Yamaha XVS 125 '00 - Service Manual

EB000000
XVS125 SERVICE MANUAL 2000 by Yamaha Motor Co.,Ltd. First edition, January 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (Periodic checks and Adjustments), where the sub-section title(-s) appears.
(In Chapter 3, Periodic checks and Adjustments, the sub-section title appears at the top of each page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. 2 1 6
3 8
4 5
EAS00009
SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting
GEN INFO
3
SPEC
4
CHK ADJ
5 6
ENG
CARB
7
CHAS
8
ELEC
9
TRBL SHTG
10
Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted

10 11 12 13 14 15 16
11
12
Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
13
14
15
16
17
18
19
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
17 18 19 20 21 22
20
21
22
Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease
23
24
Symbols 23 to 24 in the exploded diagrams indicate the following:

23 Apply locking agent (LOCTITES) 24 Replace the part
EAS00011
INDEX
GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO
1 2 3 4 5 6 7 8
SPEC
CHK ADJ
ENG
CARB
CHAS
ELEC
TRBL SHTG
GEN INFO
CHAPTER 1. GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHER/PLATE AND COTTER PINS . . . . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 1-3 1-3 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
GEN INFO
MOTORCYCLE IDENTIFICATION
EB100000
GEN INFO
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB10010
VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head.
MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
1-1
EB101000
GEN INFO
PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment. Refer to the SPECIAL TOOLS section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
1-2
EB101030
GEN INFO
OR
LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.
EB101040
BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1 Oil seal
CAUTION:
Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.
1 Bearing
EB101050
CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1 , make sure that the sharpedged corner 2 is positioned opposite the thrust 3 it receives See sectional view. 4 Shaft
1-3
CHECKING THE CONNECTIONS

EB103000
GEN INFO
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector
2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times.
3. Check: S all connections Loose connection ! Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up.
4. Connect: S lead S coupler S connector NOTE: Make sure that all connections are tight. 5. Check: S continuity (with the pocket tester) Pocket tester 90890-03112 NOTE: S If there is no continuity, clean the terminals. S When checking the wire harness, perform steps (1) to (3). S As a quick remedy, use a contact revitalizer available at most part stores.
1-4
SPECIAL TOOLS
EB102001
GEN INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Bolt 90890-01083 Weight 90890-01084 Tool name / How to use Slide hammer bolt/Weight Illustration
These tools are used to remove the rocker arm shaft.
Valve adjusting Tappet adjusting tool tool This tool is used to adjust the valve CLEARANCE. T-handle/Damper rod holder
90890-01311 Damper rod holder 90890-01365 T-handle 90890-01326
These tools are needed to loosen and tighten the damper rod holding bolt. Piston pin puller
90890-01304 This tool is used to remove the piston pin. Fuel level gauge 90890-01312 This gauge is used to measure the fuel level in the float chamber. Flywheel puller Flywheel puller 90890-01362 These tools are needed to remove the rotor. Ring nut wrench 90890-01403 This tool is used to loosen and tighten the steering stem ring nut. Weight 90890-01367 Adapter 90890-01369 Front fork seal driver weight/ Adapter (33 mm) These tools are needed when installing the slide metal, oil seal and dust seal into the fork.
1-5
SPECIAL TOOLS
Tool No. Tool name / How to use Sheave holder 90890-01701 This tool is needed to hold the rotor, when removing or installing the rotor bolt. Clutch holder 90890-04086 This tool is heed to hold the clutch when removing or installing the clutch boss nut. Valve spring compressor 90890-04019 This tool is needed to remove and install the valve assemblies. Valve guide remover (5.0 mm) 90890-04097 This tool is needed to remove the valve guide. Valve guide installer (5.0 mm) 90890-04098 This tool is needed to install the valve guides properly. Valve guide reamer (5.0 mm) 90890-04099 This tool is needed to rebore the new valve guide. Timing light 90890-03141 This tool is necessary for checloing ignition timing. Pocket toster 90890-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing engine r/min.
GEN INFO
Illustration
1-6
SPECIAL TOOLS
Tool No. Tool name / How to use Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Compression gauge set 90890-03081 These tools are needed to measure engine compression. Yamaha bond No.1215 90890-85505 This sealant (bond) is used for crankcase mating surfaces, etc.
GEN INFO
Illustration
1-7
SPEC
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 ELECTRICAL SPECIFICATONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 LUBRICATIONS POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-20 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 ENGINE OIL LUBRICATION CHART SPECIFICATIONS . . . . . . . . . . . . 2-22 ENGINE OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (with out oil and fuel) Maximum load (total of cargo, rider, passenger, and accessaries) 5JX1/5JX2 2,320 mm 910 mm 1,075 mm 670 mm 1,530 mm 150 mm 2,900 mm 156 kg 144 kg 183 kg Standard SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Limit
2-1
ENGINE SPECIFICATIONS
SPEC
Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil
Temp. _C
Standard Air-cooled, 4-stroke, SOHC 124 cm3 V-2 cylinder 41 47 mm 11.0 : 1 1,250 X 1,450 r/min 24 kPa (0.24 kg/cm2) 1,200 kPa (12 kg/cm2) at 400 r/min SSS SSS SSS SSS SSS SSS SSS SSS
Limit
Regular unleaded gasoline 11 L 3.4 L Wet sump
SSS SSS SSS SSS SSS
SAE20W40SE or SAE10W30SE
Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure (hot) Relief valve opening pressure Oil filter Oil filter type Bypass valve opening pressure Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Housing and rotor clearance
1.75 L 1.4 L 1.6 L 50 kPa at 1,300 r/min (0.5 kgf/cm2 at 1,300 r/min) 450 X 550 kPa (4.5 X 5.5 kgf/cm2) paper 450 X 550 kPa (4.5 X 5.5 kgf/cm2) Trochoidal 0.15 mm 0.03 X 0.09 mm 0.03 X 0.09 mm
SSS SSS SSS SSS SSS SSS SSS SSS 0.2 mm 0.15 mm 0.15 mm
2-2
Item Starting system type Spark plugs Model (manufacturer) Spark plug gap Cylinder head Max. warpage quantity Electric starter CR7HSA (NGK), U22FSR-U (DENSO) 0.6 X 0.7 mm SSS 1 Standard
SPEC
Limit
SSS SSS 0.05 mm
Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Camshaft lobe dimensions
Chain drive (left and right) 22.000 X 22.021 mm 21.96 X 21.98 mm 0.020 X 0.061 mm
SSS SSS SSS SSS
Intake Measurement A Measurement B Measurement C Exhaust Measurement A Measurement B Measurement C Max. camshaft runout
26.190 mm #1 : 21.045 mm #2 : 21.087 mm 5.19 mm 26.190 mm #1 : 21.087 mm #2 : 21.045 mm 5.19 mm SSS
26.15 mm 21.005 mm 21.047 mm SSS 26.15 mm 21.047 mm 21.005 mm SSS 0.015 mm
2-3
Item Timing chain Model/number of links Tensioning system Rocker arm/rocker arm shaft Bearing inside diameter Shaft outside diameter Arm-to-shaft clearance Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Standard SILENT CHAIN/110 Automatic 10.000 X 10.015 mm 9.981 X 9.991 mm 0.009 X 0.034 mm
SPEC
Limit SSS SSS 10.035 mm 9.961 mm 0.08 mm
0.08 X 0.12 mm 0.10 X 0.14 mm
SSS SSS
Head diameter
Face width
Seat width
Margin thickness
Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout
19.9 X 20.1 mm 16.9 X 17.1 mm 1.2 X 2.5 mm 1.5 X 3.0 mm 0.9 X 1.1 mm 0.9 X 1.1 mm 0.5 X 0.9 mm 0.7 X 1.3 mm 4.975 X 4.990 mm 4.960 X 4.975 mm 5.000 X 5.012 mm 5.000 X 5.012 mm 0.010 X 0.037 mm 0.025 X 0.052 mm SSS
SSS SSS SSS SSS 1.6 mm 1.6 mm SSS SSS 4.950 mm 4.953 mm 5.03 mm 5.03 mm 0.08 mm 0.10 mm 0.02 mm
Valve seat width Intake Exhaust
0.9 X 1.1 mm 0.9 X 1.1 mm
1.6 mm 1.6 mm
2-4
Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Standard
SPEC
Limit
29.71 mm 29.71 mm 25.6 mm 25.6 mm 120.6 X 138.3 N (12.06 X 13.83 kg) 120.6 X 138.3 N (12.06 X 13.83 kg)
27.81 mm 27.81 mm SSS SSS SSS SSS
Intake Exhaust Winding direction (top view) Intake Exhaust
SSS SSS Clockwise Clockwise
2.5_ /1.3 mm 2.5_ /1.3 mm SSS SSS
Cylinders Cylinder arrangement Bore stroke Compression ratio Bore
Air coded 4-stroke 41 47 mm 11.0 : 1 40.99 X 41.03 mm
SSS SSS SSS 41.1 mm
2-5
Item Pistons Piston-to-cylinder clearance Diameter D Standard 0.02 X 0.04 mm 40.96 X 41.00 mm
SPEC
Limit 0.15 mm SSS
Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring
3 mm 13.002 X 13.013 mm 0 mm Intake side 12.996 X 13.000 mm 0.002 X 0.017 mm
SSS 13.045 mm SSS SSS 12.976 mm SSS
Ring type Dimensions (B T) End gap (installed) Ring side clearance 2nd ring
Barrel 0.8 1.7 mm 0.15 X 0.30 mm 0.02 X 0.08 mm
SSS SSS 0.4 mm 0.12 mm
Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring
Taper 0.8 1.7 mm 0.15 X 0.30 mm 0.02 X 0.06 mm
SSS SSS 0.4 mm 0.12 mm
Dimensions (B T) End gap (installed)
1.5 1.6 mm 0.2 X 0.7 mm
SSS SSS
2-6
Item Connecting rods Crankshaft-pin-to-big-end-bearing clearance Crankshaft Standard 0.020 X 0.048 mm
SPEC
Limit SSS
Width A Max. runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever) Friction plates Thickness Plate quantity Clutch plates Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity
67.95 X 68.00 mm 0.40 X 1.05 mm 0.020 X 0.048 mm
SSS 0.03 mm SSS SSS
Wet, multiple disc Inner push, cam push Cable operation Left hand operation 5 X 10 mm 2.9 X 3.1 mm 5 pcs 1.9 X 2.1 mm 4 pcs SSS 34.6 mm 4 pcs
SSS SSS SSS SSS SSS 2.5 mm SSS SSS SSS 0.05 mm 33.6 mm SSS
2-7
Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Max. main axle runout Max. drive axle runout Shifting mechanism Shift mechanism type Max. shift fork guide bar bending installed shift rod length Air filter type Carburetors Model (manufacturer) quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Starter jet 1 Starter jet 2 Butterfly valve size Fuel level (above the line on the float chamber) Standard Constant mesh, 5-speed Spur gear 85/25 (3.400) Chain drive 59/16 (3.688) Left-foot operation 37/14 (2.643) 32/19 (1.684) 29/23 (1.261) 26/26 (1.000) 23/27 (0.852) SSS SSS Cam drum SSS 267.8 mm Dry element BDS26 1 (MIKUNI) 3 X 5 mm 5JX1 00 #90 #120 4DHM20-2/3 N-8 #135 0.85 #15 0.8 0.8 0.8 2 1.0 #22.5 0.7 #140 9.5 X 10.5 mm
SPEC
Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.08 mm 0.08 mm SSS 0.025 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
2-8
CHASSIS SPECIFICATIONS
SPEC
Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Double cradle 35_ 0 135 mm Spoke wheel 18 1.60 Steel 140 mm SSS SSS Spoke wheel 15 M/C Steel 100 mm SSS SSS Tube 80/100 18 47P CHENG SHIN, C-916 IRC MARBELLA, NF27 175 kPa (1.75 kg/cm2, 1.75 bar) 225 kPa (2.25 kg/cm2, 2.25 bar) 175 kPa (1.75 kg/cm2, 1.75 bar) SSS Tube 130/90 15 M/C 66P CHENG SHIN, C-915 IRC MARBELLA, NR31 200 kPa (2.0 kg/cm2, 2.0 bar) 225 kPa (2.25 kg/cm2, 2.25 bar) 200 kPa (2.0 kg/cm2, 2.0 bar) MT 3.00 Standard SSS SSS SSS SSS SSS SSS SSS 2.0 mm 2.0 mm SSS SSS SSS SSS 2.0 mm 2.0 mm SSS SSS SSS Limit
Tire pressure (cold) 0 X 90 kg 90 X 183 kg High-speed riding Min. tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 183 kg High-speed riding Min. tire tread depth
SSS SSS SSS 0.8 mm SSS SSS SSS SSS SSS SSS 0.8 mm
2-9
Item Front brakes Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness Standard Single-disc brake Right-hand operation 5 X 8 mm DOT 4 282 5 mm SSS SSS 6.2 mm
SPEC
Limit SSS SSS SSS SSS SSS 4.5 mm 0.15 mm 0.8 mm
Master cylinder inside diameter Caliper cylinder inside diameter Rear brake Brake type Operation Drum inside diameter Shoe thickness Shoe spring free length Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the innertube, with the inner tube fullycompressed, and without the fork spring) Steering Steering bearing type Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available
12.7 mm 25.4 mm and 30.1 mm Leading, trading brake Right-foot operation 130 mm 4 mm 50.5 mm Telescopic fork Coil spring/oil damper 140 mm 304.4 mm 180 mm 290.3 mm 5.2 N/mm (0.53 kgf/mm) 0 X 80 mm NO Suspension oil 10W or equivalent 311 cm3 112 mm
SSS SSS SSS SSS 131 mm 2 mm SSS SSS SSS SSS 299.4 mm SSS SSS SSS SSS SSS SSS SSS
Angular ball bearings Swingarm Coil spring/gas-oil damper 70 mm 228.5 mm 207.5 mm 17.7 N/mm (1.8 kgf/mm) 0 X 40 mm No
SSS SSS SSS SSS SSS SSS SSS SSS SSS
2-10
Item Swingarm Free play (at the end of the swingarm) Radial SSS Axial SSS Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section 428 V (DID) 146 30 X 40 mm 129.5 mm Standard
SPEC
Limit
1.0 mm 1.0 mm SSS SSS SSS SSS
2-11
ELECTRICAL SPECIFICATIONS
SPEC
Item System voltage Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Throttle position sensor standard resistance Charging system System type Model (manufacturer) Nominal output Stater coil resistance Voltage regulator Regulator type Model (manufacturer) No-load regulated voltage Rectifier Model Rectifier capacity Withstand voltage Battery Battery type Battery voltage/capacity Headlight type Indicator light type quantity quantity) 12 V 60 W/55 W 12 V 4 W 1 12 V 21 W/5 W 12 V 21 W 4 1 1 SSS SSS SSS SSS Bulbs (voltage/wattage Headlight Auxiliary light Tail/brake light Turn signal light 12 V TCI 15_ BTDC at 1,350 r/min Throttle position sensor and electrical 192 X 288 /L/Y X G/W TNDF60 (DENSO) Standard SSS SSS SSS SSS SSS SSS Limit
J0226, J0227 (DENSO) 6 mm 3.4 X 4.6 10.4 X 15.6 k 4.0 X 6.0 k
SSS SSS SSS SSS SSS
AC magneto TLMX20 (DENSO) 14 V/23 W at 5000 r/min 0.224 X 0.336 at 20_C W-W Semiconductor, short circuit type SH650D-11 (SHINDENGEN) 14.1 X 14.9 V SH650D-11/SHINDENGEN 18 A 200 V GT6B-3 12 V 6 Ah Halogen bulb LED 2
SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
2-12
Item Indicator light Meter light Electric starting system System type Starter motor Model Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) Max. amperage 12 V 1.7 W 12 V 1.7 W Standard 4 1
SPEC
Limit SSS SSS SSS SSS SSS 3.5 mm SSS SSS 21 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
Constant mesh 5JX 0.4 kW 10 mm 5.52 X 8.28 N (563 X 844 gf) 0.0171 X 0.0209 22 mm 1.5 mm MS5F-561 (JIDENCO) 180 A 4.18 X 4.62 Plain YF-12 (NIKKO) 3A Full-transistor 75 X 95 cycles/min. 21 W 2 + 3.4 W 30 A 1 15 A 1 10 A 1 10 A 1 10 A 1 4TR (NIPPON TEXAS INSTRUMENT)
quantity
Flasher relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Fuses (amperage quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Carburetor heater fuse Thermo switch Model (manufacturer)
2-13
GENERAL TORQUE SPECIFICATIONS/ CONVERSION TABLE

EB202001 EAS00028
SPEC
GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm x x MULTIPLIER 0.03937 0.03937 = = IMP ** in 0.08 in
CONVERSION TABLE
METRIC TO IMP Known Torque mSkg mSkg cmSkg cmSkg kg g km / hr km m m cm mm cc (cm3) cc (cm3) lt (liter) It (liter) Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 Result ftSlb inSlb ftSlb inSlb lb oz mph mi ft yd in in oz (IMP liq.) cuSin qt (IMP liq.) gal (IMP liq.)
Weight
A: Distance between flats B: Outside thread diameter
Distance
A (Nut)
10 mm 12 mm 14 mm 17 mm 19 mm 22 mm
B (Bolt)
6 mm 8 mm 10 mm 12 mm 14 mm 16 mm
General torque specifications

Nm 6 15 30 55 85 130 mSkg 0,6 1,5 3,0 5,5 8,5 13,0
Volume / Capacity Miscellaneous
kg / mm 55.997 lb / in kg / cm2 14.2234 psi (lb / in2) Centigrade 9/5 (_C) + 32 Fahrenheit (_F)
2-14
MAINTENANCE SPECIFICATIONS
SPEC
ENGINE Tightening torques Part to be tightened g Cylinder head and cylinder Cylinder head (timing chain side, long) Cylinder head (timing chain side, short) Cam sprocket cover (hexagon) Cam sprocket cover Cylinder head (exhaust pipe) Cylinder head cover bracket Cylinder head cover Spark plug Tappet cover Valve clearance adjusting lock nut Stopper plate Camshaft sprocket Timing chain guide stopper Plate Timing chain tensioner Timing chain tensioner cap A.C. magneto Oil pump cover and rotor housing Cover Oil pump assembly Oil filter cover Engine oil drain bolt Carburetor joint and cylinder head Air filter assembly and silencer Air filter stay and cylinder Silencer assembly Fuel pump Air filter stay and stay Exhaust pipe joint Rear exhaust pipe Front exhaust pipe and muffler Exhaust pipe cover Muffler mount Crankcase Generator cover Crankcase cover Clutch cover Clutch cable holder and clutch cover Left crankcase straight plug Oil check plug Nozzle One-way clutch Primary drive gear Clutch boss Clutch spring Push lever adjusting screw lock nut Part name Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Screw Thread size M8 M6 M6 M6 M6 M6 M6 M6 M10 M45 M5 M6 M8 M6 M6 M6 M6 M12 M6 M6 M6 M6 M35 M6 M6 M6 M6 M6 M6 M6 M6 M8 M6 M10 M6 M6 M6 M6 M6 M14 M6 M8 M8 M16 M16 M6 M6 Qty y 8 4 4 4 2 4 2 4 2 4 4 2 2 4 2 4 2 1 1 1 3 3 1 4 2 2 2 2 2 4 2 1 2 2 14 8 3 9 2 1 1 2 3 1 1 4 1 Tightening torque Nm 22 12 12 10 10 7 7 0.7 13 18 7 12 26 10 10 10 8 80 7 7 7 10 32 10 7 10 10 10 7 10 10 12 7 25 7 10 10 10 10 23 7 5 30 80 75 8 8 mSkg 2.2 1.2 1.2 1.0 1.0 0.7 0.7 0.07 1.3 1.8 0.7 1.2 2.6 1.0 1.0 1.0 0.8 8.0 0.7 0.7 0.7 1.0 3.2 1.0 0.7 1.0 1.0 1.0 0.7 1.0 1.0 1.2 0.7 2.5 0.7 1.0 1.0 1.0 1.0 2.3 0.7 0.5 3.0 8.0 7.5 0.8 0.8 Remarks
Nut Bolt Bolt Bolt Bolt Bolt Bolt Nut Screw Screw Screw Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Bolt Screw Bolt Nut Nut Screw Nut
2-15
Thread size M8 M16 M5 M6 M8 M10 M6 M5 M6
SPEC
Remarks
Part to be tightened g Push lever axle Drive sprocket Shift drum segment Shift arm Shift pedal adjuster Neutral switch Stater coil Pickup coil Starter motor
Part name Screw Nut Screw Bolt Nut
Qty y 1 1 1 1 2 1 3 2 2
Tightening torque Nm 12 60 3.8 8 10 20 7 5 10 mSkg 1.2 6.0 0.38 0.8 1.0 2.0 0.7 0.5 1.0
1 of 2 has LH thread
Screw Screw Bolt
2-16
Cylinder head tightening sequence:
SPEC
Crankcase tightening sequence:
2-17
CHASSIS Tightening torques Part to be tightened Upper bracket and inner tube Upper bracket and steering shaft Ring nut (steering shaft) Under bracket and inner tube Main switch and frame Front wheel axle shaft pinch bolt Front brake master cylinder and bracket Upper bracket and handle holder (under) Handlebar holder (upper and lower) Brake hose union bolt Brake hose holder and under bracket Front fender and front fork Headlight stay and under bracket Headlight body and unit Headlight stay and headlight Front turn signal light and under bracket Throttle cable and carburetor Engine mounting: Frame and stay (front upper) Frame and stay (front lower right) Frame and stay (rear upper) Head cover and stay (front upper) Engine and frame Engine and stay (rear upper) Engine and frame Ignition coil and frame Horn Muffler and frame Licence bracket and rear fender Taillight and rear fender Rear fender Rear turn signal light and rear fender Rear fender and wire harness holder Rectifier/regulator and battery box Starter relay and battery positive lead Starter relay and wire harness lead Pivot shaft and nut Shock absorber and swingarm Shock absorber and frame Chain case and swingarm Seal guard Tension bar and swingarm Tension bar and brake shoe plate Thread size M8 M22 M25 M12 M8 M8 M6 M10 M8 M10 M6 M6 M6 M5 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M5 M8 M8 M6 M6 M6 M12 M6 M6 M6 M12 M8 M8 M6 M5 M8 M8
SPEC
Tightening torque Nm 20 110 18 30 23 20 7 32 23 30 9 7 7 3 8 7 4 35 35 35 35 35 35 35 4 16 30 7 7 7 7 7 7 7 7 46 23 23 7 4 23 23 mSkg 2.0 11.0 1.8 3.0 2.3 2.0 0.7 3.2 2.3 3.0 0.9 0.7 0.7 0.3 0.8 0.7 0.4 3.5 3.5 3.5 3.5 3.5 3.5 3.5 0.4 1.6 3.0 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7 4.6 2.3 2.3 0.7 0.4 2.3 2.3
Remarks
See NOTE
2-18
Part to be tightened Fuel cock and tank Fuel tank bracket and frame Speedometer setting nut Speedometer cable Rides seat Passenger seat Front wheel axle shaft Rear wheel axle shaft Front brake caliper and front fork Brake disk Rear wheel sprocket Caliper bleed screw Brake hose union bolt Chain puller lock nut Sidestand bolt and nut Footrest assembly mounting Rear footrest bracket and frame Sidestand switch Sidestand switch panel and frame Thread size M6 M8 M5 M12 M6 M8 M16 M14 M10 M8 M10 M7 M10 M8 M10 M10 M8 M5 M6
SPEC
mSkg 0.7 2.3 0.3 0.3 0.7 1.6 5.9 10.4 4.0 2.3 4.0 0.6 3.0 1.6 4.0 4.0 2.6 0.4 0.7 Remarks
Tightening torque Nm 7 23 3 3 7 16 59 104 40 23 40 6 30 16 40 40 26 4 7
NOTE: 1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.
2-19
LUBRICATION POINTS AND LUBRICANT TYPES

EB203000
SPEC

ENGINE Lubrication point Oil seal lips O-ring Bearing Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX) Valve stem end (IN, EX) Timing chain drive gear shafts/sprockets Oil pump rotor (inner/outer), housing Starter idle gear Starter idle gear shaft Push rod 1, 2 Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Push rod ball Push lever assembly Crankcase mating surface Crankcase cover Yamaha bond No.1215 Yamaha bond No.1215 Symbol
2-20

EB203010
SPEC
CHASSIS Lubrication point Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever pivot bolt, contact surface Clutch lever pivot bolt, contact surface Swingarm pivot bearing inner surface Swingarm pivot oil seal lip Symbol
2-21
ENGINE OIL LUBRICATION CHART SPECIFICATIONS
SPEC
ENGINE OIL LUBRICATION CHART SPECIFICATIONS

Item Lubrication chart: Standard
2-22
ENGINE OIL FLOW DIAGRAMS

EB205000
SPEC
2-23
SPEC
2-24
SPEC
2-25
CABLE ROUTING
SPEC
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10
Right handlebar switch lead Front brake light switch lead Main switch Brake hose Clutch switch lead Left handlebar switch lead Starter cable Clutch cable Headlight lead Throttle cables
A Install the coupler between left ignition coil and right ignition coil. B Insert rubber bracket, into the relay stay tightly for the relay and thermo switch. C Route the clutch cable through forward of head pipe and outside of throttle cable.
2-26
CABLE ROUTING
1 2 3 4 5 6 7 8 9
SPEC
Rectifier/ regulator Ignition coil Front brake light switch lead Right handlebar switch lead Brake hose Throttle cables Clutch cable High tension code Rear brake light switch lead
A Connect the ignition coil read. (red lead: lower) (orange lead: upper) Connect the ignition coil lead terminal so that it faces the out side of the frame. B Route the right handlebar switch lead and front brake light switch lead through the hole of the frame from inside to outside. C Connect the rear brake light switch lead coupler between the band and the holder.
2-27
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
SPEC
Clutch switch lead Left handlebar switch lead Clutch cable Starter cable Speedometer Speedometer cable Igniter unit Starting circuit cut-off relay Fuse box Sidestand switch lead Air filter breather hose High tension code Throttle position sensor lead Carburetor heater ground lead Carburetor heater lead Flasher relay Headlight relay
18 19 20 21 22 23 24 25
Thermo switch lead Thermo switch Horn lead Horn Ignition coil Headlight lead Wire harness Throttle cables
2-28
CABLE ROUTING
SPEC
A Put in the speedometer lead cou- E Clamp the wire harness. K Clamp between the left handlepler into the fuel tank filler box. F Throttle position sensor coupler bar switch lead coupler and the B Route the speedometer cable under the wireharness. right handlebar switch lead couspeedometer lead and fuel tank G To the engine. pler. breather hose through the hole H Connect the ignition coil lead. L Line up the leads during installaof fuel tank. (red lead: lower) tion. C Clamp the white tape of wire har(gray lead: upper) M Run all leads along the frame. ness. (fix the position) Face the clamp end (extra posi- N Pass between the holder and enD Clamp the back sides of the left tion) toward the at side of the gine stay (left side). handlebar switch lead and clutch frame. switch lead couplers (3 loca- I Insert the front turn signal light tions). Face the end of the clamp leads and headlight lead from (extra position) toward the inside outside of headlight to inside. of the frame. Clamp immediately J Pass the throttle position sensor after the wireharness branch lead through the fuel hose down (leftand right hand lebar switch stream side. lead.)
2-29
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11
SPEC
Throttle cables Brake hose Battery negative () lead Regulator lead Tail/ brake light lead Starter relay Clutch cable Starter cable Alarm lead Inner panel Battery positive (+) lead
A Through the speedometer cable between frame of tank rail and wireharness. B Through the fuel tank breather hose between wireharness and leads. C Position an open side of clamp to rear frame and assemble. D Face the end of the band (extra portion) toward the bottom of the frame. Items to be clamped with a band: regulator lead, brake light lead. E To the rear fender. F Cut the end of band position: Front upper band of frame. G To the engine.
H Fasten the wireharness, high tension code, and throttle position sensor with a band. I Fasten the wireharness, left handlebar switch lead, high tension code, clutch switch lead, right handlebar switch lead and front brake light switch lead with a band. J To the fuel tank. K Fasten the wireharness, left handlebar switch lead clutch switch lead, right handlebar switch lead front brake switch lead, throttle cables, and starter cable with a band.
2-30
CABLE ROUTING
L Put an alarm coupler into this O Face the end of the band (extra position. portion) toward the bottom of the (surrounded part by vertical frame. Item to be clamped: regupanel inner wall.) lator lead, brake light lead, A, C. M To the starter motor. magneto lead, pickup coil lead, N Face the end of the clamp (extra side stand switch lead. portion) toward the inside of the P Berd the alarm lead once and frame. band to burdle it together with Item to be clamped: wireharthe wireharness. ness, battery negative leads (2 leads), starter motor lead, alarm read, A, C. magneto lead, side stand switch read.
SPEC
2-31
CHK ADJ
CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE/LUBRICATON INTERVALS . . . . . . . . . . . . 3-1 RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 FUEL TANK AND AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . CHECKING THE SPARK PUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKELIGHT SWITCH . . . . . . . . . . . . . . . CHECKING THE BRAKE HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE ADJUSTING THE STEERING HEAD . . . . . . . . . . CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND TIGHTENING THE SPOKES . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-6 3-6 3-9 3-11 3-12 3-14 3-15 3-17 3-18 3-19 3-20 3-21 3-22 3-22 3-23 3-24 3-24 3-24 3-26 3-27 3-27 3-27 3-28 3-28 3-30 3-30 3-32 3-32 3-34 3-35 3-36 3-38 3-39 3-39 3-39 3-39
CHK ADJ
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 3-40 3-46 3-47 3-48
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

EB300000
CHK ADJ
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NO. 1 2 3 4 5 6 * * * Fuel line Spark plugs Valves Air filter Clutch Front brake ITEM CHECKS AND MAINTENANCE JOBS S Check fuel hoses and vacuum hose for cracks or damage. S Replace if necessary. S Check condition. S Clean, regap or replace if necessary. S Check valve clearance. S Adjust if necessary. S Clean or replace if necessary. S Check operation. S Adjust or replace cable. S Check operation, fluid level and vehicle for fluid leakage. S Correct accordingly. S Replace brake pads if necessary. S Check operation. S Adjust brake pedal freeplay and replace brake shoes if necessary. S Check for cracks or damage. S Replace if necessary. S Check balance, runout, spoke tightness and for damage. S Tighten spokes and rebalance, replace if necessary. S S S S Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Initial 1,000 km Every 6,000 km Every 12,000 km Annual check
7 8 9
* * *
Rear brake Brake hose Wheels
10
Tires
11
Wheel bearings
S Check bearing for looseness or damage. S Replace if necessary. S Check swingarm pivoting point for play. S Correct if necessary. S Lubricate with molybdenum disulfide grease. S Check chain slack. S Adjust if necessary. Make sure that the rear wheel is properly aligned. S Clean and lubricate. S Check bearing play and steering for roughness. S Correct accordingly. S Lubricate with lithium soap base grease. S Make sure that all nuts, bolts and screws are properly tightened. S Tighten if necessary. S Check operation. S Lubricate and repair if necessary. S Check operation. S Replace if necessary. S Check operation and for oil leakage. S Correct accordingly. S Check operation and shock absorbers for oil leakage. S Replace shock absorber assembly if necessary. S Check engine idling speed and starter operation. S Adjust if necessary. S Check oil level and vehicle for oil leakage. S Correct if necessary. S Change. (Warm engine before draining.)
Every 1,000 km and after washing the motorcycle or riding in the rain
12
Swingarm g
13
Drive chain
14
Steering g bearings g
15 16 17 18 19 20 21
Chassis fasteners Sidestand
* * * * *
Sidestand switch Front fork Rear shock absorber assemblies Carburetor Engine oil
3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NO. 22 23 24 25 * * * ITEM Engine oil filter element Front and rear brake switches Moving parts and cables Lights, signals and switches CHECKS AND MAINTENANCE JOBS S Replace. S Check operation. S Correct accordingly. S Lubricate if necessary. S Check operation. S Correct if necessary. S Adjust headlight beam if necessary. Initial 1,000 km
CHK ADJ
Every 12,000 km Annual check
Every 6,000 km
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE: D The annual checks must be performed every year, except if a 6,000 km or 12,000 km maintenance is performed instead. D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. D Hydraulic brake service S Regularly check and, if necessary, correct the brake fluid level. S Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. S Replace the brake hoses every four years and if cracked or damaged.
CAUTION:
The carburetor on this motorcycle has a built-in accelerator pump. Therefore, when engine is stopped or is operated without load, do not open and shut a throttle grip. It may cause starting and revolution trouble due to over-emitting fuel of accelerating pump.
3-2
RIDER AND PASSENGER SEATS
CHK ADJ
RIDER AND PASSENGER SEATS
7 Nm (0.7 mSkg)
16 Nm (1.6 mSkg)
Order
Job/Part Removing the rider and passenger seats Passenger seat Seat bracket Riders seat
Qty
Remarks Remove the parts in the order listed.
1 2 3
1 1 1 For installation reverse the removal procedure.
3-3
FUEL TANK AND AIR FILTER
CHK ADJ
7 Nm (0.7 mSkg)
23 Nm (2.3 mSkg)
Order
Job/Part Removing the fuel tank and air filter Rider and passenger seats
Qty
Remarks Remove the parts in the order listed. Refer to RIDER AND PASSENGER SEATS. NOTE: Set the fuel cock to OFF before disconnecting the fuel hose.
Fuel hoses
2 3 4 5 6 7
Speedometer Fuel tank breather hose Speedometer cable Speedometer lead coupler Fuel tank Air filter
1 1 1 1 1 1
Disconnect.
For installation, reverse the removal procedure.
3-4

REMOVAL 1. Remove: S Ignitor plate
CHK ADJ
NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out.
INSTALLATION 1. Install: S Ignitor plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Make sure that the pin is flush with the fasteners head.
3-5
ADJUSTING THE VALVE CLEARANCE

EAS00047
CHK ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: S rider and passenger seats Refer to RIDER AND PASSENGER SEATS. S fuel tank Refer to FUEL TANK. 2. Disconnect: S spark plug caps 3. Remove: S spark plugs 4. Remove: S air filter assembly 1
5. Remove: S frame cover 1 S silencer assembly 2
6. Remove: S cylinder head side covers 1 (front cylinder) S cylinder head side covers 2 (rear cylinder)
3-6

7. Remove: S tappet covers 1
CHK ADJ
8. Remove: S camshaft sprocket cover (front cylinder) 1 S camshaft sprocket cover (rear cylinder)
9. Remove: S timing plug 1 S straight plug 2
10. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.08 0.12 mm Exhaust valve 0.10 0.14 mm
3-7
CHK ADJ
a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align either the alignment mark in the camshaft sprocket (front cylinder) a or alignment mark in the camshaft sprocket (rear cylinder) c , dependant on which cylinder you are checking, with the stationary pointer b on the cylinder head. When the hole in the camshaft sprocket plate or punch mark in the camshaft sprocket is aligned with the stationary pointer, the piston is at top dead center (TDC). c. Align the TDC mark d on the generator rotor with the stationary pointer e on the generator cover. A Front cylinder (T mark) B Rear cylinder (I mark)
d. Measure the valve clearance with a thickness gauge 1 . e. Turn the crankshaft clockwise 300_, and then measure the another cylinder.
11. Adjust S valve clearance a. Loosen the locknut. b. Insert a thickness gauge between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw 1 in direction a or b until the specified valve clearance is obtained. Valve adjusting tool 90890-01311 Direction a Direction b Valve clearance is decreased. Valve clearance is increased.
d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specification.
3-8
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED
CHK ADJ
Locknut: 7 Nm (0.7 mkg) e. Measure the valve clearance again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 12. Install: S all removed parts NOTE: Install all removed parts in the reverse order of their disassembly. Note the following points. S camshaft sprocket covers S tappet covers S spark plugs
10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) 13 Nm (1.3 mSkg)
EAS00054
ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: S engine tachometer (to the spark plug lead of cyl. #1) Engine tachometer 90890-03113 3. Check: S engine idling speed Out of specification ! Adjust. Engine idling speed 1.250 1.450 r/min 4. Adjust: S engine idling speed
3-9
ADJUSTING THE IDLING SPEED
CHK ADJ
a. Turn the pilot screw in or out until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Pilot screw 2 turns out c. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a Direction b Engine idling speed is increased. Engine idling speed is decreased.
5. Adjust: S throttle 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
3-10
ADJUSTING THE THROTTLE CABLE FREE PLAY

EAS00058
CHK ADJ
ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 5 mm 2. Remove: S fuel tank 3. Adjust: S throttle cable free play Carburetor side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.
c. Tighten the locknuts 1 . NOTE: 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 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.
c. Tighten the locknut 1 .
3-11
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS WARNING
CHK ADJ
After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
4. Install: S fuel tank

EAS00060
CHECKING THE SPARK PLUGS 1. Disconnect: S spark plug cap 2. Remove: S spark plug
CAUTION:
Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check: S spark plug type Incorrect ! Change. Spark plug type (manufacturer) CR7HSA (NGK) U22FSR-U (DENSO) 4. Check: S electrode 1 Damage/wear ! Replace the spark plug. S insulator 2 Abnormal color ! Replace the spark plug. Normal color is a medium-to-light tan color. 5. Clean: S spark plug (with a spark plug cleaner or wire brush) 6. Measure: S spark plug gap a (with a wire gauge) Out of specification ! Regap. Spark plug gap 0.6 0.7 mm
3-12
CHECKING THE SPARK PLUGS

7. Install: S spark plug
CHK ADJ
13 Nm (1.3 mSkg)
NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: S spark plug cap
3-13
CHECKING THE IGNITION TIMING

EAS00062
CHK ADJ
CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: S timing plug 1 2. Install: S timing light 1 S engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light 90890-03141 Engine tachometer 90890-03113 3. Check: S ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1.250 1.450 r/min b. Check that the mark a on the generator rotor is within the firing range b on the generator cover. Incorrect firing range ! Check the ignition system. NOTE: The ignition timing is not adjustable.
4. Install: S timing plug 1
3-14
MEASURING THE COMPRESSION PRESSURE

EAS00065
CHK ADJ
MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: S valve clearance Out of specification ! Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: S spark plug cap 4. Remove: S spark plug
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 Compression gauge set 90890-03081 6. Measure: S compression pressure Above the maximum pressure ! Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure ! Squirt a few drops of oil into the affected cylinder and measure again.
3-15
MEASURING THE COMPRESSION PRESSURE
CHK ADJ
Refer to the following table. Compression pressure (with oil applied into cylinder) Reading Higher than without oil Diagnosis Piston wear or damage ! Repair. Piston ring(-s), valves, cylinder head gasket or piston possibly defective ! Repair. Compression pressure (at sea level)
Same as without oil
Compression pressure (at sea level): Standard: 1.200 kPa (12 kg/cm2, 12 bar) Minimum: 1.100 kPa (11 kg/cm2, 11 bar) Maximum: 1.300 kPa (13 kg/cm2, 13 bar) a. Turn the main switch to ON. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
WARNING
To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2, 1 bar).
7. Install: S spark plug 8. Connect: S spark plug cap
13 Nm (1.3 mSkg)
3-16
CHECKING THE ENGINE OIL LEVEL

EAS00069
CHK ADJ
CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3. Check: S engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b . Below the minimum level mark ! Add the recommended engine oil to the proper level. Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade ACEA standard G4 or G5
CAUTION:
S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENERGY CONSERVING II b or higher. S Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
3-17
CHANGING THE ENGINE OIL

EAS00075
CHK ADJ
CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove:
WARNING
Be careful not touch the exhaust pipe when removing or attaching the engine oil filler cap 1 or when adding oil. S engine oil filler cap 1 S engine oil drain bolt 2 (along with the gasket) 4. Drain: S engine 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 element 2 . b. Check the O-ring 3 and replace it if it is cracked or damaged. c. Install the new oil filter element and the oil filter element cover. Oil filter element cover bolt 10 Nm (1.0 mSkg) 6. Check: S engine oil drain bolt gasket Damage ! Replace. 7. Install: S engine oil drain bolt 32 Nm (3.2 mSkg) (along with the gasket) S oil filter element drain bolt (along with the gasket) 8. Fill: S crankcase (with the specified amount of the recommended engine oil)
3-18
CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK ADJ
Quantity Total amount 1.75 L Without oil filter element replacement 1.4 L With oil filter element replacement 1.6 L 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12. Check: S engine oil level Refer to CHECKING THE ENGINE OIL LEVEL.
EAS00078
ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 5 10 mm 2. Adjust: S clutch cable free play Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a Direction b Clutch cable free play is increased. Clutch cable free play is decreased
c. Tighten the locknut. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. Engine side a. Loosen the locknuts 1 .
3-19
ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT
CHK ADJ
b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a Direction b Clutch cable free play is increased. Clutch cable free play is decreased
c. Tighten the locknuts 1 . CLEANING THE AIR FILTER ELEMENT 1. Remove: S air filter case assembly 1
S air filter element 2
2. Clean: S air filter element Apply compressed air to the inner surface of the air filter element.
3. Check: S air filter element Damage ! Replace. 4. Install: S air filter element S air filter case cover
3-20
CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD CAUTION:
CHK ADJ
Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks.
EAS00094
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: S fuel tank S silencer 2. Check: S carburetor joint 1 Cracks/damage ! Replace. Refer to CARBURETOR in chapter 6. 3. Install: S silencer S fuel tank
3-21
CHECKING THE FUEL HOSES/ CHECKING THE CRANKCASE BREATHER HOSE

EAS00097
CHK ADJ
CHECKING THE FUEL HOSES The following procedure applies to all of the fuel hoses. 1. Remove: S fuel tank S silencer 2. Check: S fuel hose 1 Cracks/damage ! Replace. Damage/dirt ! Replace. NOTE: S Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. 3. Install: S silencer S fuel tank
EAS00098
CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: S fuel tank S silencer 2. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly.
CAUTION:
Make sure that the crankcase breather hose is routed correctly. 3. Install: S silencer S fuel tank
3-22
CHECKING THE EXHAUST SYSTEM

EAS00100
CHK ADJ
CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipe, muffler and gaskets. 1. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. S gaskets 3 Exhaust gas leaks ! Replace. 2. Check: S tightening torque Exhaust pipe nut 4 10 Nm (1.0 mSkg) Exhaust pipe and muffler bolt 5 10 Nm (1.0 mSkg) Muffler and muffler bracket bolt 6 25 Nm (2.5 mSkg) Front exhaust pipe and muffler 7 12 Nm (1.2 mSkg)
3-23
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE

EAS00108
CHK ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE 1. Check: S brake lever free play a Out of specification ! Adjust. Brake lever free play (at the end of the brake lever) 5 8 mm 2. Adjust: S brake lever free play a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake lever free play is obtained. Direction a Direction b Brake lever free play is increased. Brake lever free play is decreased.
c. Tighten the locknut.
WARNING
A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake lever free play, make sure that there is no brake drag.
EAS00112
ADJUSTING THE REAR BRAKE 1. Check: S brake 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 (above the top of the rider footrest) 76.6 mm
3-24
ADJUSTING THE REAR BRAKE

2. Adjust: S brake pedal position
CHK ADJ
a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Direction b Brake pedal is raised. Brake pedal is lowered.
c. Tighten the locknut to specification. Locknut 10 Nm (1.0 mSkg) 3. Check: S brake pedal free play a Out of specification ! Adjust. Brake pedal free play 20 30 mm 4. Adjust: S brake pedal free play a. Turn the adjusting nut 1 in direction a or b until the specified brake pedal free play is obtained. Direction a Direction b Brake pedal free play is increased. Brake pedal free play is decreased.
CAUTION:
After adjusting the brake pedal position and free play, make sure that there is not brake drag. 5. Adjust: S rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH.
3-25
CHECKING THE BRAKE FLUID LEVEL

EAS00115
CHK ADJ
CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4
Front brake
WARNING
S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. S When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure that the top of the reservoir is horizontal.
3-26
CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH
EAS00117
CHK ADJ
CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S brake pad Wear indicators 1 almost touch the brake disc ! Replace the brake pads as a set. Refer to FRONT BRAKE in chapter 6.
EAS00126
CHECKING THE BRAKE SHOES 1. Operate the brake. 2. Check: S wear indicator 1 Reaches the wear limit line 2 ! Replace the brake shoes as a set. Refer to REAR WHEEL in chapter 6.
EAS00128
ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: S rear brake light operation timing Incorrect ! Adjust.
2. Adjust: S rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction a ! Brake light comes on sooner. Direction b ! Brake light comes on later.
3-27
CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM

EAS00129
CHK ADJ
CHECKING THE BRAKE HOSE 1. Check: S brake hose 1 Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp Loose connection ! Tighten. 3. Hold the motorcycle upright and apply the front or rear brake. 4. Check: S brake hose Activate the brake several times. Brake fluid leakage ! Replace the damaged hose. Refer to FRONT BRAKE in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system whenever: S The system was disassembled. S A brake hose was loosened or removed. S The brake fluid level is very low. S Brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. S When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. S If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.
3-28
BLEEDING THE HYDRAULIC BRAKE SYSTEM

1. Bleed: S hydraulic brake system
CHK ADJ
a. Add the recommended brake fluid to the proper level. b. Install the brake master cylinder reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . d. Place the other end of the hose into a container. e. Slowly squeeze the brake lever several times. f. Fully squeeze the brake lever without releasing it. g. Loosen the bleed screw. This will release the tension and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mSkg) k. Fill the reservoir to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL.
WARNING
After bleeding the hydraulic brake system, check the brake operation.
3-29
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK

EAS00137
CHK ADJ
ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the adjusting bolt length a . 1. Measure: S adjusting the length a Incorrect ! Adjust. Adjusting bolt length 276.8 mm 2. Adjust: S adjusting bolt length a a. Loosen both locknuts 1 b. Turn the adjusting bolt 2 in direction b or c to obtain the correct shift pedal position. Direction b ! shift pedal is raised. Direction c ! shift pedal is lowered.
EAS00141
ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
3-30
ADJUSTING THE DRIVE CHAIN SLACK
CHK ADJ
2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Check: S drive chain slack a Out of specification ! Adjust. Drive chain slack 30 40 mm 4. Adjust: S drive chain slack a. Loosen the wheel axle nut 1 . Loosen the locknut 3 . b. Turn the chain puller nut 2 in direction a or b until the specified drive chain slack is obtained. Direction a Direction b Drive chain is tightened. Drive chain is loosened.
NOTE: To maintain the proper wheel alignment, adjust both sides evenly. c. Tighten the wheel axle nut. Wheel axle nut 104 Nm (10.4 mSkg)
CAUTION:
Do not loosen the wheel axle nut after tightening it to the specified torque. If the groove in the wheel axle nut is not aligned with the cotter pin hole in the wheel axle, tighten the nut further until they are aligned.
3-31
LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD
EAS00142
CHK ADJ
LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, 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 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 chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains
EAS00146
CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding ! Adjust the steering head.
3-32
CHECKING AND ADJUSTING THE STEERING HEAD
CHK ADJ
3. Remove: S handlebar S upper bracket pinch bolt 1 S steering stem nut 2 S upper bracket 3
4. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01043 Lower ring nut (initial tightening torque) 52 Nm (5.2 mSkg) c. Loosen the lower ring nut 4 completely, then tighten it to specification.
WARNING
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 directions. If any binding is felt, remove the lower bracket and inspect the upper and lower bearings. Refer to STEERING HEAD AND HANDLEBAR in chapter 7.
3-33
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK
CHK ADJ
e. Install the rubber washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer 1 . NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
5. Install: S upper bracket S steering stem nut 110 Nm (11.0 mSkg) S upper bracket pinch bolt
20 Nm (2.0 mSkg)
EAS00149
CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Check: S inner tube Damage/scratches ! Replace. S oil seal Oil leakage ! Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: S operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Unsmooth operation ! Repair. Refer to FRONT FORK in chapter 7.
3-34
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

EAS00156
CHK ADJ
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
WARNING
Securely support the motorcycle so that there is no danger of it falling over. Spring preload
CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owners tool kit.
a. Turn the adjusting ring 1 in direction a or b. Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer).
Direction a
Direction b
Adjusting positions Standard: 2 Minimum: 1 Maximum: 5
3-35
CHECKING THE TIRES

EAS00164
CHK ADJ
CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate.
WARNING
S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. S Operation 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) Maximum load* Cold tire pressure Up to 90 kg load* 90 kg maximum load* High speed riding
156 kg
183 kg Front tire Rear tire
175 kPa 200 kPa (1.75 kgf/cm2) (2.00 kgf/cm2) 225 kPa 225 kPa 2 (2.25 kgf/cm ) (2.25 kgf/cm2) 175 kPa 200 kPa 2 (1.75 kgf/cm ) (2.00 kgf/cm2)
*: total of cargo, rider, passenger and accessories
WARNING
It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: S tire surfaces Damage/wear ! Replace the tire. Minimum tire tread depth 0.8 mm
3-36
CHECKING THE TIRES

1 Tire tread depth 2 Side wall 3 Wear indicator
CHK ADJ
WARNING
S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. S When using tube tires, be sure to install the correct tube. S Always replace a new tube tire and a new tube as a set. S To avoid pinching the tube, make sure that the wheel rim band and tube are centered in the wheel groove. S Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire S After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.
Front tire Manufacturer CHENG SHIN INOUE Type C-916 MARBELLA NF27 Size 80/100-18 47P 80/100-18 47P
3-37
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES

Rear tire Manufacturer CHENG SHIN INOUE Type C-915
CHK ADJ
Size
130 / 90-15 M / C 66P 130 / 90-15 M / C 66P
MARBELLA NR31
WARNING
S New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any highspeed riding is done. NOTE: For tires with a direction of rotation mark 1 : S Install the tire with the mark pointing in the direction of wheel rotation. S Align the mark 2 with the valve installation point.
EAS00169
CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: S spoke 1 Bends/damage ! Replace. Loose ! Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: S spoke (with a spoke wrench 2 ) NOTE: Be sure to tighten the spokes before and after break-in. Spoke nipple 3 Nm (0.3 mSkg)
3-38
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION
EAS00170
CHK ADJ
CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.
WARNING
Damaged cable sheaths may causes the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: S cable sheath Damage ! Replace. 2. Check: S cable operation Unsmooth operation ! Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable 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 of the sidestand. Recommended lubricant Engine oil
EAS00174
LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease
3-39
CHECKING AND CHARGING THE BATTERY

EB305020
CHK ADJ
ELECTRICAL SYSTEM
WARNING
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area. S Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). S DO NOT SMOKE when charging or handling batteries. S KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: External S SKIN Wash with water. S EYES Flush with water for 15 minutes and get immediate medical attention. Internal Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
CAUTION:
S This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. S Charging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
3-40
CHK ADJ
NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: S battery cover 1
2. Disconnect: S battery leads (from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: S battery 4. Check: S battery charge a. Connect a pocket tester to the battery terminals. Tester positive lead ! battery positive terminal Tester negative lead ! battery negative terminal Volt meter NOTE: S The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V. b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 30 % 5. Charge: S battery (refer to the appropriate charging method illustration)
Relationship between open-circuit voltage and charging time at 20_C Open-circuit voltage Charging time (Hours) D This varies depending on the temperature, the state of charge in battery plates and the electro lyte level.
3-41

Ambient temperature 20_C Open-circuit voltage (V)
CHK ADJ
WARNING
Do not quick charge a battery.
CAUTION:
S Make sure that the battery breather hose and battery vent are free of obstructions. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.) S To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. S Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. S Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. S If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! S As shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
Condition of charge in battery (%)
Charging
18
Ambient temperature 20_C
Open-circuit voltage (V)
17 16 15 14 13 12 11 10 0 10 20 30 40 50 60 Time (Minutes)
Check the Open-circuit voltage
3-42

Charging method using a variable-current (voltage) type charger
Charger AMP meter
CHK ADJ
Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery and start charging. Make sure the current is higher than the standard charging current written on the battery.
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
NOTE: Set the charging voltage at 16 17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)
YES
NO
By turning the charging voltage adjust dial, set the charging voltage at 20 25 V. Adjust the voltage so that current is at standard charging level. Monitor the amperage for 3 5 minutes to check if the standard charging current is reached.
NO
YES
Set the timer according to the charging time suitable for the open-circuit voltage. Refer to Battery condition checking steps.
If the current does not exceed standard charging current after 5 minutes, replace the battery.
In case that charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any charge in the amperage, readjust the voltage to obtain the standard charging current.
Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
3-43

Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging.
CHK ADJ
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and AMP meter to the battery and start charging.
YES
Make sure the current is higher than the standard charging current written on the battery.
NO
Charge the battery until the batterys charging voltage is 15 V.

NOTE: Set the charging time at 20 hours (maximum).
This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.
Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
Charger AMP meter Volt meter
Charging method using a constant-current type charger This type of battery charger cannot charge the MF battery.
3-44
CHK ADJ
6. Check: S battery breather hose and battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery
CAUTION:
S When inspecting the battery, make sure that the battery breather hose is properly attached and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the battery to contact the frame, the motorcycle and its finish may be damaged. S Make sure that the battery breather hose is properly routed away from the drive chain and from below the swingarm. 8. Connect: S battery leads (to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the negative lead 2 . 9. Check: S battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 10. Lubricate: S battery terminals Recommended lubricant Dielectric grease 11. Install: S battery cover
3-45
CHECKING THE FUSES

EAS00181
CHK ADJ
CHECKING THE FUSES The following procedure applies to all of the fuses.
CAUTION:
To avoid a short circuit, always turn the main switch to OFF when checking or replacing a fuse. 1. Remove: S left side cover 1 2. Check: S fuse a. Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the pocket tester selector to 1. Pocket tester 90890-03112 b. If the pocket tester indicates , replace the fuse. 3. Replace: S blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Fuses Main Headlight Carburetor heater Signals Ignition Reserve Reserve Reserve Amperage rating 30A 15A 10A 10A 10A 30A 15A 10A Quantity 1 1 1 1 1 1 1 1
3-46
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB WARNING
CHK ADJ
Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: S left side cover
EAS00182
REPLACING THE HEADLIGHT BULB 1. Disconnect: S connectors 1 2. Remove S headlight bulb cover 2
3. Remove: S headlight bulb holder 1 4. Remove: S headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: S headlight bulb Secure the new headlight bulb with the headlight bulb holder.
3-47
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CAUTION:
CHK ADJ
Avoid touching the glass part of the headlight 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 gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: S headlight bulb holder 7. Install: S headlight bulb cover 8. Connect: S leads
EAS00184
ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a ! Headlight beam is raised. Direction b ! Headlight beam is lowered. 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting screw 2 in direction a or b. Direction a ! Headlight beam moves to the right. Direction b ! Headlight beam moves to the left.
3-48
ENG
CHAPTER 4. ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPES . . . . . . . . . . . . . . . . . . . . LEADS, SHIFT PEDAL AND CLUTCH CABLE . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . INSTALLILNG THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLILNDERS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PISTONS AND CYLINDERS . . . . . . . . . . . . . . . . . GENERATOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL AND PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH LEVER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-3 4-4 4-5 4-6 4-6 4-7 4-8 4-10 4-11 4-11 4-15 4-16 4-16 4-17 4-18 4-20 4-21 4-21 4-23 4-25 4-25 4-27 4-28 4-28 4-30 4-31 4-31 4-33 4-33 4-34 4-35 4-36 4-37 4-38 4-38 4-40 4-42
ENG
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . INSTALLILNG THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLILNG THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . . CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 4-43 4-44 4-44 4-45 4-45 4-45 4-46 4-46 4-46 4-47 4-47 4-50 4-52 4-52 4-53 4-54 4-54 4-56 4-56 4-56 4-57 4-57 4-59 4-60 4-61 4-62 4-62 4-63 4-63 4-64 4-64 4-66 4-66 4-66 4-67 4-68
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
DRIVE SPROCKET AND EXHAUST PIPES
7 Nm (0.7 mSkg)
60 Nm (6.0 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
Order
Job/Part Removing the drive sprocket and exhaust pipes
Qty
Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycles so there is no danger of it falling over. Rider and passenger seats Fuel tank Airfilter case assembly Carburetor assembly Muffler assembly Exhaust pipe Refer to RIDER AND PASSENGER SEATS in chapter 3. Refer to FUEL TANK in chapter 3. Refer to CARBURETOR in chapter 5. 1 1
1 2
4-1
ENGINE REMOVAL
ENG
7 Nm (0.7 mSkg)
60 Nm (6.0 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
Order 3 4 5 6 7 8
Job/Part Rear brake switch lead Footrest/brake pedal Drive chain case Chain cover Sprocket holder Drive sprocket
Qty 1 1/1 1 1 1 1 Disconnect.
Remarks
4-2
ENGINE REMOVAL
LEADS, SHIFT PEDAL AND CLUTCH CABLE
ENG
Order
Job/Part Removing the leads, shift pedal and clutch cable Battery negative lead Pickup coil coupler A.C. magneto coupler Plug codes Starter motor lead Clutch cable
Qty
1 2 3 4 5 6
1 1 1 2 1 1 For installation, reverse the removal procedure.
4-3
ENGINE REMOVAL
EAS00191
ENG
ENGINE
35 Nm (3.5 mSkg)
35 Nm (3.5 mSkg)
35 Nm (3.5 mSkg)
35 Nm (3.5 mSkg)
35 Nm (3.5 mSkg)
Order 1 2 3 4 5 6 7
Job/Part Removing the engine Bolt (front upper) Bolt (front under) Bolt (rear upper) Bolt (rear under) Engine stay (front upper) Engine stay (front under) Engine stay (rear upper)
Qty 2 1 1 1 1 1 2
Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
Refer to INSTALLING THE ENGINE. For installation, reverse the removal procedure.
4-4
ENGINE
EAS00192
ENG
INSTALLING THE ENGINE 1. Install: S bolt (front under) 1 S bolt (rear under) 2 S bolt (rear upper) 3 S bolt (front upper) 4 S engine bracket 5 S engine bracket 6 S engine brackets 7 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. 35 Nm (3.5 mSkg) S self locking nut 8 S bolt (front upper) 4 35 Nm (3.5 mSkg) S engine bracket bolts 9
35 Nm (3.5 mSkg)
3. Install: S chain cover
CAUTION:
Connecting the neutral switch lead, starter motor and A.C. generator leads should be through under the neutral switch. Face the terminal cover to right-under side, then assemble the chain cover without the both leads being caught.
4. Install: S shift arm 1
10 Nm (1.0 mSkg)
NOTE: S Align the punch mark a in the shift shaft with the slot in the shift arm. S Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket. ADJUSTING bolt length b 276.8 mm
4-5
CYLINDER HEADS
ENG
CYLINDER HEADS
FRONT CYLINDER HEAD
10 Nm (1.0 mSkg) 22 Nm (2.2 mSkg)
10 Nm (1.0 mSkg)
12 Nm (1.2 mSkg)
12 Nm (1.2 mSkg) 26 Nm (2.6 mSkg)
10 Nm (1.0 mSkg)
Order
Job/Part Removing the front cylinder head Engine assembly Carburetor joint Camshaft sprocket cover Chain tensioner Camshaft sprocket Bracket Cylinder head Dowel pins Head gasket
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE REMOVAL.
1 2 3 4 5 6 7 8
1 1 1 1 1 1 2 1 For installation, reverse the removal procedure.
4-6
CYLINDER HEADS
REAR CYLINDER HEAD
22 Nm (2.2 mSkg)
ENG
12 Nm (1.2 mSkg)
26 Nm (2.6 mSkg)
12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg)
Order 1 2 3 4 5 6 7
Job/Part Removing the rear cylinder head Camshaft sprocket cover Chain tensioner Camshaft sprocket Bracket Cylinder head Dowel pins Head gasket
Qty 1 1 1 1 1 2 1
4-7
CYLINDER HEADS
ENG
REMOVING THE CYLINDER HEADS Front cylinder head 1. Remove: S camshaft sprocket cover S tappet cover S timing plug S straight plug
2. Align: S T mark a on the generator rotor (with the stationary pointer b on the crank case cover)
a. Turn the crankshaft counterclockwise. b. Align the T mark a with the stationary pointer b on the crankcase cover (left) when the rear piston is at TDC on the compression stroke. c. Check that the front piston is at TDC in the compression stroke. d. The front piston is at TDC on the compression stroke when there is clearance at both of the rocker arms. If there is no clearance then turn the crankshaft counterclockwise one full turn. e. When to T mark is aligned with the stationary pointer the alignment mark c on the camshaft sprocket should be aligned with the stationary pointer d on the cylinder head. 3. Loosen: S bolt (camshaft sprocket) 1 NOTE: Use the sheave holder 2 to hold the rotor. Sheave holder: 90890-01701
4-8
CYLINDER HEADS
4. Remove: S timing chain tensioner 1 S gasket 2
ENG
5. Remove: S bolt (camshaft sprocket) 1 S camshaft sprocket 2 NOTE: To prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: S cylinder head NOTE: S Loosen the bolts in the proper sequence. S Follow the numerical order shown in the illustration. Loosen each bolt 1/4 of a turn at a time until all of the bolts are loose. Rear cylinder head NOTE: When removing the rear cylinder head, repeat the front cylinder head removal procedures. However, note the following points. 1. Align: S I mark (with the stationary pointer) Removal steps: S Turn the crankshaft counterclockwise 300_. S Align the I mark a with the stationary pointer b on the crankcase cover (left) when the rear piston is at TDC on the compression stroke. S When the I mark is aligned with the stationary pointer the alignment mark c on the camshaft sprocket should be aligned with the stationary pointer d on the cylinder head. S The rear piston is at TDC on the compression stroke when there is clearance at both of the rocker arms.
4-9
CYLINDER HEADS
EAS00228
ENG
CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 1. Eliminate: S combustion chamber carbon deposits (with a rounded scraper)
NOTE: Do not use a sharp instrument to avoid damaging or scratching: S spark plug threads S valve seats 2. Check: S cylinder head Damage/scratches ! Replace. 3. Measure: S cylinder head warpage Out of specification ! Resurface the cylinder head. Cylinder head warpage Less than 0.05 mm
a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limited is exceeded, resurface the cylinder head as follows. d. Place 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times.
4-10
CYLINDER HEADS
EB401430
ENG
CHECKING THE TIMING CHAIN TENSIONER 1. Check: S timing chain tensioner Cracks/damage/rough movement ! Replace. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.
INSTALLING THE CYLINDER HEADS Front cylinder 1. Install: S dowel pins S gasket New 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity.
4-11
CYLINDER HEADS
ENG
3. Tighten: S bolts (cylinder head) M8 1 22 Nm (2.2 mSkg) M6 2 12 Nm (1.2 mSkg) NOTE: S Lubricate the cylinder head bolts with engine oil. S Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages.
4. Install: S camshaft sprocket a. Turn the crankshaft counterclockwise. b. Align the T mark a with the stationary pointer b on the generator cover. c. Install the camshaft sprocket with the timing mark c facing out. d. Turn the camshaft just enough to remove any slack from the intake side of the timing chain. e. Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward. f. While pushing the timing chain guide, be sure that the timing mark c and the stationary pointer d are properly aligned at TDC. 5. Install: S timing chain tensioner a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. b. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner 2 , and gasket. Then, tighten the timing chain tensioner bolts 3 to the specified torque.
4-12
CYLINDER HEADS WARNING

Always use a new gasket.
ENG
Timing chain tensioner bolt 10 Nm (1.0 mSkg) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Cap bolt 8 Nm (0.8 mSkg)
6. Install: S camshaft sprocket 1 S bolt (camshaft sprocket) 2

26 Nm (2.6 mSkg)
NOTE: S Be sure the projection on the camshaft sprocket plate is aligned with the hole in the sprocket. S Use the sheave holder to hold the rotor. Sheave holder: 90890-01701 7. Check: S alignment marks If the marks do not align ! Adjust. 8. Measure: S valve clearance Out of specification ! Adjust. Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3. Rear cylinder head NOTE: When installing the rear cylinder head, repeat the front cylinder head installation procedure. However, note the following points.
4-13
CYLINDER HEADS
1. Install: S camshaft sprocket
ENG
a. Turn the crankshaft counterclockwise 300_. b. Align the I mark a with the stationary pointer b on the generator cover. c. Install the camshaft sprocket with the timing mark c facing out. d. Turn the camshaft just enough to remove any slack from the intake side of the timing chain. e. Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward. f. While pushing the timing chain guide, be sure that the timing mark c and the stationary pointer d are properly aligned at TDC.
4-14
ROCKER ARMS AND CAMSHAFT
ENG
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
12 Nm (1.2 mSkg)
Order
Job/Part Removing the rocker arms and camshaft Cylinder head Stopper plate Camshaft bushing Rocker arm shafts Rocker arms Lock nuts Valve adjusting screw Camshaft
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD.
1 2 3 4 5 6 7
1 1 2 2 2 2 1
Refer to REMOVING/INSTALLING THE ROCKER ARM AND CAMSHAFT. Refer to REMOVING/INSTALLING THE ROCKER ARM AND CAMSHAFT.
For installation reverse the removal procedure.
4-15
ENG
REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: S lock nuts 1 S adjusting screws 2 2. Remove: S rocker arm shaft S rocker arm 3
NOTE: Remove the rocker arm shafts with the slide hammer 1 and weight. Slide hammer bolt 90890-01083 Weight: 90890-01084 3. Remove: S camshaft bushing 1 S camshaft 2 NOTE: Screw a 10 mm bolt 3 into the threaded end of the camshaft and then pull out the camshaft.
EAS00205
CHECKING THE CAMSHAFT 1. Check: S camshaft bushings Damage/wear ! Replace. 2. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Replace the camshaft. 3. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the camshaft. Camshaft lobe dimension limit Intake a 26.190 mm b #1: 21.045 mm #2: 21.087 mm Exhaust a 26.190 mm b #1: 21.087 mm #2: 21.045 mm
4-16
ENG
4. Check: S camshaft oil passage Obstruction ! Blow out with compressed air.
EAS00206
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: S rocker arm 1 Damage/wear ! Replace. 2. Check: S rocker arm lobe 2 Excessive wear ! Replace the rockerarm. 3. Check: S rocker arm shaft Blue discoloration/excessive wear/pitting/scratches ! Replace or check the lubrication system. 4. Measure: S rocker arm inside diameter a Out of specification ! Replace. Rocker arm inside diameter 10.000 10.015 mm <Limit>: 10.035 mm 5. Measure: S rocker arm shaft outside diameter b Out of specification ! Replace. Rocker arm shaft outside diameter 9.981 9.991 mm <Limit>: 9.961 mm 6. Calculate: S rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.08 mm ! Replace the defective part(-s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 0.034 mm <Limit>: 0.08 mm
4-17

EAS00220
ENG
INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: S camshaft Recommended lubricant Camshaft/Bushing Molybdenum disulfide oil 2. Install: S camshaft 1 S camshaft bushing 2
NOTE: S Make sure that the No.1 camshaft 3 is installed in the front cylinder head and the No.2 camshaft 4 is installed in the rear cylinder head.
3. Install: S stopper plate 1
12 Nm (1.2 mSkg)
4. Lubricate: S rocker arm shafts Recommended lubricant Engine oil
4-18

5. Install: S rocker arms S rocker arm shafts
ENG
NOTE: Make sure that the rocker arm shafts is completely pushed into the cylinder head.
4-19
VALVES AND VALVE SPRINGS
ENG
Order
Job/Part Removing the valves and valve springs Cylinder heads Rocker arms and camshafts
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEADS. Refer to ROCKER ARMS AND CAMSHAFTS. Refer to REMOVING/INSTALLING THE VALVES.
1 2 3 4 5 6 7
Valve cotters Valve spring retainers Valve springs Valve (intake) Valve (exhaust) Valve stem seals Valve spring seats
4 2 2 1 1 2 2
Refer to INSTALLING THE VALVES.
4-20

EAS00237
ENG
REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Check: S 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.
2. Remove: S valve cotters NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 1. Valve spring compressor 90890-04019
EAS00239
CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valve and valve guides. 1. Measure: S valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a Valve stem diameter b
4-21
ENG
Out of specification ! Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 0.037 mm <Limit>: 0.08 mm Exhaust 0.025 0.052 mm <Limit>: 0.1 mm
2. Replace. S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven.
a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (5.0 mm) 90890-04097 Valve guide installer (5.0 mm) 90890-04098 3. Eliminate: S carbon deposits (from the valve face and valve seat) 4. Check: S valve face Pitting/wear ! Grind the valve face. S valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve.
4-22
ENG
5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness Intake 0.5 0.9 mm Exhaust 0.7 1.3 mm 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout 0.02 mm
EAS00240
CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: S carbon deposits (from the valve face and valve seat) 2. Check: S valve seat Pitting/wear ! Replace the cylinder head. 3. Measure: S valve seat width a Out of specification ! Replace the cylinder head. Valve seat width limit Intake: 1.6 mm Exhaust: 1.6 mm a. Apply Mechanics blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the valve seat and valve face contacted one another, the blueing will have been removed.
4-23

4. Lap: S valve face S valve seat
ENG
NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.
a. Apply a coarse lapping compound to the valve face.
CAUTION:
Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanics blueing dye (Dykem) 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 impression. j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat.
4-24

EAS00241
ENG
CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length (intake and exhaust) 29.71 mm <Limit>: 27.81 mm 2. Measure: S compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force Intake and exhaust spring 129 N at 25.6 mm 3. Measure: S valve spring tilt c Out of specification ! Replace the valve spring. Spring tilt limit Intake and exhaust valve spring 2.5_ / 1.3 mm
EAS00245
INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: S valve stem end (with an oil stone) 2. Lubricate: S valve stem S oil seal New (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S valve S lower spring seat S oil seal New S valve spring S upper spring seat (into the cylinder head)
4-25
ENG
NOTE: Install the valve spring with the larger pitch a facing up.
b Smaller pitch
4. Install: S valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 . Valve spring compressor 90890-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
CAUTION:
Hitting the valve tip with excessive force could damage the valve.
4-26
CYLINDERS AND PISTONS
ENG
Order
Job/Part Removing the cylinders and pistons Cylinder heads Timing chain guide Cylinder Dowel pins Cylinder gasket Piston pin clips Piston pin Piston Piston ring set
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEADS.
1 2 3 4 5 6 7 8
1 1 2 1 2 1 1 1
Refer to INSTALLING THE PISTONS AND CYLINDERS. Refer to REMOVING/INSTALLING THE CYLINDERS AND PISTONS. For installation, reverse the removal procedure.
4-27

EAS00254
ENG
REMOVING THE PISTONS The following procedure applies to all of the pistons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3
CAUTION:
Do not use a hammer to drive the piston pin out. NOTE: S Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. S For reference during installation, put an identification mark on each piston crown. S Before removing the piston pin, deburr the piston pin clips groove and the pistons 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: S top ring S 2nd ring S oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
EB404405
CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: S piston wall S cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set.
4-28
ENG
2. Measure: S piston-to-cylinder clearance a. Measure cylinder bore C with the cylinder bore gauge. a 45 mm from the top of the cylinder NOTE: Measure cylinder bore C by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Standard Cylinder bore C: 40.99 41.03 mm X+Y 2
Wear limit 41.1 mm
C=
b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter P with the micrometer. b 3 mm from the bottom edge of the piston. Piston size P Standard 40.96 41.00 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 Piston skirt diameter P Piston-to-cylinder clearance 0.02 0.04 mm <Limit>: 0.15 mm f. If out of specification, replace the cylinder, and replace the piston and piston rings as a set.
4-29

EB404410
ENG
CHECKING THE PISTON RINGS 1. Measure: S piston ring side clearance Out of specification ! Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.02 0.08 mm <Limit>: 0.12 mm 2nd ring 0.02 0.06 mm <Limit>: 0.12 mm
2. Install: S piston ring (into the cylinder) NOTE: Using the piston crown pash the ring into the cylinder so that the ring will be at a right angle to the cylinder bore.
a 20 mm from the top of the cylinder 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring.
NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 0.30 mm <Limit>: 0.4 mm 2nd ring 0.15 0.30 mm <Limit>: 0.4 mm Oil ring 0.2 0.7 mm
4-30

EAS00266
ENG
CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Check: S piston pin Blue discoloration/grooves ! Replace, then inspect the lubrication system.
2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 12.996 13.000 mm 3. Measure: S piston pin bore inside diameter b Out of specification ! Replace the piston Piston pin bore inside diameter 13.002 13.013 mm 4. Calculate: S piston-pin-to-piston clearance Out of specification ! Replace the piston pin. Piston-pin-to-piston clearance = Piston pin bore size b Piston pin outside diameter a Piston-pin-to-piston clearance 0.002 0.017 mm
EB404701
INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pistons and cylinders. 1. Install: S oil ring expander S lower oil ring rail S upper oil ring rail S 2nd ring S top ring NOTE: Be sure to install the piston rings so that the manufacuturers marks or numbers face up.
4-31
ENG
2. Install: S piston 1 S piston pin 2 S piston pin clip New 3 NOTE: S Apply engine oil onto the piston pin. S Make sure that the EX mark a on the piston faces towards the exhaust side of the engine. S Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase. 3. Install: S gasket New S dowel pins 4. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring
6. Install: S cylinder
22 Nm (2.2 mSkg)
NOTE: S While compressing the piston rings with one hand, install the cylinder with the other hand. S Pass the timing chain and timing chain guide through the timing chain cavity.
4-32
GENERATOR AND STARTER CLUTCH
ENG

STATOR COIL AND PICKUP COIL
5 Nm (0.5 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
Order
Job/Part Removing the stator coil and pickup coil Engine oil A.C. magneto lead/pickup coil lead Footrest/shift pedal Generator cover Dowel pins Gasket Stator coil Pickup coil
Qty
Remarks Remove the parts in the order listed. Refer to CHANGING THE ENGINE OIL in chapter 3. Refer to ENGINE REMOVAL.
1 2 3 4 5
1 2 1 1 1 For installation, reverse the removal procedure.
4-33

GENERATOR ROTOR AND STARTER CLUTCH
ENG
80 Nm (8.0 mSkg)
Order
Job/Part Removing the generator rotor and starter clutch Generator rotor Starter clutch assembly Starter clutch drive gear Idler gear Idler gear shaft
Qty
1 2 3 4 5
4-34
ENG
REMOVING THE GENERATOR 1. Remove: S footrest/shift pedal Refer to ENGINE REMOVAL. S generator cover
2. Remove: S generator rotor nut 1 S washer NOTE: S While holding the generator rotor 2 with the sheave holder 3 , loosen the generator rotor nut. S Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 4. Remove: S generator rotor 1 (with the flywheel puller set 2 ) S woodruff key
CAUTION:
To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller sets center bolt and the crankshaft. NOTE: Make sure that the flywheel puller is centered over the generator rotor. Flywheel puller set 90890-01361
4-35

EAS00351
ENG
CHECKING THE STARTER CLUTCH 1. Check: S starter clutch idler gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(-s). 2. Check: S starter clutch gears contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear. 3. Check: S starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the starter 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 B , it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.
4-36
ENG
INSTALLING THE GENERATOR 1. Install: S starter clutch assembly S woodruff key S generator rotor S washer S generator nut NOTE: S Clean the tapered portion of the crankshaft and the generator rotor hub. S When installing the generator rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. 2. Tighten: S generator rotor nut 1
80 Nm (8.0 mSkg)
NOTE: S While holding the generator rotor 2 with the sheave holder 3 , tighten the generator rotor nut. S Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701
3. Apply: S sealant (onto stater coil assembly lead grommet) Yamaha bond No.1215 90890-85505
4. Install: S stator coil S generator cover NOTE: Tighten the generator cover bolts in stages and in a crisscross pattern. 5. Install: S footrest/shift pedal
4-37
CLUTCH
ENG
CLUTCH
CLUTCH COVER
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
Order
Job/Part Removing the clutch cover
Qty
WARNING
Securely support the motorcycle so there is no danger of it falling over. Engine oil Drain. Refer to CHANGING THE ENGINE OIL in chapter 3. Refer to ENGINE REMOVAL. 1 1
1 2
Muffler assembly Exhaust pipes Oil filter cover O-ring
4-38
CLUTCH
ENG
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
Order 3 4 5 6
Job/Part Oil filter Clutch cover Dowel pins Clutch cover gasket
Qty 1 1 2 1
Remarks
4-39
CLUTCH
CLUTCH
ENG
80 Nm (8.0 mSkg)
75 Nm (7.5 mSkg) 8 Nm (0.8 mSkg)
8 Nm (0.8 mSkg)
Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Job/Part Removing the clutch Pressure plate Push plate 1 Friction plate Clutch plate Push rod (short) Ball Push rod (long) Clutch boss nut Lock washer Clutch boss Holding plate Clutch housing Nut Lock washer
Qty 1 1 5 4 1 1 1 1 1 1 1 1 1 1
4-40
CLUTCH
ENG
80 Nm (8.0 mSkg)
75 Nm (7.5 mSkg) 8 Nm (0.8 mSkg)
8 Nm (0.8 mSkg)
Order 15 16 17 18
Job/Part Washer Primary drive gear Spacer Key
Qty 1 1 1 1
Remarks
4-41
CLUTCH
PUSH LEVER SHAFT
ENG
12 Nm (1.2 mSkg)
Order 1 2 3 4 5
Job/Part Removing the push lever shaft Push lever Spring Circlip Oil seal Bearing
Qty 1 1 1 1 1
4-42
CLUTCH
EAS00276
ENG
REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder, loosen the clutch boss nut. Universal clutch holder 90890-04068 3. Remove: S clutch boss nut 1 S lock washer 2 S clutch boss 3
EAS00279
REMOVING THE PRIMARY DRIVE GEAR 1. Straighten the lock washer tab. 2. Remove: S primary drive gear nut 1 S lock washer 2 NOTE: S While holding the generator rotor with the sheave holder, loosen the primary drive gear nut. S Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701
4-43
CLUTCH
EAS00280
ENG
CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: S friction plate Damage/wear ! Replace the friction plates as a set. 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 3.1 mm <Limit>: 2.5 mm
EAS00281
CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set. Clutch plate warpage limit Less than 0.05 mm
4-44
CLUTCH
EAS00282
ENG
CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: S clutch spring Damage ! Replace the clutch springs as a set.
2. Measure: S clutch spring free length Out of specification ! Replace the clutch springs as a set. Clutch spring free length 34.6 mm <Limit>: 33.6 mm
EAS00284
CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation.
EAS00285
CHECKING THE CLUTCH BOSS 1. Check: S clutch boss splines Damage/pitting/wear ! Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation.
4-45
CLUTCH
EAS00286
ENG
CHECKING THE PRESSURE PLATE 1. Check: S pressure plate 1 Cracks/damage ! Replace.
EAS00288
CHECKING THE CLUTCH PUSH RODS 1. Check: S O-ring 1 S short clutch push rod 2 S long clutch push rod 3 S ball 4 Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: S long clutch push rod bending limit Out of specification ! Replace the long clutch push rod. Long clutch push rod bending limit 0.5 mm
EAS00292
CHECKING THE PRIMARY DRIVE GEAR 1. Check: S primary drive gear 1 S primary driven gear 2 Damage/wear ! Replace the primary drive and primary driven gears as a set. Excessive noise during operation ! Replace the primary drive and primary driven gears as a set. 2. Check: S primary -drive-gear-to-primary-driven-gear free play Free play exists ! Replace the primary drive and primary driven gears as a set.
4-46
CLUTCH
ENG
INSTALLING THE PRIMARY DRIVE GEAR 1. Install: S straight key S primary drive gear 1 S thrust washer S lock washer 2 S primary drive gear nut 3
80 Nm (8.0 mSkg)
NOTE: While holding the generator rotor with the sheave holder, tighten the primary drive gear nut. Sheave holder 90890-01701
EAS00298
INSTALLING THE CLUTCH 1. Install: S clutch housing 1 S thrust washer 2 S clutch boss 3 S lock washer S clutch boss nut NOTE: Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss. 2. Tighten: S clutch boss nut 1
75 Nm (7.5 mSkg)
NOTE: While holding the clutch boss with the universal clutch holder, tighten the clutch boss nut. Universal clutch holder 90890-04086 3. Bend the lock washer tab along a flat side of the nut. 4. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil
4-47
CLUTCH
5. Install: S friction plates S clutch plates
ENG
NOTE: S First, install a friction plate and then alternate between a clutch plate and a friction plate. S Align the slot a in the friction plates with the marks b in the clutch housing. 6. Install: S long clutch push rod S ball 7. Install: S short clutch push rod 1 S O-ring 2 New S push plate 3 S washer 4 S nut 5
8. Install: S pressure plate 1 S clutch springs 2 S clutch spring bolts 3
8 Nm (0.8 mSkg)
NOTE: S Align the punch mark a in the clutch boss with the punch mark b in the pressure place. S Tighten the clutch spring bolts in stages and in a crisscross pattern.
9. Check: S push lever position Push lever mark a and crankcase mark b not aligned ! Correct. NOTE: Push the push lever in direction c and make sure that the marks are aligned.
4-48
CLUTCH
10. Adjust: S push lever position
ENG
a. Loosen the locknut 1 . b. Turn the adjusting screw 2 in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification.
CAUTION:
Do not overtighten the locknut since this will remove the free play between both push rods. Push lever lock nut 8Nm (0.8mSkg)
11. Install: S clutch cover 1
10 Nm (1.0 mSkg)
NOTE: Tighten the clutch cover bolts in stages and in a crisscross pattern.
4-49
OIL PUMP
ENG
OIL PUMP
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
Order
Job/Part Removing the oil pump Engine oil Clutch cover Clutch Circlip Washers Oil pump drive gear O-rings Oil pump
Qty
Remarks Remove the parts in the order listed. Drain. Refer to REMOVING THE CLUTCH COVER. Refer to REMOVING THE CLUTCH.
1 2 3 4 5
4-50
OIL PUMP
ENG
7 Nm (0.7 mSkg)
Order
1 2 3 4 5 6 7
Job/Part Disassembling the oil pump Oil pump cover Inner rotor Outer rotor Dowel pins Dowel pin Oil pump driven gear Housing
Qty 1 1 1 2 1 1 1
Remarks Disassemble the parts in the order listed.
For assembly, reverse the disassembly procedure.
4-51
OIL PUMP
ENG
CHECKING THE OIL PUMP 1. Check: S oil pump drive gear 1 S oil pump driven gear 2 S oil pump housing S oil pump housing cover Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: S inner-rotor-to-outer-rotor-tip clearance a S outer-rotor-to-oil-pump-housing clearance b S oil-pump-housing-to-inner-rotor-and-outerrotor clearance c Out of specification ! Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.15 mm <Limit>: 0.2 mm Outer-rotor-to-oil-pump-housing clearance 0.03 0.09 mm <Limit>: 0.15 mm Oil-pump-housing-to-inner-rotorand-outer-rotor clearance 0.03 0.09 mm <Limit>: 0.15 mm 3. Check: S oil pump operation Unsmooth ! Repeat steps (1) and (2) or replace the defective part(-s).
EAS00375
ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil
4-52
OIL PUMP
ENG
2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5 S pins 6 S oil pump housing 7 S screw 7 Nm (0.7 mSkg) NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4 . 3. Check: S oil pump operation Refer to CHECKING THE OIL PUMP.
EAS00376
INSTALLING THE OIL PUMP 1. Install: S O-ring S oil pump 1 S oil pump drive gear 2
7 Nm (0.7 mSkg)
CAUTION:
After tightening the bolts, make sure that the oil pump turns smoothly.
4-53
SHIFT SHAFT
ENG
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
Order
Job/Part Removing the shift shaft and stopper lever Engine oil
Qty
Remarks Remove the parts in the order listed. Drain. Refer to CHANGING THE ENGINE OIL in chapter 3. Refer to CLUTCH. Refer to OIL PUMP.
1 2 3 4 5
Clutch cover Clutch Oil pump drive gear Circlip Shift lever Spring Shift lever arm Shift shaft
1 1 1 1 1
4-54
SHIFT SHAFT
ENG
Order 6 7
Job/Part Shift cam stopper lever Collar
Qty 1 1
Remarks
4-55
SHIFT SHAFT
EAS00328
ENG
CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 S stopper lever 2 Bends/damage/wear ! Replace S stopper lever spring 3 Roller turns roughly ! Replace the shift lever.
EB408410
CHECKING THE SHIFT LEVER 1. Check: S shift lever 1 Bends/damage/wear ! Replace. S shift lever spring 2 Damage/wear ! Replace.
INSTALLING THE SHIFT SHAFT 1. Install: S stopper lever 1 S stopper lever spring 2 S shift shaft lever 3 NOTE: S Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss. S Mesh the stopper lever with the shift drum segment assembly.
4-56
CRANKSHAFT AND CONNECTING RODS
ENG

CRANKSHAFT ASSEMBLY
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
Order
Job/Part Removing the crankshaft assembly Engine assembly Cylinder head Cylinder and piston Clutch assembly A.C. magneto and starter clutch Shift shaft Oil pump Primary drive gear Chain guide Timing chain holder Timing chain
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE REMOVAL. Refer to CYLINDER HEADS. Refer to CYLINDER AND PISTONS. Refer to CLUTCH. Refer to GENERATOR AND STARTER CLUTCH. Refer to SHIFT SHAFT. Refer to OIL PUMP. Refer to CLUTCH.
1 2 3
4 1 2
4-57
ENG
10 Nm (1.0 mSkg)
10 Nm (1.0 mSkg)
Order 4 5 6
Job/Part Timing chain drive gear Crankcase (right) Dowel pins
Qty 1 1 2
Remarks
4-58

ENG
Order
Job/Part Removing the crankshaft and connecting rods Timing chain drive gear Bearings Crank Washer Crank pin Connecting rod
Qty
1 2 3 4 5 6
2 2 2 3 1 2 For installation, reverse the removal procedure.
4-59

EAS00386
ENG
DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). S The numbers embossed on the crankcase indicate the crankcase tightening sequence.
2. Remove: S right crankcase NOTE: For this removal, slits a in the crankcase can be use as shown.
CAUTION:
Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly.
4-60

EAS00394
ENG
CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: S crankshaft runout Out of specification ! Replace the crankshaft, bearing or both. NOTE: Turn the crankshaft slowly. Crankshaft runout Less than 0.03 mm 2. Measure: S big end side clearance Out of specification ! Replace the big end bearing, crankshaft pin, or connecting rod. Big end side clearance 0.40 1.05 mm Limit 1.5 mm 3. Measure: S crankshaft width Out of specification ! Replace the crankshaft. Crankshaft width 67.95 68.00 mm
4. Check: S crankshaft sprocket 1 Damage/wear ! Replace the crankshaft. S bearing 2 Cracks/damage/wear ! Replace the crankshaft.
5. Check: S crankshaft journal Scratches/wear ! Replace the crankshaft. S crankshaft journal oil passage Obstruction ! Blow out with compressed air.
4-61

EAS00401
ENG
CHECKING THE BEARINGS AND OIL SEALS 1. Check: S bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2. Check: S oil seals Damage/wear ! Replace.
EAS00207
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1. Check: S timing chain Damage/stiffness ! Replace the timing chain and camshaft sprocket as a set.
2. Check: S camshaft sprocket More than 1/4 tooth a wear ! Replace the camshaft sprocket and the timing chain as a set. a 1 / 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3. Check: S timing chain guide (exhaust side) S timing chain guide (intake side) Damage/wear ! Replace the defective part(-s).
4-62

EAS00408
ENG
INSTALLING THE CRANKSHAFT 1. Install: S crankshaft assembly 1
CAUTION:
To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing.
EAS00418
ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery a . 3. Install: S dowel pins 1
4. Tighten: S crankcase left half

7 Nm (0.7 mSkg)
NOTE: Tighten the screws in decreasing numerical order (see numbers on the illustration).
4-63
TRANSMISSION TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
ENG
Order
Job/Part Removing the transmission, shift drum assembly and shift forks Crankcase separating
Qty
Remarks Remove the parts in the order listed. Refer to CRANKCASE AND CRANKSHAFT.
1 2 3 4 5 6 7 8
Shift fork guide bar 2 (short length) Shift fork guide bar 1 (long length) Shift drum Shift fork 1 C (center) Shift fork 2 R (right) Shift fork 3 L (left) Main axle assembly Drive axle assembly
1 1 1 1 1 1 1 1
Refer to INSTALLING THE TRANSMISSION, SHIFT FORK AND SHIFT DRUM ASSEMBLY. Refer to REMOVING THE TRANSMISSION. For installation, reverse the removal procedure.
4-64
TRANSMISSION
ENG
Order
Job/Part Disassembling the drive axle and main axle Bearing Circlip Washer First wheel gear Forth wheel gear Third wheel gear Fifth wheel gear Second wheel gear Drive axle Second pinion gear Fifth pinion gear Third pinion gear Forth pinion gear Main axle Collar
Qty
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the removal procedure.
4-65
TRANSMISSION
EAS00420
ENG
REMOVING THE TRANSMISSION 1. Remove: S drive axle assembly 1 S main axle assembly 2 Remove them at same the time.
EAS00421
CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: S shift fork cam follower 1 S shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork.
2. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends ! Replace.
WARNING
Do not attempt to straighten a bent shift fork guide bar.
3. Check: S 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: S shift drum grooves Damage/scratches/wear ! Replace the shift drum. S shift drum segment Damage/wear ! Replace. S shift drum bearing Damage/pitting ! Replace.
4-66
TRANSMISSION
EAS00424
ENG
CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. Main axle runout limit 0.08 mm 2. Measure: S drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. Drive axle runout limit 0.08 mm
3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s).
S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s). 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. NOTE: When reassembling the main axle, press the 2nd pinion gear 1 onto it 2 as shown. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(-s). 6. Check: S circlips Damage/bends/looseness ! Replace.
87.2
87.4 mm
4-67
TRANSMISSION
EAS00426
ENG
INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: S shift fork 3 L (left) 1 (face the L side for the clutch side.) S shift fork 2 R (right) 2 (face the R side for the clutch side.) S shift fork 1 C (center) 3 (face the C side for the magneto side.) S shift fork guide bar 1 4 (long) S shift fork guide bar 2 5 (short) NOTE: Install the shift forks with the embossed mark to the right and in sequence (R, C, L) beginning from the right.
2. Check: S shift drum operation Unsmoothy operation ! Repair. NOTE: Check the transmission and shift forks for smooth operation by turning the shift drum with your hand.
4-68
CARB
CHAPTER 5. CARBURETOR
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-4 5-6 5-7 5-7 5-9 5-12 5-12 5-12 5-13
CARB
CARBURETOR
CARB
CARBURETOR
CARBURETOR
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
Order
Job/Part Removing the carburetor Fuel tank Air filter case assembly Silencer assembly Fuel hose Throttle position sensor lead Carburetor heater lead Carburetor Starter cable Throttle cables Thermo lead
Qty
Remarks Remove the parts in the order listed. Refer to FUEL TANK in chapter 3.
1 2 3 4 5 6 7 8 9
1 1 1 1 2 1 1 2 1
Disconnect. Disconnect. Disconnect.
5-1
CARBURETOR
CARB
Order
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16
Job/Part Disassembling the carburetor Vacuum chamber cover Piston valve spring Piston valve Jet needle holder set Jet needle set Fuel drain bolt Float chamber Float Needle valve Main jet Main jet holder Pilot screw Starter plunger Pilot air screw Heater Pilot jet
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks Disassemble the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
5-2
CARBURETOR
CARB
Order
17 18
Job/Part Throttle stop screw Throttle position sensor
Qty 1 1
Remarks
5-3
CARBURETOR
EB600031
CARB
CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic-carburetorcleaning solution. b. Blow out all of the passages and jets with compressed air. 3. Check: S float chamber body Dirt ! Clean. 4. Check: S float chamber rubber gasket Cracks/damage/wear ! Replace.
5. Check: S float Damage ! Replace.
6. Check: S needle valve 1 S needle valve seat 2 S O-ring 3 Damage/obstruction/wear ! Replace the needle valve, needle valve seat and O-ring as a set.
5-4
CARBURETOR
CARB
7. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace.
8. Check: S vacuum chamber cover 1 S piston valve spring 2 S plastic cap 3 S plastic cap 4 S spring 5 Cracks/damage ! Replace.
9. Check: S jet needle 1 S needle jet 2 S main jet 3 S Pilot screw 4 S pilot jet 5 S main air jet 6 Bends/damage/wear ! Replace. Obstruction ! Clean. Blow out the jets with compressed air. 10. Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness ! Replace the piston valve.
11. Check. S fuel feed pipes S hose joint Cracks/damage ! Replace. Obstruction ! Clean. Blow out the pipes with compressed air. 12. Check: S fuel feed hoses S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air.
5-5
CARBURETOR
EB600042
CARB
ASSEMBLING THE CARBURETOR NOTE: Before disassemblling the carburetor, make sure to note the number of times, the pilot screw is turned out from the seated position to its set position.
CAUTION:
S Before assembling the carburetors, wash all of the parts in a petroleum-based solvent. S Always use a new gasket.
1. Install: S main jet holder 1 S main jet 2 S pilot jet 3 2. Install: S needle valve seat
3. Install: S needle valve S float 1 S float pin 2
4. Install: S float chamber S pilot screw S piston valve S piston valve spring S vacuum chamber cover
5-6
CARBURETOR
EB600051
CARB
INSTALLING THE CARBURETOR 1. Adjust: S engine idling speed Engine idling speed 1,250 1,450 r/min Refer to ADJUSTING THE ENGINE IDLLING SPEED in chapter 3. 2. Adjust: S throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 5 mm Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3.
EB600063
MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (above the line on the float chamber b ) 9.5 10.5 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. Loosen the fuel drain screw 3 . e. Hold the fuel level gauge vertically next to the upper face of the float chamber. f. Measure the fuel level a . NOTE: Fuel level readings should be equal on both sides of the carburetor assembly.
5-7
CARBURETOR
2. Adjust: S fuel level
CARB
a. Remove the carburetor assembly. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1 . e. Install the carburetor assembly. f. Measure the fuel level again. g. Repeat steps (a) to (f) until the fuel level is within specification.
5-8
CARBURETOR
EAS00502
CARB
THE
CHECKING AND ADJUSTING THROTTLE POSITION SENSOR
NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: S throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sensor coupler from the wire harness. b. Connect the pocket tester ( 1k) to the throttle position sensor coupler. Positive tester probe ! blue terminal 1 Negative tester probe ! black terminal 2 c. Measure the maximum throttle position sensor resistance. Out of specification ! Replace the throttle position sensor. Maximum throttle position sensor resistance 4.0 X 6.0 k at 20_C (blue black) d. Connect the pocket tester ( throttle position sensor. 1k) to the
Positive tester probe ! yellow terminal 3 Negative tester probe ! black terminal 2 e. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified. Out of specification or the resistance changes abruptly ! Go to step 2 below. Throttle position sensor resistance (520 X 900 ) X (4.0 X 6.0 k) at 20_C (yellow black)
5-9
CARBURETOR
CARB
2. Check: S throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sensor coupler from the wire harness. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester ( 1k) to the throttle position sensor. Positive tester probe ! blue terminal 1 Negative tester probe ! black terminal 2 d. Measure the maximum throttle position sensor resistance. Out of specification ! Replace the throttle position sensor. Maximum throttle position sensor resistance 4.0 X 6.0 k at 20_C (blue black) e. Connect the pocket tester ( throttle position sensor coupler. 1k) to the
Positive tester probe ! yellow terminal 3 Negative tester probe ! black terminal 2 f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor. The slot is worn or broken ! Replace the throttle position sensor. NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified. Throttle position sensor resistance 0 X 5 1.0 k at 20_C (yellow black)
5-10
CARBURETOR
CARB
3. Adjust: S throttle position sensor angle a. Disconnect the throttle position sensor coupler from the wire harness. b. Connect the pocket tester ( 1k) to the throttle position sensor coupler. Positive tester probe ! blue terminal 1 Negative tester probe ! black terminal 2 c. Measure the throttle position sensor maximum resistance. d. Calculate the throttle position sensor maximum resistance when the throttle is fully closed. Throttle position sensor maximum resistance (throttle is fully closed) = Maximum resistance (0.13 0.15) Example If the maximum resistance = 5 k, then the throttle position sensors maximum resistance when the throttle is fully closed should be: 5 k (0.13 0.15) = 650 750 Lift the carburetor assembly slightly out of the intake manifolds. Loosen the throttle position sensor screws 4 . Connect the pocket tester ( 100) to the throttle position sensor. Positive tester probe ! yellow terminal 3 Negative tester probe ! black terminal 2 e. Adjust the throttle position sensor angle so that the measured resistance is within the specified range. Throttle position sensor resistance 650 750 (yellow black terminal) After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.
5-11
FUEL PUMP
CARB
CHECKING THE FUEL PUMP 1. Check: S fuel pump a. Turn the fuel cock OFF. b. Disconnect the fuel hose. (fuel pump-carburetor) c. Place a container under the fuel hose end. d. Turn the main switch to ON. e. Push the START switch. f. Check the fuel flows out from the fuel hose end. If fuel does not flow ! Clean or replace the fuel pump.
DISASSEMBLING THE FUEL PUMP Turn the fuel cock OFF. 1. Remove: S fuel hoses S pulser hose S fuel pump
2. Remove: S fuel pump cover 1 S diaphragm 2 S fuel pump body 3 S fuel pump cover 4
3. Check: S fuel pump body 1 Obstruction ! Clean. Cracks/damage ! Replace fuel pump assembly.
5-12
FUEL PUMP
CARB
4. Check: S diaphragms and gaskets Turn/fatigue/cracks ! Replace fuel pump assembly. 5. Check: S valves 1 Cracks/damage ! Replace fuel pump assembly.
ASSEMBLING THE FUEL PUMP Reverse the disassembly procedure. NOTE: Be sure to connect the hoses correctly.
5-13
CHAS
CHAPTER 6. CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SPEEDOMETER GEAR UNIT . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET . CHECKING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLILNG THE BRAKE SHOE PLATE . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . CHECKING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . CHECKING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . ASSEMBLLING AND INSTALLILNG THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLILNG THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-3 6-3 6-5 6-7 6-7 6-9 6-11 6-11 6-12 6-15 6-16 6-16 6-16 6-17 6-18 6-19 6-19 6-20 6-20 6-22 6-24 6-26 6-27 6-28 6-30 6-32 6-33 6-34 6-36 6-39 6-39 6-41 6-41 6-45 6-46 6-48 6-48 6-49
CHAS
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES . . . . . REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 6-52 6-54 6-54 6-55 6-57 6-57 6-58 6-59 6-59 6-60 6-60 6-61 6-62 6-62 6-64 6-66 6-67
FRONT WHEEL AND BRAKE DISC
CHAS
CHASSIS
40 Nm (4.0 mSkg) 59 Nm (5.9 mSkg)
20 Nm (2.0 mSkg) 23 Nm (2.3 mSkg)
Order
Job/Part Removing the front wheel and brake disc
Qty
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
WARNING
Securely support the motorcycle so there is no danger of it falling over. 1 2 3 4 5 6 7 Brake caliper Front wheel axle pinch bolt Front wheel axle Front wheel assembly Collars Speedometer gear Brake disc 1 1 1 1 1 1 1 Refer to REMOVING/INSTALLING THE FRONT WHEEL. Refer to INSTALLING THE FRONT WHEEL. For installation, reverse the removal procedure.
6-1
CHAS
Order
1 2 3 4 5
Job/Part Disassembling the front wheel Oil seals Speedometer clutch retainer Speedometer clutch Bearings Collar
Qty 2 1 1 2 1
6-2

EAS00519
CHAS
REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: S brake caliper 1 NOTE: Do not squeeze the brake lever when removing the brake caliper. 3. Remove: S pinch bolt (front wheel axle) 2 S front wheel axle 3 4. Elevate: S front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
EAS00526
CHECKING THE FRONT WHEEL 1. Check: S wheel axle Roll the wheel axle on a flat surface. Bends ! Replace.
WARNING
Do not attempt to straighten a bent wheel axle. 2. Check: S tire S front wheel Damage/wear ! Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3.
6-3
CHAS
3. Check: S spokes Bends/damage ! Replace. Loose ! Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: S spokes
3 Nm (0.3 mSkg)
NOTE: After tightening the spokes, measure the front wheel runout. 5. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. Front wheel radial runout limit 2.0 mm Front wheel lateral runout limit 2.0 mm 6. Check: S collars Damage/wear ! Replace.
WARNING
S New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any highspeed riding is done. 7. Check: S wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. S oil seals Damage/wear ! Replace. 8. Replace: S wheel bearings New S oil seals New
6-4
CHAS
a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface. c. Remove the wheel bearings with a general bearing puller 2 . d. Install the new wheel bearings and oil seals in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center race 4 or balls 5 . Contact should be made only with the outer race 6 . NOTE: Use a socket 3 that matches the diameter of the wheel bearing outer race and oil seal.
EAS00531
CHECKING THE BRAKE DISC 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection 1 Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.15 mm a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary.
6-5
CHAS
c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the center part of the brake disc that the brake pads touches.
3. Measure: S brake disc thickness 1 Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) Front: 4.5 mm 4. Adjust: S brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 mSkg) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
6-6
CHAS
CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: S speedometer clutch Bends/damage/wear ! Replace. 2. Check: S speedometer drive gear 1 S speedometer driven gear 2 Damage/wear ! Replace.
EAS00542
INSTALLING THE FRONT WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips S speedometer drive gear S speedometer driven gear Recommended lubricant Lithium soap base grease 2. Install: S speedometer gear unit NOTE: Make sure that the speedometer gear unit and the wheel hub are installed with the two projections meshed into the two slots respectively.
3. Install: S front wheel assembly NOTE: S Make sure that the slot b in the speedometer gear unit fits over the stopper c on the outer tube. S The arrow mark a on the tire must point in the direction of the wheel.
6-7

4. Tighten: S wheel axle 1 S wheel axle pinch bolt 2 S brake caliper bolts 3
CHAS
WARNING
Make sure that the brake cable is routed properly.
CAUTION:
Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
6-8

EAS00549
CHAS
ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1. Remove: S balancing weight (-s) NOTE: Place the front wheel on a suitable balancing stand. 2. Find: S front wheels 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 (b) through (d) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheels heavy spot X. 3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rimexactly opposite the heavy spot X. NOTE: Start with the lightest weight. b. Turn the front wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.
6-9
CHAS
4. Check: S front 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.
6-10
REAR WHEEL AND REAR BRAKE
CHAS

REAR WHEEL
23 Nm (2.3 mSkg)
104 Nm (10.4 mSkg)
16 Nm (1.6 mSkg)
16 Nm (1.6 mSkg)
Order
Job/Part Removing the rear wheel
Qty
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevant.
1 2 3 4 5 6 7 8 9
Tension bar Adjuster Pin Compression spring Rear wheel axle Nut/washer Lock nut/nut/washer Chain pullers Rear wheel assembly
1 1 1 1 1 1/1 2/2/2 2 1 For installation, reverse the removal procedure.
6-11

REAR BRAKE AND REAR WHEEL SPROCKET
CHAS
40 Nm (4.0 mSkg)
Order
Job/Part Removing the rear brake and rear wheel sprocket Shoe plate Sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub dampers Rear wheel
Qty
1 2 3 4 5 6 7 8
1 1 3 1 1 1 4 1 For installation, reverse the removal procedure.
6-12
CHAS
Order
1 2
Job/Part Disassembling the rear wheel Bearings Spacer
Qty 2 1
6-13
CHAS
10 Nm (1.0 mSkg)
Order
1 2 3 4 5 6
Job/Part Disassembling the brake shoe plate Brake shoe Tension springs Camshaft lever Indicator plate Camshaft Brake shoe plate
Qty 2 2 1 1 1 1
Remarks Disassemble the parts in the order listed. Refer to REMOVING THE REAR WHEEL/ASSEMBLING THE BRAKE SHOE PLATE. For assembly, reverse the disassembly procedure.
6-14

EAS00563
CHAS
REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S tension bar 1 3. Remove: S wheel axle 2 S rear wheel NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. 4. Remove: S brake shoe plate 5. Remove: S brake shoes 1 S brake camshaft lever 2 NOTE: Mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft.
6-15

EAS00566
CHAS
CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to FRONT WHEEL. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3. 3. Check: S spokes Refer to FRONT WHEEL. 4. Measure: S rear wheel radial runout S rear wheel lateral runout Refer to FRONT WHEEL.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub 1 Cracks/damage ! Replace. S rear wheel drive hub dampers 2 Damage/wear ! Replace.
EAS00568
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: S rear wheel sprocket More than 1/4 tooth a wear ! Replace the rear wheel sprocket. Bent teeth ! Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket 2. Replace: S 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.
6-16
CHAS
Rear wheel sprocket self-locking nut 40 Nm (4.0 mSkg) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern.
EAS00569
CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: S brake shoe lining Glazed areas ! Repair. Sand the glazed areas with course sandpaper. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. 2. Measure: S brake shoe lining thickness a Out of specification ! Replace. Brake shoe lining thickness limit (minimum) 2 mm
WARNING
Do not allow oil or grease to contact the brake shoes. NOTE: Replace the brake shoes as a set, if either is worn to the wear limit. 3. Measure: S brake drum inside diameter b Out of specification ! Replace the wheel. Brake drum inside diameter limit (maximum) 131 mm
6-17
CHAS
4. Check: S brake drum inner surface Oil deposits ! Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches ! Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: S brake camshaft Damage/wear ! Replace.
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE 1. Install: S brake camshaft 1 S spring S brake shoe wear indicator 2 a. Install the camshaft lever so its punch mark c is positioned as shown. b. Align the projection a on the brake shoe wear indicator with the notch b in the brake shoe camshaft. c. Check that the brake shoes are properly positioned.
6-18

EAS00571
CHAS
INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: S drive chain slack Drive chain slack 30 40 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3. 3. Tighten: S wheel axle nut 104 Nm (10.4 mSkg)
WARNING
Make sure that the brake hose is routed properly.
EAS00575
ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: S rear wheel static balance Refer to FRONT WHEEL.
6-19
FRONT AND REAR BRAKES
CHAS

FRONT BRAKE PADS
27 Nm (2.7 mSkg)
Order 1 2 3 4
Job/Part Removing front brake pads Retaining bolt Brake caliper Brake pads Pad spring
Qty 2 1 2 3
Remarks Remove the parts in the order listed. Refer to REPLACING THE FRONT BRAKE PADS. For installation, reverse the removal procedure.
6-20

EAS00579
CHAS
CAUTION:
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: S Never disassemble brake components unless absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. S Never use solvents on internal brake components. S Use only clean or new brake fluid for cleaning brake components. S Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt fluid immediately. S Avoid brake fluid coming into contact with the eyes as it can cause serious injury. First aid for brake fluid entering the eyes: S Flush with water for 15 minutes and get immediate medical attention.
6-21

EAS00581
CHAS
REPLACING THE FRONT BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: S retaining bolt 1 2. Remove: S brake caliper 2 3. Remove: S brake pad spring 1 S brake pads 2
4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.8 mm 5. Install: S brake pad spring S brake pads NOTE: Always install new brake pads and a new 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 mSkg) d. Install new brake pads and brake pad spring. 6. Lubricate: S retaining bolts 1
6-22
CHAS
Recommended lubricant Lithium soap base grease
CAUTION:
S Do not allow grease to contact the brake pads. S Remove any excess grease. 7. Install: S brake caliper S retaining bolt 27 Nm (2.7 mSkg) 8. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 9. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
6-23

FRONT BRAKE MASTER CYLINDER
CHAS
7 Nm (0.7 mSkg)
30 Nm (3.0 mSkg)
Order
Job/Part Removing the front brake master cylinder Brake fluid Rear view mirror Brake lever/compression spring Front brake switch Union bolt Copper washers Brake hose Master cylinder bracket Master cylinder
Qty
Remarks Remove the parts in the order listed. Drain.
1 2 3 4 5 6 7 8
1 1/1 1 1 2 1 1 1 For installation, reverse the removal procedure.
6-24
CHAS
Order
Job/Part Disassembling the front brake master cylinder Dust boot Circlip Master cylinder cup Spring
Qty
1 2 3 4
1 1 1 1 For assembly, reverse the disassembly procedure.
6-25

EAS00588
CHAS
REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before removing the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: S rear view mirror (right) S brake lever/compression spring S brake switch 1 2. Remove: S union bolt 2 S copper washers S brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 3. Remove: S master cylinder bracket S master cylinder
6-26

EAS00592
CHAS
CHECKING THE FRONT BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages 2 (brake master cylinder body) Obstruction ! Blow out with compressed air. 2. Check: S brake master cylinder kit 1 Damage/scratches/wear ! Replace.
3. Check: S brake fluid reservoir 1 Cracks/damage ! Replace. S brake fluid reservoir diaphragm 2 Cracks/damage ! Replace.
4. Check: S brake hoses 1 Cracks/damage/wear ! Replace.
6-27

EAS00598
CHAS
INSTALLING THE FRONT BRAKE MASTER CYLINDER
WARNING
S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: S brake master cylinder 1 S brake master cylinder bracket 2
7 Nm (0.7 mSkg)
NOTE: S Install the brake master cylinder bracket with the UP mark facing up. S Align the end of the brake master cylinder holder with the punch mark a on the handlebar. S First, tighten the upper bolt, then the lower bolt. 2. Install: S copper washers New 1 S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to CABLE ROUTING. NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts (e. g., wire harness, cables, leads). Correct if necessary. 3. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4
6-28
FRONT AND REAR BRAKES WARNING
CHAS
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 6. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
6-29

EAS00612
CHAS
FRONT BRAKE CALIPER
30 Nm (3.0 mSkg)
27 Nm (2.7 mSkg)
Order
Job/Part Removing the front brake caliper Brake fluid Brake hose holder Union bolt Copper washer Brake hose Retaining bolt Brake caliper assembly
Qty
Remarks Remove the parts in the order listed. Drain.
1 2 3 4 5 6
1 1 2 1 2 1
Refer to REMOVING/INSTALLING THE FRONT BRAKE CALIPER. For installation, reverse the removal procedure.
6-30
CHAS
6 Nm (0.6 mSkg)
Order
Job name/Part name Disassembling the front brake calipers Pad spring Brake caliper pistons Dust seals Caliper piston seals Bleed screw
Qty
1 2 3 4 5
1 2 2 2 1
Refer to REMOVING THE FRONT BRAKE CALIPERS. For assembly, reverse the disassembly procedure.
6-31

EAS00619
CHAS
DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.
WARNING
S Cover the brake caliper pistons with a rag. Be careful not to get injured when the pistons are expelled from the brake caliper. S Never try to pry out the brake caliper pistons. b. Remove the brake caliper piston seals.
6-32

EAS00633
CHAS
CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule: Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every two years Every two years and whenever the brake is disassembled.
1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. Piston assembly. S brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. S brake calipers 3 Cracks/damage ! Replace. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air.
WARNING
Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
2. Check: S brake caliper brackets 1 Cracks/damage ! Replace.
6-33
CHAS
THE
ASSEMBLING AND INSTALLING FRONT BRAKE CALIPER
WARNING
S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install: S brake caliper 1 (temporarily) S copper washers New 2 S brake hose 3 S union bolt 4 30 Nm (3.0 mSkg)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to CABLE ROUTING.
CAUTION:
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. Install: S brake pads S brake pad springs S brake caliper retaining bolt S brake caliper Refer to REPLACING THE BRAKE PADS.
27 Nm (2.7 mSkg)
6-34
CHAS
3. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4
WARNING
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. 6. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
6-35
FRONT FORK
EAS00646
CHAS
FRONT FORK
20 Nm (2.0 mSkg) 23 Nm (2.3 mSkg)
7 Nm (0.7 mSkg)
30 Nm 3.0 mSkg)
40 Nm (4.0 mSkg) 7 Nm (0.7 mSkg)
Order
Job/Part Removing the front fork Front wheel
Qty
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE DISC.
1 2 3 4 5 6 7 8
Brake hose holder Brake caliper assembly Front fender Turn signal light pinch bolts Upper bracket pinch bolts Cap bolts Lower bracket pinch bolts Front fork legs
1 1 1 2 2 2 2 2
Loosen. Loosen. Loosen. Loosen. For installation, reverse the removal procedure.
6-36
FRONT FORK
CHAS
23 Nm (2.3 mSkg)
30 Nm (3.0 mSkg)
Order
1 2 3 4 5 6 7 8 9
10 11
Job name/Part name Disassembling the front fork Cap bolt O-ring Spacer Spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod/rebound spring Oil seal
Qty 1 1 1 1 1 1 1 1 1 1/1 1
Refer to DISASSEMBLING/ASSEMBLING THE FRONT FORK LEGS.
6-37
FRONT FORK
CHAS
23 Nm (2.3 mSkg)
30 Nm (3.0 mSkg)
Order
12 13 14 15 16
Job name/Part name Seal spacer Outer tube bushing Inner tube/inner tube bushing Oil lock piece Outer tube
Qty 1 1 1/1 1 1
Remarks
Refer to DISASSEMBLING/ASSEMBLING THE FRONT FORK LEGS. For assembly, reverse the disassembly procedure.
6-38
FRONT FORK
EAS00649
CHAS
REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loosen: S cap bolt 1 S upper bracket pinch bolt 2 S lower bracket pinch bolt 3 S front turn signal pinch bolt 4
WARNING
Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 3. Remove: S front fork leg
DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: S cap bolt S O-ring S spacer S spring seat S fork spring 2. Drain: S fork oil 3. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver)
6-39
FRONT FORK CAUTION:
CHAS
Do not scratch the inner tube. 4. Remove: S damper rod bolt S copper washer NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the damper rod bolt 3 . Damper rod holder 90890-01365 T-Handle 90890-01326 5. Remove: S damper rod S 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 carefully.
CAUTION:
S Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. S Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.
6-40
FRONT FORK
EAS00657
CHAS
CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace.
WARNING
Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: S spring free length a Over the specified limit ! Replace. Spring free length limit 299.4 mm
3. Check: S damper rod 1 Damage/wear ! Replace. Obstruction ! Blow out all of the oil passages with compressed air. S oil lock piece 2 Damage ! Replace.
CAUTION:
S When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: S cap bolt O-ring Damage/wear ! Replace.
EAS00659
ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
WARNING
S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor handling and a loss of stability.
6-41
FRONT FORK
CHAS
NOTE: S When assembling the front fork leg, be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal S Before assembling the front fork leg, make sure that all of the components are clean. 1. Install: S damper rod 1 S oil lock piece 2
CAUTION:
Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: S inner tubes outer surface Recommended lubricant Fork oil 10 W or equivalent 3. Tighten: S damper rod bolt 1
30 Nm (3.0 mSkg)
NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , tighten the damper rod bolt. Damper rod holder 90890-01365 T-handle 90890-01326
4. Install: S outer tube bushing 1 (with the fork seal driver weight and adapter) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01369
6-42
FRONT FORK
CHAS
5. Install: S washer S oil seal 1 (with the fork seal driver weight and adapter)
CAUTION:
Make sure that the numbered side of the oil seal faces up. NOTE: S Before installing the oil seal, apply lithium soap base grease onto its lips. S Apply fork oil onto the outer surface of the inner tube. S Before installing the oil seal, cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation.
6. Install: S oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the outer tubes groove.
7. Install: S dust seal 1 (with the fork seal driver weight) Fork seal driver weight 90890-01367 Adapter 90890-01369 8. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 311 cm3 Yamaha fork and shock oil 10 W or equivalent.
6-43
FRONT FORK
CHAS
Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 112 mm NOTE: S While filling the front fork leg, keep it upright. S After filling, slowly pump the front fork leg up and down to distribute the fork oil. S Be sure to stroke the inner tube slowly because the fork oil may spurt out.
9. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt 4 NOTE: S Install the spring with the smaller pitch facing up. S Before installing the cap bolt, apply grease onto the O-ring. S Temporarily tighten the cap bolt.
6-44
FRONT FORK
EAS00662
CHAS
INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: S lower bracket pinch bolt 1 S upper bracket pinch bolt 2
30 Nm (3.0 mSkg) 20 Nm (2.0 mSkg)
S cap bolt 3 23 Nm (2.3 mSkg) S front turn signal pinch bolt 4

7 Nm (0.7 mSkg)
WARNING
Make sure that the brake hoses are routed properly.
6-45
HANDLEBAR
CHAS
HANDLEBAR
7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg)
32 Nm (3.2 mSkg)
Order
Job/Part Removing the handlebar
Qty
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 1 2 3 4 5 6 7 8 9 Plastic locking ties Rear view mirror Clutch cable Clutch lever assembly Clutch switch lead Starter cable Left handlebar switch Grip (left) Master cylinder bracket 4 2 1 1 1 1 1 1 1
6-46
HANDLEBAR
CHAS
7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg)
32 Nm (3.2 mSkg)
Order 10 11 12 13 14 15 16 17
Job/Part Master cylinder assembly Right handlebar switch Throttle cables Throttle grip assembly Handlebar holder (upper) Handlebar Cable guide Handlebar holder (lower)
Qty 1 1 2 1 2 1 1 1
Remarks
6-47
HANDLEBAR
EAS00666
CHAS
REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S front brake master cylinder assembly 1 S right handlebar switch 2 S throttle grip 3 3. Remove: S clutch lever assembly S handlebar grip (left) 1 NOTE: 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.
WARNING
Securely support the motorcycle so that there is no danger of it falling over.
2. Check: S handlebar 1 Bends/cracks/damage ! Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
6-48
HANDLEBAR
3. Install: S handlebar grip
CHAS
a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
EAS00670
INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2
23 Nm (2.3 mSkg)
CAUTION:
S First, tighten the bolts on the front side of the handlebar holder, then on the rear side. S Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: S The upper handlebar holders should be installed with the arrows a facing forward A . S Align the match marks b on the handlebar with the upper surface of the lower handlebar holders. 3. Install: S throttle grip S throttle cable S right handlebar switch
6-49
HANDLEBAR
CHAS
NOTE: Install the right handlebar switch alignment surface position so that it is perpendicular ( a = 90_) to the master cylinder alignment surface.
4. Install: S master cylinder Refer to FRONT AND REAR BRAKES.
5. Install: S clutch lever holder 1 NOTE: Align the slit in the clutch lever holder with the punch mark a in the handlebar. 6. Install: S clutch cable 7. Connect: S clutch switch NOTE: Apply a thin coat of lithium soap base grease onto the end of the clutch cable.
8 Install: S left handlebar switch NOTE: Align the clutch lever assembly matching face with the left handlebar switch matching face in a straight line a , then assemble them.
6-50
HANDLEBAR
CHAS
9. Adjust: S clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3. Clutch cable free play (at the end of the clutch lever) 5 10 mm 10. Adjust: S 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
6-51
STEERING HEAD
CHAS
STEERING HEAD
LOWER BRACKET
110 Nm (11.0 mSkg)
1st 52 Nm (5.2 mSkg) 2nd 18 Nm (1.8 mSkg)
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
Order
Job name/Part name Removing the lower bracket
Qty
WARNING
Securely support the motorcycle so that there is no danger of it falling over. Front fork legs Handlebar Headlight lens unit Leads (in the headlight body) Front turn signal light (left/right) Headlight body Brake hose holder Upper bracket Lock washer Upper ring nut Refer to FRONT FORK. Refer to HANDLEBAR. 1 1/1 1 1 1 1 1 Disconnect
1 2 3 4 5 6 7 8
6-52
STEERING HEAD
CHAS
110 Nm (11.0 mSkg)
1st 52 Nm (5.2 mSkg) 2nd 18 Nm (1.8 mSkg)
7 Nm (0.7 mSkg)
7 Nm (0.7 mSkg)
Order 9 10 11 12 13 14 15
Job name/Part name Rubber washer Lower ring nut Bearing cover Lower bracket Bearing (upper) Rubber seal Bearing (lower)
Qty 1 1 1 1 1 1 1
Remarks Refer to REMOVING THE LOWER BRACKET/INSTALLING THE STEERING HEAD.
For installaiton, reverse the removal procedure.
6-53
STEERING HEAD
EAS00677
CHAS
REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over.
2. Remove: S upper ring nut 1 S lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring nut with the ring nut wrench. Exhaust and steering nut wrench 90890-01268 Ring nut wrench 90890-01403
WARNING
Securely support the lower bracket so that there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD 1. Wash: S bearings S bearing races Recommended cleaning solvent Kerosine
2. Check S bearings 1 S bearing races 2 Damage/pitting ! Replace. 3. Replace: S bearings S bearing races
6-54
STEERING HEAD
CHAS
a. Remove the bearing reces from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing reces.
CAUTION:
If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set. S Whenever the steering head is disassembled, replace the rubber seal. 4. Check: S upper bracket S lower bracket (along with the steering stem) Bends/cracks/damage ! Replace.
EAS00683
INSTALLING THE STEERING HEAD 1. lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium soap base grease
2. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3. 3. Install: S upper bracket S steering stem nut
6-55
STEERING HEAD
CHAS
NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to FRONT FORK NOTE: Temporarily tighten the upper and lower bracket pinch bolts.
6-56
REAR SHOCK ABSORBER AND SWINGARM

EAS00685
CHAS

REAR SHOCK ABSORBER ASSEMBLY
23 Nm (2.3 mSkg)
23 Nm (2.3 mSkg)
Order
Job/Part Removing the rear shock absorber assembly Rear shock absorber assembly
Qty
2 For installation, reverse the removal procedure.
6-57

SWINGARM
CHAS
46 Nm (4.6 mSkg)
7 Nm (0.7 mSkg)
Order
Job/Part Removing the swingarm Rear wheel Rear shock absorber Muffler and exhaust pipes Chain cover Chain case Drive chain Nut/washer Pivot shaft Cover Coller Oil seal Bush
Qty
Remarks Remove the parts in order listed. Refer to REAR WHEEL AND REAR BRAKE. Refer to REMOVING/INSTALLING THE REAR SHOCK ABSORBER.
1 2 3 4 5 6 7 8 9
1 1 1 1/1 1 2 2 2 2 For installation, reverse the removal procedure.
6-58

EAS00687
CHAS
HANDLING THE REAR SHOCK ABSORBER
WARNING
This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. S Do not tamper or attempt to open the rear shock absorber. S Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. S Do not deform or damage the rear shock absorber in any way. If the rear shock absorber or both are damaged, damping performance will suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORBER a. Gas pressure must be released before disposing of a rear shock absorber. To release the gas pressure, drill 2 3 mm hole through the gas cylinder at a point 15 20 mm from its end as shown.
WARNING
Wear eye protection to prevent eye damage from released gas or metal chips.
6-59

EAS00691
CHAS
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S rear shock absorber (left and right)
EAS00706
REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S chain cover 1 S chain case 3. Remove: S drive chain 2
6-60

EAS00703
CHAS
REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S rear shock absorber assembly bolt 1 NOTE: When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 3. Check: S swingarm side play A S swingarm vertical movement B a. Check the tightening torque of the pivot shaft nut. Pivot shaft nut 46 Nm (4.6 mSkg) b. Check the swingarm side play A by moving the swingarm from side to side. c. If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play (at the end of the swingarm) 1 mm d. Check the swingarm vertical movement B by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.
6-61

EAS00696
CHAS
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. S spring Damage/wear ! Replace the rear shock absorber assembly. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace.
EAS00707
CHECKING THE SWINGARM 1. Check: S swingarm Bends/cracks/damage ! Replace.
2. Check: S pivot shaft Roll the pivot shaft on a flat surface. Bends ! Replace.
WARNING
Do not attempt to straighten a bent pivot shaft.
3. Wash: S pivot shaft S dust covers S collars S washers S bearings Recommended cleaning solvent Kerosine
6-62
CHAS
4. Check: S dust covers 1 S spacer 2 S oil seals 3 Damage/wear ! Replace. S bearings Damage/pitting ! Replace.
6-63

EAS00709
CHAS
CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Max. ten-link drive chain section 119.5 mm NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension. S Measure the length between drive chain roller 1 and 11 as shown. S Perform this measurement at two or three different places.
2. Check: S drive chain Stiffness ! Clean and lubricate or replace.
3. Clean: S drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosine and remove any remaining dirt.
6-64
CHAS
c. Remove the drive chain from the kerosine and completely dry it.
CAUTION:
This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chains internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain. Dont soak drive drain in kerosine more them ten minutes. O-ring is damage by kerosine.
4. Check: S O-rings 1 Damage ! Replace the drive chain. S drive chain rollers 2 Damage/wear ! Replace the drive chain. S drive chain side plates 3 Cracks/damage/wear ! Replace the drive chain.
5. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains
6 Check: S drive sprocket S 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 Correct 1 Drive chain roller 2 Drive chain sprocket
6-65

EAS00711
CHAS
INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: S rear shock absorber assembly S rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL.
6-66
CHAS
INSTALLING THE DRIVE CHAIN 1. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: S drive chain S chain case S chain cover
CAUTION:
Connecting the neutral switch lead, starter motor and A.C. generator leads should be through under the neutral switch . Face the terminal cover to right-under side, then assemble the chain cover without the both leads being caught. 3. Install: S rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL. 4. Adjust: S drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3. Drive chain slack 30 40 mm
CAUTION:
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.
6-67
ELEC
CHAPTER 7. ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE BULBS AND SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-5 7-5 7-5 7-7
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7-13 7-14 7-15 7-19 7-20 7-21
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7-26 7-26 7-27 7-28 7-31 7-31 7-33 7-34
CARBURETOR HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
ELEC
ELECTRICAL COMPONENTS
EB800000
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 2 3 4 5 6 7 8
Main switch Thermo switch Flasher relay Relay unit Front brake light switch Clutch switch Ignition coil Igniter unit
9 10 11 12 13 14 15 16
Fuse Starter relay Side stand switch Neutral switch Rectifier/ regulator Battery Rear brake light switch Horn
7-1
SWITCHES
EAS0010
ELEC
SWITCHES
CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
Never insert the tester probes into the coupler terminal slots 1 . Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Pocket tester 90890-03112 NOTE: S Before checking for continuity, set the pocket tester to 0 and to the 1 range. S When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. NOTE: indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between blue/red and red when the switch is set to . There is continuity between blue/red and blue, between brown/blue and red, and between blue/yellow and black when the switch is set to ON.
7-2
CHECKING THE SWITCHES

EAS00731
ELEC

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to CHECKING SWITCH CONTINUITY. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
7-3

1 2 3 4 5 6 7 8
ELEC
Clutch switch Pass switch Horn switch Dimmer switch Turn switch Front brake switch Main switch Lights switch
9 10 11 12 13 14
Engine stop switch Start switch Fuse Rear brake switch Sidestand switch Neutral switch
7-4
CHECKING THE BULBS AND BULB SOCKETS

EAS00732
ELEC
BULBS AND
CHECKING THE BULB SOCKETS
Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect. Incorrect continuity reading ! Repair or replace the bulb, bulb socket or both.
TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. S Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb. The majority of these bulbs can be removed from their respective socket by turning them counterclockwise. S Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. S Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by turn D and pulling E them out.
CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: S bulb
7-5
CHECKING THE BULBS AND BULB SOCKETS WARNING
ELEC
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
CAUTION:
S Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. S Avoid touching the glass part of the headlight 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 gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
2. Check: S bult (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to 0 and to the 1 range.
a. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 2 , and check the continuity. b. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 3 , and check the continuity. c. If either of the readings indicate no continuity, replace the bulb.
7-6
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: 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 respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.
7-7
IGNITION SYSTEM
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
3 4 6 8 9 11 13 14 15 16 17 18 26
Main switch Fuse (main) Battery Fuse (ignition) Relay unit Sidestand switch Ignitor Ignition coil #1 Ignition coil #2 Spark plug Pickup coil Neutral switch Engine stop switch
7-8
IGNITION SYSTEM
EAS00737 EAS00739
ELEC
TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. engine stop switch 10. neutral switch 11. sidestand switch 12. relay unit (diode) 13. wiring (of the entire ignition system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) riders seat 3) fuel tank 4) steering head side covers 5) tool box cover 6) left side cover 7) cylinder head covers S Troubleshoot with the following special tool(-s).
2. Battery S Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Min. open-circuit voltage 12.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00741
3. Spark plugs The following procedure applies to all of the spark plugs. S Check the condition of the spark plug. S Check the spark plug type. S Measure the spark plug gap. Refer to CHECKING THE SPARK PLUGS in chapter 3. Standard spark plug Spark plug gap 0.6 X 0.7 mm S Is the spark plug in good condition, is it of the correct type, and its gap within specification? YES NO Re-gap or replace the spark plug.
Ignition checker 90890-06754 Pocket tester 90890-03112

EAS00738
1. Main and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main and ignition fuses OK? YES NO Replace the fuse(-s).
7-9
IGNITION SYSTEM
EAS00743
ELEC
4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 as shown. S 2 Spark plug cap S Set the main switch to ON. S Measure the ignition spark gap a . S Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs.
Spark plug cap resistance 10 k at 20_C S Is the spark plug cap OK? YES NO Replace the spark plug cap.
EAS00747
6. Ignition coil resistance The following procedure applies to all of the ignition coils. S Disconnect the ignition coil connectors from the ignition coil terminals. S Connect the pocket tester ( 1) to the ignition coil as shown. Tester positive probe ! red/black Tester negative probe ! orange (gray) Min. ignition spark gap 6 mm S Is there a spark and is the spark gap within specification ? NO YES The ignition system is OK.
EAS00745
S Measure the primary coil resistance. Primary coil resistance 3.4 X 4.6 at 20_C S Connect the pocket tester ( 1k) to the ignition coil as shown. S Measure the secondary coil resistance. Tester positive probe ! spark plug lead 1 Tester negative probe ! Orange (gray) lead 2
5. Spark plug cap resistance. The following procedure applies to all of the spark plug caps. S Disconnect the spark plug cap from the spark plug. S Connect the pocket tester ( 1k) to the spark plug cap as shown. S Measure the spark plug cap resistance.
7-10
IGNITION SYSTEM
EAS00749
ELEC
8. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES NO Replace the main switch.
EAS00750
Secondary coil resistance 10.4 X 15.6 k 20_C S Is the ignition coil OK? YES NO Replace the ignition coil.
EAS00748
9. Engine stop switch S Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. S Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00751
7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester ( 100) to the pickup coil terminal. Tester positive probe ! green/white 1 Tester negative probe ! blue/yellow 2
10. Neutral switch S Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. S Is the neutral switch OK? YES NO Replace the neutral switch.
EAS00752
11. Sidestand switch S Measure the pickup coil resistance. Pickup coil resistance 192 X 288 at 20_C S Is the pickup coil OK? YES NO Replace the pickup coil. Replace the sidestand switch. S Check the sidestand switch for continuity. Refer to CHECKING THE SWITCHES. S Is the sidestand switch OK? YES NO
7-11
IGNITION SYSTEM
ELEC
EAS00760
12. Relay unit (Diode) S Disconnect the relay unit from the coupler. S Connect the pocket tester ( 1) to the starting circuit cutoff relay terminals as shown. S Measure the relay unit for continuity as follws. Tester positive probe ! blue/green 1 Tester negative probe ! blue/yellow 2 Tester positive probe ! blue/yellow 2 Tester negative probe ! blue/green 1 Tester positive probe ! light green 3 Tester negative probe ! blue/yellow 2 Tester positive probe ! blue/yellow 2 Tester negative probe ! lightgreen 3
NOTE: When you switch the and + leads of the digital pocket tester the readings in the above chart will be reversed. S Are the tester readings correct? YES NO Replace the starting circuit cut-off relay.
Continuity
EAS00754
13. Wiring No continuity S Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. S Is the ignition systems wiring properly connected and without defects? NO Properly connect or repair the ignition systems wiring. YES Replace the ignitor unit.
Continuity
No continuity
7-12
ELECTRIC STARTING SYSTEM
ELEC

CIRCUIT DIAGRAM
3 4 5 6 7 8 9 10 11 18 26 27
Main switch Fuse (main) Starter relay Battery Starter motor Fuse (ignition) Relay unit Clutch switch Sidestand switch Neutral switch Engine stop switch Start switch
7-13

EB803010
ELEC
STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on RUN and the main switch is on ON (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed). or if The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter from operating when neither of these conditions have been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions have been met however, the starting circuit cut-off relay is closed, and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED IN
1 2 3 4 5 6 7 8 9
10 11 12 13
Battery Main fuse Main switch Ignition fuse Engine stop switch Starting circuit cut-off relay Diode Clutch switch Sidestand switch Neutral switch Start switch Starter relay Starter motor
7-14

EAS00757 EAS00739
ELEC
TROUBLESHOOTING The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. relay unit (starting circuit cutoff relay) 5. relay unit (diode) 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. start switch 13. wiring (of the entire starting system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) riders seat 3) fuel tank 4) steering head side covers 5) left side cover S Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00738
2. Battery S Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Open-circuit voltage 12.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00758
3. Starter motor S Connect the battery positive terminal 1 and starter motor lead 2 with a jumper lead 3.
1. Main and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main and ignition fuses OK? YES NO Replace the fuse(-s).
WARNING
S A 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. S This check is likely to produce sparks, therefore make sure that no flammable gas or fluid is in the vicinity. S Does the starter motor turn? YES NO Repair or replace the starter motor.
7-15

EAS00759
ELEC
4. Relay unit (starting eircuit cutoff relay) S Disconnect the relay unit (starting circuit cutoff relay) from the coupler. S Connect the pocket tester ( 1) and battery (12 V) to the relay unit terminals as shown. Battery positive terminal ! red/black 1 Battery negative terminal ! black/yellow 2 Tester positive probe ! blue 3 Tester negative probe ! black 4
Tester positive probe ! light green 1 Tester negative probe ! blue/yellow 3 Tester positive probe ! blue/yellow 3 Tester negative probe ! light green 1 Tester positive probe ! blue/green 4 Tester negative probe ! blue/yellow 3 Tester positive probe ! blue/yellow 3 Tester negative probe ! blue/green 4
Continuity
No continuity
Continuity
No continuity
S Does the relay unit (starting circuit cutoff relay) have continuity between black and blue? YES NO Replace the relay unit (starting circuit cut-off relay).
EAS00760
NOTE: When you switch the and + leads of the digital pocket tester the readings in the above chart will be reversed. S Are the tester readings correct? YES NO Replace the relay unit (Diode).
5. Relay unit (Diode) S Disconnect the relay unit (Diode) from the coupler. S Connect the pocket tester ( 1) to the starting circuit cutoff relay terminals as shown. S Measure the relay unit (Diode) for continuity as follows. Tester positive probe ! light green 1 Tester negative probe ! black/yellow 2 Tester positive probe ! black/yellow 2 Tester negative probe ! light green 1
Continuity
No continuity
7-16

EAS00761 EAS00750
ELEC
6. Starter relay S Disconnect the starter relay from the coupler. S Connect the pocket tester ( 1) and battery (12 V) to the starter relay coupler as shown. Battery positive terminal ! red/white 1 Battery negative terminal ! blue 2 Tester positive probe ! red 3 Tester negative probe ! black 4
8. Engine stop switch S Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. S Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00751
S Does the starter relay have continuity between red and black? YES NO Replace the starter relay.
EAS00752
10. Sidestand switch S Check the sidestand switch for continuity. Refer to CHECKING THE SWITCHES. S Is the sidestand switch OK? YES NO Replace the stand switch. side-
EAS00749
EAS00763
11. Clutch switch S Check the clutch switch for continuity. Refer to CHECKING THE SWITCHES. S Is the clutch switch OK? YES NO Replace the clutch switch.
7-17

EAS00764
ELEC
12. Start switch S Check the start switch for continuity. Refer to CHECKING THE SWITCHES. S Is the start switch OK? YES NO Replace the right handlebar switch.
EAS00766
13. Wiring S Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM. S Is the starting systems wiring properly connected and without defects? NO Properly connect or repair the starting systems wiring. YES The starting system circuit is OK.
7-18

STARTER MOTOR
ELEC
5 Nm (0.5 mSkg)
Order 1 2
Job/Part Removing the starter motor Starter motor lead Starter motor assembly
Qty 1 1

1 2 3 4 5 6 7 8 9
10
Disassembling the starter motor Starter motor front cover Washer Washer Oil seal Bearing Armature assembly O-ring Brush holder/brush Starter motor rear cover Starter motor yoke
Disassembly the parts in the order listed. 1 1 1 1 1 1 1 1/1 1 1
7-19

EAS00769
ELEC
CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Min. commutator diameter 22 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 1.5 mm NOTE: The mica must be undercut to ensure proper operation of the commutator.
4. Measure: S armature assembly resistances (commutator 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 Armature coil resistance 1 0.0171 X 0.0209 at 20_C Insulation resistance 2 Above 1 M at 20_C b. If any resistance is out of specification, replace the starter motor.
7-20
ELEC
5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Min. brush length 3.5 mm
6. Measure: S brush spring force free length a Out of specification ! Replace the brush springs as a set. Brush spring force 5.52 X 8.28 N (563 X 844 gf)
7. Check: S gear teeth Damage/wear ! Replace the gear. 8. Check: S oil seal Damage/wear ! Replace the defective part(-s).
EAS00772
ASSEMBLING THE STARTER MOTOR 1. Install: S brush S commutator 1
2. Install: S starter motor yoke 1
7-21
ELEC
3. Install: S Starter motor front cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover.
7-22
CHARGING SYSTEM
ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
1 2 4 6
A.C. magneto Rectifier/ regulator Fuse (main) Battery
7-23
CHARGING SYSTEM
EAS00774 EAS00739
ELEC
TROUBLESHOOTING The battery is not being charged. Check: 1. main fuses 2. battery 3. charging voltage 4. stator coil assembly resistance 5. wiring (of the entire charging system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) riders seat 3) left side cover S Troubleshoot with the following special tool(-s).
2. Battery S Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Open-circuit voltage 12.8 V or more at 20_C S Is the battery OK YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00775
3. Charging voltage Engine tachometer 90890-03113 Pocket tester 90890-03112 S Connect the engine tachometer to the spark plug lead of cylinder #1. S Connect the pocket tester (DC 20 V) to the battery as shown. Tester positive probe ! battery positive terminal Tester negative probe ! battery negative terminal
EAS00738
1. Main fuse S Check the main fuse for continuity. Refer to CHECKING THE FUSES in chapter 3. S Is the main fuse OK? YES NO Replace the fuse. S Start the engine and let it run at approximately 5,000 r/min. S Measure the charging voltage. Charging voltage 14 V at 5,000 r/min
7-24
CHARGING SYSTEM
EAS00779
ELEC
NOTE: Make sure that the battery is fully charged. S Is the charging voltage within specification? NO YES The charging circuit is OK.
EAS00776
5. Wiring S Check the wiring connections of the entire charging system. Refer to CIRCUIT DIAGRAM. S Is the charging systems wiring properly connected and without defects? NO Properly connect or repair the charging systems wiring. YES Replace the rectifier/regulator.
4. Stator coil assembly resistances S Remove the generator cover. S Connect the pocket tester ( 1) to the stator coil assembly coupler as shown. Tester positive probe ! white 1 Tester negative probe ! white 2 Tester positive probe ! white 1 Tester negative probe ! white 3
S Measure the stator coil assembly resistances. Stator coil resistance 0.224 X 0.336 at 20_C S Is the stator coil assembly OK? YES NO Replace the stator coil assembly.
7-25
LIGHTING SYSTEM
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
3 4 6 22 24 28 30 31 36 37 42 46
Main switch Fuse (main) Battery High beam indicator light Meter light Light switch Pass switch Dimmer switch Headlight Auxiliary light Fuse (headlight) Tail/ brake light
7-26
LIGHTING SYSTEM
EAS00781 EAS00739
ELEC
TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. main and headlight fuses 2. battery 3. main switch 4. lights switch 5. dimmer switch 6. pass switch 7. wiring (of the entire lighting system) NOTE: S Before troubleshooting, remove the following part(-s). 1) battery cover 2) riders seat 3) fuel tank 4) steering head side covers 5) headlight lens unit 6) tool box cover S Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00738
EAS00749
1. Main, and headlight fuses S Check the main, and headlight fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main, and headlight fuses OK? YES NO Replace the fuse(-s).
EAS00783
4. Lights switch S Check the lights switch for continuity. Refer to CHECKING THE SWITCHES. S Is the lights switch OK? YES NO The lights switch is faulty. Replace the right handlebar switch.
7-27
LIGHTING SYSTEM
EAS00784 EAS00788
ELEC
5. Dimmer switch S Check the dimmer switch for continuity. Refer to CHECKING THE SWITCHES. S Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch.
CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to came on. 1. Headlight bulb and socket S Check the headlight bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.
EAS00786
6. Pass switch S Check the pass switch for continuity. Refer to CHECKING THE SWITCHES. S Is the pass switch OK? 2. Voltage YES NO The pass switch is faulty. Replace the left handlebar switch.
S Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.
A When the dimmer switch is set to B When the dimmer switch is set to
EAS00787
7. Wiring S Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. S Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CHECKING THE LIGHTING SYSTEM. NO Properly connect or repair the lighting systems wiring.
Headlight Tester positive probe ! yellow 1 or green 2 Tester negative probe ! black 3 High beam indicator light Tester positive probe ! yellow 4 Tester negative probe ! black 5 Headlight coupler (wire harness side)
G Y
7-28
LIGHTING SYSTEM
2. Voltage
ELEC
S Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe ! blue 1 Tester negative probe ! black 2
S Set the main switch to ON. S Set the light switch to . S Set the dimmer switch to or . S Measure the voltage (12 V) of yellow 1 or green 2 on the headlight coupler (headlight side). S Measure the voltage (12 V) of yellow 4 on the meter assembly coupler. S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.
S Set the main switch to ON. S Set the light switch to or . S Measure the voltage (12 V) of blue 1 on the meter assembly coupler (wire harness side). S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.
EAS00789
2. A meter light fails to come on. 1. Meter light bulb and socket. S Check the meter light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the meter light bulb and socket OK? YES NO Replace the meter light bulb, socket or both.
EAS00790
3. A tail/brake light fails to come on. 1. Tail/brake light bulb and socket S Check the tail/brake light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the tail/brake light bulb and socket OK? YES NO Replace the tail/ brake light bulb, socket or both.
7-29
LIGHTING SYSTEM
2. Voltage S Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Tester positive probe ! blue 1 Tester negative probe ! black 2 2. Voltage
ELEC
S Connect the pocket tester (DC 20 V) to the auxiliary light couplers (wire harness side) as shown. Tester positive probe ! blue/red 1 Tester negative probe ! black 2
S Set the main switch to ON S Set the light switch to or . S Measure the voltage (12 V) of blue 1 on the tail/brake light coupler (wire harness side). S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
S Set the main switch to ON S Set the light switch to or . S Measure the voltage (12 V) of blue/red 1 on the auxiliary light couplers (wire harness side). S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the auxiliary light connectors is faulty and must be repaired.
EB05413
4. The auxiliary light fails to come on. 1. Auxiliary light bulb and socket S Check the auxiliary light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the auxiliary light bulb and socket OK? YES NO Replace the auxiliary light bulb, socket or both.
7-30
SIGNALING SYSTEM
ELEC
SIGNALING SYSTEM
CIRCUIT DIAGRAM
7-31
SIGNALING SYSTEM
3 4 6 9 18 21 23 32 33 34 35 38 39 40 41 43 44 45 46
ELEC
Main switch Fuse (main) Battery Relay unit (Diode) Neutral switch Neutral indicator light Turn signal indicator light Horn switch Turn signal switch Horn Flasher relay Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Fuse (signal) Rear stop switch Front stop switch Tail/ brake light
7-32
SIGNALING SYSTEM
EB806010 EAS00739
ELEC
TROUBLESHOOTING S Any of the following fail to light: turn signal light, brake light or an indicator light. S The forn fails to sound. Check: 1. main and signaling system fuses 2. battery 3. main switch 4. wiring (of the entrire signaling system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) riders seat 3) fuel tank 4) steering head side covers 5) headlight lens unit 6) tool box cover 7) left side cover S Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00738
2. Battery S Check the condition of the battery. Refer to CHECKING AND CHRGING THE BATTERY in chapter 3. Open-circuit voltage 12.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00749
3. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES Replace switch. NO the main
1. Main, and signaling system fuses

EAS00795
S Check the main ignition and signaling system fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main ignition and signaling system fuses OK? YES NO Replace the fuse(-s).
4. Wiring S Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM. S Is the signaling systems wiring properly connected and without defects? YES Check the condition of each of the signaling systems circuits. Refer to CHECKING THE SIGNALING SYSTEM. NO Properly connect or repair the signaling systems wring.
7-33
SIGNALING SYSTEM
EAS00796
ELEC
CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch S Check the forn switch for continuity. Refer to CHECKING THE SWITCHES. S Is the horn switch OK? YES NO Replace the left handlebar switch.
3. Horn S Disconnect the pink connector at the horn terminal. S Connect a jumper lead 1 to the horn terminal and ground the jumper lead. S Set the main switch to ON. S Does the horn sound?
Br
2. Voltage S Connect the pocket tester (DC 20 V) to the horn connecter at the horn terminal as shown. Tester positive probe ! brown 1 Tester negative probe ! ground
Br P
NO
YES The horn is OK.
4. Voltage S Connect the pocket tester (DC 20 V) to the horn connecter at the pink terminal as shown. Tester positive probe ! pink 1 Tester negative probe ! ground
Br P
S Set the main switch to ON. S Measure the voltage (12 V) of brown at the horn terminal. S Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connecter is faulty and must be repaired.
S Set the main switch to ON. S Measure the voltage (12 V) of pink 1 at the horn terminal. S Is the voltage within specification? YES Repair or replace the horn. NO Replace the horn.
7-34
SIGNALING SYSTEM
EAS00797
ELEC
2. A tail/brake light fails to come on. 1. Tail/brake light bulb and socket S Check the tail/brake light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the tail/brake light bulb and socket OK? YES NO Replace the tail/ brake light bulb, socket or both.
S Set the main switch to ON. S Pull in the brake lever or push down on the brake pedal. S Measure the voltage (12 V) of yellow at the tail/brake light coupler (wire harness side). S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must bne repaired.
2. Brake light switches S Check the brake light switches for continuity. Refer to CHECKING THE SWITCHES. S Is the brake light switch OK? YES NO Replace the brake light switch.
EAS00799
3. A turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal light bulb and socket S Check the turn signal light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the turn signal light bulb and socket OK? YES NO Replace the turn signal light bulb, socket or both.
3. Voltage S Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Tester positive probe ! yellow 1 Tester negative probe ! black 2
7-35
SIGNALING SYSTEM
2. Turn signal switch S Check the turn signal for continuity. Refer to CHECKING THE SWITCHES. S Is the turn signal switch OK? YES NO Replace the left handlebar switch. 3. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Tester positive prove ! brown 1 Tester negative prove ! ground
ELEC
Tester positive probe ! brown/white 1 Tester negative probe ! ground
S Set the main switch to ON. S Set the turn signal switch to or . S Measure the voltage (12 V) of brown/white at the flasher relay coupler (wire harness side). S Is the voltage within specification? YES NO The flasher relay is faulty and must be replaced. 5. Voltage S Connect the pocket tester (DC 20 V) to the turn signal light connectors or the meter assembly coupler (wire harness side) as shown.
A Turn signal light B Turn signal indicator light
S Set the main switch to ON. S Measure the voltage (12 V) of brown 1 at the flasher relay coupler (wire harness side). S Is the voltage within specification? YES NO The wiring circuit from the main switch to the flasher relay coupler (flasher relay side) is faulty and must be repaired. 4. Voltage S Connect the tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown.
Left turn signal light Tester positive probe ! chocolate 1 Tester negative probe ! ground Right turn signal light Tester positive probe ! dark green 2 Tester negative probe ! ground A B
7-36
SIGNALING SYSTEM
S Set the main switch to ON. S Set the turn signal switch to or . S Measure the voltage (12 V) of chocolate 1 or dark green 2 at the turn signal light connector (wire harness side). S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must repaired. 3. Voltage
ELEC
S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe ! brown 1 Tester negative probe ! sky blue 2
EAS00800
4. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket S Check the neutral indicator light bulb and socket for continuity. Refer to CHECKING THE BULBS AND BULB SOCKETS. S Are the neutral indicator light bulb and socket OK? YES NO Replace the neutral indicator light bulb, socket or both.
S Set the main switch to ON. S Measure the voltage (12 V) of brown 1 and sky blue 2 at the meter assembly coupler. S Is the voltage with specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired.
7-37
CARBURETOR HEATER SYSTEM
ELEC

CIRCUIT DIAGRAM
3 4 6 47 48 49 50
Main switch Fuse (main) Battery Fuse (carburetor heater) Thermo switch Carburetor heater Carburetor heater ground
7-38

EAS00781 EAS00739
ELEC
TROUBLESHOOTING The carburetor heater fails to operate. Check: 1. main, and carburetor heater fuses 2. battery 3. main switch 4. thermo switch 5. carburetor heater 6. wiring (of the entire carburetor heater system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) riders seat 3) fuel tank 4) steering head side covers 5) tool box cover S Troubleshoot with the following special tool (-s). Pocket tester 90890-03112
EAS00738
EAS00749
1. Main, and carburetor heater fuses S Check the main, and carburetor heater fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main, and carburetor heater fuses OK? YES NO Replace the fuse(-s).
4. Thermo switch S Remove the thermo switch from the thermo switch plate. S Connect the pocket tester to the thermo switch lead. Tester (+) lead ! Brown/Yellow terminal 1 Tester () lead ! Black/Yellow terminal 2
7-39

5. Carburetor heater
ELEC
S Remove the carburetor heater from the carburetor body. S Connect the pocket tester to the carburetor heater. Tester (+) lead ! Heater terminal 1 Tester () lead ! Heater body 2
S Immerse the thermo switch in the water 3 . S Check the thermo switch for continuity. Note the temperatures while heating the water with the temperature gauge 4 . Test step 1 2 3 4 Water temperature Less than 23 3_C More than 23 3_C More than 12 4_C Less than 12 4_C f Good condition f
S Measure the heater resistance. Carburetor heater resistance: 12 V 30 W : 6 X 10 at 20_C S Is the carburetor heater OK? YES NO Replace the carburetor heater.
Test 1 & 2 : Heat-up test Test 3 & 4 : Cool-down test f : Continuity : No continuity
EAS00766
6. Wiring S Check the entire carburetor heater systems wiring. Refer to CIRCUIT DIAGRAM. S Is the carburetor heater systems wiring properly connected and without defects? NO YES The carburetor heater system circuit is OK.
OFF
ON Thermoswitch 12 4_C Thermoswitch 23 3_C
S Is the thermo switch OK? YES NO Replace the thermo switch.
Properly connect or repair the carburetor heater systems wiring.
7-40
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The XVS125 features self-diagnosis. When the main switch is turned to ON, the following items are monitored and the condition codes are displayed on the engine indicator light (irrespective of whether the engine is running or not). NOTE: The XVS125 features a self-diagnosing system. In the XVS125, when the main switch is turned on the Engine indicator light in the speedometer comes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds, goes off and then begins flashing. (However, it is on while the engine is running.)
Display condition code Item Condition Response When engine is stationary Blinks in Fault code: 3 When engine is running Light on
Throttle position sensor (TPS)
Disconnected Short-circuit Locked
S Enables the motorcycle to run so that the ignition timing is fixed when the throttle is fully opened. S Displays the condition code on the engine indicator light.
Speed sensor (5JX2)
Disconnected short-circuit Missing coupler Failure in the electronic component
S Displays the condition code on the enigne indicator light.
Blinks in Fault code: 4
Light on
Display order on the engine indicator light
(Example: for throttle position sensor trouble)
1 2 3 4 Light on
Light on (seconds) . . . . . Light off (seconds) . . . . . Number of blinks . . . . . . Light off (seconds) . . . . .
0.5 seconds 0.5 seconds Fault code 3 seconds
Light off
2 3 4
Repetition
7-41
SELF-DIAGNOSIS
EAS00835
ELEC
TROUBLESHOOTING The engine warning light starts to display the self-diagnosis sequence. Check: 1. throttle position sensor NOTE: S Before troubleshooting, remove the following part(-s): 1) rider seat and passenger seat 2) fuel tank 3) air filter assembly 4) silencer assembly S Troubleshoot with the following special tool(-s). Pocket tester 90890-03112
EAS00836
1. Wire harness S Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. S Is the wire harness OK? YES NO Repair or replace the wire harness.
EB812401
2. Throttle position sensor S Check the throttle position sensor for continuity. Refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR in chapter 6. S Is the throttle position sensor OK? YES NO Replace the throttle position sensor.
1. Throttle position sensor CIRCUIT DIAGRAM
Replace the ignitor unit.
12 Throttle position sensor 13 Ignitor unit
7-42
SELF-DIAGNOSIS
2. Speed sensor (5JX2) CIRCUIT DIAGRAM NOTE: The speed sensor into the speedometer. 1. Wire harness
ELEC
S Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. S Is the wire harness OK? YES Replace the speed meter. NO Repair or replace the wire harness.
13 Ignitor unit 19 Meter
7-43
TRBL SHTG
CHAPTER 8. TROUBLESHOOTING
STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2 FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY FRONT LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY LIGHTNING AND SIGNALING SYSTEMS . . . . . . . . . . . . . . . . 8-5
TRBL SHTG
STARTING PROBLEMS
EAS00844
TRBL SHTG
TROUBLESHOOTING
NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE Cylinders and cylinder head(-s) S Loose spark plug S Loose cylinder head S Damaged cylinder head gasket S Worn or damaged cylinder S Incorrect valve clearance S Incorrectly sealed valve S Incorrect valve-to-valve-seat contact S Incorrect valve timing S Faulty valve spring S Seized valve Pistons and piston rings S Incorrectly installed piston ring S Damaged, worn or fatigued piston ring S Seized piston ring S Seized or damaged piston Air filter S Incorrectly installed air filter S Clogged air filter element Crankcase and crankshaft S Incorrectly assembled crankcase S Seized crankshaft ELECTRICAL SYSTEMS Battery S Faulty battery S Discharged battery Fuse S Blown, damaged or incorrect fuse S Incorrectly installed fuse Spark plug S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Ignition coil S Damaged ignition coil S Broken or shorted primary or secondary coils S Faulty spark plug lead FUEL SYSTEM Fuel tank S Empty fuel tank S Clogged fuel filter S Clogged fuel tank breather hole S Deteriorated or contaminated fuel Fuel cock S Clogged or damaged fuel hose Carburetor S Deteriorated or contaminated fuel S Clogged pilot jet S Clogged pilot air passage S Sucked-in air S Damaged float S Worn needle valve S Incorrectly installed needle valve seat S Incorrect fuel level S Incorrectly installed pilot jet S Clogged starter jet S Faulty starter plunger S Incorrectly adjusted starter cable
Ignition system S Faulty TCI unit S Faulty pickup coil Switches and wiring S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring S Faulty neutral switch S Faulty start switch S Faulty sidestand switch S Faulty clutch switch S Incorrectly grounded circuit S Loose connections Starting system S Faulty starter motor S Faulty starter relay S Faulty neutral relay S Faulty starter clutch
8-1
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM ANDHIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING

EAS00846
TRBL SHTG
INCORRECT ENGINE IDLING SPEED

ENGINE Cylinders and cylinder head S Incorrect valve clearance S Damaged valve train components Air filter S Clogged air filter element FUEL SYSTEM Carburetor S Faulty starter plunger S Loose or clogged pilot jet S Loose or clogged pilot air jet S Damaged or loose carburetor joint S Incorrectly adjusted engine idling speed (throttle stop screw) S Incorrect throttle cable free play S Flooded carburetor ELECTRICAL SYSTEMS Battery S Faulty battery S Discharged battery Spark plug S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Ignition coil S Broken or shorted primary or secondary coils S Faulty spark plug lead S Damaged ignition coil Ignition system S Faulty CDI unit S Faulty pickup coil
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to STARTING PROBLEMS. ENGINE Air filter S Clogged air filter element FUEL SYSTEM Carburetors S Faulty diaphragm S Incorrect fuel level S Loose or clogged main jet
EAS00850
FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS. SHIFT PEDAL DOES NOT MOVE Shift shaft S Incorrectly adjusted shift rod S Bent shift shaft Shift drum and shift forks S Foreign object in a shift drum groove S Seized shift fork S Bent shift fork guide bar Transmission S Seized transmission gear S Foreign object between transmission gears S Incorrectly assembled transmission JUMPS OUT OF GEAR Shift shaft S Incorrect shift pedal position S Incorrectly returned stopper lever Shift forks S Worn shift fork Shift drum S Incorrect axial play S Worn shift drum groove Transmission S Worn gear dog
8-2
FAULTY CLUTCH/OVERHEATING
EAS00851
TRBL SHTG
FAULTY CLUTCH
CLUTCH SLIPS Clutch S Incorrectly assembled clutch S Incorrectly adjusted clutch cable S Loose or fatigued clutch spring S Worn friction plate S Worn clutch plate Engine oil S Incorrect oil level S Incorrect oil viscosity (low) S Deteriorated oil CLUTCH DRAGS Clutch S Unevenly tensioned clutch spring S Warped pressure plate S Bent clutch plate S Swollen friction plate S Bent clutch push rod S Damaged clutch boss S Burnt primary driven gear bushing S Match marks not aligned Engine oil S Incorrect oil level S Incorrect oil viscosity (high) S Deteriorated oil
EAS00854
OVERHEATING
ENGINE Cylinder head(-s) and piston(-s) S Heavy carbon buildup Engine oil S Incorrect oil level S Incorrect oil viscosity S Inferior oil quality FUEL SYSTEM Carburetors S Incorrect main jet setting S Incorrect fuel level S Damaged or loose carburetor joint Air filter S Clogged air filter element CHASSIS Brakes S Dragging brake ELECTRICAL SYSTEMS Spark plugs S Incorrect spark plug gap S Incorrect spark plug heat range Ignition system S Faulty CDI unit
8-3
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING

EAS00859
TRBL SHTG
POOR BRAKING PERFORMANCE

Front brake S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper piston seal S Loose union bolt S Damaged brake hose S Oil or grease on the brake disc S Oil or grease on the brake pad S Incorrect brake fluid level Rear brake S Improper brake pedal adjustment S Worn brake shoe S Improper brake shoe contact S Worn camshaft S Worn brake drum S Mud or water into brake drum inside S Oily or greasy brake lining S Faulty brake cable S Broken or fatigued tension spring S Faulty camshaft, cam lever
EAS00861
FAULTY FRONT FORK LEGS

LEAKING OIL S Bent, damaged or rusty inner tube S Damaged outer tube S Incorrectly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod assembly bolt S Damaged damper rod assembly, bolt, or copper washer S Damaged cap bolt O-ring MALFUNCTION S Bent or damaged inner tube S Bent or damaged outer tube S Damaged fork spring S Worn or damaged outer tube busing S Bent or damaged damper rod S Incorrect oil viscosity S Incorrect oil level
EAS00864
UNSTABLE HANDLING
Handlebar S Bent or incorrectly installed handlebar Steering head components S Incorrectly installed upper bracket S Incorrectly installed lower bracket (incorrectly tightened ring nut) S Bent steering stem S Damaged ball bearing or bearing race Front fork legs S Unevenoil levels (both front fork legs) S Unevenly tensioned fork spring (both front fork legs) S Damaged fork spring S Bent or damaged inner tube S Bent or damaged outer tube Swingarm S Worn bearing or bushing S Bent or damaged swingarm Rear shock absorber assembly S Faulty rear shock absorber spring S Leaking oil or gas Tires S Uneven tire pressures (front and rear) S Incorrect tire pressure S Uneven tire wear Wheels S Incorrect wheel balance S Loose sporks S Deformed wheel rim S Damaged wheel bearing S Bent or loose wheel axle S Excessive wheel runout Frame S Bent frame S Damaged steering head pipe S Incorrectly installed bearing race
8-4
FAULTY LIGHTING AND SIGNALING SYSTEMS

EAS00866
TRBL SHTG
FAULTY LIGHTING AND SIGNALING SYSTEMS

HEADLIGHT DOES NOT LIGHT S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Incorrectly grounded circuit S Poor contacts (main or light switch) S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Incorrectly grounded circuit S Faulty main switch S Faulty light switch S Headlight bulb life expired TAIL/BRAKE LIGHT DOES NOT LIGHT S Wrong tail/brake light bulb S Too may electrical accessories S Incorrect connection S Burnt-out tail/brake light bulb TAIL/BRAKE LIGHT BULB BURNT OUT S Wrong tail/brake light bulb S Faulty battery S Incorrectly adjusted rear brake light switch S Tail/brake light bulb life expired TURN SIGNAL DOES NOT LIGHT S Faulty turn signal switch S Faulty flasher relay S Burnt-out turn signal bulb S Incorrect connection S Damaged or faulty wire harness S Incorrectly grounded circuit S Faulty battery S Blown, damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY S Faulty flasher relay S Faulty main switch S Faulty turn signal switch S Wrong turn signal bulb TURN SIGNAL REMAINS LIT S Faulty flasher relay S Burnt-out-turn signal bulb TURN SIGNAL BLINKS QUICKLY S Incorrect turn signal bulb S Faulty flasher relay S Burnt-out turn signal bulb HORN DOES NOT SOUND S Incorrectly adjusted horn S Damaged or faulty horn S Faulty main switch S Faulty horn switch S Faulty battery S Blown, damaged or incorrect fuse S Faulty wire harness
8-5
XVS125 2000 WIRING DIAGRAM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
A.C. magneto Rectifier/ regulator Main switch Fuse (main) Starter relay Battery Starter motor Fuse (ignition) Relay unit Clutch switch Sidestand switch Throttle position sensor Ignitor unit Ignition coil #1 Ignition coil #2 Spark plug Pickup coil Neutral switch Meter Engine warning light Neutral indicator light High beam indicator light Turn signal indicator light Meter light Right handlebar switch Engine stop switch Start switch Light switch Left handlebar switch Pass switch Dimmer switch Horn switch Turn signal switch Horn Flasher relay Headlight Auxiliary light Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Fuse (headlight) Fuse (signal) Rear stop switch Front stop switch Tail/ brake light Fuse (carburetor heater) Thermo switch Carburetor heater Carburetor heater ground Red/ Blue Red/ White Red/ Yellow White/ Black WHite/ Green White/ Red
COLOR CODE
B ..... Br . . . . Ch . . . Dg . . . G .... Gy . . . L ..... Black Brown Chocolate Dark green Green Gray Blue Lg . . . . O .... P ..... R..... Sb . . . . W .... Y ..... Light green Orange Pink Red Sky blue White Yellow B/ L . . . B/ R . . . B/ Y . . . Br/ L . . Br/ W . Br/ Y . . G/W . . Black/ Blue Black/ Red Black/ Yellow Brown/ Blue Brown/ White Brown/ Yellow Green / White G/Y . . L/B . . . L/G . . . L/R . . . L/W . . L/Y . . . R/ B . . . Green / Yellow Blue/ Black Blue/ Green Blue/ Red Blue/ White Blue/ Yellow Red/ Black R/ L . . . R/ W . . R/ Y . . . W/ B . . W/ G . . W/ R . .

Yamaha XVS 125 &#39;00 - Service Manual

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Yamaha XVS 125 &#39;00 - Service Manual

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HOW TO USE THIS MANUAL

Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted

Symbols 23 to 24 in the exploded diagrams indicate the following:

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CHECKING THE CONNECTIONS

CHECKING THE CONNECTIONS

These tools are used to remove the rocker arm shaft.

90890-01311 Damper rod holder 90890-01365 T-handle 90890-01326

Regular unleaded gasoline 11 L 3.4 L Wet sump

SSS SSS SSS SSS SSS

SSS SSS 0.05 mm

SSS SSS SSS SSS

26.190 mm #1 : 21.045 mm #2 : 21.087 mm 5.19 mm 26.190 mm #1 : 21.087 mm #2 : 21.045 mm 5.19 mm SSS

26.15 mm 21.005 mm 21.047 mm SSS 26.15 mm 21.047 mm 21.005 mm SSS 0.015 mm

0.08 X 0.12 mm 0.10 X 0.14 mm

Valve seat width Intake Exhaust

0.9 X 1.1 mm 0.9 X 1.1 mm

27.81 mm 27.81 mm SSS SSS SSS SSS

Intake Exhaust Winding direction (top view) Intake Exhaust

SSS SSS Clockwise Clockwise

2.5_ /1.3 mm 2.5_ /1.3 mm SSS SSS

Cylinders Cylinder arrangement Bore stroke Compression ratio Bore

Air coded 4-stroke 41 47 mm 11.0 : 1 40.99 X 41.03 mm

SSS SSS SSS 41.1 mm

3 mm 13.002 X 13.013 mm 0 mm Intake side 12.996 X 13.000 mm 0.002 X 0.017 mm

SSS 13.045 mm SSS SSS 12.976 mm SSS

Barrel 0.8 1.7 mm 0.15 X 0.30 mm 0.02 X 0.08 mm

SSS SSS 0.4 mm 0.12 mm

Taper 0.8 1.7 mm 0.15 X 0.30 mm 0.02 X 0.06 mm

SSS SSS 0.4 mm 0.12 mm

Dimensions (B T) End gap (installed)

1.5 1.6 mm 0.2 X 0.7 mm

67.95 X 68.00 mm 0.40 X 1.05 mm 0.020 X 0.048 mm

SSS 0.03 mm SSS SSS

SSS SSS SSS SSS SSS SSS SSS SSS SSS

1.0 mm 1.0 mm SSS SSS SSS SSS

J0226, J0227 (DENSO) 6 mm 3.4 X 4.6 10.4 X 15.6 k 4.0 X 6.0 k

SSS SSS SSS SSS SSS

GENERAL TORQUE SPECIFICATIONS/ CONVERSION TABLE

GENERAL TORQUE SPECIFICATIONS

A: Distance between flats B: Outside thread diameter

General torque specifications

Volume / Capacity Miscellaneous

Part name Screw Nut Screw Bolt Nut

Screw Screw Bolt

Crankcase tightening sequence:

Tightening torque Nm 7 23 3 3 7 16 59 104 40 23 40 6 30 16 40 40 26 4 7

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE OIL LUBRICATION CHART SPECIFICATIONS

ENGINE OIL LUBRICATION CHART SPECIFICATIONS

ENGINE OIL FLOW DIAGRAMS

ENGINE OIL FLOW DIAGRAMS

ENGINE OIL FLOW DIAGRAMS

ENGINE OIL FLOW DIAGRAMS

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Rear brake Brake hose Wheels

Chassis fasteners Sidestand

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

RIDER AND PASSENGER SEATS

Yamaha XVS 125 '00 - Service Manual

Yamaha XVS 125 '00 - Service Manual