Yamaha YX600A Service Manual Download Page 266

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Summary of Contents for YX600A

Page 1: ...OYAMAHA II LIT 11616 06 16 ...

Page 2: ...D HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE WARNING A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or p...

Page 3: ...g system Carburetion Chassis J Electrical Appendices Illustrated symbols to are used to identify the specifications appearing in tlie text Filling fluid Lubricant Tightening Wear limit clearance l Engine speed n V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel ...

Page 4: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL APPENDICES GEN INFO ENG _________ APPX ...

Page 5: ...1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 ALL REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND 0 RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 SPECIAL TOOLS 1 3 FOR TUNE UP 1 3 FOR ENGINE SERVICE 1 4 FOR CHASSIS SERVICE 1 7 FOR ELECTRICAL COMPONENTS 1 7 ...

Page 6: ...tion number is used to iden tify your motorcycle and may be used to register your motorcycle with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the left rear section of the engine Starting Serial Number VX600S Except for California 1UJ 000101 VX600SC For California 1UL 000101 NOTE The first three digits of these numbers ...

Page 7: ...reassembly Apply grease to the oil seal lips LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers Plates G and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened BEARINGS AND OIL SEALS 1 Install the bearing s and oil seal s with their manufacturer s marks or numbers facing out ward In other w...

Page 8: ...of improper tools or improvised techniques FOR TUNE UP 1 Inductive Tachometer P N YU 08036 This tool is needed for detecting engine rpm 2 Inductive Timing Light P N YU 08037 This tool is necessary for adjusting timing 3 Compression Gauge P N YU 33223 This gauge is used to measure the engine com pression 4 Fuel Level Gauge P N YM 01312 This gauge is used to measure the fuel level in the float chamb...

Page 9: ...uge is needed for carburetor synchroni zation FOR ENGINE SERVICE 1 Universal Clutch Holder P N YM 91042 This tool is used to hold the clutch when remov ing or installing the clutch boss locknut 2 Tappet Adjusting Tool P N YM 01245 This tool is necessary to replace valve adjusting pads 3 Valve Spring Compressor P N YM 04019 This tool is needed to remove and install the valve assemblies 1 4 ...

Page 10: ...tool is used to rebore the new valve guide 6 Valve Guide Installer P N YM 04065 This tool is needed to install the valve guides properly together with valve guide remover 7 Valve Seat Cutter Set P N YM 91043 This tool is needed to resurface the valve seat 8 Rotor Puller G P N YM 01080 Pin P N YM 04052 This tool is needed to remove the A C Genera tor rotor ...

Page 11: ...se to hold the pistons during cylinder installation 11 Piston Pin Puller P N YU 01304 This tool is used to remove the piston pin 12 Rotor Holding Tool P N YM 04043 This tool is used to hold the A C Generator ro tor during removal and installation 13 Plastigage Set Green P N YU 33210 This gauge is needed to measure the clearance for the connecting rod bearing 1 6 ...

Page 12: ... Weight CD P N YM 33963 Adapter 2 P N YM 08010 These tools are used when installing the fork seal 3 Ring Nut Wrench PIN YU 33975 This tool is used to loosen and tighten the steer ing ring nut FOR ELECTRICAL COMPONENTS 1 Electro Tester P N YU 33260 This instrument is necessary for checking the ig nition system components 2 Pocket Tester P N YU 03112 This instrument is invaluable for checking the el...

Page 13: ...ANING 2 20 CHASSIS 2 20 FUEL COCK CLEANING 2 20 FRONT BRAKE FLUID INSPECTION 2 21 FRONT BRAKE PAD INSPECTION 2 22 FRONT BRAKE LEVER FREE PLAY ADJUSTMENT 2 22 REAR BRAKE PEDAL HEIGHT ADJUSTMENT 2 23 BRAKE PEDAL FREE PLAY ADJUSTitilENT 2 23 REAR BRAKE LINING INSPECTION 2 24 REAR BRAKE LIGHT SWITCH ADJUSTMENT 2 24 DRIVE CHAIN SLACK CHECK 2 25 DRIVE CHAIN SLACK ADJUSTMENT 2 25 DRIVE CHAIN LUBRICATION ...

Page 14: ...HECK 2 33 SPARK PLUG INSPECTION 2 34 BATTERY INSPECTION 2 35 FUSE INSPECTION 2 37 HEADLIGHT BEAM ADJUSTMENT 2 38 HEADLIGHT BULB REPLACEMENT 2 39 TAILLIGHT BULB REPLACEMENT 2 40 CARBURETOR AIR VENT SYSTEM INSPECTION CALIFORNIA ONLY 2 40 ...

Page 15: ...eter readings 1 2 3 No Item Remarks 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi 1 Cam chain Adjust chain tension O 0 0 0 0 0 Valve Check and adjust valve 2 clearance clearance when engine is 0 cold Check condition Adjust Spark gap and clean Replace at 3 13...

Page 16: ...oes if necessary Rear 5 Clutch Adjust free 0 0 0 0 0 0 play Check chain condition SAE 6 Drive chain Adjust and 30W 50W Every 500 km 300 mi lubricate motor oil chain thoroughly Yamaha chain Control Apply chain and cable 7 and meter lube lube or SAE 0 0 0 0 0 0 cable thoroughtly 10W30 motor oil Check bear ing assembly Midium Rear arm for looseness weight wheel 8 pivot Moderately bearing Repack beari...

Page 17: ...ator ator brushes Check and 17 Sidestand clean or 0 switch replace if necessary 1 If ambient temperature does not go below 5 C 41 F 2 If ambient temperature does not go below 15 C 59 F Odometer readings 1 2 3 7 000 km 13 000 km 19 000 km 25 000 km or or or or 7 months 13 months 19 months 25 months 4 400 mO 8 200 mi 12 000 mO 15 800 mi 0 0 0 0 0 0 0 Repack 0 0 0 0 0 0 0 0 0 0 0 0 0 0 It is recommen...

Page 18: ...must be measured and adjusted when the engine is cool to the touch Measure and adjust valve clearance when piston is at TDC on compression stroke 1 Remove Seat 2 Turn the fuel cock to ON position 3 Remove Cover G 4 Disconnect Fuel pipe G Vacuum pipe Fuel tank breather pipe 5 Remove Fuel tank 2 4 ...

Page 19: ...n the T mark CD on the timing plate with the pickup coil mark 2 or when the piston is at Top Dead Center T D C on compression stroke NOTE Compression T D C can be found when the cam lobes are apart from each other as shown Measure the valve clearance by aligning the T mark with the upper pickup coil mark 2 for the 1 and 4 cylinders and with the lower pickup coil mark for the 2 and 3 cylinders ...

Page 20: ...4 3 10 Adjust Valve clearance Valve clearance adjustment steps Position the valve lifter slots intake and ex haust opposite each other Turn the camshaft until the lobe fully depresses the valve lifter and opens the valve Attach the Tappet Adjusting Tool CD YM 01245 onto the cylinder head NOTE Make sure that the tool contacts the lifter only and not the pad Carefully rotate the camshaft so that the...

Page 21: ...arked on the pad face that contacts the valve lifter not the cam Round off the hundredths digit of the original pad number to the nearest 0 05 mm incre ment Hundredths digit Rounded valve 0 or 2 0 5 NOT ROUNDED OFF 8 10 EXAMPLE Original pad number 258 2 58 mm Rounded off digit 260 NOTE Pads can only be selected in 0 05 mm 0 002 in increments Locate the Installed Pad Number on the chart and then fi...

Page 22: ... 100 in 1 31 1 35 320 Always install pad with number down EXHAUST 00 INSTALLED PAD NUMBER MEASURED CLEARANCE 200 205 210 215 220 225 230 235 240 245 255 260 265 270 275 280 285 290 295 300 305 310 315 320 0 00 0 05 200 205 210 215 220 225 230 240 245 250 255 260 265 270 275 280 285 290 295 300 305 0 06 0 10 200 205 210 215 220 225 230 235 245 250 255 260 265 270 275 280 285 290 295 300 305 310 0 1...

Page 23: ...nt steps until the proper clearance is obtained 11 Install Reverse removal steps Crankcase cover Left Cylinder head cover Horn Spark plugs Fuel tank Screw Crankcase Cover 10 Nm 1 0 m kg 7 2 ft lb Bolt Cylinder Head Cover 10 Nm 1 0 m kg 7 2 ft lbl Spark Plug 18 Nm 1 8 m kg 13 ft lb CAM CHAIN ADJUSTMENT 1 Remove Crankcase cover Left 2 Turn crankshaft counterclockwise 3 Align the timing plate C mark ...

Page 24: ... tensioner Locknut 6 Nm 0 6 m kg 4 3 ft lb Stopper Bolt 9 Nm 0 9 m kg 6 5 ft lb 6 Install Crankcase cover Left Screw Crankcase Cover 10 Nm 1 0 m kg 7 2 ft lb CARBURETOR SYNCHRONIZATION Carburetors must be adjusted to open and close simultaneously NOTE Valve clearance must be set properly before syn chronizing the carburetors 1 Remove Vacuum plugs CD 2 10 ...

Page 25: ...hronize carburetor No 1 to carburetor No 2 by turning synchronizing screw CD until both gauges read the same Rev the engine for a fraction of a second two or three times and check the synchronization again Vacuum Pressure at Idle Speed 22 7 24 0 kPa 170 180 mm Hg 6 69 7 09 in Hg Vacuum Synchronous Difference 1 33 kPa 10 mm Hg 0 4 in Hg Repeat the above steps to synchronize car buretor No 4 to carb...

Page 26: ... in Engine speed is increased Turn out Engine speed is decreased ENGINE OIL LEVEL INSPECTION g I 1 Place the motorcycle on its centerstand and warm up the engine for several minutes NOTE Position motorcycle straight up when checking oil level a slight tilt to the side can produce false readings 2 Stop the engine and visually check the oil level throught the level window G 3 Inspect Oil level Oil l...

Page 27: ...0W40 Type SE Motor Oil At 15 C 60 F or Lower SAE 10W30 Type SE Motor Oil ENGINE OIL REPLACEMENT Without Filter Change 1 Warm up the engine for several minutes then place a receptacle under the engine 2 Remove Oil filler cap 3 Remove Drain plug CD Drain the engine oil 4 Install Drain plug CD I 43 Nm 4 3 m kg 31 ft lbl 5 Fill Crankcase 1 1112 2L 11 9 Imp qt 2 3 US qt Do not allow foreign material to...

Page 28: ...er Change 1 Warm up the engine for several minutes then place a receptacle under the engine 2 Remove Oil filler cap Drain plug CD Drain the engine oil 3 Remove Oil filter bolt CD Filter cover CZ Oil filter 4 Install Drain plug Oil filter New Plain washer Spring Filter cover Oil filter bolt NOTE Be sure the 0 ring CD is positioned properly Drain Plug 43 Nm 4 3 m kg 31 ft lb Oil Filter Bolt 15 Nm 1 ...

Page 29: ... Stop engine instantly if leaking occurs Leaks Check cause After replacing the engine oil be sure to check the oil flow in the following proce dures Slightly loosen the oil gallery bolt j in the cylinder head Start the engine and keep it idling until oil begins to seep from the oil gallery bolt If no oil comes out after one minute turn the engine off so it will not seize Restart the engine after s...

Page 30: ...ay is decreased I Free Play I _D ____1_0_ _1s_m_m_ o_ 4_ _o_ 6_in_ _____ g 3 If free play can not be adjusted adjust free play by the adjuster G at right side of the crankcase 4 Loosen Locknut 5 Adjust Clutch lever free play Turn the adjuster in or out Turn in Turn out 6 Tighten Locknut Free play is increased Free play is decreased COMPRESSION PRESSURE MEASUREMENT NOTE Insufficient compression pre...

Page 31: ...ter be sure the battery is fully charged with the throttle wide open until the compression reading on the gauge stabilizes Check readings with specified levels See chart Compression Pressure At sea level Standard 1 079 kPa 11 kg cm2 156 psi Minimum 980 kPa 10 kg cm2 142 psi Maximum 1 128 kPa 11 5 kg cm2 164 psi WARNING When cranking the engine ground spark plug lead to prevent sparking Repeat the ...

Page 32: ... Above Inspect cylinder head maximum valve surfaces or piston level crown for carbon deposits NOTE The difference between the highest and lowest g cylinder compression readings must not vary more than the specified value Difference Between Each Cylinder Less than 98 kPa 1 kg cm2 14 psi FUEL LINE INSPECTION 1 Remove Cover CD 2 Inspect Fuel pipe CD Vacuum pipe CZ Cracks Damage Replace CARBURETOR JOI...

Page 33: ...ntilation pipe CD Cracks Damage Replace EXHAUST SYSTEM INSPECTION 1 Inspect Exhaust pipe Muffler Cracks Damage Replace Gaskets Exhaust gas leaks Replace AIR FILTER CLEANING 1 Remove Cover Carburetor CD Side cover Left 2 Remove Air filter case cover Left 3 Remove Air filter element CD The engine should never be run without the air filter element excessive piston and cylinder wear may result ...

Page 34: ...ir filter element Damage Replace 6 Install Air filter element Air filter case cover Left Side cover Left Cover Carburetor CHASSIS FUEL COCK CLEANING 1 Turn the fuel cock to ON position 2 Remove Cover Fuel tank G Seat 3 Disconnect Fuel pipe G Vacuum pipe Fuel tank breather pipe 4 Remove Fuel tank 5 Drain Fuel 2 20 ...

Page 35: ...the vicinity an open flame 6 Remove Fuel cock 7 Clean Filter screen CD Clean it with solvent 8 Inspect Filter screen 0 ring Damage Replace 9 Install Fuel cock Fuel tank Seat Cover Fuel tank NOTE Be careful not to clamp the fuel cock too tightly as this may unseat the 0 ring and lead to a fuel leak FRONT BRAKE FLUID INSPECTION 1 Inspect Brake fluid level Fluid at lower level Replenish CD Front brak...

Page 36: ...aster cylinder when refilling Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts FRONT BRAKE PAD INSPECTION 1 Depress the brake lever 2 Inspect Wear indicator CD Indicator almost contacts disc Replace pads FRONT BRAKE LEVER FREE PLAY ADJUSTMENT 1 Loosen Locknut CD 2 Adjust Free play Turn the adjuster 2 in or out Turn in Free play is decreased Turn out Free pla...

Page 37: ... 2 Adjust Brake pedal height Turn the adjuster in or out Turn in Pedal height is increased Turn out Pedal height is decreased Pedal Height 15 mm 0 6 in Below the top of the footrest WARNING After adjusting the pedal height adjust brake pedal free play BRAKE PEDAL FREE PLAY ADJUSTMENT 1 Adjust Free play Turn the adjuster CD in or out Turn in Free play is decreased Turn out Free play is increased ...

Page 38: ...CD Indicator reaches the wear limit line Replace shoes REAR BRAKE LIGHT SWITCH ADJUSTMENT 1 Remove Cover Carburetor CD Side cover Right 2 Remove Battery case cover CD 3 Adjust Rear brake light switch Hold the switch body CD with your hand so it does not rotate and turn the adjuster NOTE Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect 2 24 ...

Page 39: ...this tight chain position 1 Place the motorcycle on the centerstand 2 Measure Drive chain slack Out of specification Adjust Drive Chain Slack 20 30 mm 0 8 1 2 in DRIVE CHAIN SLACK ADJUSTMENT 1 Remove Cotter pin CD 2 Loosen Nut Rear axle Locknut 3 Adjust Chain slack Turn the adjuster in or out Turn in Chain slack is decreased Turn out Chain slack is increased NOTE There are marks on each side of re...

Page 40: ...the chain is not maintain ed properly it will wear out rapidly therefore form the habit of periodically servicing the chain This service is especially necessary when riding in dusty conditions SAE 10W30 Motor Oil CABLE INSPECTION AND LUBRICATION Cable inspection and lubrication steps Hold cable end high and apply several drops of lubricant to cable Coat metal surface of disassembled throttle twist...

Page 41: ...l Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil CENTERSTAND AND SIDESTAND LUBRICATION Lubricate centerstand and sidestand at their pivot points Yamaha Chain and Cable Lube or SAE 10W30 Motor Oil FRONT FORK OIL CHANGE 1 Place the motorcycle on the centerstand 2 Remove Handlebar 3 Loosen Bolt CD Handle crown 4 Remove Cap bolt 2 5 Place a receptacle under the drain hole 6 Remove Drain screw CD D...

Page 42: ...et Drain screw WearI Damage Replace 8 Install Drain screw Gasket 9 Fill Front fork Recommended Oil Yamaha Fork Oil 10WT or Equivalent For Oil Capacity Each Fork 320 cm3 11 3 Imp oz 10 8 US oz 10 After filling pump the forks slowly up and down to distribute the oil 11 Tighten Cap bolt Bolt Handle crown Cap Bolt 23 Nm 2 3 m kg 17 ft lb Bolt Handle Crown 23 Nm 2 3 m kg 17 ft lb 12 Install Handlebar N...

Page 43: ...setting Uneven adjustment can cause poor handling and loss of stability Recommended Rear Shock Absorber Settings Use this table as a guide for specific riding and motorcycle load conditions Rear shock absorber llllHARD SOFT 1 2 3 4 5 Solo rider SPRING ADJUSTER Position 1 2 2 29 Loading condition With accessories With accessories With and equipment passenger equipment and passenger 3 5 3 5 5 STEERI...

Page 44: ... Wrench CD YU 33975 Ring Nut 38 Nm 3 8 m kg 27 ft lb NOTE If steering is binded loosen the ring nut so that there is no free play on bearing 5 Install Handle crown Bolt Steering Stem 54 Nm 5 4 m kg 39 ft lb Bolt Handle Crown 20 Nm 2 0 m kg 14 ft lb FRONT WHEEL BEARING INSPECTION 1 Raise the front end of the motorcycle and spin the wheel by hand Touch the axle or front fender while spinning the whe...

Page 45: ...NT section 5 Tighten Nut Rear axle Nut Rear axle 105 Nm 10 5 m kg 75 ft lb 6 Install Cotter pin New TUBELESS TIRES AND ALUMINUM WHEELS INSPECTION WARNING Do not attempt to use tubeless tires on a wheel designed for tube type tires only Tire failure and personal injury may result from sudden deflation Wheel Tire Tube type Tube type only Tubeless Tube type or tubeless Be sure to install the correct ...

Page 46: ...53 lb load 28 psi 32 psi 160 kg 353 lb 196 kPa 245 kPa 2 0 kg cm2 2 5 kg cm2 Maximum load 28 psi 36 psi 196 kPa 226 kPa High speed riding 2 0 kg cm2 2 3 kg cm2 28 psi 32 psi Load is the total weight of cargo rider passenger and accessories 2 Inspect Tire surfaces WearI Damage Replace Minimum Tire Tread Depth Front and Rear 0 8 mm 0 03 in CD Tread depth Side wall Wear indicator 3 Inspect Aluminum w...

Page 47: ...ABLE ADJUSTMENT 1 Loosen Lock nut CD 2 Adjust Throttle cable free play Turn the adjuster in or out Turn in Free play is increased Torn out Free play is decreased Free play 2 5 mm 0 08 0 20 in ELECTRICAL IGNITION TIMING CHECK 1 Remove Crankcase cover Left 2 Connect Timing light YM 33277 To the 1 spark plug lead 3 Warm up the engine and allow it to idle at the specified speed Engine Idle Speed 1 250...

Page 48: ... cover SPARK PLUG INSPECTION 1 Inspect Electrode CD Wear Damage Replace Insulator color bl Normal condition is a medium to light tan color Distinctly different color Check the engine condition Spark plug gap 2 Clean Spark plug Clean the spark plug with a spark plug cleaner or wire brush 3 Inspect Spark plug type Incorrect Replace Standard Spark Plug D8EA NGK X24ESU N D 4 Measure Spark plug gap Out...

Page 49: ... you are installing a spark plug a good estimate of the cor rect torque is 1 4 to 1 2 turns part finger tight Have the spark plug torqued to the correct value as soon as possible with a torque wrench BATTERY INSPECTION 1 Remove Side cover Right CD 2 Inspect Fluid level should be between upper CD and lower level marks Incorrect Refill Refill with distilles water only tap water con tains minerals ha...

Page 50: ...5 Check Specific gravity Less than 1 280 Recharge battery Charging Current 1 2 amps 10 hrs Specific Gravity 1 280 at 20 C 68 F Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging Sulfation of one or more cells occurs as in dicated by the plates turning white or an ac cumulation of material exists in the bottom of the ce...

Page 51: ...NTERNAL Drink large quantities of water or milk follow with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE wh...

Page 52: ...tion of elec trical device If fuse blows immediately again check circuit in question WARNING Do not use fuses of higher amperage rating than recommended Extensive electrical system damage and fire could result from substitution of a fuse of improper amperage HEADLIGHT BEAM ADJUSTMENT 1 Remove Cover CD 2 Adjust Horizontal beam direction Loosen the adjusting screw CD and move the headlight body righ...

Page 53: ... the bulb holder counterclockwise to release bulb WARNING Keep flammable products or your hands away from the bulb while it is on it will be hot Do not touch the bulb until it cools down 4 Install Bulb New Secure the new bulb with the bulb holder Avoid touching glass part of bulb Also keep it free from oil otherwise transparency of glass bulb life and illuminous flux will be adversely affected If ...

Page 54: ...t 2 Remove Bulb socket Turn the bulb socket approximately 30 counterclockwise 3 Replace Defective bulb 4 Install Bulb socket Seat CARBURETOR AIR VENT SYSTEM INSPECTION CALIFORNIA ONLY 1 Inspect Hoses Air vent control valve Refer to CHAPTER 6 CARBURETOR AIR VENT SYSTEM section 2 40 ...

Page 55: ...2 41 ...

Page 56: ...ATOR 3 11 CLUTCH 3 12 OIL PUMP AND SHIFT SHAFT 3 13 CRANKCASE DISASSEMBLY 3 14 UPPER CRANKCASE 3 15 LOWER CRANKCASE 3 16 INSPECTION AND REPAIR 3 17 CYLINDER HEAD 3 17 VALVE VALVE GUIDE VALVE SEATS AND VALVE SPRING 3 18 CAMSHAFT CAM CHAIN AND CAM SPROCKET 3 25 CYLINDER 3 27 PISTON PISTON RING AND PISTON PIN 3 28 CRANKSHAFT AND CONNECTING ROD 3 31 OIL PUMP 3 35 PRIMARY DRIVE 3 36 STARTER DRIVES 3 36...

Page 57: ...ER CRANKCASE 3 44 UPPER CRANKCASE 3 48 CRANKCASE ASSEMBLY 3 49 OIL PUMP AND SHIFT SHAFT 3 54 CLUTCH 3 56 PICKUP COIL AND GENERATOR 3 60 PISTON AND INTAKE SIDE CAM CHAIN GUIDE 3 62 CYLINDER 3 64 CYLINDER HEAD 3 66 CAMSHAFT 3 68 REMOUNTING ENGINE 3 73 ...

Page 58: ...bly 2 Use proper tools and cleaning equipment Refer to CHAPTER 1 GENERAL INFOR MATION SPECIAL TOOLS section NOTE When disassembling the engine keep mated parts together This includes gears cylinder piston and other parts that have been mated through nor mal wear Mated parts must be reused as an as sembly or replaced 3 During engine disassembly clean all parts and place them in trays in the order o...

Page 59: ...ion oil completely Refer to CHAPTER 2 PERODIC INSPECTIONS AND ADJUSTMENTS ENGINE OIL REPLACEMENT section SEAT AND FUEL TANK 1 Place the motorcyCle on its centerstand 2 Turn the fuel cock to ON position 3 Remove Seat Cover Fuel cock CD 4 Remove Cover Carburetor Al Left side ID Right side 3 2 ...

Page 60: ...m pipe CZ Fuel tank breather pipe 6 Remove Fuel tank CARBURETOR 1 Remove Side cover Al Left side 6 Right side 2 Remove Battery case cover CD Battery Disconnect the negative lead first and then disconnect the positive lead 3 Remove Screws Fuse box lgnitor unit ...

Page 61: ...e Bolts Air cleaner case Bolts Battery case 5 Loosen ENG 1 1 Screws Carburetor joints 6 Slide the air cleaner case and the battery case backward 7 Remove Starter cable CD Throttle cable Air vent hoses Carburetor assembly 3 4 ...

Page 62: ...3 5 EXHAUST PIPES AND MUFFLERS 1 Remove Nuts Exhaust pipes 2 Loosen Bolts Exhaust pipes 3 Remove Exhaust pipes 4 Remove Mufflers DRIVE CHAIN 1 Remove Footrest Left Change pedal Drive sprocket cover ...

Page 63: ...ove Drive sprocket Drive chain CABLE AND PIPE 1 Loosen Adjusters clutch cable 2 Remove Clutch cable 3 Disconnect Crankcase ventilation hose CD LEADS 1 Disconnect Sidestand switch leads 2 Remove Starter motor lead Starter motor 3 6 ...

Page 64: ... leads Oil level switch leads Neutral switch leads AC magneto leads 4 Remove Spark plug leads CANISTER CALIFORNIA ONLY 1 Remove Canister CD at front of the engine ENGINE REMOVAL 1 Remove Footrest Right Brake pedal 2 Remove Horn CD ...

Page 65: ... Mounting bolts Engine assembly from right chassis ENGINE DISASSEMBLY CYLINDER HEAD AND CAMSHAFT 1 Remove Cylinder head cover CD Spark plugs 2 Remove Crankcase cover Left 3 Turn Crankshaft Counterclockwise 4 Align Timing plate T mark CD with the upper pickup coil mark 2 3 8 ...

Page 66: ...uide 6 Remove Chain guide stopper CD Chain guide Exhaust side 7 Remove Intake cam cap 3 Exhaust cam cap 3 8 Remove Bolts Camshaft sprocket 9 Dismount the sprockets from camshaft sprocket seats 10 Remove Cam caps Dowel pins Do not rotate the camshaft or valve damage may occur ...

Page 67: ...to pre vent it from falling i nio the crankcase 12 Remove Cylinder head NOTE Loosen the nuts in their proper loosening se quence 13 Remove Damper CD Front engine mount spacer CZ Nut Cylinder PISTON AND INlAKE SIDE CAM CHAIN GUIDE 1 Mark Pistons with piston number CD designations as shown 3 10 ...

Page 68: ...s Pistons NOTE Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin groove is deburred and piston pin is still difficult to re move use Piston Pin Puller YU 01304 Do not use a hammer to drive the piston pin out 4 Remove Bolt G Plate washer 2 Spring Stopper shaft Intake side cam chain guide PICKUP COIL AND GENERATOR 1 Remove Bolt G Timing plate ...

Page 69: ...Remove Stator coil CD 4 Remove Rotor securing bolt CD Rotor Use Rotor Holding Tool CV YM 04043 Rotor Puller YM 01080 and Pin YM 04052 CLUTCH 1 Remove Right crankcase cover CD Dowel pins Gasket 2 Remove Bolts CD Plate washers CZ Springs Pressure plate Friction plates Clutch plates 3 12 ...

Page 70: ... rag G or lead between the primary drive gears Then loosen the drive gear nut 4 Remove Nut G Lock washer Clutch boss Thrust washer Clutch housing OIL PUMP AND SHIFT SHAFT 1 Remove Circlip G Oil pump driven gear Oil pump assembly 0 rings 2 Remove Collar G Plate washer from left side shift shaft 3 Unhook the shift lever 2 and pull the shift shaft ...

Page 71: ...ASE DISASSEMBLY 1 Remove Right front crankcase cover 2 Remove Oil pan 3 Remove Upper crankcase bolts Al Lower crankcase bolts ill NOTE Remove the bolts starting with the highest num bered one The embossed numbers in the crankcase desig nate the crankcase tightening sequence e 8 mm 0 32 in Bolt 0 6 mm 0 24 in Bolt 3 14 ...

Page 72: ...KCASE 1 Remove Nut CD Lock washer C2 Primary drive gear Collar 2 Remove Screw CD Cover plate C2 Oil spray nozzle Bearing housing A C G shaft 3 Remove Starter clutch damper assembly CD Crankshaft assembly C2 Cam chain HY VO chain 4 Remove Screws CD Bearing stopper C2 Shaft Starter idler gear ...

Page 73: ...bly 2 Remove Lock washer CD Stopper screw Screws Guide bar stopper Bearing stopper 3 Remove Guide bar CD Shift forks Shift cam assembly 4 Remove HY VO chain guide CD HY VO chain tensioner Tensioner plunger Spring 5 Remove Oil strainer CD Screw Strainer housing Relief valve Tensioner side relief valve 3 16 ...

Page 74: ...lace 2 Attach Valve Spring Compressor YM 04019 CD 3 Remove Valve retainers CD Valve spring seat Valve springs Oil seal Valve spring seat Valve NOTE Deburr any deformed valve stem end Use an oil stone to smooth the stem end CD Deburr CZ Valve stem 4 Eliminate Carbon deposit from combustion chamber Use rounded scraper NOTE Do not use a sharp instrument and avoid damag ing or scratching Spark plug th...

Page 75: ... Stem Clearance Valve Guide Inside Diameter G Valve Stem Diameter Out of specification Replace valve or guide Valve Stem Clearance Maximum Intake Exhaust Bore gauge 2 Measure 0 010 0 037 mm 0 0004 0 0015 in 0 025 0 052 mm 0 0010 0 0020 in Valve face Pitting Wear Regrind Out of specification Replace Minimum Thickness Service Limit G 0 7 mm 0 0276 in 0 10 mm 0 004 in 0 12 mm 0 005 in Beveled 0 5 mm ...

Page 76: ...t IN 6 045 mm 0 238 in EX 6 020 mm 0 237 in 5 Inspect Valve guide Wear Oil leakage Replace NOTE Heat the cylinder head in an oven to 100 C 212 F to ease valve guide removal and reinstal lation and to maintain correct interference fit Valve Guide Replacement 1 Remove Valve guide Use Valve Guide Remover YM 04064 G NOTE Always replace valve guide if valve is replaced Always replace oil seal if valve ...

Page 77: ...dard width Wear limit Valve seat width 3 Apply 1 0 0 1 mm 2 0 mm 0 039 0 0039 in 0 078 in Mechanic s bluing dye Dykem to valve and seat 4 Position Valve into cylinder head 5 Spin it rapidly back and forth then lift valve and clean off all grinding compound 6 Inspect Valve seat surface Wherever valve seat and valve face made contact bluing will have been removed 7 Measure Valve seat width Valve sea...

Page 78: ...imeter of valve face but too wide or too narrow or not centered on valve face Cut Valve Seat As Follows Section A 0 Cutter Section B 45 Cutter Section C 60 Cutter Valve face indicates that valve seat is centered on valve face but is wide See a diagram Valve Seat Cutter Set Desired Result 0 Cutter to reduce valve Use seat width 60 Cutter Valve seat is in the middle of the valve face but too narrow ...

Page 79: ...e See d diagram Valve Seat Cutter Set Desired Result 60 Cutter first to obtain correct seat Use 45 Cutter width NOTE Lap valve valve seat assembly if Valve face valve seat are used or severely worn Valve and valve guide has been replaced Valve seat has been cut Valve Valve Seat Assembly Lapping 1 Apply Coarse lapping compound Small amount to valve face 2 Position Valve in cylinder head 3 Rotate Va...

Page 80: ...ndicat ed by grey surface all around valve face where bluing was removed 8 Apply Solvent into each intake and exhaust port Leakage past valve seat Replace valve until seal is complete NOTE Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of head parts Relapping steps Disassemble head parts Repeat lapping steps using fine lapping compound Clean all par...

Page 81: ...h Inner spring Outer spring Standard Wear limit Standard Wear limit 35 5 mm 33 5 mm 37 2 mm 1 398 in 1 319 in 1 465 in 2 Measure Valve spring installed force CD Out of specification Replace 35 2 mm 1 386 in Valve Spring Installed Force Inner spring Outer spring CD CD 30 5 mm 9 3 kg 32 0 mm 18 5 kg 1 20 in 20 5 lb 1 26 in 40 8 lb Installed length 3 24 ...

Page 82: ...l Valve springs Valve spring seat Valve retainers NOTE Install all springs with wider gapped coils facing upwards as shown CAMSHAFT CAM CHAIN AND CAM SPROCKET Camshaft 1 Measure Large cam lobe length CD Small cam lobe length Use a micrometer Out of specification Replace Intake Exhaust CD 36 25 36 35 mm 35 75 35 85 mm 1 427 1 431 in 11 408 1 411 in 28 10 28 20 mm 28 05 28 15 mm 1 106 1 110 in 1 104...

Page 83: ... with Plastigage 4 Remove Camshaft caps 5 Measure Width of Plastigage CD Out of specification Follow step 6 Camshaft to cap Clearance Standard 0 020 0 054 mm 0 0008 0 0021 in Maximum 0 160 mm 0 006 in 6 Measure Camshaft bearing surface diameter Use micrometer Out of specification Replace camshaft Within specification Replace cylinder head Bearing surface Diameter Standard 24 967 24 980 mm 0 9830 0...

Page 84: ...Exhaust side chain guide Intake side chain guide Chain guide stopper Spring Guide stopper plate WearI Damage Replace Cam Chain Tensioner 1 Inspect All parts Damage Wear Replace CD Tensioner rod Small Damper Tensioner rod Large Spring Gasket Tensioner body J 0 ring CYLINDER 1 Inspect Cylinder walls Vertical scratches Rebore or Replace cylinder ...

Page 85: ...ylinder taper T 0 05 mm 0 002 in C Maximum D T Maximum D1 D2 Minimum Ds 06 PISTON PISTON RING AND PISTON PIN Piston 1 Measure Piston skirt diameter P NOTE Measure the piston skirt diameter where the dis tance 1 o mm m 21s inl CD trom the piston bot tom edge Piston size Standard 58 50 mm 2 303 in Oversize 2 59 00 mm 2 323 in Oversize 4 60 00 mm 2 362 in 2 Measure Piston clearance Out of specificati...

Page 86: ...0 02 0 06 mm 0 0008 0 0024 in NOTE Insert a ring into cylinder and push it approxi mately 20 mm 0 8 in into cylinder Push ring with piston crown so that ring will be at a right angle to cylinder bore 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure end gap on expander spacer of oil control ring If oil control ring rails show ex cessive gap replace all three rings Standar...

Page 87: ... ring oil control ring is color coded to identify sizes Size Oversize 2 Oversize 4 Piston Pin 1 Lubricate Piston pin Lightly 2 Install Piston pin Color Blue Yellow into small end of connecting rod 3 Check Free play Free play Inspect connecting rod for wear Wear Replace connecting rod and piston pin 4 Position Piston pin into piston 5 Check Free play into piston Free play Replace piston pin and or ...

Page 88: ...ecting Rod Bearings 1 Inspect Bearings Burns Flaking Roughness Scratches Replace Connecting Rod Bearing Clearance 1 Clean all parts throughly 2 Install Connecting rod bearings into connecting rod and cap 3 Attach Plastigage onto crankpin 4 Position Connecting rod onto crankshaft Connecting rod cap 5 Apply Molybdenum disulfide grease to bolt threads Torque both ends of rod cap evenly NOTE Do not mo...

Page 89: ...18 ft lb 6 Remove Connecting rod cap Remove carefully 7 Measure Plastigage width CD Out of specification Replace connecting rod bearing Connecting Rod Bearing Clearance 0 016 0 040 mm 0 0006 0 0016 in Crankshaft Main Bearing Clearance Measurement 1 Clean all parts 2 Position Upper crankcase half Place on a bench in an upside down po sition 3 Install Bearings into the upper crankcase 4 Attach Plast...

Page 90: ...rque in torque sequence cast on the crankcase 8 mm 0 3 in Bolt 24 Nm 2 4 m kg 17 ft lb 7 Remove Bolts Reverse assembly order Lower crankcase Use care in removing 8 Measure Plastigage width CD YU 33210 Out of specification Replace bearings replace crankshaft if necessary Main Bearing Oil Clearance 0 021 0 044 mm 0 0008 0 0017 in ...

Page 91: ...ers starting with the left journal The four 4 rod bearing journal numbers follow in the same sequence The upper crankcase half is numbered J1 J2 J3 J4 and J5 on the rear right bosse as shown The connecting rods are numbered 4 or 5 The numbers are stamped in ink on the rod cap G Bearing color code No 1 Blue No 2 Black No 3 Brown No 4 Green No 5 Yellow No 5 applies only to the crankshaft main bear i...

Page 92: ...d bearing If the connecting rod P1 and crank shaft P1 sizes are No 4 and No 1 repective ly the bearing size No is Bearing size No Connecting rod No crankshaft No 4 1 3 Brown OIL PUMP 1 Remove Screw CD Pump cover 2 Shaft Pin Inner rotor Outer rotor Pump housing J 2 Measure Clearance A between inner rotor CD and outer rotor 2 Clearance B between outer rotor 2 and pump housing l Oil Pump Clearance Cl...

Page 93: ...rimary drive gear Primary driven gear Wear Damage Replace both gears Excessive noises during operation Replace 1 111 both gears Primary reduction ratio No of teeth I I 22 21 65 28 STARTER DRIVES Electric Starter Clutch 1 Check Ball operation Spring operation Spring cap operation Ratio 2 431 Unsmooth operation Replace one way clutch 2 Inspect Surface of the idle gear Pitting Wear Damage Replace 3 3...

Page 94: ...t c Install Spring Spring cap Ball Idle gear Collar Starter Clutch Shaft 1 Check Shaft CD WearI Damage Replace Bearing Unsmooth operation Replace CLUTCH 1 Inspect Clutch housing dogs CD Cracks Pitting edges Moderate Deburr Severe Replace clutch housing NOTE Pitting on friction plate dogs of clutch housing will cause erratic operation 2 Inspect Clutch housing bearing Damage Replace ...

Page 95: ...te warpage Al Friction plate thickness ID Out of specification Replace Clutch or friction plate as a set Friction plate thickness Clutch plate warp limit 5 Inspect Standard 2 9 3 1 mm 0 114 0 122 in Washer CD Thrust bearing Pull rod Damage Replace 6 Measure Clutch spring free play Wear limit 2 7 mm 0 106 in 0 15 mm 0 006 in Out of specification Replace spring as a set Clutch Spring Minimum Free Le...

Page 96: ...e plate Shift cam stopper plate circlip and stopper WearI Damage Replace 4 Measure Transmission shaft runout Use centering device and dial gauge Out of specification Replace bent shaft I Runout Limit 0 08 mm 0 0031 in 5 Inspect Gear teeth Blue discoloration Pitting Wear Replace Mated dogs Rounded edges Cracks Missing portions Replace 6 Check Proper gear engagement Each gear to its counter part Inc...

Page 97: ...eplace 2 Check HY VO chain tensioner CD Oil delivery pipe CV 0 ring Cotter pin Damage Replace RELIEF VALVES 1 Check Relief valve body CD Plunger CV Spring 0 ring Damage Wear Replace 2 Check Tensioner side relief valve body CD Plunger CV Spring Damage Wear Replace CRANKCASE 1 Inspect Case halves Bearing seat Fitting Damage Replace 3 40 ...

Page 98: ...IL SEALS 1 Inspect Bearing Clean and lubricate then rotate inner race with finger Roughness Replace bearing see Re moval 2 Inspect Oil seals Damage Wear Replace see Removal CIRCLIPS AND WASHERS 1 Inspect Circlips Washers Damage Looseness Bends Replace ...

Page 99: ...EMBLY AND ADJUSTMENT SHIFTER CD Guide bar 2 Shift fork 3 Shift fork 2 Shift fork 1 Shift cam assembly l a I I22 Nm 2 2 m kg 16 ft lb I 110 Nm 1 0 m kg 7 2 ft lb I a 10 Nm 1 0 m kg 7 2 ft lb 3 ENG I I I I I 4 3 42 ...

Page 100: ...late washer 1st wheel gear 5th wheel gear Washer 4th wheel gear 3 43 A RUNOUT LIMIT 0 08 mm 0 0031 in 3rd wheel gear 6th wheel gear 2nd wheel gear Bearing 0 ring Oil seal Collar Drive sprocket Drive axle Main axle 5th pinion gear 3rd 4th pinion gear 6th pinion gear 2nd pinion gear 9 ...

Page 101: ...Relief valve 2 Strainer housing Screws I 10 Nm 1 0 m kg 7 2 ft lbl Oil strainer 2 Install HY VO chain tensioner CD Screw 10 Nm 1 0 m kg 7 2 ft lb Apply LOCTITE HV VO chain guide 2 Spring Tensioner plunger 3 Install Shift cam assembly CD Shift forks 2 Guide bar NOTE All shift fork numbers should face the right side and be in sequence 1 2 3 beginning from the right 3 44 ...

Page 102: ...Nm 2 2 m kg 16 ft lb Apply LOCTITE Lock washer NOTE Bend lockwasher tab along nut flat 5 Install Circlips CD Oil seal 6 Install Transmission assembly CD NOTE Be sure axle circlips are fitted to bearings and cir clips have been positioned in circlip grooves 7 Check Shifter operation Unsmooth operation Repair Transmission operation Unsmooth operation Repair ...

Page 103: ...DJUSTMENT IENG I 1 STARTER CD Primary drive gear Starter idle gear Bearing Starter clutch Starter clutch damper assembly HY VO chain J A C G shaft HY VO chain guide 50 Nm 5 0 m kg 36 ft lb 4 I10 Nm 1 0 m kg 7 2 ft lb I 3 46 ...

Page 104: ... rod Big end cap Bearing Crankshaft assembly Bearing Oil seal A CRANKSHAFT RUNOUT LIMIT 0 03 mm 0 0012 in CONNECTING ROD BEARING B CLEARANCE 0 016 0 040 mm 0 0006 0 0016 in 4 3 47 25 Nm 2 5 m kg 18 ft lb MAIN BEARING OIL CLEARANCE C 0 021 0 044 mm 0 0008 0 0017 in ...

Page 105: ...t assembly Starter clutch damper assembly NOTE The crankshaft pin timing plate stopper pin should face to the left Pass the cam chain through the cam chain cavi ty Be sure to attach a retaining wire j to the cam chain 3 Install A C G shaft CD Bearing housing Oil spray nozzle Cover plate Screw 10 Nm 1 0 m kg 7 2 ft lb Apply LOCTITE 4 Install Collar CD Primary drive gear Lock washer Nut 3 48 ...

Page 106: ...tact with the oil gallery 0 ring or crankshaft bearings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the bearings 2 Set shift cam and transmission gears in NEU TRAL position 3 Place suitable bar on the upper crankcase 4 Place lower crankcase assembly on the up per crankcase assembly NOTE Push HY VO chain damper to prevent tensioner plunger from falling into crankcase cavity 5 Install Lowe...

Page 107: ...ts correctly while hand turning the shift cam 6 Tighten Lower crankcase bolt lli Upper crankcase bolt Al Follow proper tightening sequence Io mm 0 24 in 12 Nm 1 2 m kg 8 7 ft lb 8 mm 0 31 in 24 Nm 2 4 m kg 17 ft lb NOTE Install the clamp CD on Bolt No 26 Install the ground lead on Bolt No 32 7 Install Oil pan I 10 Nm 1 0 m kg 7 2 ft lbl 3 50 ...

Page 108: ...ENG I I ENGINE ASSEMBLY AND ADJUSTMENT 8 Install Right front crankcase cover I 10 Nm 1 0 m kg 7 2 ft lb 3 51 ...

Page 109: ...ENGINE ASSEMBLY AND ADJUSTMENT IENG I I OIL PUMP CD Oil pump drive gear 2 Shaft Pin Oil pump housing Rotor Pump cover J 0 ring 7 Nm 0 7 m kg 5 1 ft lbl r r L I 3 52 ...

Page 110: ...I ENG I 1 1 ENGINE ASSEMBLY AND ADJUSTMENT SHIFT SHAFT CD Shift shaft Collar Spring Circlip Plain washer Stopper lever f Spring 3 53 Plain washer Oil seal Plain washer Collar Change pedal ...

Page 111: ...shaft assembly CD 2 Mesh the stopper lever 2 with shift cam stopper 3 Pull the shift lever 2 and push shift shaft assembly 4 Install Plate washer CD Collar 2 on left side shift shaft 5 Install 0 rings CD Oil pump assembly 2 I 7 Nm 0 7 m kg 5 1 ft lbl Oil pump driven gear Circlip 3 54 ...

Page 112: ...seal Circlip Lock washer Clutch plate 1 Friction plate 1 J Wire clip 3 55 Clutch plate Clutch boss spring Seat Thrust plate Bearing Pull rod Match mark ID ICLUTCH PLATE POSITION I 1 6 CLUTCH PLATE WARP LIMIT 0 15 mm 0 006 in FRICTION PLATE C WEAR LIMIT 2 7 mm 0 106 in ...

Page 113: ... folded rag between the teeth of the drive gear and driven gear to lock them Nut Clutch Boss 70 Nm 7 0 m kg 50 ft lb Nut Primary Drive Gear 50 Nm 5 0 m kg 36 ft lb NOTE Bend the lock washer tab along the nut flat 3 Install Friction plates Clutch plates NOTE Mount friction and clutch plates alternately Align the clutch plate mark CD as shown 4 Install Thrust bearing 2 Plate washer on the pull rod P...

Page 114: ...late CD Spring Plate washer Bolt I 8 Nm 0 8 m kg 5 8 ft lb NOTE Align the pressure plate mark CD with the clutch boss mark 6 Install Gasket CD Dowel pins Right crankcase cover I 10 Nm 1 0 m kg 7 2 ft lb NOTE Be sure the pull rod gear CD face to rear of engine 2 Upper ...

Page 115: ...____E_N_G_l_N_E_A_s_s_EM_B_L_Y_A_N_D_A_D_J_u_s_T_M_E_N_T1 G1 1 GENERATOR CD Startor coil CZ Rotor Brush assembly BRUSH LENGTH A 83 2 mm 3 27 in LIMIT 10 mm 0 39 in 8 Nm 0 8 m kg 5 8 ft lbl 3 58 ...

Page 116: ...IENG j 1 ENGINE ASSEMBLY AND ADJUSTMENT PICKUP COIL CD Pickup coil assembly Pin Timing plate 3 59 8 Nm 0 8 m kg 5 8 ft lb I a A PICKUP COIL RESISTANCE 108 1320 at 20 C 68 Fl 3 24 Nm 2 4 m kg 17 ft lb ...

Page 117: ...2 Install Stator coil CD NOTE Align the stator core grooves with the bolt holes 3 Install Generator cover Pickup coil assembly CD Screw Pickup Coil Assembly 8 Nm 0 8 m kg 5 8 ft lb Apply LOCTITE 4 Install Timing plate CD Screw I 24 Nm 2 4 m kg 17 ft lbl Mesh the timing plate groove with the crankshaft pin 5 Clamp the A C G leads and pickup leads 3 60 ...

Page 118: ...ring Lower rail Second ring Oil ring Upper rail 3 61 A B c IDI PISTON RING INSTALLATION I PISTON RING END GAP TOP AND 2nd 0 15 0 30 mm 0 0059 0 0118 in OIL 0 2 0 7 mm 0 008 0 028 in PISTON RING SIDE CLEARANCE TOP 0 03 0 07 mm 0 0012 0 0028 in 2nd 0 02 0 06 mm 0 0008 0 0024 in PISTON CLEARANCE 0 025 0 045 mm 0 0010 0 0019 in ...

Page 119: ...TE Be sure to install rings so that Manufacturer s marks or numbers are located on the top side of the rings Oil the pistons and rings liberally 3 Install Piston pin Piston Piston pin circlip New NOTE Be sure the piston arrow mark CD face to ex haust side Before installing piston pin circlip cover crank case with a clean rag to prevent circlip from fall ing into crankcase cavity Be sure the marked...

Page 120: ... AND ADJUSTMENT CYLINDER CD Cylinder Z 0 ring Gasket Dowel pin 0 ring A CYLINDER BORE C CYLINDER TAPER T TANDARD 58 5 mm 2 303 in 10 Nm 1 0 m kg 7 2 ft lb 3 63 WEAR LIMIT 58 6 mm 2 307 in 0 05 mm 0 002 in 20 Nm 2 0 m kg 14 ft lb ...

Page 121: ...s 3 Set Top ring end CD Oil ring end Lower Oil ring end Upper 2nd ring end 4 Install Cylinder Use Piston YM 04047 YM 01067 Ring Compressor and Piston Base Pass the cam chain and exhaust side cam chain guide through cam chain cavity 5 Tighten Cylinder nut CD l l 20 Nm 2 0 m kg 14 ft lb 6 Install Front engine mount spacer Damper 3 64 ...

Page 122: ... Spark plug Valve guide Circlip Q Stud bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Nm 0 5 m kg 3 6 ft lb 3 65 I A ITIGHTENING SEQUENCE I ID IFRONT I 0 E USE COPPER WASHERS 10 Nm 1 0 m kg 7 2 ft lb B ITYPE GAP DBEA N G K X24ESU N D 0 6 0 7 mm 0 024 0 028 in C CYLINDER HEAD WARP LIMIT 0 03 mm 0 0012 in ...

Page 123: ...Gl I CYLINDER HEAD 1 Install Dowel pins CD 0 rings Z Head gasket New Cylinder head 2 Tighten Cylinder head nuts In sequence as shown and torque nuts in two stages Nut No CD 22 Nm 2 2 m kg 16 ft lb Nut No 10 Nm 1 0 m kg 7 2 ft lb NOTE Use copper washers 3 66 D ...

Page 124: ...od Small 3 67 Guide stopper plate Upper chain guide Exhaust side chain guide Intake side chain guide Adjusting pad Valve lifter Valve retainer Spring seat Inner spring Outer spring Spring seat Oil seal Valve Chain guide stopper Match mark A VALVE CLEARANCE COLD B INTAKE 0 11 0 15 mm 0 004 0 006 in c EXHAUST 0 16 0 20 mm 0 006 0 008 in 8 Nm 0 8 m kg 5 8 ft lbl 9 Nm 0 9 m kg 6 5 ft lb ...

Page 125: ...ression stroke 3 Install Cam chain sprockets on the camshafts I and E camshafts Apply engine oil to camshaft bearing surfaces before installing camshafts 4 Remove Retaining wire CD NOTE I mark CD for intake camshaft E mark CZ for exhaust camshaft 5 Install Dowel pins Cam caps I 10 Nm 1 0 m kg 7 2 ltolbl NOTE Do not install No 3 intake 0 3 and No 3 exhaust E 3 cam caps at in this stage 3 68 ...

Page 126: ...arrow mark Do not rotate the camshaft over 1 2 turn or damage to the piston and valve will result 3 Position Cam chain onto sprockets 4 Install Sprockets onto camshafts 5 Force the exhaust sprocket clockwise view ing from left side engine to remove all cam chain slack 6 Align _ Sprocket hole with the exhaust camshaft thread hole NOTE If the sprocket hole do not align with the cam shaft hole adjust...

Page 127: ...aft over 1 2 turn or damage to the piston and valve will result 10 Force the intake sprocket clockwise viewing from left side engine to remove all cam chain slack 11 Align Intake sprocket hole with the intake camshaft thread hole NOTE If the sprocket hole do not align with the cam shaft thread hole adjust chain links between ex haust and intake camshafts 12 Install Intake sprocket bolt temporarily...

Page 128: ...upper pickup coil mark 13 Rotate Crankshaft Counterclockwise 14 Align Timing plate T mark CD with the upper pickup coil mark 2 1 15 Install Exhaust side chain guide CD Chain guide stopper CZ Bolt Lock washer 16 Bend the lock washer tab against bolt flat 17 Install Upper chain guide CD 18 Install Cam chain tensioner CD I 10 Nm 1 0 m kg 7 2 ft lbl 19 Loosen Locknut CZ Tensioner lock bolt ...

Page 129: ...sioner installation steps Install the spring large tensioner rod damper small spring and small ten sioner rod CD into the tensioner body Push the tensioner rod assembly into the body NOTE Face the large rod surface to the lock bolt j Tighten lock bolt Lock the locknut Gasket 21 Rotate Crankshaft Counterclockwise 22 Install Sprocket bolts all I 24 Nm 2 4 m kg 18 ft lb 3 72 ...

Page 130: ... ft lbl 25 Install Spark plug CD l 111 5 Nm 1 75 m kg 12 7 ft lbl Head cover gasket Head cover I Bolt 10 Nm 1 0 m kg 7 2 ft lb REMOUNTING ENGINE Reverse the removal procedure Note the follow ing points 1 Tighten Engine mounting bolts Front Upper Bolts G 42 Nm 4 2 m kg 30 ft lb Front Bracket Bolt 32 Nm 3 2 m kg 23 ft lb Front Lower Bolts 42 Nm 4 2 m kg 30 ft lb Rear Bolts 90 Nm 9 0 m kg 65 ft lb ...

Page 131: ...otrest I 70 Nm 17 0 m kg 50 ft lbl 4 Install Brake pedal NOTE Align the punch marks on the brake shaft and the pedal 5 Install Starter motor Bolt Starter Motor 10 Nm 1 0 m kg 7 2 ft lb 6 Install Drive chain Drive sprocket Bolts Drive Sprocket 10 Nm 1 0 m kg 7 2 ft lb 3 74 ...

Page 132: ...m 2 5 m kg 18 ft lb Bolt 25 Nm 2 5 m kg 18 ft lb 9 Install Exhaust pipes Nuts Exhaust Pipe 10 Nm 1 0 m kg 7 2 ft lb Bolts Exhaust Pipe Joint 20 Nm 2 0 m kg 14 ft lb 10 Fill Crankcase Recommended Oil Vamalube 4 SAE 20W40 Type SE Motor oil or SAE 10W30 Type SE Motor oil Refer to CHAPTER 2 ENGINE OIL LEV EL INSPECTION section CD Level window 2 Maximum mark Minimum mark ...

Page 133: ... 5 mm 0 08 0 20 in Refer to CHAPTER 2 BRAKE LEVER FREE PLAY ADJUSTMENT section CD Locknut 2 Adjuster 13 Adjust Clutch lever free play I I Free Play 10 15 mm 0 4 0 6 in Refer to CHAPTER 2 CLUTCH LEVER FREE PLAY ADJUSTMENT section CD Locknut 2 Adjuster 14 Adjust Cam chain Refer to CHAPTER 2 CAM CHAIN AD JUSTMENT section 15 Adjust Idle speed 1w11 250 1 350 r min Refer to CHAPTER 2 IDLE SPEED ADJUST M...

Page 134: ...IENG I I___ M EMMo 3 77 ...

Page 135: ...CHAPTER 4 CARBURETION CARBURETOR 4 1 SECTION VIEW 4 2 REMOVAL 4 3 DISASSEMBLY 4 5 INSPECTION 4 7 ASSEMBLY 4 8 INSTALLATION 4 9 ADJUSTMENT 4 10 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 4 13 ...

Page 136: ...tarter lever Synchronizing screw Throttle stop screw 13 Nm 0 3 m kg 2 2 ft lb l 1 I_ 2 Nm 0 2 m kg 1 4 ft lb 4 1 SPECIFICATIONS MAIN JET MAIN AIR JET PILOT JET PILOT AIR JET JET NEEDLE 1 AND 4 2 AND 3 PILOT SCREW THROTTLE VALVE ENGINE IDLE SPEED FUEL LEVEL FLOAT HEIGHT 97 5 140 30 135 4CHP2 4CHP4 PRESET 140 1 250 1 350 r min 2 0 5 mm 0 08 0 02 in 20 1 0 mm 0 8 0 04 in 5 Nm 0 5 m kg 3 6 ft lb ...

Page 137: ...SECTION VIEW CD Throttle valve 2 Pilot air jet Jet needle Pilot jet Main jet Main nozzle J Valve seat Float Starter plunger Starter jet _ 1 1 _J L__ 4 I IA Main metering system BJ Float system Starter system J Air 1 Fuel Mixture 4 2 ...

Page 138: ..._________ 4 3 REMOVAL 1 Turn the fuel cock to ON position 2 Remove Seat Cover Fuel cock CD 3 Remove Cover Carburetor Al Left side ID Right side 4 Disconnect Fuel pipe CD Vacuum pipe 2 Fuel tank breather pipe 5 Remove Fuel tank ...

Page 139: ... cover A Left side ID Right side 7 Remove Battery case cover CD Battery Disconnect the negative lead first and then disconnect the positive lead 8 Remove Screws Fuse box lgnitor unit 9 Remove Bolts Battery case Bolts Air cleaner case 4 4 ...

Page 140: ...2 3 Remove Vacuum chamber cover G Spring 2 Throttle valve assembly 4 Remove Jet needle cover G Spring 2 Jet needle 5 Remove Float chamber cover Gasket Float pin G Float 2 Valve seat plate Valve seat assembly 6 Remove Main jet G Washer 2 Pilot jet Main nozzle 4 6 ...

Page 141: ...er case and the battery case backward 12 Remove Starter cable CD Throttle cable 2 Air bent hoses Carburetor assembly DISASSEMBLY NOTE The following parts can be cleaned and inspected without carburetor separation Throttle valve Starter plunger Float chamber components 1 Remove Starter lever shaft ...

Page 142: ...el passage Contamination Clean as indicated Carburetor cleaning steps Wash carburetor in petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all passages and jets with com pressed air 2 Inspect Floats Damage Replace 3 Inspect Float needle valve CD Seat 0 ring Damage WearI Contamination Replace as a set ...

Page 143: ... Inspect Starter plunger WearI Damage Replace 7 Check Free movement Insert the throttle valve into the carburetor body and check for free movement Stick Replace ASSEMBLY To assemble the carburetor reverse the disassem bly procedures Note the following points Before reassembling wash all parts in clean gasoline Always use a new gasket 4 8 ...

Page 144: ...er cover Vacuum chamber cover Screw Float Chamber Cover 2 Nm 0 2 m kg 1 4 ft lb Screw Vacuum Chamber Cover 3 Nm 0 3 m kg 2 2 ft lb 3 Install Upper bracket Lower bracket Screw Upper Bracket 3 Nm 0 3 m kg 2 2 ft lb Screw Lower Bracket 5 Nm 0 5 m kg 3 6 ft lb 4 Install Starter lever shaft Screw Starter Lever Shaft 3 Nm 0 3 m kg 2 2 ft lb Apply LOCTITE INSTALLATION 1 Install Carburetor assembly Reserv...

Page 145: ...t Out of specification Adjust it by the follow ing adjustment steps Float Height 20 0 1 0 mm 0 8 0 04 in Float height measurement steps Hold the carburetor in an upside down po sition Incline the carburetor at 60 70 so that the end of the float valve does not hang down as a result of float weight Measure the distance from the mating surface of the float chamber gasket removed to the top of the flo...

Page 146: ...t by the follow ing adjustment steps Fuel Level 2 0 0 5 mm 0 08 0 02 in Below the Carburetor Body Edge Fuel level measurement steps Place the motorcycle on the level place Install the Fuel Level Gauge Adapter YM 01329 to the drain hole of the carburetor Connect the Fuel Level Gauge YM 01312 to the Adapter Place the Gauge vertically next to the center of the mating line of the mixing body and float...

Page 147: ...emove the carburetor assembly Refer to REMOVAL section Remove the float valve seat and the needle valve Inspect the valve seat and the needle valve If either is worn replace as a set If both are fine adjust the float height by bending the float tang G Recheck the fuel level 4 12 ...

Page 148: ..._R_A_N_o_c_R_A_N_K_c_A_c_E_v_E_N_T_1L_A_T_1_o_N_ AIR CLEANER AND CRANKCASE VENTILATION SYSTEM Refer to CHAPTER2_ AIR CLEANER CLEAN ING for air cleaner maintenance 4 13 CD Air cleaner Carburetor Fresh air Blow by gas 2 ...

Page 149: ...ON 5 17 MASTER CYLINDER DISASSEMBLY 5 18 INSPECTION 5 19 INSTALLATION 5 20 AIR BLEEDING 5 21 FRONT FORK 5 23 REMOVAL 5 24 DISASSEMBLY 5 25 INSPECTION 5 26 REASSEMBLY 5 27 INSTALLATION 5 29 STEERING HEAD 5 31 REMOVAL 5 32 INSPECTION 5 35 INSTALLATION 5 36 REAR SHOCK ABSORBER 5 39 REMOVAL 5 40 INSPECTION 5 40 INSTALLATION 5 40 SWINGARM 5 41 REMOVAL 5 42 INSPECTION 5 43 ADJUSTMENT 5 44 INSTALLATION 5...

Page 150: ...WHEEL Collar J Bearing CD Front axle Oil seal Met er clutch fE Bearing Cl t W Spacer 1111 Oi s lretainer cer F rn assembly Flange spa LY Gear u t ront wheel B RIM SIZE MT 2 50x16 RIM RUNO VERTICALUT LIMIT C 2 0 mm 0 LATERAL 08 in 2 0 mm 0 08 in 5 1 ...

Page 151: ...e Axle Front wheel NOTE Do not depress the brake lever when the wheel is off the motorcycle otherwise the brake pads will be forced shut INSPECTION 1 Eliminate any corrosion from parts 2 Inspect Front axle Roll the axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent axle 3 Measure Wheel runout Out of specification Check the wheel and the bearing play Rim Runout Limits ...

Page 152: ... wheel hub Remove the bearing using a general bearing puller G Install the new bearing NOTE Use a socket that matches the outside diameter of the race of the bearing Do not strike the inner race of balls of the bearing Contact should be made only with the outer race 6 Check Wheel balance Wheel is not statically balanced if it comes to rest at the same point after several light rotations Out of bal...

Page 153: ... valve stem locknut G to specification Valve Stem Locknut 1 5 Nm 0 15 m kg 1 1 ft lb INSTALLATION When installing the front wheel reverse the removal procedure Note the following points 1 Apply Lithium base grease Lightly grease to the oil seal and gear unit 2 Install Gear unit assembly NOTE Make sure the projections inside the gear unit are meshed with the flats in the wheel hub 3 Install Front w...

Page 154: ... cHAsl 50 IFRONT WHEEL 5 5 4 Tighten Axle nut I 105 Nm 10 5 m kg 75 ft lbl Bolts Brake caliper 1 135Nm 3 5 m kg 25 ft lbl Pinch bolt I 20 Nm 2 0 m kg 14 ft lbl ...

Page 155: ...FRONT WHEEL icHAsl I MEMO 5 6 ...

Page 156: ...el Bearing Hub QJ Drive chain Driven sprocket Collar Bearing Oil seal Collar 20 Nm 2 0 m kg 14 ft lb 5 7 TIRE SIZE A 130 90 16 67H B WHEEL SIZE MT 3 00x16 WHEEL RUNOUT LIMIT C VERTICAL 2 0 mm 0 08 in LATERAL 2 0 mm 0 08 in BRAKE LINING WEAR LIMIT 2 mm 0 08 in E BRAKE DRUN WEAR LIMIT 181 mm 7 12 in IBALL 6303RS I BALL 6304 32 Nm 3 2 m kg 23 ft lb ...

Page 157: ...erstand WARNING Support the motorcycle securely so there is no danger of it falling over 2 Remove Adjuster Spring Pin 3 Remove Cotter pin Nut Spring washer Plain washer Bolt 4 Loosen Lock nuts Drive chain Adjuster Drive chain 5 Remove Cotter pin Nut Rear axle Rear wheel 5 8 ...

Page 158: ... WHEEL INSPECTION section 4 Check Wheel bearings Refer to FRONT WHEEL INSPECTION section 5 Check Wheel balance Refer to FRONT WHEEL INSPECTION section 6 Inspect Brake lining surface Glazed areas Remove Use a coarse sand paper NOTE After using the sand paper clean of the polished particles with cloth 7 Measure Brake lining thickness Out of specification Replace CD Measuring points Brake Lining Thic...

Page 159: ... emery cloth lightly and evenly polishing 9 Measure Brake drum inside diameter Out of specification Replace rear wheel Brake Drum Inside Diameter 180 mm 7 08 in Wear Limit 181 mm 7 12 in 10 Inspect Camshaft face Wear Replace ASSEMBLY BRAKE SHOE PLATE When assemblying the brake shoe plate reverse the disassembly procedure Note the following points 1 Apply Lithium soap base grease to the brake cam s...

Page 160: ...the rear wheel reverse the removal procedure Note the following points 1 Apply Lithuim base grease Lightly gerase to the oil seal lips 2 Adjust Drive chain slack Drive Chain Slack 20 30 mm 0 8 1 2 in Refer to CHAPTER 2 DRIVE CHAIN SLACK ADJUSTMENT section 3 Tighten Axle nut l l 105 Nm 110 5 m kg 75 ft lbl Nut Tension bar l l 20 Nm 2 0 m kg 14 ft lbl ...

Page 161: ...G Always use a new cotter pin on the axle nut 5 Adjust Brake pedal free play 1 0 Free Play v J 20 30 mm 0 8 1 2 in Refer to CHAPTER 2 BRAKE PEDAL FREE PLAY ADJUSTMENT section WARNING Check the operation of the brake light after adjusting the rear brake 5 12 ...

Page 162: ...ake caliper Left Piston FRONT BRAKE Piston seal J Dust seal Brake pad Pad spring Install the pad spring with its longer tangs facing towards the disc rotation direction BRAKE PAD WEAR LIMIT 0 5 mm 0 02 in 3 5 13 6 Nm 0 6 m kg 4 3 ft lb 35 Nm 3 5 m kg 25 ft lb 2 BRAKE DISC WEAR LIMIT 4 mm 0 15 in ...

Page 163: ...ly Master cylinder cap Rubber seal Master cylinder kit Copper washer Brake hose J Joint FRONT BRAKE lcHAslb 0 I 2 Nm 0 2 m kg 1 4 ft lb A BRAKE FLUID TYPE I I I I 25 Nm 2 5 m kg 18 ft lbl DOT 3 8 Nm 0 8 m kg 5 8 ft lbl 25 Nm 2 5 m kg 18 ft lbl 5 14 ...

Page 164: ...sembly Do not use solvents on brake internal components Solvents will cause seals to swell and distort Use only clean brake fluid for cleaning Use care with brake fluid Brake fluid is injurious to eyes and will damage painted surfaces and plastic parts CALIPER PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove Cover Clips CD ...

Page 165: ...ake caliper 2 Remove Brake pad Refer to CALIPER PAD REPLACEMENT section 3 Remove Piston CD Piston seal Dust seal Caliper piston removal steps Using a rag lock the right side piston Blow compressed air into the hose joint open ing to force out the left side piston from the caliper body Remove the dust and piston seals and reinstall the piston Repeat previous step to force out the right side piston ...

Page 166: ...ecification Replace I Pad Wear Limit 0 5 mm 0 02 in INSTALLATION 1 Assemble Brake caliper s Reverse disassembly steps WARNING All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the dust and piston seals whenever a caliper is disassembled 2 Install Brake caliper Brake hose ...

Page 167: ...mended Brake Fluid DOT 3 5 Bleed the air completely from the brake system Refer to AIR BLEEDING section 6 Check Brake fluid level Refer to CHAPTER 2 FRONT BRAKE FLUID INSPECTION section MASTER CYLINDER DISASSEMBLY NOTE Before disassemblying the master cylinder drain the brake fluid 1 Disconnect Brake switch leads CD 2 Remove Brake hose CD Brake lever 2 Spring 5 18 ...

Page 168: ...der cap Rubber seal 5 Remove Dust boot CD Circlip Master cylinder kit INSPECTION 1 Inspect Master cylinder body Scratches Wear Replace NOTE Claen all passages with new brake fluid Brake hoses Cracks WearI Damage Replace Master cylinder kit Scratches Wear Replace CD Oil baffle plate ...

Page 169: ...ver NOTE Grease the pivot point 3 Tighten Bolts Master cylinder bracket Bolt Brake hose Bolts Master cylinder bracket 8 Nm 0 8 m kg 5 8 ft lb Bolt Brake hose 25 Nm 2 5 m kg 18 ft lb 4 Connect Brake switch leads 5 Fill Brake system ifh Recommended Brake Fluid U DOT 3 6 Bleed the air completely from the brake system Refer to AIR BLEEDING section 7 Check Brake fluid level Refer to CHAPTER 2 FRONT BRA...

Page 170: ...de dia tightly to the caliper bleed screw G d Place the other end of the tube into a container e Slowly apply the brake lever several times f Pull the lever in Hold the lever in position g Loosen the bleed screw and allow the lever to travel towards its limit h Tighten the bleed screw when the lever limit has been reached then release the lever i Repeat steps e to h until of the air bubles have be...

Page 171: ...FRONT eRAKE lcHAsl I MEMO 5 22 ...

Page 172: ...ining clip Oil seal l Plain washer Guide bush Outer fork tube Drain screw FORK SPRING A 320 cm3 11 3 Imp oz 10 8 US oz B MINIMUM FREE LENGTH 537 mm 21 1 in 5 23 GRADE Fork oil 10WT or equivalent 23 Nm 2 3 m kg 17 ft lb I I I I I I I I I I r 1 I 23 m 2 3 m kg 17 ft lb I ___ I I I I ____ J 7 I fj j I I I I I I Ii I I I I I I I I I I l I I I I 2 Nm 0 2 m kg 1 4 ft lb I I I I __ _ _ _ _ _ _ _ _ _ _ _ ...

Page 173: ...curely so there is no danger of it falling over 2 Remove Bolts Brake caliper 3 Remove Front wheel Refer to FRONT WHEEL REMOVAL section 4 Remove Front fork brace CD Front fender 5 Loosen Pinch bolt Handle crown CD Cap bolt 6 Loosen Pinch bolts Urider bracket Support the fork before loosening the pinch bolts 5 24 ...

Page 174: ...ve Front fork DISASSEMBLY 1 Remove Cap bolt CD Spring seat Fork spring 2 Drain Fork oil 3 Remove Dust seal CD Retaining clip 4 Remove Cylinder securing bolt Use the Holder YM 33298 CD and T Handle YM 01326 to lock the damper rod 5 Remove Damper rod ...

Page 175: ...nd or bushings The oil seal and bushings must be replaced Avoid bottoming the inner tube in the outer tube during the above procedure as the oil lock piece will be damaged 7 Remove Oil seal CD Plain washer 2 Guide bush Oil lock piece INSPECTION 1 Inspect Inner fork tube Scratches Bends Replace WARNING Do not attempt to straighten a bent inner fork tube as this may dangerously weaken the tube 2 Ins...

Page 176: ...ect Damper rod CD Ring 2 WearI Damage Replace NOTE Blow out all oil passages with compressed air 5 Inspect Oil lock piece CD 0 ring 2 Damage Replace REASSEMBLY NOTE In front fork reassembly be sure to use follow ing new parts Guide bush Slide bush Oil seal Dust seal Make sure all components are clean before reassembly 1 Install Damper rod CD Rebound spring 2 Oil lock piece Inner fork tube ...

Page 177: ...al Driver Weight YM 33963 and Adapter YM 08010 CD Inner tube Outer tube 4 Install Plain washer Oil seal New Use the Fork Seal Driver Weight YM 33963 CD and Adapter YM 08010 Retaining clip Dust seal 5 Fill Front fork Each Fork 320 cm3 11 3 Imp oz 10 8 US oz Fork Oil 10 WT or equivalent After filling slowly pump the fork up and down to distribute oil 6 Install Fork spring with smaller pitch side up ...

Page 178: ... NOTE Level the top of the cap bolt with the top of the handle crown CD Flush 2 Tighten Pinch bolts Under bracket Pinch Bolt Under Bracket 23 Nm 2 3 m kg 17 ft lb NOTE Do not tighten the handle crown pinch bolt 3 Tighten Cap bolt Pinch bolt Handle crown Cap Bolt 23 Nm 2 3 m kg 17 ft lb Pinch Bolt Handle crown 20 Nm 2 0 m kg 14 ft lb 4 Install Front fender Front fork brace Bolts Front Fender 8 Nm 0...

Page 179: ...5 Install Front wheel Brake caliper Refer to FRONT WHEEL INSTALLATION section Nut Front Axle 105 Nm 10 5 m kg 75 ft lb Bolts Brake Caliper 35 Nm 3 5 m kg 25 ft lb 5 30 ...

Page 180: ...race Bearing BEARING SIZE 1 4 in A QUANTITY LOWER 19 pcs UPPER 19 pcs J Bearing race Bearing race Bearing Bearing race Dust seal Under bracket 154 Nm 5 4 m kg 39 ft lb I 20 Nm 2 0 m kg 14 ft lb 5 31 Tighten to specified torque If steering is binded loosen the ring nut so that there is no free play on bearing ...

Page 181: ...on the centerstand WARNING Securely support the motorcycle so there is no danger of it falling over 2 Remove Front wheel Refer to FRONT WHEEL REMOVAL section 3 Remove Front fork brace G Front fender 2 4 Loosen Steering stem bolt G 5 Remove Front forks 5 32 ...

Page 182: ...nt cover CD Headlight lens unit 2 7 Disconnect Meter leads Handlebar switch leads Flasher light leads 8 Remove Headlight body 9 Remove Clutch cable CD Starter cable 2 10 Remove Bolts Brake hose joint CD Headlight stay 2 ...

Page 183: ...sen Screws Right handlebar switch 12 Remove Handlebar 13 Remove Meter assembly Main switch 14 Remove Handle crown CD 15 Remove Ring nut CD Use Ring Nut Wrench YU 33975 WARNING Support the under bracket so that it may not fall down 5 34 ...

Page 184: ...sh the bearings in a solvent 2 Inspect Bearings Ball races Pitting Damage Replace NOTE Always replace bearings and races as a set Bearing race replacement steps Remove the bearing races using long rod CD and the hammer as shown Remove the bearing race on the under bracket using the floor chisel 2 and the hammer as shown Install the new dust seal and races ...

Page 185: ...ngs around race and apply more grease Ball Quantity Size Upper 19 pcs 1 4 in Lower 19 pcs 1 4 in 3 Install Under bracket Hold the under bracket until it is secured 4 Tighten Ring nut Use Ring Nut Wrench YU 33975 I fl Nm 13 7 m kg Zl ft lbl NOTE If steering is binded loosen the ring nut so that there is no free play on bearings 5 Tighten Bolts Handlebar I 20 Nm 12 0 m kg 14 ft lb 5 36 ...

Page 186: ...andlebar switch leads Flasher light leads NOTE The leads of identical colors should be connected 8 Install Front forks Refer to FRONT FORK INSTALLATION section Pinch Bolts Under Bracket 23 Nm 2 3 m kg 17 ft lb Pinch Bolts Handle Crown 20 Nm 2 0 m kg 14 ft lb 9 Tighten Steering stem bolt CD 1 154Nm 5 4 m kg 39 ft lbl 10 Install Front fender Front fork brance Bolt Front Fender 8 Nm 0 8 m kg 5 8 ft l...

Page 187: ...eel Brake caliper Refer to FRONT WHEEL INSTALLATION section Nut Front Axle 105 Nm 10 5 m kg 75 ft lb Bolts Brake Caliper 35 Nm 3 5 m kg 25 ft lb 12 Bleed the air completely from the brake system Refer to FRONT BRAKE AIR BLEEDING section 5 38 ...

Page 188: ...lcHAsicl Y0 IREAR sHocK ABSORBER REAR SHOCK ABSORBER CD Rear shock absorber Right Rear shock absorber Left 5 39 30 Nm 3 0 m kg 22 ft lb 20 Nm 2 0 m kg 14 ft lb ...

Page 189: ...Inspect Rear shock absorber Oil leaks Damage Replace INSTALLATION Reverse the removal procedure Note the following points 1 Install Rear shock absorber Bolt Shock Absorber and Frame 20 Nm 2 0 m kg 14 ft lb Bolt Shock Absorber and Swingarm 30 Nm 3 0 m kg 22 ft lb 2 Install Muffler Bolt Muffler and Footrest Bracket 25 Nm 2 5 m kg 18 ft lb 5 40 ...

Page 190: ...lcHAs 0 s W l N GA R M SWINGARM CD Swingarm Thrust cover Shim Bearing Bush A SIDE PLAY 1 0 mm 0 04 in SIDE CLEARANCE B 0 2 0 4 mm 0 008 0 016 in 90 Nm 9 0 m kg 65 ft lbl 5 41 ...

Page 191: ...its centerstand WARNING Support the motorcycle securely so there is no danger of it falling over 2 Remove Mufflers IA Left side 8 J Right side 3 Remove Rear wheel Refer to REAR WHEEL REMOVAL section 4 Remove Rear shock absorbers IA Left side 8 J Right side 5 42 ...

Page 192: ... and adjust side play using shims Move swingarm from side to side Side Play At End of Swingarm 1 0 mm 0 04 in 7 Check Swingarm Vertical movement Tightness Binding Rough Sports Replace bearings Move swingarm up and down 8 Remove Swingarm INSPECTION 1 Inspect Oil seal CD Damage Replace thrust cover ...

Page 193: ...e at tention to the following points Bearings should be exactly located as shown in the illustration Grease them liberally with wheel bearing grease CD Bearing Bush Swingarm Flash 1 Measure Bush length I 1 I Out of specification Replace bush Standard Length 197 4 197 6 mm 7 77 7 78 in 2 Measure Swingarm end length 5 44 ...

Page 194: ...arm side play A B Standard Side Play A B 0 2 0 4 mm 0 008 0 016 in Available Shim Thickness 1 9 2 0 mm 0 0748 0 0787 in 2 0 2 1 mm 0 0787 0 0826 in 2 1 2 2 mm 0 0826 0 0866 in I I INSTALLATION Reverse the removal procedure Note the following points 1 Install Swingarm Nut Pivot Shaft B r II II II II 1 90 Nm 9 0 m kg 56 ft lb ...

Page 195: ...e 20 Nm 2 0 m kg 14 ft lb Bolt Shock Absorber and Swingarm 30 Nm 3 0 m kg 22 ft lb 3 Install Rear wheel Refer to REAR WHEEL INSTALLATION section Axle Nut 105 Nm 10 5 m kg 75 ft lb 4 Install Mufflers Bolt Muffler and Footrest Bracket 25 Nm 2 5 m kg 18 ft lb 5 46 ...

Page 196: ...he rear brake Holding plate Drive sprocket Drive chain Drive Sprocket 1 Remove Rear wheel Refer to REAR WHEEL REMOVAL section 2 Remove Nuts drive sprocket Driven sprocket INSPECTION Drive Chain 1 Inspect 0 rings Damage Miss Replace Rollers and side plates Damage Wear Replace Drive and Driven Sprockets 1 Inspect Drive and driven sprockets WearI Damage Replace CD 1 4 tooth lJ Correct Roller Sprocket...

Page 197: ...procket Nuts driven sprocket Bolts Drive Sprocket 10 Nm 1 0 m kg 7 2 ft lb Nuts Driven Sprocket 2 Adjust 32 Nm 3 2 m kg 23 ft lb Apply LOCTITE Drive chain slack Rear brake free play Refer to CHAPTER 2 DRIVE CHAIN SLACK ADJUSTMENT and BRAKE PEDAL FREE PLAY ADJUSTMENT section Drive Chain Slack 20 30 mm 0 8 1 2 in Rear Brake Free Play 20 30 mm 0 8 1 2 in 5 48 ...

Page 198: ...lcHAs M E uM o 5 49 ...

Page 199: ...N 6 27 OPERATION 6 27 PICKUP UNIT 6 27 TROUBLESHOOTING 6 28 CHARGING SYSTEM 6 37 CIRCUIT DIAGRAM 6 37 TROUBLESHOOTING 6 39 LIGHTING SYSTEM 6 45 CIRCUIT DIAGRAM 6 45 TROUBLESHOOTING 6 47 LIGHTING SYSTEM TEST AND CHECKS 6 52 SIGNAL SYSTEM 6 55 CIRCUIT DIAGRAM 6 55 TROUBLESHOOTING 6 57 SIGNAL SYSTEM TEST AND CHECKS 6 61 OIL LEVEL SWITCH TEST 6 64 CARBURETOR AIR VENT SYSTEM 6 65 CIRCUIT DIAGRAM 6 65 D...

Page 200: ...IELEc Ia ICIRCUIT DIAGRAM ELECTRICAL VX600S SC CIRCUIT DIAGRAM WWW G Br Sb 1 __ WIG r tl i R W t B Y o o L Y 1 R W B ___ ___ r l Brl I e I 1 d l I L _________ J R W R W 6 1 ...

Page 201: ...r Oil level switch Flasher light Left Flasher light Right TURN indicator light Air vent control valve California only Relay assembly Flasher relay Included in relay assembly Flasher cancelling unit Included in relay assembly Starting circuit cut off relay Included in relay assembly Reed switch TURN switch NEUTRAL indicator light Neutral switch Rear brake switch l Front brake switch LIGHTS Dimmer s...

Page 202: ...IELEc Ie I ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS CD Main switch Sidestand relay Relay assembly Diode assembly Rear brake switch Sidestand switch J Oil level switch Horn 6 3 3 4 ...

Page 203: ...CD RectifierI Regulator 2 Starter relay lgnitor unit Battery Ignition coil For 1 4 cylinder Ignition coil For 2 3 cylinder J Neutral switch ELECTRICAL coMPONENTs IeLec Ie I 6 4 ...

Page 204: ...IELEc Ia I ELECTRICAL STARTING svsTEM ELECTRICAL STARTING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows starter circuit 6 5 ...

Page 205: ...color codes see page 6 2 Fuse MAIN Main switch Battery Starter relay Starter motor Fuse IGNITION Cf START switch ENGINE STOP swi ch 6 Diode Diode Clutch switch Sidestand switch Starting circuit cut off relay Included in relay assembly Neutral switch 6 6 ...

Page 206: ...s on and clutch lever is pulled in clutch switch is on CD Battery 2 Starter motor Starter relay Starting circuit cut off relay To ENGINE STOP switch To main switch START switch Clutch switch Neutral switch Sidestand switch Sidestand relay To ignitor unit 6 7 Turn main switch to ON and ENGIE STOP switch to RUN Transmission is Push starter switch Engine will start Sidestand is up Sidestand is up and...

Page 207: ...oting remove following parts Seat Fuel tank CD Side cover Right Headlight lens unit Cover Front 1 Fuse inspection Remove fuse MAIN and fuse IGNITION Connect Pocket Tester YU 03112 to fuse and check it for continuity NOTE Set tester selector to fl x 1 position Continuity Om IReplace fuse l Discontinuity oo 6 8 ...

Page 208: ...a battery 3 Battery terminal inspection Inspect battery terminal and connections OK Dirty or poor connection Clean battery terminals using wire brush NOTE After cleaning terminals apply grease lightly to both terminals Connect battery leads correctly 4 Battery fluid specific gravity inspection Remove caps Inspect specific gravity of all cell using Bat tery Hydrometer G Specific Gravity 1 280 0 01 ...

Page 209: ...rks flame cigarettes etc away Ventilate when charging or using in an enclosed space Al ways shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN OK l Low_ specific gravity Recharge battery Charging Current 1 2 amps 10 hrs NOTE Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging Sulfation of one or ...

Page 210: ...ter relay Starter motor runs l Starter motor does not run Inspect and repair the starter motor Refer to STARTER MOTOR section 6 Starter relay conduct check Disconnect starter relay leads Blue White Red White and connect them to battery positive and negative lead use a jumper leads CD Positive lead Negative lead Starter motor runs l Starter motor does not run Starter relay is faulty replace it 7 St...

Page 211: ...Use full charge battery Set tester selector to O x 1 position Continuity 00 l Discontinuity oo Starting circuit cut off relay is faulty replace relay assembly 8 Diode assembly condition check Remove diode assembly G Connect Pocket Tester YU 03112 to diode assembly terminals and check diode D2 and DJ condition Refer to following table NOTE Set tester selector to O x 1 position 6 12 ...

Page 212: ...reversed ac cording to the pocket tester polarity OK Defective element IReplace diode assembly 9 Main switch conduct check Disconnect main switch coupler Brown Red Blue Connect Pocket Tester YU 03112 to main switch leads Brown Red Tester lead Red lead Tester lead Brown lead NOTE Set tester selector to Ox 1 position Turn main switch to ON position and check it for continuity ...

Page 213: ... to han dlebar switch leads Blue White Black Tester lead Blue White lead Tester lead Black lead NOTE Set tester selector to Q x 1 position Push on START switch and check it for continuity Continuity Onl l Discontinuity oo START switch is faulty replace han dlebar switch 11 ENGINE STOP switch conduct check Disconnect handlebar switch Right leads Red White Red White Red Yellow Blue Black Blue White ...

Page 214: ...ar switch 12 Clutch switch conduct check Disconnect handlebar switch Left leads Chocolate Yellow Red Black Yellow Brown White Dark Green Blue Yellow Connect Pocket Tester YU 03112 to clutch switch leads Black Yellow Blue Yellow Tester lead Black Yellow lead Tester lead Blue Yellow lead NOTE Set tester selector to Q x 1 position Clutch lever is pulled and check clutch switch for continuity Continui...

Page 215: ...1 position Transmission is in neutral and check neutral switch for continuity Continuity 00 l Discontinuity oo Neutral switch is faulty replace it 14 Sidestand switch conduct check Disconnect sidestand leads Blue Yellow Black Connect Pocket Tester YU 03112 to side stand switch leads Tester lead Blue Yellow lead Tester lead Black lead NOTE Set tester selector to Ox 1 position Place motorcycle on ce...

Page 216: ...sTEM 6 17 Continuity 00 l Discontinuity oo Sidestand switch is faulty replace it 15 Check entire electrical starting system for connections Refer to WIRING DIAGRAM section OK Poor connection ICorrect Electrical starting system is good ...

Page 217: ...ter motor lead Yoke assembly J Brush assembly 5 ELECTRICAL STARTING svsTEM IeLec Is I A COMMUTATOR DIAMETER LIMIT 27 mm 1 06 in B MICA UNDERCUT 1 6 mm 0 06 in c ARMATURE COIL RESISTANCE 0 0120 at 20 c 68 FI 4 D MINIMUM BRUSH LENGTH 5 mm 0 2 in 10 Nm 1 0 m kg 7 2 ft lb 6 18 ...

Page 218: ...CAL STARTING svsTEM 6 19 Removal 1 Remove Footrest Left Change pedal Cover Drive sprocket 2 Remove Starter motor lead 3 Remove Starter motor Disassembly 1 Remove Screws 2 Remove Yoke assembly CD Armature coil assembly 2 ...

Page 219: ...age Replace 3 Inspect Commutator Outer surface Grooved wear Burning Scratches Smooth out using a sandpaper 500 600 NOTE Sand the commutator outer surface lightly and evenly 4 Measure Commutator diameter Out of specification Replace Outside Diameter Limit 27 mm 1 06 in 5 Measure Mica undercut Out of specification Scrape mica using a hacksaw blade Mica Undercut 1 6 mm 0 06 in 6 20 ...

Page 220: ...sistance Out of specification Replace Armature Coil Resistance 0 0120 at 20 c 68 F 7 Check Armature coil insulation Set the pocket tester selector to Ox 1K position Continuity Replace Assembly Reverse the Disassembly procedure Note the following points 1 Install Brush assembly NOTE Fit the projection onto the recess 2 Install Bracket CD NOTE Fit the recess to the projection ...

Page 221: ...s to the projection 4 Apply Lithium soap base grease 5 Install Gear assembly CD NOTE Fit the pin into the ring gear recess 6 Install Brush cap NOTE Align the match mark CD on the brush cap with the match mark on the yoke assembly 7 Install Screws I 10 Nm 11 0 m kg 7 2 ft lbl 6 22 ...

Page 222: ...lation Reverse the Removal procedure Note the fol lowing points 1 Apply Lithium soap base grease 2 Install Starter motor I 10 Nm 11 0 m kg 7 2 ft lb 3 Install Cover Drive sprocket Change pedal Footrest Left Bolt Change pedal 10 Nm 1 0 m kg 7 2 ft lb Bolt Footrest 70 Nm 7 0 m kg 50 ft lb ...

Page 223: ...ELECTRICAL STARTING SYSTEM IELEC I I MEMO 6 24 ...

Page 224: ...IELEc Ie I GNITION svsTEM IGNITION SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows ignition circuit 6 25 ...

Page 225: ...or the color codes see page 6 2 Fuse MAIN Main switch Battery Fuse IGNITION ENGINE STOP switch Sidestand switch IGNITION SYSTEM IELEC I I Sidestand relay Igniter unit Ignition coil Spark plug Pickup coil 6 26 ...

Page 226: ...dability of the system by eliminating the mechanical advancer This TCI system consists of two units a pickup unit and an ignitor unit OPERATION The TCI functions on the same principle as a con ventional DC ignition system with the exception of using magnetic pickup coils and a transistor control box TCI in place of contact breaker points CD TCI unit PICKUP UNIT The pickup unit consists of two pick...

Page 227: ...T TENT SPARK Before this troubleshooting remove following parts Seat Fuel tank CD Side cover Right 1 Fuse inspection Remove fuse MAIN and fuse IGNITION Connect Pocket Tester YU 03112 to fuse and check it for continuity NOTE Set tester selector to x 1 position Continuity O IReplace fuse l Discontinuity CX 6 28 ...

Page 228: ...s harmful to a battery 3 Battery terminal inspection Inspect battery terminal and connections OK l Dirty or _poor connection Clean battery terminals using wire brush NOTE After cleaning terminals apply grease lightly to both terminals Connect battery leads correctly 4 Battery fluid specific gravity inspection Remove caps Inspect specific gravity of all cell using Bat tery Hydrometer G Specific Gra...

Page 229: ...ame cigarettes etc away Ventilate when charging or using in an enclosed space Al ways shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN OK l Low_ specific gravity Recharge battery Charging Current 1 2 amps 10 hrs NOTE Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging Sulfation of one or more c...

Page 230: ...PECTION section Plug Gap 0 6 0 7 mm 0 024 0 028 in OK No good IReplace or regap spark plug 6 Ignition spark gap test Connect Electro Tester YU 33260 CD as shown Spark plug lead Spark plug Start the engine and increase the spark gap until misfire occurs Test at various r min between idle and red line Do not run the engine in neutral above 6 000 r min for more than 1 or 2 seconds Minimum Spark Gap 6...

Page 231: ...attery Set tester selector to Q x 1 position Discontinuity oo nContinuity Om Sidestand relay is faulty replace it 8 Main switch conduct check Disconnect main switch coupler Brown Red Blue Connect Pocket Tester YU 03112 to main switch leads Brown Red Tester lead Red lead Tester lead Brown lead NOTE Set tester selector to x 1 position Turn main switch to ON position and check it for continuity ...

Page 232: ...12 to han dlebar switch lead Red White Red White Tester lead Red White lead Tester lead Red White lead NOTE Set tester selector to Q x 1 position Turn ENGINE STOP switch to RUN po sition Continuity wm l Discontinuity oo ENGINE STOP switch is faulty replace handlebar switch 10 Sidestand switch conduct check Disconnect sidestand leads Blue Yellow Black Connect Pocket Tester YU 03112 to side stand sw...

Page 233: ...place it 11 Ignition coil resistance test Disconnect ignition coil leads and spark plug leads Connect Pocket Tester YU 03112 to igni tion coil lead Ignition coil for 1 4 cylinder Tester lead Orange lead G Tester lead Red White lead Bl Ignition coil for 2 3 cylinder Tester lead Gray lead Tester lead Red White lead Measure primary coil resistance Primary Coil Resistance 2 43 2 97 Q at 20 C 68 F NOTE...

Page 234: ...tance 10 56 15 84 kn at 20 c 68 F NOTE Set tester selector to x 1K position Both resistances l Out of meet specifications specification Ignition coil is faulty replace it 12 Pickup coil resistance test Disconnect pickup coil leads Orange Gray Black at ignitor unit Connect Pocket Tester YU 03112 to pick up coil leads Tester lead Orange lead Tester lead Black lead Tester lead Gray lead Tester lead B...

Page 235: ...pecifications specification Both resistances 1 Out of Pickup coil is faulty replace it 13 Check entire ignition system for connections Refer to WIRING DIAGRAM section OK Poor connection ICorrect Ilgnitor unit is faulty replace it 6 36 ...

Page 236: ...IELEC I ICHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows charging circuit 6 37 ...

Page 237: ...CHARGING SYSTEM IELEC I s I NOTE For the color codes see page 6 2 CD AC Magneto RectifierI Regulator Fuse MAIN Battery 6 38 ...

Page 238: ...MAIN Connect Pocket Tester YU 03112 to fuse and check it for continuity NOTE Set tester selector to fl x 1 position Continuity Om I Replace fuse l Discontinuity oo 2 Battery fluid level inspection Fluid level should be between upper CD and lower 2 level mark Correct Incorrect Refill battery fluid Refill with distilled water only tap water contains minerals harmful to a battery ...

Page 239: ... 280 0 01 at 20 c 68 F WARNING Battery electrolyte is poisonous and dange rous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of r 1 water or milk Follow with milk of magne L 1111 sia beaten egg or vegetable oil Call a phy sician immediately Eyes Flush with water for 15 minutes and get p...

Page 240: ...s turning white or an accumulation of materi ad exists in the bottom of the cell Specific gravity readings after a long slow charge indicate on cell to be low er than the rest Warpage or buckling of plates or in sulators is evident 5 Charging voltage test Connect Pocket Tester YU 03112 to battery NOTE Set tester selector to DC20V position Tester lead Battery terminal Tester lead Battery terminal S...

Page 241: ...U 03112 to AC magneto leads NOTE Set tester selector to Q x 1 position Stator Coil 1 Tester lead White lead CD Tester lead White lead Stator Coil 2 Tester lead White lead Tester lead White lead Measure stator coil resistance l J Stator Coil Resistance White CD White 0 5 0 6 Q at 20 C 68 F White White 0 5 0 6 n at 20 C 68 F Both resistances meet specifications specification 1Out of Stator coil is f...

Page 242: ...d Green lead Tester lead Brown lead Measure field coil resistance Field Coil Resistance 2 7 3 30 at 20 C 68 F Resistance meets JOut of specification specification Flied coil is faulty replace it 8 Check entire charging system for connec tions Refer to WIRING DIAGRAM section 1Poor connection OK I L_c_o_rr_e_c_t ________________________ I Rectifier Regulator is faulty replace it ...

Page 243: ...CHARGING SYSTEM IELEC I I MEMO 6 44 ...

Page 244: ...IELEc Ie I LIGHTING svsTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows lighting circuit 6 45 ...

Page 245: ... color codes see page 6 2 Fuse MAIN Main switch Battery Fuse HEAD j START switch l LIGHTS Dimmer switch LIGHTING SYSTEM IELEC Is I Tail Brake light License light Meter light Headlight HIGH BEAM indicator light 6 46 ...

Page 246: ...of the above fail to operate proceed fur ther Low battery voltage indicates either a faulty battery low battery fluid level or a defective charging system Also check fuse condition Replace any Open fuses HEADLIGHT TAILLIGHT LICENSE LIGHT AND METER LIGHT DO NOT COME ON Before this troubleshooting remove follow ing parts Seat Fuel tank CD Side cover Right 2 ...

Page 247: ...ester YU 03112 to fuse and check it for continuity NOTE Set tester selector to x 1 position Continuity O I Replace fuse l Discontinuity oo 2 Battery fluid level inspection Fluid level should be between upper CD and lower CZ level mark Correct Incorrect Refill battery fluid Refill with distilled water only tap water contains minerals harmful to a battery 6 48 ...

Page 248: ... 1 280 0 01 at 20 c 68 F WARNING Battery electrolyte is poisonous and danger ous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magne sia beaten egg or vegetable oil Call a phy sician immediately Eyes Flush with water for 15 minutes and get prompt med...

Page 249: ... an accumulation of materi al exists in the bottom of the cell Specific gravity readings after a long slow charge indicate on cell to be low er than the rest Warpage or buckling of plates or in sulators is evident 5 Main switch conduct check Disconnect main switch coupler Brown Red Blue Connect Pocket Tester YU 03112 to main switch leads Tester lead Red lead Tester lead Brown lead Tester lead Red ...

Page 250: ...leads Red White Red White Red Yellow Blue Black Blue White Black Connect Pocket Tester YU 03112 to han dlebar switch leads Blue Black Red Yellow Tester lead Blue Black lead Tester lead Red Yellow lead NOTE Set tester selector to Q x 1 position Continuity QQ l Discontinuity oo START switch is faulty replace han dlebar switch 7 Check entire lighting system for connections Refer to WIRING DIAGRAM sec...

Page 251: ...not come on Turn main switch to ON position I Check for voltage 12V on Blue White INo voltag Wiring circuit from START lead at LIGHTS Dimmer switch con switch to LIGHTS Dimmer nectar I switch if faulty repair OK _ Turn LIGHTS Dimmer switch LO po I sition No voltage Check for voltage 12V on Green lead I LIGHTS Dimmer switch is at LIGHTS Dimmer switch connector I faulty replace handlebar switch Left...

Page 252: ...ain switch to ON position I _________ ___________ No voltage I Check for voltage 12V on Blue Black 1 __le_a_d_a_t_s p_e_e_d_om_e_te_r_lreaTd_c_o_nn_e_c_t_or_ ____ I OK I Meter light bulb socket is faulty replace it I Taillight and or license light do not come on Turn main switch to ON position 6 53 LIGHTS Dimmer switch is faulty replace handlebar switch Left Wiring circuit from START switch to spe...

Page 253: ...l brake light lead connector is No voltage faulty repair OK II I Tail Brake light bulb socket is faulty replace I it No voltage I Check for voltage 12Vl on Blue lead at I Wiring circuit from START switch license light lead connector I to license light lead connector is faulty repair OK II I License light bulb socket is faulty replace it I 6 54 ...

Page 254: ...IELEc a I SIGNAL svsTEM SIGNAL SYSTEM CIRCUIT DIAGRAM Below circuit diagram shows signal circuit ff B B B B 11 11 6 55 ...

Page 255: ...OIL indicator light Resistor Oil level switch Flasher light Left SIGNAL svsTEM IELEc Is I Flasher light Right TURN indicator light Flasher relay Included in relay assembly Flasher cancelling unit Included in relay assembly Reed switch TURN switch NEUTRAL indicator light Neutral switch Rear brake switch Front brake switch Tail Brake light 6 56 ...

Page 256: ... battery low battery fluid level or a defective charging system Also check fuse condition Replace any open fuses Before this troubleshooting remove following parts Seat Fuel tank CD Side cover Right C2 Headlight lens unit Cover Front 1 Fuse inspection Remove fuse MAIN fuse IGNITION and fuse SIGNAL Connect Pocket Tester YU 03112 to fuse and check it for continuity NOTE Set tester selector to O x 1 ...

Page 257: ...l mark Correct I Incorrect Refill battery fluid Refill with distilled water only tap water contains minerals harmful to a battery 3 Battery terminal inspection Inspect battery terminal and connections OK l Dirty or _poor connection Clean battery terminals using wire brush NOTE After cleaning terminals apply grease lightly to both terminals Connect battery leads correctly 6 58 ...

Page 258: ... vegetable oil Call a phy sician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Al ways shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN OK l Low_ specific gravity Recharge battery Charging Current 1 2 amps 10 hrs...

Page 259: ... check Disconnect main 4S itch coupler Brown Red Blue Connect Pocket Tester YU 03112 to main switch leads Tester lead Red lead Tester lead Brown lead NOTE Set tester selector to Q x 1 position Turn main switch to ON position and check it for continuity Continuity Om JDiscontinuity oo Main switch is faulty replace it 6 Check entire signal system for connections Refer to WIRING DIAGRAM section 6 60 ...

Page 260: ...HECKS section No voltage Check for voltage 12Vl on Br lead at horn terminal OK No voltage Check for voltage 12Vl on P lead at HORN switch connector OK r Discontinuity 6 61 Check for continuity of HORN switch when pushing HORN switch Continuity Adjust horn replace it damage Wiring circuit from fuse to horn ter minal is faulty repair Horn is faulty replace r HORN switch is faulty replace ...

Page 261: ...ying rear brake OK Brake light bulb socket is faulty replace it INo voltag _ I No voltage I I I NEUTRAL indicator light does not come on r No voltage Check for voltage 12V on Br lead at indi cator light connector OK No voltage Check for voltage 12V on Sb lead at neutral switch connector OK Check for continuity of neutral switch Discontinuity repair Wiring circuit from fuse to rear brake switch con...

Page 262: ...et is faulty replace it OIL indicator light does not come on No voltage Check for voltage 12V on R W lead at indicator light connector OK N o voltage 6 63 Check for voltage 12V on B R lead at oil level switch connector OK Check for condition of oil level switch Refer to OIL LEVEL SWITCH TEST section Wiring circuit from fuse to flasher relay terminal is faulty repair Flasher relay is faulty replace...

Page 263: ...vel switch CD 2 Connect the Pocket Tester YU 03112 Teser lead Oil level switch lead Tester lead Oil level switch base NOTE Set the tester selector to Ox 1 position 3 Check Oil level switch Upside down position Continuity Replace Upright position Discontinuity Replace 6 64 ...

Page 264: ...IELEC Is I CARBURETOR AIR VENT SYSTEM CARBURETOR AIR VENT SYSTEM CALIFORNIA ONLY CIRCUIT DIAGRAM Below circuit diagram shows carburetor air vent circuit 6 65 ...

Page 265: ...CARBURETOR AIR VENT SYSTEM IELEC I I NOTE For the color codes see page 6 2 Fuse MAIN Main switch Battery Fuse SIGNAL Air vent control valve California only 6 66 ...

Page 266: ...el vapor and carburetor air vent into the atmosphere OPERATION The carburetor air vent is controlled by the air vent control valve when the main switch is turned to ON position 6 67 CD Fuel tank Air vent control valve Carburetor Canister Roll over valve Nozzle Main switch is turned to OFF J Main switch is turned to ON 3 ...

Page 267: ...proceed further Low battery voltage indicates either a faulty battery low battery fluid level or a defective charging system Also check fuse condition Replace any open fuses Before this troubleshooting remove the follow ing parts Seat Fuel tank CD THE AIR VENT CONTROL VALVE DOES NOT OPERATE THE ENGINE LOSES POWER 1 Check hose connection OK l Faulty ICorrect 6 68 ...

Page 268: ...nspection Remove fuse MAIN and fuse SIGNAL Connect Pocket Tester YU 03112 to fuse and check it for continuity NOTE Set tester selector to Q x 1 position Continuity Om I Replace fuse l Discontinuity oo 4 Battery fluid level inspection Fluid level should be between upper CD and lower CZ level mark ...

Page 269: ...s apply grease lightly to both terminals Connect battery leads correctly 6 Battery fluid specific gravity inspection Remove caps Inspect specific gravity of all cell using Bat tery Hydrometer G Specific Gravity 1 280 0 01 at 20 C 68 F WARNING Battery electrolyte is poisonous and danger ous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL...

Page 270: ...HILDREN OK l Low_ specific gravity Recharge battery Charging Current 1 2 amps 10 hrs NOTE Replace the battery if Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging Sulfation of one or more cells occurs as indicated by the plates turning white or an accumulation of materi al exists in the bottom of the cell Specific gravity readings after a l...

Page 271: ...uity Continuity OQ l No continuity oo Main switch is faulty replace it 10 Air vent control valve test Remove air vent control valve Connect 12V battery to air vent control valve as shown Blow air inside at nozzle CD which is open to atmosphere Check for air escape at nozzle on canister side No air escape Valve is faulty Air escape Valve is good Disconnect battery and blow air inside at nozzle CD w...

Page 272: ...R AIR VENT SYSTEM OK Faulty 6 73 IReplace air vent control valve 11 Check entire air vent control valve system for connections Refer to WIRING DIAGRAM section OK Poor connection ICorrect ICarburetor air vent system is good ...

Page 273: ...FICATIONS 7 1 GENERAL SPECIFICATIONS 7 1 MAINTENANCE SPECIFICATIONS 7 4 GENERAL TORQUE SPECIFICATIONS 7 18 DEFINITION OF UNITS 7 19 CONVERSION TABLES 7 19 LUBRICATION DIAGRAM 7 20 CABLE ROUTING 7 22 YX600S YX600SC WIRING DIAGRAM ...

Page 274: ...dic Oil Change With Oil Filter Replacement Total Amount Air Filter 7 1 APPENDICES YX600S YX600SC 1UJ For YX600Sl 1UL For YX600SC JYA1UJOO GA000101 For YX600Sl JYA1ULOO GA000101 For YX600SCl 1UJ 000101 For YX600S 1UL 000101 For YX600SC 2 075 mm 81 7 in 770 mm 30 3 in 1 095 mm 43 1 in 765 mm 30 1 in 1 385 mm 54 5 in 145 mm 5 7 in 197 kg 434 lb 2 400 mm 94 5 in Air cooled 4 stroke gasoline DOHC 4 cyl...

Page 275: ...peration Left foot operation Gear Ratio 1st 41 15 2 733 2nd 37 19 1 947 3rd 34 22 1 545 4th 31 25 1 240 5th 29 28 1 036 6th 27 30 0 900 Chassis Frame Type Tubular steel double cradle Caster Angle 27 Trail 128 mm 5 04 in Tire Front Rear Type Tubeless Tubeless Size 110 90 16 59H 130 90 16 67H Manufacture Type DUNLOP DUNLOP K355F K355 BRIDGESTONE BRIDGESTONE G527 G528 Tire Pressure Cold tire Front Re...

Page 276: ...pring oil damper Wheel Travel Front Wheel Travel 140 mm 5 5 in Rear Wheel Travel 98 mm 3 9 in Electrical Ignition System T C I Full Transistor ignition Generator System A C generator Battery Type or Model 12N12A 4A Battery Capacity 12V 12AH Headlight Type Bulb Quartz bulb Bulb Wattage Quantity Headlight 60W 55W 1 pcs Tail Brake Light 8W 27W 1 pcs Flasher Light 27W 4 pcs License Light 3 8W 2 pcs Me...

Page 277: ...lve Seat Valve Guide Valve Clearance Cold IN EX A Face Width YX600S YX600SC 0 03 mm 0 001 in Lines indicate straightedge measurement 58 50 mm 2 303 in 0 05 mm 0 002 in 0 01 mm 0 0004 in Chain drive Center 25 8 21 mm 0 9449 80008 in 25 88 mm 0 9448 888 in 0 020 0 054 mm 0 0008 0 0021 in 36 25 36 35 mm 1 427 1 431 in 36 2 mm 1 43 in 28 1 28 2 mm 1 106 1 11 in 28 05 mm 1 1 in 8 3 mm 0 327 in 8 1 mm 0...

Page 278: ... 0 008 in 5 975 5 990 mm 2 2352 0 2358 in 5 960 5 975 mm 0 2346 0 2352 in 6 0 6 012 mm 0 2362 0 2367 in 6 0 6 012 mm 0 2362 0 2367 in 0 010 0 037 mm 0 0004 0 0015 in 0 025 0 052 mm 0 0010 0 0020 in 0 03 mm 0 001 in 0 9 1 1 mm 0 0390 0 0398 in 0 9 1 1 mm 0 0390 0 0398 in 2 0 mm 0 08 in EX 2 0 mm 0 08 in Valve Spring 7 5 Free Length Inner Spring Outer Spring IN EX IN 35 5 mm 1 398 in 35 5 mm 1 398 i...

Page 279: ...0S YX600SC Inner spring IN and EX Clockwise 58 50 mm 2 30 in 7 0 mm 0 276 in Outer spring IN and EX Counter clockwise n From bottom line of piston skirt 0 025 0 045 mm 0 0010 0 0018 in 59 00 mm 2 32 in 60 00 mm 2 36 in Barrel B 1 0 mm 0 039 in T 2 3 mm 0 090 in Taper B 1 2 mm 0 047 in T 2 3 mm 0 090 in Expander B 2 5 mm 0 10 in T 2 8 mm 0 11 in 0 15 0 30 mm 0 0059 0 0118 in 0 7 mm 0 0276 in 0 15 0...

Page 280: ...e Carburetor 7 7 Type Manufacture Quantity l D Mark Main Jet Main Air Jet Jet Needle clip Position For No 1 and 4 Cylinder For No 2 and 3 Cylinder M J M A J J N YX600S YX600SC 0 016 0 040 mm 0 0006 0 0016 in 1 Blue 2 Black 3 Brown 4 Green 312 4 0 6 mm 12 30 0 024 in 0 03 mm 0 0012 in 0 16 0 262 mm 0 006 0 010 in 0 021 0 044 mm 0 0008 0 0017 in 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 3 0 0 1 mm 0 1...

Page 281: ... Float Height 20 1 0 mm 0 8 0 04 in Engine Idling Speed 1 300 50 r min Vacuum Pressure at Idling Speed 23 3 0 667 kPa 175 5 mmHg 6 890 0 1969 inHg Vacuum Synchronous Difference Below 10 kPa 10 mmHg 0 4 inHg Lubrication System Oil Filter Type Paper Oil Pump Type Trochoid pump Tip Clearance 0 09 0 15 mm 0 0035 0 0060 in Limit 0 2 mm 0 008 in Side Clearance 0 03 0 08 mm 0 0012 0 0031 in Limit 0 15 mm...

Page 282: ...Model Lubrication Chart Crankcase Tightening Sequence Upper case 7 9 YX600S YX600SC Pressured feed Splashed IN camshaft Lifter EX camshaft Lifter 11 Oil filter Bypass vlave __________ I c I II Oil pump Relief valve II Oil pan Lower case ...

Page 283: ...ly oil Cylinder and crankcase Nut MB P1 25 1 20 2 0 14 Connecting rod and rod cap Nut M7 P0 75 B 25 2 5 1B Camshaft and sprocket Bolt M7 P1 0 4 24 2 4 17 Cam chain tensioner Bolt MB P1 0 1 B O B 5 7 stopper bolt Cam chain tensioner case Bolt M6 P1 0 1 10 1 0 7 2 and cylinder Cam chain tensioner case Nut M6 P1 0 1 10 1 0 7 2 and cylinder Cam chain tensioner Nut MB P1 25 1 9 0 9 6 5 lock nut Crankca...

Page 284: ...0 7 5 1 Reliet valve and crankcase 1 20 2 0 14 HY VO chain tensioner Bolt M6 P1 0 2 10 1 0 7 2 Use LOCTITE Primary drive gear Nut M16 P1 5 1 50 5 0 36 Bearing cover plate Screw M6 P1 0 2 10 1 0 7 2 Use LOCTITE Starter clutch Bolt M8 P1 25 3 25 2 5 18 Use LOCTITE Shift shaft stopper Screw M8 P1 25 1 22 2 2 16 Shift cam bearing plate Screw M6 P1 0 1 10 1 0 7 2 7 12 ...

Page 285: ...l 10WT or equivalent 80 mm 3 1 in 222 4 mm 8 76 in Ki 17 6 N mm 1 8 kg mm 99 1 lb in 0 0 52 mm 0 0 2 04 in K1 25 5 N mm 2 6 kg mm 143 2 lb in 52 80 mm 2 04 3 15 in No Optional Spring Adjustment Spring Position stiffer Std 5 I 4 I 3 Rear Arm Swingarm Free Play Limit End 1 0 mm 0 039 in Wheel Front Wheel Type Rear Wheel Type Front Rim Size Material Rear Rim Size Material Rim Runout Limit Drive Chain...

Page 286: ...ng Brake Drum Inside Diameter 180 mm 7 08 in Limit 181 mm 7 12 in Lining Thickness 4 mm 0 16 in Limit 2 mm 0 08 in Shoe Spring Free Length 68 mm 2 68 in Brake Lever Brake Pedal Brake Lever Free Play at lever end 2 5 mm 0 08 0 20 in Brake Pedal Free Play 20 30 mm 0 8 0 12 in Brake Pedal Position 15 mm 0 6 in Vertical height below footrest top Clutch Lever Free Play at lever end 10 15 mm 0 4 0 6 in ...

Page 287: ... bleed screw M8 x 1 25 6 0 6 4 3 Brake hose M10x 1 25 26 2 6 19 Handlebar upper holder M8 x 1 25 20 2 0 14 Engine mounting Front upper M10x1 25 42 4 2 30 Front under M10x1 25 42 4 2 30 Rear M12x1 25 70 7 0 50 Engine stay and frame M8x 1 25 20 2 0 14 Muffler bracket and frame M10x1 25 42 4 2 30 Footrest M12x1 25 70 7 0 50 Brake pedal and brake shaft M6 x 1 0 9 0 9 6 5 Pivot axle and locknut M14x1 5...

Page 288: ...gnition Coil ModelI Manufacturer CM12 10 HITACHI Minimum Spark Gap 6 mm 0 24 in or more at 500 r min Primary Winding Resistance 2 43 2 97Q at 20 C 68 F Secondary Winding Resistance 10 56 15 84KQ at 20 C 68 F Spark Plug Cap Resistance 10KQ Charging System Type A C Generator A C Generator Model Manufacturer LD117 13 HITACHI Nominal Output 14V 17A at 5 000 r min Field Coil Resistance 2 7 3 3Q at 20 C...

Page 289: ...ing 150A Coil Resistance 3 40 at 20 c 68 Fl Horn Type Quantity Plane Type 1 pcs Model Manufacturer YF 12 NIKKO Maximum Amperage 2 5A Flasher Relay Relay Assembly Type Semi transistor type Model Manufacturer FX257N NIPPON DENSO Self Cancelling Device Yes Flasher Frequency 85 10 cycle min Wattage 27W x 2 pcs 3 4W Sidestand Relay Model Manufacturer 4U8 01 OMRON Coil Winding Resistance 750 10 at 20 C ...

Page 290: ...warpage tighten multi fastener assem blies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room tem perature A Distance across flats B Outside thred diameter A Nut 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B Bolt Nm 6 mm 6 8 mm 15 10 mm 30 12 mm 55 14 mm 85 16 mm 130 General tor...

Page 291: ...t lb ft lb 0 13826 m kg m kg 86 80 in lb in lb 0 01152 m kg cm kg 0 0723 ft lb ft lb 13 831 cm kg cm kg 0 8680 in lb in lb 1 1521 cm kg kg 2 205 lb lb 0 4535 kg g 0 03527 oz oz 28 352 g km lit 2 352 mpg mpg 0 4252 km lit km hr 0 6214 mph mph 1 609 km hr km 0 6214 mi mi 1 609 km m 3 281 ft ft 0 3048 m m 1 094 yd yd 0 9141 m cm 0 3937 in in 2 54 cm mm 0 03937 in in 25 4 mm cc cm3 0 03382 oz US liq c...

Page 292: ...LUBRICATION DIAGRAM IAPPXI I LUBRICATION DIAGRAM CD Crankshaft 7 20 ...

Page 293: ...jAPPxl ILueR1cAT10N 01AGRAM CD Generator shaft Crankshaft Main axle Oil filter Drive axle 7 21 ...

Page 294: ...tch lead 6 CABLE ROUTING IAPPXI I Outer cover Tachometer lead Flasher light lead Right Flasher light lead Left Speedometer light lead J Indicator light lead IA Speedometer cable Pass the speedometer cable outside the outer cover 6 Clutch cable Pass the clutch cable behind the outer cover stay Q Connect the couplers inside the outer cover 7 22 ...

Page 295: ... 4 mark 4 cylinder 3 mark 3 cylinder 2 mark 2 cylinder 1 mark 1 cylinder Al Pass the starter cable between the locating damper and ignition coil ID After connecting the couplers locate them above the ignition coil CJ Pass the horn lead between the ignition coils Q Guide Clamp the wire harness E Cable holder Pass the speedometer cable through the cable holder E Pass the ignition coil leads through ...

Page 296: ...icense light lead Taillight lead Rear flasher light lead Left CABLE ROUTING IAPPXI I IA White tape Align the white tape with the cross pipe as shown 6 Pass the wire harness between air cleaner box and battery box Q Pass the flasher light lead between the frame and rear fender IQ Locate the couplers and leads inside the rear fender 7 24 ...

Page 297: ...itch lead l Sidestand switch lead II 7 25 IA After connecting the couplers locate the couplers behind the battery box ID Clamp the earth lead with the ignition coil securing screw Q Pass the throttle cable under the locating damper Q Pass the clutch cable through the guide and between EX pipe 2 and 3 6 EJ Pass the battery negative lead inside the battery box El Clamp the earth lead with the batter...

Page 298: ... Pass the battery breather pipe through the guide hole on the stop switch bracket CABLE ROUTING IAPPXI I ID Pass the fuel tank and battery breather pipe between the rear arm corss tube and rear arm pivot Pass the breather pipes through the guide I I I CD r EB 1 I I I I 7 26 ...

Page 299: ...IAPPxl6 IcABLE ROUTING I CALIFORNIA ONLY I CD Ignition coil Roll over valve Air vent control valve 3 Carburetor 2 Carburetor From fuel tank J To canister 8 7 27 Clamp Crankcase Frame c _ __ ...

Page 300: ... switch Headlight J HIGH BEAM indicator light NEUTRAL indicator light OIL indicator light TURN indicator light Reed switch Meter light Tachometer Horn Main switch Front brake switch START switch ENGINE STOP switch Front flasher light R Sidestand switch Sidestand relay Relay assembly lgnitor unit Rear brake switch Starter motor Starter relay Battery Fuse License light Rear flasher light R Tail Brak...

Page 301: ...is Supplemen tary Service Manual together with following manual YX600S SC Service Manual LIT 11616 05 06 YX600U YX600UC SUPPLEMENTARY SERVICE MANUAL 1987 by Yamaha Motor Corporation U S A 1st Edition July 1987 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 06 16 ...

Page 302: ... HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE WARNING A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or pe...

Page 303: ... system Carburetion Chassis j Electrical Appendices Illustrated symbols to are used to iden tify the specifications appearing Filling fluid Lubricant Tightening Wear limit clearance Engine speed n V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease ...

Page 304: ...ion number is used to iden tify your motorcycle and may be used to register your motorcycle with the licensing authority in your state ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the left rear section of the engine 1 Starting Serial Number YX OOU Except for California 1UJ 047101 YX OOUC For California 1UL 00701 NOTE The first three digits of these numbers ...

Page 305: ... Light GENERAL SPECIFICATIONS IAPPXI I APPENDICES YX600U YX600UC 2WY For YX600U 2XA For YX600UC JYA1UJEO JA000101 For YX600U JYA1ULCO JA000101 For YX600UC 1UJ 047101 For YX600U 1UL 00701 For YX600UC 60W 55W 1 pcs 8W 27W 1 pcs Flasher Light Front Front Position Light 27W 8W 2 pcs Flasher Light Rear 27W 2 pcs License Light 3 8W 2 pcs Meter Light 3 4W 4 pcs 2 ...

Page 306: ...J Dll L 8 L y 81 W Y R _ y Sb DI R W R W I I R y l I B W I y I l m I Sidestand relay EJ 1 l R W L R W R W R W r t t B Y it t 1t 1r 11 R W W A W A 8 Y I Gv uGv 11 Gv B 1 X X 1 1 Y R Brtw Y R 1r 1r 1 t 1 t 1r t e Br w 1 _ ll t 1 _ 1 _ t 1 er _ 4 4 4 ___ Flasher relay 6 io Gvll ll i B B _ e J 11 JF I 1 4 l Gv lf t 4 t 1 o _J R W II m lgnitor unit if l RIW cd 0 Gy II Ill it l __ t __ _ i i 4 A JBIWll ...

Page 307: ...nual together with following manual YX600S SC Service Manual LIT 11616 05 06 YX600VNC Supplementary Service Manual LIT 11616 06 16 YX600W YX600WC SUPPLEMENTARY SERVICE MANUAL 1989 by Yamaha Motor Corporation U S A 1st Edition January 1989 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A ...

Page 308: ...D HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE WARNING A NOTE provides key information to make procedures easier or clearer A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or p...

Page 309: ...ng system Carburetion Chassis J Electrical Appendices Illustrated symbols to are used to identify the specifications appearing in the text Filling fluid Lubricant Tightening Wear limit clearance Engine speed O V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel be...

Page 310: ...n number is used to iden tify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 1 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the left rear section of the engine Starting Serial Number YX600W Except for California 3LT 000101 YX600WC For California 3LT 007101 NOTE The first three digits of these numbers a...

Page 311: ...600W 3LT 007101 For YX600WC YX600W YX600WC Dual disc 267 x 5 mm 10 5 x 0 2 in Inner 5 5 mm 0 21 in Limit 0 5 mm 0 019 in Outer 5 5 mm 0 21 in Limit 0 5 mm 0 019 in 15 87 mm 0 62 in 42 8 mm 1 50 in DOT 3 or DOT 4 Clutch Lever Free Play At Lever Pivot Point 2 3 mm 0 08 0 10 in Electrical Model YX600W YX600WC T C I Pickup Coil Resistance 81 121n at 20 c 68 F Color White Red White Black T C I Unit Man...

Page 312: ...ITSUBA Output 0 5 kw Armature Coil Resistance 0 012n 10 at 20 c 68 F Brush Overall Length 12 5 mm 0 50 in Limit 4 mm 0 16 in Spring Force 340 460 g 12 0 16 2 oz Commutator Dia 28 mm 1 10 in Wear Limit 27 mm 1 06 in Mica Undercut 0 8 mm 0 03 in Starter Relay Model Manufacturer JAY HITACHI Amperage Rating 100A Coil Resistance 4 3n at 20 c 68 F Flasher Relay Relay Assembly Type Semi transistor type M...

Page 313: ...5 7 stopper bolt Cam chain tensioner case Bolt M6 Pl O 2 10 1 0 7 2 and cylinder Cam chain tensioner case Nut MB P1 25 1 9 0 9 6 5 lock nut Crankcase Plug M10 P1 25 1 10 1 0 7 2 Rotor housing and pump Screw M6 Pl O cover 1 7 0 7 5 1 Oil pump ass y and Screw M6 Pl O 3 7 0 7 5 1 crankcase Strainer housing and Bolt M6 P1 0 2 10 1 0 7 2 crankcase Strainer cover and crankcase Bolt M6 Pl O 12 10 1 0 7 2...

Page 314: ...ew M5 PO B 1 4 0 4 2 9 Use LOCTITE Cam segment Bolt M6 P1 0 1 10 1 0 7 2 Use LOCTITE Change pedal Bolt M6 P1 0 1 10 1 0 7 2 A C magneto Bolt M10 P1 25 1 BO B 0 5B Stator Bolt M6 P1 0 3 10 1 0 7 2 Use LOCTITE Pickup coil base Screw M6 P1 0 2 B 0 B 5 B Starter motor Bolt M6 P1 0 2 10 1 0 7 2 Neutral switch Screw M5 PO B 3 3 5 0 35 2 5 Use LOCTITE Oil level gauge switch Bolt M6 P1 0 2 7 0 7 5 1 Relie...

Page 315: ...c1Rcu1T DIAGRAM leLeclIii I ELECTRICAL YX600W WC CIRCUIT DIAGRAM L R Y R W W R W B 6 R W 0 j ...

Page 316: ...w White G Green p Pink Dg Dark green Ch Chocolate Gy Gray Sb Sky blue Neutral switch Front brake switch Rear brake switch Horn HORN switch Tachometer Flasher relay TURN switch Reed switch Front position light Flasher light Rear flasher light TU RN indicator light Right TURN indicator light Left Fuse Head LIGHTS Dimmer switch Meter light Headlight HIGH BEAM indicator light Licence light Tail Brake ...

Page 317: ...IGNITION SYSTEM Cl RCUIT DIAGRAM IGNITION SYSTEM IELECI Iii I ...

Page 318: ...CD Battery Fuse MAIN Main switch Fuse IGNITION ENGINE STOP switch IGNITION SYSTEM jELECI iii I lgrntor unit Ignition coil Spark plug Pickup coil Sidestand switch 9 ...

Page 319: ...udes the control unit for the electric fuel pump 10 Al Pickup coil ffil Wave shape shaping circuit CJ Edge detection circuit QJ Latch circuit EJ Microprocessor El Free running counter ill Comparison circuit 8 Register rn Flip flop circuit DJ Driving circuit IBJ Ignition coil _ Digital ignitor unit OPERATION The following operations are digitally performed by signal from the pickup coil signal 1 De...

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