yamaha tdm850 96 service manual eng

EB000000

TDM850 ’96SERVICE MANUAL

1996 by Yamaha Motor Co., Ltd.First edition, March 1996

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

is expressly prohibited.

WARNING

CAUTION:

NOTICEThis manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and theirqualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is as-sumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have abasic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.Without such knowledge, attempted repairs or service to this model may render if unfit to use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifi-cations and significant changes in specifications or procedures will be forwarded to all Authorized Yamahadealers and will, where applicable, appear in future editions of this manual.

PARTICULARY IMPORTANT INFORMATIONThis material is distinguished by the following notation.

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

Failure to follow WARNING instructions could result in severe injury ordeath to the motorcycle operator, a bystander, or a person inspecting orrepairing the motorcycle.

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

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

12 4

6

5

7

3

8

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 each section.It is located in the upper left corner of the page.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied bycorresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removaland 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 by acircle indicates a disassembly step.3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . Themeanings 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 to theexploded diagram and the job instruction chart.

22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELECCHAS

COOL

INSPADJ

TRBLSHTG

EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on topright of each page and indicate the subject of eachchapter.

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 lubrica-tion 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 grease

Illustrated symbols 24 to 25 in the exploded dia-grams indicate where to apply a locking agent 24

and when to install new parts 25 .

24 Apply locking agent (LOCTITE )25 Replace

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION ANDADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1SPEC 2

3ENG 4

COOL 5CARB 6CHAS 7ELEC 8TRBLSHTG 9

INSPADJ

INDEX

GENINFO

CHAPTER 1.GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALL REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS, AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THE CONVERSION TABLE 1-5. . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENINFO

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

NOTE:

NOTE:

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.

The vehicle identification number is used to identi-fy the motorcycle and may be used to register themotorcycle with a licensing authority.

EB100030

ENGINE SERIAL NUMBERThe engine serial number 1 is stamped into thecrankcase.

The first three digits of the engine serial numberindicate the model type; the remaining digits arethe unit production number.

MODEL LABELThe model label 1 is affixed to the frame. This in-formation will be needed to order spare parts.

1-2

IMPORTANT INFORMATIONGENINFO

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL1. Remove all dirt, mud dust, and foreign material

before removal and disassembly.

2. Use proper tools and cleaning equipment.Refer to “SPECIAL TOOLS”.

3. When disassembling the motorcycle keepmated parts together. This includes gears, cyl-inders, pistons, and other mated parts thathave been “mated” through normal wear.Mated parts must be reused as an assembly orreplaced.

4. During the motorcycle disassembly, clean allparts and place them in trays in the order of dis-assembly. This will speed up assembly timeand help assure that all parts are correctly rein-stalled.

5. Keep away from fire.

ALL REPLACEMENT PARTS1. Use only genuine Yamaha parts for all replace-

ments. Use oil and/or grease recommendedby Yamaha for assembly and adjustment. Oth-er brands may be similar in function and ap-pearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS1. All gaskets, seals and O-rings should be re-

placed when an engine is overhauled.All gaskets surfaces, oil seal lips and O-ringsmust be cleaned.

2. Properly oil all mating parts and bearing duringreassembly. Apply grease to the oil seal lips.

1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

LOCK WASHERS/PLATES AND COTTER PINS1. All lock washers/plates 1 and cotter pins

must be replaced when they are removed.Lock tab(s) should be bent along the bolt or nutflat(s) after the bolt or nut has been properlytightened.

BEARINGS AND OIL SEALS1. Install the bearing(s) and oil seal(s) with their

manufacturer’s marks or numbers facing out-ward. (In other word, the stamped letters mustbe on the side exposed to view.) When instal-ling oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oilthe bearings liberally when installing.

1 Oil seal

Do not use compressed air to spin the bear-ings dry. This causes damage to the bearingsurfaces.

2 Bearing

CIRCLIPS1. All circlips should be inspected carefully before

reassembly. Always replace piston pin clips af-ter one use. Replace distorted circlips. Wheninstalling a circlips 1 , make sure that the sharpedged corner 2 is positioned opposite to thethrust 3 it receives. See the sectional view.

4 Shaft

1-4

CHECKING OF CONNECTIONSGENINFO

NOTE:

NOTE:

CHECKING OF CONNECTIONSDealing with stains, rust, moisture, etc. on the con-nector.1. Disconnect:Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two orthree times.

4. Pull the lead to check that it will not come off.5. If the terminal comes off, bend up the pin 1

and reinsert the terminal into the connector.

6. Connect:Connector

The two connectors “click” together.

7. Check for continuity with a tester.

If there is no continuity, clean the terminals.Be sure to perform the steps 1 to 7 listed above

when checking the wireharness.For a field remedy, use a contact revitalizer avail-

able on the market.Use the tester on the connector as shown.

1-5

HOW TO USE THE CONVERSION TABLEGENINFO

HOW TO USE THE CONVERSIONTABLEAll specification data in this manual are listed in SIand METRIC UNITS.Use this table to convert METRIC unit data to IM-PERIAL unit data.

Ex.METRIC MULTIPLIER IMPERIAL

**mm 0.03937 = **in2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Torque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kg 2.205 lbWeight gg 0.03527 oz

Speed km/hr 0.6214 mph

Dis-tance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume/Capacity

cc (cm3)cc (cm3)lit (liter)lit (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)

Miscel-laneous

kg/mmkg/cm2

Centigrade(C)

55.99714.22349/5+32

lb/ inpsi (lb/ in2)Fahrenheit(F)

1-6

SPECIAL TOOLSGENINFO

SPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly.Using the correct special tool will help prevent damage caused by the use of improper tools or improvisedtechniques. The shape and part number used for the special tool differ by country, so two types are pro-vided. Refer to the list provided to avoid errors when placing an order.

Tool No. Tool name/How to use Illustration

90890-0108390890-01084

Slide hammer boltWeight

These tools are used to remove themain axle assembly cover.

90890-01304 Piston pin puller

This tool is used to remove the pistonpin.

90890-01312 Fuel level gauge

This gauge is used to measure the fuellevel in the float chamber.

90890-0132590890-01352

Radiator cap testerAdapter

This tester is needed for checking thecooling system.

90890-0136290890-01382

Flywheel pullerCrankshaft protector

These tools are used to remove the A.C.magneto.

90890-0136790890-01374

Fork seal driver weightAdapter

These tools are used when installing thefork seal.

90890-0132690890-01465

T-handleDamper rod holderThese tools are used to loosen andtighten the front fork damper rodholding bolt.

90890-01403 Ring nut wrench

This tool is used to loosen and tightenthe steering ring nut.

1-7



90890-01701 Sheave holder

This tool is used to hold the rotor whenloosening and tightening the rotor bolt.

90890-03081 Compression gauge

This gauge is used to measure theengine compression.

90890-03094 Vacuum gauge

This gauge is needed for carburetorsynchronization.

90890-03112 Pocket tester

This instrument is invaluable forchecking the electrical system.

90890-03113 Engine tachometer

This tool is needed for detectingengine rpm.

90890-03141 Timing light

This tool is necessary for checkingignition timing.

90890-04016 Valve guide remover, installer andreamer (5.5 mm)

These tools are used to remove, installand rebore the valve guide.

90890-0401990890-04108

Valve spring compressorAttachment

These tools are needed to remove andinstall the valve assemblies.

90890-04086 Universal clutch holder

This tool is used to hold the clutch whenremoving or installing the clutch bossnut.

90890-06754 Ignition checker

This instrument is necessary forchecking the ignition system components.

1-8



90890-85505 Yamaha bond No. 1215

This sealant (bond) is used on crankcasemating surfaces, etc.

SPEC

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINT AND GRADE OF LUBRICANT 2-18. . . . . . . . . . . . . . . . ENGINE 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard

Model: TDM850

Model code: 4TX1

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,165 mm, 2,200 mm (D, DK, SF, N, S)790 mm1,285 mm805 mm1,475 mm165 mm2,900 mm

Basic weight (With oil and full fuel tank): 229 kg

Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting system

Liquid-cooled 4-stroke, DOHC, 5 valveForward-inclined parallel 2-cylinder0.849 L89.5 67.5 mm10.5 : 11,200 kPa (12 kg/cm2, 12 bar) at 300 r/minElectric starter

Lubrication system: Dry sump

Oil type or grade:Engine oil

API Standard:API SE or higher grade

Oil capacity:Engine oilPeriodic oil changeWith oil filter replacementTotal amount

3.5 L3.6 L4.2 L

2-2


Item Standard

Air filter: Dry type element

Fuel:TypeFuel tank capacityFuel reserve amount

Regular unleaded gasoline20 L3.1 L

Carburetor:Type/quantityManufacturer

BDST38/2MIKUNI

Spark plug:TypeManufacturerSpark plug gap

DPR8EA-9/X24EPR-U9NGK/NIPPONDENSO0.8 0.9 mm

Clutch type: Wet, multiple-disc

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st

2nd3rd4th5th

Spur gear67/39 (1.718)Chain drive42/17 (2.471)Constant mesh 5-speedLeft foot operation37/13 (2.846)37/20 (1.850)30/21 (1.429)27/23 (1.174)28/27 (1.037)

Chassis:Frame typeCaster angleTrail

Diamond24.5103 mm

Tire:TypeSize front

rearManufacturer front

rearType front

rear

Tubeless110/80 ZR18150/70 ZR17BRIDGESTONE/PIRELLI/MICHELINBRIDGESTONE/PIRELLI/MICHELINBT54F/MTR03/MACADAM90XBT54R/MTR04/MACADAM90X

2-3


Item Standard

Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A*

frontrear

Loading condition B*frontrear

High speed ridingfrontrear

180 kg0 90 kg225 kPa (2.25 kg/cm2, 2.25 bar)275 kPa (2.75 kg/cm2, 2.75 bar)90 180 kg225 kPa (2.25 kg/cm2, 2.25 bar)275 kPa (2.75 kg/cm2, 2.75 bar)

225 kPa (2.25 kg/cm2, 2.25 bar)275 kPa (2.75 kg/cm2, 2.75 kg/cm2)

Brake:Front brake type

operationRear brake type

operation

Dual disc brakeRight hand operationSingle disc brakeRight foot operation

Suspension:Front suspensionRear suspension

Telescopic forkSwingarm (monocross)

Shock absorber:Front shock absorberRear shock absorber

Coil spring/Oil damperCoil spring/Gas-oil damper

Wheel travel:Front wheel travelRear wheel travel

149 mm144 mm

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

T.C.I. (digital)A.C. magnetoGT12B-412 V 10 AH

Headlight type: Quartz bulb (halogen)

Bulb wattage quantity:HeadlightAuxiliary lightTail /brake lightFlasher lightMeter light

Indicator lightsNeutralTurnHigh beam

12 V 55 W 212 V 5 W 112 V 5/21 W 212 V 21 W 412 V 3.4 W 112 V 1.7 W 212 V 3.0 W 1

12 V 3.4 W 112 V 3.4 W 112 V 3.4 W 1

* Load is total weight of cargo, rider, passenger and accessories

2-4

MAINTENANCE SPECIFICATIONS SPEC

Head Dia Face Width Seat Width Margin Thickness

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Cylinder head:Warp limit 0.03 mm

Cylinder:Bore sizeTaper limitOut of round limit

89.500 89.505 mm

89.6 mm0.05 mm0.03 mm

Camshaft:Drive methodCamshaft cap inside diameterCamshaft outside diameterCamshaft-to-cap clearanceCam dimensions

Timing chain (right)25.000 25.021 mm24.967 24.980 mm0.020 0.054 mm

Intake “A”“B”“C”

Exhaust “A”“B”“C”

Camshaft runout limit

35.95 36.05 mm27.95 28.05 mm7.9 8.1 mm35.95 36.05 mm27.95 28.05 mm7.9 8.1 mm

35.85mm27.85mm

35.85 mm27.85 mm

0.03 mm

Cam chain:Cam chain type/No. of linksCam chain adjustment method

82RH2015/138Automatic

Valve, valve seat, valve guide:Valve clearance (cold) IN

EXValve dimensions:

0.15 0.20 mm0.25 0.30 mm

“A” head diameter INEX

25.9 26.1 mm27.9 28.1 mm

2-5


Item Standard Limit

“B” face width INEX

“C” seat width INEX

“D” margin thickness INEX

Stem outside diameter INEX

2.06 2.46 mm2.06 2.46 mm0.9 1.1 mm0.9 1.1 mm0.8 1.2 mm0.8 1.2 mm5.475 5.490 mm5 460 5 475 mm

5.445 mm5 43 mmEX

Guide inside diameter INEX

Stem-to-guide clearance INEX

Stem runout limit

5.460 5.475 mm5.500 5.512 mm5.500 5.512 mm0.010 0.037 mm0.025 0.052 mm

5.43 mm5.55 mm5.55 mm0.08 mm0.10 mm0.01 mm

Valve seat width INEX

0.9 1.1 mm0.9 1.1 mm

1.6 mm1.6 mm

Valve spring:Free length IN

EXSet length (valve closed) IN

EXCompressed pressure(installed) IN

EXTilt li it IN

37.29 mm37.29 mm30.39 mm30.39 mm

10.0 11.6 kg10 0 11 6 k

35.2 mm35.2 mm

Tilt limit INEX

10.0 11.6 kg

2.5/1.7 mm2.5/1.7 mm

Direction of winding(top view) IN

EXClockwiseClockwise

2-6


Item Standard Limit

Piston:Piston to cylinder clearancePiston size “D”

Measuring point “H”Piston off-setPiston off-set directionPiston pin bore inside diameterPiston pin outside diameter

0.065 0.085 mm89.420 89.435 mm

4.5 mm1 mmIN side20.002 20.013 mm19.991 20.000 mm

0.15 mm

20.043 mm19.975 mm

Piston rings:Top ring:

TypeDimensions (B T)End gap (installed)Side clearance (installed)

2nd ring:

TypeDimensions (B T)End gap (installed)Side clearance (installed)

Oil ring:

Dimensions (B T)End gap (installed)

Barrel1.0 3.5 mm0.30 0.45 mm0.035 0.070 mm

Taper1.0 3.5 mm0.30 0.45 mm0.035 0.070 mm

2.00 2.85 mm0.2 0.7 mm

0.7 mm0.12 mm

0.8 mm0.12 mm

Connecting rod:Oil clearance 0.026 0.050 mm 0.09 mm

2-7


Item Standard Limit

Crankshaft:

Assembly width “A” Crank width “B”Runout limit “C”Big end side clearance “D”Small end free play “F”Journal oil clearance

153.6 154.4 mm64.75 65.25 mm

0.160 0.272 mm0.8 1.0 mm0.020 0.038 mm

0.035 mm0.5 mm

0.1 mm

Balancer:Balancer drive method Gear

Clutch:Friction plate thicknessQuantity

Clutch plate thicknessQuantityWarp limit

Clutch spring free lengthQuantity

Clutch release method

2.9 3.1 mm91.9 2.1 mm8

55 mm6Outer pull, rack & pinion pull

2.8 mm

0.1 mm53 mm

Transmission: Main axle deflection limit Drive axle deflection limit

0.08 mm0.08 mm

Shifter:Shifter typeGuide bar bending limit

Guide bar

0.1 mm

Carburetor:I.D.markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Pilot air jet 1 (P.A.J.1)Pilot air jet 2 (P.A.J.2)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Bypass 2 (B.P.2)Bypass 3 (B.P.3)Pilot screw (P.S)

4TX 00#142.5#605EI85-2/3Y-2#701.40.9#450.80.90.82.0

2-8


Item Standard Limit

Valve seat size (V.S)Starter jet 1 (G.S.1)Starter jet 2 (G.S.2)Throttle valve size (Th. V)Fuel level (F.L)Engine idle speedIntake vacuum

1.7#750.8#13015.8 16.8 mm1,050 1,250 r/min36.0 38.7 kPa (270 290 mmHg)

Fuel pump:TypeModel/manufacturerOutput pressure

Vacuum type4NX/MIKUNI10 kPa (0.1 kg/cm2, 0.1 bar)

Lubrication system:Oil filter typeOil pump typeTip clearanceSide clearanceBypass valve setting pressure

Relief valve operating pressure

Paper typeTrochoid type0 0.12 mm0.03 0.08 mm39 78 kPa (0.4 0.8 kg/cm2,0.4 0.8 bar)343 441 kPa (3.5 4.5 kg/cm2,3.5 4.5 bar)

0.17 mm0.15 mm

Cooling system:Radiator core sizeWidth/height/ thickness

Radiator cap opening pressure

Reservoir tank capacity<From low to full level>Water pumpTypeReduction ratio

300/180.6/27 mm75 105 kPa (0.75 1.05 kg/cm2,0.75 1.05 bar)0.3 L0.2 L

Single suction centrifugal pump44/44 38/27 (1.407)

2-9


Tightening torques

Part to be tightened Part nameThreadsize

Q’tyTightening

torque Remarksgsize

yNm mkg

Camshaft capCylinder head

Cylinder head coverCoolant drain bolt (cylinder body)Spark plugConnecting rodRotorCamshaft sprocketTiming chain tensionerRadiatorDelivery hose (crankcase-cylinder)

Oil pump assemblyOil baffle plateDrain bolt (oil pan)Oil strainerStay (relief valve)Oil filter cover

Ring nut (exhaust pipe)Exhaust pipe (CO test)Exhaust pipe and frameExhaust pipe and mufflerMufflerCrankcase

Balancer shaftBalancer holderChain coverDrive sprocket coverOil tank case 2Engine bracketCrankcase cover (left)Starter clutchClutch springClutch bossMain axle bearing housingDrive sprocketDrive axle cover plateShift cam stopper leverShift fork guideShift armShift rodShift pedalStopper bolt

Flange boltNutBoltBoltBolt—

NutFlange boltFlange bolt

BoltFlange bolt

BoltBolt

ScrewFlange bolt

BoltScrew

Flange boltFlange boltFlange bolt

NutBolt

Flange boltScrewBolt

Flange boltFlange boltFlange bolt

ScrewFlange boltFlange boltFlange boltFlange boltFlange boltFlange bolt

BoltScrew

NutScrew

NutBoltBolt

Flange boltFlange bolt

NutBoltBolt

M6M10M6M6M6

M12M9

M12M7M6M6

M10M6M6M6

M14M6M6

M10M6M8M6M8M8

M10M10M6M8M6M6M6M6M6M8M6M6M6

M20M6

M18M6M6M6M6M6M8M8

166281241424226214111421126

12112425221361315121211

10401010101848

13024107

21106

10357

1030102010242024401224121055

102410108

701270101012128

2222

1.04.01.01.01.01.84.8

13.02.41.00.72.11.00.61.03.50.71.03.01.02.01.02.42.02.44.01.22.41.21.00.50.51.02.41.01.00.87.01.27.01.01.01.21.20.82.22.2

Stake

Use lock washer

Use lock washer

2-10


Part to be tightened Part nameThread

size Q’tyTightening

torque Remarksg size yNm mkg

Stator coilStarter motorThermo switchThermo switch housing

ScrewFlange bolt

——

M6M6M6

PT1/8

3211

7102815

0.71.02.81.5

Crankcase tightening sequence:

2-11


CHASSIS

Item Standard Limit

Steering system:Steering bearing type Angular bearing

Front suspension:Front fork travelFork spring free lengthSpring rate (K1)Stroke (K1)Optional springOil capacity (per fork tube)Oil levelOil grade

149 mm505 mm6.4 N/mm (0.64 kg/mm)0 149 mmNo0.515 L130 mmFork oil 01 or equivalent

500 mm

Rear suspension:Shock absorber travelSpring free length (K1/K2)Fitting length (K1/K2)Spring rate (K1/K2)

Stroke (K1/K2)Optional spring

47 mm144 mm/69 mm136 mm/65 mm260 N/mm (26.0 kg/mm)/182 N/mm(18.2 kg/mm)0 30/30 47 mmNo

Swingarm:Free play limit end

side

1 mm0.3 mm

Front wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Cast wheel18 MT3.00Aluminum

1 mm0.5 mm

Rear wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Cast wheel17 MT4.00Aluminum

1 mm0.5 mm

Drive chain:Type/manufacturerNo. of linksChain slack

525HV/DAIDO11440 50 mm

2-12


Item Standard Limit

Front disc brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness innerPad thickness outerMaster cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

Dual298 4 mm

5.5 mm5.5 mm15.8 mm33.96 + 30.23 mmDOT 4

0.2 mm0.5 mm0.5 mm

Rear disc brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness innerPad thickness outerMaster cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

Single245 5 mm

5.5 mm5.5 mm14 mm42.8 mmDOT 4

0.15 mm0.5 mm0.5 mm

Controls:Brake lever slack (at lever pivot)Brake pedal heightBrake pedal slackClutch lever slack (at lever end)Throttle cable slack

0 mm29 mm0 mm10 15 mm3 5 mm

2-13


Tightening torques

Part to be tightened Threadsize

Tighteningtorque Remarksg size

Nm mkg

Upper bracket and inner tubeUpper bracket and steering stemSteering stem and ring nutInner tube and under bracketHorn bracket and brake hose holderBrake hose holder and under bracketFront brake hose union boltCowling stay and frameMeter and cowling stayHandlebar and grip endFront master cylinderUpper bracket and handlebar holder (upper)Upper bracket and cable holderUpper bracket and cable guideEngine mount (rear-upper)Engine mount (rear-lower)Engine bracket and frameEngine bracket and engine (upper)Engine bracket and engine (rear-lower)Pivot shaft and nutRear shock absorber and swingarmRear shock absorber and frameChain case and swingarmChain protectorSwingarm and brake hose guideRear fender cover and swingarmFuel cock and fuel tankFuel tank bracket and fuel tankFuel tank bracket and frameFuel tank (rear) and frameIgnition coil and frameVacuum pump stay and vacuum pumpVacuum pump stay and frameFuel cock and frameTail cover and frame (front)Battery box and frameCoolant reservoir tank and frameRear fender and frameTaillight bracket and frameTaillightRectifier/regulator and cowling staySide cover and frameRear fender stay and taillight bracketSidestandSidestand bolt and locknutFootrest bracket and frameRear footrest bracket and frameRear master cylinder and frameFootrest bracket and footrestFootrest and footrest tabBrake pedal and brake shaftFront wheel axleRear wheel axle and nutFront brake caliper and front forkRear brake caliper and caliper bracket

M8M22M25M10M6M6M10M8M6M16M6M8M6M6M10M10M8M10M8M14M10M12M6M6M6M6M6M6M8M8M5M6M6M6M6M6M6M6M8M6M6M6M8M10M10M8M8M8M10M8M6M16M16M10M10

23108163010103030726923778964306030906464777777161647777777237771646393030236416858

1074040

2.310.81.63.01.01.03.03.00.72.60.92.30.70.78.96.43.06.03.09.06.46.40.70.70.70.70.70.71.61.60.40.70.70.70.70.70.70.72.30.70.70.71.64.63.93.03.02.36.41.60.85.810.74.04.0

See “NOTE”

2-14


NOTE:

Part to be tightenedThread

size

Tighteningtorque Remarksg size

Nm mkg

Caliper bracket and swingarmBrake disc and wheel hub (front and rear)Driven sprocket and rear hubBleed screw and brake caliperRear brake hose union boltFront wheel axle pinch boltBrake hose joint and brake hoseChain puller and locknutFront fender and front forkBrake hose joint and front forkRear brake caliper and brake hose joint

M10M8

M10M8

M10M8

M10M8M6M6

M10

3520606

301914169

1040

3.52.06.00.63.01.91.41.60.91.04.0

1. First, tighten the ring nut approximately 48 Nm (4.8 mkg) by using the torque wrench, then loosen the ring nut completely.

2. Retighten the ring nut to specification.

2-15


ELECTRICAL

Item Standard Limit

Voltage: 12 V

Ignition system:Ignition timing (B.T.D.C.)Advancer type

10 at 1,150 r/minElectrical type

T.C.I.:Pickup coil resistance/color 192 288 Ω at 20C/Blue/Yellow –

T.C.I. unit model/manufacturer

Green/WhiteTNDF33/NIPPONDENSO

Ignition coil:Model/manufacturerMinimum spark gap

J0300/NIPPONDENSO6 mm

Minimum s ark gaPrimary winding resistanceSecondary winding resistance

6 mm3.4 4.6 Ω at 20C10.4 15.6 kΩ at 20C

Spark plug cap:TypeResistance

Resin type10 kΩ

Charging system:TypeModel/manufacturerNormal outputStator coil resistance

A.C. magnetoLNZ29/NIPPONDENSO14 V 25 A at 5,000 r/min0.23 0.35 Ω at 20C/W-W

Rectifier:Model/manufacturerWithstand voltage

SH650A-12/SHINDENGEN240 V

Battery:Specific gravity 1.320

Electric starter system:TypeStarter motor:Model/manufacturerOutputArmature coil resistanceBrush overall lengthSpring forceCommutator diameterMica undercut

Constant mesh type

SM-13/MITSUBA0.8 kW0.01 Ω at 20C12.5 mm570 920 g28 mm0.7 mm

5 mm

27 mm

Starter relay:Model/manufacturerAmperage ratingCoil winding resistance

9768042/JIDECO100 A4.2 4.6 Ω at 20C

2-16


Item Standard Limit

Horn:TypeQuantityModel/manufacturerMaximum amperage

Plane type1YF-12/NIKKO2.5 A

Flasher relay:TypeModel/manufacturerSelf cancelling deviceFlasher frequencyWattage

Semi transistor typeFE246BH/NIPPONDENSONo75 95 cycle/min21 W 2 + 3.4 W

Starting circuit cut off relay:Model/manufacturerCoil winding resistanceDiode

G8R-30Y-F/OMRON180 270 Ω at 20CYes

Thermostatic switch:Model/manufacurer 2EL/NIHON THERMOSTAT

Thermo unit:Model/manufacturer 11H/NIPPON SEIKI

Circuit breakers:TypeAmperage for individual circuitsMain fuseHeadlight fuseSignal system fuseIgnition fuseRadiator fan fuseReserve fuseReserve fuseReserve fuse

Fuse

30 A 115 A 115 A 17.5 A 17.5 A 130 A 115 A 27.5 A 1

2-17

GENERAL TORQUE SPECIFICATIONS SPEC

GENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fastenerswith standard I.S.O. pitch threads.Torque specifications for special components orassemblies are included in the applicable sec-tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, inprogressive stages, until full torque is reached.Unless otherwise specified, torque specificationscall for clean, dry threads. Components should beat room temperature.

A : Distance across flatsB : Outside thread diameter

A(Nut)

B(Bolt)

General torquespecifications

(Nut) (Bolt)Nm mkg

10 mm 6 mm 6 0.6

12 mm 8 mm 15 1.5

14 mm 10 mm 30 3.0

17 mm 12 mm 55 5.5

19 mm 14 mm 85 8.5

22 mm 16 mm 130 13.0

2-18

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

LUBRICATION POINT AND GRADE OF LUBRICANTENGINE

Lubrication point Lubricant type

Oil seal lips

O-ring

Bearing

Crankshaft (big end)

Piston surface

Piston pin

Cylinder

Piston ring, oil ring

Connecting rod bolt

Crankshaft journal

Balancer (bearing/shaft)

Camshaft, camshaft cap

Valve stem (IN/EX)

Valve stem end

Water pump impeller shaft

Oil pump assembly (inner)

Oil strainer assembly

Push rod

Idle gear surface

Starter clutch ball

Primary driven gear

Transmission gear (wheel/pinion)

Axle (main/drive)

Shift cam

Shift fork, guide bar

Shift shaft assembly

Shift boss (inner)

2-19

LUBRICATION POINT AND GRADE OF LUBRICANT SPEC

CHASSIS

Lubrication point Lubricant type

Steering bearing and bearing race (upper/ lower)

Front wheel oil seal (right / left)

Rear wheel oil seal

Clutch hub oil seal

Clutch hub fitting area

Rear brake pedal shaft

Sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever bolt, sliding surface

Clutch lever bolt, sliding surface

Rear shock absorber (lower)

Swingarm pivot bearing

Pivot shaft

Thrust cover (inner)

2-20

1 Oil pump (for pumping oil to the oil tank)2 Oil pump (for lubricating the engine parts)3 Oil strainer4 Oil filter5 Drain bolt6 Oil tank

LUBRICATION DIAGRAMS SPEC

LUBRICATION DIAGRAMS

2-21


1 Front balancer2 Oil strainer3 Oil pump4 Relief valve5 Oil pump (for pumping oil to the oil tank)6 Oil pump (for lubricating the engine parts)

2-22


1 Camshaft2 Rear balancer3 Main axle4 Drive axle5 Drain bolt6 Front balancer

2-23


1 Cylinder head2 Rear balancer3 Crankshaft4 Drain bolt

2-24


1 Main axle2 Drive axle

2-25

CABLE ROUTING SPEC

1 Throttle cable2 Right handlebar switch lead3 Brake hose4 Main switch lead5 Clutch cable6 Left handlebar switch lead7 Horn lead8 Starter cable9 Coolant reservoir hose10 Headlight lead

11 Meter light lead12 Thermo switch lead13 Fan motor lead14 Ignition coil (left) lead15 Ignition coil (right) lead

A Fasten the right handlebar switch lead with a plastic band.B Fasten the left handlebar switch lead with a plastic band.C 50 mm

CABLE ROUTING

2-26

CABLE ROUTING SPEC

D Fasten the horn lead with a plastic band.E 60 mmF Fasten the brake hose with plastic bands.G Fasten the coolant reservoir hose with a plastic

clamp.H Fasten the right handlebar switch lead, meter light

lead and headlight lead with a plastic clampI Fasten the wire harness with a plastic clamp..

J Fasten the wire harness, right handlebar switch lead, meter light lead and headlight lead with a plastic band.

K To the throttle position sensor.L Fasten the wire harness and ignition coil (left) lead

with a plastic clamp.M Fasten the wire harness, right handlebar switch lead,

main switch lead and fan motor lead with a plastic clamp.

2-27

CABLE ROUTING SPEC

1 Front flasher light (left) lead2 Main switch lead3 Starter cable4 Left handlebar switch lead5 Spark plug lead6 Carburetor breather hose7 Fuel hose8 Vacuum hose (#2)9 Coolant reservoir hose10 Sidestand switch lead

11 Neutral switch lead12 A.C. magneto lead13 Air filter case breather hose14 Carburetor heater hose15 Speedometer cable16 Brake hose17 Wire harness18 Flasher relay lead19 Fuel hose 5

2-28

CABLE ROUTING SPEC

A Fasten the left handlebar switch lead and main switch lead with a plastic clamp.

B To the air filter case.C Fasten the coolant reservoir hose, A.C. magneto

lead, neutral switch lead and sidestand switch leadwith a plastic clamp.

D Fasten the rear flasher light (left) lead with a plastic clamp.

E Fasten the sidestand switch lead, neutral switch lead and A.C. magneto lead with a plastic clamp.

F Fasten the sidestand switch lead and air filter case breather hose with a metal band.

G Pass the air filter case breather hose over the carbu-retor heater hose.

H Pass the speedometer cable through the guides.

2-29

CABLE ROUTING SPEC

1 Starter motor lead2 Fuel tank breather hose3 Spark plug lead4 Right handlebar switch lead5 Clutch cable6 Brake hose7 Throttle cable8 Headlight lead9 Meter light lead10 Carburetor heater hose11 Vacuum hose (#1)

12 Coolant reservoir breather hose13 Carburetor breather hose14 Rear brake switch lead15 Battery positive lead16 Battery negative lead

A Pass the battery positive lead and battery negative lead through the guide.

B Fasten the wire harness coolant reservoir hose and flasher relay lead with a plastic clamp.

C Pass the carburetor breather hoses through the metal band.

2-30

D Pass the carburetor breather hoses and vacuum hose (#1) through the guide.

E Pass the vacuum hose (#1) through the guide.F Fasten the coolant reservoir hose with a plastic

clamp.G Fasten the wire harness, right handlebar switch lead,

meter light lead and headlight lead with a plastic clamp.

H Fasten the right handlebar switch lead with a plastic clamp.

I Fasten the throttle cables with a plastic clamp.

CABLE ROUTING SPEC

J Pass the coolant reservoir hose over the throttle cables.

K Fasten the wire harness, right handlebar switch lead, meter light lead and headlight lead with a plastic band.

L Pass the clutch cable through the guide.M Pass the carburetor air vent hose through the guide.N Pass the coolant reservoir breather hose, fuel tank

breather hose and carburetor breather hoses throughthe guide.

2-31

CABLE ROUTING SPEC

O Pass the fuel tank breather hose through the hole of the frame bracket.

P Pass the coolant reservoir breather hose and fuel tank breather hose through the guide.

Q Pass the rear brake switch lead through the guide.R Fasten the wire harness and rear flasher light (right)

lead with a plastic clamp.

S Fasten the wire harness with plastic clamps.T To the engine.U Fasten the coolant reservoir breather hose with a

plastic clamp.V To the starter relay.W Pass the carburetor breather hoses through the

guide.

2-32

1 Headlight lead2 Wire harness3 Meter light lead4 Throttle stop screw cable5 Vacuum hose (#1)6 Carburetor air vent hose7 Carburetor breather hose8 Starter motor lead9 Battery positive lead10 Battery negative lead11 Coolant reservoir breather hose

CARBLE ROUTING SPEC

12 Coolant reservoir hose13 Vacuum hose (#2)14 Fuel hose15 Carburetor breather hose16 Cylinder head breather hose17 Air filter case breather hose18 Throttle cable

A Fasten the meter light lead, head-light lead and wire harness with aplastic clamp.

B Fasten the wire harness and cool-ant reservoir hose with a plasticclamp.

C Pass the starter relay lead throughthe guide.

2-33

CABLE ROUTING SPEC

D Fasten the taillight lead with a plastic band to the tail-light bracket.

E 50 mmF Fasten the carburetor breather hoses with a plastic

clamp.G Fasten the wire harness with a plastic clamp.H To the front flasher light (left).I To the headlight.J To the meter light.K Fasten the headlight lead with a plastic clamp.L To the auxiliary light.

M Fasten the meter light lead and headlight lead withplastic clamps.

N Fasten the meter light lead, headlight lead and frontflasher light lead connector with a plastic clamp.

O To the front flasher light (right).P Fasten the meter light lead, headlight lead, starting

circuit cut-off relay lead and front flasher light (right)lead with a plastic clamp.

Q To the rear brake switch.

INSPADJ

CHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . . . . .

COWLINGS, SEAT, TAIL COVER AND FUEL TANK 3-3. . . . . . . . . . . . . . . . . . COWLINGS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT, TAIL COVER AND FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CASE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR SYNCHRONIZATION 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . IDLING SPEED ADJUSTMENT 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE CABLE ADJUSTMENT 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG INSPECTION 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION TIMING CHECK 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION PRESSURE MEASUREMENT 3-20. . . . . . . . . . . . . . . . . . . ENGINE OIL LEVEL INSPECTION 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH ADJUSTMENT 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CLEANING 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR JOINT INSPECTION 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LINE INSPECTION 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BREATHER HOSE INSPECTION 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM INSPECTION 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT LEVEL INSPECTION 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT REPLACEMENT 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM INSPECTION 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE ADJUSTMENT 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE ADJUSTMET 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE FLUID LEVEL INSPECTION 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD INSPECTION 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE LIGHT SWITCH ADJUSTMENT 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE HOSE INSPECTION 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BLEEDING 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (HYDRAULIC BRAKE SYSTEM)SHIFT PEDAL ADJUSTMENT 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN SLACK ADJUSTMENT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE CHAIN LUBRICATION 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD INSPECTION 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK INSPECTION 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK ADJUSTMENT 3-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ADJUSTMENT 3-45. . . . . . . . . . . . . . . . . . . . . .

INSPADJ

TIRE INSPECTION 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE INSPECTION AND LUBRICATION 3-49. . . . . . . . . . . . . . . . . . . . . . . LEVER AND PEDAL LUBRICATION 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND LUBRICATION 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION LUBRICATION 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE INSPECTION 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BEAM ADJUSTMENT 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REPLACEMENT 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSPADJ

PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter includes all information necessary to perform recommended inspections and adjustments. Thesepreventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer servicelife. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already inservice as well as new vehicles that are being prepared for sale. All service technicians should be familiar with thisentire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALSEVERY

ITEM ROUTINEBRAKE-IN

1,000 km

6,000 km

or

6 months

12,000 km

or

12 months

Valves* Check valve clearance. Adjust if necessary. EVERY 42,000 km or 42 months

Spark plugs Check condition. Clean or replace if necessary.

Air filter Clean. Replace if necessary.

Carburetor* Check idle speed /synchronization/starter operation. Adjust if necessary.

Fuel line* Check fuel hose and vacuum pipe for cracks or damage. Replace if necessary.

Engine oil Replace (Warm engine before draining).

Engine oil filter* Replace.

Brake* Check operation / fluid leakage /See NOTE. Correct if necessary.

Clutch Check operation. Adjust if necessary.

Swingarm pivot* Check swingarm assembly for looseness. Correct if necessary. Moderately repack every 24,000 km or 24 months.***

Wheels* Check balance /damage/ runout. Replace if necessary.

Wheel bearings* Check bearing assembly for looseness /damage. Replace if damaged.

Steering bearings* Check bearing assembly for looseness. Correct if necessary. Moderately repack every 24,000 km or 24 months.**

Front forks* Check operation /oil leakage. Repair if necessary.

Rear shock absorber* Check operation /oil leakage. Repair if necessary.

Cooling system Check coolant leakage. Repair if necessary. Replace coolant every 24,000 km or 24 months

Drive chain Check chain slack /alignment. Adjust if necessary. Clean and lube.

EVERY 500 km

Fittings/Fasteners* Check all chassis fittings and fasteners. Correct if necessary.

Sidestand* Check operation. Repair if necessary.

Sidestand switch* Check operation. Replace if necessary.

* : If is recommended that these items be serviced by a Yamaha dealer.** : Lithium soap base grease.*** : Molybdenum disulfide grease.

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJ

NOTE:Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check

the brake fluid level and add the fluid as required.2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.3. Replace the brake hoses every four years, or if cracked or damaged.

3-3

COWLINGS, SEAT, TAIL COVER AND FUEL TANKINSPADJ

Order Job name/Part name Q’ty Remarks

123456789

1011

Cowlings removalSide cowling (left and right)Meter panelDamperWind shieldInner panelFront flasher light leadFront flasher light (left and right)Auxiliary light lead couplerHeadlight lead couplerFront cowlingHeadlight unit

21111421111

Remove the parts in the order below.

Disconnect

DisconnectDisconnect

For installation, reverse the removalprocedure.

COWLINGS, SEAT, TAIL COVER AND FUEL TANKCOWLINGS

3-4

COWLINGS, SEAT, TAIL COVER AND FUEL TANKINSPADJ


123456

78

Seat, tail cover and fuel tank removalSide cowlingSeatTaillight lead couplerTail coverSide coverFuel hose (RES)Fuel hose (ON)

Fuel tank breather hoseFuel tank

111211

11

Remove the parts in the order below.Refer to “COWLINGS”.

Disconnect

Set the fuel cock (fuel tank side) to “OFF”before disconnecting the fuel hoses.


NOTE:

16 Nm (1.6 mkg)

SEAT, TAIL COVER AND FUEL TANK

3-5

AIR FILTER CASEINSPADJ


1234

Air filter case removalSide cowling, seat, side cover and fueltankCylinder head breather hoseAir filter case breather hoseCarburetor clampAir filter case

1121

Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAILCOVER AND FUEL TANK”.

Loosen


AIR FILTER CASEAIR FILTER CASE

3-6

VALVE CLEARANCE ADJUSTMENTINSPADJ

NOTE:

ENGINEVALVE CLEARANCE ADJUSTMENT

The valve clearance should be adjusted whenthe engine is cool to touch.

The piston must be at Top Dead Center (T.D.C.)on compression stroke to check or adjust thevalve clearance.

1. Remove:Side cowlingSeatSide coverFuel tank

Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK”.

Air filter caseRefer to “AIR FILTER CASE”.

2. Drain:Coolant

Refer to “COOLANT REPLACEMENT”.

3. Disconnect:Hose 2 1Hose 3 2Coolant reservoir hose

(from radiator side)Fan motor lead coupler

4. Remove:Radiator 1

3-7


NOTE:

5. Disconnect:Thermo unit lead 1Thermo switch lead 2Ground lead 3Thermostatic valve housing 4

6. Remove:Spark plug capsSpark plugsCylinder head cover

7. Remove:Timing plug 1Straight plug 2O-ring

8. Check:Valve clearance

Out of specification Adjust.

Valve clearance (cold):Intake valve:

0.15 0.20 mmExhaust valve:

0.25 0.30 mm

Checking steps:Turn the crankshaft counterclockwise with a

wrench.Align the T.D.C. mark a on the rotor with the

align mark b on the crankcase cover when #1piston is at T.D.C. on compression stroke.

TDC on compression stroke can be found whenthe cam lobes are opposite each other as shown.

3-8


NOTE:

NOTE:

NOTE:

NOTE:

Measure the valve clearance using a feelergauge 2 .

Record the measured reading if the clearance isincorrect.

Rotate the crankshaft 270 counterclockwiseand check the clearance of piston #2.

Make sure that the camshaft lobes are oppositeeach other when the piston is at TDC on the com-pression stroke.

9. Adjust:Valve clearance

Adjustment steps:Loosen the timing chain tensioner cap bolt.Remove the timing chain tensioner 1 , timing

chain guide (upper) 2 , timing chain guide (ex-haust side) 3 and camshaft caps.

Remove the camshaft cap bolts in a crisscrosspattern from the outside working inwards.

Remove the camshaft (intake and exhaust 1 ).

Attach a wire 2 to the timing chain to prevent itfrom falling into the crankcase.

3-9


NOTE:

NOTE:

NOTE:

Remove the valve lifters 1 and the pads 2 .

Place a rag in the timing chain space to preventpads from falling into the crankcase.

Identify each valve lifter 1 and pad 2 positionvery carefully so that they can be reinstalled intheir original place.

Select the proper pad using the pad selectingtable:

Pad range Pad Availability:25 increments

No. 120

No. 240

1.20 mm

2.40 mm

Pads are available in0.05 mm increments

The thickness a of each pad is indicated in hun-dreths of millimeters on the pad upper surface.

Round off the last digit of the installed pad num-ber to the nearest increment.

Last digit of padnumber

Rounded value

0 or 2 0

5 (NOT ROUNDED OFF)

8 10

EXAMPLE:Installed pad number = 148Rounded off value = 150

Pads can only be selected in 0.05 mm increments.

3-10


NOTE:

NOTE:

10 Nm (1.0 mkg)

NOTE:

Locate the rounded-off value and the mea-sured valve clearance in the chart “PADSELECTION TABLE”. The field where thesetwo coordinates intersect shows the new padnumber to use.

Use the new pad number only as a guide whenverifying the valve clearance adjustment.

Install the new pads 1 and the valve lifters 2 .

Lubricate the valve lifters and pads with molyb-denum disulfide oil.

Valve lifter must turn smoothly when rotated witha finger.

Be careful to reinstall valve lifters and pads intheir original place.

Install the new pads so that the side with the padnumber faces up (toward the valve lifter).

Install the camshafts (exhaust and intake), thetiming chain and the camshaft caps.

Lubricate the cylinder head mating surfaces camlobes and camshaft journals.

Install the exhaust camshaft first.Align the matching marks.Turn the crankshaft counterclockwise several

turns so that the installed parts settle into theright position.

Refer to “CAMSHAFT” in CHAPTER 4.

3-11


VALVE CLEARANCE (cold): 0.15 0.20 mmExample: Installed is 175 Measured clearance is 0.27 mmReplace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

VALVE CLEARANCE (cold): 0.25 0.30 mmExample: Installed is 175 Measured clearance is 0.37 mmReplace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

STANDARD CLEARANCE

STANDARD CLEARANCE

INTAKE

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.05 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.10 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.15 0.200.21 0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.26 0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.31 0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.36 0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.41 0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.46 0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.51 0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.56 0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.61 0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.66 0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.71 0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.76 0.80 180 185 190 195 200 205 210 215 220 225 230 235 2400.81 0.85 185 190 195 200 205 210 215 220 225 230 235 2400.86 0.90 190 195 200 205 210 215 220 225 230 235 2400.91 0.95 195 200 205 210 215 220 225 230 235 2400.96 1.00 200 205 210 215 220 225 230 235 2401.01 1.05 205 210 215 220 225 230 235 2401.06 1.10 210 215 220 225 230 235 2401.11 1.15 215 220 225 230 235 2401.16 1.20 220 225 230 235 2401.21 1.25 225 230 235 2401.26 1.30 230 235 2401.31 1.35 235 2401.36 1.40 240

EXHAUST

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 2102150.05 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2152200.10 0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2202250.15 0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2252300.20 0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2302350.25 0.300.31 0.35 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.36 0.40 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.41 0.45 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.46 0.50 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.51 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.56 0.60 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.61 0.65 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.66 0.70 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.71 0.75 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.76 0.80 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.81 0.85 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.86 0.90 180 185 190 195 200 205 210 215 220 225 230 235 2400.91 0.95 185 190 195 200 205 210 215 220 225 230 235 2400.96 1.00 190 195 200 205 210 215 220 225 230 235 2401.01 1.05 195 200 205 210 215 220 225 230 235 2401.06 1.10 200 205 210 215 220 225 230 235 2401.11 1.15 205 210 215 220 225 230 235 2401.16 1.20 210 215 220 225 230 235 2401.21 1.25 215 220 225 230 235 2401.26 1.30 220 225 230 235 2401.31 1.35 225 230 235 2401.36 1.40 230 235 2401.41 1.45 235 2401.46 1.50 240

3-12


NOTE:

10 Nm (1.0 mkg)

18 Nm (1.8 mkg)

Recheck the valve clearance. If the clearance is still incorrect, repeat all the

clearance adjustment steps until the specifiedclearance is obtained.

10. Install:All removed parts

Install all removed parts in reversed order of theirremoval. Note the following points.

11. Install:Chain guide (exhaust side)Chain guide (upper)Timing chain tensioner

Refer to “CAMSHAFT” in CHAPTER 4.

12. Install:Cylinder head coverSpark plugs

3-13

CARBURETOR SYNCHRONIZATIONINSPADJ

NOTE:

NOTE:

CARBURETOR SYNCHRONIZATION

Valve clearance and idling speed should be ad-justed properly before synchronizing the carbure-tors.

1. Place the motorcycle on a level surface.

Place the motorcycle on its centerstand if a cen-terstand is equipped. If not, place a suitable standunder the motorcycle.



3. Remove:Vacuum hose 1 (#1 carburetor) 1Vacuum hose 2 (#2 carburetor) 2

4. Attach:AdaptersVacuum gauge 1Engine tachometer 2

(to #1 spark plug lead)

Vacuum gauge:90890-03094

Engine tachometer:90890-03113

5. Start the engine and let it warm up for severalminutes.

6. Check:Engine idling speed

Out of specification Adjust.Refer to “ENGINE IDLING SPEED ADJUST-MENT”.

Engine idling speed:1,050 1,250 r /min

3-14

CARBURETOR SYNCHRONIZATIONINSPADJ

NOTE:

7. Adjust:Carburetor synchronization

Adjustment steps:Synchronize carburetor #1 to carburetor #2 by

turning synchronizing screw 1 until bothgauges read the same.

Race the engine for less than a second, two orthree times and check the synchronizationagain.

Intake vacuum at idle speed:36.0 38.7 kPa (270 290 mm Hg)

The difference between both carburetors shouldbe 0.67 kPa (5 mm Hg) or less.


Out of specification Adjust.9. Stop the engine and detach the measuring

equipment.

10. Adjust:Throttle cable free play

Refer to “THROTTLE CABLE FREE PLAY AD-JUSTMENT”.

Free play:3 5 mm

At throttle grip flange

11. Install:Fuel tankSide coverSeatSide cowling


3-15

IDLING SPEED ADJUSTMENTINSPADJ

NOTE:

IDLING SPEED ADJUSTMENT

The carburetor synchronization should be ad-justed properly before adjusting the idling speed.


2. Attach:Engine tachometer 1

(to the #1 spark plug lead).




Engine idling speed:1,050 1,250 r /min




5. Adjust:Engine idling speed

Adjustment steps:Turn the pilot screw 1 until it is lightly seated.Turn out the pilot screw for the specified num-

ber of turns.

Pilot screw: 2.0 turns out

3-16

IDLING SPEED ADJUSTMENT/THROTTLE CABLE ADJUSTMENT

INSPADJ

NOTE:

Turn the throttle stop screw 2 in or out untilspecified idling speed is obtained.

Turnning in: Idling speed is increased.

Turnning out: Idling speed is decreased.


Refer to “THROTTLE CABLE FREE PLAY AD-JUSTMENT”.

Free play:3 5 mm

At throttle grip flange

THROTTLE CABLE ADJUSTMENT

Engine idling speed and carburetor synchroniza-tion should be adjusted properly before adjustingthe throttle cable free play.

1. Check:Throttle cable free play a


Free play:3 5 mmAt throttle grip flange




3-17

THROTTLE CABLE ADJUSTMENTINSPADJ

NOTE:

WARNING


Adjustment steps:First step:Loosen the locknut 1Turn the adjuster 2 in or out until the specified

free play is obtained.

Turnning in: Free play is increased.

Turnning out: Free play is decreased.

Tighten the locknuts.

If the free play can not be adjusted here, adjust it atthe throttle grip side of the cable.

Final step:Loosen the locknut 3 .Turn the adjuster 4 in or out until the specified

free play is obtained.

Turnning in: Free play is decreased.

Turnning out: Free play is increased.

Tighten the locknut.

After adjusting, turn the handlebar to the rightand left, making sure that the engine idlingspeed does not change.

4. Install:Air filter case

Refer to “AIR FILTER CASE”.Fuel tankSide coverSeatSide cowling


3-18

SPARK PLUG INSPECTIONINSPADJ

CAUTION:

18 Nm (1.8 mkg)

NOTE:

SPARK PLUG INSPECTION1. Remove:Spark plug capsSpark plugs

Before completely removing the spark plug,use compressed air to clean the cylinder headcover areas to prevent dirt from falling into theengine.

2. Inspect:Spark plug type

Incorrect Replace.

Standard spark plug:DPR8EA-9 (NGK)X24EPR-U9 (NIPPONDENSO)

3. Inspect:Electrode 1

Wear/Damage Replace. Insulator 2

Abnormal color Replace.Normal color is a medium-to-light tan color.

4. Clean:Spark plug

(with spark plug cleaner or wire brush)5. Measure:Spark plug gap a

Use a wire gauge.Out of specification Adjust.

Spark plug gap:0.8 0.9 mm

6. Install:Spark plug

Before installing a spark plug, clean the gasketsurface and plug surface.

3-19

IGNITION TIMING CHECKINSPADJ

NOTE:

NOTE:

IGNITION TIMING CHECK

Carburetor synchronization, engine idle speedand throttle cable free play should be adjustedproperly before checking the ignition timing.

1. Remove:Timing plug 1

2. Attach:Timing lightEngine tachometer

(to the #1 spark plug lead)

Timing light:90890-03141


3. Check: Ignition timing

Checking steps:Start the engine and let it warm up. Let the en-

gine run at the specified speed.

Engine speed:1,050 1,250 r /min

Visually check the stationary pointer a is with-in the firing range b on the A.C. magneto.Incorrect firing range Check rotor and pick-up assembly.

The ignition timing is not adjustable.

4. Install:Timing plug

3-20

COMPRESSION PRESSURE MEASUREMENTINSPADJ

NOTE:

CAUTION:

COMPRESSION PRESSURE MEASUREMENT

Insufficient compression pressure will result inperformance loss.

1. Check:Valve clearance

Out of specification Adjust.Refer to “VALVE CLEARANCE ADJUST-MENT”.


3. Stop the engine.

4. Remove:Spark plug capsSpark plugs

Before completely removing the spark plug,use compressed air to clean the cylinder headcover areas to prevent dirt from falling into theengine.

5. Attach:Compression gauge 1Adapter

Compression gauge:90890-03081

6. Measure: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.Refer to the table below.

3-21

COMPRESSION PRESSURE MEASUREMENTINSPADJ

WARNING

NOTE:

18 Nm (1.8 mkg)

Compression pressure(With oil applied into cylinder)

Reading Diagnosis

Higher thanwithout oil

Worn or damagedpistons/pistonrings Repair

Same as without oil

Defective ring(s),valves, cylinderhead gasket or pis-ton is possible

Repair

Compression pressure (at sea level):Standard:

1,200 kPa (12.0 kg/cm 2, 12.0 bar)Minimum:

1,000 kPa (10.0 kg/cm 2, 10.0 bar)Cylinder difference:

100 kPa (1.0 kg/cm 2, 1.0 bar)

Measurement steps:Crank over the engine with the throttle wide-

open until the reading on the compressiongauge stabilizes.

Before cranking the engine, ground all sparkplug leads to prevent sparking.

Repeat the previous steps for the other cylin-ders.

The difference of compression pressure betweenthe highest and lowest cylinder compressionreadings should be 100 kPa (1 kg/cm2, 1 bar) orless.

7. Install:Spark plugsSpark plug caps

3-22

ENGINE OIL LEVEL INSPECTIONINSPADJ

NOTE:

NOTE:

CAUTION:

NOTE:

ENGINE OIL LEVEL INSPECTION

Position the motorcycle straight up when inspect-ing the oil level.


After idling the engine for 15 minutes, be sure themotorcycle is vertical, then check that the oil lev-el is between the maximum and minimum marks.

Place the motorcycle on its centerstand if a cen-terstand is equipped. If not, place a suitablestand under the motorcycle.

2. Inspect:Oil level

Oil level should be between the maximum aand minimum b marks.Oil level is below the minimum mark Add oilup to the proper level.

Recommended oil:Refer to the following chart for selection of oils which are suited to the atmospheric temperatures.

Recommended engine oil classifica-tion:

API STANDARD:API “SE” or higher grade

Do not put in any chemical additives or useoils with a grade of CD a or higher.

Be sure not to use oils labeled “ENERGYCONSERVING II” b or higher. Engine oil alsolubricates the clutch and additives couldcause clutch slippage.

Be sure no foreign material enters the crank-case.


4. Turn off the engine and check the oil levelagain.

Before checking the oil level, wait a few minutesuntil the oil settles.

3-23

ENGINE OIL REPLACEMENTINSPADJ

New35 Nm (3.5 mkg)

30 Nm (3.0 mkg)

ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for several

minutes.2. Stop the engine and place an oil pan under the

drain bolt.3. Remove:Oil filler plug 1

4. Remove:Drain bolt (with gasket) 1Oil filter drain bolt (with gasket) 2

Drain the crankcase and oil tank of its oil.

5. If the oil filter is to be replaced during this oilchange, remove the following parts and rein-stall them.

Replacement steps:Remove the oil filter cover 1 and oil filter ele-

ment 2 .Check the O-rings 3 , if cracked or damaged,

replace them with a new one. Install the oil filter element and oil filter cover.

Oil filter cover (M10):10 Nm (1.0 mkg)

6. Install:Gaskets Drain boltOil filter drain bolt

3-24

ENGINE OIL REPLACEMENTINSPADJ

CAUTION:

7. Fill:Crankcase

The engine should be filled with oil in twosteps. First fill the engine with 3.2 liters of oil.Then start the engine and race it five or sixtimes. Stop the engine and fill it with oil to thespecified level.

Oil quantity:Total amount: 4.2 LPeriodic oil change: 3.5 LWith oil filter replacement: 3.6 L

8. Install:Oil filler plug

9. Inspect:Engine (for oil leaks)Oil level

Refer to “ENGINE OIL LEVEL INSPECTION”.

10. Check:Oil pressure

Checking steps:Slightly loosen the oil gallery bolt 1 .Start the engine and keep it idling until oil starts

to seep from the oil gallery bolt. If no oil comesout after one minute, turn the engine off so it willnot seize.

Check oil passages, oil filter and oil pump fordamage or leakage.

Start the engine after solving the problem(s)and recheck the oil pressure.

Tighten the oil gallery bolt to specification.

Oil gallery bolt:10 Nm (1.0 mkg)

3-25

CLUTCH ADJUSTMENT/ AIR FILTER CLEANINGINSPADJ

A B

CAUTION:

CLUTCH ADJUSTMENT1. Check:Clutch cable free play a


Free play:10 15 mmAt clutch lever end

2. Adjust:Clutch cable free play

Adjustment steps:Loosen the locknut(s) 1 .Turn the adjuster(s) 2 in or out until the speci-

fied free play is obtained.

Turnning in: Free play is increased.

Turnning out: Free play is decreased.

Tighten the locknut(s).

A Handlebar side

B Engine side

AIR FILTER CLEANING1. Remove:Side cowlingSeatSide coverFuel tank


Air filter case cover 1 .

2. Remove:Air filter element 2

The engine should never be run without the airfilter element, otherwise excessive pistonand/or cylinder wear may result.

3-26

AIR FILTER CLEANING/CARBURETOR JOINT INSPECTION

INSPADJ

NOTE:

NOTE:

NOTE:

3. Inspect:Air filter element

Damage Replace.4. Clean:Air filter element

Blow off dust from the outer surface of the ele-ment with compressed air.

5. Install:Air filter elementAir filter case cover

Make sure the element is properly seated in the fil-ter case.


Install all removed parts in reversed order of theirremoval.

CARBURETOR JOINT INSPECTION1. Remove:Side cowlingSeatSide coverFuel tank



2. Inspect:Carburetor joints 1

Cracks/Damage Replace.Refer to “CARBURETOR” in CHAPTER 6.



3-27

FUEL LINE INSPECTION/BREATHER HOSE INSPECTION

INSPADJ

NOTE:

NOTE:

NOTE:

FUEL LINE INSPECTION1. Remove:Side cowlingSeatSide coverFuel tank


2. Inspect:Vacuum hoses 1Fuel hoses 2

Cracks/Damage Replace.Loose connection Connect properly.

Drain and flush the fuel tank if abrasive damage toany components is evident.



BREATHER HOSE INSPECTION1. Remove:Side cowlingSeatSide coverFuel tank



2. Inspect:Breather hose 1

Cracks/Damage Replace.Loosen connection Connect properly.



3-28

EXHAUST SYSTEM INSPECTION/COOLANT LEVEL INSPECTION

INSPADJ

20 Nm (2.0 mkg)

24 Nm (2.4 mkg)

24 Nm (2.4 mkg)

20 Nm (2.0 mkg)

NOTE:

NOTE:

EXHAUST SYSTEM INSPECTION1. Inspect:Exhaust pipesMufflers

Cracks/Damage Replace.Gaskets

Exhaust gas leaks Replace.

2. Check:Exhaust pipe nut 1Exhaust pipe bolt 2Muffler bolt 3Bolt (exhaust pipe and muffler) 4

COOLANT LEVEL INSPECTION

Position the motorcycle straight up when inspect-ing the coolant level.



2. Inspect:Coolant level

Coolant level should be between maximum aand minimum b marks.Coolant level low Add soft water (tap water)to proper level.

3-29

COOLANT LEVEL INSPECTION/COOLANT REPLACEMENT

INSPADJ

CAUTION:

WARNING

NOTE:

NOTE:

Hard water or salt water is harmful to the en-gine parts; use boiled or distilled water if youcan’t get soft water.

COOLANT REPLACEMENT1. Remove:Side cowling (right)Seat


Do not remove the radiator cap when the en-gine and radiator are hot. Scalding hot fluidand steam may be blown out under pressure,which could cause serious injury. When theengine has cooled, open the radiator cap byfollowing this procedure:Place a thick rag or a towel over the radiatorcap. Slowly rotate the cap counterclockwise tothe detent. This allows any residual pressureto escape. When the hissing sound hasstopped, press down on the cap while turningcounterclockwise and remove it.

Position the motorcycle straight up when replac-ing the coolant.



3. Remove:Water pump drain bolt (with gasket) 1Cylinder drain bolt (with gasket) 2Radiator cap 3

Drain the radiator and engine of its coolant.4. Disconnect:Coolant reservoir hose 4

3-30

COOLANT REPLACEMENTINSPADJ

New10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

NOTE:

WARNING

5. Install:Gaskets Drain bolt 1Cylinder drain bolt

6. Connect:Coolant reservoir hose

7. Fill:Cooling system (radiator and engine)

(to specified level a )

Recommended coolant:High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminum engines

Coolant and water mix ratio:50% – 50%

Radiator capacity(including all routes):

1.7 LReservoir tank capacity:

0.3 LFrom lower to upper level:

0.2 L

Put the sidestand down so the motorcycle leans tothe side and fill with coolant. To help dissipate thecoolant throughout the cooling system, hold themotorcycle in the upright position for a few se-conds. Then lean it back to the side and continuefilling with coolant.

Handling notes for coolant:Coolant is harmful and should be handled withspecial care.

If coolant splashes in your eyes:Thoroughly wash your eyes with water andsee a doctor.

If coolant splashes on your clothes.Quickly wash it away with water and thenwith soap.

If coolant is swallowed.Quickly make the patient vomit and take himto a doctor.

3-31

COOLANT REPLACEMENTINSPADJ

CAUTION:

NOTE:

Hard water or salt water is harmful to the en-gine parts. Use boiled or distilled water if youcan’t get soft water.

Do not use water containing impurities or oil.Take care that no coolant splashes onto

painted surfaces. If it does, wash it away withwater immediately.

Do not mix different types of ethylene glycolantifreeze containing corrosion inhibitors foraluminium engines.

8. Install:Radiator cap

9. Fill:Coolant reservoir 1

(to upper level mark)10. Install:Coolant reservoir cap


12. Stop the engine and inspect the level.Refer to “COOLANT LEVEL INSPECTION”.

Wait a few minutes until the coolant settles beforeinspecting the coolant level.

13. Install:SeatSide cowling (right)


3-32

COOLANT REPLACEMENT/COOLING SYSTEM INSPECTION

INSPADJ

COOLING SYSTEM INSPECTION1. Inspect:Radiator 1Hose 2 2Hose 3 3

Cracks/Damage Replace.Refer to “RADIATOR” in CHAPTER 5.

3-33

FRONT BRAKE ADJUSTMENTINSPADJ

a

a

b

c

WARNING

CAUTION:

WARNING

CHASSISFRONT BRAKE ADJUSTMENT1. Adjust:Brake lever position

(distance a from handle grip to front brake le-ver)

Adjustment steps:Turn the adjuster 1 while pushing the front

brake lever forward until the desired lever posi-tion is obtained.

Direction Distance is the largest

Direction Distance is the smallest

After adjusting the front brake lever position(distance), make sure align the mark on the ad-juster with the mark on the brake lever.

Make sure that the brake does not drag afteradjusting it.

A soft or spongy feeling in the brake lever canindicate the presence of air in the brake sys-tem. This air must be removed by bleeding thebrake system before the motorcycle is oper-ated. Air in the system will cause greatly di-minished braking capability and can result inloss of control and an accident. Inspect andbleed the system if necessary.

3-34

REAR BRAKE ADJUSTMENTINSPADJ

WARNING

CAUTION:

WARNING

REAR BRAKE ADJUSTMENT1. Check:Brake pedal height a


Brake pedal height:29 mm

Below top of footrest.

2. Adjust:Brake pedal height

Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 in or out until the specified

pedal height is obtained.

Turnning in: Height is decreased.

Turnning out: Height is increased.

After adjusting brake pedal height, visuallycheck the adjuster end through the hole a .The adjuster end b must be visible within thishole.

Tighten the locknut 1 .

Make sure that the brake does not drag afteradjusting it.

A soft or spongy feeling in the brake pedal canindicate the presence of air in the brake sys-tem. This air must be removed by bleeding thebrake system before the motorcycle is oper-ated. Air in the system will cause greatly di-minished braking capability and can result inloss of control and an accident.Inspect and bleed the system if necessary.

3. Adjust:Brake light switch

Refer to “BRAKE LIGHT SWITCH ADJUST-MENT”.

3-35

BRAKE FLUID LEVEL INSPECTIONINSPADJ

A

B

NOTE:

NOTE:

NOTE:

CAUTION:

WARNING

BRAKE FLUID LEVEL INSPECTION

Position the motorcycle straight up when inspect-ing the fluid level.



2. Inspect:Fluid level

Fluid level is under “LOWER” level line a Fill to proper level.

A Front B Rear

Recommended fluid:DOT 4

When inspecting the fluid level in the reservoir onthe handlebar, make sure the master cylinder topis horizontal.

Brake fluid may corrode painted surfaces orplastic parts. Always clean up spilled fluid im-mediately.

Use only the designated quality fluid. Other-wise, the rubber seals may deteriorate caus-ing leakage and poor brake performance.

Refill with the same type of fluid. Mixingfluids may result in a harmful chemical reac-tion leading to poor brake performance.

Be careful that water does no enter the mas-ter cylinder when refilling. Water will signifi-cantly lower the boiling point of the fluid andcould cause vapor lock.

3-36

BRAKE PAD INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT

INSPADJ

A

B

NOTE:

BRAKE PAD INSPECTION1. Activate the brake lever or brake pedal.2. Inspect:Brake pad

Wear indicator 1 almost contacting the brakedisc Replace brake pad as a set.Refer to “FRONT AND REAR BRAKE” inCHAPTER 7.

A FrontB Rear

BRAKE LIGHT SWITCH ADJUSTMENT

The brake light switch is operated by movement ofthe brake pedal.Proper adjustment is achieved when the brakelight comes on just before the brake begins to takeeffect.

1. Check:Brake light operation

Incorrect Adjust.2. Adjust:Brake light operating timing

Adjustment steps:Hold the main body 1 of the switch with your

hand so that it does not rotate, and turn the ad-juster 2 in or out until the operating timing is cor-rect.

Turnning in: Brake light on later.

Turnning out: Brake light on sooner.

3-37

A

B

BRAKE HOSE INSPECTION/AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

INSPADJ

WARNING

WARNING

BRAKE HOSE INSPECTION1. Inspect:Brake hoses 1Brake pipe 2

Cracks/Wear/Damage Replace.

The brake pipe must not be disassembled. Donot loosen the bolts 3 .

2. Check:Brake hose clamp

Loosen Tighten.3. Hold the motorcycle on upright position.4. Check:Brake hoses

Activate the brake lever or pedal several times.Fluid leakage Replace the hose.Refer to “FRONT AND REAR BRAKE” inCHAPTER 7.

AIR BLEEDING(HYDRAULIC BRAKE SYSTEM)

Bleed the brake system if:The system has been disassembled.A brake hose has been loosened or removed.The brake fluid has been very low.The brake operation has been faulty.A loss of braking performance may occur if thebrake system is not properly bled.

1. Bleed:Brake system

Air bleeding steps:a. Add proper brake fluid to the reservoir.b. Install the diaphragm. Be careful not to spill any

fluid or allow the reservoir to overflow.c. Connect a clear plastic hose 1 tightly to the

caliper bleed screw 2 .

A FrontB Rear

3-38

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/SHIFT PEDAL ADJUSTMENT

INSPADJ

NOTE:

WARNING

d. Place the other end of the hose into a contain-er.

e. Slowly apply the brake lever or pedal severaltimes.

f. Pull the lever in or push down on the pedal.Hold the lever or pedal in position.

g. Loosen the bleed screw and allow the lever orpedal to travel towards its limit.

h. Tighten the bleed screw when the lever or ped-al limit has been reached, then release the le-ver or pedal.

i. Repeat steps (e) to (h) until all air bubbles havedisappeared from the fluid.

j. Tighten the bleed screw.

Bleed screw:6 Nm (0.6 mkg)

If bleeding is difficult, it may be necessary to let thebrake fluid settle for a few hours.Repeat the bleeding procedure when the tinybubbles in the system have disappeared.

k. Add brake fluid to proper level.Refer to “BRAKE FLUID LEVEL INSPEC-TION”.

Check the operation of the brake after bleed-ing the brake system.

EB304080

SHIFT PEDAL ADJUSTMENT1. Check:Shift pedal position

The top of the shift pedal 1 should be alignedwith the crankcase 2 .

3-39

SHIFT PEDAL ADJUSTMENT/DRIVE CHAIN SLACK ADJUSTMENT

INSPADJ

NOTE:

CAUTION:

WARNING

NOTE:

2. Adjust:Change pedal position

Adjustment steps:Remove the drive sprocket cover 1 .Loosen both locknuts 2 .Turn the shift pedal link 3 in or out to obtain the

correct pedal position.

Turnning in: Shift pedal is raised.

Turnning out: Shift pedal is lowered.

Tighten both locknuts. Install the drive sprocket cover.

DRIVE CHAIN SLACK ADJUSTMENT

Before checking and/or adjusting, rotate the rearwheel several revolutions and check slack at sev-eral points to find the tightest point. Check and/oradjust the chain slack with the rear wheel is in this“tightest” position.

Too little chain slack will overload the engineand other vital parts; keep the slack within thespecified limits.

Securely support the motorcycle so there isno danger of it falling over.

1. Place the motorcycle on a level place, and holdit in an upright position.

Both wheels should be on the ground without a rid-er on the motorcycle.

3-40

DRIVE CHAIN SLACK ADJUSTMENTINSPADJ

NOTE:

2. Check:Drive chain slack a


Drive chain slack:40 50 mm

3. Loosen:Caliper bracket bolt 1Axle nut 2

4. Adjust:Drive chain slack

Adjustment steps:Loosen both locknuts 3 .Turn the adjusters 4 in or out until the speci-

fied slack is obtained.

Turnning in: Slack is decreases.

Turnning out: Slack is increases.

Turn each adjuster exactly the same amount tomaintain correct axle alignment.(There are marks a on each side of the swin-garm. Use them to check for proper alignment.)

Tighten the axle nut and caliper bracket bolt tospecification, while pushing the chain tight.

Axle nut:107 Nm (10.7 mkg)

Caliper bracket bolt:35 Nm (3.5 mkg)

Tighten the locknuts.

3-41

DRIVE CHAIN LUBRICATION/STEERING HEAD INSPECTION

INSPADJ

WARNING

DRIVE CHAIN LUBRICATIONThe chain consists of many parts that work witheach other. If the chain is not maintained properly,it will wear out rapidly.Therefore, form the habit of periodically servicingthe chain. This service is especially necessarywhen riding in dusty conditions.This motorcycle has a drive chain with small rub-ber O-rings between the chain plates. Steamcleaning, high-pressure washes, and certain sol-vents can damage these O-rings. Use only kero-sene to clean the drive chain. Wipe dry, and thor-oughly lubricate it with SAE30 50W motor oil.Do not use any other lubricants on the drive chain.They may contain solvents that could damage theO-rings.

Recommended lubricant:SAE30 50W motor oil or chainlubricant suitable for O-ringchains.

STEERING HEAD INSPECTION


1. Place the motorcycle on a level place.2. Elevate the front wheel by placing a suitable

stand under the engine.3. Check:Steering assembly bearings

Grasp the bottom of the front forks and gentlyrock the fork assembly back and forth.Looseness Adjust the steering head.

3-42

STEERING HEAD INSPECTIONINSPADJ

NOTE:

WARNING

4. Remove:Starter cable holder 1Cable guide 2Handlebar holder (upper) 3 (with plugs)Handlebar 4

5. Loosen:Upper bracket pinch bolts 1

6. Remove:Handle crown nut 2Upper bracket 3

7. Adjust:Steering head

Adjustment steps:Remove the special washer 1 , ring nut (up-

per) 2 and rubber washer 3 .Loosen the ring nut (lower) 4 .Tighten the ring nut (lower) using the ring nut

wrench 5 .

Set the torque wrench to the ring nut wrench sothat they form a right angle.

Ring nut wrench:90890-01403

Ring nut (initial tightening)48 Nm (4.8 mkg)

Loosen the ring nut (lower) 4 completely, thenretighten it to specification.

Ring nut (final tightening)16 Nm (1.6 mkg)

Do not overtighten.

3-43

STEERING HEAD INSPECTION/FRONT FORK INSPECTION

INSPADJ

NOTE:

108 Nm (10.8 mkg)

23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

WARNING

Check the steering head by turning it lock tolock. If it binds, remove the steering stem as-sembly and inspect the steering bearings.Refer to “STEERING HEAD” in CHAPTER 7.

Install the rubber washer 3 . Install the ring nut (upper) 2 .Finger tighten the ring nut (upper) 2 , then

align the slots of both ring nuts. If necessary,hold the ring nut (lower) and tighten the ring nut(upper) until their slots are aligned.

Install the special washer 1 .

Make sure the special washer tabs sit correctly inthe slots.

8. Install:Upper bracketHandle crown nutUpper bracket pinch bolts

HandlebarHandlebar holder (upper) bolts (with plugs)

Cable guideStarter cable holder

FRONT FORK INSPECTION


1. Place the motorcycle on a level place.

3-44

FRONT FORK INSPECTION/FRONT FORK ADJUSTMENT

INSPADJ

WARNING

a

b

CAUTION:

2. Check: Inner tube 1

Scratches/Bent/Damage Replace.Oil seal

Excessive oil leakage Replace.

3. Hold the motorcycle in an upright position andapply the front brake.

4. Check:Operation

Pump the front fork up and down for severaltimes.Unsmooth operation Repair.Refer to “FRONT FORK” in CHAPTER 7.

FRONT FORK ADJUSTMENT

Always adjust each fork to the same setting.Uneven adjustment can cause poor handlingand loss of stability.


Spring preload1. Adjust:Spring preload

Turn the adjuster 1 in or out.

Turnningin :

Spring preload isincreased.

Turnningout :

Spring preload isdecreased.

Adjuster position:Standard: 3Minimum: 1Maximum: 5

2 Setting position

Grooves are provided to show the adjustinglevel.

Always keep the adjustment level equal onboth forks.

Never turn the adjuster beyond the maximumor minimum setting.

3-45

FRONT FORK ADJUSTMENT/REAR SHOCK ABSORBER ADJUSTMENT

INSPADJ

a

b

CAUTION:

WARNING

Damping force1. Adjust:Damping force


Turnningin :

Damping force isincreased.

Turnningout :

Damping force isdecreased.

Adjuster position:Standard: 4 clicks outMinimum: 5 clicks outMaximum: 0 clicks out

*: From the fully turned-in position.

Always keep the adjustment level equal onboth forks.


REAR SHOCK ABSORBER ADJUSTMENT


Spring preload1. Adjust:Spring preload

Coarse adjustment (top)Turn the adjuster 1 “S” or “H”.

Adjuster position:Rider only = SRider and passenger = H

3-46

REAR SHOCK ABSORBER ADJUSTMENTINSPADJ

a

b

CAUTION:

a

b

CAUTION:

2. Adjust:Spring preload

Fine adjustment (bottom)

Adjustment steps:Loosen the locknut 1 .Turn the adjuster 2 in or out.

Turnningin :

Spring preload isincreased.

Turnningout :

Spring preload isdecreased.

Measurement length c :Standard: 61 mmMinimum: 59 mmMaximum: 63 mm

Tighten the locknut.

Lock nut:70 Nm (7.0 mkg)

Always tighten the locknut against the springadjusting nut and tighten the locknut to thespecified torque.

Damping force1. Adjust:Damping force


Turnningin :

Damping force isincreased.

Turnningout :

Damping force isdecreased.

Adjuster position:Standard: 20 clicks outMinimum: 10 clicks outMaximum: 0 clicks out

*: From the fully turned-in position.


3-47

TIRE INSPECTIONINSPADJ

WARNING

TIRE INSPECTION1. Measure:Tire pressure


Tire inflation pressure should only bechecked and adjusted when the tire tempera-ture equals the ambient air temperature. Tireinflation pressure and suspension must beadjusted according to the total weight of thecargo, rider, passenger and accessories(fairing, saddlebags, etc. if approved for thismodel), and according to whether the motor-cycle will be operated at high speed or not.

NEVER OVERLOAD THE MOTORCYCLE.Operation of an overloaded motorcycle

could cause tire damage, accident or injury.

Basic weight:With oil andfull fuel tank

229 kg

Maximumload*:

180 kg

Cold tirepressure:

Front Rear

Up to 90 kgload*

225 kPa(2.25

kg/cm 2,2.25 bar)

275 kPa(2.75

kg/cm 2,2.75 bar)

90 kg Maximumload*

225 kPa(2.25

kg/cm 2,2.25 bar)

275 kPa(2.75

kg/cm 2,2.75 bar)

High speedriding

225 kPa(2.25

kg/cm 2,2.25 bar)

275 kPa(2.75

kg/cm 2,2.75 bar)

*: Load is the total weight of cargo, rider, passen-ger, and accessories.

2. Inspect:Tire surfaces

Wear/Damage Replace.

Minimum tire tread depth:(front and rear):

1.6 mm

1 Tread depth

2 Side wall3 Wear indicator

3-48

A B

TIRE INSPECTIONINSPADJ

WARNING

WARNING

It is dangerous to ride with a worn-out tire.When a tire tread begins to show lines, re-place the tire immediately.

Do not use tubeless tires on a wheel de-signed for tube type tires only. Tire failureand personal injury may result from suddendeflation.

A TireB Wheel

Tube type wheel Tube type tire only.

Tubeless typewheel

Tube type or tubelesstire.

Be sure to install the correct tube when usingtube type tires.

After extensive tests, the tires mentioned be-low have been approved by Yamaha Motor Co.Ltd. for this model. No guarantee for handlingcharacteristics can be given if a tire combina-tions other than the approved is used on thismotorcycle. The front and rear tires should al-ways be of the same manufacture and design.

FRONT TIRE:

Manufacture Size Type

BRIDGE-STONE

110/80 ZR18 BT54F

PIRELLI 110/80 ZR18 MTR03

MICHELIN 110/80 ZR18 MACADAM90X

REAR TIRE:

Manufacture Size Type

BRIDGE-STONE

150/70 ZR17 BT54R

PIRELLI 150/70 ZR17 MTR04

MICHELIN 150/70 ZR17 MACADAM90X

3-49

TIRE INSPECTION/WHEEL INSPECTION/CABLE INSPECTION AND LUBRICATION

INSPADJ

NOTE:

WARNING

NOTE:

WARNING

WARNING

NOTE:

For tires with a “DRIVE” mark 1 : Install the wheel with the “DRIVE” mark pointing

in direction in which the wheel will rotate.

After mounting a tire, ride conservatively for awhile to give the tire time to seat itself properlyin the rim. Failure to do so could lead to an ac-cident with possible injury to the rider or dam-age to the motorcycle.

WHEEL INSPECTION1. Inspect:Wheels

Damage/Bends Replace.

Always balance the wheel when a tire or wheelhas been changed or replaced.

Never attempt to make any repairs to thewheel.

CABLE INSPECTION AND LUBRICATION

Damaged cable sheaths may cause corrosionand interfere with the cable movement. Re-place damaged cables as soon as possible.

1. Inspect:Cable sheath

Damage Replace.2. Check:Cable operation

Unsmooth operation Lubricate.

Recommended lubricant:Engine oil

Hold cable end up and pour a few drops of lubri-cant into the cable sheath.

3-50

LEVER AND PEDAL LUBRICATION/SIDESTANDLUBRICATION/REAR SUSPENSION LUBRICATION

INSPADJ

LEVER AND PEDAL LUBRICATIONLubricate levers and pedals at their pivotingpoints.


SIDESTAND LUBRICATIONLubricate the sidestand at pivoting points.


REAR SUSPENSION LUBRICATIONLubricate the rear suspension at pivoting points.

Recommended lubricant:Molybdenum disulfide grease

3-51


123456

Battery removalSeat

Brake hose guideRear master cylinderRear brake switchBattery negative lead terminalBattery positive lead terminalBattery assembly

111111

Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK”.

Refer to “Battery removal”.

Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK”.


7 Nm (0.7 mkg)

23 Nm (2.3 mkg)

7 Nm (0.7 mkg)

8 Nm (0.8 mkg)

30 Nm (3.0 mkg)

BATTERYINSPADJ

ELECTRICALBATTERY

3-52

REMOVALINSPADJ

WARNING

WARNING

NOTE:

REMOVAL

Immediately after removing the battery leads,securely cover the terminals with the covers1 to prevent the battery leads from beingshorted.

1. Remove:Seat


2. Remove:Negative terminal cover 1Positive terminal cover 2

First disconnect the negative lead 1 , then dis-connect the positive lead 2 .

3. Remove:Battery assembly

Slide the battery assembly around the right side ofthe shock absorber and then pull it outward to re-move.

4. Remove:Battery negative lead 1Battery positive lead 2Battery 3Battery box 4

3-53

INSPECTIONINSPADJ

NOTE:

CAUTION:

WARNING

INSPECTION

Since the MF battery is a sealed type battery, it isnot possible to measure the specific gravity of theelectrolyte in order to check the charge state of thebattery. Therefore the charge of the battery has tobe checked by measuring the voltage at the bat-tery terminals.

This is a sealed type battery. Never removethe sealing caps. If the sealing caps havebeen removed, the balance will not be main-tained and battery performance will deterio-rate.

Charging time, charging current and charg-ing voltage for the MF battery are differentfrom those of general type batteries. The MFbattery should be charged as explained in“CHARGING METHOD”. If the battery is over-charged, the electrolyte level will drop con-siderably. Therefore, take special care whencharging the battery.

Batteries generate explosive hydrogen gas.Always follow the following preventive mea-sures:Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks or open

flames (e.g., welding equipment, lighted cig-arettes, etc.)

DO NOT SMOKE when charging or handlingbatteries.

KEEP BATTERIES AND ELECTROLYTE OUTOF REACH OF CHILDREN.

3-54

INSPECTIONINSPADJ

16151413121110

5 6.5 10

100 75 50 30 25 20 0

0 10 20 30 40

11.5

12.0

12.5

13.0

17

18

10

11

12

1314

(V)

50 60

Volt meter

Relationship between the open-circuit voltageand the charging time at 20C

Charging time (hours)This varies depending on the temperature, the state of charge

in the battery plates and the electrolyte level.

Ope

n-ci

rcui

t vol

tage

Ope

n-ci

rcui

t vol

tage

(V

)

Ambient temperature 20C

Condition of the charge in the battery (%)

Ope

n-ci

rcui

t vol

tage

(V

)

Charging Ambient temperature20C

Time (minutes)Check the open-circuitvoltage

NOTE:

CAUTION:

1. Check:Battery condition

Battery condition checking steps:Connect a digital voltmeter to the battery termi-

nals.

Tester (+) lead battery (+) terminalTester (–) lead battery (–) terminal

The charge state of an MF battery can be checkedby measuring the open-circuit voltage (i.e. thevoltage when the positive terminal is discon-nected).

Open-circuit voltage Charging time

12.8 V or higher No charging isnecessary.

Check the condition of the battery using the fol-lowing charts.

Example:Open-circuit voltage = 12.0 VCharging time = 6.5 hoursCharge condition of the battery = 20 30%Charging method for MF batteriesCharging method

If it is impossible to set the standard chargingcurrent, be careful not to overcharge.

When charging the battery, be sure to removeit from the motorcycle. (If charging has to bedone with the battery mounted on the motor-cycle, be sure to disconnect the wire at thenegative terminal.)

Never remove the sealing caps of an MF bat-tery,

Make sure that the charging clips are in fullcontact with the terminal and that they arenot shorted together. (A corroded clip on thecharger may cause the battery to generateheat in the contact area. A weak clip springmay cause sparks.)

3-55

INSPECTIONINSPADJ

WARNING

Before removing the clips from the batteryterminals, be sure to turn off the charger’spower switch.

The open-circuit voltage variation for the MFbattery after charging is shown below. Asshown in the figure, the open circuit voltagestabilizes about 30 minutes after charginghas been completed.Therefore, wait 30 minutes after charging iscompleted before measuring the opencircuitvoltage.

Do not quick charge the battery.

3-56

Connect a charger and AMPmeter to the battery and startcharging.

Adjust the voltage so that thecurrent is at the standard charg-ing level.

Set the timer according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps.”

Set the charging voltage at 16 17 V.(If the setting is lower, charging will beinsufficient. If too high, the battery willbe over-charged.)

Measure the open-circuitvoltage prior to charging.

Make sure that the current ishigher than the standardcharging current written onthe battery.

By turning the charging voltageadjust dial, set the charging volt-age at 20 25 V.

Monitor the amperage for 3 5minutes to check if the standardcharging current is reached.

If the current does not exceedthe standard charging currentafter 5 minutes, replace thebattery.

If charging requires more than 5 hours, it is advisable to check the charg-ing current after a lapse of 5 hours. If there is any change in the amperage,readjust the voltage to obtain the standard charging current.

Measure the battery open-circuit voltage after leaving the batteryunused for more than 30 minutes.12.8 V or more --- Charging is complete.R12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.

YES NO

YES

NO

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

NOTE:AMP meter

Charger

INSPECTIONINSPADJ

Charging method using a variable-current (voltage) type charger

3-57

Make sure that the currentis higher than the standardcharging current writtenon the battery.

Connect a charger andAMP meter to the batteryand start charging.

Measure the open-circuitvoltage prior to charging.

This type of battery charger cannotcharge the MF battery. A variable volt-age charger is recommended.

NOTE:Voltage should be measured 30 min-utes after the machine is stopped.

Charge the battery until the battery’scharging voltage is 15 V.

NOTE:Set the charging time at 20 hours (maxi-mum).

YES NO

Charging method using a constant-current type chargerThis type of battery charger cannot charge the MF battery.

Volt meter

Charger

AMP meter

Measure the battery open-circuit volt-age after leaving the battery unused formore than 30 minutes.12.8 V or more --- Charging is com-plete.12.7 V or less --- Recharging is re-quired.Under 12.0 V --- Replace the battery.

INSPECTIONINSPADJ

Charging method using a constant-voltage type charger

3-58

INSPECTION/INSTALLATION/FUSE INSPECTIONINSPADJ

NOTE:

NOTE:

NOTE:

CAUTION:

2. Inspect:Battery terminal

Dirty Clean with a wire brush.Poor connection Correct.

After cleaning the terminals, grease them lightly.

INSTALLATION1. Install:Battery assembly 1

During installation, be sure the projection a onthe battery box aligns with the grommet on theframe.

Pass the battery leads through the cable guide2 .

2. Install:Positive terminal cover 1Negative terminal cover 2

Connect the battery positive lead first and thenthe negative lead.

After connecting the leads, securely cover theterminals with the covers.

FUSE INSPECTION

Always turn off the main switch when check-ing or replacing the fuse. Otherwise, a shortcircuit may occur.

1. Remove:Seat


3-59

FUEL INSPECTIONINSPADJ

NOTE:

WARNING

2. Inspect:Fuses 1

Inspection steps:Connect the pocket tester to the fuse and

check it for continuity.

Set the tester selector to “Ω 1”

Pocket tester:90890-03112

If the tester indicates ∞, replace the fuse.

3. Replace:Blown fuse

Replacement steps:Turn off the ignition. Install a new fuse of proper amperage.Turn on the switches to verify operation of re-

lated electrical devices. If the fuse immediately blows again, check the

electrical circuit.

Description Amperage Quantity

Main 30A 1

Head 15A 1

Signal 15A 1

Ignition 7.5A 1

Fan 7.5A 1

Never use a fuse with a rating other than speci-fied. Never use other materials in place of afuse. An improper fuse may cause extensivedamage to the electrical system, malfunctionof lighting and ignition and possibly cause afire.

4. Install:Seat


3-60

HEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENT

INSPADJ

WARNING

EB305021

HEADLIGHT BEAM ADJUSTMENT1. Adjust:Headlight beam (vertically)


Turnning in: Headlight beam islowered.

Turnning out: Headlight beam is raised.

2. Adjust:Headlight beam (horizontally)

Turn the adjuster 2 in or out.Right headlight:

Turnning in: Headlight beam is to theright.

Turnning out: Headlight beam is to theleft.

Left headlight:

Turnning in: Headlight beam is to theleft.

Turnning out: Headlight beam is to theright.

HEADLIGHT BULB REPLACEMENT1. Remove:Cover 1

2. Disconnect:Headlight leads 1

3. Unhook:Bulb holder 2

4. Remove:Bulb

Keep flammable products and your handsaway from the bulb while it is on, as it will behot. Do not touch the bulb until it has cooleddown.

3-61

HEADLIGHT BULB REPLACEMENTINSPADJ

New

CAUTION:

5. Install:Bulb

Secure the new bulb with the bulb holder.

Avoid touching the glass part of the bulb.Keep it free from oil; otherwise, the transpar-ency of the glass, life of the bulb, and luminousflux will be adversely affected. If oil gets on thebulb, thoroughly clean it with a cloth moist-ened with alcohol or lacquer thinner.

6. Hook:Bulb holder

7. Connect:Headlight leads

8. Install:Cover

INSPADJ

ENG

CHAPTER 4.ENGINE OVERHAUL

ENGINE ASSEMBLY 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER 4-2. . . . . . . . . . . . . . ENGINE ASSEMBLY 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE AND VALVE SPRING 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER AND PISTON 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE COVER (RIGHT) 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE COVER (LEFT) 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

A.C. MAGNETO AND STARTER WHEEL GEAR 4-37. . . . . . . . . . . . . . . . . . . . . STATOR COIL 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND STARTER WHEEL GEAR 4-38. . . . . . . . . . . . . . . . . . REMOVAL 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP COVER AND OIL PUMP DRIVEN GEARS 4-41. . . . . . . . . . . . . . OIL PUMP 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL TANK 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL HOSE 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL TANK 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALANCER 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT ASSEMBLY 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING ROD 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION, SHIFT CAM AND SHIFT FORK 4-63. . . . . . . . . . . . . . . . . . . . REMOVAL 4-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 4-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

WARNING


12

3456

Leads disconnectSide cowling, seat, side cover and fueltank.Battery negative leadBattery positive lead

Starter motor leadStartor coil lead/pickup coil lead couplerNeutral switch lead couplerClamp

11

11/111

Disconnect the parts in the order below.Refer to “COWLINGS, SEAT, TAIL COV-ER AND FUEL TANK” in CHAPTER 3.

Disconnect the negative lead first andthen disconnect the positive lead.

Immediately after removing the batteryleads, securely cover the terminals withthe covers to prevent the batteryleads from being shorted

10 Nm (1.0 mkg)

DisconnectDisconnect

For connecting, reverse the disconnectionprocedure.

1

ENGINE ASSEMBLY ENG

ENGINE OVERHAULENGINE ASSEMBLYLEADS

4-2


123456789

Drive sprocket and exhaust pipe/muffler removalAir filter caseCarburetor assemblyRadiator assemblyThermostatic valve assembly

Drive sprocket cover 1Shift armDrive sprocket cover 2Nut/Lock washerDrive sprocket/Drive chainExhaust pipe/MufflerExhaust pipe gasketClutch cableSpark plug caps

111

1/11/11/1212


Refer to “AIR FILTER CASE” in CHAPTER 3.Refer to “CARBURETOR” in CHAPTER 6.Refer to “RADIATOR” in CHAPTER 5.Refer to “THERMOSTATIC VALVE”in CHAPTER 5.


20 Nm (2.0 mkg)

20 Nm (2.0 mkg) 24 Nm (2.4 mkg)

5 Nm (0.5 mkg)

70 Nm (7.0 mkg)

24 Nm (2.4 mkg)

12 Nm (1.2 mkg)

ENGINE ASSEMBLY ENG

DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER

4-3


123456789

1011

Engine removal

Starter motor

Vacuum hoseBreather hoseBoltBoltBoltEngine bracket (left)Engine bracket (right)PlugBoltBoltEngine assembly

1

21211112111


Place suitable stand under the frame andengine.

Refer to “STARTER MOTOR” in CHAP-TER 8.

= 45 mm = 25 mm = 60 mm

= 230 mm = 115 mmRefer to “INSTALLATION”.

NOTE:

60 Nm (6.0 mkg)

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

30 Nm (3.0 mkg)

60 Nm (6.0 mkg)

89 Nm (8.9 mkg)

64 Nm (6.4 mkg)

30 Nm (3.0 mkg)

ENGINE ASSEMBLY ENG

ENGINE ASSEMBLY

4-4

ENGINE ASSEMBLY ENG


1213

Engine stay (left)Engine bracket (lower)

11


60 Nm (6.0 mkg)

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

30 Nm (3.0 mkg)

60 Nm (6.0 mkg)

89 Nm (8.9 mkg)

64 Nm (6.4 mkg)

30 Nm (3.0 mkg)

4-5

ENGINE ASSEMBLY ENG

NOTE:

1

2

3

4

5

6

12 Nm (1.2 mkg)

NOTE:

INSTALLATION1. Install:Bolt 1 6

Do not fully tighten.

2. Tighten:Tighten the bolts in the order below.

1 Bolt 30 Nm (3.0 mkg)






3. Install:Shift arm 1

Align the punched mark a on the shift shaft withthe slot on the shift arm.

The top of the shift pedal 1 should be alignedwith the crankcase 2 .

4-6


12345

Cylinder head cover removalSide cowling, seat, side cover and fueltankAir filter case

Coolant

RadiatorCarburetor assemblyThermostatic assembly

Breather hoseSpark plug capBoltCylinder head coverCylinder head cover gasket

12

1/6/113

Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAILCOVER AND FUEL TANK” in CHAPTER 3.Refer to “AIR FILTER CASE” inCHAPTER 3.Refer to “COOLANT REPLACEMENT”in CHAPTER 3.Refer to “RADIATOR” in CHAPTER 5.Refer to “CARBURETOR” in CHAPTER 6.Refer to “THERMOSTATIC VALVE” inCHAPTER 5.

= 68/27/58 mm


10 Nm (1.0 mkg)

CAMSHAFT ENG

CAMSHAFTCYLINDER HEAD COVER

4-7

CAMSHAFT ENG


123456789

10

Camshaft removalSpark plugPlug/O-ringTiming chain guide (upper)Timing chain tensioner/GasketCamshaft sprocketTiming chain guide (exhaust)Camshaft capDowel pinIntake camshaftExhaust camshaft

22/21

1/1214811



Refer to “REMOVAL”, and“INSTALLATION”.

24 Nm (2.4 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

18 Nm (1.8 mkg)

10 Nm (1.0 mkg)

20 Nm (2.0 mkg)

CAMSHAFT

4-8

CAMSHAFT ENG

NOTE:

NOTE:

REMOVAL1. Remove:Timing plug 1Straight plug 2

2. Align: “T” mark

(with stationary pointer)

Turn the crankshaft counterclockwise and alignthe “T” mark a with the stationary pointer bwhen #1 piston is at TDC on compression stroke.

The #1 piston is in compression stroke TDCwhen the cam lobes are turned away from eachother.

3. Remove:Timing chain guide (upper) 1

4. Loosen:Camshaft sprocket bolts 2

5. Loosen:Tensioner cap bolt 1

6. Remove:Timing chain tensioner 2

7. Remove:Camshaft sprockets 1

Attach a wire 2 to the timing chain to prevent itfrom falling into the crankcase.

4-9

CAMSHAFT ENG

NOTE:

CAUTION:

8. Remove:Timing chain guide (exhaust)Camshaft cap 1

Remove the camshaft cap bolts in a crisscrosspattern, working from the inside to the outside.

The bolts (camshaft caps) must be removedevenly to prevent damage to the cylinder head,camshafts or camshaft caps.

INSPECTION1. Inspect:Cam lobes

Pitting/Scratches/Blue discoloration Re-place.

2. Measure:Cam lobes length a and b

Out of specification Replace.

Cam lobes length limit:Intake:

a 35.85 mmb 27.85 mm

Exhaust:a 35.85 mmb 27.85 mm

3. Measure:Runout (camshaft)


Runout (camshaft):Less than 0.03 mm

4-10

CAMSHAFT ENG

10 Nm (1.0 mkg)

NOTE:

4. Measure:Camshaft-to-cap clearance

Out of specification Measure bearing diam-eter (camshaft)

Camshaft-to-cap clearance:0.020 0.054 mm

Measurement steps: Install the camshaft onto the cylinder head.Position a strip of Plastigauge 1 onto the

camshaft. Install the dowel pins and camshaft caps.

Tighten the bolts (camshaft cap) in a crisscrosspattern from innermost to outer caps.

Do not turn the camshaft when measuring clear-ance with the Plastigauge .

Remove the camshaft caps and measure thewidth of the Plastigauge 1 .

5. Measure:Outside diameter (camshaft) a

Out of specification Replace the camshaft.Within specification Replace camshaft caseand camshaft caps as a set.

Outside diameter (camshaft):24.967 24.980 mm

6. Inspect:Timing chain

Stiffness/damage Replace the chain andthe sprockets as a set.

4-11

CAMSHAFT ENG

NOTE:

10 Nm (1.0 mkg)

NOTE:

CAUTION:

NOTE:

INSTALLATION1. Install:Exhaust camshaft 1 Intake camshaft 2

(with camshaft sprocket temporarily tighten)Dowel pins 3

Install the camshaft with the punch mark a facingupward.

2. Install:Camshaft caps

Install the camshaft cap with the arrow mark aembossed facing timing chain of the engine.

Tighten the camshaft cap bolts in a crisscrosspattern from the inside to outwards.

Do not install the bolts at b marked place in thisstage.

The camshaft cap bolts must be tightenedevenly or damage to the cylinder head, cam-shaft caps and camshaft will result.

3. Install:Camshaft sprockets

Installation steps:Turn the crankshaft counterclockwise until the

“T” mark a on the A.C. magneto is aligned withthe stationary pointer b on the crankcase cover(left) when #1 piston is at TDC.

Fit the timing chain onto both camshaft sprocketsand install the camshaft sprockets on the cam-shafts.

When installing the camshaft sprockets, start withthe exhaust camshaft to keep the timing chain astense as possible on the exhaust side, and set thematch marks c to be parallel with the case sur-face on the corresponding sides.

“I”: Intake side“E”: Exhaust side

4-12

CAMSHAFT ENG

CAUTION:

New

24 Nm (2.4 mkg)

Do not turn the crankshaft during the cam-shaft installation. Damage or improper valvetiming will result.

Make sure that marks d and e are aligned afterthe crankshaft is rotated twice and the piston is atTDC.

4. Install:Timing chain guide (exhaust)

5. Install:Timing chain tensioner

Installation steps:Remove the tensioner cap bolt 1 , washer 2

and springs 3 .Release the timing chain tensioner one-way cam

4 and push the tensioner rod 5 all the way in. Install a gasket 6 . Install the timing chain tensioner.

Timing chain tensioner:10 Nm (1.0 mkg)

Install the springs 3 and washer 2 . Install the tensioner cap bolt 1 .

Cap bolt:20 Nm (2.0 mkg)

6. Turn:Crankshaft

Counterclockwise several turns7. Check:A.C. magneto “T” mark

Align with the crankcase stationary pointer.Camshaft punched marks

Align with the camshaft cap embossed marks.Out of alignment Adjust.

8. Tighten:Camshaft sprocket bolts.

4-13

CYLINDER HEAD ENG


12345678

Cylinder head removalExhaust pipeCamshaftUnion boltCopper washerOil delivery pipeClipVacuum hoseCylinder headCylinder head gasketDowel pin

12122112

Remove the parts in the order below.Refer to “ENGINE ASSEMBLY”.Refer to “CAMSHAFT”.


Refer to “INSTALLATION”.

40 Nm (4.0 mkg)

10 Nm (1.0 mkg)

60 Nm (6,0 mkg)

21 Nm (2.1 mkg)

10 Nm (1.0 mkg)

60 Nm (6.0 mkg)

CYLINDER HEAD

4-14

CYLINDER HEAD ENG

NOTE:

NOTE:

New40 Nm (4.0 mkg)Nut10 Nm (1.0 mkg)Bolt

NOTE:

INSPECTION1. Eliminate:Carbon deposit

(from combustion chamber)Use rounded scraper.

Do not use a sharp instrument to avoid damagingor scratching:Spark plug threadsValve seat

2. Inspect:Cylinder head

Scratches/Damage Replace.3. Measure:Cylinder head warpage

Out of specification Resurface.

Cylinder head warp limit:Less than 0.03 mm

Warp limit measurement and resurfacementsteps:Hold a straight edge and a thickness gauge to

the cylinder head.Measure the warpage. If the warpage is out of specification, resurface

the cylinder head.Place a 400 600 grit wet sandpaper on the sur-

face plate, and resurface the head using a figure-eight sanding pattern.

Rotate the head several times to avoid removingtoo much material from one side.

INSTALLATION1. Install:Dowel pinsCylinder head gasket Cylinder head

Apply the engine oil onto the nut threads.Tighten the nuts in a crisscross pattern.

4-15

VALVE AND VALVE SPRING ENG


123456789

10

Valve and valve spring removalCylinder head coverCylinder headValve lifterAdjusting padValve cotterValve retainerValve springStem sealValve spring seatExhaust valveIntake valve (center)Intake valve (left and right)

55

105555212

Remove the parts in the order below.Refer to “CYLINDER HEAD COVER”.Refer to “CYLINDER HEAD”.

For installation, reverse the removal pro-cedure.


VALVE AND VALVE SPRING

4-16

VALVE AND VALE SPRING ENG

NOTE:

NOTE:

REMOVAL1. Remove:Valve lifters 1Pads 2

Identify each lifter 1 and pad 2 position verycarefully so that they can be reinstalled in theiroriginal place.

2. Check:Valve sealing

Leakage at valve seat Inspect the valveface, valve seat and the valve seat width.

Checking steps:Pour a clean solvent a into the intake and ex-

haust ports.Check the valve seating.

There should be no leakage at the valve seat 1 .

3. Remove:Valve cotters 1

Attach the valve spring compressor 2 and at-tachment 3 between the valve spring retainerand cylinder head to remove the valve cotters.

Valve spring compressor:90890-04019

Attachment:90890-04108

4-17


NOTE:

NOTE:

INSPECTION1. Measure:Stem-to-guide clearance

Stem-to-guide clearance =Valve guide inside diameter a –Valve stem diameter b

Out of specification Replace valve guide.

Stem-to-guide clearance:Intake:

0.010 0.037 mm<Limit>: 0.08 mm

Exhaust:0.025 0.052 mm<Limit>: 0.10 mm

2. Replace:Valve guide

Replacement steps:

Heat the cylinder head in an oven to 100C toease guide removal and installation and to main-tain correct interference fit.

Remove the valve guide using the valve guideremover 1 .

Install the valve guide (new) using the valveguide installer 2 and valve guide remover 1 .

After installing the valve guide, bore the valveguide using the valve guide reamer 3 to obtainproper stem-to-guide clearance.

Valve guide remover, installer andreamer (5.5 mm):

90890-04016

Reface the valve seat after replacing the valveguide.

4-18


NOTE:

3. Eliminate:Carbon deposit

(from valve face)4. Inspect:Valve face

Pitting/Wear Reface the face.Valve stem end

Mushroom shape or diameter larger than restof stem Replace.

5. Measure:Margin thickness a


Margin thickness:0.8 1.2 mm

6. Measure:Runout (valve stem)


Runout limit:0.01 mm

Always replace the guide if the valve is replaced.Always replace the oil seal if the valve is re-

moved.

7. Eliminate:Carbon deposit

(from valve face and valve seat)8. Inspect:Valve seat

Pitting/Wear Reface valve seat.

9. Measure:Valve seat width a

Out of specification Reface valve seat.

Valve seat width:Intake: 0.9 1.1 mmExhaust: 0.9 1.1 mm

4-19


NOTE:

CAUTION:

Measurement steps:Apply the Mechanic’s blueing dye (Dykem) b to

the valve face. Install the valve into the cylinder head.Press the valve through the valve guide and onto

the valve seat to make a clear pattern.Measure the valve seat width. Where the valve

seat and valve face made contact, blueing willhave been removed.

If the valve seat is too wide, too narrow, or theseat is not centered, the valve seat must be re-faced.

10. Lap:Valve faceValve seat

After refacing the valve seat or replacing the valveand valve guide, the valve seat and valve faceshould be lapped.

Lapping steps:Apply a coarse lapping compound a to the

valve face.

Be sure no compound enters the gap betweenthe valve stem and guide.

Apply molybdenum disulfide oil to the valvestem.

Install the valve into the cylinder head.Turn the valve until the valve face and valve seat

are evenly polished, then clean off all compound.

4-20


NOTE:

NOTE:

To obtain the best lapping result, lightly tap thevalve seat while rotating the valve back and forthbetween your hand.

Apply a fine lapping compound to the valve faceand repeat the above steps.

Be sure to clean off all compound from the valveface and valve seat after every lapping operation.

Apply the Mechanic’s blueing dye (Dykem) b tothe valve face.

Install the valve into the cylinder head.Press the valve through the valve guide and onto

the valve seat to make a clear pattern.Measure the valve seat width c again. If the

valve seat width is out of specification, refaceand lap the valve seat.

11. Measure:Free length (valve spring) a


Free length (valve spring):37.29 mm

<Limit>35.20 mm

12. Measure:Compressed force (valve spring) a

Out of specification Replace.b Installed length

Compressed force:10.0 11.6 kg at 30.39 mm

4-21


New

NOTE:

13. Measure:Spring tilt a


Spring tilt limit:2.5 /1.7 mm

INSTALLATION1. Install:Stem seal ValveSpring seatValve springValve retainer

(into cylinder head)

Make sure that each valve is installed in its origi-nal place, also referring to the embossed markas follows:

Intake (right/ left): “3LD:”Intake (middle): “3LD.”Exhaust “3LD”

Install the valve spring with the larger pitch afacing upwards.

b Smaller pitch

4-22


NOTE:

NOTE:

NOTE:

2. Install:Valve cotters 1

Install the valve cotters while compressing thevalve spring with the valve spring compressor.

Valve spring compressor 2 :90890-04019

Attachment 3 :90890-04108

3. Secure the valve cotters 1 onto the valve stemby tapping lightly with a piece of wood.

Do not hit so much as to damage the valve.

4. Install:Pads 1Valve lifters 2

The valve lifters must move smoothly when ro-tated with the finger.

Each valve lifter and pad must be reinstalled intheir original position.

Refer to “VALVE CLEARANCE ADJUSTMENT” inCHAPTER 3.

4-23

CYLINDER AND PISTON ENG


123456789

1011

Cylinder and piston removalCylinder headJointO-ringO-ringDowel pinCylinderCylinder gasketO-ringCirclipPiston pinPistonPiston ring set

11141124222

Remove the parts in the order below.Refer to “CYLINDER HEAD”.



10 Nm (1.0 mkg)

CYLINDER AND PISTON

4-24


NOTE:

CAUTION:

NOTE:

REMOVAL1. Remove:Piston circlips 1Piston pins 2Pistons 3

Before removing the piston pin clip, cover thecrankcase with a clean rag to prevent the pistonpin clip from falling into the crankcase cavity.

Put identification marks on each piston head forreference during reinstallation.

Before removing the piston pin, deburr the clipgroove and pin hole area. If the piston pin grooveis deburred and piston pin is still difficult to re-move, use the piston pin puller 4 .

Piston pin puller:90890-01304

Do not use a hammer to drive the piston pinout.

INSPECTION1. Inspect:Cylinder and piston walls

Vertical scratches Rebore or replace cylin-der and piston.

2. Measure:Piston-to-cylinder clearance

Measurement steps:1st step:Measure the cylinder bore “C” with a cylinder

bore gauge.

Measure the cylinder bore “C” in parallel to and atright angles to the crankshaft. Then, find the aver-age of the measurements.

4-25


Cylinder bore “C” 89.500 89.505 mm

Taper limit “T” 0.05 mm

Out of round “R” 0.03 mm

“C” = Maximum D

“T” = (Maximum D1, or D2) – (Maximum D5or D6)

“R” = (Maximum D1, D3 or D5)

– (Minimum D2, D4 or D6)

If out of specification, rebore or replace the cylin-der, and replace the piston and piston rings asset.

2nd step:Measure the piston skirt diameter “P” with a mi-

crometer.

a 5.5 mm from the piston bottom edge.

Piston size P

Standard 89.420 89.435mm

Oversize 2 0.50 mm

Oversize 4 1.00 mm

If out of specification, replace the piston and pis-ton rings as a set.

3rd step:Calculate the piston-to-cylinder clearance with

following formula:

Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance:0.065 0.085 mm<Limit>: 0.15 mm

If out of specification, rebore or replace the cylin-der, and replace the piston and piston rings asset.

4-26


NOTE:

NOTE:

NOTE:

3. Measure:Side clearance

Out of specification Replace piston andrings as a set.

Eliminate the carbon deposits from the piston ringgrooves and rings before measuring the sideclearance.

Side clearance:Top ring:

0.035 0.070 mm2nd ring:

0.035 0.070 mm

4. Position:Piston ring

(into cylinder)

Push the ring with the piston crown so that the ringwill be at a right angle to the cylinder bore.

a 5 mm

5. Measure:End gap


You cannot measure the end gap on the expanderspacer of the oil control ring. If the oil control ringrails show excessive gap, replace all three rings.

End gap:Top ring:

0.30 0.45 mm2nd ring:

0.30 0.45 mmOil ring:

0.20 0.70 mm

4-27


NOTE:

6. Inspect:Piston pin

Blue discoloration/Grooves Replace, theninspect lubrication system.

7. Measure:Piston pin-to-piston clearance

Measurement steps:Measure the piston pin outside diameter a .

If out of specification, replace the piston pin.

Outside diameter (piston pin):19.991 20.000 mm<Limit>: 19.975 mm

Measure the piston inside diameter b .Calculate the piston pin-to-piston clearance with

following formula:

Piston pin-to-piston clearance =Bore size (piston pin) b –Outside diameter (piston pin) a

If out of specification, replace the piston.

Piston pin-to-piston clearance =0.002 0.022 mm<Limit>: 0.07 mm

INSTALLATION1. Install:Piston rings

Be sure to install rings so that “T” mark is locatedon the upper side of the rings. Oil the pistons andrings liberally.

4-28


NOTE:

NewNew

NOTE:

2. Install:Piston pins 1Pistons 2Piston circlips 3

Apply engine oil to the piston pins.Be sure that the arrow mark a on the piston

points to the exhaust side of the engine.Before installing the piston, cover the crankcase

with a clean rag to prevent the piston from fallinginto the crankcase.

3. Position:Top ring2nd ringOil ring

Offset the piston ring end gaps as shown.

a Top ring end

b Oil ring end (lower)

c Oil ring end (upper)

d 2nd ring end

4. Install:Dowel pinsO-rings Cylinder gasket Cylinder

Install the cylinder with one hand while compres-sing the piston rings with the other hand.

Pass the timing chain and timing chain guide (in-take) through the timing chain cavity.

4-29

CLUTCH ENG


Crankcase cover (right) removalEngine oil

Clutch cableCrankcase cover (right)

GasketDowel pinCirclipPlain washerPull leverTorsion springPlain washer

11

1211111

Remove the parts in the order below.Refer to “ENGINE OIL REPLACEMENT”in CHAPTER 3.


Loosen the bolts in a crisscross pattern.NOTE:

12

3456789

10 Nm (1.0 mkg)

CLUTCHCRANKCASE COVER (RIGHT)

4-30

CLUTCH ENG


123456789

1011121314

Clutch removalClutch springPressure platePlain washer/BearingPull rodFriction plateClutch plateClutch boss nutLock washerClutch bossThrust plateSpacer/BearingClutch housingThrust plate 2Thrust plate 1

61

1/11981111

1/1111




70 Nm (7.0 mkg)

8 Nm (0.8 mkg)

CLUTCH

4-31

CLUTCH ENG

NOTE:

NOTE:

REMOVAL1. Straighten the lock washer tab.2. Remove:Clutch boss nut 1Lock washer 2Clutch boss 3

Loosen the clutch boss nut 1 while holding theclutch boss 3 with the universal clutch holder.

Universal clutch holder:90890-04086

3. Remove:Spacer 1Bearing 2

Install 6 mm bolts 3 onto the spacer. Then re-move the spacer by pulling.

INSPECTION1. Measure:Friction plate thickness

Out of specification Replace friction platesas a set.Measure at four points.

Thickness:2.9 3.1 mm<Limit>: 2.8 mm

2. Measure:Clutch plate warpage

Out of specification Replace clutch plate asa set.Use a surface plate and feeler gauge 1 .

Warp limit:Less than 0.1 mm

3. Measure:Free length (clutch spring) a

Out of specification Replace springs as aset.

Free length (clutch spring):55 mm<Limit>: 53 mm

4-32

CLUTCH ENG

NOTE:

NOTE:

New

70 Nm (7.0 mkg)

NOTE:

NOTE:

4. Inspect:Dogs

(on the clutch housing)Pitting/Wear/Damage Deburr or replace.

Clutch housing bearingWear/Damage Replace clutch housing.

Pitting on the clutch housing dogs will cause errat-ic operation.

Clutch boss splinesPitting/Wear/Damage Replace clutchboss.

Pitting on the clutch boss splines will cause erraticoperation.

INSTALLATION1. Install:Clutch boss 1Lock washer 2 Clutch boss nut 3

Tighten the clutch boss nut while holding theclutch boss with the universal clutch holder 4 .

Universal clutch holder:90890-04086

2. Bend the lock washer tab along a flat side of thenut.

3. Install:Friction platesClutch plates

Mount friction and clutch plate alternately.Lubricate the friction plates with engine oil.

4-33

CLUTCH ENG

NOTE:

8 Nm (0.8 mkg)

NOTE:

New

10 Nm (1.0 mkg)

NOTE:

New

NOTE:

4. Install:Pressure plate

Align the punched mark a on the clutch boss withthe punched mark b on the pressure plate.

5. Install:Clutch springs 1Clutch spring bolts 2

Tighten the clutch spring bolts in stage, using acrisscross pattern.

6. Install:Dowel pinsGasket Crankcase cover (right)

Install the pull rod so that the splines a are towardthe back, then install the crankcase cover (right).

7. Install:Plain washer 1Torsion spring 2Pull lever 3Plain washer 4Circlip 5

Align the punched mark a on the clutch pull levershaft with the mark b on the crankcase cover.

4-34


123

4567

Crankcase cover (left) removalEngine oil

Drive sprocket cover 1/2Shift armCrankcase cover (left)

GasketDowel pinCirclipPlain washer

1/111

1211

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.


Loosen the bolts in a crisscross pattern.

NOTE:

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

5 Nm (0.5 mkg)

CRANKCASE COVER (LEFT) ENG

CRANKCASE COVER (LEFT)

4-35

SHIFT SHAFT ENG


1234567

Shift shaft removalClutchShift armShift shaftCirclipPlain washerTorsion springStopper levelBearing retainerTorsion spring

1111111

Remove the parts in the order below.Refer to “CLUTCH”.Refer to “CRANKCASE COVER (LEFT)”.



10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

SHIFT SHAFT

4-36

SHIFT SHAFT ENG

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

NOTE:

INSPECTION1. Inspect:Stopper lever 1

Roller turns roughly Replace.Bends/Damage Replace.

2. Inspect:Torsion spring (shift shaft) 1Torsion spring (stopper lever) 2


3. Inspect:Shift shaft 1Shift pawls 2

Bends/Wear/Damage Replace.

INSTALLATION1. Install:Return spring 1Bearing retainer 2Stopper lever 3

Be sure the stopper lever roller fits into the shiftcam segment.

4-37

A.C. MAGNETO AND STARTER WHEEL GEAR ENG


123456

Stator coil removalEngine oil

Crankcase cover (left)Stator coil lead/Pickup coil leadCrankcase cover (left)GasketDowel pinClamp/Pickup coilStator coil

1/1112

1/11

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “CRANKCASE COVER (LEFT)”.


7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

A.C. MAGNETO AND STARTER WHEEL GEARSTATOR COIL

4-38



12

34

567

A.C. magneto and starter wheelgear removalRotorShaft

Starter idle gearStarter clutch

Plate washerWoodruff keyStarter wheel gear

11

11

111



After reassembling the starter clutch stakethe top of the bolts.

NOTE:

Refer to “REMOVAL” and“INSTALLATION”.

130 Nm (13.0 mkg)

10 Nm (1.0 mkg)

A.C. MAGNETO AND STARTER WHEEL GEAR

4-39


NOTE:

NOTE:

REMOVAL1. Remove:Bolt (rotor) 1Washer 2

Loosen the bolt (rotor) 1 while holding the mag-neto with the sheave holder 3 .

Do not allow the sheave holder 3 to touch theprojection on the rotor.

Sheave holder:90890-01701

2. Remove:A.C. magneto 1

Remove the rotor 1 using the rotor puller 2 andcrankshaft protector 3 .

Fully tighten the tool holding bolts, but make surethe tool body is parallel with the magneto. If nec-essary, one screw may be backed out slightly tolevel tool body.

Flywheel puller:90890-01362

Crankshaft protector:90890-01382

INSPECTION1. Check:Starter clutch operation

Clutch operation checking steps: Install the starter wheel gear to the starter clutch,

and hold the starter clutch.When turning the starter wheel gear clockwise

A , the starter clutch and the wheel gear shouldbe engaged.If not, the starter clutch is faulty. Replace it.

When turning the starter wheel gear counter-clockwise B , the starter wheel gear should turnfreely.If not, the starter clutch is faulty. Replace it.

4-40


NOTE:

130 Nm (13.0mkg)

NOTE:

2. Inspect:Starter wheel gear 1

(contacting surfaces)Pitting/Wear/Damage Replace.

INSTALLATION1. Install:Starter wheel gear 1Woodruff key 2

2. Install:Plate washerRotor 1Washer

Clean the tapered portions of the crankshaft androtor.

When installing the magneto, make sure thewoodruff key is properly seated in the key way ofthe crankshaft.

3. Install:Bolt (rotor) 1

Tighten the bolt (rotor) 1 while holding the mag-neto with the sheave holder 2 .

Do not allow the sheave holder 2 to touch theprojection on the rotor.

Sheave holder:90890-01701

4-41

OIL PUMP ENG


123456789

Oil pump cover and oil pump drivengear removalEngine oil

Oil pipeO-ringOil pump coverGasketDowel pinCollarGasketCirclipOil pump driven gear

1

11121122


Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.

For installation, reverse the removal procedure.

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

OIL PUMPOIL PUMP COVER AND OIL PUMP DRIVEN GEARS

4-42

OIL PUMP ENG


1

234

5

Oil pump removalOil pump assembly 1(For pumping oil to the oil tank)GasketDowel pinOil pump assembly 2(For lubricating the engine parts)Gasket

1

111

1



6 Nm (0.6 mkg)

6 Nm (0.6 mkg)

OIL PUMP

4-43

OIL PUMP ENG

INSPECTION1. Inspect:Oil pump driven gears

Wear/Cracks/Damage Replace.

2. Measure:Tip clearance a

(between the inner rotor 1 and the outer rotor2 )

Side clearance b(between the outer rotor 2 and the pumphousing 3 )(between the inner rotor 1 /outer rotor 2 andthe pump housing 3 )

Side clearance cOut of specification Replace the oil pump as-sembly.

Tip clearance a :0 0.12 mm

Side clearance b :0.03 0.08 mm

Side clearance c :0.03 0.08 mm

3. Check:Oil pump operation

Unsmooth Repeat steps 1 and 2 or replacedefective parts.

4-44

OIL TANK ENG


1234567

Oil hose removalEngine oil

EngineUnion boltCopper washerOil delivery pipeOil hoseO-ringOil pipeO-ring

2411212

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”.


21 Nm (2.1 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

OIL TANKOIL HOSE

4-45

OIL TANK ENG


123456

Oil tank removalEngine oil

EngineOil tank case (upper)GasketDowel pinOil tank case (lower)GasketDowel pin

112122

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

OIL TANK

4-46


1234

5678

Oil pan removalEngine oil

EngineOil hoseOil filter coverO-ringCollarOil filter

Oil panGasketDowel pinO-ring/collar

1211

112

2/2

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”.Refer to “OIL TANK”.


Install the oil filter with the projectiontowards the oil filter cover.

NOTE:

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

OIL PAN ENG

OIL PANOIL PAN

4-47

OIL PAN ENG


123

Balancer weight removalEngine oil

EnginePistonShift shaftA.C. magneto

Oil pump assemblyOil tankOil panPlateRear balancer holder/Dowel pinRear balancer shaft /O-ring

21/21/1

Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”.Refer to “CYLINDER AND PISTON”.Refer to “SHIFT SHAFT”.Refer to “A.C. MAGNETO ANDSTARTER WHEEL GEAR”.Refer to “OIL PUMP”.Refer to “OIL TANK”.Refer to “OIL PAN”.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg) 12 Nm (1.2 mkg)

BALANCER

4-48

OIL PAN ENG


4567

Rear balancer weightFront balancer holder/Dowel pinFront balancer shaft /O-ringFront balancer weight

11/21/11



10 Nm (1.0 mkg)

10 Nm (1.0 mkg) 12 Nm (1.2 mkg)

4-49

OIL PAN ENG

REMOVAL1. Remove:Plate 1

2. Remove:Rear balancer holder 1Dowel pins

3. Remove:Rear balancer shaft 1Rear balancer weight 2

4. Remove:Front balancer holder 1Dowel pins

5. Remove:Front balancer shaft 1Front blancer weight 2

4-50

OIL PAN ENG

New

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

New

12 Nm (1.2 mkg)

INSTALLATION1. Install:Front balancer weight 1Front balancer shaft 2O-ring 3 Plate (balancer shaft)

Installation steps:Turn the crankshaft until the keyway a is

aligned with the embossed mark b on thecrankcase.

While holding the crankshaft, install the ba-lancer weight and align the mark c on the frontbalancer gear with the embossed mark d onthe crankcase.

Install the front balancer shaft.

2. Install:Dowel pinsFront balancer holder 1

3. Install:Rear balancer weight 1Rear balancer shaft 2O-ring 3 Plate (balancer shaft)

4-51

OIL PAN ENG

10 Nm (1.0 mkg)

Installing steps:Turn the crankshaft until the keyway a is

aligned with embossed mark b on the crank-case.

While holding the crankshaft, install the balancerweight and align the mark c on the rear balanc-er gear with the embossed mark d on the crank-case.

Install the rear balancer shaft.

4. Install:Dowel pinsRear balancer holder 1

4-52

CRANKSHAFT ENG

(M6)


123456789

Crankshaft removalBalancer weightWater pumpTiming chainCover plateLower crankcaseDowel pinNozzleCrankshaft assemblyMain journal bearingPinTiming chain guide (intake)

111111611

Remove the parts in the order below.Refer to “BALANCER”.Refer to “WATER PUMP” in CHAPTER 5.

For installation, reverse the removal proce-dure.


12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

40 Nm (4.0 mkg) 24 Nm (2.4 mkg)

CRANKSHAFTCRANKSHAFT ASSEMBLY

4-53

CRANKSHAFT ENG


12345

Connecting rod removalNutConnecting rod boltConnecting rodConnecting rod capConnecting rod bearing

44224




48 Nm (4.8 mkg)

CONNECTING ROD

4-54

A

B

CRANKSHAFT ENG

NOTE:

CAUTION:

REMOVAL1. Remove:Cover plate 1

2. Remove:Upper crankcaseLower crankcaseDowel pins

Loosen the bolts 1/4 turn each and remove themafter all are loosened.

Remove the bolts starting with the highest num-bered one.

The embossed numbers in the crankcase desig-nate the crankcase tightening sequence.

A Upper crankcase

B Lower crankcase

Use a soft hammer to tap on the case half. Taponly on reinforced portions of the case. Do nottap on the gasket mating surface. Work slowlyand carefully. Make sure that the case halvesseparate evenly.

3. Remove:Crankshaft assembly 1

4-55

CRANKSHAFT ENG

NOTE:

NOTE:

4. Remove:Main journal bearings 1

Identify each plain bearing position very carefullyso that it can be reinstalled in its original place.

5. Remove:Pin 1Timing chain guide (intake) 2

6. Remove:Connecting rod cap 1Connecting rod 2Connecting rod bearing 3

Identify each bearing position very careful so thatit can be reinstalled in its original place.

INSPECTION1. Measure:Runout (crankshaft)


Runout:Less than 0.035 mm

2. Inspect:Main journal surfacesCrank pin surfacesBearing surfaces

Wear/Scratches Replace.

4-56

CRANKSHAFT ENG

CAUTION:

NOTE:

NOTE:

NOTE:

3. Measure:Oil clearance (main journal)

Out of specification Replace bearing.

Oil clearance:0.020 0.038 mm<Limit>: 0.1 mm

Measurement steps:

Do not interchange the bearings and connect-ing rod. They must be installed in their originalpositions, or the correct oil clearance may notbe obtained causing engine damage.

Clean the bearings, main journals and bearingportions of the crankcase.

Place the upper crankcase on a bench in an up-side down position.

Install the upper half of the bearings 1 and thecrankshaft into the upper crankcase.

Align the projection a of the bearing with thenotch b in the crankcase.

Put a piece of Plastigauge c on each mainjournal.

Do not put the Plastigauge over the oil hole in themain journal of the crankshaft.

Install the lower half of the bearings into the lowercrankcase and assemble the crankcase halves.

Align the projection of the bearing with the notchin the crankcase.

Do not move the crankshaft until the oil clear-ance has been completed.

4-57

A

B

CRANKSHAFT ENG

NOTE:

CAUTION:

Tighten the bolt to specification in the tighten-ing sequence cast on the crankcase.

1 6 (M10):40 Nm (4.0 mkg)

7 10 , 13 , 15 , 20 25 (M8)24 Nm (2.4 mkg)

11 , 12 , 14 , 16 19 , 26 , 27 (M6)12 Nm (1.2 mkg)

A Upper crankcase

B Lower crankcase

Lubricate the threads of bolts 1 6 with mo-lybdenum disulfide motor oil.

Lubricate the threads of bolts 7 27 with en-gine oil.

Remove the lower crankcase and lower half ofthe bearing.

Measure the compressed Plastigauge width don each main journal.If oil clearance is out of specification, select a re-placement bearing.

4. Measure:Oil clearance (crank pin)

Out of specification Replace bearing.

Oil clearance:0.020 0.038 mm<Limit>: 0.1 mm

Measurement steps:

Do not interchange the bearings and connect-ing rod. They must be installed in their originalpositions, or the correct oil clearance may notbe obtained causing engine damage.

Clean the bearings, crank pins and bearingportions of the connecting rods.

4-58

CRANKSHAFT ENG

NOTE:

CAUTION:

Install the upper half of the bearing into the con-necting rod and lower half of the bearing into theconnecting rod cap.

Put a piece of Plastigauge a on the crank pin.Assemble the connecting rod halves.

Do not move the connecting rod or crankshaftuntil the oil clearance measurement has beencompleted.

Apply molybdenum disulfide grease to the bolts,threads and nut seats.

Make sure the “Y” marks on the connecting rodsface the left side of the crankshaft.

Make sure that the letters on both componentsalign to form a perfect character.

Tighten the nuts.

Nut (connecting rod):48 Nm (4.8 mkg)

When you reach 35 Nm (3.5 m kg), keep tight-ening until the final torque is obtained. Applycontinuous torque until the specified torque isobtained.

Remove the connecting rods and bearings.Measure the compressed Plastigauge width b

on each crank pin.If oil clearance is out of specification, select a re-placement bearing.

4-59

CRANKSHAFT ENG

5. Select:Main journal bearing (J1 J3)Connecting rod bearing (P1 P2)

Selection of bearings:Example 1: Main journal bearing If “J1” on the crankcase is “6” and “2” on the

crankweb, then the bearing size for “J1” is:

Bearing size of J 1:Crankcase J 1 – Crankweb J 1 =6 – 2 = 4 (Green)

BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

5 Yellow

6 Pink

7 Red

Example 2: Connecting rod bearing If “P1” on the connecting rod is “4” and “1” on the

crankweb, then the bearing size for “P1” is :

Bearing size of P 1:Connecting rod P 1 – Crankweb P 1 =4 – 1 = 3 (Brown)

BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

4-60

CRANKSHAFT ENG

NOTE:

48 Nm (4.8 mkg)

CAUTION:

INSTALLATION1. Apply:Molybdenum disulfide grease

(onto threads of bolts and nut seats)Engine oil

(onto crank pins and inner surfaces of connect-ing rod bearings)

2. Install:Connecting rod bearings 1Connecting rods 2Connecting rod caps 3

(onto crank pins)

Align the projection of bearing with the groove ofthe caps and connecting rod.

Make sure to reinstall each connecting rod bear-ing in its original place.

The stamped “Y” mark a on the connecting rodsshould face towards the left of the crankshaft.

Be sure that the letter b on both componentsalign to form a perfect character.

3. Align:Bolt head

(with connecting rod cap)4. Tighten:Connecting rod nuts

When you reach 3.5 Nm (3.5 m kg), keep tight-ening until the final torque is obtained. Applycontinuous torque until the specified torque isobtained.

4-61

CRANKSHAFT ENG

NOTE:

NOTE:

5. Install:Timing chain guide (intake)Pin

6. Install:Main journal bearings

Align the projection a of the bearing with thenotch b in the crankcase.

Install each bearing in its original place.

7. Apply:Engine oil

(onto inner surfaces of main journal bearings)Sealant

(onto crankcase mating surfaces)

Yamaha bond No. 1215:90890-85505

DO NOT ALLOW any sealant to come in contactwith the oil gallery or crankshaft bearings.

8. Install:Dowel pin 1

9. Install:Crankshaft assembly 1

(onto upper crankcase)

4-62

A

B

CRANKSHAFT ENG

CAUTION:

NOTE:

10 Nm (1.0 mkg)

10. Install:Lower crankcase 1

(onto upper crankcase 2 )Place the lower crankcase assembly onto theupper crankcase assembly.

Before tightening the crankcase bolts, checkthe following point:Be sure the gears shift correctly when the

shift cam is turned by hand.

11. Tighten:Lower crankcase bolt

(follow the proper tightening sequence)Upper crankcase bolt

1 6 (M10):40 Nm (4.0 mkg)

7 10 , 13 , 15 , 20 25 (M8)24 Nm (2.4 mkg)

11 , 12 , 13 , 15 19 , 26 , 27 (M6)12 Nm (1.2 mkg)

A Upper crankcase

B Lower crankcase

Lubricate the threads of bolts (No. 1 6 ) withmolybdenum disulfide motor oil.

Lubricate the threads of bolts (No. 7 27 ) withengine oil.

Install a copper washer on bolts No. 18 , 21 , 23 ,25 .

Install a lead holder on bolt No. 20 .Tighten the bolts in the tightening sequence cast

on the crankcase.

12. Install:Cover plate

4-63

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG


123456789

1011

Transmission, shift cam and shiftfork removalLower crankcaseDrive axle assembly/Oil sealCirclipShift fork guide bar 2Shift fork “R”Shift fork “L”Shift fork guide bar 1Shift fork “C”Shift camBearing housingCoverMain axle assembly

1/11111111111


Refer to “CRANKSHAFT”.

For installation, reverse the removal proce-dure.


12 Nm (1.2 mkg)

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-64


NOTE:

REMOVAL1. Remove:Drive axle assembly 1

2. Remove:Shift fork guide bars 1Shift fork “R” 2Shift fork “L” 3Shift fork “C” 4Shift cam 5

3. Remove:Bearing housing 1

(use the torx wrench)

4. Remove:Cover 1

Attach the slide hammer bolt 2 and weight 3 intothe cover, then remove the cover by pulling.

Slide hammer bolt:90890-01083

Weight:90890-01084

5. Remove:Main axle assembly 1

(Push out of clutch side)

4-65


WARNING

INSPECTION1. Inspect:Shift fork cam follower 1Shift fork pawl 2

Scoring/Bends/Wear/Damage Replace.

2. Inspect:Guide bar

Roll the guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent guide bar.

3. Check:Shift fork movement

(on its guide bar)Unsmooth operation Replace the fork andguide bar.

4. Inspect:Shift cam grooves

Wear/Damage/Scratches Replace.Shift cam segment 1

Damage/Wear Replace.Shift cam bearing 2

Pitting/Damage Replace.

5. Measure:Axle runout (main and drive)

Use a centering device and dial gauge 1 .Out of specification Replace.

Runout limit:0.08 mm

4-66

116.6 116.68 mm


NOTE:

12 Nm (1.2 mkg)

NOTE:

6. Inspect:Gear teeth

Blue discoloration/Pitting/Wear Replace.Mated dogs

Rounded edges/Cracks/Missing portions Replace.

7. Check:Proper gear engagement (each gear)

(with its counterpart)Incorrect Reassemble.

Gear movementRoughness Replace.

Main axle reassembling point:Press the 2nd pinion gear 1 in the main axle asshown.

8. Inspect:Circlips

Damage/Looseness/Bends Replace.

INSTALLATION1. Install:Main axle assembly 1

Use a pin 2 to align the bolt holes in the bearinghousing with the holes in the lower crankcase andinstall the main axle assembly.

2. Install:CoverBearing housing 1

After tightening the bearing housing bolts, tap theouter edge of the bolt head with a punch 2 to pre-vent it from loosening.

4-67

TRANSMISSION,SHIFT CAM AND SHIFT FORK ENG

NOTE:

NOTE:

NOTE:

3. Install:Shift cam 1Shift fork “C” 2Shift fork “L” 3Shift fork “R” 4Shift for guide bars 5

Install the shift forks with the embossed mark tothe right and in sequence (R, C, L) beginningfrom the right.

Install the shift fork guide bars with the taperedend a toward the clutch.

4. Install:Circlip 1

5. Install:Drive axle assembly 1

The drive axle bearing pin must point to the frontside of the crankcase.

Be sure that the drive axle bearing circlips are in-serted into the upper crankcase positioninggrooves a .

6. Check:Transmission

Unsmooth rotation Repair.

Oil each gear and bearing thoroughly.

COOL

CHAPTER 5.COOLING SYSTEM

RADIATOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTATIC VALVE 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTATIC VALVE ASSEMBLY 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTATIC VALVE 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

RADIATOR COOL


12345

Radiator removalCoolant

Side cowling, seat, side cover andfuel tankAir filter case

Fan motor leadCoolant reservoir hoseCoolant hose 3Coolant hose 2Radiator assembly

11111

Remove the parts in the order below.Refer to “COOLANT REPLACEMENT” inCHAPTER 3.Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK” in CHAPTER 3.Refer to “AIR FILTER CASE” inCHAPTER 3.DisconnectDisconnect


Refer to “INSTALLA-TION”.

5 Nm (0.5 mkg)

7 Nm (0.7 mkg)

7 Nm (0.7 mkg)

COOLING SYSTEMRADIATOR

5-2

RADIATOR COOL

INSPECTION1. Inspect:Radiator core 1

Obstruction Blow out with compressed airthrough rear of the radiator.Flattened fin Repair /Replace.

2. Inspect:Fan 2Cracks/Damage Replace.

3. Inspect:Radiator hoses

Crancks/Damage Replace.

4. Measure:Radiator cap opening pressure

Radiator cap opens at pressure below the spe-cified pressure Replace.

Radiator cap opening pressure:75 105 kPa(0.75 1.05 kg/cm 2, 0.75 1.05 bar)

Measurement steps:Attach the radiator cap tester 1 and adapter 2

to the radiator cap 3 .

Radiator cap tester:90890-01325

Adapter:90890-01352

Apply the specified pressure for 10 seconds, andmake sure there is no pressure drop.

5-3

RADIATOR COOL

7 Nm (0.7 mkg)

CAUTION:

INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install:Radiator assembly

2. Fill:Cooling system

Refer to “COOLANT REPLACEMENT” inCHAPTER 3.

3. Inspect:Cooling system

Decrease of pressure (leaks) Repair as re-quired.

Inspection steps:Attach the radiator cap tester 1 to the radiator.

Radiator cap tester:90890-01325

Adapter:90890-01352

Apply 100 kPa (1.0 kg/cm2, 1.0 bar) pressure.

Do not apply pressure that is more than thespecification mentioned above.

Measure the indicated pressure with the gauge.

5-4

THERMOSTATIC VALVE COOL


123456

Thermostatic valve assemblyremovalCoolant

Side cowling, seat, side cover andfuel tankAir filter caseRadiator assemblyGround leadThermo switch lead couplerThermo unit leadCoolant hose 1Coolant hose 4Thermostatic valve assembly

111111


Refer to “COOLANT REPLACEMENT” inCHAPTER 3.Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK” in CHAPTER 3.Refer to “AIR FILTER CASE” in CHAPTER 3.Refer to “RADIATOR”.DisconnectDisconnectDisconnect


10 Nm (1.0 mkg)

THERMOSTATIC VALVETHERMOSTATIC VALVE ASSEMBLY

5-5



Thermostatic valve housing disas-semblyThermo switchThermo unitGround leadThermostatic valve coverO-ringThermostatic valveThermostatic valve housing

1111111



Refer to “ASSEMBLY”.

1234567

28 Nm (2.8 mkg)

15 Nm (1.5 mkg)

10 Nm (1.0 mkg)

THERMOSTATIC VALVE

5-6


NOTE:

NOTE:

28 Nm (2.8 mkg)

15 Nm (1.5 mkg)

CAUTION:

INSPECTION1. Inspect:Thermostatic valve 1

Valve does not open at 80 84C Replace.

Inspection steps:Suspend thermostatic valve in a vessel.Place reliable thermometer in a water.Observe thermometer, while stirring water con-

tinually.

1 Thermometer

2 Water

3 Thermostatic valve

4 Vessel

A CLOSE

B OPEN

Thermostatic valve is sealed and its setting is spe-cialized work. If its accuracy is in doubt, replace it.A faulty unit could cause serious overheating orover-cooling.

ASSEMBLY1. Install:Thermostatic valve housing 1Thermostatic valve 2O-ring 3Thermostatic valve cover 4

Install the thermostatic valve with the breatherhole a facing up.

2. Install:Thermo switch 1

Thermo unit 2

Be very careful when handling the thermoswitch and thermo unit. Replace parts that weresubjected to impacts or were dropped.

5-7

WATER PUMP COOL


12345678

Water pump removalCoolant

Coolant hose 3Water pump coverO-ringWater pump housingWasherCirclipImpellerO-ring

11111111

Remove the parts in the order below.Refer to “COOLANT REPLACEMENT” inCHAPTER 3.



10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

WATER PUMPWATER PUMP

5-8

WATER PUMP COOL

NOTE:

New

NOTE:

New

10 Nm (1.0 mkg)

INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.

It is not necessary to remove and inspect the wa-ter pump if the coolant is not unusually low or if ithas no engine oil mixed in it.

Always replace the entire water pump.

1. Install: Impeller 1Circlip 2

After installation, check that the impeller shaft ro-tates smoothly.

2. Install:O-ring 1

3. Install:Water pump housingWater pump coverCoolant hose 3

CARB

CHAPTER 6.CARBURETION

CARBURETOR 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR ASSEMBLY 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TPS (THROTTLE POSITION SENSOR)

ADJUSTMENT AND INSPECTION 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

CARBURETOR CARB


12345678

Carburetor assembly removalSide cowling, seat, side cover andfuel tank

Air filter case

Throttle position sensor lead couplerCarburetor heater hose (inlet)Carburetor heater hose (outlet)Throttle stop screwFuel hoseStarter cableThrottle cable (pull)Throttle cable (push)

11111111

Remove the parts in the order below.Refer to ”COWLINGS, SEAT, TAILCOVER AND FUEL TANK” in CHAPTER 3.Refer to ”AIR FILTER CASE” inCHAPTER 3.Disconnect

From frame


After loosening the throttle cable locknut andremoving the carburetor assembly, remove the throttle cables.

NOTE:

CARBURETIONCARBURETORCARBURETOR ASSEMBLY

6-2

CARBURETOR CARB


Carburetor disassemblyCarburetor heater hoseFloat chamberNeedle valveFloatStarter jetMain jetPilot jetJet housingJet needleThrottle valve

1111111111

Disassemble the parts in the order below.

Refer to ”INSTALLATION”.

12345678910

CARBURETOR

6-3

CARBURETOR CARB


Needle jetPilot air jet 1Main air jet 2DiaphragmStarter plungerPilot screw

111111

For assembly, reverse the disassemblyprocedure.

11

1213

14

1516

6-4

CARBURETOR CARB

CAUTION:

NOTE:

ASSEMBLY

Before reassembling, wash all parts in cleanpetroleum based solvent.

Always use a new gasket.

1. Install:Main jet 1Starter jet 2Pilot jet 3

2. Install:Valve seat

Make sure that projection a on the valve seat isaligned with the slot b on the carburetor body.

3. Install:O-ring 1Diaphragm 2

4. Install:Pilot screw 1

Pilot screw (turns out):2.0

6-5

CARBURETOR CARB

NOTE:

NOTE:

FUEL LEVEL ADJUSTMENT1. Measure:Fuel level a

Fuel level:15.8 16.8 mmBelow the MIKUNI mark


Adjust the float level by slightly bending the floattang 1 .

Fuel level measurement and adjustmentsteps:Place the motorcycle on a level surface.Use a garage jack under the engine to ensure

that the carburetors are positioned vertically.Connect the fuel level gauge 2 to the drain pipe.

Fuel level gauge:90890-01312

Loosen the drain screw.Hold the gauge vertically next to the MIKUNI

mark 3 .Measure the fuel level a with the gauge.

THROTTLE POSITION SENSOR (TPS) AD-JUSTMENT AND INSPECTION

Idle speed should be adjusted properly beforeadjusting the TPS (throttle position sensor).

When installing the TPS (throttle position sen-sor), observe the display on the tachometer andadjust the angle accordingly. Refer to the adjust-ment procedure below.

6-6

CARBURETOR CARB

NOTE:

NOTE:

4 Nm (0.4 mkg)

NOTE:

1. Adjust:TPS (throttle position sensor) position

Adjustment steps:Turn the main switch to ”ON”.Disconnect the TPS (throttle position sensor)

coupler.Reconnect the TPS (throttle position sensor)

coupler.

When the above procedure is commenced, themachine switches to TPS (throttle position sen-sor) adjustment mode.

Loosen the TPS (throttle position sensor) screws1 .

Adjust the TPS (throttle position sensor) posi-tion.

The angle of the TPS (throttle position sensor) isshown on the tachometer.

Adjust the angle of the TPS (throttle position sen-sor) as appropriate as shown below.

When the angle is correct, the tachometerreads 4,000 rpm.

When the angle is too wide, the tachometerreads 8,000 rpm.

When the angle is too narrow, the tachome-ter reads 1,000 rpm.

After adjusting the angle, tighten the TPS(throttle position sensor) screws.

To return to normal mode, start the engine or resetthe main switch.

6-7

CARBURETOR CARB

2. Inspect:TPS (throttle position sensor)

Inspection steps:Disconnect the TPS (throttle position sensor)

coupler.Remove the TPS (throttle position sensor) from

carburetor.Connect the pocket tester (Ω 1k) to the TPS

(throttle position sensor) couplers.

Tester (+) lead Blue terminal 1Tester (–) lead Black/Blue terminal 2

Check the TPS (throttle position sensor) resis-tance.

TPS (throttle position sensor)resistance:

3.5 6.5 kΩ at 20C(Blue – Black/Blue)

Out of specification Replace the TPS (throttleposition sensor).

Connect the pocket tester (Ω 1k) to TPS(throttle position sensor) coupler.

Tester (+) lead Yellow terminal 1Tester (–) lead Black/Blue terminal 3

Check the TPS (throttle position sensor) resis-tance while turning throttle slowly.

TPS (throttle position sensor)resistance:

0 5 ± 1.5 kΩ at 20C(Yellow – Black/Blue)

Out of specification Replace the TPS (throttleposition sensor).

CHAS

CHAPTER 7.CHASSIS

FRONT WHEEL AND BRAKE DISCS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATIC WHEEL BALANCE ADJUSTMENT 7-6. . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET 7-8. . . . . . . . . . . . . REAR WHEEL 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC AND DRIVEN SPROCKET 7-9. . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATIC WHEEL BALANCE ADJUSTMENT 7-12. . . . . . . . . . . . . . . . . . . . . . .

FRONT AND REAR BRAKE 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PAD 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PAD 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PAD REPLACEMENT 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER INSPECTION 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER ASSEMBLY 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE CALIPER 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER DISASSEMBLY 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSPECTION AND REPAIR 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER ASSEMBLY 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CALIPER INSTALLATION 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 7-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 7-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS

REAR SHOCK ABSORBER AND RELAY ARM 7-50. . . . . . . . . . . . . . . . . . . . . . HANDLING NOTES 7-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTES ON DISPOSAL 7-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWINGARM AND DRIVE CHAIN 7-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1


123456789

Front wheel and brake disc removal

Speedometer cablePinch bolt (front wheel axle)Cable guideBrake caliper (left / right)Front wheel axleFront wheelSpeedometer gear unitCollarBrake disc (left / right)

111

1/11111

1/1


Elevate the front wheel by placing a suitablestand under the engine.

DisconnectLoosen


NOTE:


58 Nm (5.8 mkg)

19 Nm (1.9 mkg)

40 Nm (4.0 mkg)

20 Nm (2.0 mkg)

FRONT WHEEL AND BRAKE DISCS CHAS

CHASSISFRONT WHEEL AND BRAKE DISCS

7-2



Front wheel disassemblyOil sealClutch retainerMeter clutchOil sealBearingSpacerBearing

1111111

Disassemble the parts in order below.



1234567

7-3


WARNING

NOTE:

INSPECTION1. Inspect:Front wheel axle. Roll it on a flat surface.

Bends Replace.

Do not attempt to straighten a bent axle.

2. Measure:Wheel runoutOver the specified limit Replace.

Rim runout limits:Radial a : 1 mmLateral b : 0.5 mm

3. Inspect:Wheel bearings

Bearings allow free play in the wheel hub orwheel turns roughly Replace.

Oil sealsWear/Damage Replace.

Wheel bearing and oil seal replacement steps:Clean the outside of the wheel hub.Remove the oil seals using a flat-head screw

driver.

Place a rag on the outer edge to prevent damage.

Remove the bearing 1 using a general bearingpuller 2 .

Install the new bearing and oil seal by reversingthe previous steps.

7-4


NOTE:

CAUTION:

NOTE:

NOTE:

Use a socket 3 that matches the outside diame-ter of the race of the bearing and oil seal.

Do not strike the center race 4 or balls 5 ofthe bearing. Contact should be made only withthe outer race 6 .

4. Inspect:Collar

Wear/Damage Replace collar and oil sealas set.

5. Measure:Brake disc deflection

Out of specification Inspect wheel runout.If wheel runout is in good condition, replace thebrake disc(s).

Remove the brake caliper before inspecting thebrake disc deflection.

Maximum deflection:0.2 mm

Brake disc thicknessOut of specification Replace.

Minimum thickness:3.5 mm

Measuring point 1 3 mm

Replacement steps:Remove the brake disc(s). Install the new brake disc(s).

Brake disc:20 Nm (2.0 mkg)

Tighten the bolts (brake disc) in stage using acrisscross pattern.

7-5


NOTE:

58 Nm (5.8 mkg)

NOTE:

19 Nm (1.9 mkg)

40 Nm (4.0 mkg)

ASSEMBLYReverse the “DISASSEMBLY” procedure.Note the following points.1. Lubricate:BearingsOil seals (lips)

Recommended lubricant:Lithium soap base grease

INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Lubricate:Front wheel axleDrive/Driven gear (speedometer)

Recommended lubricant:Lithium soap base grease

2. Install:Speedometer gear unit 1

Be sure that two projections a inside the wheelhub mesh with the two slots b in the gear unit as-sembly.

3. Install:Front wheelFront wheel axle

Be sure that the projection (torque stopper) a ofthe gear unit housing is positioned correctly.

4. Install:Pinch boltBrake caliper (left / right) and cable guide

7-6


NOTE:

NOTE:

STATIC WHEEL BALANCE ADJUSTMENT

After replacing the tire and/or rim, wheel balanceshould be adjusted.

Adjust the wheel balance with brake diskinstalled.

1. Remove:Balancing weight

2. Set the wheel on a suitable stand.

3. Find:Heavy spot

Procedure:a. Spin the wheel and wait for it to rest.b. Put an “X1” mark on the wheel bottom spot.c. Turn the wheel so that the “X1” mark is 90 up.d. Left the wheel fall and wait for it to rest.

Put an “X2” mark on the wheel bottom spot.e. Repeat the above b., c., and d. several times

until these marks come to the same spot.f. This spot is the heavy spot “X”.

4. Adjust:Wheel balance

Adjusting steps: Install a balancing weight 1 on the rim exactly

opposite to the heavy spot “X”.

Start with the smallest weight.

7-7


Turn the wheel so that the heavy spot is 90 up.Check that the heavy spot is at rest there.

If not, try another weight until the wheel is bal-anced.

5. Check:Wheel balance

Checking steps:Turn the wheel so that is comes to each point as

shown.Check that the wheel is at rest at each point. If

not, readjust the wheel balance.

7-8

REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS


1234567

Rear wheel removal

Brake caliperCaliper bracket boltRear wheel axle nutPlain washerRear wheel axleChain pullerRear wheel

1112121


Loosen


Elevate the rear wheel by placing a suita-ble stand under the engine.

NOTE:

107 Nm (10.7 mkg)

16 Nm (1.6 mkg)

35 Nm (3.5 mkg)

40 Nm (4.0 mkg)

REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKETREAR WHEEL

7-9



12345678

Brake disc and driven sprocketremovalCollar (left / right)Brake discDriven sprocketClutch hubRubber damperCollarOil sealBearing

1/11116111



60 Nm (6.0 mkg)

20 Nm (2.0 mkg)

BRAKE DISC AND DRIVEN SPROCKET

7-10



Rear wheel disassemblyOil sealBearingCollarBearing

1111

Disassembly the parts in the order below.


1234

7-11


NOTE:

INSPECTION1. Inspect:Rear wheel axle

Refer to “FRONT WHEEL AND BRAKE DISC”.2. Measure:Wheel runout

Refer to “FRONT WHEEL AND BRAKE DISC”.3. Install:Wheel bearingsOil sealsCollars

Refer to “FRONT WHEEL AND BRAKE DISC”.4. Measure:Brake disc deflection

Out of specification Inspect wheel runout.If wheel runout is in good condition, replace thebrake disc(s).

Remove the brake caliper before inspecting thebrake disc deflection.

Maximum deflection:0.15 mm

Brake disc thicknessOut of specification Replace.

Minimum thickness:4.5 mm

Measuring point 1 3 mm

5. Inspect:Clutch hub 1

Cracks/Damage Replace.Rubber dampers 2


7-12


NOTE:

NOTE:

6. Inspect:Driven sprocket

More than 1/4 teeth a wear Replacesprocket.Bent teeth Replace sprocket.

b Correct

1 Roller

2 Sprocket

Driven sprocket replacement steps:Remove the self locknuts and driven sprocket.Clean the hub, especially on the surfaces in con-

tact with the sprocket, using a clean cloth. Install the new driven sprocket.

Driven sprocket:60 Nm (6.0 mkg)

Tighten the self locknuts in stage, using a criss-cross pattern.

STATIC WHEEL BALANCE ADJUSTMENT

After replacing the tire and/or rim, wheel balanceshould be adjusted.

Adjust the wheel balance with brake disc andhub installed.

1. Adjust:Wheel balance

Refer to “FRONT WHEEL AND BRAKEDISCS”.

7-13

FRONT AND REAR BRAKE CHAS


12345678

Front brake pad removalCable guidePad coverRetaining clipRetaining pinPad springBrake padPad shimBleed screw

11221221



Refer to “BRAKE PAD REPLACE-MENT”.

40 Nm (4.0 mkg)

6 Nm (0.6 mkg)

FRONT AND REAR BRAKEFRONT BRAKE PAD

7-14



1234567

Rear brake pad removalPad coverRetaining clipRetaining pinPad springBrake padPad shim (left / right)Bleed screw

12212

1/12



40 Nm (4.0 mkg)

6 Nm (0.6 mkg)

REAR BRAKE PAD

7-15


CAUTION:

NOTE:

NOTE:

Disc brake components rarely require disas-sembly. DO NOT:Disassemble components unless absolutely

necessary.Use solvents on internal brake components.Use contaminated brake fluid for cleaning.

Use only clean brake fluid.Allow brake fluid to come in contact with the

eyes, otherwise eye injury may occur.Allow brake fluid to contact painted surfaces

or plastic parts otherwise damage may oc-cur.

Disconnect any hydraulic connection other-wise the entire system must be disas-sembled, drained, cleaned, and then properlyfilled and bled after reassembly.

BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake cali-per and brake hose to replace the brake pads.

Front brake1. Remove:Brake pads 1

Do not depress the brake lever when the wheel isoff the motorcycle otherwise the brake pads willbe forced shut.

Install new brake pad spring and shims when thebrake pads have to be replaced.

Replace the pads as a set if either is found to beworn to the wear limit a .

Wear limit a :0.5 mm

7-16


New

New

New

NOTE:

NOTE:

2. Install:Pad shims

(onto brake pads)Brake pads Pad spring

Installation steps:Connect a suitable hose 1 tightly to the caliper

bleed screw 2 . Put the other end of this hoseinto an open container.

Loosen the caliper bleed screw and push the pis-tons into the caliper with the finger.

Tighten the caliper bleed screw 2 .


Install the pad shims on the brake pad. Install the brake pads and pad spring.

The arrow mark a of the pad spring must point inthe direction of the disc rotation.

After installing the retaining clip, turn the retain-ing pin so that the heads of the retaining clipsface towards the center of the brake pad spring.

3. Inspect:Brake fluid level

Refer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3.

4. Check:Brake lever operation

A soft or spongy feeling Bleed brake system.Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.

Rear brake1. Remove:Brake pads 1

Do not depress the brake pedal while the caliperis removed.

When pads replacement is required, also re-place the pad spring and shims.

7-17


New

New

New

NOTE:

NOTE:

Replace the pads as a set if either is found to beworn to the wear limit a .

Wear limit a :0.5 mm


(onto brake pads)Brake pads Pad spring

Installation steps:Connect a suitable hose 1 tightly to the caliper

bleed screw 2 . Then, place the other end of thishose into an open container.

Loosen the caliper bleed screw and push the pis-tons into the caliper with the finger.

Tighten the caliper bleed screw 2 .


Install the pad shims 3 on the brake pad 4 .

The arrow mark a on the pad shim must point inthe direction of the disc rotation.

Install the brake pads and pad spring 5 .

The longer tangs b of the pad spring must point inthe direction of the disc rotation.



4. Check:Brake pedal operation


7-18



1234567

Front brake master cylinder removalBrake fluidBrake leverFront brake switch lead couplerFront brake switchUnion boltCopper washer/Brake hoseMaster cylinder bracketMaster cylinder assembly

1111

2/111

Remove the parts in the order below.Drain

Disconnect

Refer to “MASTER CYLINDERASSEMBLY”.For installation, reverse the removalprocedure.

9 Nm (0.9 mkg)

30 Nm (3.0 mkg)

FRONT BRAKE MASTER CYLINDER

7-19



Front brake master cylinder disas-semblyAdjusterSpringPlateBootCirclipMaster cylinder kitMaster cylinder body

1111111



1234567

7-20



123

4567

Rear brake master cylinder removalBrake fluidUnion boltCopper washer/Brake hoseBrake reservoir hose

Cotter pinClevis pinPlain washerMaster cylinder

12/11

1111


Refer to “MASTER CYLINDERASSEMBLY”.For installation, reverse the removalprocedure.

Remove from the master cylinder side.

NOTE:

7 Nm (0.7 mkg)

30 Nm (3.0 mkg)

23 Nm (2.3 mkg)

REAR BRAKE MASTER CYLINDER

7-21



Rear brake master cylinder discon-nectionBootCirclipMaster cylinder kitMaster cylinder body

1111

Disconnect the parts in the order below.

For assembly, reverse the disconnectionprocedure.

1234

7-22

B

A B

A


WARNING

MASTER CYLINDER INSPECTION1. Inspect:Master cylinder 1

Wear/Scratches Replace the master cylin-der assembly.

Master cylinder body 2Cracks/Damage Replace.

Oil delivery passage (master cylinder body)Blow out with compressed air.

A Front

B Rear

2. Inspect:Master cylinder kit 1

Scratches/Wear/Damage Replace as aset.

A Front

B Rear

MASTER CYLINDER ASSEMBLY

All internal parts should be cleaned in newbrake fluid only.

Internal parts should be lubricated with brakefluid when installed.

Recommended brake fluid:DOT 4

Replace the piston seals and dust sealswhenever a caliper is disassembled.

7-23


9 Nm (0.9 mkg)

CAUTION:

New

30 Nm (3.0 mkg)

WARNING

CAUTION:

Front brake1. Install:Master cylinder 1Master cylinder bracket 2

Align the end of the holder with the punchmark a on the handlebar.

Tighten first the upper bolt, then the lowerbolt.

2. Install:Copper washers 1 Brake hose 2Union bolt 3

Proper hose routing is essential to insuresafe motorcycle operation. Refer to “CABLEROUTING”.

Always use new copper washers.

3. Fill:Brake reservoir


Brake fluid may erode painted surfaces orplastic parts. Always clean up spilled fluid im-mediately.

7-24


WARNING

New

30 Nm (3.0 mkg)

CAUTION:

WARNING

Use only the designated quality brake fluid:otherwise, the rubber seals may deteriorate,causing leakage and poor brake perfor-mance.

Refill with the same type of brake fluid: mix-ing fluids may result in a harmful chemicalreaction and lead to poor performance.

Be careful that water does not enter the mas-ter cylinder when refilling. Water will signifi-cantly lower the boiling point of the fluid andmay result in vapor lock.

4. Air bleed:Brake system

Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.



6. Check:Brake level operation


Rear brake1. Install:Copper washer 1 Brake hose 2Union bolt 3

When installing the brake hose on the mastercylinder, take care that the pipe touches theprojection a as shown.

Proper hose routing is essential to insuresafe motorcycle operation. Refer to “CABLEROUTING”.


7-25


New

2. Install:Clevis pin 1WasherCotter pin

3. Fill:Brake reservoir

Refer to “MASTER CYLINDER ASSEMBLY –Front brake”.



5. Check:Brake pedal operation


6. Adjust:Brake pedal height

Refer to “REAR BRAKE ADJUSTMENT” inCHAPTER 3.

7. Adjust:Brake light switch

Refer to “BRAKE LIGHT SWITCH ADJUST-MENT” in CHAPTER 3.

7-26



1234

56

Front brake caliper removalBrake fluidCable guideUnion boltCopper washerStay

Brake hose and brake pipeBrake caliper assembly

112

11


Refer to “CALIPER INSTALLATION”.


The brake pipe must not be disassembled.Do not loosen the bolts indicated by “ ”.

WARNING

40 Nm (4.0 mkg)

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

FRONT BRAKE CALIPER

7-27



Front brake caliper disassemblyPad coverRetaining clipRetaining pinPad springBrake padPad shimBleed screwBrake caliper pistonPiston seal

122122148


For assembly, reverse the disassembly procedure.

Refer to “CALIPER DISASSEMBLY”and “CALIPER ASSEMBLY”.

6 Nm (0.6 mkg)

123456789

7-28



1234

Rear brake caliper removalBrake fluidBrake hoseBrake hose jointCopper washerBrake caliper assembly

1111



Refer to “CALIPER INSTALLATION”.

40 Nm (4.0 mkg)

14 Nm (1.4 mkg)

40 Nm (4.0 mkg)

REAR BRAKE CALIPER

7-29



Rear brake caliper disassemblyPad coverRetaining clipRetaining pinPad springBrake padPad shimBleed screwBrake caliper pistonPiston seal

122122224


For assembly, reverse the disassembly procedure.

Refer to “CALIPER DISASSEMBLY”and “CALIPER ASSEMBLY”.

12

456789

3

6 Nm (0.6 mkg)

7-30

A

B


NOTE:

WARNING

CALIPER DISASSEMBLY

Before disassembling the front brake caliper orrear brake caliper, drain the brake hose, mastercylinder, brake caliper and brake reservoir of theirbrake fluid.

1. Remove:PistonsPiston seals 1

Removal steps:Using a wood piece 2 , lock the right side piston.Blow compressed air into the hose joint opening

a to force out the left side piston from the caliperbody.

Remove the piston seals and reinstall the piston.Repeat previous step to force out the right side

piston from the caliper body.

Never try to pry out the piston.Do not loosen the bolts 3 .

A Front

B Rear

7-31


WARNING

WARNING

WARNING

CALIPER INSPECTION AND REPAIR

Recommended brake componentpreplacement schedule:

Brake pads As required

Piston seal,Every two yearsdust seal Every two years

Brake hoses Every two years

Replace only whenBrake fluid

p ybrakes aredisassembled.

All internal brake components should becleaned in new brake fluid only. Do not use sol-vents as they will cause seals to swell and dis-tort.

1. Inspect:Caliper piston 1

Scratches/Rust/Wear Replace caliper as-sembly.

Caliper cylinder 2Wear/Scratches Replace caliper assembly.

Caliper body 3Cracks/Damage Replace.

Oil delivery passage (caliper body)Blow out with compressed air.

Replace the piston seals and dust seals when-ever the caliper is disassembled.

CALIPER ASSEMBLY

All internal parts should be cleaned in newbrake fluid only.

Internal parts should be lubricated with brakefluid when installed.


Replace the piston seals and dust sealswhenever a caliper is disassembled.

7-32


New

30 Nm (3.0 mkg)

CAUTION:

NOTE:

40 Nm (4.0 mkg)

14 Nm (1.4 mkg)

WARNING

40 Nm (4.0 mkg)

CALIPER INSTALLATION1. Install:Front brakeBrake caliper 1 (temporarily)Copper washers Brake hose 2Union bolt 3

When installing the brake hose on the caliper1 , take care that the pipe touches the projec-tion a on the brake caliper.

Make sure that the damper of the brake pipe is incontact with the front fender. If it’s not in contact,loosen holding bolt B (left and right) and move thebrake pipe so that the damper contacts the fender.Then tighten the holding bolt.

Rear brakeBrake caliper 1 (temporarily)Copper washerBrake hose joint 2Brake hose 3

Proper hose routing is essential to insuresafe motorcycle operation. Rear to “CABLEROUTING”.



(onto brake pads)Brake padsPad springRetaining pinsRetaining clipsPad coverBrake caliper

Refer to “BRAKE PAD REPLACEMENT”.3. Fill:Brake reservoir

Refer to “MASTER CYLINDER ASSEMBLY –Front brake”.

7-33

FRONT FORK CHAS


1234567

Front fork removalFront wheel

Cable guideFront fenderPlastic bandPinch bolt (upper bracket)Cap boltPinch bolt (lower bracket)Front fork (left / right)

114222

1/1

Remove the parts in the order below.Refer to “FRONT WHEEL ANDBRAKE DISCS”.

LoosenLoosenLoosenLoosen


Refer to “INSTAL-LATION”.

24 Nm (2.4 mkg)

23 Nm (2.3 mkg)

10 Nm (1.0 mkg)

9 Nm (0.9 mkg)

30 Nm (3.0 mkg)

10 Nm (1.0 mkg)

FRONT FORK

7-34

FRONT FORK CHAS


Front fork disassemblyCap boltO-ringWasherFork springDust sealRetaining clipDamper rod bolt /GasketOil sealPlain washer

111111

1/111

Disassemble the parts in the order below.Drain the fork oil

Refer to “DISASSEMBLY” and“ASSEMBLY”.

30 Nm (3.0 mkg)

24 Nm (2.4 mkg)

123456789

7-35

FRONT FORK CHAS


Inner tube/Piston metalOil lock pieceDamper rod/Damper rod springSlide metalOuter tube

1/11

1/111


Refer to “DISASSEMBLY” and“ASSEMBLY”.

24 Nm (2.4 mkg)

30 Nm (3.0 mkg)

10

11121314

7-36

FRONT FORK CHAS

NOTE:

CAUTION:

NOTE:

CAUTION:

DISASSEMBLY

Do not reuse the front fork protector that was re-moved from the outer tube.

When installing a new front fork protector, besure it is not twisted and will not come off easily.

1. Remove:Dust seal 1Retaining clip 2

Use a slotted-head screwdriver.

Take care not to scratch the inner tube.

2. Remove:Damper rod bolt

Loosen the damper rod bolt while holding thedamper rod with the T-handle 2 and holder 1 .

Damper rod holder:90890-01465

T-handle:90890-01326

3. Remove:Damper rodDamper rod spring

4. Remove: Inner tube

Removal steps:Hold the fork leg holizontally.Clamp the caliper mounting boss of the outer

tube securely in a vise with soft jaws.Pull out the inner tube from the outer tube by

forcefully, but carefully, with drawing the innertube.

Excessive force will damage the oil sealand/or the bushes. Damaged oil seal andbushes must be replaced.

Avoid bottoming the inner tube in the outertube during the above procedure, as the oillock piece will be damaged.

7-37

FRONT FORK CHAS

WARNING

CAUTION:

INSPECTION1. Inspect: Inner fork tube 1Outer fork tube 2

Scratches/Bends/Damage Replace.

Do not attempt to straighten a bent inner forktube as this may dangerously weaken thetube.

2. Measure:Fork spring free length a

Over specified limit Replace.

Fork spring free length (limit):500 mm

3. Inspect:Cap bolt

Bend/Damage Replace.

ASSEMBLY1. Install:Damper rod

Allow the damper rod to slide slowly down theinner tube until it protrudes from the bottom,being careful not to damage the inner tube.

7-38

FRONT FORK CHAS

New

30 Nm (3.0 mkg)

NOTE:

New

New

2. Lubricate: Inner fork tube (outer surface)

Recommended lubricant:Fork oil 10W or equivalent

3. Install:Piston metal 1 Damper rod 2Oil lock piece 3

4. Tighten:Damper bolt 1

Tighten the damper rod bolt while holding thedamper rod with the T-handle and holder.

T-handle:90890-01326

Damper rod holder:90890-01465

5. Install:Slide metal 1 Plain washer

Use the fork seal driver weight 2 and adapter3 .

6. Install:Oil seal 1

Use the fork seal driver weight 2 and adapter3 .

Fork seal driver weight:90890-01367

Adapter:90890-01374

7-39

NOTE:

FRONT FORK CHAS

CAUTION:

NOTE:

New

NOTE:

Before installing the oil seal, apply the lithium soapbase grease onto the oil seal lips.

Be sure that the oil seal numbered side faceupward.

7. Install:Dust seal 1

Use the fork seal driver weight.

Fork seal driver weight:90890-01367

8. Fill:Fork oil

Each fork:0.515 LFor oil 10W or equivalent. Afterfilling, slowly pump the fork upand down to distribute oil.

Oil level:130 mm(from the top of inner tube fullycompressed without spring)

Place the fork on upright position.

9. Install:O-ring Cap bolt 1

Align the end of the cap bolt rod with the hole in thedamper rod, then install the cap bolt rod and tem-porarily install the cap bolt.

7-40

FRONT FORK CHAS

CAUTION:

30 Nm (3.0 mkg)

24 Nm (2.4 mkg)

23 Nm (2.3 mkg)

WARNING

INSTALLATION1. Install:Front fork(s)

Temporarily tighten the pinch bolts.

Make sure that the inner tube end is flush withthe top of the upper bracket.

2. Tighten:Pinch bolts (lower bracket) 1

Cap bolts 2Pinch bolts (upper bracket) 3

Make sure that the brake hoses are routedproperly.

7-41

HANDLEBAR CHAS


123456789

1011

Handlebar removalBandClutch cableClutch switch lead couplerClutch switchLeft handlebar switchClutch leverGrip endFront brake switch lead couplerMaster cylinder bracketMaster cylinder assemblyCollar

21111121111


Disconnect

Disconnect


23 Nm (2.3 mkg)

9 Nm (0.9 mkg)

26 Nm (2.6 mkg)

HANDLEBAR

7-42

HANDLEBAR CHAS


12131415161718192021

Right handlebar switchThrottle cable housing coverThrottle cable housingThrottle cableThrottle gripPlugHandlebar holder (upper)Handlebar grip (left)Clutch lever holderHandlebar

1112142111




23 Nm (2.3 mkg)

9 Nm (0.9 mkg)

26 Nm (2.6 mkg)

7-43

HANDLEBAR CHAS

WARNING

NOTE:

WARNING

23 Nm (2.3 mkg)

NOTE:

CAUTION:

INSPECTION1. Inspect:Handlebar

Bends/Crancks/Damage Replace.

Do not attempt to straighten a bent handlebaras this may dangerously weaken the handle-bar.

Handlebar grip (left) replacement steps:Remove the handlebar grip.Apply a light coat of an adhesive for rubber on the

handlebar end. Install the handlebar grip.

Wipe off excess adhesive with a clean rag.

Leave the handlebar intact until the adhesivebecomes dry enough to make the grip andhandlebar stuck securely.

INSTALLATION1. Install:HandlebarHandlebar holders (upper)

The handlebar holders (upper) should beinstalled with the arrow mark a forward A .

Install the handlebar so that the widths of thematch marks b are equal.

Align the match mark c on the handlebar withthe top of the handlebar holder (lower).

First, tighten the bolt on the front side of thehandlebar holder, and then tighten the bolton the rear side.

Check the handlebar by turning it from onelock to the other. If there is any contact withthe fuel tank, adjust the handlebar position.

7-44

HANDLEBAR CHAS

WARNING

NOTE:

9 Nm (0.9 mkg)

CAUTION:

NOTE:

2. Install:Throttle grip 1Throttle cable housing 2Throttle cables 3Throttle cable housing cover

Align the projection a on the throttle cablehousing with the hole b on the handlebar.

3. Install:Right handlebar switch 1

Align the projection a on the handlebar switchwith the hole b on the handlebar.

4. Install:CollarMaster cylinder assembly 1Master cylinder bracket 2

Align the slit in the master cylinder bracketwith the punched mark a on the handlebar.

Tighten first the upper bolt, then the lowerbolt.

5. Install:Clutch lever holder 1

Align the slit in clutch lever holder with thepunched mark a on the handlebar.

7-45

HANDLEBAR CHAS

NOTE:

6. Install:Left handlebar switch 1

Align the projection a on the handlebar switchwith the hole b on the handlebar.

7. Adjust:Clutch cable free play

Refer to “CLUTCH ADJUSTMENT” in CHAP-TER 3.


Refer to “THROTTLE CABLE ADJUSTMENT”in CHAPTER 3.

7-46

STEERING HEAD CHAS


123456789

10

Lower bracket removalFront wheel

Front forkHandlebarMain switch lead couplerStarter cable holderCable guideHorn/Horn lead couplerBrake hose holderSteering stem nutPlate washerUpper bracketSpecial washerRing nut (upper)

111

1/1111111

Remove the parts in the order below.Refer to “FRONT WHEEL ANDBRAKE DISC”.Refer to “FRONT FORK”.Refer to “HANDLEBAR”.Disconnect

Disconnect

Refer to “REMOVAL”.

7 Nm (0.7 mkg)

108 Nm (10.8 mkg)

10 Nm (1.0 mkg)

48 Nm (4.8 mkg)16 Nm (1.6 mkg)

1st

7 Nm (0.7 mkg)

2 nd

STEERING HEADLOWER BRACKET

7-47

STEERING HEAD CHAS


1112131415161718

Plate sealRing nut (lower)Plate washerLower bracketBearing (upper)Rubber sealBearing (lower)Dust seal

11111111



7 Nm (0.7 mkg)

108 Nm (10.8 mkg)

10 Nm (1.0 mkg)

48 Nm (4.8 mkg)16 Nm (1.6 mkg)

1st2nd

7 Nm (0.7 mkg)

7-48

STEERING HEAD CHAS

WARNING

NOTE:

CAUTION:

REMOVAL1. Remove:Ring nut (lower) 1

Use the ring nut wrench 2 .


Support the lower bracket so that it may notfall down.

INSPECTION1. Wash the bearing and bearing races with a sol-

vent.2. Inspect:BearingsBearing races

Pitting/Damage Replace.

Bearing race replacement steps:Remove the bearing races on the head pipe us-

ing long rod 1 and the hammer as shown. Install the new races.

Always replace bearings and races as a set.

If the bearing race is not fitted squarely, thehead pipe could be damaged.

7-49

STEERING HEAD CHAS

NOTE:

WARNING

NOTE:

INSTALLATION1. Tighten:Ring nuts (lower and upper)

Tightening steps:Tighten the ring nut (lower) 1 using the ring nut

wrench 2 .

Ring nut:48 Nm (4.8 mkg)

Set the torque wrench to the ring nut wrench sothat they form a right angle.


Turn the steering stem left and right for severaltimes.

Loosen the ring nut completely and retighten it tospecification.

Ring nut:16 Nm (1.6 mkg)

Do not overtighten.

Check the steering stem by turning lock to lock. Ifthere is any binding, remove the steering stemassembly and inspect the steering bearings.

Install the plate washer. Install the ring nut (upper).Finger tighten the ring nut, then align the slots of

both ring nuts. If not aligned, hold the lower ringnut and tighten the other until they are aligned.

Install the special washer.

Make sure that the special washer tab is placed inthe slots.

7-50

REAR SHOCK ABSORBER CHAS


12345678

Rear shock absorber removalSeat

Self locknutPlain washerBoltCollarCapSelf locknutBoltRear shock absorber

11111111

Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAILCOVER AND FUEL TANK” in CHAP-TER 3.


64 Nm (6.4 mkg)

64 Nm (6.4 mkg)

REAR SHOCK ABSORBER

7-51

REAR SHOCK ABSORBER CHAS

WARNING

WARNING

HANDLING NOTES

This shock absorber contains highly com-pressed nitrogen gas. Rear and understandthe following information before handling theshock absorber. The manufacturer cannot beheld responsible for property damage or per-sonal injury that may result from improperhandling.1. Do not tamper or attempt to open the cylin-

der assembly.2. Do not subject shock absorber to an open

flame or other high heat. This may causethe unit to explode due to excessive gaspressure.

3. Do not deform or damage the cylinder inany way. Cylinder damage will result in poordamping performance.

NOTES ON DISPOSAL

Shock absorber disposal steps:Gas pressure must be released before disposing

of the shock absorber. To do so, drill a 2 3 mmhole through the cylinder wall at a point 15 20mm a from the end of the gas chamber.

Wear eye protection to prevent eyes damagefrom escaping gas and/or metal chips.

7-52

SWINGARM AND DRIVE CHAIN CHAS


1234567

Swingarm and drive chain removalRear wheel

Rear shock absorberDrive sprocket

Brake hose holderCollarRear fenderDrive chain caseCaliper bracketCapPivot shaft

1211121

Remove the parts in the order below.Refer to “REAR WHEEL, BRAKEDISC AND DRIVE SPROCKET”.Refer to “REAR SHOCK ABSORBER”.Refer to “ENGINE ASSEMBLY” inCHAPTER 4.

90 Nm (9.0 mkg)

7 Nm (0.7 mkg)

35 Nm (3.5 mkg)

7 Nm (0.7 mkg)

3SWINGARM AND DRIVE CHAIN

7-53



89

1011121314

SwingarmDrive chainChain protectorCollarThrust coverBushBearing

1113212


90 Nm (9.0 mkg)

7 Nm (0.7 mkg)

35 Nm (3.5 mkg)

7 Nm (0.7 mkg)

7-54


NOTE:

CAUTION:

INSPECTION1. Measure:10 link length (drive chain) a

Out of specification Replace drive chain.

10 link length limit:159 mm

For measurement make the chain tense by fin-ger.

10 link length is a measurement between the in-sides of the 1 and 11 rollers as shown.

Two or three different 10 link length should bemeasured.

2. Clean:Drive chain

Place it in kerosene, and brush off as much dirtas possible. Then remove the chain from thekerosene and dry the chain.

This motorcycle has a drive chain with smallrubber O-rings 1 between the chain plates.Steam cleaning, high pressure washes, andcertain solvent can damage these O-rings.Use only kerosene to clean the drive chain.

3. Inspect:O-rings (drive chain) 1

Damage Replace drive chain.Rollers 2Side plates 3

Damage/Wear Replace drive chain.

7-55


90 Nm (9.0 mkg)

4. Lubricate:Drive chain

Drive chain lubricant:SAE 30 50W motor oil or chainlubricants suitable for “O-ring”chains

5. Inspect:Drive chain stiffness

Stiff Clean and lubricate or replace.

6. Check:Swingarm free play

Inspection steps:Check the tightening torque of the pivot shaft

(swingarm) 1 securing nut.

Check the swingarm side play A by moving itfrom side to side.If side play is noticeable, check the inner collar,bearing, washer and thrust cover.

Side play (at end of swigarm):0.3 mm

Check the swingarm vertical movement B bymoving it up and down.If vertical movement is tight, binding or rough,check the inner collar, bearing, washer andthrust cover.

ELEC

CHAPTER 8.ELECTRICAL

ELECTRICAL COMPONENTS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH INSPECTION 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH INSPECTION 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTING A SWITCH SHOWN IN THE MANUAL 8-2. . . . . . . . . . . . . . . SWITCH CONTINUITY INSPECTION 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT OPERATION 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTING SYSTEM CHECK 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGNAL SYSTEM CHECK 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS 8-44. . . . . . . . . . . . CIRCUIT DIAGRAM 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

ELECTRICAL COMPONENTS ELEC

Fuse boxBatteryRear brake switchSidestand switchNeutral switchIgnition coilHorn

Ignitor unitStarting circuit cut-off relayRectifier / regulatorMain switchThermo switchThermo unitFlasher relayStarter relay

12345678

9101112131415

ELECTRICAL

ELECTRICAL COMPONENTS

8-2

SWITCH INSPECTION ELEC

NOTE:

SWITCH INSPECTIONSWITCH INSPECTIONUse a pocket tester to check the terminals for con-tinuity. If the continuity is faulty as any point, re-place the switch.


Set the pocket tester to “0” before starting thetest.

The pocket tester should be set to the “ 1” Ωrange when testing the switch for continuity.

Turn the switch on and off a few times whenchecking it.

INSPECTING A SWITCH SHOWN INTHE MANUALThe terminal connections for switches (mainswitch, handlebar switch, engine stop switch, lightswitch, etc.) are shown in a chart similar to the oneon the left.This chart shows the switch positions in the col-umn and the switch lead colors in the top row.For each switch position, “ ” indicates theterminals with continuity.The example chart shows that:1 There is continuity between the “Black and

Black/White” leads when the switch is set to“OFF”.

2 There is continuity between the “Red andBrown” leads when the switch is set to “ON”.

8-3

Rear brake switchFuseEngine stop switchStart switchFront brake switchMain switchClutch switchHorn switchLights switchDimmer switchPass switchTurn switchSidestand switchGear position switch

12345678

91011121314

SWITCH INSPECTION ELEC

SWITCH CONTINUITY INSPECTIONRefer to “SWITCH INSPECTION” and check for continuity between lead terminals.Poor connection, no continuity Correct or replace.* The coupler locations are circled.

8-4

A.C

. mag

neto

/Pic

kup

coil

Mai

n sw

itch

Bat

tery

Mai

n fu

seS

tart

ing

circ

uit c

ut-o

ff re

lay

1 3 4 5 8 9 10 12 13 14 45

Neu

tral

sw

itch

Sid

esta

nd s

witc

hIg

nito

r un

itIg

nitio

n co

ilS

park

plu

gE

ngin

e st

op s

witc

hIg

nitio

n fu

se47

IGNITION SYSTEM ELEC

IGNITION SYSTEMCIRCUIT DIAGRAM

8-5


NOTE:

Refer to “SWITCH INSPECTION”.

1. Fuse (main and ignition)

Replace fuse(s).

NO CONTINUITY

Check the battery condition.Refer to “BATTERY INSPECTION” in CHAP-TER 3.

2. Battery

CONTINUITY

Open-circuit voltage:12.8 V or more at 20 C

Clean battery terminals.Recharge or replace the battery.

INCORRECT

CORRECT

TROUBLESHOOTING

IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK)

ProcedureCheck:1. Fuse (main and ignition)2. Battery3. Spark plug4. Ignition spark gap5. Spark plug cap resistance6. Ignition coil resistance7. Pickup coil resistance

8. Main switch9. Engine stop switch

10. Neutral switch11. Sidestand switch12. Wiring connection

(entire ignition system)

Remove the following parts before troubleshoot-ing.

1) Seat2) Side cowlings3) Side covers4) Fuel tank5) Air filter caseUse the following special tool(s) in this trouble-

shooting.

Ignition checker:90890-06754


8-6

Check the spark plug condition.Check the spark plug type.Check the spark plug gap.

Refer to “SPARK PLUG INSPECTION” inCHAPTER 3.

3. Spark plug

Spark plug gap:0.8 0.9 mm

Ignition system is good.

MEETS SPECIFICATION

Disconnect the spark plug cap from sparkplug.

Connect the ignition checker as shown.Spark plug cap

Turn the main switch to “ON”.

4. Ignition spark gap

Repair or replace spark plug.

INCORRECT

Standard spark plug:DPR8EA-9/X24EPR-U9NGK/NIPPONDENSO

CORRECT

12

Check the ignition spark gap .Crank the engine by pushing the starter

switch, and increase the spark gap until a mis-fire occurs.

Minimum spark gap:6.0 mm

a

OUT OFSPECIFICATIONOR NO SPARK

Remove the spark plug cap.Connect the pocket tester (Ω 1k) to the

spark plug cap.

5. Spark plug cap resistance


8-7

Check the spark plug cap for specified resis-tance.

OUT OF SPECIFICATION

MEETSSPECIFICATION

Tester (+) lead Red/Black terminal Tester (–) lead Orange (Gray) terminal

12

Connect the pocket tester (Ω 1k) to the igni-tion coil.

Replace spark plug cap.

Disconnect the ignition coil connector from thewire harness.

Connect the pocket tester (Ω 1) to the igni-tion coil.

6. Ignition coil resistance

Spark plug cap resistance:10 kΩ at 20C

Tester (+) lead Spark plug lead Tester (–) lead Red/Black terminal

Check the primary coil for specified resistance.

Primary coil resistance:3.4 4.6 Ω at 20C

Check the secondary coil for specified resis-tance.

Secondary coil resistance:10.4 15.6 kΩ at 20C


Replace ignition coil.

BOTH MEETSPECIFICATION

12


8-8


INCORRECT

MEETSPECIFICATION

Replace main switch.

Disconnect the pickup coil coupler from thewire harness.

Connect the pocket tester (Ω 100) to thepickup coil terminal.

7. Pickup coil resistance

Check the pickup coil for specified resistance.

Pickup coil resistance:192 288 Ω at 20C(Green/White – Blue/Yellow)


Replace pickup coil.

CORRECT

Tester (+) lead Green/White terminal Tester (–) lead Blue/Yellow terminal

12


8. Main switch

CORRECT


9. Engine stop switch

CORRECT

INCORRECT

Replace handlebar switch (right).


10. Neutral switch

CORRECT

INCORRECT

Replace neutral switch.


11. Sidestand switchINCORRECT

Replace sidestand switch.

8-9


12. Wiring connection

Check the entire ignition system for connec-tions.Refer to “CIRCUIT DIAGRAM”.

Replace ignitor unit.

POOR CONNECTION

Correct.

CORRECT

8-10

Mai

n sw

itch

Bat

tery

Mai

n fu

seS

tart

er r

elay

Sta

rter

mot

orS

tart

ing

circ

uit c

ut-o

ff re

lay

Neu

tral

sw

itch

Sid

esta

nd s

witc

hC

lutc

h sw

itch

Eng

ine

stop

sw

itch

Sta

rt s

witc

hIg

nitio

n fu

se

3 4 5 6 7 8 9 10 35 45 46 47

ELECTRIC STARTING SYSTEM ELEC

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-11


STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and the starting circuitcut-off relay. If the “ENGINE STOP” switch and themain switch are both closed, the starter motor canoperate only if:

The transmission is in neutral (the neutralswitch is closed).

or ifThe clutch lever is pulled to the handlebar(the clutch switch is closed) and the sidestandis up (the sidestand switch is closed).

The starting circuit cut-off relay prevents the start-er from operating when neither of these conditionshas been met. In this instance, the starting circuitcut-off relay is open so current cannot reach thestarter motor.When at least one of the above conditions hasbeen met however, the starting circuit cut-off relayis closed, and the engine can be started by press-ing the starter switch.

WHEN THE TRANSMISSION IS INNEUTRALWHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED IN

1 Battery

2 Main fuse

3 Main switch

4 Ignition fuse

5 Engine stop switch

6 Starting circuit cut-off relay

7 Diode

8 Clutch switch

9 Sidestand switch

10 Neutral switch

11 Start switch

12 Starter relay

13 Starter motor

8-12


NOTE:


1. Fuse (main and ignition)

Replace fuse(s).

NO CONTINUITY


2. Battery

CONTINUITY

Open circuit voltage:12.8 V or more at 20 C


INCORRECT

CORRECT

TROUBLESHOOTING

STARTER MOTOR DOES NOT OPERATE.

ProcedureCheck:1. Fuse (main and ignition)2. Battery3. Starter motor4. Starting circuit cut-off relay5. Starter relay6. Main switch7. Engine stop switch

8. Neutral switch9. Sidestand switch

10. Clutch switch11. Start switch12. Wiring connection

(entire starting system)



shooting.


8-13

Remove the starter motor from the engine.Check the starter motor.

Refer to “INSPECTION AND REPAIR”.

3. Starter motor

Check the starting circuit cut-off relay for conti-nuity.

DOES NOT MOVE

Repair or replace starter motor.Refer to “INSPECTION AND REPAIR”.

NO CONTINUITY

Replace starting circuit cut-off relay.

MOVES

Disconnect the starting circuit cut-off relaycoupler from the wire harness.

Connect the pocket tester (Ω 1) and battery(12 V) to the starting circuit cut-off relay cou-pler terminals.

4. Starting circuit cut-off relay

Battery (+) terminal

Red/Black terminal Battery (–) terminal

Black/Yellow terminal

1

2

Tester (+) terminal Blue/White terminal Tester (–) terminal Blue/White terminal

CONTINUITY

WARNING

This check is likely to produce sparks, so besure that no flammable gas or fluid is in thevicinity.

34


8-14


INCORRECT

CONTINUITY


Disconnect the relay unit coupler from the wireharness.

Connect the pocket tester (Ω 1) and battery(12 V) to the relay unit coupler terminals.

5. Starter relay

NO CONTINUITY

Replace starter relay.

CORRECT

Battery (+) terminal

Red/White terminal Battery (–) terminal

Blue/White terminal

1

2


6. Main switch

CORRECT


7. Engine stop switch

CORRECT

INCORRECT



8. Neutral switch

CORRECT

INCORRECT

Replace gear position switch


9. Sidestand switchINCORRECT

Replace sidestand switch.

Tester (+) lead Red terminal Tester (–) lead Black terminal

34

Check the starter relay for continuity.

8-15


INCORRECT

Replace clutch switch.


10. Clutch switch

CORRECT


11. Start switch

CORRECT

INCORRECT


Check the entire starting system for connec-tions.Refer to “CIRCUIT DIAGRAM”.

12. Wiring connection.

POOR CONNECTION

Correct.

8-16



12

Starter motor removalExhaust pipe and muffler assembly

Starter motor/O-ringStarter motor lead

Starter motor disassembly

Front bracketWasher kitRear bracketWasher kitBrush seat/Brush 1

Armature coil

1/11

1121

1/1

1

Remove the parts in the order below.Refer to “ENGINE ASSEMBLY” in CHAP-TER 4.


For assembly, reverse the disassembly pro-cedure.

Be sure to remove the installation nut onbrush #1 first.

NOTE:


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

12345

6

STARTER MOTOR

8-17


NOTE:

Inspection and repair1. Inspect:Commutator

Dirty Clean it with #600 grit sandpaper.2. Measure:Commutator diameter a

Out of specification Replace starter motor.

Commutator wear limit:27 mm

3. Measure:Mica undercut b

Out of specification Scrape the mica to prop-er value using a hacksaw blade can be groundto fit.

Mica undercut:0.7 mm

The mica insulation of the commutator must beundercut to ensure proper operation of commuta-tor.

4. Inspect:Armature coil (insulation/continuity)

Defects Replace starter motor.

Inspecting steps:Connect the pocket tester for continuity check

1 and insulation check 2 .Measure the armature resistances.

Armature coil resistance:Continuity check 1 : 0.01 Ω at 20CInsulation check 2 : More than 1 M Ω at 20C

If the resistance is incorrect, replace the startermotor.

8-18


NOTE:

5. Measure:Brush length a


Brush length limit:5 mm

6. Measure:Brush spring force

Fatigue/Out of specification Replace as aset.

Brush spring force:570 920 g

7. Inspect:Bearing

Roughness Replace.Oil sealO-ringsBushing


AssemblyReverse the “Removal” procedure.Note the following points.1. Install:Brush seat 1

Align the projection a on the brush seat with theslot on the housing.

2. Install:Shim 1Armature coil 2

8-19


New

New

NewNOTE:

3. Install:Gasket 1 Yoke 2Washer kit 3Gasket 4 Front bracket 5O-ring 6

Align the match marks a on the yoke with thematch marks b on the brackets.

8-20

A.C

. mag

neto

/pic

kup

coil

Rec

tifie

r/re

fula

tor

Bat

tery

Mai

n fu

se

1 2 4 5

CHARGING SYSTEM ELEC

CHARGING SYSTEMCIRCUIT DIAGRAM

8-21


NOTE:


1. Fuse (main)

Replace fuse(s).

NO CONTINUITY


2. Battery

CONTINUITY



INCORRECT

CORRECT

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

ProcedureCheck:1. Fuse (main)2. Battery3. Charging voltage

4. Stator coil resistance5. Wiring connection

(entire charging system)


1) Seat2) Side cowlings3) Side covers4) Fuel tankUse the following special tool(s) in this trouble-

shooting.



8-22


OUT OFSPECIFICATION

Replace stator assembly.

Connect the engine tachometer to spark pluglead #1.

Connect the pocket tester (DC 20 V) to the bat-tery.

3. Charging voltage

MEETS SPECIFICATION

Replace battery.

Tester (+) lead Battery (+) leadTester (–) lead Battery (–) lead

Disconnect A.C. magneto coupler from thewire harness.

Connect the pocket tester “Ω 1” to the statorcoils.

Measure the stator coil resistance.

4. Stator coil resistance

BOTH MEETSPECIFICATION

Start the engine, accelerate to about, 5,000r/min then check the measured voltage.

Check battery voltage.

Charging voltage = measuredvoltage – terminal voltage:

Difference of 0.5 2.5 V

NOTE:

Use a fully charged battery.

Stator coil resistance:0.23 0.35 Ω at 20C

Tester (+) lead White lead Tester (–) lead White lead

Tester (+) lead White lead Tester (–) lead White lead

12

13


8-23



Check the entire starting system for connec-tions.Refer to “CIRCUIT DIAGRAM”.

Replace rectifier/regulator.

POOR CONNECTION

Correct.

CORRECT

8-24

Mai

n sw

itch

Bat

tery

Mai

n fu

seM

eter

ligh

t

3 4 5 19

Hig

h be

am in

dica

tor

light

21

Hea

dlig

ht25

Aux

iliar

y lig

ht26

Ligh

ts s

witc

h30

Dim

mer

sw

itch

31

Pas

s sw

itch

32

Tail/

brak

e lig

ht39

Hea

dlig

ht fu

se40

Dio

de48

LIGHTING SYSTEM ELEC

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-25


NOTE:


1. Fuse (main and head)

Replace fuse(s).

NO CONTINUITY


2. Battery

CONTINUITY



INCORRECT

CORRECT


3. Main switch

CORRECT


INCORRECT

TROUBLESHOOTING

HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT AND/OR METERLIGHT DO NOT COME ON.

ProcedureCheck:1. Fuse (main and head)2. Battery3. Main switch4. Lights switch/Dimmer switch

5. Pass switch6. Wiring connection

(entire lighting system)



shooting.


8-26

Remove the diode from the wire harness.Check for continuity as follows:

Terminal – terminal

5. Diode

Tester (+) lead Terminal Tester (–) lead Terminal

Replace the diode.

INCORRECT

CORRECT


4. Lights switch/Dimmer switch

Lights switch/Dimmer switch are faulty, replacehandlebar switch (left).

INCORRECT

CORRECT

1 2

12

Tester (+) lead Terminal Tester (–) lead Terminal 1

2

Continuity

No Continu-ity

When you switch the “–” and “+” leads of the dig-ital pocket tester the readings in the above chartwill be reversed.

NOTE:

CORRECT


6. Pass switch

Pass switch is faulty, replace handlebar switch(left).

INCORRECT

CORRECT

Check the entire lighting system for connec-tions.Refer to “WIRING DIAGRAM”.


Correct.

POOR CONNECTION

Check condition of each circuit for lighting sys-tem.Refer to “LIGHTING SYSTEM CHECK”.


8-27

1. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers.

When dimmer switch is “LO” position.When dimmer switch is “HI” position.

AB

Headlight: Tester (+) lead Yellow or Green lead. Tester (–) lead Black lead.High beam indicator light: Tester (+) lead Yellow lead. Tester (–) lead Black lead.

B

1 23

45

Turn the main switch to “ON”.Turn the lights switch to “ON” position.Turn the dimmer switch to “LO” or “HI” position.Check for voltage (12 V) on the “Green” and

“Yellow” lead at bulb socket connectors.

Wiring circuit from main switch to bulb socketconnector is faulty, repair.


MEETSSPECIFICATION

Meter connectorHeadlight connector.

This circuit is good.

Dimmer switch Headlight

Hi

Lo


LIGHTING SYSTEM CHECK1. Headlight and high beam indicator light does

not come on.

8-28

1. Voltage

Connect the pocket tester (20 V) to the bulbsocket coupler.

Tester (+) lead Blue terminal Tester (–) lead Black terminal

12

Turn the main switch to “ON”.Turn the lights switch to “ON” or “PO” position.Check for voltage (12 V) on the “Blue” lead at

the bulb socket connector.




MEETSSPECIFICATION

1. Voltage

Connect the pocket tester (DC 20 V) to thebulb socket connector.

Tester (+) lead Blue/Red terminal Tester (–) lead Black terminal

12

Turn the main switch to “ON”.Turn the lights switch to “ON” or “PO” position.Check for voltage (12 V) on the “Blue/Red”

lead at the bulb socket connector.

MEETSSPECIFICATION Wiring circuit from main switch to bulb socket

connector is faulty, repair.




2. Meter light does not come on.

3. Taillight does not come on.

8-29

1. Voltage


Tester (+) lead Blue/Red lead Tester (–) lead Black lead

12

Turn the main switch to “ON”.Turn the light switch to “ON” or “PO” position.Check for voltage (12 V) on the “Blue/Red”

lead at the bulb socket connector.



MEETSSPECIFICATION



4. Auxiliary light does not come on.

8-30


8-31

SIGNAL SYSTEM ELEC

SIGNAL SYSTEMCIRCUIT DIAGRAM

8-32

29 Horn33 Turn switch34 Flasher relay39 Tail /brake light40 Headlight fuse41 Rear brake switch42 Signal system fuse44 Front brake switch

SIGNAL SYSTEM ELEC

3 Main switch4 Battery5 Fuse (main)8 Starting circuit cut-off relay9 Neutral switch17 Tachometer20 Neutral indicator light22 Turn indicator light23 Rear flasher light24 Front flasher light28 Horn switch

8-33

SIGNAL SYSTEM ELEC

NOTE:


1. Fuse (main, head and signal)

Replace fuse(s).

NO CONTINUITY


2. Battery

CONTINUITY



INCORRECT

CORRECT

TROUBLESHOOTING

FLASHER LIGHTS, BRAKE LIGHT AND/OR INDICATOR LIGHTS DO NOT COME ON.HORN DOES NOT SOUND.

ProcedureCheck:1. Fuse (main, head and signal)2. Battery3. Main switch4. Wiring connection

(entire signal system)


1) Seat2) Side cowlings3) Side covers4) Fuel tank5) Air filter caseUse the following special tool in this trouble-

shooting.


8-34

SIGNAL SYSTEM ELEC

POOR CONNECTION

Correct.

INCORRECT


MEETSSPECIFICATION


3. Main switch

CORRECT

Check the entire signal system for connec-tions.Refer to “WIRING DIAGRAM”.


CORRECT

INCORRECT

Replace handlebar switch (left).


1. Horn switch

CORRECT

Connect the pocket tester (DC 20 V) to thehorn lead.

2. Voltage


Wiring circuit from main switch to horn terminalis faulty, repair.

Check condition of each circuit for signal sys-tem. Refer to “SIGNAL SYSTEM CHECK”.

Tester (+) lead Black/White lead Tester (–) lead Frame ground

Turn the main switch to “ON”.Push the horn switch.Check for voltage (12 V) on the “Black/White”

lead at the horn terminal.

1

SIGNAL SYSTEM CHECK1. Horn does not sound.

8-35

3. Voltage

Connect the pocket tester (DC 20 V) to thehorn at the “Black” terminal.

Tester (+) lead Black lead Tester (–) lead Frame ground

1

Turn the main switch to “ON”.Push the horn switch.Check for voltage (0 V) on the “Black” lead at

the horn terminal.

Replace horn.


Adjust or replace horn.

MEETSSPECIFICATION

1. Brake switch (front, rear)


CORRECT

Replace brake switch.

INCORRECT

2. Voltage


Tester (+) lead Yellow lead Tester (–) lead Black lead

12

SIGNAL SYSTEM ELEC

2. Brake light does not come on.

8-36

2. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay coupler.

Tester (+) lead Brown terminal Tester (–) lead Frame ground

1

Turn the main switch to “ON”.Turn brake lever is pulled in or brake pedal is

stepped down.Check for voltage (12 V) on the “Yellow” lead at

the bulb socket connector.

Replace handlebar switch (left).

INCORRECT


MEETSSPECIFICATION

1. Turn switch


MEETSSPECIFICATION



Turn the main switch to “ON”.Check for voltage (12 V) on the “Brown” lead at

the flasher relay terminal.

Wiring circuit from main switch to flasher relayconnector is faulty, repair.


CORRECT

SIGNAL SYSTEM ELEC

3. Flasher light and/or turn indicator light doesnot blink.

8-37

SIGNAL SYSTEM ELEC

3. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay lead.

Tester (+) lead Brown/White terminal Tester (–) lead Frame ground

1

Turn the main switch to “ON”.Turn the turn switch to “L” or “R”.Check for voltage (12 V) on the “Chocolate“

lead or ”Dark green” lead at the bulb socketconnector.

Replace flasher relay.



4. Voltage


MEETSSPECIFICATION

Turn the main switch to “ON”.Check for voltage (12 V) on the “Brown/White”

lead at the flasher relay terminal.

Wiring circuit from turn switch to bulb socketconnector is faulty, repair.


A B Flasher lightsTurn indicator light

At flasher light (left):Tester (+) lead Chocolate lead Tester (–) lead Frame ground

AB

At flasher light (right):Tester (+) lead Dark green lead Tester (–) lead Frame ground

1

2

MEETSSPECIFICATION

8-38

2. Voltage

Connect the pocket tester (DC 20 V) to thebulb socket coupler.

Tester (+) lead Brown terminal Tester (–) lead Sky blue terminal

1

Replace neutral switch.

NO CONTINUITY


1. Neutral switch


MEETSSPECIFICATION

Turn the main switch to “ON”.Check for voltage (12 V).



CONTINUITY

2

SIGNAL SYSTEM ELEC

4. Neutral indicator light does not come on.

8-39

Mai

n sw

itch

Bat

tery

Fus

e (m

ain)

The

rmo

unit

3 4 5 15

Wat

er te

mpe

ratu

re m

eter

18

Fan

mot

or36

The

rmo

switc

h37

Rad

iato

r fa

n fu

se38

Sig

nal s

yste

m fu

se42

COOLING SYSTEM ELEC

COOLING SYSTEMCIRCUIT DIAGRAM

8-40

COOLING SYSTEM ELEC

NOTE:

Fuse is faulty, replace it.

NO CONTINUITY1. Fuse (main, signal and fan)


CONTINUITY

2. Battery


CORRECT



INCORRECT

TROUBLESHOOTING

FAN MOTOR DOES NOT MOVE.WATER TEMPERATURE METER DOES NOT MOVE, WHEN ENGINE IS WARM.

ProcedureCheck:1. Fuse (main, signal and fan)2. Battery3. Main switch4. Fan motor5. Thermo switch

6. Thermo unit7. Water temperature8. Wiring connection

(entire cooling system)


1) Seat2) Side cowlings3) Side covers4) Fuel tank5) Air filter caseUse the following special tool in this trouble-

shooting.


8-41

4. Fan motors

Disconnect the fan motor couplers.Connect the battery (12 V) as shown.

Battery (+) lead Blue lead Battery (–) lead Black lead

1

Main switch is faulty, replace it.

INCORRECT3. Main switch


Check the fan motors for operation. Fan motor(s) is faulty, replace it(them).

DOES NOT MOVES

CORRECT

2

MOVES

COOLING SYSTEM ELEC

8-42

COOLING SYSTEM ELEC

5. Thermo switch

Remove the thermo switch from the radiator.Connect the pocket tester (Ω 1) to the ther-

mo switch . Immerse the thermo switch in the water .Check the thermo switch for continuity.

Note temperatures while heating the waterwith the temperature gauge .

Replace thermo switch.

BAD CONDITION

GOODCONDITION

THERMO SWITCH “ON”THERMO SWITCH “OFF”

AB

12

3

WARNING

Handle the thermo switch with special care.Never subject it to strong shock or allow it to be

dropped. Should it be dropped, it must be re-place.

8-43

6. Thermo unit

Remove the thermo unit from the radiator.Connect the pocket tester (Ω 10) to the ther-

mo unit . Immerse the thermo unit in the water .Measure the resistance.

Thermo unit resistance:80C: 47 53 Ω100C: 26 30 Ω

Replace thermo unit.

BAD CONDITION


Check the entire cooling system for connec-tions. Refer to “CIRCUIT DIAGRAM”.

Correct.

POOR CONNECTION

CORRECT

GOODCONDITION

12

WARNINGHandle the thermo unit with special care.Never subject it to strong shock or allow it

to be dropped. Should it be dropped, itmust be replaced.

Replace the temperature meter.

COOLING SYSTEM ELEC

8-44

Revolution(103 r /min)

Tachometer display

Engine speed

time(seconds)

TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS ELEC

123

NOTE:

TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS

CIRCUIT DIAGRAM If the needle of the tachometer shows the follow-ing pattern while the engine is running, the throttleposition sensor circuit is broken, shorted, or theTPS (throttle position sensor) is locked. In thatcase, it would be best to inspect it.

0 rpm – 3 seconds3,000 rpm – 2.5 secondspresent engine revolutions – 3 seconds

The above pattern is repeated.

The needle of the tachometer keeps pointing to“0” rpm for 6 seconds when the engine is not run-ning.

If any trouble occurs in the TPS, the ignition tim-ing signal transmitted from the TPS to the ignitorunit is limited to the full-open state signal.

11 TPS (throttle position sensor)

12 Ignitor unit

8-45

TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS ELEC

NOTE:

Replace TPS (throttle position sensor).

BAD CONDITION

1. TPS (throttle position sensor)

Disconnect the throttle position sensor couplerfrom the wire harness.

Connect the pocket tester (Ω 1) to thethrottle position sensor.Refer to “TPS (THROTTLE POSITION SEN-SOR) ADJUSTMENT AND INSPECTION” inCHAPTER 6.

GOODCONDITION

2. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

CONTINUITY

Replace the ignitor unit.

Repair or replace wire harness.

NO CONTINUITY

Check the TPS (throttle position sensor) forcontinuity.

TROUBLESHOOTING

IF THE TACHOMETER’S TPS (THROTTLE POSITION SENSOR) SELF-DIAGNOSIS OPERATES.

ProcedureCheck:1. TPS (throttle position sensor)2. Wire harness

Use the following special tool(s) in this trouble-shooting.


TRBLSHTG

CHAPTER 9.TROUBLESHOOTING

STARTING FAILURE/HARD STARTING 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR IDLE SPEED PERFORMANCE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR IDLE SPEED PERFORMANCE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-2. . . . . . . . . . . . . . . . POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-2. . . . . . . . . . . . .

FAULTY GEAR SHIFTING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARD SHIFTING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMP-OUT GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH SLIPPING/DRAGGING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPPING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGGING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEATING 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY BRAKE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR BRAKING EFFECT 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK OIL LEAKAGE AND FORK MALFUNCTION 9-4. . . . . . . . . . . OIL LEAKAGE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTABLE HANDLING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTABLE HANDLING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY LIGHTING AND SIGNAL SYSTEM 9-5. . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT DARK 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULB BURNT OUT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER DOES NOT LIGHT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER WINKS SLOWER 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER KEEPS ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER WINKS QUICKER 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN IS INOPERATIVE 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

9-1

STARTING FAILURE/HARD STARTINGTRBLSHTG

NOTE:

TROUBLESHOOTING

The following troubleshooting does not cover all the possible causes of trouble. If should be helpful, howev-er, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustmentand replacement of parts.

STARTING FAILURE/HARD STARTINGFUEL SYSTEMFuel tankEmptyClogged fuel strainerClogged fuel tank drain hoseDeteriorated fuel or fuel containing water or for-

eign materialFuel cockClogged fuel hose/vacuum hose

CarburetorDeteriorated fuel, fuel containing water or foreign

materialClogged pilot jetClogged pilot air passageSucked-in airDeformed floatGroove-worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jetClogged starter jetStarter plunger malfunction Improperly adjusted starter cableAir cleanerClogged air filterFuel pumpFaulty fuel pump

ELECTRICAL SYSTEMSpark plug Improper plug gapWorn electrodesWire between terminals broken Improper heat rangeFaulty spark plug capIgnition coilBroken or shorted primary/secondaryFaulty spark plug leadBroken bodyFull-transistor systemFaulty ignitor unitFaulty pickup coil

Switches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switchStarter motorFaulty starter motorFaulty starter relayFaulty circuit cut-off relayFaulty starter clutch

9-2

STARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM AND HIGH SPEED PERFORMANCE

TRBLSHTG

COMPRESSION SYSTEMCylinder and cylinder headLoose spark plugLoose cylinder head or cylinderBroken cylinder head gasketWorn, damaged or seized cylinder Improperly sealed valve Improperly contacted valve and valve seat Improper valve timingBroken valve spring

Piston and piston rings Improperly installed piston ringWorn, fatigued or broken piston ringSeized piston ringSeized or damaged pistonCrankcase and crankshaft Improperly seated crankcaseSeized crankshaft

POOR IDLE SPEED PERFORMANCEPOOR IDLE SPEED PERFORMANCECarburetor Improperly returned starter plungerLoose pilot jetClogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed (throttle stop

screw) Improper throttle cable free playFlooded carburetor

Electrical systemFaulty batteryFaulty spark plugFaulty ignitor unitFaulty pickup coilFaulty ignition coilValve train Improperly adjsted valve clearanceAir CleanerClogged air filter

POOR MEDIUM AND HIGH SPEED PERFORMANCEPOOR MEDIUM AND HIGH SPEED PERFORMANCERefer to “Starting failure/Hard starting”. (Fuel system, electrical system, compression system and valvetrain.)

CarburetorDiaphragm malfunction Improperly adjusted fuel levelClogged or loose main jet

Air cleanerClogged air filter elementFuel pumpFaulty fuel pump

9-3

FAULTY GEAR SHIFTING/CLUTCH SLIPPING/DRAGGING

TRBLSHTG

FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “Clutch dragging.”

SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rodBent shift shaftShift cam, shift forkGroove jammed with impuritiesSeized shift forkBent shift fork guide bar

TransmissionSeized transmission gear Jammed impurities Incorrectly assembled transmission

JUMP-OUT GEARShift shaft Improperly adjusted shift lever position Improperly returned stopper levelShift forkWorn shift fork

Shift cam Improper thrust playWorn shift cam grooveTransmissionWorn gear dog

CLUTCH SLIPPING/DRAGGINGCLUTCH SLIPPINGClutch Improperly adjusted clutch cableLoose clutch springFatigued clutch springWorn friction plate/clutch plate Incorrectly assembled clutch

Engine oilLow oil level Improper quality/(low viscosity)Deterioration

CLUTCH DRAGGINGClutchWarped pressure plateUnevenly tensioned clutch springsBent push rodBroken clutch bossBurnt primary driven gear bushing.Bent clutch plateSwollen friction plate

Engine oil Improper oil level Improper quality (high viscosity)Deterioration

9-4

OVERHEATING/FAULTY BRAKE/FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

TRBLSHTG

OVERHEATINGOVERHEATINGIgnition system Improper spark plug gap Improper spark plug heat rangeFaulty ignitor unitFuel system Improper carburetor main jet (improper setting) Improperly adjusted fuel levelClogged air filler element

Compression systemHeavy carbon build-upEngine oil Incorrect oil level Improper oil viscosity Inferior oil quality.BrakeDragging brakeCooling systemFaulty water temperature gaugeFaulty thermo unit Incorrect coolant levelFaulty thermostatic valveFaulty thermo switchClogged or damaged radiatorFaulty radiator capSeized impeller shaft Inoperative fan motor

FAULTY BRAKEPOOR BRAKING EFFECTDisc brakeWorn brake padsWorn discAir in brake fluidLeaking brake fluidFaulty cylinder cup kitFaulty caliper seal kitLoose union boltBroken brake hoseOily or greasy disc/brake pads Improper brake fluid level

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTIONOIL LEAKAGEBent, damaged or rusty inner tubeDamaged or cracked outer tubeDamaged oil seal lip Improperly installed oil seal Improper oil level (too much)Loose damper rod holding boltBroken cap bolt O-ring

MALFUNCTIONBent, deformed or damaged inner tubeBent or deformed outer tubeDamaged fork springWorn or damaged slide metalBent or damaged damper rod Improper oil viscosity Improper oil level

9-5

INSTABLE HANDLING/FAULTY LIGHTING AND SIGNAL SYSTEM

TRBLSHTG

INSTABLE HANDLINGINSTABLE HANDLINGHandlebar Improperly installed or bentSteering Improperly installed handlebar crownBent steering stem Improperly installed steering shaft (Improperly

tightened ring nut)Damaged ball bearing or bearing raceSwingarmWorn bearing or bushBent or damagedRear shock absorberFatigued springOil and gas leakageTiresUneven tire pressures on both sides Incorrect tire pressureUnevenly worn tires

Front forksUneven oil levels on both sidesUneven spring tension (uneven damping force

adjuster position)Broken springTwisted front forksWheels Incorrect wheel balanceDeformed wheelDamaged bearingBent or loose wheel axleExcessive wheel run-outFrameTwistedDamaged head pipe Improperly installed bearing race

FAULTY LIGHTING AND SIGNAL SYSTEMHEADLIGHT DARK Improper bulbToo many electric accessoriesHard charging (broken stator coil wire, faulty rec-

tifier/regulator) Incorrect connection Improperly groundedPoor contacts (main or light switch)Bulb life expires

BULB BURNT OUT Improper bulbFaulty batteryFaulty rectifier/regulator Improperly groundedFaulty main and/or light switchBulb life expired

FLASHER DOES NOT LIGHT Improperly groundedDischarged batteryFaulty turn switchFaulty flasher relayBroken wire harnessLoosely connected couplerBulb burnt outFaulty fuse

FLASHER WINKS SLOWERFaulty flasher relayFaulty main and/or turn switch Improper bulb

9-6

FAULTY LIGHTING AND SIGNAL SYSTEMTRBLSHTG

FLASHER KEEPS ONFaulty flasher relayBulb burnt out

FLASHER WINKS QUICKER Improper bulbFaulty flasher relayBulb burnt out

HORN IS INOPERATIVEFaulty batteryFaulty fuseFaulty main and/or horn switch Improperly adjusted hornFaulty hornBroken wire harness

COLOR CODEB Black. . . . . . Br Brown. . . . . Ch Chocolate. . . . Dg Dark green. . . . G Green. . . . . Gy Gray. . . .

L Blue. . . . . . Lg Light green. . . . . O Orange. . . . . R Red. . . . . . Sb Sky blue. . . . . W White. . . . .

Y Yellow. . . . . . B/L Black/Blue. . . . B/R Black/Red. . . . B/W Black/White. . . B/Y Black/Yellow. . . . Br /L Brown/Blue. . .

Br /W Brown/White. . G/R Green/Red. . . G/W Green/White. . . G/Y Green/Yellow. . . L /B Blue/Black. . . . L /R Blue/Red. . . .

L /W Blue/White. . . L /Y Blue/Yellow. . . . R/B Red/Black. . . . R/W Red/White. . . R/Y Red/Yellow. . . .

1 A.C. magneto/pickup coil2 Rectifier / regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Starting circuit cut-off relay9 Gear position switch10 Sidestand switch11 T.P.S. (throttle position sensor)12 Ignitor unit13 Ignition coil14 Spark plug15 Thermo unit16 Meter assembly17 Tachometer18 Water temperature meter19 Meter light20 Neutral indicator light21 High beam indicator light22 Turn indicator light23 Rear flasher light24 Front flasher light25 Headlight26 Auxiliary light27 Left handlebar switch28 Horn switch29 Horn30 Lights switch31 Dimmer switch32 Pass switch33 Turn switch34 Flasher relay35 Clutch switch36 Fan motor37 Thermo switch38 Radiator fan fuse39 Tail /brake light40 Headlight fuse41 Rear brake switch42 Signal system fuse43 Right handlebar switch44 Front brake switch45 Engine stop switch46 Start switch47 Ignition fuse48 Diode

TDM850 ’96 WIRING DIAGRAM

yamaha tdm850 96 service manual eng

Documents