Yamaha XJR1300 (L) '99 Service Manual Download

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Summary of Contents for XJR1300 (L) '99

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Page 3: ...JR1300 L 99 SERVICE MANUAL 1998 by Yamaha Motor Co Ltd 1st Edition August 1998 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...td is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Autho rized yamaha dealers and will where applicable appear in future editions of this manual PARTICURARLY IMPORTANT INFORMATION This materials distinguished by the following notation The Safety Alert Symbol means ATTENTION BECOME AL...

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

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

Page 7: ...O SPEC ENG CARB CHAS ELEC CHK ADJ TRBL SHTG GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETORS CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 EAS00013 INDEX ...

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Page 9: ...ATION NUMBER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 10: ...GEN INFO ...

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

Page 12: ...n all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance b...

Page 13: ...arks or numbers are vis ible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlip...

Page 14: ...ins Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with a pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quic...

Page 15: ...ing nut 90890 01304 Piston pin puller This tool is used to remove the piston pins 90890 01312 Fuel level gauge This tool is used to measure the fuel level in the float chamber 90890 01367 90890 01374 Fork seal driver weight Fork seal driver attachment ø43 These tools are used when installing the fork seal 90890 01326 90890 01327 T handle Damper rod holder These tools are used to hold the damper ro...

Page 16: ...s are used to rebore remove and install the valve guide 90890 04019 Valve spring compressor This tool is used to remove or install the valve assemblies 90890 03153 90890 03124 Oil pressure gauge Oil pressure adaptor B These tools are used to measure the engine oil pressure 90890 04086 Clutch holding tool This tool is used to hold the clutch boss when removing or installing the clutch boss nut 9089...

Page 17: ... No Tool name Function Illustration 90890 06754 Ignition checker This tool is used to check the ignition sys tem components 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces ...

Page 18: ...GEN INFO ...

Page 19: ...IONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 CONVERSION TABLE 2 20 GENERAL TIGHTENING TORQUES 2 20 LUBRICATION POINT AND GRADE OF LUBRICANT 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING 2 26 ...

Page 20: ...SPEC ...

Page 21: ...ngine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure STD Starting system Lubrication system Air cooled 4 stroke DOHC Forward inclined parallel 4 cylinder 1250 cm3 79 0 63 8 mm 9 7 1 1050 kPa 10 5 kg cm2 10 5 bar at 400 r min Electric starter Wet sump Oil type or grade Engine oil SE or higher grade Engine oil Periodic oil change With oil filter replacement...

Page 22: ...0 33 21 1 571 31 24 1 292 29 26 1 115 Chassis Frame type Caster angle Trail Double cradle 25 5 100 mm Tire Type Size front rear Manufacturer front rear Type front rear Tubeless 120 70ZR17 58W 180 55ZR17 73W MICHELIN DUNLOP BRIDGESTONE MICHELIN DUNLOP BRIDGESTONE MACADAM 90X D207F BT57F MACADAM 90X D207 BT57R Tire pressure cold tire Maximum load except motorcycle Loading condition A front rear Load...

Page 23: ...ring Gas oil damper Wheel travel Front wheel travel Rear wheel travel 130 mm 110 mm Electrical Ignition system Generator system Battery type Battery capacity T C I Digital A C generator GT14B 4 12 V 12AH Headlight type Halogen bulb Bulb wattage quantity Headlight Auxiliary light Tail brake light Flasher light Meter light Neutral indicator light High beam indicator light Oil level indicator light T...

Page 24: ...9 01 mm 0 05 mm 0 05 mm 79 1 mm Camshaft Drive method Cam cap inside diameter Camshaft outside diameter Shaft to cap clearance Cam dimensions Chain drive Center 25 000 25 021 mm 24 967 24 980 mm 0 020 0 054 mm Intake A B C Exhaust A B C Camshaft runout limit 35 95 36 05 mm 28 248 28 348 mm 7 95 8 05 mm 35 95 36 05 mm 28 248 28 348 mm 7 95 8 05 mm 35 85 mm 28 15 mm 35 85 mm 28 15 mm 0 03 mm ...

Page 25: ... A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem outside diameter IN EX Guide inside diameter IN EX Stem to guide clearance IN EX Stem runout limit 28 9 29 1 mm 24 9 25 1 mm 1 98 2 55 mm 1 98 2 55 mm 0 9 1 1 mm 0 9 1 1 mm 0 8 1 2 mm 0 8 1 2 mm 5 475 5 490 mm 5 460 5 475 mm 5 500 5 512 mm 5 500 5 512 mm 0 010 0 037 mm 0 025 0 052 mm 5 445 mm 5 43 mm 5 552 m...

Page 26: ...ngth IN EX Set length valve closed IN EX Compressed pressure installed IN EX Tilt limit IN EX Direction of winding top view IN EX Clockwise Clockwise 41 1 mm 41 1 mm 34 8 mm 34 8 mm 130 4 154 0 N 13 3 15 7 kg 130 4 154 0 N 13 3 15 7 kg Counterclockwise Counterclockwise 39 mm 39 mm 2 5 1 7 mm 2 5 1 7 mm Piston Piston to cylinder clearance Piston size D 0 015 0 040 mm 78 970 78 985 mm 0 15 mm Measur...

Page 27: ... End gap installed Side clearance installed Oil ring Taper 1 2 3 0 mm 0 35 0 50 mm 0 03 0 07 mm 0 75 mm 0 1 mm Dimensions B T End gap installed Side clearance 2 5 2 9 mm 0 2 0 5 mm 0 050 0 155 mm Connecting rod Oil clearance 0 017 0 040 mm 0 08 mm Crankshaft Crank width A Assembly width B Runout limit C Big end side clearance D Journal oil clearance 62 25 63 85 mm 382 0 383 2 mm 0 02 mm 0 160 0 26...

Page 28: ...in axle deflection limit Drive axle deflection limit 0 06 mm 0 06 mm Shifter Shifter type Guide bar bending limit Guide bar 0 1 mm Carburetor I D mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot jet P A J 1 Pilot outlet P O Pilot jet P J Bypass 1 B P 1 Bypass 2 B P 2 Bypass 3 B P 3 Pilot screw P S Valve seat size V S Starter jet G S 1 Starter jet G S 2 Throttle valve size T...

Page 29: ...arance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure hot Pressure check location Paper type Trochoid type 0 12 0 17 mm 0 03 0 08 mm 0 03 0 08 mm 180 220 kPa 1 8 2 2 kg cm2 1 8 2 2 bar 480 580 kPa 4 8 5 8 kg cm2 4 8 5 8 bar 80 kPa 0 8 kg cm2 0 8 bar at 1000 r min MAIN GALLERY 0 2 mm 0 15 mm 0 15 mm ...

Page 30: ...e cover Crankcase cover right Clutch cover Drive sprocket cover Clutch release cylinder Crankcase Bolt Screw Cap nut Bolt Stud bolt Nut Nut Nut Bolt Bolt Bolt Bolt Plug Screw Bolt Bolt Union bolt Bolt Plug Plug Screw Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Screw Bolt Bolt Screw Bolt Screw Bolt Bolt Bolt Bolt M6 1 0 M6 1 0 M12 1 25 M10 1 25 M6 1 0 M8 1 25 M8 1 25 M6 1 0 M8 0 75 M7 1 0...

Page 31: ...r clutch idle gear shaft Stopper lever Side plate Shift arm Shift lod A C generator Oil level sensor Rotor Bolt Bolt Plug Bolt Bolt Screw Bolt Nut Bolt Bolt Nut Screw Screw Bolt Screw Bolt Nut Bolt Bolt Bolt M8 1 25 M10 1 25 M20 1 5 M5 0 8 M6 1 0 M6 1 0 M6 1 0 M20 1 5 M6 1 0 M6 1 0 M22 1 5 M8 1 25 M6 1 0 M6 1 0 M5 0 8 M6 1 0 M6 1 0 M8 1 25 M6 1 0 M10 1 25 17 5 3 3 1 3 2 1 6 2 1 1 2 1 1 1 2 2 2 1 2...

Page 32: ...2 12 SPEC MAINTENANCE SPECIFICATIONS Tightening sequence Cylinder head Crankcase ...

Page 33: ...ure feed Splashed Generator shaft Clutch Transmission Ex camshaft Lifter IN camshaft Lifter Timing chain area Piston Cylinder Connecting rod bearing Crankshaft bearings Main gallery Oil filter Relief valve Oil pump Oil cooler Oil pan Oil strainer Model XJR1300 L ...

Page 34: ...83 mm 83 130 mm No 538 cm3 137 mm Fork oil 10W or equivalent 395 mm Rear suspension Shock absorber travel Spring free length Fitting length Spring rate K1 K2 Stroke K1 K2 88 mm 210 mm 190 mm 20 6 N mm 2 1 kg mm 31 4 N mm 3 2 kg mm 0 50 mm 50 88 mm 206 mm Front wheel Type Rim size Rim material Rim runout limit radial lateral Cast wheel 17 MT3 50 Aluminum 1 mm 0 5 mm Rear wheel Type Rim size Rim mat...

Page 35: ...de diameter Caliper cylinder inside diameter Brake fluid type 14 mm 30 2 mm and 27 mm DOT 4 Rear disc brake Type Disc outside diameter thickness Disc deflection limit Pad thickness Single 267 5 mm 5 5 mm 0 15 mm 0 5 mm Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type 12 7 mm 42 85 mm DOT 4 Brake lever brake pedal Brake pedal position 45 mm Throttle grip free play 3...

Page 36: ... Seat lock Fuel sender Side cover and frame Tail light Rear fender and frame Rear fender cover and cover Rear fender cover and frame Grab bar Ignitor Rear turn signal light and rear fender Bolt Nut Nut Bolt Bolt Nut Bolt Bolt Nut Bolt Nut Bolt Cap nut Bolt Nut Nut Bolt Bolt Nut Nut and Bolt Nut Bolt Bolt Bolt Screw Bolt Screw Screw Nut Bolt Screw Nut Bolt Screw Screw Bolt Screw Nut M8 1 25 M22 1 0...

Page 37: ... Rear brake hose Rear brake caliper and bleed screw Rear brake disc and hub Screw Bolt Bolt Bolt Nut Screw Bolt Bolt Bolt Screw Bolt Nut and Bolt Bolt Bolt Bolt Union bolt Nut and bolt Nut Nut Bolt Nut Union bolt Bolt M6 1 0 M6 1 0 M8 1 25 M10 1 25 M10 1 25 M5 0 8 M8 1 25 M8 1 25 M10 1 25 M6 1 0 M8 1 25 M10 1 25 M16 1 5 M8 1 0 M10 1 25 M8 1 25 M8 1 25 M10 1 25 M8 1 25 M8 1 25 M8 1 25 M10 1 25 M18 ...

Page 38: ... 14 3 kΩ Spark plug cap Type Resistance Resin type 10 kΩ Charging system Type Model manufacturer Normal output Rotor coil resistance Stator coil resistance Brush overall length Spring force A C generator B3G B DENSO 13 5 V 28 A 3000 r min 2 8 3 0 Ω 0 19 0 21 Ω 13 7 mm 5 10 5 69 N 0 52 0 58 kg 4 7 mm Voltage regulator Type Model manufacturer No load regulated voltage Semi conductor field control ty...

Page 39: ...lasher frequency Full transistor type FE246BH DENSO No 75 95 cyl min Oil level switch Model manufacturer 5G2 DENSO Fuel gauge Model manufacturer Sender unit resistance full empty 4 KG NIPPON SEIKI 4 10 Ω 90 100 Ω Starting circuit cut off relay Model manufacturer Coil winding resistance Diode G8R 30Y J OMRON 162 198 Ω Yes Oil level switch relay Model manufacturer G8D 117Y 2 OMRON Circuit breaker Ty...

Page 40: ...MP liq Miscella neous kg mm kg cm2 Centigrade 55 997 14 2234 9 5 C 32 lb in psi lb in2 Fahrenheit F EAS00029 GENERAL TIGHTENING TORQUES This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies i...

Page 41: ...e journal Valve stem IN EX Valve stem end IN EX Valve lifter Oil pump rotor inner outer housing Oil strainer assembly Starter idle gear inner surface Starter wheel gear inner surface Starter clutch outer roller Crankcase cover push rod hole Primary drive gear damper Transmission gear wheel pinion Shift cam Shift fork guide bar Shift shaft assembly Crankcase mating surfaces Yamaha bond No 1215 Blin...

Page 42: ...t right Rear wheel oil seal left right Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface Tube guide throttle grip inner surface Brake lever bolt sliding surface Clutch lever bolt sliding surface Rear footrest pivot Swingarm pivot bearing Swingarm pivot shaft outer surface Swingarm thrust cover lip ...

Page 43: ...2 23 1 Camshaft intake 2 Camshaft exhaust 3 Main gallery 4 Oil strainer 5 Oil pump 6 Main axle 7 Crankshaft SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS ...

Page 44: ...2 24 1 Oil cooler 2 Starter clutch 3 Main axle 4 Drive axle 5 Oil pump 6 Oil pan 7 Relief valve 8 Main gallery SPEC LUBRICATION DIAGRAMS ...

Page 45: ...2 25 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter SPEC LUBRICATION DIAGRAMS ...

Page 46: ...ten the wireharness with the steel clamp on the frame 9 Throttle position sensor 10 Ignition coil lead 2 3 11 Throttle cable 12 Engine ground lead 13 Air ventilation hose 14 Rear brake switch 15 Starting circuit cutoff relay 1 Starter motor cable 2 Battery negative lead 3 Battery negative lead con nector 4 AC generator connector 5 Rear brake switch lead connec tor 6 Neutral lead 7 Pickup lead 8 Si...

Page 47: ...band through the hole of plastic panel and then fasten the throttle cables with it Make sure that the end of band inside of motorcycle H Fasten the wireharness to the frame with a plastic band Make sure that the end of band down ward D Route the wireharness and start er motor cable in front of the res ervoir tank bracket and the bat tery negative lead behind the reservoir tank bracket And fas ten ...

Page 48: ...e side cover bracket and fasten them with a plastic band at front of the bracket M Align the white paint marks of the fuel tank drain hose fuel tank breather hose and air filter case drain hose N Touch the brake pipe to the brake caliper stopper SPEC CABLE ROUTING ...

Page 49: ...astic panel and then fasten the clutch hose with it Make sure that the end of band inside of motorcycle B To headlight lower hole C Route the wireharness and start er cable through the guide D Connect the ignition lead with white marking tape to the ignition coil 1 4 1 Clutch hose 2 Starter cable 3 Air filter case drain hose 4 Frame ground 5 Flasher relay connector 6 Oil light relay connector 7 Ig...

Page 50: ...er cover AC generator and starter motor to the right side of motorcycle L Fasten the clutch hose with steel clamp on the frame M Clamp the gromet on the clutch hose with wire holder on the frame SPEC CABLE ROUTING H Fasten the seat lock cable to the seat real with a plastic band Make sure that the end of band down ward I Route the air filter case drain hose over the starter motor to right side of ...

Page 51: ...ble 14 Seat lock 15 Battery positive lead 16 Fuse box 17 Starter relay connector 18 Flasher relay 19 Oil light relay 20 Igniter unit 21 Fuel sender connector 22 Starter cable 23 Ignition coil 1 4 SPEC CABLE ROUTING 1 Throttle cables 2 Ignition coil 2 3 3 Throttle position sensor 4 Neutral switch connector 5 Pickup coil connector 6 Sidestand switch connector 7 Battery 8 Reservoir tank 9 Battery neg...

Page 52: ...y positive lead connector on the groove of the battery with the battery rubber band H Position the starter motor cable at 45 degree out side of the mo torcycle I Position the wireharness tail light lead and rear turn signal light leads left and right be tween the taillight bracket and rear fender rib E Connect the fuel sender connec tor neutral switch connector pickup coil connector and side stand...

Page 53: ...gnal light leads left and right with steel clamp on the frame make sure that the end of clamp forward O Route the rear turn signal light leads left and right through the each holes of the rear fender P Touch the starter cable to the stopper and position it vertical of the motorcyle ...

Page 54: ... To front brake master cylinder A Route the throttle cables through the guide on the headlight stay B Route the meter leads main switch lead into the upper hole of the headlight body C Route the handlebar switch lead left inside of the clutch hose Fasten the handlebar switch lead left clutch hose and start er cable with a plastic band 1 Meter leads 2 Main switch lead 3 Starter cable 4 Handlebar sw...

Page 55: ...stop per I Route the handlebar switch lead right and front turn signal light lead right into the right under hole of the headlight stay J Fasten the handlebar switch lead right and front brake hose with a plastic band SPEC CABLE ROUTING ...

Page 56: ...SPEC ...

Page 57: ...0 CLEANING THE AIR FILTER ELEMENT 3 22 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 3 23 CHECKING THE FUEL AND VACUUM HOSES 3 23 CHECKING THE CRANKCASE BREATHER HOSE 3 24 CHECKING THE EXHAUST SYSTEM 3 24 CHASSIS 3 25 ADJUSTING THE FRONT BRAKE 3 25 ADJUSTING THE REAR BRAKE 3 25 CHECKING THE BRAKE FLUID LEVEL 3 26 CHECKING THE BRAKE PADS 3 27 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 27 BLEEDIN...

Page 58: ...AND 3 40 LUBRICATING THE CENTERSTAND 3 40 LUBRICATING THE REAR SUSPENSION 3 40 ELECTRICAL SYSTEM 3 41 CHECKING AND CHARGING THE BATTERY 3 41 CHECKING THE FUSES 3 46 REPLACING THE HEADLIGHT BULB 3 48 ADJUSTING THE HEADLIGHT BEAM 3 49 ...

Page 59: ...f necessary Fuel filter Check condition Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter Replace Brake Check operation fluid leakage See NOTE Correct if necessary Clutch Check operation fluid leakage See NOTE Correct if necessary Swingarm pivot Check swingarm assembly for looseness Correct if necessary Moderately repack every 24 000 km or 24 months Rear suspens...

Page 60: ...replacement 1 When disassembling the master cylinder caliper cylinder or clutch release cylinder replace the brake fluid Normally check the brake fluid level and add the fluid as required 2 On the inner parts of the master cylinder caliper cylinder and clutch release cylinder replace the oil seals every two years 3 Replace the brake and clutch hoses every four years or if cracked or damaged ...

Page 61: ...l tank Seat Side cover left Side cover right Fuel hose Fuel tank Fuel sender lead Drain hose Grab bar Rear fender cover 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Disconnect the fuel pipe set the fuel cock lever ON or RES position For installation reverse the removal procedure NOTE 30 Nm 3 0 mSkg SEAT SIDE COVER AND FUEL TANK ...

Page 62: ...e valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Sseat Sside covers Sfuel tank Refer to SEAT SIDE COVER AND FUEL TANK 2 Remove Soil cooler 1 Sair ducts 2 3 Remove Sspark plugs 1 Scylinder head cover 2 Stiming plate cover 3 4 Measure Svalve clearance Out of specification Adjust Valve clearance cold Intake valve 0 11 0 15 mm...

Page 63: ... from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 3 A Front d For each cylinder starting with cylinder 1 at TDC turn the crankshaft counterclockwise as specified in the following table B Degrees that the cra...

Page 64: ...ter with a small screwdriver and a pair of twee zers Make a note of the position of each valve pad and valve pad number so they can be installed in the correct place f Select the proper valve pad from the follow ing table Valve pad thickness range Available valve pads No 200 No 320 2 00 mm 3 20 mm 25 thicknesses in 0 05 mm incre ments SThe thickness of each valve pad is marked in hundredths of mil...

Page 65: ...5 300 305 310 315 320 0 86 0 90 275 280 285 290 295 300 305 310 315 320 0 91 0 95 280 285 290 295 300 305 310 315 320 0 96 1 00 285 290 295 300 305 310 315 320 1 01 1 05 290 295 300 305 310 315 320 1 06 1 10 295 300 305 310 315 320 1 11 1 15 300 305 310 315 320 1 16 1 20 305 310 315 320 1 21 1 25 310 315 320 1 26 1 30 315 320 1 31 1 35 320 EXHAUST 200 205 210 215 220 225 230 235 240 245 250 255 26...

Page 66: ...e clearance must be measured again and the above steps should be repeated if the measurement is still incorrect i Install the new valve pad with the numbered side facing down j Remove the tappet adjusting tool INTAKE EXHAUST k Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat al of the valve clearance adjust ment steps until the specified clearance is...

Page 67: ... Install Svacuum gauge 1 Sengine tachometer 2 to the spark plug lead of cyl 1 Vacuum gauge 90890 03094 Engine tachometer 90890 03113 4 Start the engine and let it warm up for several minutes 5 Check Sengine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 1 000 1 100 r min 6 Adjust Scarburetor synchronization a Synchronize carburetor 1 to carb...

Page 68: ...kPa 10 mm Hg 0 4 in Hg 7 Check Sengine idling speed Out of specification Adjust 8 Stop the engine and remove the measuring equipment 9 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the throttle grip 3 5 mm 10 Install Sfuel tank Sseat Sside covers Refer to SEAT SIDE COVER AND FUEL TANK EAS00054 ADJUSTING THE ENGINE IDLING SPEED Prior to...

Page 69: ...the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is in creased Direction Engine idling speed is de creased 5 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 5 mm EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusti...

Page 70: ...tained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased e Tighten the locknuts If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 7 b Turn the adjusting nut 8 in direction a or b until the specified throttle cable free play is ...

Page 71: ... 4 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color 5 Clean spark plug with a spark plug cleaner or wire brush 6 Measure spark plug gap a with a wire gauge Out of specification Regap Spark plug gap 0 8 0 9 mm 7 Install spark plug Spark plug 18 Nm 1 8 m kg Before installing the spark plug clean the spa...

Page 72: ...the pickup coil a is within the fir ing range b on th timing plate Incorrect firing range Check the ignition system The ignition timing is not adjustable 4 Remove engine tachometer timing light 5 Install timing plate cover Timing plate cover bolt 7 Nm 0 7 m kg LOCTITE EAS00065 MEASURING THE COMPRESSION PRES SURE The following procedure applies to all of the cyl inders Insufficient compression pres...

Page 73: ...ylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again SRefer to the following table Compression pressure With oil applied into cylinder Reading Diagnosis Higher than without oil Piston wear or damage Repair Same as without oil Piston ring s valves cyl inder head gasket or piston possibly de...

Page 74: ...Nm 1 8 mSkg 8 Connect Sspark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface SPlace the motorcycle on a suitable stand SMake sure that the motorcycle is upright 2 Let the engine idle for a few minutes and then stop it 3 Check Sengine oil level The engine oil level should be between the minimum level marks a and maximum level marks b Below the minimum level...

Page 75: ...AS00075 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Sengine oil filler cap Sengine oil drain bolt 1 4 Drain Sengine oil completely from the crankcase 5 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter...

Page 76: ...IL PRESSURE 1 Check Sengine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Smain ga...

Page 77: ... viscosity too high 6 Install Smain gallery bolt Main gallery bolt 12 Nm 1 2 mSkg EAS00082 ADJUSTING THE CLUTCH LEVER 1 Adjust Sclutch lever position distance a from the handlebar grip to the clutch lever a While pushing the clutch lever forward turn the adjusting dial 1 until the clutch lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on th...

Page 78: ...of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance SWhen refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the clutch fluid and could cause vapor lock Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spi...

Page 79: ... recommended clutch fluid to the proper level b Install the clutch master cylinder reservoir di aphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly squeeze the clutch lever several times f Fully squeeze the clutch lever without re leasing it g Loosen the bleed screw This will release the tension and cause the clutch lev...

Page 80: ...ment Damage Replace 5 Install Sair filter element Sair filter case cover along with the gasket Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor en gine performance and possible overheat ing Make s...

Page 81: ... TANK 2 Check Scarburetor joint 1 Sintake manifold 2 Cracks damage Replace Refer to CARBURETOR in chapter 6 3 Install Sfuel tank Sside cover Sseat Refer to SEAT SIDE COVER AND FUEL TANK EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove Sseat Sfuel tank Refer to SEAT SIDE COVER AND FUEL TANK 2 Check Svacuum hose 1 Sfuel hose 2 C...

Page 82: ...AS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes mufflers and gaskets 1 Check Sexhaust pipe 1 Smuffler 2 Cracks damage Replace Sgasket 3 4 5 Exhaust gas leaks Replace 2 Check Stightening torque Exhaust pipe nut 6 25 Nm 2 5 mSkg Exhaust pipe and exhaust chamber screw 7 20 Nm 2 0 mSkg Muffler bracket bolt 8 20 Nm 2 0 mSkg Exhaust chamber bolt 9 25 Nm 2...

Page 83: ...t After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the ad justing dial EAS00110 ADJUSTING THE REAR BRAKE 1 Check Sbrake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust Brake pedal position below the top of the rider footrest 45 mm 2 Adjust Sbrake pedal p...

Page 84: ...edal position make sure that there is no brake drag 3 Adjust Srear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00115 CHECKING THE BRAKE FLUID LEVEL 1 Stand the motorcycle on a level surface SPlace the motorcycle on a suitable stand SMake sure that the motorcycle is upright 2 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake fluid to the prop...

Page 85: ...e 2 Check Sfront brake pad Srear brake pad Brake pad almost worn to the wear indicator line 1 Replace the brake pads as a set Refer to REPLACING THE FRONT BRAKE PADS and REPLACING THE REAR BRAKE PADS in chapter 6 A Front brake B Rear brake EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly a...

Page 86: ...rake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Shydraulic brake system a Add the recommended brake fluid to the proper level b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 A Front B Rear d Place the other end of the hose into a ...

Page 87: ...The angle a should be approximately 90_ Incorrect Adjust 2 Adjust Sshift pedal position a Loosen both locknuts 2 b Turn the shift rod 3 in direction a or b to obtain the correct shift pedal position Direction Shift pedal is raised Direction Shift pedal is lowered STighten both locknuts EAS00140 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain...

Page 88: ...hain slack a Out of specification Adjust Drive chain slack 20 30 mm 4 Adjust Sdrive chain slack a Loosen the tensionbar bolt b Loosen the wheel axle nut 1 c Loosen both locknuts 2 d Turn both adjusting bolt 3 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain is tightened Direction Drive chain is loosened To maintain the proper wheel alignment adjust both ...

Page 89: ...ned prop erly it will wear out rapidly Therefore the drive chain should be serviced especially when the motorcycle is used in dusty areas This motorcycle has a drive chain with small rubber O rings 1 between each side plate Steam cleaning high pressure washing certain solvents and the use of a coarse brush can damage these O rings therefore use only kerosine to clean the drive chain Wipe the drive...

Page 90: ...falling over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check Ssteering head Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head 3 Remove Sseat Sfuel tank Refer to SEAT SIDE COVER AND FUEL TANK 4 Remove Sheadlight unit 1 5 Remove Sheadlight body 1 6 Disconnect Sspeed meter cable 1 7 Remove Smeter a...

Page 91: ...que wrench at a right angle to the ring nut wrench Ring nut wrench 90890 01403 Lower ring nut initial tightening torque 52 Nm 5 2 mSkg c Loosen the lower ring nut 4 completely then tighten it to specification Do not overtighten the lower ring nut Lower ring nut final tightening torque 18 Nm 1 8 mSkg d Check the steering head for looseness or binding by turning the front fork all the way in both di...

Page 92: ...all Shandle crown Steering stem nut 110 Nm 11 0 mSkg Upper bracket pinch bolt 30 Nm 3 0 mSkg 12 Install Shandlebar 13 Install Supper handlebar holder Handlebar holder bolt 23 Nm 2 3 mSkg EAS00149 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check Sinner tube Damage scratches Replace Soil seal Oil l...

Page 93: ...urely support the motorcycle so that there is no danger of it falling over Spring preload SGrooves are provided to indicate the ad justment position SNever go beyond the maximum or mini mum adjustment positions 1 Adjust Sspring preload a Turn the adjusting bolt 1 in direction a or b Direction Spring preload is in creased suspension is harder Direction Spring preload is de creased suspension is sof...

Page 94: ...r shock absorber assemblies evenly Uneven adjustment can result in poor handling and loss of sta bility Spring preload Never go beyond the maximum or minimum adjustment positions 1 Adjust Sspring preload Adjust the spring preload with the special wrench and extension bar in cluded in the own er s tool kit a Turn the spring seat 1 in direction a or b Direction Spring preload is increased suspension...

Page 95: ...rider passenger and ac cessories and the anticipated riding speed SOperation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 253 kg Maxim m load 207 kg Maximum load 207 kg Cold tire pressure Front tire Rear tire Up to 90 kg load 250 kPa 2 5 kg cm2 2 5 bar 250 kPa 2 5 kg cm2 2 5 bar 90 kg Maximum l...

Page 96: ...tire and a new tube as a set STo avoid pinching the tube make sure that the wheel rim band and tube are centered in the wheel groove SPatching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement A Tire B Wheel Tube wheel Tube tire only Tubebeless wheel Tube or tubeless tire After extens...

Page 97: ...rface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done For tires with a direction of rotation mark 1 SInstall the tire with the mark pointing in the direction of wheel rotation SAlign the mark 2 with the valve installation point EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels...

Page 98: ...a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Engine oil EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts...

Page 99: ... electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SSKIN Wash with water SEYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion SThis is a sealed battery Never remove the sealing ...

Page 100: ...Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive terminal Tester negative lead battery negative terminal SThe charge state of a MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected SNo charging is necessary when the open cir cuit voltage equals or exceeds ...

Page 101: ...sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure that the battery charger lead clips are in full contact with the battery ter minal and that they are not shorted A cor roded battery charger lead clip may gener ate heat i...

Page 102: ...ace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am perage readjust the voltage to obtain the standard charging amper age Leave the battery unused for more than 30 minutes before measur ing its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Repla...

Page 103: ...the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is re quired Under 12 0 V Replace the battery NOTE Set the charging time to a maximum of 20 hours YES NO V...

Page 104: ... Sbattery terminals Dirt Clean with a wire brush Loose connection Connect properly 10 Lubricate Sbattery terminals Recommended lubricant Dielectric grease 11 Install Sseat EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove Sseat 2 Check Sfuse a Connect the pocket test...

Page 105: ...the fuse immediately blows again check the electrical circuit Fuses Amperage rating Quantity Main fuse 30 A 1 Headlight fuse 15 A 1 Signaling system fuse 15 A 1 Ignition fuse 7 5 A 1 Reserve 30 A 1 15 A 1 7 5 A 1 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause t...

Page 106: ...s extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Sheadlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb...

Page 107: ...all Sheadlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Sheadlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust Sheadlight beam horizontally a Turn the adjusting knob 2 in direction a or b Direction Headlight beam moves to the right Direction Headlight beam moves to the left ...

Page 108: ...CHK ADJ ...

Page 109: ...RINGS 4 18 REMOVING THE VALVES 4 19 CHECKING THE VALVES AND VALVE GUIDES 4 20 CHECKING THE VALVE SEATS 4 22 CHECKING THE VALVE SPRINGS 4 23 CHECKING THE VALVE LIFTERS 4 24 INSTALLING THE VALVES 4 24 CYLINDERS AND PISTONS 4 26 REMOVING THE CYLINDERS AND PISTONS 4 27 CHECKING THE CYLINDERS AND PISTONS 4 27 CHECKING THE PISTON RINGS 4 29 INSTALLING THE PISTONS AND CYLINDERS 4 30 CLUTCH 4 32 CLUTCH CO...

Page 110: ...HECKING THE STOPPER LEVER 4 57 INSTALLING THE SHIFT SHAFT 4 57 TIMING PLATE AND PICKUP COIL 4 59 OIL PAN 4 60 REMOVING THE OIL PAN 4 61 CHECKING THE RELIEF VALVE 4 61 CHECKING THE OIL DELIVERY PIPES 4 61 CHECKING THE OIL STRAINER 4 61 INSTALLING THE OIL STRAINER 4 62 INSTALLING THE OIL PAN 4 62 CRANKCASE 4 63 DISASSEMBLING THE CRANKCASE 4 65 CHECKING THE CRANKCASE 4 66 ASSEMBLING THE CRANKCASE 4 6...

Page 111: ...NG THE CONNECTING RODS 4 79 INSTALLING THE CRANKSHAFT 4 81 TRANSMISSION 4 82 SHIFT CAM AND SHIFT FORK 4 85 CHECKING THE SHIFT FORK 4 86 CHECKING THE SHIFT DRUM ASSEMBLY 4 86 CHECKING THE TRANSMISSION 4 86 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 4 87 INSTALLING THE TRANSMISSION 4 88 ...

Page 112: ...ENG ...

Page 113: ...haust chamber Exhaust chamber bracket Oil cooler Air duct left right 6 4 4 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEAT SIDE COVER AND FUEL TANK in Chapter 3 Refer to CARBURETOR in Chapter 5 Drain 12 Nm 1 2 m kg 20 Nm 2 0 m kg 20 Nm 2 0 m kg 25 Nm 2 5 m kg 25 Nm 2 5 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg New New EAS0018 ENGINE OVERHAULE ENGINE LEADS HOSES AND EXHAUST...

Page 114: ...round lead Crankcase breather hose 2 1 1 For installation reverse the removal pro cedure Disconnect ground lead NOTE 9 10 11 12 Nm 1 2 m kg 20 Nm 2 0 m kg 25 Nm 2 5 m kg 25 Nm 2 5 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg New New ...

Page 115: ...nerator lead A C generator Clutch release cylinder comp Shift arm Drive sprocket cover Dowel pins Gasket Nut 1 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Refer to INSTALLING THE ENGINE Disconnect starter motor lead NOTE 25 Nm 2 5 m kg 10 Nm 1 0 m kg 85 Nm 8 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg New New ENG ENGINE EAS00190 LEADS AND DRIVE SPROCKET ...

Page 116: ...NE Order Job Part Q ty Remarks 12 13 14 Lock washer Drive sprocket Drive chain 1 1 1 For installation reverse the removal procedure 25 Nm 2 5 m kg 10 Nm 1 0 m kg 85 Nm 8 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg New New ...

Page 117: ...ngine bracket rear lower Engine 1 1 2 1 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure Place a suitable stand under the frame and engine NOTE Refer to INSTALLING THE ENGINE 88 Nm 8 8 m kg 28 Nm 2 8 m kg 26 Nm 2 6 m kg 30 Nm 3 0 m kg 64 Nm 6 4 m kg 48 Nm 4 8 m kg 55 Nm 5 5 m kg 64 Nm 6 4 m kg ENG ENGINE ENGINE ...

Page 118: ...48 Nm 4 8 m kg Bolt 3 55 Nm 5 5 m kg Bolt 4 30 Nm 3 0 m kg Bolt 5 64 Nm 6 4 m kg Nut 6 64 Nm 6 4 m kg 2 Install shift arm 1 Align the punch mark b in the shift shaft with the punched mark a on the shift arm Align the bottom edge of the shift pedal with the mark on the frame to swingarm bracket Shift arm bolt 10 Nm 1 0 m kg ...

Page 119: ...ad covers Seat fuel tank Bolts Air duct left right Plug cap Cylinder head cover Gasket 2 1 1 4 1 1 Remove the parts in the order listed Refer to SEAT SIDE COVER AND FUEL TANK For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg CAMSHAFT CYLINDER HEAD COVER ...

Page 120: ...ly Timing chain guide exhaust side Camshaft caps Dowel pins Camshaft intake Camshaft exhaust Camshaft sprockets 4 1 1 1 1 1 8 16 1 1 2 Remove the parts in the order listed For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CAMSHAFTS 12 Nm 1 2 m kg 18 Nm 1 8 m kg 20 Nm 2 0 m kg 20 Nm 2 0 m kg 10 Nm 1 0 m kg New ENG CAMSHAFTS EAS00196 CAMSHAFTS ...

Page 121: ...rom each other 2 Remove timing chain guide top side 1 3 Loosen camshaft sprocket bolts 4 Loosen cap bolt 2 5 Remove timing chain tensioner To prevent the timing chain from falling into the crankcase fasten it with a wire 5 6 Remove timing chain guide exhaust side camshaft caps 3 For reference during installation put identifica tion marks on each camshaft cap To prevent damage to the cylinder head ...

Page 122: ... clear ance Out of specification Measure the camshaft journal diameter Camshaft journal to camshaft cap clearance 0 020 0 054 mm a Install the camshaft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Tighten the camshaft cap bolts in stages and in a crisscross pattern w...

Page 123: ...ckets and timing chain guides 1 Check camshaft sprocket Damage wear Replace the camshaft sprockets and the timing chain as a set 2 Check timing chain guide exhaust side timing chain guide top side Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage Replace 2 Check one way cam operation Rough movement Replace the timing ...

Page 124: ...stallation Damage or improper valve timing will result b Fit the timing chain onto both camshaft sprockets and install the camshafts Install the exhaust camshaft 1 first then the intake camshaft 2 Install the camshafts with the punched mark facing upward Keep the timing chain as tense as possible on the exhaust side c Install the camshaft caps 3 with dowel pins Make sure that each camshaft cap is ...

Page 125: ...safety wire from the timing chain 3 Install timing chain tensioner Installation steps a Remove the tensioner cap bolt 1 washer 2 and springs 3 b Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way into the timing chain tensioner housing c Install the timing chain tensioner with a gas ket 6 onto the cylinder Always use a new gasket The timing chain tensioner te...

Page 126: ... with the stationary pointer b Check if both the camshaft timing punch marks a are aligning with the camshaft cap hole b 5 Tighten Bolts cam sprockets Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine Bolts cam sprockets 20 Nm 2 0 m kg ...

Page 127: ...1 1 2 2 4 Remove the parts in the order listed Refer to CAMSHAFTS For installation reverse the removal procedure NOTE Refer to REMOVING INSTALLING THE CYLINDER HEAD Remove the engine mount front and move the engine to front side 35 Nm 3 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg New New ENG CYLINDER HEAD EAS00221 CYLINDER HEAD ...

Page 128: ...posits with a rounded scraper Do not use a sharp instrument to avoid damag ing or scratching spark plug threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 1 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the lim...

Page 129: ...Install cylinder head washers copper washers cylinder head nuts Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages Cylinder head Cap nut 35 Nm 3 5 m kg Cylinder head nut 10 Nm 1 0 m kg 3 Install exhaust camshaft intake camshaft Refer to INSTALLING THE CAMSHAFTS ...

Page 130: ...fters Valve cotters Upper springs seats Valve springs outer Valve springs inner Intake valves Exhaust valves Lower spring seats Oil seals 16 16 32 16 16 16 8 8 16 16 Remove the parts in the order listed Refer to CAMSHAFTS Refer to CYLINDER HEAD For installation reverse the removal procedure Refer to REMOVING INSTALLING THE VALVES EAS00236 VALVES AND VALVE SPRINGS ...

Page 131: ...of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent 1 into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 2 3 Remove valve...

Page 132: ... procedure applies to all of the valves and valve guides 1 Measure Svalve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification Replace the valve guide Valve stem to valve guide clear ance Intake 0 010 0 037 mm Limit 0 08 mm Exhaust 0 025 0 052 mm Limit 0 10 mm 2 Replace Svalve guide To ease valve guide removal an...

Page 133: ...e guide remover reamer installer 5 5 mm 90890 04016 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure valve margin thickness a Out of specification Replace the valve Valve margin thickness 0 8 mm 1 2 mm 6 Measure valve stem r...

Page 134: ...lve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap valve face valve seat After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face sho...

Page 135: ...re be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat ...

Page 136: ...uter spring 130 4 154 0 N 13 3 15 7 kg at 34 8 mm 3 Measure Svalve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake and exhaust inner spring 2 5_ 1 7 mm Intake and exhaust outer spring 2 5_ 1 7 mm EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Svalve lifter Damage scratches Replace the valve lift ers and c...

Page 137: ...lve cotters by compressing the valve spring with the valve spring compressor 2 Valve spring compressor 90890 04019 4 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive force could damage the valve 5 Install valve pad 1 valve lifter 2 Apply molybdenum disulfide oil onto the valve lifter and valve pad The valve lif...

Page 138: ...der head Cylinder block Dowel pins Gasket Piston pin clips Piston pins Pistons Oil ring sets Remove the parts in the order listed Refer to CYLINDER HEAD For installation removal procedure Refer to REMOVING INSTALLING THE CYLINDERS AND PISTONS 1 2 1 8 4 4 4 20 Nm 2 0 m kg New New New EAS00252 CYLINDERS AND PISTONS ...

Page 139: ... crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller 90890 01304 2 Remove top ring 2nd ring oil ring When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston...

Page 140: ...ion replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 2 0 mm from the bottom edge of the piston Piston size P Standard 78 970 78 985 mm d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore C ...

Page 141: ... side clearance Top ring 0 045 0 080 mm Limit 0 1 mm 2nd ring 0 03 0 07 mm Limit 0 1 mm 2 Install piston ring into the cylinder Level the piston ring in the cylinder with the pis ton crown as shown a 30 mm 3 Measure piston ring end gap Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three pi...

Page 142: ...re lo cated on the upper side of the rings The piston rings that have an R mark must be installed into the 2nd ring groove 2 Install piston 1 piston pin 2 piston pin clip New 3 Apply engine oil onto the piston pin Make sure that the arrow mark a on the piston points towards the exhaust side of the engine Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent ...

Page 143: ...mended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A forward 6 Install cylinder block Install pistons 2 and 3 before installing pis tons 1 and 4 Pass the timing chain and timing chain guide intake side through the timing chain cavity ...

Page 144: ...ks 1 2 3 Removing the clutch cover Engine oil Clutch cover Gasket Dowel pins 1 1 2 Remove the parts in the order listed Drain For installation reverse the removal procedure 10 Nm 1 0 m kg New ENG CLUTCH EAS00273 CLUTCH CLUTCH COVER ...

Page 145: ...re plate Clutch push rod short Ball Clutch push rod long O ring Friction plates Clutch plates Friction plates Clutch boss nut Lock washer 1 1 1 1 1 1 1 1 1 6 6 1 1 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH Refer to REMOVING INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg New New ENG CLUTCH EAS00274 CLUTCH ...

Page 146: ...ss Stopper ring Clutch plate Clutch spring plate Clutch spring plate seat Friction plates narrow Thrust washer Spacer Bearing Clutch housing 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg New New ...

Page 147: ...s 3 thrust washer 4 spacer 5 bearing 6 clutch housing 7 Insert two 6 mm bolts 8 into the spacer and then remove the spacer by pulling on the bolts EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction pla...

Page 148: ...ness gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit Less than 0 1 mm CHECKING THE CLUTCH SPRING 1 Check Clutch spring Damage Replace as a set 2 Measure Clutch spring free height Out of specification Replace spring as a set Free height limit clutch spring 6 0 mm EAS00283 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate Damage Replace 2 Check c...

Page 149: ... on the clutch housing dogs will cause er ratic clutch operation 2 Check bearing Damage wear Replace the clutch hous ing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check pressure plate Cracks damage Replace ...

Page 150: ...s 2 Measure long clutch push rod bending limit Out of specification Replace the long clutch push rod Long clutch push rod bending limit 0 3 mm INSTALLING THE CLUTCH 1 Install clutch housing 1 Engage the notch of clutch housing and the pro jection on the oil pump drive gear 2 Install bearing 1 spacer 2 thrust washer 3 Install the spacer with the two screw holes fac ing towards the clutch boss ...

Page 151: ...er 90890 04086 Clutch boss nut 70 Nm 7 0 m kg 4 Bend the lock washer tab along a flat side of the nut 5 Lubricate long clutch push rod 1 ball 2 short clutch push rod 3 with the recommended lubricant Recommended lubricant Lithium soap base grease 6 Install clutch spring plate seat 1 clutch spring plate 2 Install the spring plate with the letters OUT SIDE facing outward ...

Page 152: ...stall the stopper ring onto the groove around the clutch boss with both ends of the ring fitted in the hole a on the boss c Install the other 6 clutch plates and the 6 fric tion plates of wide contact face alternately d Install the another friction plate of narrow face 8 Install Pressure plate 1 Spring housing 2 Clutch spring 3 Plate 4 Bolts clutch spring Tighten the bolts clutch spring in stages ...

Page 153: ...Clutch lever holder Clutch master cylinder 1 1 1 1 2 1 1 1 Remove the parts in the order listed Before removing the clutch master cylin der drain the clutch fluid from the entire clutch system For installation reverse the removal procedure NOTE Refer to INSTALLING THE CLUTCH MASTER CYLINDER 10 Nm 1 0 m kg 30 Nm 3 0 m kg New ENG CLUTCH EAS00305 CLUTCH MASTER CYLINDER ...

Page 154: ... Remarks Disassembling the clutch master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 New ENG CLUTCH ...

Page 155: ...arts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00308 CHECKING THE CLUTCH MASTER CYL INDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every ...

Page 156: ... as they will cause the piston seals to swell and distort Whenever a clutch master cylinder is dis assembled replace the piston seals Recommended clutch fluid Brake fluid DOT 4 EAS00310 INSTALLING THE CLUTCH MASTER CYL INDER 1 Install clutch master cylinder 1 Install the clutch lever holder with the UP mark facing up Align the end of the clutch lever holder with the punch mark a in the handlebar F...

Page 157: ...fill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the clutch fluid and could cause vapor lock Clutch fluid may damage painted surfaces or plastic parts Therefore ...

Page 158: ...um level mark a Add the recommended clutch fluid to the proper lev el Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 7 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 ...

Page 159: ...1 1 1 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH RELEASE CYLINDER Before removing the clutch releace cylin der drain the clutch fluid from the entire clutch system NOTE For installation reverse the removal procedure Refer to INSTALLING THE CLUTCH RELEASE CYLINDER 30 Nm 3 0 m kg 10 Nm 1 0 m kg ENG CLUTCH EAS00311 CLUTCH RELEASE CYLINDER ...

Page 160: ...ng the clutch release cylinder Clutch release cylinder Piston seal Clutch release cylinder piston Piston seal Spring 1 1 1 1 1 Disassembly the parts in the order listed Refer to DISASSEMBLING THE CLUTCH RELEASE CYLINDER For assembly reverse the disassembly procedure ...

Page 161: ...e cylinder Never try to pry out the clutch release cylin der piston b Remove the clutch release cylinder piston seals EAS00314 CHECKING THE CLUTCH RELEASE CYL INDER Recommended clutch component p replacement schedule Piston seals Every two years Clutch hose Every two years Clutch fluid Every two years and whenever the clutch is disassembled 1 Check clutch release cylinder body Cracks damage Replac...

Page 162: ...id DOT 4 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch perfor mance When refilling be careful that water does not enter the reservoir Water will ...

Page 163: ... Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 4 Check clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper lev el Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 5 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 ...

Page 164: ...asher Oil buffer plate Circlip Oil pump driven gear Washer Oil pump Dowel pin Collar O ring 1 1 1 1 1 1 1 1 1 1 3 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH Refer to INSTALLING THE OIL PUMP For installation reverse the removal procedure New 4 Nm 0 4 m kg 10 Nm 1 0 m kg ENG OIL PUMP OIL PUMP ...

Page 165: ...using Inner rotor Outer rotor Pin Dowel pin Oil pump housing Inner rotor Outer rotor Pin Oil pump shaft Oil pump cover 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed Refer to ASSEMBLING THE OIL PUMP For assembly reverse the disassembly procedure 1 10 11 2 3 4 5 6 7 8 9 ...

Page 166: ...ing clearance B oil pump housing to inner rotor and outer rotor clearance C Outer of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 12 0 17 mm Limit 0 2 mm Outer rotor to oil pump housing clearance 0 03 0 08 mm Limit 0 15 mm Oil pump housing to inner rotor and outer rotor clearance 0 03 0 08 mm Limit 0 15 mm 3 Check oil ...

Page 167: ...rotor 5 pin 6 oil pump housing 7 screw Oil pump housing screw 10 Nm 1 0 m kg When installing the inner rotor align the pin 3 in the oil pump shaft with the groove on the inner rotor 4 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 Oil pump bolt 10 Nm 1 0 m kg After tightening the bolts make sure that the oil pump turns smoothly Align...

Page 168: ...er Circlip Washer Shift shaft Washer Shift lever spring Bolt Stopper lever Stopper lever spring 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to OIL PUMP Refer to ENGINE Refer to INSTALLING THE SHIFT SHAFT For installation reverse the removal procedure 10 Nm 1 0 m kg New ENG SHIFT SHAFT EAS00327 SHIFT SHAFT ...

Page 169: ...Check stopper lever 1 Bends damage Replace Roller turns roughly Replace the stopper lever EAS00331 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 shift shaft lever 3 Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly 2 Install washer 1 shift shaft 2 circlip 3 ...

Page 170: ...4 58 ENG SHIFT SHAFT NOTE Lubricate the oil seal lips with lithium soap base grease Hook the end of the shift lever spring onto the shift lever spring stopper 4 ...

Page 171: ...r fuel tank Pickup coil read Timing plate cover Gasket Pickup coil Timing plate Dowel pin Pickup base 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 4 Nm 0 4 m kg 45 Nm 4 5 m kg 7 Nm 0 7 m kg ENG TIMING PLATE AND PICKUP COIL TIMING PLATE AND PICKUP COIL ...

Page 172: ...n Dowel pin Gasket Relief valve O ring Relief valve O ring Oil strainer Oil strainer housing Gasket 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to REMOVING INSTALLING THE OIL PAN Refer to INSTALLING THE OIL STRAINER For installation reverse the removal procedure New New New New New ENG OIL PAN OIL PAN ...

Page 173: ...0365 CHECKING THE RELIEF VALVE 1 Check relief valve body 1 relief valve 2 spring 3 Cover 4 Damage wear Replace the defective part s circlip 5 EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer Da...

Page 174: ...ll oil strainer cover 1 relief valve 2 The arrow a on the oil strainer cover must point towards the front of the engine EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket New oil pan 1 oil level switch 2 engine oil drain bolt Always use new copper washers Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch s O ring with en gine oil Oil pan bolt 1...

Page 175: ...r Spring rod Chain guide Cover 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS Refer to CYLINDER HEAD Refer to CYLINDERS AND PISTONS Refer to CLUTCH Refer to OIL PUMP Refer to SHIFT SHAFT Refer to TIMING PLATE AND PICKUP COIL Refer to OIL PAN 24 Nm 2 4 m kg 35 Nm 3 5 m kg 12Nm 1 2 m kg 10 Nm 1 0 m kg 35 Nm 3 5 m kg 12Nm 1 2 m kg 10Nm 1 0 m kg CRANKCASE ...

Page 176: ...5 6 Bearing cover Crankcase lower Dowel pin 1 1 2 Refer to DISASSEMBLING ASSEM BLING THE CRANKCASE For installation reverse the removal pro cedure 24 Nm 2 4 m kg 35 Nm 3 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg 35 Nm 3 5 m kg 12 Nm 1 2 m kg ...

Page 177: ...g sequence 2 Place the engine upside down 3 Remove Slower crankcase A Upper crankcase l M10 bolts M8 bolts M6 bolts Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly 4 Remove Sdowel pins SO ring B Lower crankcase l M10 bolts...

Page 178: ...the recommended lubricant Recommended lubricant Engine oil 2 Apply sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings 3 Install dowel pin 4 Install crankshaft journal lower bearings into the lower crank...

Page 179: ...ed by hand SCarefully position the shift forks so that they mesh smoothly with the transmission gears SMesh shift fork center with the 2nd pinion gear 3 on the main axle 7 Install Slower crankcase bolts Supper crankcase bolts Tighten the bolts in the tightening sequence cast on the crankcase A Upper crankcase B Lower crankcase l M10 bolt 16 17 31 X 33 35 Nm 3 5 mSkg M8 bolt 1 X 15 27 29 24 Nm 2 4 ...

Page 180: ... seal Nozzle Generator shaft Bearing Starter clutch drive gear Starter clutch gear Collar Circlip Starter clutch roller Stopper plate 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE Refer to INSTALLING THE STARTER CLUTCH 7 Nm 0 7 m kg 10 Nm 1 0 m kg Refer to INSTALLING THE STARTER CLUTCH EAS00342 STARTER CLUTCH ...

Page 181: ...4 69 ENG STARTER CLUTCH Order Job Part Q ty Remarks 13 14 15 Idle gear shaft Starter clutch idle gear Bearing 1 1 1 For installation reverse the removal pro cedure 7 Nm 0 7 m kg 10 Nm 1 0 m kg New ...

Page 182: ...operation a Install the starter clutch gear 4 onto the starter clutch and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the start er clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear counterclockwise...

Page 183: ...il passages 3 Dirt obstruction Wash the generator shaft and then blow out the oil passages with com pressed air bearing 4 Rough movement Replace INSTALLING THE STARTER CLUTCH ROLL ER 1 Install circlip 1 starter clutch roller 2 starter clutch drive gear 3 Be sure to install the starter clutch roller to the starter clutch drive gear so that the cir clip is outside ...

Page 184: ... HY VO chain Crankshaft journal bearings HY VO chain guide 1 1 1 1 1 10 1 Remove the parts in the order listed Refer to CRANKCASE Refer to STARTER CLUTCH Refer to REMOVING INSTALLING THE CRANKSHAFT ASSEMBLY For installation reverse the removal pro cedure Refer to INSTALLING THE CRANKSHAFT ASSEMBLY ENG CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ...

Page 185: ... Connecting rod bolt Coonecting rod Connecting rod cap Connecting rod bearing 8 8 4 4 8 Remove the parts in the order listed For installation reverse the removal procedur Refer to REMOVING INSTALLING THE CONNECTING RODS Refer to INSTALLING THE CONNEECTING RODS 36 Nm 3 6 m kg CONNECTING ROD ...

Page 186: ...SHAFT AND CON NECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Crankshaft runout Less than 0 02 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal...

Page 187: ...he Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves SAlign the projections a of the crankshaft jour nal lower bearings with the notches b in the crankcase SDo not move the crankshaft until the clearance measurement has been completed f Tighten the bolts to specification in the tight en...

Page 188: ...r example if the crankcase J1 and crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is Bearing size for J1 J1 crankcase J1 crankshaft web 6 2 4 green CRANKSHAFT JOURNAL BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 5 Measure crankshaft pin to big end bearing clear ance Out of specification Replace the big end bearings Crankshaft pin to big end bear ing ...

Page 189: ...d Assemble the connecting rod halves Do not move the connecting rod or crankshaft until the clearance measurement has been completed Apply molybdenum disulfide grease onto the bolts threads and nuts seats Make sure that the Y mark c on the connect ing rod faces towards the left side of the crank shaft Make sure that the characters d on both the connecting rod and connecting rod cap are aligned e T...

Page 190: ... big end bearings 6 Select big end bearings P1 X P4 The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P1 X P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 4 and 1 re spectively then the bearing size for P1 is Bearing s...

Page 191: ...401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace EAS00402 CHECKING THE CIRCLIPS AND WASHERS 1 Check circlips Bends damage looseness Replace washers Bends damage Replace EAS00403 INSTALLING THE CONNECTING RODS 1 Lubricate bolt threads nut seats with the r...

Page 192: ...shaft Make sure that the characters b on both the connecting rod and connecting rod cap are aligned 4 Align bolt heads 1 with the connecting rod caps 5 Tighten connecting rod nuts Connecting rod nuts 36 Nm 3 6 m kg When tightening the connecting rod nuts be sure to use an F type torque wrench Without pausing tighten the connecting rod nuts to the specified torque Apply con tinuous torque between 2...

Page 193: ...shaft jour nal upper bearings with the notches b in the crankcase Be sure to install each crankshaft journal up per bearing in its original place 2 Install HY VO chain 1 timing chain 2 onto the crankshaft sprocket crankshaft assembly 3 Pass the timing chain through the timing chain cavity To prevent the timing chain from falling into the crankcase fasten it with a wire ...

Page 194: ...sembly and shift forks Crankcase Main axle assembly Oil seal Bearing Drive axle assembly Collar O ring Oil seal Circlip Bearing 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal procedure Refer to INSTALLING THE TRANSMIS SION EAS00419 TRANSMISSION ...

Page 195: ...sion Washer 1st wheel gear Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear collar Washer 5th wheel gear Circlip Washer 2nd wheel gear collar Drive axle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 12 13 New New New ...

Page 196: ...rt Q ty Remarks 2nd pinion gear 5th pinion gear collar Washer 3rd pinion gear Circlip Washer 4th pinion gear Main axle 1st pinion gear 1 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 14 15 16 17 18 19 20 21 New New New ...

Page 197: ...m and shift fork Crankcase Shif fork quide bar Shift fork L Shift fork C Shift fork R Stopper plate Shift drum 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE For installation reverse the removal produre Refer to INSTALLING THE TRANSMISSION SHIFT CAM AND SHIFT FORK ...

Page 198: ...mpt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage scratches wear Replace the shift drum shift drum segment 1 Damage wear Replace shift drum bearing 2 Damage pitting Replace EAS00424 CHECKING THE TRAN...

Page 199: ... pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips Damage bends looseness Replace EAS00426 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install shift drum aseembly 1 shift ...

Page 200: ...e that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase The drive axle bearing pin 5 must face to wards the rear of the crankcase and the main axle bearing pin 6 must face towards the front of the crankcase 2 Check transmission Rough movement Repair Oil each gear shaft and bearing thoroughly ...

Page 201: ...ING THE CARBURETORS 5 4 ASSEMBLING THE CARBURETORS 5 5 INSTALLING THE CARBURETORS 5 7 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 5 8 CHECKING THE FUEL COCK 5 10 CHECKING THE FUEL COCK OPERATION 5 10 ...

Page 202: ...CARB ...

Page 203: ...ir filter joint screws Bolts Air filter case Throttle position sensor lead Starter cable Throttle cables Carburetors 1 1 1 4 4 3 1 1 1 2 1 Remove the parts in the order listed Refer to SEAT SIDE COVER AND FUEL TANK in Chapter 3 Loosen Loosen Loosen Move to rear ward Disconnect For installation reverse the removal procedure CARB CARBURETORS EAS00481 CARBURETORS CARBURETORS ...

Page 204: ...tle stop screw set Carburetors Throttle cable bracket Starter plunger set Vacuum chamber cover Piston valve spring Piston valve Jet needle Pilot air jet Pilot screw 1 4 1 1 1 4 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed The following procedure applies to all of the carburetors NOTE Refer to ASSEMBLING THE CARBURE TORS New CARB CARBURETORS ...

Page 205: ... 17 18 19 20 Float chamber Float chamber gasket Float pin Float Needle valve ass y Pilot jet Main jet Needle jet 1 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to ASSEMBLING THE CARBURE TORS New CARB CARBURETORS EAS00484 ...

Page 206: ...s and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check O ring 3 Damage wear Replace the needle valve needle valve seat and O ring as a set 8 Check piston va...

Page 207: ...eed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 13 Check fuel feed hoses fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air EAS00489 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors Before assembling the carburetors wash all of the parts in a petroleum based sol vent...

Page 208: ...sing it c If the float height is not within specification inspect the needle valve seat and needle valve d If either the needle valve seat or needle valve is worn replace them both e If both the needle valve seat and needle valve are fine adjust the float height by bend ing the float tang 1 f Check the float height again 3 Install piston valve piston valve spring vacuum chamber cover 4 Install con...

Page 209: ... chapter 3 EAS00497 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level below the line on the float chamber 3 5 4 5 mm a Stand the motorcycle on a level surface b Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c Install the fuel level gauge 1 to the fuel drain pipe 2 Fuel level gauge 90890 01312 d Loos...

Page 210: ...the tachometer Refer to the adjustment procedure below 1 Check Sthrottle position sensor a Disconnect the throttle position sensor cou pler b Remove the throttle position sensor from the carburetor c Connect the pocket tester Ω 1k to the throttle position sensor Tester positive lead Blue terminal Tester negative lead Black Blue terminal d Check the throttle position sensor maximum resistance Out o...

Page 211: ...eter switches to the throttle position sensor adjustment mode d Loosen the throttle position sensor screws 1 e Adjust the throttle position sensor angle ac cording to the following table The angle of the throttle position sensor is indi cated by the r min which are displayed on the tachometer Tachometer reading Throttle position sensor angle 1 000 r min 1 Too small 5 000 r min 2 Correct 10 000 r m...

Page 212: ...NG THE FUEL COCK OPERATION After installing the fuel cock check its opera tion 1 Check that the fuel cock lever is positioned to ON or R 2 Place a container under the end of the fuel hose 3 Check fuel cock operation a Suck on the end of the vacuum hose Fuel flows Fuel cock is OK Fuel does not flows Replace the fuel cock ...

Page 213: ...D REAR BRAKES 6 14 FRONT BRAKE PADS 6 14 REAR BRAKE PADS 6 15 REPLACING THE FRONT BRAKE PADS 6 16 REPLACING THE REAR BRAKE PADS 6 18 FRONT BRAKE MASTER CYLINDER 6 20 REAR BRAKE MASTER CYLINDER 6 22 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6 24 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 6 24 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 6 25 ASSEMBLING AND INSTALLING THE FRONT BRAKE MAS...

Page 214: ...NSTALLING THE HANDLEBAR 6 54 STEERING HEAD 6 57 LOWER BRACKET 6 57 REMOVING THE LOWER BRACKET 6 59 CHECKING THE STEERING HEAD 6 59 INSTALLING THE STEERING HEAD 6 60 REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN 6 61 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 6 63 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 6 63 REMOVING THE SWINGARM 6 64 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND ...

Page 215: ...it Collar Brake disc left right 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated NOTE Refer to REMOVING INSTALLING THE FRONT WHEEL For installation reverse the removal procedure 73 Nm 7 3 m kg 19 Nm 1 9 m kg 20 Nm 2 0 m kg 40 Nm 4 0 m kg CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DIS...

Page 216: ...Q ty Remarks Disassembling the front wheel Oil seal Bearing Spacer Bearing 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 ...

Page 217: ...ot squeeze the brake lever when removing the brake calipers 4 Loosen pinch bolt front wheel axle 1 front wheel axle 2 5 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage...

Page 218: ...g 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing center race 5 or balls 6 Contact should be made only with the outer race 7 Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal EAS00531 CHE...

Page 219: ...the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit minimum Front 4 5 mm Rear 4 5 mm 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Tighten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt...

Page 220: ...in a crisscross pattern 3 Install speedometer gear unit Make sure that the speedometer gear unit and the wheel hub are installed with the two projec tions a meshed into the two slots b respec tively 4 Install front wheel Make sure that the slot a in the speedometer gear unit fits over the stopper b on the outer tube 5 Tighten wheel axle 1 wheel axle pinch bolt 2 Wheel axle 73 Nm 7 3 m kg Wheel axl...

Page 221: ...ke discs installed 1 Remove balancing weight s Place the front wheel on a suitable balancing stand 2 Find front wheel s heavy spot a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps ...

Page 222: ...n the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Sfront wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 223: ... Rear wheel 2 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated NOTE Refer to REMOVING INSTALLING THE REAR WHEEL For installation reverse the removal procedure 150 Nm 15 0 m kg CHAS REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET EAS00550 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL ...

Page 224: ...t Collar Brake disc Clutch hub Collar Rear wheel sprocket Clutch dampers Oil seal Bearing 1 1 1 1 1 5 1 1 Remove the parts in the order listed For installation the removal procedure 20 Nm 2 0 m kg 60 Nm 6 0 m kg CHAS REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 225: ...levated 2 Loosen adjusting bolt 1 locknut 2 3 Remove wheel axle nut 3 wheel axle 4 rear wheel right collar 5 Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to INSPECTING THE TIRES and INSPECTING THE WHEEL...

Page 226: ...n 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprock et b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket Rear wheel sprocket sel...

Page 227: ...nt Lithium soap base grease 2 Tighten wheel axle nut Wheel axle nut 150 Nm 15 0 m kg EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance Refer to FRONT WHEEL ...

Page 228: ...ront brake pads Clip Pad pin Pad support Brake pad 4 2 2 4 Remove the parts in the order listed Refer to REPLACING THE FRONT BRAKE PADS For installation reverse the removal procedure CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 229: ...e pads Caliper Cover Clip Pad pin Pad spring Brake pad Caliper shim 1 1 2 2 1 2 2 Remove the parts in the order listed Refer to REPLACING THE REAR BRAKE PADS For installation reverse the removal procedure 40 Nm 4 0 m kg CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS ...

Page 230: ...lean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure ap...

Page 231: ...ke pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install new brake pads and a new brake pad spring The arrow a on the brake pad spring must ...

Page 232: ...or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake caliper 1 2 Remove brake pad cover 1 brake pad clips 2 brake pad pins 3 brake pad spring 4 3 Remove brake pads 5 along with the brake...

Page 233: ...d screw Bleed screw 6 Nm 0 6 m kg d Install new brake pad shims onto the new brake pads e Install new brake pads and a new brake pad spring The longer tangs a on the brake pad spring must point in the direction of disc rotation 6 Install brake pad pins brake pad clips brake pad cover brake caliper Brake caliper bolt 40 Nm 4 0 m kg 7 Check brake fluid level Below the minimum level mark a Add the re...

Page 234: ... bolt Copper washers Brake hose Master cylinder bracket Master cylinder 1 2 1 1 2 1 1 1 Remove the parts in the order listed Drain Refer to DISASSEMBLING ASSEM BLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER For installation reverse the removal procedure 10 Nm 1 0 m kg 30 Nm 3 0 m kg New CHAS FRONT AND REAR BRAKES EAS00586 FRONT BRAKE MASTER CYLINDER ...

Page 235: ...der Job Part Q ty Remarks Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 New ...

Page 236: ...e Clip reservoir hose Cotter pin copper washer Pin Master cylinder ass y Reservoir tank 2 1 1 1 2 1 2 1 1 1 1 1 1 Remove the parts in the order listed Drain Refer to DISASSEMBLING ASSEM BLING THE REAR BRAKE MASTER CYLINDER For installation reverse removal procedure 30 Nm 3 0 m kg 28 Nm 2 8 m kg 23 Nm 2 3 m kg CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 237: ...der Job Part Q ty Remarks Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 New ...

Page 238: ...the brake switch 3 Remove union bolt 3 copper washers 4 brake hose 5 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MAS TER CYLINDER Before disassembling the rear brake master cylinder drain the brake fluid from the entire brake system 1 Remove union bolt 1 copper washers 2 brake hose 3 To collect...

Page 239: ...ke master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace C Front D Rear 3 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake mater cylinder reservoir dia phragm 2 Damage wear Replace rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks da...

Page 240: ... end of the brake master cylinder holder with the punch mark a on the handle bar First tighten the upper bolt then the lower bolt Brake master cylinder bolt 10 Nm 1 0 m kg 2 Install copper washers New 1 brake hose 2 union bolt 3 Union bolt 30 Nm 3 0 m kg Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake ...

Page 241: ...e perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level ...

Page 242: ...id reservoir Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not ent...

Page 243: ...l mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest a 45 mm 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 ...

Page 244: ... washers Brake hoses Caliper ass y 2 4 2 2 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 7 Nm 0 7 m kg 30 Nm 3 0 m kg 40 Nm 4 0 m kg CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPER ...

Page 245: ...ollowing procedure applies to both of the front brake calipers Clips Pad pin Pad spring Brake pads shims Caliper pistons Bleed screw Dust seals Piston seals 2 1 1 2 2 4 1 4 4 Disassembly the parts in the order listed For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS 6 Nm 0 6 m kg ...

Page 246: ...Copper washers Brake hose Caliper ass y 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to DISASSEMBLING ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 40 Nm 4 0 m kg 30 Nm 3 0 m kg New CHAS FRONT AND REAR BRAKES ESA00616 REAR BRAKE CALIPER ...

Page 247: ...Pad pins Pad support Brake pads shims Caliper pistons Dust seals Piston seals Bleed screws 1 2 2 1 2 2 2 2 2 2 Disassembly the parts in the order listed For assembly reverse the disassembly procedure Refer to DISASSEMBLING THE REAR BRAKE CALIPER 6 Nm 0 6 m kg New New New New CHAS FRONT AND REAR BRAKES ...

Page 248: ...f the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper c Remove the brake caliper piston seals d Repeat the previous steps to force ou...

Page 249: ... and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts c Remove the brake caliper piston seals ...

Page 250: ... Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper piston seals A Front B Rear EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedu...

Page 251: ...3 0 m kg Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the projection b on the brake caliper 2 Remove brake caliper 3 Install brake pads brake pad springs brake caliper retaining bolt bake caliper brake hose holder Refer to REPLACING THE BRAKE PADS Br...

Page 252: ...ter does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark a Add the recommend...

Page 253: ...ll and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches t...

Page 254: ...ance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level...

Page 255: ...cket Cap bolts Bolts lower bracket Front fork left right 2 1 2 2 4 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS 23 Nm 2 3 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg 7 Nm 0 7 m kg CHAS FRONT FORK EAS00647 FRONT FORK ...

Page 256: ...rk Cap bolts O rings Plates Spacers Spring seats Fork springs Dust seals Oil seal clips Oil seals Seal spacers Outer tube bushings Bolts damper rod Gaskets 2 2 2 2 2 2 2 2 2 2 2 2 2 Disassembly the parts in the order listed Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 23 Nm 2 3 m kg 23 Nm 2 3 m kg ...

Page 257: ...4 15 16 17 18 19 Inner tubes Inner tube bushings Oil flow stoppers Damper rods Damper rod springs Outer tubes 2 2 2 2 2 2 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 23 Nm 2 3 m kg 23 Nm 2 3 m kg ...

Page 258: ... motorcycle on a suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Loosen the spring preload adjuster fully 2...

Page 259: ... 30 mm 90890 01327 T Handle 90890 01326 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner tube int...

Page 260: ...er the specified limit Replace Spring free length limit 395 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper 2 Damage Replace The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and assembling the f...

Page 261: ...seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod 1 Allow the damper rod to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate inner tube s outer surface Recommended lubricant Yamaha fork and shock oil 10W or equivalent 3 Tighten damper rod ...

Page 262: ...0890 01367 Adapter 90890 01374 Make sure that the numbered side of the oil seal faces up Before installing the oil seal apply lithium soap base grease onto its lips Apply fork oil onto the outer surface of the inner tube 5 Install oil seal clip 1 Adjust the oil seal clip so that it fits into the outer tube groove 6 Install dust seal 1 with the fork seal driver weight 2 ...

Page 263: ...have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 9 After filling up slowly pump the fork up and down to distribute the fork oil 10 Measure Oil level a Out of specfication Adjust Oil level 137 mm from the top of the inner tube fully compressed and without the fork spring Hold the fork in ...

Page 264: ...Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the upper bracket 2 Tighten lower bracket pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 Lower bracket pinch bolt 23 Nm 2 3 m kg Cap bolt 23 Nm 2 3 m kg Upper bracket pinch bolt 30 Nm 3 0 m kg Make sure that the brake hoses are routed properly 3 Adjust ...

Page 265: ...Grip end right Throttle grip Master cylinder bracket Master cylinder clutch Handlebar switch left Starter lever Starter cable Grip end left 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to INSTALLING THE HANDLEBAR Refer to INSTALLING THE HANDLEBAR Refer to REMOVING INSTALLING THE HANDLEBAR 26 Nm 2 6 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg 23 Nm 2 3 m kg CHAS HAND...

Page 266: ...r grip Collar Upper handlebar holders Handlebar 1 1 2 1 Referto REMOVINGTHEHANDLEBAR 26 Nm 2 6 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg 23 Nm 2 3 m kg Refer to INSTALLING THE HANDLEBAR For installation reverse the removal procedure CHAS HANDLEBAR ...

Page 267: ...e cable housing pull back the rubber cover 2 3 Remove handlebar grip left 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace Do not attemp...

Page 268: ...otorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 1 upper handlebar holders 2 Upper handlebar holder bolt 23 Nm 2 3 m kg First tighten the bolts on the front side of the handlebar holder then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handleb...

Page 269: ...cylinder clutch 1 master cylinder bracket 2 Align the mating surfaces of the master cylinder with the punch mark a on the handlebar 6 Install throttle grip 1 throttle cable housing 2 throttle cables 3 Apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar Make sure that the pin a on the throttle cable housing is aligned with the hole b ...

Page 270: ...dlebar There should be 1 3 mm of clearance b be tween the throttle grip and the right grip end 8 Install master cylinder ass y front brake 9 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 271: ...Lower bracket Rubber seal Bearing cover Bearing 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT FORK Refer to HANDLEBAR Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD Refer to INSTALLING THE STEERING HEAD 110 Nm 11 0 m kg 40 Nm 4 0 m kg 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg CHAS STEERING HEAD EAS00676 STEERING HEAD LO...

Page 272: ...ob Part Q ty Remarks 11 12 13 Bearing Dust seal Lower handlebar holders 1 1 2 For installation reverse the removal procedure 110 Nm 11 0 m kg 40 Nm 4 0 m kg 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg CHAS STEERING HEAD ...

Page 273: ... lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 90890 01268 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearing balls bearing races Recommended cleaning solvent Kerosine 2 Check bearing balls 1 Damage...

Page 274: ...henever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer 2 upper ring nut 3 lock washer 4 Refer to INSPECTING THE STEERI...

Page 275: ...ket Pivot shaft Swingarm Drive chain guide Dust covers Washers Bush 1 1 2 1 1 1 1 1 2 2 1 Remove the parts in the order listed Refer to REAR WHEEL BRAKEDISC AND REAR WHEEL SPROCKET Refer to ENGINE in chapter 4 Refer to REMOVING THE SWINGARM 23 Nm 2 3 m kg 125 Nm 12 5 m kg 7 Nm 0 7 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg 7 Nm 0 7 m kg CHAS REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN REAR SHOCK ABSORBER...

Page 276: ... Remarks 11 12 Bearings Drive chain 2 1 For installation reverse the removal procedure 23 Nm 2 3 m kg 125 Nm 12 5 m kg 7 Nm 0 7 m kg 23 Nm 2 3 m kg 30 Nm 3 0 m kg 7 Nm 0 7 m kg CHAS REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN ...

Page 277: ...pen the rear shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pres sure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING O...

Page 278: ...hold the swingarm so that it does not drop down 3 Check swingarm side play swingarm vertical movement a Check the tightening torque of the pivot shaft nut Pivot shaft nut 125 Nm 12 5 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the en of th...

Page 279: ...assembly spring 2 Damage wear Replace the rear shock ab sorber assembly gas cylinder 3 Damage gas leaks Replace bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft...

Page 280: ...urement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosine and remove any remaining dirt c Remove the drive chain from the kerosine and completely dry it This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never us...

Page 281: ...ve chain and make sure that the battery breather hose is proper ly routed away from the drive chain and be low the swingarm 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set b Corr...

Page 282: ...CHAS ...

Page 283: ...CUIT DIAGRAM 7 8 TROUBLESHOOTING 7 9 ELECTRIC STARTING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 7 14 TROUBLESHOOTING 7 15 STARTER MOTOR 7 19 CHARGING SYSTEM 7 22 CIRCUIT DIAGRAM 7 22 TROUBLESHOOTING 7 23 A C GENERATOR 7 26 LIGHTING SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 TROUBLESHOOTING 7 28 CHECKING THE LIGHTING SYSTEM 7 29 SIGNALING SYSTEM 7 32 CIRCUIT DIAGRAM 7 32 TROU...

Page 284: ...ELEC ...

Page 285: ...el switch Horns Ignition coils Main switch Fuel sender Starter relay Starting circuit cutoff relay Battery Oil level relay Flasher relay Ignitior unit Neutral switch Sidestand switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EAS00729 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 286: ...checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a continuity of electricity betwe...

Page 287: ...heck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 288: ...Fuse Side stand switch Neutral switch Oil level switch 1 for Europe 2 for AUS Horn switch Clutch switch Dimmer switch Pass switch Turn signal switch Main switch Front brake switch Engine stop switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ELEC CHECKING THE SWITCHES ...

Page 289: ...shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their re spective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise ...

Page 290: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 291: ... tester No continuity Replace Pocket tester 90890 03112 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb soc...

Page 292: ... 12 14 15 18 Main fuse Battery Main switch Ignition fuse Ignitor unit Ignition coils Spark plugs Pickup coil Neutral switch Sidestand switch Engine stop switch ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 293: ... SPARK PLUGS in chapter 3 Standard spark plug DPR 8EA 9 NGK X24EPR U9 DENSO Spark plug gap 0 8 X 0 9 mm SIs the spark plug in good condition is it of the correct type and its gap within specification YES Re gap or replace the spark plug NO EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition ...

Page 294: ...the spark plug SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20_C SIs the spark plug cap OK YES Replace the spark plug cap NO EAS00747 6 Ignition coil resistance The following procedure applies to all of the ignition coils SDisconnect the ignition coil connectors from the ignition coil terminals SConnect the...

Page 295: ... resistance EAS00749 SCheck the main switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EAS00750 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES Replace the right handlebar switch NO 9 Engine stop switch EAS00751 SCheck the neutral switch for continuity Refer to CHECK...

Page 296: ...tion system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects NO Replace the ignitor unit YES 13 Wiring Properly connect or repair the ignition system s wiring ELEC IGNITION SYSTEM ...

Page 297: ...ry Starter relay Main switch Ignition fuse Starter motor Starting circuit cutoff relay Neutral switch Sidestand switch Start switch Engine stop switch Clutch switch 38 ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 298: ...f relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the en gine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE...

Page 299: ...r NO EAS00758 1 3 2 WARNING SA wire that is used as a jumper lead must have at least the same capacity of the battery lead otherwise the jumper lead may burn SThis check is likely to produce sparks therefore make sure that no flammable gas or fluid is in the vicinity SDoes the starter motor turn EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 st...

Page 300: ...ite 5 Diode Disconnect the starting circuit cutoff relay from the coupler Connect the pocket tester Ω 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows YES Replace the relay unit NO Tester positive probe light green Tester negative probe black yellow 1 2 Continuity NOTE When you switch the and leads of the digital pocket t...

Page 301: ... SWITCHES Is the neutral switch OK YES Replace the neutral switch NO 9 Neutral switch EAS00752 Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK YES Replace the sidestand switch NO 10 Sidestand switch EAS00763 Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES Replace the clutch switch NO 11 Clutch swi...

Page 302: ...on nected and without defects NO The starting system circuit is OK YES 13 Wiring Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES Replace the right handlebar switch NO 12 Start switch Properly connect or repair the starting system s wiring ELEC ELECTRIC STARTING SYSTEM EAS00764 ...

Page 303: ...he starter motor Starter motor front cover Washer set Starter motor rear cover washer set Brush holder brush Armature assembly Starter motor yoke 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Disassembly the pats in the order listed For assembly reverse the disassembly procedure 10 Nm 1 0 m kg STARTER MOTOR ...

Page 304: ...hacksaw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 03112 Armature assembly Commutator resistance...

Page 305: ...1 N 0 780 X 1 021 kg 7 Check gear teeth Damage wear Replace the gear 8 Check oil seal Damage wear Replace the defective part s EAS00772 Assembling The Starter Motor 1 Install brush holder 1 Align the tab a on the brush holder with the slot b in the starter motor rear cover 2 Install starter motor yoke 1 O rings 2 starter motor front cover 3 starter motor rear cover 4 bolts Align the match marks a ...

Page 306: ...7 22 CHARGING SYSTEM ELEC 1 2 3 5 Generator Main fuse Battery Main switch EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 307: ...ocket tester DC 20 V to the battery as shown Charging voltage 14 V at 5 000 r min Tester positive probe battery positive terminal Tester negative probe battery negative terminal SStart the engine and let it run at approximate ly 5 000 r min SMeasure the charging voltage EAS00774 TROUBLESHOOTING The battery is not being charged Check 1 main fuse 2 battery 3 charging voltage 4 startor coil assembly ...

Page 308: ...r coil assembly OK YES Replace the stator coil assembly NO Tester positive probe white Tester negative probe black 1 2 SMeasure the stator coil assembly resis tances Tester positive probe white Tester negative probe black 1 3 5 Brush check SRemove the brush holder Brush spring force 5 10 X 5 69 N 0 52 X 0 58 kg Brush overall length wear limit 13 7 mm 4 7 mm SAre the brush spring and brush OK YES R...

Page 309: ...eck the mian switch for continuity Refer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 7 Main switch EAS00779 SCheck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly con nected and without defects NO Replace the rectifier YES 8 Wiring Properly connect or repair the charging system s wiring CHARG...

Page 310: ...r Brush holder Regulator Rectifier cover Rectifier Rear cover Rotor assembly Bearing cover Bearing Bearing Stator assembly 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order list For assembly reverse the disassembly procedure 7 Nm 0 7 m kg 25 Nm 2 5 m kg CHARGING SYSTEM ELEC A C GENERATOR ...

Page 311: ...46 Main fuse Battery Main switch Lights switch Meter light High beam indicator light Pass switch Dimmer switch Headlight fuse Auxiliary light Tail brake light Headlight 47 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 312: ...n switch OK YES Replace the main switch NO 3 Main switch EAS00783 SCheck the lights switch for continuity Refer to CHECKING THE SWITCHES SIs the lights switch OK YES The lights switch is faulty Replace the right handlebar switch NO 4 Lights switch for Europe EAS00781 TROUBLESHOOTING Any of the following fail to light head light high beam indicator light taillight auxiliary light for Europe or mete...

Page 313: ...connect or repair the lighting system s wiring NO 7 Wiring Check the condition of each of the light ing system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES Replace the head light bulb socket or both NO 1 Headlight bulb and socket 2 Voltage Connect the pocke...

Page 314: ... main switch to the headlight cou pler is faulty and must be repaired NO YES 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown Tester positive probe blue Tester negative probe black 1 2 This circuit is OK Replace the tail brake light bulb sock et or both NO YES The wiring circuit from the main switch to the meter assem bly coupler is faulty and must ...

Page 315: ...13 4 The auxiliary light fails to come on for Eu rope 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the auxiliary light bulb and socket OK YES 2 Voltage Connect the pocket tester DC 20 V to the auxiliary light couplers wire harness side as shown Tester positive probe blue red Tester negative probe black 1...

Page 316: ...h Horn Flasher relay Oil level switch Fuel gauge 30 Fuel sender 31 Neutral indicator light 33 Turn signal indicator 34 Turn signal indicator 35 Oil level warning light 36 Turn signal switch 39 Horn switch 40 Tail brake light 46 Front turn signal light 48 Rear turn signal light 49 light left light right SIGNALING SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 317: ...ry OK NO EAS00795 4 Wiring SCheck the entire signaling system s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wiring Check the condition of each of the signal ing system s circuits Refer to CHECKING THE SIGNALING SYSTEM SIGNALING SYSTEM ELEC NOTE EB806010 TROUBLESHOOTING SAny of the fo...

Page 318: ... to ON Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connector at the black terminal as shown Tester positive probe black Tester negative probe ground 1 Set the main switch to ON Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired NO Y...

Page 319: ...ake light switch OK YES 2 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired NO This circuit is OK Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification Replace the turn sig nal light bulb socket...

Page 320: ...ication 1 4 Voltage Connect the tester DC 20 V to the flasher relay coupler wire harness side as shown The flasher relay is faulty and must be re placed NO YES 1 Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V or brown white at the flasher relay coupler wire harness side Is the voltage within specification Tester positive probe brown white Tester negative probe ...

Page 321: ... turn signal light con nector wire harness side Is the voltage within specification 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES 3 Diode Disconnect the starting circuit cutoff relay from the coupler Connect the pocket tester Ω 1 to the starting circuit cutoff relay terminals as shown Measure t...

Page 322: ... bulb and socket Check the oil level warnig light bulb and sock et for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the oil level warnig light bulb and socket OK YES Replace the oil level switch NO 2 Oil level switch Drain the engine oil and remove the oil level switch from the oil pan Check the oil level switch for continuity Refer to CHECKING THE SWITCHES Is the oil level switch O...

Page 323: ...easure the voltage 12 V of brown and black red at the meter assembly coupler SIs the voltage within specification YES The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired NO This circuit is OK EAS00804 6 The fuel level gauge fails to operate 1 Replace the fuel sender NO 1 Fuel sender SDisconnect the fuel sender coupler from the wire harness SDrain ...

Page 324: ...to the me ter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe black 1 2 YES The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired NO Set the main switch to ON Measure the voltage 12 V Is the voltage within specification YES Replace the fuel level gauge NO NOTE 3 Fuel level gauge Set the main switch to ON...

Page 325: ...n the tachome ter when the main switch is set to ON irrespective of whether the engine is running or not The engine is not operated condition code at 2 000 r min Circuit Defect s System response Condition code Throttle posi tion sensor Disconnected Short circuit Locked The ignitor unit stays set to the wide open throttle ignition timing The motorcycle can be ridden The tachometer displays the cond...

Page 326: ...er 6 Is the throttle position sensor OK YES Replace the throttle position sensor Replace the ignitor unit NOTE 13 Throttle position sensor 9 Ignitor unit EAS00835 TROUBLESHOOTING The tachometer starts to display the self diagnosis sequence Check 1 throttle position sensor 2 ignition circuit Before troubleshooting remove the following part s 1 rider seat 2 fuel tank 3 air filter case Troubleshoot w...

Page 327: ...nect the starting circuit cutoff relay from the coupler Connect the pocket tester Ω 1 to the starting circuit cutoff relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows Tester positive probe light green Tester negative probe blue yellow 1 2 Continuity Tester positive probe blue yellow Tester negative probe light green 2 1 No continuity SELF DIAGNOSIS ELEC 5...

Page 328: ...e the relay unit NO When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed Are the tester readings correct YES Replace the ignitor unit NOTE SELF DIAGNOSIS ELEC ...

Page 329: ...AR 8 2 FAULTY CLUTCH 8 3 CLUTCH SLIPS 8 3 CLUTCH DRAGS 8 3 OVERHEATING 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 CHASSIS 8 3 ELECTRICAL SYSTEMS 8 3 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT FORK LEGS 8 4 LEAKING OIL 8 4 MALFUNCTION 8 4 UNSTABLE HANDLING 8 4 FAULTY LIGHTING AND SIGNALING SYSTEM 8 5 HEADLIGHT DOES NOT LIGHT 8 5 HEADLIGHT BULB BURNT OUT 8 5 TAIL BRAKE LIGHT DOES NOT LIGHT 8 5 TAIL BRAKE LIGHT B...

Page 330: ...TRBL SHTG ...

Page 331: ... Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose vacuum hose Carburetors Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Incorrectly installed needle valve seat Incorrect fuel level Incorrectly installed pilot jet Clogged starter jet Faulty starter plunger Incorrectly adjusted starter cable ELECTRI...

Page 332: ...spark plug cap Ignition coils Broken or shorted primary or secondary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty ignition unit Faulty pickup coil EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter Clogged air filter element FUEL SYSTEM Carburetors Faulty diaphragm Incorrect fuel level Loose or clogged main jet EAS00850 FAULTY ...

Page 333: ...ate Swollen friction plate Bent clutch pull rod Damaged clutch boss Burnt primary driven gear bushing Damaged clutch release cylinder Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS00854 OVERHEATING ENGINE Cylinder head s and piston s Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality FUEL SYSTEM...

Page 334: ...amper rod Incorrect oil viscosity Incorrect oil level EAS00862 UNSTABLE HANDLING Handlebar Bent or incorrectly installed right handlebar Bent or incorrectly installed left handlebar Steering head components Incorrectly installed upper bracket Incorrectly installed lower bracket incorrectly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork legs Unevenoil levels b...

Page 335: ... BULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Incorrectly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Fa...

Page 336: ...TRBL SHTG ...

Page 337: ...l 13 TPS throttle position sensor 14 Neutral switch 15 Sidestand switch 16 Oil level relay 17 Start switch 18 Engine stop switch 19 Front brake switch 20 Handlebar switches right 21 Lights switch 22 Fuse signal 23 Rear brake switch 24 Horn 25 Flasher relay 26 Oil level switch 27 Connector 28 Meter assembly 29 Tachometer 30 Fuel gauge 31 Fuel sender 32 Meter lights 33 Neutral indicator light 34 Tur...

Page 338: ...1 Spark plug 12 Pickup coil 13 TPS throttle position sensor 14 Neutral switch 15 Sidestand switch 16 Oil level relay 17 Start switch 18 Engine stop switch 19 Front brake switch 20 Handlebar switches right 22 Fuse signal 23 Rear brake switch 24 Horn 25 Flasher relay 26 Oil level switch 28 Meter assembly 29 Tachometer 30 Fuel gauge 31 Fuel sender 32 Meter lights 33 Neutral indicator light 34 Turn si...

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Yamaha XJR1300 (L) '99, Service Manual

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