FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theXVS1100 (N). For complete service information procedures it is necessary to use this SupplementaryService Manual together with the following manual.

XVS1100 (L) SERVICE MANUAL: 5EL1-AE1

EB000000

XVS1100 (N)SUPPLEMENTARY SERVICE MANUAL

2000 by Yamaha Motor Co.,Ltd.First edition, September 2000

All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir 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 mo-torcycles 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 andunfit for use.

Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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EB002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of eachsection. It is located in the upper right corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-moval and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed bya circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks6 . The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition tothe exploded diagram and the job instruction chart.

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13

11

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CHKADJ

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on thetop right of each page and indicate the subject ofeach chapter.

1 General information2 Specifications3 Periodic inspections and adjustments4 Engine5 Cooling system6 Carburetion7 Chassis8 Electrical9 Troubleshooting

Illustrated symbols 10 to 17 are used to identifythe specifications appearing in the text.10 Can be serviced with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Torque15 Wear limit, clearance16 Engine speed17 Ω, V, A

Illustrated symbols 18 to 23 in the exploded dia-grams indicate the types of lubricants and lu-brication points.18 Apply engine oil19 Apply gear oil20 Apply molybdenum disulfide oil21 Apply wheel bearing grease22 Apply lightweight lithium-soap base grease23 Apply molybdenum disulfide greaseIllustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply locking agent 24

and when to install new parts 25 .24 Apply locking agent (LOCTITE)25 Replace

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 16. . . . . . . . . . .

ELECTRICAL SYSTEM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULB 18. . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAM 19. . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETION

AIR INDUCTION SYSTEM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 20. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 22. . . . . . . . . . . . . . . . . . .

CHASSIS

FRONT AND REAR BRAKES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE CALIPERS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–1–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard

Model code: XVS1100: 5PB2

Basic weight:With oil and a full fuel tank 275 kg

Tire:TypeSize front

rearManufacturer front

rearType front

rear

With tube110/90-18 61S170/80-15M/C 77SDUNLOPDUNLOPK555FK555

Maximum load-except motorcycle: 200 kg

–2–

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Camshaft:Drive methodCam cap inside diameterCamshaft outside diameterShaft-to-cap clearanceCam dimensions

Intake “A”“B”“C”

Exhaust “A”“B”“C”

Camshaft runout limit

Chain drive (left & right)25.000 25.021 mm24.96 24.98 mm0.020 0.061 mm

39.112 39.212 mm32.093 32.193 mm7.162 mm39.112 39.212 mm32.127 32.227 mm7.162 mm

39.012 mm31.993 mm7.012 mm39.012 mm32.027 mm7.012 mm0.03 mm

–3–

MAINTENANCE SPECIFICATIONS SPEC

CHASSIS

Item Standard Limit

Front suspension:Front fork travelFork spring free lengthFitting lengthCollar lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)Optional springOil capacityOil levelOil grade

140 mm356.9 mm319.4 mm183 mm4.41 N/mm (0.9 kg/mm)6.37 N/mm (1.3 kg/mm)0 77.5 mm77.5 140 mmNo0.464 L108 mmFork oil 10W or equivalent

350 mm

Rear suspension:Shock absorber travelSpring free lengthFitting lengthSpring rate (K1)Stroke (K1)Optional spring

50 mm179.5 mm163 mm117.7 N/mm (12 kg/mm)0 50 mmNo

Tightening torques

Part to be tightened Thread sizeTightening

torque RemarksgNm mkg ftlb

Brake caliper and bracket M10 27 2.7 20

–4–

MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Item Standard Limit

Ignition coil:Model/manufacturerPrimary winding resistanceSecondary winding resistance

F6T541/MITSUBISHI3.57 4.83 Ω at 20C10.7 14.5 kΩ at 20C

Charging system:TypeModel/manufacturerNominal outputStator coil resistance/color

A.C. magnetoF4T654/MITSUBISHI14 V 305 W at 5,000 r/min0.36 0.44 Ω at 20C/White – White

Electric starter system:TypeStarter motor:

Model/manufacturerOutputArmature coil resistanceBrush overall lengthBrush spring pressureCommutator diameterMica undercut

Starter relay:Model/manufacturerAmperage rating

Constant mesh type

SM-13/MITSUBA0.6 kW0.026 0.034 Ω at 20C10 mm7.65 10.01 N (780 1021 g)28 mm0.7 mm

MS5F-421/JIDECO180 A

5 mm

27 mm

–5–

CABLE ROUTING SPEC

1 Clutch cable2 Starter cable3 Handlebar switch lead (left)4 Handlebar switch lead (right)5 High tension code6 Throttle cable7 Fuel hose (fuel cock-filter)8 Fuel breather hose (fuel tank-roll

over valve) (for CAL)9 Fuse box10 Alarm connector11 Fuel pump lead

12 Speed sensor lead13 Sidestand switch lead14 Neutral switch lead15 Pickup coil lead16 To engine17 A.C. magneto lead18 Ventilation hose19 Sensing hose (AIS-carburetor

joint)20 Fuel hose (carburetor-fuel pump)21 Clip22 Brake hose

EB206000

CABLE ROUTING23 Heat protector24 Speed meter lead25 Wireharness26 Purge hose (carburetor-sole-

noid valve) (for CAL)27 Fitting plate28 Fuel hose (inlet) (fuel filter-fuel

pump)29 Fuel hose (outlet) (carburetor-

fuel pump)30 Alarm connector lead31 Wireharness

–6–

A Fasten the handlebar switchlead (left and rihgt) to the hand-lebar with plastic locking tie andcut the end of tie.

B Fasten the mainharness with a plastic clamp at the back of the cable guide.

C Clamp the wireharness with thehook of frame side.

D When installing the pipe ofthrottle cable press it inside.

E Clamp the fuel hoses to theframe with the clamp.

F Change the fuel hose (fuel cockside) and fuel hose (carburetorside) between guide of frameand clamp. (carburetor side isupper)

G When connecting the sensinghose (carburetor joint-AIS) witha nozzle.

H Push the sensing hose inside ofthe LID and not bend the sensinghose.

I Push the wireharness inside ofthe side cover.

CABLE ROUTING SPEC27

–7–

J Position the all connectors insideof the connector cover.

K Through the wireharness of so-lenoid valve between AIS ductand fuel hose (for CAL).

L Fasten the alarm lead with aplastic band on the LID.

M Fasten the sidestand switch leadto the bracket of LID with plasticlocking tie.

N Fasten the lead with locking tienear the side cover.

O Route the clutch cable throughthe cable guide.

P Position the throtlle cable andstarter cable as shown andclamp them with holder.

Q Fasten the handlebar switchleads (left and right) under thehandle crown with a plasticband. Set the band at fournotches and install it no slacking.

R Route the each hoses through theframe guide and do not pinch it.

S When installing the fitting plate,do not pinch the each hoses andwireharness.

T Wher install the AIS push thewireharness to space of rearside.

CABLE ROUTING SPEC

–8–

1 Battery2 Battery positive (+) lead3 Starter motor positive lead4 Speedmeter lead5 Fuel hose (carburetor-fuel pump)6 High tension code7 Main switch lead8 Throttle cable9 Brake hose10 Handlebar switch lead (right)11 Headlight lead

12 Ignition coil13 Breather hose14 Purge hose (carburetor-solenoid

valve) (for CAL)15 Rear brake switch16 Reserve hose17 Air filter drain hose18 Delay relay19 Battery negative (–) lead20 Starter motor positive (+) lead21 Oil level switch lead

22 Rear brake switch lead23 Carburetor heater connecter24 Light reduce relay25 Rectifier / regulator26 Stay. 127 Down tube28 frame29 Stay. 230 Battery box31 Carburetor heater lead32 Light reduce lelay lead

CABLE ROUTING SPEC

–9–

33 Flasher relay34 Handlebar switch lead (left)35 Silencer36 Throttle position sensor lead37 Carburetor heater lead38 Thermo switch lead39 Starting circuit cut-off relay40 Horn41 Rectifire/regulator and light (re-

duce relay) lead

A Clamp the battery positive (+)lead to the battery with batteryband.

B Connect the battery negative (–)lead and push it in to the spacebetween battery box and battery.

C Push the wireharness into thespace between frame and start-er motor relay.

D Route the rectifire/regulatorlead, wireharness and startermotor positive (+) lead throughthe out of frame bracket and fas-ten them to the frame with a plas-tic locking tie. The place to fixmust be between 0 mm and10 mm from the top of thediverging point of the lead on theharness side whitch connectedthe battery negative (–) lead.

CABLE ROUTING SPEC

–10–

M Fasten the rear brake switch leadand master cylinder reservoirhose to the down tube with a plas-tic locking tie, and cut the end oflocking tie and position is inside offrame.

N About 20 mm from bead end.O Locate the band to forward of

down tube.P Route the rectifire/regulator lead

and carburetor heater leadthrough inside of battery box holeto outside it and connect them.

CABLE ROUTING SPEC

I Fasten the rear brake switchlead to the rear brake switchbracket with a plastic locking tieand cut of the end, inside of frame.

J Fasten the wireharness, startermotor positive (+) lead and bat-tery negative (–) lead to theframe with a plastic locking tie.

K From the engine.L About 70 mm

E Connect the purge hose (carbu-retor side-solenoid valve side)with joint, knob is out side of frame.

F Route the front turn signal /posi-tion light lead and headlight leadthrough the rear of headlightbody hole.

G Connect the ignition coil lead atred tape to the right side.

H Knob of clip is rearside of body.

–11–

Q To rear brake.R Fasten the rear brake switch

lead with a band to down tube.(four point)

S Cutting part at the edge of theband.

T About 30 45

CABLE ROUTING SPEC

U Fasten the oil level sensor leadwith a locking tie to battery box.Fix to the battery box with theband. To fix, algin the band to thebottom of the box’s hole while fix-ing the lead to the back of the box(inside the body). The cutting partat the edge of the band comes tothe front side of the body.

V Clamp the handlebar switch lead(right) to the frame with a holder.The part to open and shut is out-side of the body.

W Arrange the throttle position sen-sor connector, carburetor heaterconnector and thermo switchconnector between the startingcircuit cut off relay and high ten-sion code.

X Put the light reduce relay lead,carburetor heater lead into thebottom of the groove.

–12–

1 Brake hose2 Throttle cable3 Master cylinder reservoir hose4 High tension code5 Purge hose (carburetor-solenoid

valve) (for CAL)6 Rear brake switch lead7 Fuel hose (carburetor-fuel pump)8 Delay relay9 Battery negative (–) lead10 Battery negative (–) lead con-

nector11 Battery

CABLE ROUTING SPEC

12 Battery positive (+) lead13 Taillight lead14 Starter relay15 Starter motor positive (+) lead16 Fuel tank breather hose (fuel

tank-roll over valve) (for CAL)17 Outlet18 Inlet19 Ventilation hose20 Starter cable21 Sensing hose (AIS-carburetor

joint)22 Fuel hose (fuel cock-fuel filter)

23 Throttle position sensor lead24 Carburetor heater lead25 Tappet cover26 Clutch cable27 Thermo switch lead28 Wireharness29 Frame30 Igniter unit31 LID. 232 Mud guard33 Fuel filter34 LID.35 Ignitor unit lead36 Speed meter lead connecter

–13–

A Clamp the throttle cables withthe holder. Position the end ofclip downword.

B Route the rear brake switch leadunder the master cylinder reser-vor hose.

C Position the band end of rightside bracket.

D Position the steel band end toforward.

CABLE ROUTING SPEC

E Position the steel band end toright side.

F Route the battery positive (+)lead through the slit of the bat-tery box.

G Clamp the igniter unit lead to theframe with a holder.

H To the rear fender.

I Connect the wireharness to theignitar unit through the hole ofLID. 2.

J Route the fuel tank breatherhose under the fuel filter andconnect it (fuel tank sideroll overvalve side) with a joint. Positionthe end of clip outside.

–14–

K Position the mark on the steelband to forward.

L Fasten the wireharness with aband on the tool box plate.

M Fasten the wireharness to theframe with a plastic locking tie.Position the locking tie front ofthe holder.

N Route the wireharness outsideof the guide on the frame.

CABLE ROUTING SPEC

O Clamp the clutch cable and start-er cable with a holder.Position the end of holder downside.

P Route the igniter lead throughthe igniter plate hole to the wire-harness.

Q To the wireharness.R Clamp the taillight lead with mud

guard clamp.

S Clamp the taillight lead with aholder on the mud guard.

T Position the locking tie upward.U The front direction of the level

body.

–15–

CABLE ROUTING SPEC

1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hose7 Handlebar switch lead (right)

A Route the handlebar switchlead (right) rear side of thethrottle cable.

–16–

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHKADJ

NOTE:

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjust-ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

The annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.

From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √

2 * Fuel filter Check condition. √ √

Check condition.√ √

3 Spark plugs Clean and regap. √ √

Replace. √ √

4 * Valves Check valve clearance. Adjust

√ √ √ √

5 Air filter element Clean. √ √

5 Air filter element Replace. √ √

6 Clutch Check operation. Adjust.

√ √ √ √ √

7 * Front brake

Check operation, fluid level and vehicle for fluidleakage. (See NOTE)

√ √ √ √ √ √

Replace brake pads. Whenever worn to the limit

8 * Rear brake

Check operation, fluid level and vehicle for fluidleakage. (See NOTE)

√ √ √ √ √ √

Replace brake pads. Whenever worn to the limit

9 * Brake hose Check for cracks or damage. √ √ √ √ √

9 * Brake hose Replace. (See NOTE) Every 4 years

10 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.

√ √ √ √

11 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

√ √ √ √

12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √

13 * Steering bearings Check bearing play and steering for roughness. √ √ √ √ √

13 * Steering bearings Lubricate with lithium-soap-based grease. Every 20,000 km

14 * Chassis fasteners Make sure that all nuts, bolts and screws are

properly tightened.√ √ √ √ √

15 Sidestand Check operation. Lubricate.

√ √ √ √ √

16 * Sidestand switch Check operation. √ √ √ √ √ √

–17–

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHKADJ

NOTE:

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

17 * Front fork Check operation and for oil leakage. √ √ √ √

18 *Rear shock

Check operation and shock absorber for oil leak-age.

√ √ √ √18 * absorber assembly

Lubricate the pivoting points with molybdenumdisulfide grease.

√ √

19 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.

√ √ √ √ √ √

20 Engine oil Change. √ √ √ √ √ √

21Engine oil filterelement Replace. √ √ √

22 Final gear oil Check oil level and vehicle for oil leakage. √ √ √

22 Final gear oil Change. √ √ √

23Moving parts andcables Lubricate. √ √ √ √ √

24 *Lights, signalsand switches

Check operation. Adjust headlight beam.

√ √ √ √ √ √

EAU03541

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service– Regularly check and, if necessary, correct the brake fluid level.– Every two years replace the internal components of the brake master cylinder and caliper, and

change the brake fluid.– Replace the brake hoses every four years and if cracked or damaged.

–18–

REPLACING THE HEADLIGHT BULBCHKADJ

WARNING

CAUTION:

ELECTRICAL SYSTEMEAS00182

REPLACING THE HEADLIGHT BULB1. Disconnect:connector 1

2. Removeheadlight bulb cover 2

3. Remove:headlight bulb holder 1

4. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

5. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

6. Install:headlight bulb holder

7. Install:headlight bulb cover

8. Connect: leads

–19–

ADJUSTING THE HEADLIGHT BEAMCHKADJ

a

b

a

b

EAS00184

ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)

a. Turn the adjusting screw 1 in direction a orb .

Direction Headlight beam is raised.

Direction Headlight beam islowered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 2 in direction a orb .

Direction Headlight beam moves tothe right.

Direction Headlight beam moves tothe left.

–20–

AIR INDUCTION SYSTEM CARB

NOTE:

CARBURETIONAIR INDUCTION SYSTEMAIR INDUCTION SYSTEM DIAGRAMS

1 Reed valve2 Air filter3 Orifice4 Carburetor joint (near cylinder)A To the front cylinder headB To the rear cylinder headC To the orificeD To the carburetor joint (rear cylinder)E To the air cut-off valve

The orifice 3 should be installed with the arrowmark facing the air cut-off valve side.

–21–

Order Job name/Part name Q’ty Remarks

12345678

9

Removeing the air induction systemSide coverAir filterAir filter to air cut valve hoseAir cut valveVacuume hose 2OrificeVacuum hose 1Reed valve case to rear cylinder headpipeReed valve case to rear cylinder headpipe

11111111

1

Remove the parts in the order listed.

For installation, reverse the removalprocedure.

AIR INDUCTION SYSTEM CARB

–22–

AIR INDUCTION SYSTEM CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.

3. Measure: reed valve bending aOut of specification Replace the reedvalve.

Maximum reed valve bending0.4 mm

1 Surface plate

4. Check:air cutoff valveCracks/damage Replace.

5. Check:air cleanerCracks/damage Replace.Clogged Clean.

–23–

Order Job name/Part name Q’ty Remarks

123456

Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetaining boltBrake caliper assembly

112121

Remove the parts in the order listed.Drain

For installation, reverse the removalprocedure.

Refer to “REMOVING/INSTALLINGTHE FRONT BRAKE CALIPERS”.

6 Nm (0.6 mkg)

27 Nm (2.7 mkg)

30 Nm (3.0 mkg)

FRONT AND REAR BRAKES CHAS

CHASSISFRONT AND REAR BRAKESFRONT BRAKE CALIPERS

–24–

Order Job name/Part name Q’ty Remarks

12345678

Removing the lower bracket

Front fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Front turn signal/position light (left/right)Headlight bodyBrake hose joint/holderUpper bracketLock washerUpper ring nut

1–

1/11

1/1111

Remove the parts in the order listed.Stand the motorcycle on a level surface.

Securely support the motorcycle sothat there is no danger of it falling over.

Refer to “FRONT FORK”.Refer to “HANDLEBAR”.

Disconnect

WARNING

1st2nd

52 Nm (5.2 mkg)18 Nm (1.8 mkg)

110 Nm (11.0 mkg)

7 Nm (0.7 mkg)

STEERING HEAD CHAS

STEERING HEAD

–25–

Order Job name/Part name Q’ty Remarks

9101112131415

Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)

1111111

For installaiton, reverse the removalprocedure.

Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.

1st2nd

52 Nm (5.2 mkg)18 Nm (1.8 mkg)

110 Nm (11.0 mkg)

7 Nm (0.7 mkg)

STEERING HEAD CHAS