joint Is the throttle cable joint OK YES NO Repair or replace the throttle cables 5 Throttle cables Replace the cruise control unit Checke the throttle cables and throttle housing condition Is the throttle cables OK YES NO Adjust the free play Refer to ADJUST ING THE THROTTLE CABLE FREE PLAY in CHAPTER 3 1 Throttle cable free play Is the...

Page 469: ... blue white blue red 1 2 Is the actuator operating YES NO Replace the vacuum pump Replace the cruise control unit YES NO Replace the vacuum pump 5 Vacuum pump 2 Is the actuator diagram stying 4 Vehicle speed fluctuate during the cruising 1 Speed sensor NO Faulty YES Normal Replace the cruise control unit Replace the speed sensor 5 Cruising speed can not be increased or re sume can not be operated ...

Page 470: ...ne stop switch and stop the en gine 5 Wait for 10 seconds 6 Push the cruise control switch to the SET and RES alternatively three times total of 6 times within 2 seconds while pressing the cancel switch Then the indicator light will be lit and the cruise control system will enter the self diagnosis mode 1 The SET and RES indicator lights will then blink alternatively three times When the cruise co...

Page 471: ...the cancel switch signal 1 The SET indicator light is lit 2 Operate the cancel front brake rear brake and clutch switches If the SET indicator light is not extinguished after any one of these switches is operated it mean that the relevant switch is in failure Example If the cancel switch is operated and the SET indicator light is not extinguished it means that the cancel switch is in failure ...

Page 472: ...at the front brake switch is infailure 3 Trouble diagnosis of the throttle drive 1 Push the cruise control switch to RES The throttle will be then opened fully in approx 2 5 seconds and kept fully open for 3 seconds The throttle will be fully closed approx 2 5 seconds later Check the closing throttle for noises and op eration If noise is heard from the vacuum pump but the throttle is not operating...

Page 473: ... the speedome ter comes on tor 1 4 seconds then goes off However if there is a malfunction it comes on for 1 4 se conds goes off and then begins flashing However it is on while the engine is running Display condition code Item Condition Response When engine is stationary When engine is running Throttle position sensor TPS Disconnected Short circuit Locked Enables the motorcycle to run so that the ...

Page 474: ...seconds 0 5 seconds Light off seconds 0 5 seconds Number of blinks Fault code 4 Light off seconds 3 seconds Number of blinks Fault code 3 1 2 3 4 Light on Light off Repetition Light on Light off Repetition SELF DIAGNOSIS ELEC Display order on the engine warning light When one item being monitored When more than one item is being monitored ...

Page 475: ...for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK NO YES Repair or replace the wire harness NOTE EAS00835 TROUBLESHOOTING The tachometer starts to display the self diagnosis sequence Check 1 throttle position sensor 2 speed sensor 3 emergency stop switch Before troubleshooting remove the following part s 1 rider seat 2 fuel tank 3 air filter case Troubleshoot with the following specia...

Page 476: ...heck the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK NO YES Repair or replace the wire harness 2 Speedometer Check the speedometer operation Is the speedometer OK NO YES Replace the speed sensor Replace the ignitor unit 3 Emergency stop switch CIRCUIT DIAGRAM Ignitor unit Emergency stop switch 13 27 2 Speed sensor CIRCUIT DIAGRAM 13 Ignitor unit 66 Speed sensor ...

Page 477: ... gency stop switch 2 Emergency stop switch SRemove the emergency stop switch SConnect the pocket tester Ω 1 to the emergency stop switch coupler as shown SWhen turn the emergency stop switch approx 50_ the resistance reading is 0 Ω to Ω SIs the emergency stop switch OK Replace the ignitor unit 1 2 50_ EB812401 ...

Page 478: ...t off 3 seconds 1 cycle 3 times repetition 1 2 3 4 Light on 0 5 seconds Light off 0 5 seconds 1 2 Light on Light off Repetition Light on Light off Repetition 5 2 FUEL METER The fuel meter is indicated the fault displays as follows Fuel sender Fuel thermistor Fuel meter display sequence Fuel sender ...

Page 479: ... 5 seconds Light off 0 5 seconds Number of blinks 8 times Light off 3 seconds 1 cycle 3 times repetition 1 2 3 4 Light on 0 5 seconds Light off 0 5 seconds 1 2 5 Light on Light off Repetition Light on Light off Repetition Fuel thermistor ...

Page 480: ...K NO YES Repair or replace the wire harness 2 Fuel thermistor CIRCUIT DIAGRAM Fuel meter Fuel sender unit thermistor 57 68 NOTE EAS00835 TROUBLESHOOTING The tuel meter starts to display the self diagnosis sequence Check 1 fuel sender 2 fuel thermistor Before troubleshooting remove the following part s 1 rider seat 2 fuel tank 3 air filter case Troubleshoot with the following special tool s Pocket ...

Page 481: ...tinuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the fuel me ter NO YES Repair or replace the wire harness 2 Fuel thermistor Check the fuel thermistor operation When set the main switch to on the fuel level indicator light comes on After 1 4 second the fuel level indicator light goes off Is the fuel thermistor OK EB812401 ...

Page 482: ...is run ning or not Display condition Item Condition When engines is stationary When engine is running Fault code Cruise control unit Disconnected Short circuit Blinks in Blinks in 1 Vacuum pump Disconnected Shart circuit Blinks in Blinks in 2 Concel switch Front brake switch Rear brake switch or Clutch switch Disconnected Short circuit Blinks in Blinks in 3 Speed sensor Illegality palse Blinks in ...

Page 483: ...8 85 ELEC A A A A A A B B B B B B A B Light on Light off Fault code 1 2 3 4 5 6 1 0 5 seconds 2 0 5 seconds 3 Number of blinks Fault code 4 3 seconds ...

Page 484: ...t brake switch rear brake switch and clutch switch Check the switches for continuity Refer to CRUISE CONTROL SYSTEM Are the switches OK NO YES Repair or replace the faulty switch es Replace the cruise control unit NOTE EAS00835 TROUBLESHOOTING The SET RES indicator light starts to display the self diagnosis sequence Check 1 cruise control unit 2 vacuum pump 3 cancel switch front brake switch rear ...

Page 485: ...8 87 SELF DIAGNOSIS ELEC Front brake switch CANCEL switch Rear brake switch Clutch switch Cruise control unit 18 22 40 49 90 CIRCUIT DIAGRAM ...

Page 486: ... the speed sensor 5 Ignition coil CIRCUIT DIAGRAM Ignition coil Cruise control unit 14 90 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK NO YES Repair or replace the wire harness EB812401 Replace the cruise control unit 4 Speed sensor CIRCUIT DIAGRAM 66 Speed sensor 90 Cruise control unit ...

Page 487: ...i tion from the idling to full opening the throttle Is the engine condition OK NO YES Replace the ignition coil Replace the cruise control unit Tester positive prove pink white pink black Tester negative prove black NO YES The cruise control switch is faulty Replace the right handlebar switch 2 Cruise control switch Disconnect the rihgt handlebar switch cou pler from the wire harness Connect the p...

Page 488: ...8 90 SELF DIAGNOSIS ELEC CIRCUIT DIAGRAM ...

Page 489: ...TRBL SHTG 9 ...

Page 490: ...CE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING 9 3 SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 OVERHEATING 9 4 ENGINE 9 4 FUEL SYSTEM 9 4 ELECTRICAL SYSTEMS 9 4 COOLING SYSTEM 9 4 CHASSIS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKAGE OIL 9 5 MALFUNC...

Page 491: ...GNALING SYSTEM 9 6 HEADLIGHT DOES NOT LIGHT 9 6 TURN SIGNAL DOES NOT LIGHT 9 6 HORN DOES NOT SOUND 9 6 HEADLIGHT BULB BURNT OUT 9 6 TURN SIGNAL BLINKS SLOWLY 9 6 TURN SIGNAL REMAINS LIT 9 6 TURN SIGNAL BLINKS QUICKLY 9 6 ...

Page 492: ...r as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING PROBLEMS ENGINE Cylinder s and cylinder head s Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty va...

Page 493: ...ystem Faulty ignitor unit Faulty pickup coil Broken generator rotor woodruff key ELECTRICAL SYSTEMS Battery Improperly charged battery Faulty battery Fuse s Blown damaged or incorrect fuse Improperly installed fuse Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Starting system Faulty ...

Page 494: ...Refer to STARTING PROBLEMS ENGINE Air filter Clogged air filter element Air intake system Bent clogged or disconnected carburetor air vent hose Clogged or leaking air duct EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift fork s Foreign object in the shift drum groove S...

Page 495: ...ENGINE Clogged coolant passages Cylinder head s and piston s Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality FUEL SYSTEM Carburetor s Incorrect main jet setting Incorrect fuel level Air leak at carburetor joint Air filter Clogged air filter element ELECTRICAL SYSTEMS Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Ignition syst...

Page 496: ...pe Improperly installed bearing race EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bolt copper washer Cracked or damaged cap bolt O ring EAS00862 UNSTABLE HANDLING Handleber Bent or improperly installed handlebar Steering ...

Page 497: ...asher relay Burnt out turn signal bulb EAS00866 FAULTY SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Incorrect ground Poor contacts main or light switch Burnt out headlight bulb TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty flasher relay Bumt out turn signal bulb Incorrect connection Damaged or defect...

Page 498: ...tch 41 Horn 2 42 Horn 1 43 Flasher relay 44 Handlebar switch left 45 Dimmer switch 46 Horn switch 47 Turn signal switch 48 PASS switch 49 Clutch switch 50 Meter assembly 51 Engine trouble indicator light 52 Oil level indicator light 53 Engine overheat indicator light 54 Over drive indicator light 55 Neutral indicater light 56 Fuel level indicator light 57 Speedometer Fuel meter 58 High beam indica...

Page 499: ...Blue White L Y Blue Yellow O L Orange Blue P B Pink Black P L Pink Blue P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow W G White Green W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Y W Yellow White MCU CUISE CONTROL UNIT CRUISE SWITCH D C OUTLET 80 Fuse audio 81 MCU 82 Speaker front 83 Speaker front 84 Speaker ...

Page 500: ...orn 2 40 Horn 1 41 Flasher relay 42 Handlebar switch left 43 Dimmer switch 44 Horn switch 45 Turn signal switch 46 PASS switch 47 Clutch switch 48 Meter assembly 49 Engine trouble indicator light 50 Oil level indicator light 51 Engine overheat indicator light 52 Over drive indicator light 53 Neutral indicator light 54 Fuel level indicator light 55 Speedometer Fuel meter 56 High beam indicator ligh...

Page 501: ...te L Y Blue Yellow O L Orange Blue P B Pink Black P L Pink Blue P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow W G White Green W L White Blue W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Y W Yellow White MCU CUISE CONTROL UNIT CRUISE SWITCH D C OUTLET 77 Fuse audio 78 MCU 79 Speaker front 80 Speaker front 81 S...

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