EAS00001

XVZ13TF (L) SERVICE MANUAL ©1999 by Yamaha Motor Co., Ltd. First edition, January 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd is expressly prohibited.

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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: S This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. S Designs and specifications are subject to change without notice.

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IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION:
NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS” on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear.

(In Chapter 3, “Periodic Inspection and Adjustments”, the sub-section title appears at the top of each page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. 2 1 4

3 5

8

6 7

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1

2

SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.
1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting

GEN INFO
3

SPEC
4

CHK ADJ
5 6

ENG

COOL
7

CARB
8

CHAS
9

ELEC
10

Symbols 10 to 17 indicate the following.
10 11 12 13 14 15 16 17

TRBL SHTG
11 12

Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data

13

14

15

16

17

18

19

20

Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 21 22 23

21

22

23

Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease

24

25

Symbols 24 to 25 in the exploded diagrams indicate the following:
24 Apply locking agent (LOCTITER) 25 Replace the part

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TABLE OF CONTENTS
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO

1 2 3 4 5 6 7 8 9

SPEC

CHK ADJ

ENG

COOL

CARB

CHAS

ELEC

TRBL SHTG

GEN INFO

1

GEN INFO
CONTENTS GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIGITAL SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-4 1-5 1-13 1-13 1-13 1-13 1-14 1-14 1-14

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

GEN INFO .

This information will be needed to order spare parts.MOTORCYCLE IDENTIFICATION EAS00014 GEN INFO GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. 1-1 .

When putting it back. 1-2 . which is cancelled by any steps. is memorized and when the operating speed is in the range of approx. S Do not remove the air cleaner cover of the vacuum pump in order not to cause a malfunction in cancellation of the cruise control by dirt. 50-130 km/h. it continues flashing until the speed returns to that memorized. 3 “SET” indicator light This indicator light comes on when the motorcycle is operating at a set speed. To cancel the cruise control system. push the switch to “OFF” or main switch to the “OFF” position. CAUTION: S Giving a severe load like using as a trailer/tractor or driving on a steep slope could remove the cruise control. S Do not set the cruise control while idling the rear tires for the preparation. 4 “RES” indicator light This light comes on when the set speed. 2 “ON” indicator light This indicator light comes on when the cruise control systems preset (when “ON” is selected by the “CRUISE” switch). Set speed ride Minute adjustment of set speed Consecutive adjustment of set speed “RESUME” system 6 “CANCEL” switch Push this switch to cancel the set speed ride in the cruise control system. 3 “SET” indicator light 5 Cruise control switch 1 “CRUISE” switch 6 “CANCEL” switch 2 “ON” indicator light 4 “RES” indicator light Cruise control switch functions 1 “CRUISE” switch Push this switch to “ON” when the cruise control system is preset. S Never remove the cruise control actuator rubber cover. Once the switch is released it will return to the center (Hold) position.FEATURES EAS00019 GEN INFO FEATURES CRUISE CONTROL This motorcycle is equipped with cruise control which designed to maintain a set speed. bolts or other parts will be caught and the cruise control wire can be locked. The “ON” indicator light will come on. Refer to the “Operation chart” for details. S Do not drive without holding the steering wheel whether the cruise control is ON or OFF. trash etc. S Do not disassemble the vacuum pump. If the resume system is operated while this light is on. 5 Cruise control switch This switch is capable of the following controls.

2) To operate the system.4sec) SET SET RES ON SET RES ON Flash Cruise control function 1) The cruise control can only be activated when riding in 4th. S Control unit S Actuator cable S Logical error in cut off signal S Error signal in speed sensor signal S Error signal in engine revolution S Cruise control switch lead (“SET”/“RES”) 9) When main switch is cut off once. the speed can be successively increased or decreased slowly. In case of gear position is moved to gears other than of 4th. the “CRUISE” switch should be turned “ON”.6 km/h. 8) Auto cruise function is canceled. the control switch in the direction of either “ACC” or “DEC”.5 seconds). 5th. 5) If the control switch is held in the “ACC” or “DEC” position (longer than 0. In case of systems fines any faulty signal in the following systems. b. 5th gear and traveling between the speed of 50 and 130 km/h. In case of current speed drops 8 km/h less than the originally set speed.5 seconds). the speed is returned to the one set before the cancellation by pushing the control switch once in the “RES” direction. a. c. 3) When push the cruise control switch to “SET”. 1-3 . 4) By pushing (in shorter than 0.FEATURES Operation chart Operation Cruise SW ON CRUISE GEN INFO Resume Mannual acceleration SET cancel Clutch SET Out of range Rear brake Front brake Speed Out of range IndicaRES tor ON (After1. “resume” is canceled. the set speed can be changed in increments or decrements of approximately 1. the cruise control system will be set the set speed. 7) After canceling. 6) The cruise control will be deactivated if the front or rear brake is applied or if the clutch is disengaged or if the “CANCEL” switch is pushed.

select it by pushing the “SELECT” button and push the “RESET” button. If you do not reset the fuel reserve trip meter manually. the display automatically returns to the prior mode. “TRIP 1” or “TRIP 2”). To reset the fuel reserve trip meter. select it by pushing the “SELECT” button and push the “RESET” button. trip odometer and odometer modes in the following order: “TRIP F” ! “TRIP 1” ! “TRIP 2” ! “ODO” ! “TRIP F” 2) Resetting a meter To reset a trip odometer to 0. the display always returns to the “TRIP 1” mode. and a different mode was selected prior to resetting the fuel reserve trip meter. the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point.0. Push the “SELECT” button to change between the fuel reserve tripmeter. The display will return to prior mode (“ODO”. it will automatically reset and retum to “TRIP 1” after refueling and the motorcycle has traveled both 5km. S If the fuel reserve trip meter appears. and a different mode was NOT selected prior to resetting the fuel reserve trip meter. “ODO” ! “TRIP 1” ! “TRIP 2” ! “ODO” If the fuel level indicator light comes on. 1-4 . NOTE: S If the fuel reserve trip meter appears.FEATURES DIGITAL SPEEDOMETER This speedometer is equipped with: S An odometer S Two trip odometers S A fuel reserve trip meter S A clock GEN INFO Odometer and trip meter modes 1) Selecting a mode Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer modes “TRIP 1” and “TRIP 2” in the following order.

b. d. Push both the “SELECT” and “RESET” buttons for at least two seconds. Push the “RESET” button to set the minutes. Push the “SELECT” button and the minute digits will start flashing. push the “RESET” button to set the hours. S To turn on the power for the audio system. Push the “SELECT” button to start the clock. otherwise the clock will not be set. AUDIO SYSTEM 1. push the “RESET” button.FEATURES GEN INFO Clock mode To change the display to the clock mode. push both the “SELECT” and “RESET” buttons. POWERING ON/OFF THE AUDIO SYSTEM Turning on/off the audio system Turn the main switch to the “ACC” or “ON” position. push the audio button “AUDIO” continuously for 1 second or more. To change the display back to odometer mode. 1-5 . push the audio button “AUDIO”. 1) To set the clock a. S To turn off the audio system. be sure to push the “SELECT” button before turning the main switch to “OFF”. When the hour digits start flashing. NOTE: After setting the clock. e. c.

. Pushing the switch in direction “n” will search in the forward direction. (i. push the updown button in the opposite direction that it was originally pushed. the number of song that are being skipped will appear. Turn the volume control knob to set the volume level. (i. When searching in the forward direction. To stop a searching operation. “-1”. meaning one song is being skipped) The maxmum number of songs that can be skipped in either direction is 9. meaning one track is being skipped) When searching the reverse direction. If a tape is aleady loaded in the cassette deck.e. CASSETTE DESK OPERATION The cassette tape deck has the following functions. the number of song that are being skipped will appear along with a minus sign before the number. S Song search S Change tape play direction S Dolby noise reduction S Blank tape skip a. c. Push the witch once for each song to be skipped. Insert a cassette tape into the cassette deck.. Turn the main switch to the “ACC” or “ON” position and push the “AUDIO”button to turn on the power. push the “AUDIO” button until “PLAY” appears. push the updown switch 1 for less than one second. Track searching To search for a song on the tape. d. “1”. b. The “APC” (auto program control) indicator will appear in the display. Pushing the switch in direction “o” will search in the reserve direction.FEATURES GEN INFO 2.e. The volume level can be set from 0 to 30. 1-6 . The tape will start playing.

Ejecting the cassette tape Push the “EJECT” button to eject the tape from the cassette dack. When the noise reduction is on. Blank skipping When there is a blank portion on the cassette tape the “BLS” indicator light will come on and the cassette deck automatically fast forwards the tape to the next track.FEATURES GEN INFO Reserving tape play direction Push the up-down button 1 in either direction for more than one second to reverse tape play. the “BNR” indicator appears in the display. When the tape is playing in the reverse direction. Dolby noise reduction The Dolby noise reduction can be turned on or off by pushing the “EJECT” button for at least two seconds. When the tape is playing the forward direction. the “F” indicator will appear. 1-7 . the “R” indicator will appear.

The tuner will automatically stop at the first station that has a strong enough radio wave. S Switching the receiving band S Switching the receiving station S Automatic tuning (Seek) S Manual tuning S Programing preset stations in memory S Automatic writing of stations in memory (Auto store operation) Switching the receiving bands This radio system has 3 bands for FM and 1 band for AM. b. Manually turning When a radio wave is too weak to be picked up automatically. ³ TAPE ³ FM1 ³ FM2 ³ FM3 AUX. 6 stations can be set for each band. The display will change as follows. 1-8 . Push the up-down switch 1 for less than 1 second in either direction and the ferequency will change in 0. Select the station desired to be preset.1 MHz steps for FM and in 9 kHz for AM.FEATURES GEN INFO 3. ² CD(option) ² AM ² Automatic tuning (Seek operation) Push the up-down switch 1 in either direction and hold it for as least 1 second. a. Presetting station in memory Station can be preset either automatically or manually. it can be selected manually as follows. Push the “SELECT” button until “RADIO” station appears. Push the “SELECT” button for as least 2 seconds unitl the radio frequency and the channel “Ch” start flashing. RADIO OPERATION The radio has the following functions. Preset station either manually or automatically by the following procedure. Select a band by pushing the “AUDIO” button for less than 1 second.

Repeat this procedure for the remaining stations desired to be preset in the memory. It is recommended to use this function only in areas with strong radio frequencies. Stations can be also be automatically preset by the following procedure. Push the “SELECT” button to programing the channels in memory. When the desired station is found. a. b. e. Push the up-down switch 1 in either direction to select the channel number to be set for the current station. Ch5 and Ch6) d. Ch4. c. push the up-down switch for less than one second to select the channel number to be set for that station. Repeat this procedure for the remaining stations desived to be preset in memory. c. Programing preset stations in memory automatically Setting up to 6 channels can be made by the following procedure. Push the up-down switch 1 in either direction to select channel “A”. Press the “SELECT” button to start the random channel selection and the tuner will automatically write the channels in memory.FEATURES GEN INFO c. Push the “SELECT” button until the radio frequency and the channel “Ch” start flashing. d. b. (Ch1. Push the “SELECT” button until the radio frequency and the channel “Ch” start flashing. Ch2. Ch3. Push the up-down button in either direction for at least 1 second to automatically tune in a station. a. 1-9 . NOTE: Stations will be starting from the station preset at chanel 6. Press the “SELECT” button to programing the channel in memory.

BASIC SETTINGS AUDIO system The following settings can be made in the audio system.VOL² b. Audio system ³ OUTPUT ³ BASS ³ TREB ³ FADE RADIO station ³ AVC ³ INT. a. On each press of the button.FEATURES GEN INFO “AUX” (Auxiliary) operation Auxiliary audio equipment can be used to play through the audio system. Push the “AUDIO” button until “AUX” appears and the auxiliary equipment can be used to play through the audio system. ³ TAPE ³ FM1 ³ FM2 ³ FM3 AUX. the mode changes as follows. 1-10 . auxiliary mode and CD Changer. Push the up-down switch 1 in either direction to change the setting for any mode. Selecting output between speakers and a headset assembly Controlling bass level Controlling treble level Controlling fader (balance between the front and the rear speakers) Controlling intercom volume level Changing auto volume level Setting procedure The following setting procedures apply to the audio system. Insert the output plug of the auxiliary equipment into the jack located at the right side of the dassette deck. ² CD(option) ² AM ² 5. Select the desired setting mode by pushing the “SELECT” button. b. a.

b. Controlling the fader (balance between front and rear speakers) a. Controlling the intercom volume level a. NOTE: The speaker and headset cannot be used the same time. The treble level can be set from –6 to +6. Controllingthe treble level a. To control the treble level. The fader level can be adjusted from F9 to R9. 1-11 . b. To change between speaker and headset. The intercom volume level can be set from 0 to 20.FEATURES GEN INFO Selecting the output for speaker or headset (optional) To select the output for speaker or headset. To control the intercom volume level. push the up-down switch 1 in either direction. Push the up-down switch 1 in either direction to change the level. Push the up-down switch 1 in either direction to change the balance. Controlling the bass level a. b. Push the up-down switch 1 in either direction to change the volume level. push the “SELECT” button until the “BASS” indicator appears. b. Push the up-down switch 1 in either direction to change the level. To control the bass level. push the “SELECT” button until the “FAD” indicator appears. push the “SELECT” button until the “TREB” indicator appears. push the “SELECT” button until the “IC:” indicator appears. To control the fader. push the “SELECT” button and the “SP” (speaker) or “HS” (headset) indicator will appear.

Push the up-down switch 1 in either direction to change the volume level. To control the level for the auto volume control system. 1-12 .FEATURES GEN INFO Changing the level for auto volume control system a. b. push the “SELECT” button untill the “AV:” indicator appears. The auto volume control rate of compensation can be adjusted from 0 to 5.

When disassembling. This will speed up assembly and allow for the correct installation of all parts. Use only the proper tools and cleaning equipment. replace all gaskets. properly oil all mating parts and bearings and apply grease onto the oil seal lips. remove all dirt. Use oil and grease recommended by Yamaha for all lubrication jobs. During reassembly. 2. EAS00021 REPLACEMENT PARTS 1. OIL SEALS AND O-RINGS 1. dust and foreign material. Refer to the “SPECIAL TOOLS” section. Other brands may be similar in-function and appearance. cylinders. oil seal lips and O-rings must be cleaned. 4. Use only genuine Yamaha parts for all replacements. but inferior in quality.IMPORTANT INFORMATION EAS00020 GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. 1-13 . pistons and other parts that have been “mated” through normal wear. All gasket surfaces. During disassembly. 3. When overhauling the engine. Before removal and disassembly. 5. mud. clean all of the parts and place them in trays in the order of disassembly. Mated parts must always be reused or replaced as an assembly. seals and O-rings. always keep mated parts together. Keep all parts away from any source of fire. 2. EAS00022 GASKETS. This includes gears.

EAS00024 BEARINGS AND OIL SEALS 1. check all circlips carefully and replace damaged or distorted circlips. 1 Bearing EAS00025 CIRCLIPS 1. Oil bearings liberally when installing. 1 Oil seal CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.IMPORTANT INFORMATION EAS00023 GEN INFO LOCK WASHERS/PLATES AND COTTER PINS 1. Always replace piston pin clips after one use. After removal. apply a light coat of lithium soap base grease onto the oil seal lips. Before reassembly. When installing a circlip 1 . replace all lock washers/plates 1 and cotter pins. make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. if appropriate. bend the lock tabs along a flat of the bolt or nut. After the bolt or nut has been tightened to specification. 4 Shaft 1-14 . Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals.

5. moisture. Connect: S lead S coupler S connector NOTE: Make sure that all connections are tight. 4. bend it up. 3. couplers. S When checking the wire harness. and connectors for stains. perform steps 1 to 3. Check: S all connections Loose connection ! Connect properly.CHECKING THE CONNECTIONS EAS00026 GEN INFO CHECKING THE CONNECTIONS Check the leads.90890-03112 NOTE: S If there is no continuity. S As a quick remedy. clean the terminals. 1. Check: S continuity (with a pocket tester) Pocket tester YU-03112. use a contact revitalizer available at most part stores. Rust/stains ! Connect and disconnect several times. 1-15 . Check: S lead S coupler S connector Moisture ! Dry with an air blower. etc. rust. Disconnect: S lead S coupler S connector 2. NOTE: If the pin 1 on the terminal is flattened.

YK. CDN Tool No. Compression gauge/Set YU-33223 90890-03081 These tools are needed to measure engine compression. Special tools.YM-. YM-33961 90890-04105 Tool name/Usage Tappet adjusting tool This tool is needed to rotate the camshaft for access to the valve lifter and valve pad Vacuum gauge YU-08030-A 90890-03094 Illustration This gauge is needed for carburetor synchronization. Pressure gauge/adapter Gauge 90890-03153 Adapter 90890-03124 These tools are needed to measure engine oil pressure. refer to the list provided below to avoid any mistakes.90890Except for US. part umbers or both may differ depending on the country. CDN YS-. Oil filter wrench YU-38411 90890-01426 This tool is needed to remove and install the oil filter. Timing light YU-33277-A 90890-03141 This tool is necessary for checking ignition timing. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order. 1-16 . P/N. Engine tachometer YU-08036-A 90890-03113 This tool is needed for observing engine rpm.ACCP/N. YUFOr US.SPECIAL TOOLS EAS00027 GEN INFO SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly.

0 mm) YM-04066 90890-04066 This tool is needed to rebore the new valve guide. Valve guide reamer (6.0 mm) YM-04065-A 90890-04065 This tool is needed to install the valve guide.0 mm) This tool is needed to remove and install the valve guide. Valve guide remover (6. Sheave holder YS-01880 90890-01701 Puller YU-33270 90890-01362 Adapter YM-33282 90890-04089 This tool is needed to hold the rotor when removing or installing the rotor bolt. Pocket tester YU-03112 90890-03112 Compressor YM-04019 90890-04019 Adapter YM-01253-1 90890-04114 YM-4064-A 90890-04064 This instrument is needed for checking the electrical system. Flywheel puller/adapter These tools are needed to remove the rotor.SPECIAL TOOLS Tool No. 1-17 . Universal clutch holder YM-91042 90890-04085 This tool is needed to hold the clutch when removing or installing the clutch boss nut. Valve spring compressor/adapter These tools are needed to remove and install the valve assemblies. YU-01268 90890-01268 YU-33975 90890-01403 Tool name/Usage Ring nut wrench GEN INFO Illustration This tool is needed to loosen and tighten the steering stem ring nut. Vale guide installer (6.

Piston pin puller YU-01304 90890-01304 GEN INFO Illustration This tool is used to remove the piston pin. 1-18 . Dial gauge YU-03097 90890-03097 This tool is used to measure the middle gear backlash.SPECIAL TOOLS Tool No. Universal joint holder YM-04062 90890-04062 This tool is needed when removing or installing the driven pinion gear nut.1215 This sealant (bond) is used on crankcase mating surfaces. ACC-1100-15-01 90890-85505 Tool name/Usage Quick gasket® Yamaha Bond No. Offset wrench (55 mm) YM-04054 90890-04054 This tool is needed when removing or installing the middle drive gear nut. Middle drive gear holder YM-33222 90890-04080 This tool is needed for the gear backlash adjustment. etc. Middle drive gear holder This tool is needed to remove and install the middle drive pinion gear. This tool is also used for the gear backlash adjustment. Piston ring compressor YM-8037 90890-05158 This tool is used to compress the piston rings when installing the piston into the cylinder. Damper spring compressor YM-33286 90890-04090 This tool is needed when removing or installing the damper spring.

Bearing retainer wrench YM-04050 90890-04050 This tool is needed when removing or installing the final drive shaft bearing. Damper rod holder/T-handle These tools are needed to loosen and tighten the damper rod holding bolt. Fuel level gauge This gauge is used to measure the fuel level in the float chamber. Dynamic spark tester Ignition checker GEN INFO Illustration YM-34487 90890-06754 1-19 . oil seal and dust seal into the fork. Fork seal driver weight/adapter These tools are needed when installing the slide metal.SPECIAL TOOLS Tool No. Tester YU-24460-01 90890-01325 Adapter YU-33984 YM-01312-A 90890-01312 Rod holder YM-01300-1 90890-01294 T-handle YM-01326 90890-01326 Weight YM-33963 90890-01367 Adapter YM-8020 90890-01374 YM-01230 90890-01230 Tool name/Usage Radiator cap tester/adapter This tester and its adapter are needed for checking the cooling system. Final gear backlash band This tool is needed when measuring final gear backlash. Coupling gear/middle shaft tool YM-01229 90890-01229 This tool is needed when removing or installing the coupling gear nut.

GEN INFO .

SPEC 2 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . 2-4 2-4 2-14 2-18 2-21 GENERAL TIGHTENING TORQUE SPECIFICATIONS . 2-25 LUBRICATION DIAGRAMS . 2-24 COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 LUBRICATION POINTS AND LUBRICANT TYPES . . . . . 2-30 . . . . . . . . . . . . . . . . . . . . 2-23 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC .

5 L 3. GR) XVZ13TFL: 5JL1 (for OCE) 2. I.500 mm 366 kg 394 kg Liquid cooled 4-stroke. G. SF.705 mm 155 mm 3. A. S.294 cm3 79 66 mm 10 : 1 1.3 L 0. 15.520 kPa (15. B.2 L 3. D.5 L 2-1 . N.5 L 3. DOHC V-type 4-cylinder 1.565 mm (except for G) 1. F.705 mm 900 mm 1. P.GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code: Standard XVZ13TF: 5JC1 (for GB. E. NL.2 bar) at 175 r/min Electric starter Wet sump Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning redius Basic weight: Dri weight With oil and a full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Oil type or grade: Engine oil Yamalube 4 (20W40) or SAE20W40 type SE motor oil Yamalube 4 (10W30) or SAE10W30 type SE motor oil Final gear oil: Engine oil Periodic oil change With oil filter replacement Total amount Final gear case oil Total amount Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount SAE80API “GL-4” Hypoid Gear Oil 3.380 mm (for G) 750 mm 1.5 L Dry type element Regular unleaded gasoline 22.2 kg/cm2.7 L 4.

8 X 0. 2.776) Shaft drive 21/27 33/10 (2.80 kg/cm2.10_ 152 mm Tubeless 150/80B16 71H 150/90B15M/C 74H BRIDGESTONE/DUNLOP BRIDGESTONE/DUNLOP G705/D404F G702/D404 Standard SPEC front rear front rear front rear 250 kPa (2.632) 30/25 (1.567) Constant mesh 5-speed Left foot operation 43/17 (2. 2. 2.529) 31/19 (1. multiple-disc Spur gear 87/49 (1. Dual disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link suspension) Brake: Front brake Rear brake Suspension: Front suspension Rear suspension type operation type operation 2-2 .50 bar) 280 kPa (2.50 kg/cm2.200) 24/25 (0.786) Double cradle 29.9 mm Wet.50 bar) 250 kPa (2.50 bar) 250 kPa (2.960) 22/28 (0.GENERAL SPECIFICATIONS Item Carburetor: Type/quantity Manufacturer Spark plug: Type Manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction radio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size Manufacturer Type Tire pressure (cold tire): 0 X 90 kg load* 90 X 190 kg load* front rear front rear BDS32/4 MIKUNI DPR8EA-9/X24EPR-U9 NGK/DENSO 0. 2. passenger and accessories.80 bar) * Load is the total weight of the cargo.50 kg/cm2.50 kg/cm2. rider.

7 W 12 V 1.7 W 12 V 1.7 W 14 V 3. (Digital) A. magneto YTX20L-BS 12 V 18 AH Halogen bulb 12 V 60 W /55 W 1 12 V 4 W 1 12 V 21 W/5 W 1 12 V 21 W 2 12 V 21 W 2 12 V 5 W 2 12 V 1.I.7 W 12 V 1.7W x 1 12V1.0 W 12 V 1.7 W 12 V 1.C.7W x 1 12V1.7 W 12V1.7W x 1 1 2 1 1 1 1 1 SPEC 2-3 .GENERAL SPECIFICATIONS Item Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capaity Headlight type: Bulb wattage quantity: Headlight Auxiliary light Tail/brake light Front flasher light Rear flasher light License light Indicator light Neutral indicator light Turn indicator light High beam indicator light Fuel level indicator light Oil level indicator light Engine overheat indicator light Engine trouble indicator light Over drive indicator light “SET” indicator light “RES” indicator light “ON” indicator light Standard Coil-air spring/Oil damper Coil-air spring/Oil damper 140 mm 105 mm T.C.7W x 1 12V1.

016 mm 40 mm SSS SSS Out of round limit Camshaft: Drive method Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions SSS Chain drive (Center) 25.020 X 0.95 X 28.MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head: Warp limit SSS Standard SPEC Limit 0.967 X 24.75 X 35.65 mm 27.75 X 35.85 mm 2-4 .05 mm 35.65 mm 27.85 mm 27.980 mm 0.05 mm 35.021 mm 24.95 X 28.05 mm SSS SSS SSS SSS Intake Exhaust “A” “B“ “A” “B” 35.03 mm Cylinder: Bore size Measuring point* * 78.967 X 79.85 mm 27.85 mm 35.054 mm 0.000 X 25.

975 X 5. valve seat.9 X 1.7 mm 5.052 mm 1.012 mm 0.8 X 1.4 mm 0.4 mm 1.975 mm 6.03 mm Cam chain: Cam chain type/No.2 mm 0.16 X 0.11 X 0.012 mm 6.3 X 3.05 mm 0.9 X 24.025 X 0.1 mm 0.9 X 1.2 mm 5.9 mm 0.010 X 0.15 mm 0.2 mm 1.6 X 2.1 mm 23.000 X 6.7 mm 0.20 mm Head Dia Face Width Seat Width Margin Thickness “A” head diameter “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance IN EX IN EX IN EX IN EX IN EX IN EX IN EX 28.037 mm 0.1 mm 2-5 .990 mm 5.960 X 5.MAINTENANCE SPECIFICATIONS Item Camshaft runout limit SSS Standard SPEC Limit 0.05 mm 6.08 mm 0.000 X 6.9 X 29.92 mm 6.945 mm 5.1 mm 0.1 mm 1. of links Cam chain adjustment method Valve.8 X 1. valve guide: Valve clearance (cold) Valve dimensions: IN EX BF05M/118 Automatic 0.

57 X 5.37 kg 4.37 kg SSS SSS 35.6 mm 2.5_/1.8 mm 4.7 mm Direction of winding (top view) IN EX Clockwise Clockwise SSS SSS 2-6 .01 mm Valve spring: Inner: Free length Set length (valve closed) Compressed pressure (installed) Tilt limit* IN EX IN EX IN EX IN EX 37.25 mm 37.7 mm 2.5_/1.MAINTENANCE SPECIFICATIONS Item Stem runout limit SSS Standard SPEC Limit 0.9 kg 10.3 mm 35.3 mm 37.45 mm 33.6 mm Direction of winding (top view) Valve spring: Outer: Free length Set length (valve closed) Compressed pressure (installed) Tilt limit* IN EX Counter clockwise Counter clockwise SSS SSS IN EX IN EX IN EX IN EX 39.3 mm SSS SSS SSS SSS 2.3 mm 31.45 mm 39.8 mm 10.8 mm 33.1 X 11.9 kg SSS SSS 37.5_/1.8 mm 31.5_/1.1 X 11.25 mm SSS SSS SSS SSS 2.57 X 5.

1 1.5 mm 0.MAINTENANCE SPECIFICATIONS Item Piston: Piston to cylinder clearance Piston size “D” Standard 0.015 mm 18.1 1.1 2.926 X 78.045 mm 18.12 mm Dimensions (B T) End gap (installed) 3.000 mm SSS SSS 19.06 mm SSS SSS 0.975 mm Type Dimensions (B T) End gap (installed) Side clearance (installed) 2nd ring: Barrel 3.35 X 0.069 mm 78.03 X 0.12 mm Type Dimensions (B T) End gap (installed) Side clearance Oil ring: Taper 3.004 X 19.07 mm SSS SSS 0.15 mm SSS Measuring point “H” Piston off-set Piston pin bore inside diameter Piston pin outside diameter Piston rings: Top ring: 4 mm 0 mm 19.3 X 0.50 mm 0.8 mm 0.55 mm 0.2 mm 0.35 mm 0.055 X 0.20 X 0.9 mm SSS SSS 2-7 .991 X 19.933 mm SPEC Limit 0.0 mm 0.02 X 0.

97 mm 242.053 mm Hydraulic inner push SSS SSS SSS 0.10 X 0.72 X 243.8 mm SSS SSS 0.5 mm 2-8 .264 mm 0.1 mm SSS SSS SSS 2.09 mm SSS Crank width “A” Assembly width “B” Runout limit “C” Big end side clearance “D” Big end radial clearance Journal oil clearance Color code (corresponding size) Ballancer: Ballancer drive method Clutch: Friction plate thickness Quantity Friction plate wear limit Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit 83.5 mm SSS SSS SSS 0.92 X 83.021 X 0.2 X 2.2 mm SSS SSS 6.1 mm 8 SSS 2.039 mm 0.03 mm SSS SSS 0.17 mm SSS 0.038 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red Gear 2.MAINTENANCE SPECIFICATION Item Connecting rod: Oil clearance Color code (corresponding size) Crankshaft: Standard 0.37 mm 0.4 mm 7 SSS 7 mm 1 SSS 0.9 X 3.017 X 0.160 X 0.021 X 0.039 mm 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink SPEC Limit 0.020 X 0.

5 #3 : #117.2 kg/cm2.1) (B. 2 : #122.J.S.P.P.J) (P.4 X 5.1) (G.4 X 5.mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Fuel level Engine idle speed Intake vacuum Fuel pump: Type Model/manufacturer Consumption amperage Output pressure SSS SSS Guide bar SSS 5JC1 00 #1.MAINTENANCE SPECIFICATIONS Item Transmission: Main axle runout limit Drive axle runout limit Shifter: Shifter type Guide bar bending limit Carburetor: I.08 mm SSS 0.2 kg/cm2.A.D.000 r/min Standard SPEC Limit 0.6 bar) 58 kPa (0.08 mm 80 X 120 kPa (0.J) (B.5 #110 17 mm 950 X 1.A.S) (G.6 kg/cm2.2 bar) Paper type Trochoid type 0 X 0.08 mm 0. 4.O) (P.12 mm 0.03 X 0.2 bar) 440 X 560 kPa (4.1) (P.8 0.050 r/min 36 kPa (270 mmHg) Electrical type 4NK/MITSUBISHI 1A 15 X 20 kPa (0.S.025 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.8 1.08 mm SSS SSS SSS (M.J) (M.2) (Th.8 X 1.5 #35 0. 0.5 #4 : #120 #110 5DL41-54 P-0 #85 1.2) (B.3) (V.J) (J. V) (F. 0.N) (N.8 X 1.P.L) <max> Lubrication system: Oil filter type Oil pump type Inner rotor to outer rotor clearance Outer rotor to oil pump housing clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) 2-9 .17 mm 0.58 kg/cm2) at 1.1 #15 0.8 0.

25 kg/cm2.25 bar) 0.25 L> Single suction centrifugal pump 31/21 (1.MAINTENANCE SPECIFICATIONS Item Cooling system: Radiator core size Width Height Thickness Radiator cap opening pressure Reservoir tank capacity <From low to full level> Water pump Type Reduction ratio Shaft drive: Middle gear backlash Final gear backlash Standard SPEC Limit 257.95 X 1.1 X 0. 0.4 mm 360 mm 27 mm 95 X 125 kPa (0.95 X 1.476) 0.12 mm 0.84 L <0.05 X 0.2 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 2-10 .

MAINTENANCE SPECIFICATIONS SPEC Item Crankcase tightening sequence: Standard 2-11 .

6 13.8 M5 M8 1.0 0.25 M8 1.25 M6 1.0 Q’ty y 32 6 8 4 16 16 16 8 1 8 1 4 2 1 2 4 2 1 2 1 2 1 2 1 1 1 1 1 4 4 2 14 2 2 8 16 1 8 4 3 2 SPEC Tightening torque Nm 10 55 15 18 43 10 10 36 130 20 24 12 20 43 7 10 10 50 12 43 12 5 18 20 18 12 17 4 3 3 3 3 25 20 20 9 12 40 25 7 7 mSkg 1.0 M20 1.0 2.3 0.0 M20 1.4 1.5 M8 1.0 M6 1.5 M5 0.25 M10 1.0 M8 0.25 M10 1.2 1.0 1.7 0.5 0.25 M8 1.0 M6 1.2 2.0 3.5 M6 1.9 1.4 0.0 5.25 M20 M10 1.0 M5 0.0 M16 M14 M6 1.25 M10 1.3 0.0 1.8 1.25 M8 1.25 M6 1.8 4.7 Remarks 2-12 .8 M4 0.3 2.3 1.0 M18 1.0 M8 1.2 4.3 0.25 M6 1.2 0.2 4.8 2.25 M8 1.75 M12 1.MAINTENANCE SPECIFICATIONS Tightening torques Part to be tightened g Camshaft cap Blind plug Exhaust pipe Spark plug Cylinder head Cylinder head cover Chrome cover Connecting rod AC magneto Camshaft sprocket Timing chain damper bracket Timing chain tensioner Cap bolt (tensioner) Water pump drain plug Radiator Radiator side cover Radiator cap pipe Oil filter mounting bolt Oil gallery pipe Oil drain plug Oil baffle plate Oil gallery bolt Oil delivery pipe (head) Oil delivery pipe (cover) Oil pipe Stay 1 Oil filter Clamp bolt (clutch hose) Carburetor joint Air filter joint Air filter assembly Air filter case cover Clamp bolt (exhaust pipe) Clamp bolt (muffer) Exhaust pipe Cylinder Main gallery blind plug Crankcase Middle gear bearing retainer Main axle bearing retainer Crankcase cover plate Part name Bolt Plug Stand bolt Nut Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Plug Bolt Bolt Bolt Union bolt Bolt Plug Bolt Screw Union bolt Union bolt Union bolt Bolt Bolt Screw Screw Screw Screw Bolt Bolt Nut Stud bolt Plug Bolt Screw Screw Screw Thread size M6 1.0 2.0 4.8 M5 x 0.0 1.7 1.3 1.0 M14 M6 1.25 M12 1.0 5.0 2.25 M6 1.5 1.5 1.0 M6 1.8 M8 1.25 M7 1.0 2.7 0.3 0.0 M6 1.5 1.8 M4 0.5 2.0 1.

5 0.0 1.3 4.0 2.25 1.0 1.8 2.0 1.9 11.25 1.25 1.25 1.0 2.0 1.0 1.0 0.4 0.8 1.25 1.MAINTENANCE SPECIFICATIONS Part to be tightened g Oil drain plug (crankcase) Starter clutch Clutch spring plate Clutch boss Clutch release cylinder Air bleed screw Clutch pipe Middle drive pinion gear Middle driven pinion gear Middle driven gear housing Shift cam segment Shift cam plate Shift cam retainer Shift shaft spring stopper Stopper lever Shift pedal bracket Shift arm Shift rod Shift rod Shift pedal link Shift lever assembly Final gear case (rear arm) Final gear case (bearing housing) Coupling gear Bearing housing Drain plug (final gear case) Filler plug (final gear case) Stator coil Starter motor Neutral switch Oil level switch Thermo unit Thermo switch Ignition coil assembly Ignitor unit assembly Part name Bolt Bolt Bolt Nut Bolt Screw Union bolt Nut Nut Bolt Torx Screw Screw Bolt Bolt Screw Bolt Nut Nut Bolt Bolt Stud bolt Stud bolt Nut Nut Bolt Plug Plug Screw Bolt Screw Bolt Thread size M12 M8 M6 M20 M6 M8 M10 M44 M16 M8 M6 M5 M6 M8 M6 M6 M6 M6 M6 M6 M6 M10 M8 M16 M8 M10 M14 M14 M6 M6 M5 M6 M10 M18 M5 M6 1.25 1.0 1.0 1.5 1.0 1.5 11.25 1.8 2.7 1.0 1.0 9.0 0.7 2.0 0.7 Left hand thread Bolt Nut 2-13 .2 0.6 2.25 1.0 0.3 2.8 7.0 1.0 1.0 1.8 1.25 1.0 Q’ty y 1 6 6 1 2 1 1 1 1 3 1 1 3 1 1 1 1 1 1 1 1 4 6 1 6 2 1 1 3 2 3 2 1 1 8 2 SPEC Remarks Tightening torque Nm mSkg 38 24 8 70 12 6 25 110 90 30 12 4 7 22 10 7 10 10 10 10 18 18 9 110 23 40 23 23 7 10 4 10 8 23 4 7 3.0 1.3 0.2 1.0 3.25 1.0 1.4 0.5 1.4 1.0 1.0 0.8 1.0 1.0 1.25 1.0 1.2 0.8 0.25 1.3 0.25 1.4 0.25 1.8 1.0 1.7 1.

5 mm 165.5 mm SSS SSS SSS SSS SSS SSS end side 0 mm 0 mm SSS SSS SSS 1 mm 0.0 bar) SSS SSS Cast wheel 16 MT3.50 Aluminum SSS SSS Cast wheel 15M/C MT4.0 kgf/cm2.5 mm 147 N/mm (14.00 Aluminum SSS SSS SPEC Limit SSS SSS 568 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 181.5 mm SSS SSS SSS 1 mm 0.9 kg/mm) 0 X 140 mm No 0. 0 X 4.7 kg/mm) 0 X 45 mm No 0 kPa (0 kgf/cm2. 0 bar) 0 X 400 kPa (0 X 4. 0 bar) 0 X 50 kPa (0 X 0.MAINTENANCE SPECIFICATIONS CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Collar length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade Endosed gas/air pressure (STD) (Min X Max) Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate (K1) Stroke (K1) Optional spring Enclosed gas/air pressure (STD) (Min X Max) Swingarm: Free play limit Front wheel: Type Rim size Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout Standard Taper roller bearing 140 mm 573 mm 50 mm 8.553 L 117 mm Yamaha fork oil 5WT 0 kPa (0 kgf/cm2. 0 X 0.83 N/mm (0.5 kgf/cm2.5 bar) 45 mm 186.5 mm radial lateral radial lateral 2-14 .

5 mm thickness inner outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake: Type Disc outside diameter Pad thickness Pad thickness 15.3 mm DOT 4 Single 320 7 mm 7.1 mm 33.5 mm thickness inner outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever & brake pedal: Brake lever free play (at lever end) Brake pedal position 12.7 mm 33.9 mm 30.5 mm 0.87 mm 30.5 mm 0.5 mm 7.5 mm SSS SSS SSS SSS SSS SSS 0.2 mm DOT 4 2 X 5 mm 100 mm SSS SSS SSS SSS SSS SSS Brake pedal free play 0 mm SSS 2-15 .GENERAL SPECIFICATIONS Item Front disc brake: Type Disc outside diameter Pad thickness Pad thickness Dual 298 5 mm 6 mm 6 mm Standard SPEC Limit SSS SSS 0.

3 0.4 0.7 0.0 5.7 0.8 0.4 0.0 1.7 0.5 6.7 0.0 4.2 3.MAINTENANCE SPECIFICATIONS Tightening torques Part to be tightened g Upper bracket and inner tube Upper bracket and steering shaft Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) Brake hose joint and lower bracket Front master cylinder cap (brake and clutch) Handlebar holder (lower) Front master cylinder (brake and clutch) Union bolt (brake hose) Clutch hose and clutch pipe Engine mounting: Mounting bolt (engine and front frame) Mounting bolt (engine and rear frame) Frame and down tube Cylinder head stay and frame Frame and rear fender stay (rear frame) Muffler stay and muffler Ignitor unit Ignition coil Ignition bracket Swingarm pivot shaft (left) Swingarm pivot shaft (right) Swingarm pivot shaft locknut (right) Relay arm and frame Relay arm and connecting rod Connecting rod and swingarm Rear shock absorber and frame Rear shock absorber and connecting rod Fuel petcock and fuel tank Fuel sender and fuel tank Fuel tank (front) and frame Fuel tank (rear) and frame Fuel pump bracket and bridge plate Cover and fuel tank Rider seat and frame Passenger seat and frame Starter relay and battery positive lead Starter relay and starter motor lead Thread size M6 M22 M8 M25 M6 M4 M12 M6 M10 M10 M10 M12 M10 M10 M10 M10 M6 M5 M6 M25 M25 M25 M10 M12 M12 M12 M12 M6 M5 M6 M8 M6 M6 M6 M6 M6 M6 SPEC Tightening torque Nm 10 130 28 3 7 2 32 10 30 19 40 78 45 64 48 30 7 4 7 100 7 100 48 50 50 59 59 7 4 7 16 7 7 7 7 7 7 mSkg 1.0 0.7 0.7 1.9 4.8 4.6 0.0 5.0 3.0 0.7 10.2 1.4 4.0 7.7 Remarks See NOTE 2-16 .7 0.0 2.9 5.9 0.8 3.7 0.0 13.8 5.7 0.7 10.

0 2.3 7. 2-17 . First.4 3.0 4.9 15.3 3.MAINTENANCE SPECIFICATIONS Part to be tightened g Rear fender side mold and rear fender stay Main switch and frame Sidestand bolt and nut Footrest bracket and frame Rear footrest and frame Rear master cylinder and rear brake bracket Rear master cylinder and brake hose joint Brake hose joint and brake hose Rear brake reservoir tank Union bolt (rear brake hose) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Front wheel axle Front wheel axle pinch bolt Rear wheel axle nut Front brake caliper Rear brake caliper Brake disc and wheel Caliper bleed screw Thread size M8 M8 M12 M10 M8 M8 M10 M10 M6 M10 M8 M8 M18 M8 M18 M10 M10 M8 M8 SPEC Remarks Tightening toque Nm 23 30 122 52 23 23 30 26 4 30 23 23 78 19 150 40 40 23 6 mSkg 2. tighten the ring nut approximately 52 Nm (5.0 4.6 NOTE: 1. then loosen the ring nut completely.3 2.2 5.0 2.3 2.0 2.8 1.0 12.3 0.2 2.3 3. Retighten the ring nut to specification.2 mSkg) by using the torque wrench.6 0. 2.

49 kΩ at 20_C Resin type 10 kΩ A.9 22 A 200 V Standard SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 2-18 .I.D.) T.C.71 X 14.T. short-circuit type SH678-11/SHINDENGEN 14.T.I.) Advanced timing (B.83 Ω at 20_C 10.000 r/min 0.D.341 Ω at 20_C/White – White Semi-conductor.C.: Pickup coil resistance/color T.C.C. magneto generator F4T655 /MITSUBISHI 14 V 29 A at 5.279 X 0. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Nominal output Stator coil resistance/color Rectifier/regulator: Type Model/manufacturer No load regulated voltage Capacity Withstand voltage 12 V 5_ at 1.000 r/min 189 X 231 Ω at 20_C/Gray/Black JT112/MITSUBISHI F6T541 /MITSUBISHI 6 mm 3.C.MAINTENANCE SPECIFICATIONS ELECTRICAL Item Voltage: Ignition system: Ignition timing (B.57 X 4.000 r/min 45_ at 5.1 X 14.

8 kW 10 mm 28 mm 0.62 Ω at 20_C Plane type (for EUR) Eddy type (for OCE) SPEC Limit SSS SSS SSS SSS SSS 5 mm 27 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Standard 2 YF-12/ NIKKO (for EUR) YFM-12 / NIKKO (for OCE) 3 A (for EUR) 4 A (for OCE) Full transistor type FE246BH/DENSO No 75 X 95 cycle/min 21 W 2 + 3.5 X 247.MAINTENANCE SPECIFICATIONS Item Battery: Specific gravity Electric starter system: Type Starter motor: Model/manufacturer I.D.4 4XY/DENSO 4XY/NIPPON SEIKI G8R-30Y-B/OMRON 202.5 Ω Yes G8R-30Y-J/OMRON 4XY/DENSO 2-19 .320 Constant mesh type SM-13/MITSUBA SM-13 0. number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model/manufacturer Amperage rating Coil winding resistance Horn: Type Quantity Model/manufacturer Maximum amperage Flasher relay: Type Model/manufacturer Self cancelling device Flasher frequency Wattage Oil level switch: Model/manufacturer Fuel sensor: Model/manufacturer Sidestand relay: Model/manufacturer Coil winding resistance Diode Fuel pump relay: Model/manufacturer Electric fan: Model/manufacturer 1.7 mm MS5F-441 /JIDECO 180 A 4.18 X 4.

MAINTENANCE SPECIFICATIONS Item Thermo switch: Model/manufacturer Thermo unit: Model/manufacturer Vacume actuator: Vacume pump: Circuit breaker: Type Amperage for individual circuit MAIN HEAD SIGNAL IGNITION FAN Back up (odometer) Cruse control Carburetor Audio DC outlet Reserve Reserve Reserve Reserve Standard 5EB/NIPPON THERMOSTAT 3YX/NIPPON SEIKI 4XY/MITSUBISHI 4XY/MITSUBISHI Fuse 30 A 15 A 15 A 10 A 10 A 10 A 10 A 10 A 10 A 5A 10 A 15 A 30 A 5A 1 1 1 1 1 1 1 1 1 2 2 1 1 1 SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 2-20 .

75 cm/sec. Normal and Metal 2-21 . Stereo for reproduction 4. 2-channel.MAINTENANCE SPECIFICATIONS AUDIO SYSTEM SPECIFICATIONS Item AM/FM Radio: Tuning Range: AM FM Intermediate Frequency: AM FM Bass Treb Amplifier: Output Power Auto-Vol.602 KHz 87.5 X 108 MHz 450 KHz 10.7 MHz "10dB/100 HZ "10dB/10KHz 14W x 4 (SP)/1W x 2 (HS) 5 steps 4Ω 8 Ω X 16 Ω Standard SPEC 4-track. Range Output Impedance: Speaker Headset Deck: Circuit System Tape Speed Taper 531 X 1.

tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. dry threads. tightening torque specifications require clean.0 ftSlb 4. Unless otherwise specified. To avoid warpage.5 8. Components should be at room temperature.5 13. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.3 11 22 40 61 94 22 mm 2-22 .6 1. A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm A: Distance between flats B: Outside thread diameter B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General torque specifications Nm 6 15 30 55 85 130 mSkg 0.0 5.GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00030 SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.5 3.

EX) Valve lifter Water pump impeller shaft Oil pump rotor (inner/outer). EX) Valve stem end (IN.LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Symbol Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Timing chain tensioner Valve stem (IN. housing Oil strainer assembly Idle gear surface Starter idle gear Starter idle gear shaft Starter clutch (outer/roller) Push rod ball Pressure plate bearing Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Shift pedal Shift lever joint Middle drive shaft (drive damper cam/driven damper cam) 2-23 .

contact surface Swingarm pivot shaft Swingarm pivot bearing Swingarm pivot oil seal Relay arm bearing (inner) Rear shock absorber bearing (inner) Connecting rod bearing (inner) Symbol 2-24 . contact surface Clutch lever bolt.LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 SPEC CHASSIS Lubrication Point Steering bearing (upper/lower) Steering bearing cover Steering lock Steering head pipe lower oil seal Front wheel oil seal (right/left) Rear wheel oil seal Clutch hub fitting area Rear brake pedal shaft Shift pedal Front footrest pivot Rear footrest pivot Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever pivot bolt.

COOLING SYSTEM DIAGRAMS EAS00033 SPEC COOLING SYSTEM DIAGRAMS 1 2 3 4 5 Radiator cap Thermostatic valve housing Radiator hose Radiator Water pump A To coolant reservoir tank. 2-25 .

LUBRICATION DIAGRAMS EAS00034 SPEC LUBRICATION DIAGRAMS 1 2 3 4 5 6 7 8 9 Camshaft (intake) Camshaft (exhaust) Water pump impeller shaft Water pump drive gear Main gallery Oil filter Crankshaft Oil strainer Oil pump 10 Main axle 11 Drive axle 2-26 .

LUBRICATION DIAGRAMS 1 2 3 4 SPEC Camshaft Main gallery Crankshaft Oil level switch 2-27 .

LUBRICATION DIAGRAMS 1 2 3 4 SPEC Main axle Drive axle Middle driven pinion gear Middle drive pinion gear 2-28 .

LUBRICATION DIAGRAMS 1 2 3 4 5 6 SPEC Crankshaft Oil pipe Oil filter Water pump drive gear Oil strainer Oil pump 2-29 .

H Fasten teh side stand switch lead. To rear brake switch Position the vacuum hose as shown. To regulator Fasten the wire harness with a plastic clamp. A B C D E F 2-30 . Fasten the side stand switch lead. G Align the projection downward. fan motor lead and noise filter lead with a plastic clamp.CABLE ROUTING EAS00035 SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Under cover (right) Cruise control unit Wire harness Radiator assembly Cruise control cable Vacuum actuator Sidestand switch lead Fan motor lead Noise filter lead Frame complete Fasten the wire harness with a plastic clamp. fan motor lead and noise filter lead with a plastic clamp.

fan motor lead and noise filter lead inside the pipe. 2-31 .CABLE ROUTING I Fasten the regulator lead with a steel clamp. L Route the side stand switch lead. N Route the cruise control cable and wire harness outside of the steel clamp. M Fasten the cruise control cable and wire harness with a plastic clamp. J Route the rear brake switch lead between the wire harness and cover. SPEC O Align the white mark on the rear brake switch lead with the metal clamp. fan motor lead and noise filter lead with a plastic clamp. K Fasten the side stand switch lead. Make sure that the leads are not come out of the pipe.

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 SPEC Antenna lead (with cover) Auxiliary terminal CD code Meter lead Hazard relay DC outlet lead Speaker lead Hazard relay lead Antenna lead Handlebar switch lead (right) Front brake switch lead Handlebar switch lead (left) Plastic clamp 14 15 16 17 18 19 20 21 22 23 24 25 26 Headlight harness Antenna lead Front head set lead Handlebar switch lead (left) Handlebar switch lead (right) Front brake switch lead Wire harness sub lead (right) Ground lead Headlight harness Meter lead Antenna lead (with cover) Handlebar switch lead (right) Front brake switch lead 27 28 29 30 31 32 33 34 35 36 37 Flasher relay Ground lead “CRUISE” switch lead Front brake switch lead Handlebar switch lead (left) CD cord 13P (green) CD cord (option) Auxiliary terminal lead Front remote controller 13P (blue) EXT lead 5P (white) Head set lead 5P (red) 2-32 .

L Fasten the headlight harness to the pipe with a plastic clamp.CABLE ROUTING A To the “CRUISE” switch. P To the headlight harness. K To the speedometer. O Fasten the handlebar switch lead (left and right) and front brake switch lead with a plastic clamp. F To headlight. C Fasten the headlight harness and handlebar switch (left and right) lead with a plastic clamp. G Fasten the audio coupler and headlight harness with a plastic clamp. N Connect the handlebar switch lead (right) with the headlight harness. SPEC J Fasten the headlight harness to the pipe with plastic clamp. 2-33 . Q Put the plug for CD cord under the cassette deck. M To the headlight (harness). B Connect the couplers with same color. E To the turn signal light. D Fasten the turn signal lead with a plastic clamp. I Fasten the handlebar switch lead (right) and front brake switch lead with a plastic clamp. H Fasten the meter lead and antenna harness with a plastic clamp.

T For installing the stay. Route the head light harness so that DIN cable set comes upper side. V At the white tape on the antenna lead attach a plastic clamp. U Put it under the cassette deck sideways. S Clamp the head light harness (right). SPEC 2-34 . do not catch the throttle cable. Not clamped.CABLE ROUTING R Align the ground lead paint mark and main harness sub lead with a plastic clamp.

CABLE ROUTING 1 2 3 4 5 6 7 SPEC Brake hose Clutch hose Handlebar switch lead (left) Remote controller lead Throttle cable Handlebar switch lead (right) Wire harness assembly A B C D E F G H I Pass the clutch hose through the guide. To the upper cowling. To the fan motor. To the thermo switch. To the ignition coil #2. To the engine stop switch. To the right under cowling. Fasten the ignition coil lead with a plastic clamp (with the end towards the under side of the motorcycle). To the left under cowling. 2-35 .

To the air cleaner. 2-36 .CABLE ROUTING 1 2 3 4 5 SPEC Wire harness Starter lead Brake hose Battery negative lead Wire harness A B C D E F G H To the rear fender. Fasten the starter lead with a plastic clamp (with the end towards the front side of the motorcycle). To the carburetor. From the radiator (breather hose). From the fuel tank (breather hose). To the wire harness. I Align the white mark on the wire harness with the plastic clamp (with the end towards the front side of the motor cycle). From the fuel tank.

To the horn. Fasten the wire harness with a plastic clamp (with the end towards the front side of the motorcycle).CABLE ROUTING J K L M N O Same rute with air cleaner drain hose. From the engine. From the coolant reservoir tank. P To the relay. SPEC 2-37 . Front the air cleaner.

Insert the hose through the metal clilp. To the under cowling. To the fuel tank. Fasten the wire harness sub lead with a plastic clamp. CD lead (option) and ground lead with a plastic clamp. To the upper cowling. Clamp the coolant hose inside of the motorcycle with hose clamp. To the AIS.CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 SPEC Plastic clamp Emergency stop switch Bolt (ground) Platic clamp Bolt (ground) Carburetor heater relay Flasher relay Thermo switch High tension code AIS hose Coolant reservoir hose A B C D E F G H I J K L Route the high tension cord throgh the guide on the air induction box. Fasten the audio lead. Route the audio lead tensely. 2-38 . Fasten the ground lead and engine stop switch lead. Fasten the audio lead and CD lead (option) with a plastic clamp.

W Fasten the high tension cord #1 and #3 with a plastic clamp. N Position the end of clamp to the rear side of the motorcycle. SPEC V To the coolant reservoir tank cap. T Fasten the wire harness with a plastic clamp. U To the rear fender. P Clamp the horn lead white mark and ground lead. 2-39 . flasher relay and thermo switch lead with a plastic clamp. R To the AIS.CABLE ROUTING M Position the end of clamp to the rear side of the motorcycle. Y Clamp the AIS hose as far as possible from the frame. Q Route the battery negative lead between the wire harness and pipe. O To the engine. S Fasten the wire harness. X Align the cover on the high tension cord with the clamp.

I Align the marking tape on the head set lead. E Position the throttle cable (return side) at inside of the cable holder. antenna lead and CB cord and fasten them. CD cord (option). B Route the head set lead to the switch cover on the fuel tank. antenna lead and head set lead with a plastic clamp. C Fasten the wire harness sub lead. D Fasten the throttle cable with a plastic clamp. K Clamp the speed sensor lead in the clip on the rear arms. At the cover on the antenna lead attach a clamp. H Fasten the speed sensor lead and wire harness. J Position the lead wires on the rear fender as shown. F Position the throttle cable (pull side) at outside of the cable holder. Align the wire harness sub lead and mark on the head set lead with the clamp. 2-40 . tail lead and DC outlet lead with a plastic clamp. G Route the wire harness with the frame guide (T-bar).CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 SPEC Front remote controller TPS lead Carburetor heater lead Speed sensor lead Main harness Fuel tank breather hose Audio lead Coolant reservoir hose Fuel hose (from fuel tank) Fuel hose (from fuel pump) AIS hose Breather hose Air cleaner case drain hose Wire harness Support stay A Connect the fuel sender lead on the fuel tank.

AC magneto lead. ignition coil sub lead and oil level gauge lead with a plastic clamp. M Fasten the speed sensor lead with a plastic clamp. T Fasten the starter lead. R From engine. fuel pump lead and fuse box lead with a plastic clamp. O Route the wire harness behind the igniter unit. N Turn the lead wire to clamp on the rear arm section.CABLE ROUTING L Fasten the speed sensor lead. Q From air cleaner case. pick up lead. P From coolant reservoir tank. neutral switch lead. U From fuel tank V Make sure that the sidestand switch lead has no loosening. S Route the hoses on the left side of the engine leads. SPEC 2-41 .

B’ To under cowling C’ Insert the hose through the metal clip. M’ So that the white painted mark is exposed to view. I’ Position the throttle cables do not outside of the carburetors. 2-42 . L’ Fasten the clutch hose and support stay with a plastic clamp (with the end towards the in side of the motorcycle). J’ To plastic clamp on the cross pipe. Z Fasten the sidestand switch lead with a metal band. K’ To wire harness assembly. SPEC G’ Insert the wire harness into the air induction box guide and hold it with clamp. throttle cable. E’ To upper cowling. X Fasten the side stand switch lead with a plastic clamp. A’ Fasten the clutch pipe with a plastic clamp.CABLE ROUTING W Fasten the side stand switch lead with a plastic clamp. F’ Fasten the wire harness sub lead. head set lead and clutch hose with a plastic clamp. D’ Through the brake hose in the guide wire. H’ Fasten the fuel hose on the carburetor with a plastic clamp. Y To under cowling.

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SPEC Fuel tank breather hose Bracket Head set lead CD code (option) Antenna lead Ground lead Wire harness Plastic clamp CD cord (option) DC outlet Screw Fuel sender lead Plastic clamp Wire harness Ground lead DC outlet 17 18 19 20 21 Tail/ brake light lead Head set lead CD cord (option) Antenna lead Plastic clamp A Fasten the handlebar switch lead (right) and clutch hose with a plastic clamp. main switch lead and fuel sender lead with a plastic clamp. E Be sure not to squeeze each leads. B Fasten the handlebar switch lead (right) with a plastic clamp. 2-43 . C Fasten the wirek harness. D Fasten the wire harness. main switch lead and ignition coil #4 lead with a plastic clamp.

CABLE ROUTING F Positon the clip end at upper. J Fix the connector with a clamp as shwon. V Fasten the handlebar switch lead (left). 2-44 . L Route the CD cord (option) outside the rear frame into the hole on the cover. fasten them with clamp. clutch hose and remote controler lead with a plastic clamp. K Route the wireharness between bracket and rear fender. N O P Q R S T SPEC Route the wire harness with the guide (T-bar). Route the antenna lead at the left side. H Route the tail / brake light lead through the hole in the cover at the back of the frame. Route the AIS hose between the carburetor joints. The protector section must be exposed. Fasten the handlebar switch lead and remote controller lead with a plastic clamp. U Route the ignition coil lead downward the main harness. Fasten the wire harness with a plastic clamp. To the fuel cock. I After routing the leads. M Make sure if the lead wires go to the left or right side. G Route the AIS hose through the clip.

CHK ADJ 3 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY . . CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC CLUTCH SYSTEM . . . . . CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS . . . . . . . . . . . . CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . CHECKING THE FINAL DRIVE OIL LEVEL . . . 3-6 SADDLEBAGS . . . . . . . . . . . . . . CHECKING THE CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT . 3-3 REMOVING THE FRONT COWLING COVER . . . . . . . . . CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 FUEL TANK . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 FRONT COWLING . . . . . . . ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 INSTALLING THE FRONT COWLING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK . . . CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-8 3-13 3-15 3-15 3-17 3-18 3-19 3-21 3-22 3-24 3-26 3-27 3-28 3-29 3-30 3-31 3-31 3-31 3-32 3-33 3-37 3-38 3-38 3-39 3-40 3-40 3-41 3-42 3-42 3-43 3-45 . . . . . . . . . . .CHK ADJ CONTENTS PERIODIC CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FINAL DRIVE OIL . . . . . . . . . . . . . . . 3-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . CHASSIS ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES . . . . . . . CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 RIDER AND PASSENGER SEATS . . . . . . . . . . 3-7 ENGINE . MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . .CHK ADJ ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAM . . LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES . . . 3-45 3-46 3-48 3-49 3-49 3-49 3-49 3-50 3-50 3-55 3-57 3-58 . . . . . . . . . . . . . . . . . . CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . CHECKING THE TIRES . . . . . .

S Check vlave clearance. S Replace if necessary. S Adjust if necessary. S Check tread depth and for damage. S Lubricate with molybdenum disulfide grease every 24. S Check operation. S Make sure that all nuts. S Check bearing play and steering for roughness. S Lubricate with molybdenum disulfide grease every 24.000 km or 6 months (whichever comes first) √ 12. S Check balance. S Replace if necessary. fluid level and vehicle for fluid leakage. regap or replace if necessary. PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EVERY NO. (See NOTE) S Correct accordingly. S Clean or replace if necessary. fluid level and vehicle for fluid leakage. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. S Replace brake pads if necessary. S Check condition.000 km or 24 months (whichever comes first). ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1.000 km or 24 months (whichever comes first). S Replace shock absorber assembly if necessary. S Check operation. runout and for damage.INTRODUCTION/PERIODICK MAINTENANCE AND LUBRICATION INTERVALS CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments.000 km) 6. S Correct if necessary. √ √ * Valves Air filter Every 42. S Correct accordingly. S Check operation. S Check bearing for looseness or damage. S Replace if necessary. S Check operation and for oil leakage. All service technicians should be familiar with this entire chapter. S Check condition. S Lubricate with lithium soap base grease every 24. a longer service life and reduce the need for costly overhaul work. S Check operation. (See NOTE) S Correct accordingly. S Check operation. (See NOTE) S Correct accordingly. these preventive maintenance procedures will ensure more reliable vehicle operation. If followed. S Tighten if necessary. fluid level and vehicle for fluid leakage. S Clean. S Replace if necessary. S Check operation. S Correct accordingly. S Check operation and shock absorber for oil leakage. S Rebalance or replace if necessary. bolts and screws are properly tightened.000 km or 42 months (whichever comes first) √ √ √ √ * Clutch 7 * Front brake √ √ √ 8 * Rear brake √ √ √ 9 * Wheels √ √ 10 * Tires √ √ 11 * Wheel bearings √ √ 12 * Swingarm √ √ 13 * Steering bearings √ √ 14 * 15 16 * 17 * 18 * Chassis fasteners Sidestand Sidestand switch Front fork Rear shock absorber assembly Rear suspension relay arm and connecting arm pivoting points √ √ √ √ √ √ √ √ √ √ √ √ 19 * 3-1 .000 km or 12 months (whichever comes first) √ √ √ √ √ 1 2 3 4 5 6 * * Fuel line Fuel filter Spark plugs S Check fuel hoses for cracks or damage. S Check air pressure. S Check swingarm pivoting point for play. S Replace brake pads if necessary. S Lubricate and repair if necessary. S Correct if necessary.000 km or 24 months (whichever comes first). S Replace if necessary.

caliper cylinder or clutch relase cylinder. S Replace the brake and clutch hoses every four yeras or if cracked or damaged.000 km or 6 months (whichever comes first) √ 12.000 km) 20 * Carburetors S Check engine idling speed. S Check oil level and vehicle for oil leakage. they should be serviced by a Yamaha dealer. D Hydraulic brake and clutch systems S After disassembling the master cylinder. S Check coolant level and vehicle for coolant leakage. S Change. synchronization and starter operation. data and technical skills. S Correct if necessary. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1. √ 21 22 23 * Engien oil Engine oil filter cartridge Cooling system √ √ √ √ √ √ √ 24 Final gear oil √ √ √ * Since these items require special tools. (Warm engine before draining. caliper cylinder and clutch release cylinder every two years.000 km or 24 months (whichever comes first). S Change coolant every 24. S Check oil level and vehicle for oil leakage. S Change oil at initial 1. NOTE: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. always replace the brake fluid. S Replace the oil seals on the inner parts of the master cylinder. S Correct if necessary.PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ EVERY 6. 3-2 . S Adjust if necessary.000 km and thereafter every 24. Check the brake fluid level of the master cylinder and clutch release cylinder regularly and fill as required.000 km or 24 months (whichever comes first).000 km or 12 months (whichever comes first) √ NO.) S Replace.

” 1 1 1 1/1/1 Disconnect 1 For installation. Refer to “REMOVING/INSTALLING THE FRONT COWLING COVER.FRONT COWLING FRONT COWLING CHK ADJ Order 1 2 3 4 5 6 Job/Part Removing the front cowling Front cowling chrome cover Wind shield Front cowling Headlight unit MCU lead/speedometer lead/ headlight lead Front pannel Q’ty 1 Remarks Remove the parts in the order listed. reverse the removal procedure. 3-3 .

INSTALLING THE FRONT COWLING COVER 1. lift up each side of the cowling cover 2 .FRONT COWLING CHK ADJ REMOVING THE FRONT COWLING COVER 1. Loosen the bolt 1 b. push the center portion of the cover 3 inward and lift the entire cover upward. Tighten the bolts 3 . b. Install S front cowling cover a. c. c. First. insert each side of the cowling cover 1 into the cowling. While pushing the center portion of the cowling cover 2 inward. Then. Remove S front cowling cover a. 3-4 . push downward to install. First.

1 2 1 1 For installation. reverse the removal procedure. 3-5 .RIDER AND PASSENGER SEATS EB302001 CHK ADJ RIDER AND PASSENGER SEATS Order Job/Part Removing the rider and passenger seats Rider seat Passenger seat Q’ty Remarks Remove the parts in the order listed.

7mSkg) 16 Nm (1. 3-6 . Refer to “RIDER AND PASSENGER SEATS”. turn the fuel cock “OFF”. For installation.FUEL TANK EB302002 CHK ADJ FUEL TANK 7 Nm (0. reverse the removal procedure.6mSkg) Order Job/Part Removing the fuel tank Rider seat Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 5 Top cover Fuel tank breather hose Fuel sender lead coupler Fuel hose Fuel tank 1 1 1 1 1 Disconnect Disconnect NOTE: Before disconnecting the hose.

SADDLEBAGS SADDLEBAGS 7.75 mSkg) 6.5 Nm (0. reverse the removal procedure. 3-7 .5 Nm (0.5 Nm (0.2 mSkg) Order 1 2 3 4 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the trunk and saddlebags 1 Antenna 1/1/1 Disconnect Antenna/trunk/wire harness lead 1 Trunk 2 Saddlebags For installation.65 mSkg) CHK ADJ 12 Nm (1.25 mSkg) 6.65 mSkg) 2.5 Nm (0.

Remove: S spark plugs S cylinder head cover 1 6. the piston must be at top dead center (TDC) on the compression stroke.11 X 0.16 X 0.20 mm 3-8 . Measure: S valve clearance Out of specification ! Adjust. S When the valve clearance is to be measured or adjusted. Remove: S rider seat S fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK”. 1. 3.15 mm Exhaust valve: 0.ADJUSTING THE VALVE CLEARANCE EAS00044 CHK ADJ ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. Disconnect: S spark plug leads S coolant hose 1 4. Drain: S coolant Refer to “CHANGING THE COOLANT”. S cylinder head stay S under cowling 2. Remove: S chrome cylinder head covers 2 5. at room temperature. NOTE: S Valve clearance adjustment should be made on a cold engine. Valve clearance (cold): Intake valve: 0. S air induction box S carburetor assembly Refer to “CARBURETOR” in CHAPTER 6.

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase cover. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thickness gauge 1 . NOTE: S If the valve clearance is incorrect, record the measured reading. S Measure the valve clearance in the following sequence.

Valve clearance measuring sequence Cylinder #1 ! #3 ! #2 ! #4
A Front d. For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table.

B Degrees that the crankshaft is turned counterclockwise C Cylinder D Combustion cycle

#3 Cylinder #2 Cylinder #4 Cylinder

180_ 430_ 610_

7. Adjust: S valve clearance a. Align he intake and exhaust valve lifter slots with each other. b. Position the tappet adjusting tool 1 between the camshaft and the valve lifter. Tappet adjusting tool: YM-33961, 90890-04105
3-9

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

NOTE: Make sure that the tappet adjusting tool touches only the valve lifter 2 , not the valve pad 3 . c. Slowly turn the tappet adjusting tool so that the valve pad can be removed. d. Remove the valve pad from the valve lifter with a small screwdriver and a pair of tweezers. Make a note of the position of each valve pad and valve pad number so they can be installed in the correct place. e. Select the proper valve pad from the following table. Valve pad thickness range No.200 X 2.00 X 320 3.20 mm Available valve pads 25 thickness in 0.05 mm increments

NOTE: S The thickness of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter (not the camshaft). S Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original.

3-10

ADJUSTING THE VALVE CLEARANCE
INTAKE
MEASURED CLEARANCE

CHK ADJ

0.00 X 0.05 0.06 X 0.10 0.11 X 0.15 0.16 X 0.20 0.21 X 0.25 0.26 X 0.30 0.31 X 0.35 0.36 X 0.40 0.41 X 0.45 0.46 X 0.50 0.51 X 0.55 0.56 X 0.60 0.61 X 0.65 0.66 X 0.70 0.71 X 0.75 0.76 X 0.80 0.81 X 0.85 0.86 X 0.90 0.91 X 0.95 0.96 X 1.00 1.01 X 1.05 1.06 X 1.10 1.11 X 1.15 1.16 X 1.20 1.21 X 1.25 1.26 X 1.30 1.31 X 1.35

INSTALLED PAD NUMBER 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 STANDARD CLEARANCE 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 255 260 265 270 275 280 285 290 295 300 305 310 315 320 260 265 270 275 280 285 290 295 300 305 310 315 320 265 270 275 280 285 290 295 300 305 310 315 320 VALVE CLEARANCE (cold): 270 275 280 285 290 295 300 305 310 315 320 0.11 X 0.15 mm 275 280 285 290 295 300 305 310 315 320 280 285 290 295 300 305 310 315 320 Example: Installed is pad 250 285 290 295 300 305 310 315 320 Measured clearance is 0.23 mm 290 295 300 305 310 315 320 Replace pad 250 with pad 260 295 300 305 310 315 320 Pad number: (example) 300 305 310 315 320 Pad No. 250 = 2.50 mm 305 310 315 320 Pad No. 260 = 2.60 mm 310 315 320 Always install pad with number down. 315 320 320

EXHAUST
MEASURED CLEARANCE

0.00 X 0.05 0.06 X 0.10 0.11 X 0.15 0.16 X 0.20 0.21 X 0.25 0.26 X 0.30 0.31 X 0.35 0.36 X 0.40 0.41 X 0.45 0.46 X 0.50 0.51 X 0.55 0.56 X 0.60 0.61 X 0.65 0.66 X 0.70 0.71 X 0.75 0.76 X 0.80 0.81 X 0.86 0.86 X 0.90 0.91 X 0.95 0.96 X 1.00 1.01 X 1.05 1.06 X 1.10 1.11 X 1.15 1.16 X 1.20 1.21 X 1.25 1.26 X 1.30 1.31 X 1.35 1.36 X 1.40

200 205 210 215 200 200 205 200 205 210 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

220 205 210 215 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

225 210 215 220 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

230 215 220 225 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

235 220 225 230 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320

INSTALLED PAD NUMBER 240 245 250 255 260 265 270 275 280 285 290 295 300 305 225 230 235 240 245 250 255 260 265 270 275 280 285 290 230 235 240 245 250 255 260 265 270 275 280 285 290 295 235 240 245 250 255 260 265 270 275 280 285 290 295 300 STANDARD CLEARANCE 245 250 255 260 265 270 275 280 285 290 295 300 305 310 250 255 260 265 270 275 280 285 290 295 300 305 310 315 255 260 265 270 275 280 285 290 295 300 305 310 315 320 260 265 270 275 280 285 290 295 300 305 310 315 320 265 270 275 280 285 290 295 300 305 310 315 320 270 275 280 285 290 295 300 305 310 315 320 275 280 285 290 295 300 305 310 315 320 280 285 290 295 300 305 310 315 320 285 290 295 300 305 310 315 320 290 295 300 305 310 315 320 295 300 305 310 315 320 300 305 310 315 320 305 310 315 320 VALVE CLEARANCE (cold): 310 315 320 0.16 X 0.20 mm 315 320 Example: Installed is pad 250 320

310 295 300 305

315 320 300 305 305 310 310 315

315 320 320

Measured clearance is 0.32 mm Replace pad 250 with pad 265 Pad number: (example) Pad No. 250 = 2.50 mm Pad No. 265 = 2.65 mm Always install pad with number down.

3-11

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

f. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10

EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm) Rounded value = 250 g. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. h. Install the new valve pad with the numbered side facing down. i. Remove the tappet adjusting tool. j. Measure the valve clearance again. k. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 8. Install: S all removed parts NOTE: For installation, reverse the removal procedure. Note the following points. 9. Install: S cylinder head cover
10 Nm (1.0 mSkg)

S spark plugs 18 Nm (1.8 mSkg) S chrome cylinder head cover
10 Nm (1.0 mSkg)

S cylinder head stay
64 Nm (6.4 mSkg)

S carburetor assembly S air induction box S under cowling S fuel tank S rider seat
3-12

SYNCHRONIZING THE CARBURETORS
EAS00050

CHK ADJ

SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: S vacuum plugs

3. Install: S adapters S vacuum gauge 1 S engine tachometer 2 (to the spark plug lead of cyl. #1) Vacuum gauge YU-08030-A, 90890-03094 Engine tachometer YU-08036-A, 90890-03113 4. Start the engine and let it warm up for several minutes. 5. Check: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 950 X 1,050 r/min 6. Adjust: S carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same.

3-13

SYNCHRONIZING THE CARBURETORS

CHK ADJ

NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.

b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same. Vacuum pressure at engine idling speed 37 kPa (280 mmHg) NOTE: The difference in vacuum pressure between two carburetors should not exceed 1.33 kPa (10.0 mmHg).

7. Check: S engine idling speed Out of specification ! Adjust. 8. Stop the engine and remove the measuring equipment. 9. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm 10. Install: S vacuum plugs

3-14

ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY
EAS00053

CHK ADJ

ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: S engine tachometer (to the spark plug lead of cyl. #1) Engine tachometer YU-08036-A,90890-03113 3. Check: S engine idling speed Out of specification !I! Adjust. 4. Adjust: S engine idling speed Engine idling speed 950 X 1,050 r/min

a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a ! Engine idling speed is increased. Direction b ! Engine idling speed is decreased. 5. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm
EAS00055

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly.
3-15

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK ADJ

1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm 2. Remove: S rider seat S fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK”. 3. Adjust: S throttle cable free play a. Loosen the lock nut 1 on the throttle cable. b. Loosen the lock nut 2 on the cruise control cable. c. Turn the adjusting nut 3 in direction a or b to take up any slack on the throttle cable. Direction a ! Throttle cable free play is increased. Direction b ! Throttle cable free play is decreased. d. Tighten the lock nut 1 . e. Turn the adjusting nut 4 in direction c or d to take up any slack on the cruise control cable. Direction c ! Cruise control cable free play is increased. Direction d ! Cruise control cable free play is decreased. Cruise control cable free play 1 X 2mm f. Tighten the lock nut 2 .

WARNING
Adjusting only on the carburetor side cannot obtain the specified throttle cable free. So the adjustment on the handlebar side also has to be done. Handlebar side a. Loosen the locknut 7 . b. Turn the adjuster 8 in direction a or b until the specified throttle cable free play is obtained.
3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS

CHK ADJ

Direction a ! Throttle cable free play is increased. Direction b ! Throttle cable free play is decreased. c. Tighten the locknut.

WARNING
After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

WARNING
Pay attention to the mark on throttle cable (1) and throttle rotor (2), when installing. Refer to ”HANDLEBAR” in chapter 7. 4. Check: S throttle grip movement Stroke the cruise control wire, when throttle grip movement. 5. Install: S fuel tank S rider seat Refer to “FUEL TANK” and “RIDER AND PASSENGER SEATS”.
EAS00059

CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: S spark plug cap 2. Remove: S spark plug

CAUTION:
Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 3. Check: S spark plug type Incorrect ! Change. Spark plug type (manufacturer) DPR8EA-9 (NGK) X24EPR-U9 (DENSO) 4. Check: S electrode 1 Damage/wear ! Replace the spark plug. S insulator 2 Abnormal color ! Replace the spark plug. Normal color is a medium-to-light tan color.
3-17

CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING

CHK ADJ

5. Clean: S spark plug (with a spark plug cleaner or wire brush) 6. Measure: S spark plug gap a (with a wire gauge) Out of specification ! Regap. Spark plug gap 0.8 X 0.9 mm 7. Install: S spark plug

18 Nm (1.8 mSkg)

NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: S spark plug cap

EAS00064

CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion.

1. Remove: S timing plug 1

2. Install: S timing light 1 S engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light YU-33277-A, 90890-03141 Engine tachometer YU-08036-A, 90890-03113

3-18

CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE
3. Check: S ignition timing

CHK ADJ

a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 950 X 1,050 r/min b. Check that the stationary pointer a is within the firing range b on the generator rotor. Incorrect firing range ! Check the ignition system. NOTE: The ignition timing is not adjustable.

4. Remove: S timing light S engine tachometer 5. Install: S timing plug 1

EAS00065

MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Check: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: S spark plug cap

3-19

MEASURING THE COMPRESSION PRESSURE
4. Remove: S spark plug

CHK ADJ

CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.

5. Install: S compression gauge 1 Compression gauge YU-33223, 90890-03081 6. Measure: S compression pressure Above the maximum pressure ! Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure ! Squirt a few drops of oil into the affected cylinder and measure again. S Refer to the following table. Compression pressure (with oil applied in the cylinder) Reading Higher than without oil Same as without oil Diagnosis Piston wear or damage ! Repair. Piston ring(-s), valves, cylinder head gasket or piston possibly defective ! Repair.

Compression pressure (at sea level) Standard: 1,520 kPa (15,2 kg/cm2, 15.2 bar) Minimum: 1,300 kPa (13,0 kg/cm2, 13.0 bar) Maximum: 1,700 kPa (17,0 kg/cm2, 17.0 bar)

3-20

MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL

CHK ADJ

a. Turn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

WARNING
To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa

7. Install: S spark plug

18 Nm (1,8 mSkg)

8. Connect: S spark plug cap

EAS00071

CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b . Below the minimum level mark ! Add the recommended engine oil to the proper level. Recommended oil: Yamalube 4 (10W–30) or SAE 10W–30 type SE motor oil Yamalube 4 (20W–40) or SAE 20W–40 type SE motor oil
3-21

CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL
CAUTION:

CHK ADJ

S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. S Do not allow foreign materials to enter the crankcase. NOTE: API Service “SE”, “SF” and “SG” type or equivalent (e.g., “SF-SE”, “SF-SE-CC”, “SF-SE-SD”) 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
EAS00073

CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt.

3. Remove: S engine oil filler cap 1 S engine oil drain bolt 2 4. Drain: S engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure.

a. Remove the rectifier/regulator 1

3-22

CHANGING THE ENGINE OIL

CHK ADJ

a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench YU-38411, 90890-01426

b. Apply a thin coat of engine oil onto the O-ring 3 of the new oil filter cartridge.

CAUTION:
Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.

c. Tighten the new oil filter cartridge 1 to specification with an oil filter wrench 2 . Oil filter cartridge 17 Nm (1.7 mSkg) 6. Check: S engine oil drain bolt gasket Damage ! Replace. 7. Install: S engine oil drain bolt
43 Nm (4.3 mSkg)

8. Fill: S crankcase (with the specified amount of the recommended engine oil) Quantity Total amount 4.3 L Without oil filter cartridge replacement 3.5 L With oil filter cartridge replacement 3.7 L 9. Install: S engine oil filler cap

3-23

CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE

CHK ADJ

10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 13. Check: S engine oil pressure a. Slightly loosen the oil gallery bolt 1 . b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “CHECKING THE OIL PUMP” in chapter 4. d. Start the engine after solving the problem(-s) and check the engine oil pressure again. e. Tighten the oil gallery bolt to specification. Oil gallery bolt 5 Nm (0.5 mSkg)

EAS00077

MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off.

CAUTION:
When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine.

3-24

MEASURING THE ENGINE OIL PRESSURE
3. Remove: S main gallery bolt 1

CHK ADJ

WARNING
The engine, muffler and engine oil are extremely hot.

4. Install: S oil pressure gauge 1 S adapter 2 Oil pressure gauge 90890-03153 Adapter 90890-03124 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 250 X 350 kPa (2.5 X 3.5 kg/cm2, 2.5 X 3.5 bar) Engine speed Approx. 5,000 r/min Engine oil temperature 100_C Out of specification ! Adjust. Engine oil pressure Possible causes

Faulty oil pump Clogged oil filter Below specification Leaking oil passage Broken or damaged oil seal Leaking oil passage Faulty oil filter Above specification Oil viscosity too high 6. Install: S main gallery bolt
12 Nm (1.2 mSkg)

3-25

CHECKING THE CLUTCH FLUID LEVEL
EAS00083

CHK ADJ

CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper level. Recommended clutch fluid Brake fluid DOT 4

WARNING
S Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. S Refill with the same type of clutch fluid that is already in the system. Mixing clutch fluids may result in a harmful chemical reaction, leading to poor clutch performance. S When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock.

CAUTION:
Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reservoir is horizontal.

3-26

NOTE: S Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to overflow. e. S a clutch hose was loosened or removed. Ignoring this precaution could allow air to enter the hydraulic clutch system. h. make sure that there is always enough clutch fluid before applying the clutch lever. S If bleeding is difficult. Add the recommended clutch fluid to the proper level. it may be necessary to let the clutch fluid settle for a few hours. Tighten the bleed screw to specification.BLEEDING THE HYDRAULIC CLUTCH SYSTEM EAS00084 CHK ADJ BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING Bleed the hydraulic clutch system whenever: S the system was disassembled. j. Place the other end of the hose into a container. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Add the recommended clutch fluid to the proper level. Bleed screw 6 Nm (0. Bleed: S hydraulic clutch system a. g. considerably lengthening the bleeding procedure. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. Refer to “CHECKING THE CLUTCH FLUID LEVEL”. b. f. S clutch operation is faulty. Fully squeeze the clutch lever without releasing it. Slowly squeeze the clutch lever several times. i. 1.6 mSkg) k. 3-27 . This will release the tension and cause the clutch lever to contact the handlebar grip. Install the clutch master cylinder reservoir diaphragm. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the clutch fluid in the plastic hose. S the clutch fluid level is very low. c. d. Loosen the bleed screw. S When bleeding the hydraulic clutch system. Tighten the bleed screw and then release the clutch lever. Remove: S left rear cylinder side cover 1 2.

check the clutch operation. 3-28 . EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S air filter case 1 3. Clean: S air filter element Apply compressed air to the inner surface of the air filter element.BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT WARNING CHK ADJ After bleeding the hydraulic clutch system. Check: S air filter element Damage ! Replace. Remove: S under cover 1 2. Remove: S air filter case cover 4. Remove: S air filter element 5. 6.

Unfiltered air will cause rapid wear of engine parts and may damage the engine. S Make sure that the air filter is installed with its mesh side facing towards the rear of the motorcycle.CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 7. leading to poor engine performance and possible overheating. Install: S air filter element S air filter case cover CHK ADJ CAUTION: Never operate the engine without the air filter element installed. Connect: S breather hoses EAS00095 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the carburetor joints and intake manifolds. 1. 3-29 . Refer to “CARBURETOR” in CHAPTER 6. Operating the engine without the air filter element will also affect the carburetor tuning. 8. Check: S carburetor joint 1 S intake manifold 2 Cracks/damage ! Replace. Install: S air filter case 9. NOTE: S Make sure that the air filter element is properly installed in the air filter case.

5. 2. S fuel filter 2 Damage/dirt ! Replace. Install: S left side cover S right side cover 3-30 .CHECKING THE FUEL HOSES AND FUEL FILTER EAS090097 CHK ADJ CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. NOTE: S Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. Install: S rear inner cover 6. S The arrow mark a on the fuel filter should face to the side of the fuel pump 3 . Check: S fuel hose 1 Cracks/damage ! Replace. Remove: S rear inner cover 4. Remove: S left side cover S right side cover 3.Remove: S rider seat S fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK”. 1.

CAUTION: Make sure that the crankcase breather hose is routed correctly. 2. Install: S fuel tank S rider seat Refer to “FUEL TANK” and “RIDER AND PASSENGER SEAT”.CHECKING THE FUEL HOSE AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM / CHECKING THE COOLANT LEVEL CHK ADJ 7. S gasket 3 Exhaust gas leaks ! Replace.0 mSkg) Exhaust pipe bolt 5 25 Nm (2. Loose connection ! Connect properly. Check: S tightening torque Exhaust pipe nut 4 20 Nm (2.0 mSkg) EAS00102 CHECKING THE COOLANT LEVEL 1.5 mSkg) Muffler and muffler bracket bolt 6 30 Nm (3. 2. Stand the motorcycle on a level surface. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. 1. S Make sure that the motorcycle is upright. EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes.0 mSkg) Muffler bolt 7 20 Nm (2. mufflers and gaskets. Check: S crankcase breather hose 1 Cracks/damage ! Replace. NOTE: S Place the motorcycle on a suitable stand. Remove: S side cover right 1 3-31 .

Install: S under cowling S fuel tank S rider seat Refer to “FUEL TANK” and “RIDER AND PASSENGER SEATS”. 5. S under cowling. Soft water may be used if distilled water is not available. Install: S side cover right EAS00104 CHECKING THE COOLING SYSTEM 1. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level marks b . Remove: S rider seat S fuel tank Refer to “SEATS” and “FUEL TANK”. Start the engine. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 Cracks/damage ! Replace. 6. and then turn it off. Refer to “COOLING SYSTEM” in CHAPTER 5. If water is used instead of coolant. 2. CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. 3. 3-32 . wait a few minutes until it settles. check and correct the antifreeze concentration of the coolant. 4.CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ 3. Below the minimum level mark ! Add the recommended coolant to the proper level. Check: S coolant level NOTE: Before checking the coolant level. S Use only distilled water. warm it up for several minutes.

open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly rotate the radiator cap counterclockwise toward the detent to allow any residual pressure to escape.CHANGING THE COOLANT EAS00105 CHK ADJ CHANGING THE COOLANT 1. Remove: S rider seat S fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK”. Remove: S left side cover S right side cover S rear inner cover 3. Remove: S reservoir tank 1 Drain the reservoir tank of its coolant. 3-33 . Scalding hot fluid and steam may be blown out. and then remove it. while still pressing down turn it counterclockwise. do-not remove the radiator cap when the engine is hot. Remove: S cylinder side covers 5. 2. 4. Remove: S radiator cap 1 WARNING A hot radiator is under pressure. which could cause serious injury. When the engine has cooled. press down on the radiator cap. Therefore. When the hissing sound has stopped. The following procedure applies to all of the coolant drain bolts and copper washers.

3 mSkg) 11. Drain: S coolant (from the engine and radiator) 9. Install: S drain plugs (cylinders) S coolant drain bolt (radiator) 25 Nm (0. 10. Remove: S drain plugs (cylinders) 1 Drain the coolant. Fill: S cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mix ratio 50 % antifreeze/50 % water 3-34 . NOTE: To remove the drain plug (cylinder) screw a spark plug into the threaded hole and pull on the spark plug. 8. Remove: S coolant drain bolt (radiator) 1 (along with the copper washer) S coolant drain bolt (water pump) 2 (along with the copper washer) 7.CHANGING THE COOLANT CHK ADJ 6.25mSkg) S coolant drain bolt (water pump) 43 Nm (4. Check: S rubber washer 1 (coolant drain bolt-radiator 2) S copper washer 3 (coolant drain bolt-water pump 4 ) Damage ! Replace.

S If coolant is swallowed. If water is used instead of coolant. Soft water may be used if distilled water is not available. quickly wash it away with water and then with soap and water.CHANGING THE COOLANT CHK ADJ Quantity Total amount 3. S Do not mix different types of antifreeze. check. CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. thoroughly wash them with water and consult a doctor.25 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care. and if necessary. immediately wash them with water. 12. correct the antifreeze concentration of the coolant. Install: S radiator cap 3-35 .84 L From minimum to maximum level mark 0. induce vomiting and get immediate medical attention. S If coolant comes into contact with painted surfaces. S Use only distilled water. WARNING S If coolant splashes in your eyes. S If coolant splashes on your clothes.5 L Coolant reservoir capacity 0.

Start the engine. Check: S coolant level Refer to “CHECKING THE COOLANT LEVEL”. Turn off the engine and inspect the coolant level. 3-36 . and then turn it off. Refer to “CHECKING THE COOLANT LEVEL”.CHANGING THE COOLANT CHK ADJ 13. wait a few minutes until the coolant has settled. 16. 20. Install: S coolant reservoir cap 15. wait a few minutes until it settles. 17. NOTE: Before checking the coolant level. Install: S rear inner cover S right side cover S left side cover 18. Start the engine and let it warm up for several minutes. Install: S fuel tank S rider seat Refer to “FUEL TANK” and “RIDER AND PASSENGER SEATS”. NOTE: Before inspecting the coolant level. 19. Fill: S coolant reservoir (with the recommended coolant to the maximum level mark a ) 14. warm it up for several minutes.

Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. the air must be removed by bleeding the brake system. Adjust: S brake pedal position a. Brake pedal position (below the top of the rider footrest) 100 mm 2. Tighten the locknut 1 to specification. Locknut 26 Nm (2. c.6 mSkg) WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. WARNING After adjusting the brake pedal height. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Before the vehicle is operated. 3-37 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. check that the adjuster end b is in the center of the projections a . inspect and. bleed the brake system. Direction b ! Brake pedal is lowered.ADJUSTING THE REAR BRAKE EAS00111 CHK ADJ CHASSIS ADJUSTING THE REAR BRAKE 1. Direction a ! Brake pedal is raised. make sure that there is no brake drag. CAUTION: After adjusting the brake pedal position. if necessary. 3. Loosen the locknut 1 . Therefore.

Therefore. leading to poor brake performance. Stand the motorcycle on a level surface. NOTE: In order to ensure a correct reading of the brake fluid level. S When refilling. 1.CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE BRAKE PADS A EAS00115 CHK ADJ CHECKING THE BRAKE FLUID LEVEL 1. be careful that water does not enter the reservoir. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Operate the brake. causing leakage and poor brake performance. make sure that the top of the reservoir is horizontal. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. Mixing brake fluids may result in a harmful chemical reaction. Recommended brake fluid DOT 4 A Front brake B Rear brake B WARNING S Use only the designated brake fluid. EAS00118 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. Other brake fluids may cause the rubber seals to deteriorate. 3-38 . always clean up any spilt brake fluid immediately. CAUTION: Brake fluid may damage painted surfaces and plastic parts. 2. S Refill with the same type of brake fluid that is already in the system.

Adjustment is correct when the brake light comes on by depressing the brake pedal less than 3 X 8 mm. the cruise control cannot be canceled. 3-39 . Direction a ! Brake light comes on sooner. Check: S front brake pad S rear brake pad Wear indicators 1 almost touch the brake disc. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Replace the brake pads as a set. A Front brake B Rear brake B EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. 2. Adjust: S rear brake light operation timing a. Direction b ! Brake light comes on later. Refer to “FRONT AND REAR BRAKES” in CHAPTER 7.CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH A CHK ADJ 2. CAUTION: S When on adjustment of the brake light switch is wrong. 1. Check: S rear brake light operation timing Incorrect ! Adjust. the period of time to cancel the cruise control is shortened S When the brake light comes on too late. S When the brake light comes on too early. the cruise control is not operated correctly.

3-40 . Brake fluid leakage ! Replace the damaged hose. S If bleeding is difficult. 3. 2. make sure that there is always enough brake fluid before applying the brake. S When bleeding the hydraulic brake system. Check: S brake hose Activate the brake several times. 4. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. S brake operation is faulty. it may be necessary to let the brake fluid settle for a few hours. Check: S brake hose clamp Loose connection ! Tighten. 1. Check: S brake hose Cracks/damage/wear ! Replace. Hold the motorcycle upright and apply the brake. Ignoring this precaution could allow air to enter the hydraulic brake system. EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: S the system was disassembled. considerably lengthening the bleeding procedure. NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHK ADJ CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. Refer to “FRONT AND REAR BRAKES” in CHAPTER 7. S a brake hose was loosened or removed. S the brake fluid level is very low.

check the brake operation. WARNING After bleeding the hydraulic brake system. c.BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL 3-41 CHK ADJ 2. Tighten the bleed screw and then release the brake lever or brake pedal. Fill the reservoir to the proper level. h. This will release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. Loosen the bleed screw. Bleed screw 6 Nm (0. b.8 mm 3-41 . A Front B Rear d. j. Refer to “CHECKING THE BRAKE FLUID LEVEL”. Slowly apply the brake several times. Tighten the bleed screw to specification. Connect a clear plastic hose 1 tightly to the bleed screw 2 . If the position is incorrect ! Adjust. i. Check: S shift pedal position Check the shift pedal rod length a . e. g. Place the other end of the hose into a container. EAS00136 ADJUSTING THE SHIFT PEDAL 1. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. f. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). Bleed: S hydraulic brake system a.6 mSkg) k. Add the recommended brake fluid to the proper level. Shift pedal rod length: 26.

NOTE: S Place the motorcycle on a suitable stand. Place a container under the final drive housing. 2. 3-42 . Check: S final drive oil level The final drive oil level should be to the bottom brim 2 of the filler hole. Direction a ! Shift pedal is raised. 2.3 mSkg) EAS00145 CHANGING THE FINAL DRIVE OIL 1. Direction b ! Shift pedal is lowered. Below the bottom brim ! Add the recommended final drive oil to the proper level. “GL-5” or “GL-6” or multi-purpose SAE 80W 90 hypoid gear oil 4. 3.ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL 2. Recommended final drive oil SAE 80 hypoid gear oil graded “GL-4”. Adjust: S shift pedal position CHK ADJ a. S Tighten both locknuts. S Make sure that the motorcycle is upright. Install: S final drive housing oil filler bolt 23 Nm (2. b. EAS00144 CHECKING THE FINAL DRIVE OIL LEVEL 1. Loosen both locknuts 1 . Stand the motorcycle on a level surface. Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position. Remove: S final drive housing oil filler bolt 1 S final drive housing oil drain bolt 2 Completely drain the final drive housing of its oil. Check: S final drive housing oil drain bolt gasket Damage ! Replace. Remove: S final drive housing oil filler bolt 1 3.

Remove: S handlebar 1 5.CHANGING THE FINAL DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 23 Nm (2. EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Loosen S upper bracket pinch bolts 1 6. Remove S steering stem nut 2 S upper bracket 3 3-43 . Stand the motorcycle on a level surface. Fill: S final drive housing (with the specified amount of the recommended final drive oil) Quantity 0.3 mSkg) 4. 4. 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Remove: S front cowling Refer to “FRONT COWLING”. Looseness or binding ! Adjust the steering head. 3. WARNING Securely support the motorcycle so that there is no danger of it falling over. Install: S final drive housing oil drain bolt 5.2 L Refer to “CHECKING THE FINAL DRIVE OIL LEVEL”.

Refer to “STEERING HEAD AND HANDLEBAR” in CHAPTER 7. Install the upper ring nut 7 . Finger tighten the upper ring nut. Lower ring nut (final tightening torque) 3 Nm (0. Check the steering head for looseness or binding by turning the front fork all the way in both directions. NOTE: Set the torque wrench at a right angle to the ring nut wrench. Remove the lock washer 1 . hold the lower ring nut and tighten the upper ring nut until their slots are aligned. Install the lock washer 8 . Loosen the lower ring nut 4 completely.2 mSkg) c. b. Install: S upper bracket S steering stem nut 130 Nm (13. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . then align the slots of both ring nuts. remove the lower bracket and inspect the upper and lower bearings. NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b . If necessary. and the rubber washer 3 . Ring nut wrench YU-33975. e.3 mSkg) d. Adjust: S steering head CHK ADJ a.0 mSkg) 3-44 . the upper ring nut 2 . 90890-01403 Lower ring nut (initial tightening torque) 52 Nm (5. h. WARNING Do not overtighten the lower ring nut. g.CHECKING AND ADJUSTING THE STEERING HEAD 7. Install the rubber washer 6 . then tighten it to specification. f. If any binding is felt. 8.

4. Unsmooth operation ! Repair. Stand the motorcycle on a level surface. Refer to “FRONT FORK” in CHAPTER 7. Hold the motorcycle upright and apply the front brake. 0 X 0.CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBRY CHK ADJ 9. 0 X 4. WARNING Securely support the motorcycle so that there is no danger of it falling over.5 bar) Rear 0 X 400 kPa (0 X 4. Check: S inner tube Damage/scratches ! Replace. EAS00156 ADJUSTING THE FRONT AND SHOCK ABSORBER ASSEMBLY REAR WARNING Securely support the motorcycle so that there is no danger of it falling over. 3. S oil seal Oil leakage ! Replace. Check: S shock absorber air pressure A Front B Rear Out of specification → Adjust Air pressure Front 0 X 50 kPa (0 X 0.0 kgf/cm2. 2. Check: S operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.0 bar) 3-45 .5 kgf/cm2. Install: S front cowling EAS00149 CHECKING THE FRONT FORK 1. A B 1.

NEVER OVERLOAD THE MOTORCYCLE. 2. 1. Measure: S tire pressure Out of specification ! Regulate.50 kgf/ (2. 2. S The tire pressure and the suspension must be adjusted according to the total weight including cargo.CHECKING THE TIRES / CHECKING THE FRONT FORK /ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBRY EAS00166 CHK ADJ CHECKING THE TIRES The following procedure applies to both of the tires.50 kgf/ 2. S Operation of an overloaded motorcycle could cause tire damage. passenger and accessories WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit.50 bar) cm2. 2.80 bar) 250 kPa 280 kPa (2. 3-46 .50 bar) cm 250 kPa 280 kPa (2. rider. Basic weight (with oil and 394 kg full fuel tank) Maximum load* Cold tire pressure Up to 90 kg load* 90 kg X maximum load* High speed riding 190 kg Front tire Rear tire 250 kPa 250 kPa (2.80 kgf/ cm2.80 bar) *: total of cargo. 2. 2. replace the tire immediately. passenger and accessories) and the anticipated riding speed. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. rider. an accident or an injury.80 kgf/ cm2.50 kgf/ (2. 2.50 bar) cm2.50 bar) cm2.50 kgf/ (2.

FRONT TIRE: Manufacturer BRIDGESTONE DUNLOP REAR TIRE: Manufacturer BRIDGESTONE DUNLOP 3-47 A B Size 150/80-16 71H 150/80-16 71H Type G705 D404F Size 150/90B15M/C 74H 150/90B15M/C 74H Type G702 D404 . S When using tube tires. for this model. If it is absolutely necessary to do so.CHECKING THE TIRES CHK ADJ 2.. Check: S tire surfaces Damage/wear ! Replace the tire. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. S To avoid pinching the tube. The front and rear tires should always be by the same manufacturer and of the same design. Ltd.0 mm 1 2 3 Tire tread depth Side wall Wear indicator WARNING S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. S Patching a punctured tube is not recommended. the tires listed below have been approved by Yamaha Motor Co. be sure to install the correct tube. use great care and replace the tube as soon as possible with a good quality replacement. make sure that the wheel rim band and tube are centered in the wheel groove. A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire S After extensive tests. Minimum tire tread depth 1. S Always replace a new tube tire and a new tube as a set.

ride conservatively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. S After a tire has been repaired or replaced. NOTE: After a tire or wheel has been changed or replaced. be sure to tighten the tire valve stem locknut 1 to specification. S Align the mark 2 with the valve installation point. Tire valve stem locknut 1. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle. Check: S wheel Damage/out-of-round ! Replace. NOTE: For tires with a direction of rotation mark 1 : S Install the tire with the mark pointing in the direction of wheel rotation.CHECKING THE TIRES/CHECKING THE WHEELS WARNING CHK ADJ S After mounting a new tire. WARNING Never attempt to make any repairs to the wheel.16 mSkg) EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. always balance the wheel.6 Nm (0. 3-48 .

Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device. Check: S cable sheath Damage ! Replace. 1. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Check: S cable operation Unsmooth operation ! Lubricate. Recommended lubricant Engine oil EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Engine oil EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension.CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS / LUBRICATINGTHE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHK ADJ CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Molybdenum disulfide grease 3-49 . 2. Replace damaged cable sheaths and cables as soon as possible.

take special care when charging the battery. S DO NOT SMOKE when charging or handling batteries.CHECKING AND CHARGING THE BATTERY EAS00178 CHK ADJ ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. S Charge batteries in a well-ventilated area. welding equipment. charging amperage and charging voltage for a MF battery are different from those of conventional batteries. S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. the electrolyte level will drop considerably. If the battery is overcharged. The MF battery should be charged as explained in the charging method illustrations. CAUTION: S This is a sealed battery. Therefore..g. lighted cigarettes). Therefore. Internal Drink large quantities of water or milk followed with milk of magnesia. beaten egg or vegetable oil. Get immediate medical attention. S KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. 3-50 . S Keep batteries away from fire. sparks or open flames (e. S EYES – Flush with water for 15 minutes and get immediate medical attention. First aid in case of bodily contact: External S SKIN – Wash with water. always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charging time.

8 V. the voltage when the positive terminal is disconnected). then the positive lead 2 . as shown in the charts and the following example.CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed. the charge of the battery has to be checked by measuring the voltage at the battery terminals. Example c.e.. S No charging is necessary when the open-circuit voltage equals or exceeds 12. Remove: S rider seat Refer to “RIDER SEATS”.0 V d. 3. Open-circuit voltage = 12. Charge of the battery = 20 X 30 % 3-51 . Charging time = 6. it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Remove: S battery 4. Disconnect: S battery leads (fron the battery terminals) CAUTION: First.5 hours e. b. Check: S battery charge a. 2. 1. disconnect the negative lead 1 . Therefore. Check he charge of the battery. Connect a pocket tester to the battery terminals. Tester positive lead ! battery positive terminal Tester negative lead ! battery negative terminal NOTE: S The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.

) S To reduce the chance of sparks. CAUTION: S Make sure that the battery breather hose and battery vent are free of obstructions. disconnect the negative lead from the battery terminal. Therefore. be sure to turn off the battery charger. be careful not to overcharge the battery. 3-52 . (If charging has to be done with the battery mounted on the motorcycle. do not plug in the battery charger until the battery charger leads are connected to the battery. S Do not use a high-rate battery charger. Charge: S battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. S Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corrected battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. be sure to remove it from the motorcycle. wait 30 minutes after charging is completed before measuring the open-circuit voltage. S When charging a battery. disconnect the battery charger and let the battery cool before reconnecting it. S Never remove the MF battery sealing caps. Hot batteries can explode! S As shown in the following illustration. S If the battery becomes hot to the touch at any time during the charging process.CHECKING AND CHARGING THE BATTERY CHK ADJ 5. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger. the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. S Before removing the battery charger lead clips from the battery terminals.

replace the battery. readjust the voltage to obtain the standard charging current.8 V or more – Charging is complete. NOTE: Set the charging voltage at 16 X 17 V. it is advisable to check he charging current after a lapse of 5 hours. If there is any charge in the amperage. (If the setting is lower. Make sure that current is higher than the standard charging current written on the battery. set the charging voltage at 20 X 25 V.7 V or less – Recharging is required. In case that charging requires more than 5 hours. the battery will be over-charged.0 V – Replace the battery. If the current does not exceeds standard charging current after 5 minutes. 12. YES Monitor the amperage for 3 X 5 minutes to check if the standard charging current is reached.) YES NO By turning the charging voltage adjust dial. Refer to “Battery condition checking steps”. Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes. NO Set the timer according to the charging time suitable for the open-circuit voltage. CHK ADJ NOTE: Voltage should be measured 30 minutes after the machine is stopped.CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Measure the open-circuit voltage prior to charging. If too high. 12. charging will be insufficient. Connect a charger and AMP meter to the battery and start charging. 3-53 . Under 12. Adjust the voltage so that current is at standard charging level.

YES Make sure the current is higher than the standard charging current written on the battery.8 V or more – Charging is complete. Measure the battery open-circuit voltage after having left the battery unused for more than 30 minutes. 3-54 . 12. This type of battery charger cannot charge the MF battery. Connect a charger and AMP meter to the battery and start charging. Under 12. NOTE: Set the charging time at 20 hours (maximum). 12. CHK ADJ NOTE: Voltage should be measured 30 minutes after the machine is stopped. A variable voltage charger is recommended.CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging. NO Charge the battery until the battery’s charging voltage is 15 V.0 V – Replace the battery.7 V or less – Recharging is required. Charging method using a constant-current type charger This type of battery charger cannot charge the MF battery.

CAUTION: To avoid a short circuit. Connect: S battery leads (to he battery terminals) CAUTION: First. EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. Lubricate: S battery terminals Recommended lubricant Dielectric grease 11. Remove: S side cover left 2. Check: S fuse 3-55 . 10.CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Check: S battery terminals Dirt ! Clean with a wire brush. then the negative lead 2 . Install: S rider seat Refer to “RIDER AND PASSENGER SEAT”. Install: S battery CHK ADJ 8. 7. Loose connection ! Connect properly. Check: S battery. 9. 1. Damage ! Replace. always turn the main switch to “OFF” when checking or replacing a fuse. connect the positive lead 1 .

c. cause the lighting and ignition systems to malfunction and could possibly cause a fire. NOTE: Set the pocket tester selector to “Ω Pocket tester YU-03112. If the fuse immediately blows again. Replace: S blown fuse a. Amperage rating 30 A 15 A 15 A 10 A 10 A 10 A 30 A 15 A 10A 5A 1”. Install a new fuse of the correct amperage rating. If the pocket tester indicates “∞”. replace the fuse. Turn on the switches to verify if the electrical circuit is operational. b. 90890-03112 b.CHECKING THE FUSES CHK ADJ a. 3. d. Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Digital clock fuse Radiator fan fuse Reserve fuse Quantity 1 1 1 1 1 1 1 1 2 1 WARNING Never use a fuse with an amperage rating other than that specified. Turn off the ignition. 3-56 . Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system. check the electrical circuit. Connect the pocket tester to the fuse and check it for continuity.

3-57 . Remove: S headlight unit 2. the life of the bulb and the luminous flux will be adversely affected. thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil. Remove: S headlight bulb holder 1 5. Install: S side cover left CHK ADJ EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot. 6. otherwise the transparency of the glass.REPLACING THE HEADLIGHT BULB 4. If the headlight bulb gets soiled. Install: S headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder. Disconnect: S headlight leads 1 3. keep flammable products and your hands away from the bulb until it has cooled down. Remove: S bulb cover 2 4.

Direction a ! Headlight beam is raised. 3-58 . Install: S bulb cover 9. Turn the adjusting knob 1 in direction a or b. Install: S headlight bulb holder 8. Adjust: S headlight beam (vertically) a. Direction b ! Headlight beam is lowered.REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Install: S headlight unit CHK ADJ EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Connect: S headlight leads 10.

ENG 4 .

. . . . . . . 4-24 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLERS AND EXHAUSTS . CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENG CONTENTS ENGINE ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT SPROCKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR AND AIS . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CLUTCH RELEASE CYLINDER . . . . . . . REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS . . . . . . . . . . . . INSTALLING THE ENGINE . . . . . . . 4-24 INSTALLING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . CABLES AND HOSES . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH MASTER CYLINDER . . 4-26 4-27 4-28 4-30 4-32 4-32 4-33 4-35 4-35 4-37 4-38 4-38 4-43 4-43 4-44 4-44 4-46 4-47 4-49 4-49 4-50 4-50 4-50 4-50 . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES . . . . . . . . . . . . . . . . CLUCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS . . . . 4-1 4-1 4-3 4-4 4-5 4-6 4-8 4-9 4-9 4-11 4-12 4-14 4-16 4-16 4-17 CYLINDER HEADS . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONERS . . . . . . . . . . REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . 4-23 CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . CHECKING THE TIMING CHAINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH . . . . . . . . . . CHECKING THE FRICTION PLATES . . . . . ASSEMBLYNG THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . CYLINDER HEAD COVERS . . . CLUCH COVER . . . . . . . . . . . . . . . . CHECKING THE CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN AND BRAKE PEDAL . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING . . CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . CHECKING THE CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . LEADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . INSTALLING THE PISTON AND CONNECTING RODS . . . . . . . . . . REMOVING THE GENERATOR . CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER . . . . . . . . . . CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP . . . . . . . . . . . . . CRANKSHAFT . INSTALLING THE OIL GALLERY PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH AND GENERATOR . . . . . . . . . STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN . . . . CHECKING THE BALANCER SHAFT . . . . . INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENG CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . ASSEMBLING THE CRANKCASE . . 4-51 CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . 4-51 INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL GALLERY PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT . . . . . . ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 4-54 4-56 4-56 4-56 4-57 4-57 4-59 4-60 4-60 4-61 4-62 4-65 4-65 4-66 4-66 4-66 4-66 4-67 4-67 4-68 4-68 4-69 4-72 4-73 4-74 4-77 4-78 4-78 4-82 4-86 4-86 4-87 4-88 4-89 4-90 4-92 4-93 4-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN . . . . . . . . STATOR COIL . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENG TRANSMISSION . . . . . . . . ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . ADJUSTING THE MIDDLE GEAR BACKLASH . . . . . . . . . . ALIGNING THE MIDDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT FORKS . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE GEAE . . . . . DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . 4-98 4-101 4-101 4-102 4-102 4-103 4-103 4-104 4-106 4-107 4-107 4-108 4-108 4-109 4-111 4-113 . . . . . . . CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . . . CHECKING THE BEARINGS AND OIL SEALS . . . ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . .

ENG .

Stand the motorcycle on a level surface. cables and hoses Q’ty Remarks Disconnecting the parts in the order listed. fuel tank 4-1 . CABLES AND HOSES 64 Nm (6.ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL LEADS. Drain Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3. Drain Refer to “CHARGING THE COOLANT” in CHAPTER 3.4 mSkg) Order Job/Part Disconnecting the leads. Engine oil Drain Refer to “CHARGING THE ENGINE OIL” in CHAPTER 3. WARNING Securely support the motorcycle so there is no danger of it falling over. Coolant Clutch fluid Rider seat.

reverse the disconnection procedure. disconnect the negative lead. Disconnect Disconnect 2 3 4 5 6 7 8 9 10 Battery Cylinder head stays Spark plug leads Hoses (coolant) Side covers (left and right) Rear inner cover Plastic shroud Under covers Air cleaner box 1 2 4 2 2 1 1 2 2 Disconnect For connecting.4 mSkg) Order 1 Battery leads Job/Part Q’ty 2 Remarks Disconnect NOTE: First.ENGINE REMOVAL ENG 64 Nm (6. then the positive lead. 4-2 .

4-3 . For EUR. Refer to “RADIATOR” in CHAPTER 5. For installation.ENGINE REMOVAL RADIATOR AND AIS ENG Order 1 2 3 4 5 6 7 Job/Part Removing the radiator and AIS Radiator Engine guards and horn (left and right) Starter lead AIS pipe Reed valve Air cutoff valve Air cleaner Q’ty 1 2 1 2 1 1 1 Remarks Remove the parts in the order listed. reverse the removal procedure.

0 mSkg) 30 Nm (3. 4-4 .ENGINE REMOVAL MUFFLERS AND EXHAUSTS ENG 30 Nm (3. 1 2 3 4 5 6 7 4 2 4 4 1 1 2 Disconnect Refer to “CLUTCH RELEASE CYLINDER”.0 mSkg) 20 Nm (2. reverse the removal procedure.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Removing the mufflers and exhausts Carburetors Air induction box Cylinder side covers Muffler assemblies Exhaust pipes Copper gaskets Shift pedal link Clutch release cylinder AIS pipe Q’ty Remarks Remove the parts in the order listed. Refer to “CARBURETORS” in CHAPTER 6.0 mSkg) 25 Nm (2. For installation.5 mSkg) 20 Nm (2.

For installation. reverse the removal procedure. Disconnect For OCE. For OCE.ENGINE REMOVAL HORN AND BRAKE PEDAL ENG 52 Nm (5.2 mSkg) Order 1 2 3 4 5 6 Job/Part Removing the Horn and brake pedal Horn leads Horn Ground lead Spring (rear brake switch) Reservoir tank (rear brake) Brake pedal assembly Q’ty 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Disconnect Refer to “FRONT AND REAR BRAKES” in CHAPTER 7. 4-5 .

5 mSkg) 75 M10 30 (4) 40 Nm (4.0 mSkg) M10 70 (6) 40 Nm (4. WARNING Securely support the motorcycle so there is no danger of it falling over. . NOTE: Place a suitable stand under the frame and engine. 1 2 3 4 5 6 7 8 Rear brake switch leads Rear brake switch Rectifier/regulator coupler Rear brake hose protector Bolts (engine bracket) Bolts (front-lower/upper) Bolts (down tube) Down tube (right side) 4-6 2 1 1 1 6 4 4 1 Disconnect Disconnect Refer to “INSTALLING THE ENGINE”.8 mSkg) M12 45 Nm (4.0 mSkg) M10 70 (4) Order Job/Part Removing the engine Q’ty Remarks Remove the parts in the order listed.ENGINE REMOVAL ENGINE ENG 78 Nm (7.

0 mSkg) M10 70 (6) 40 Nm (4. 4-7 . For installation. reverse the removal procedure.ENGINE REMOVAL ENG 78 Nm (7.0 mSkg) M10 70 (4) Order 9 10 11 Job/Part Engine bracket Bolts (rear) Engine assembly Q’ty 1 2 1 Remarks Refer to “INSTALLING THE ENGINE”.5 mSkg) 75 M10 30 (4) 40 Nm (4.8 mSkg) M12 45 Nm (4. NOTE: Remove the engine assembly from the right side of the motorcycle.

Bolts (rear) 1 78 Nm (7. Install: S bolts (rear) 1 S down tube (right) 2 S engine bracket 3 S rear brake switch S bolts (front-lower) 4 S bolts (front-upper) 5 S cylinder head stay 6 NOTE: Do not fully tighten the bolts 3. Install: S shift arm 1 10 Nm (1. Bolts (front-upper) 5 40 Nm (4.5 mSkg) 3.0 mSkg) 4. Bolts (cylinder head stay) 6 64 Nm (6. Tighten the bolts in the following order.0 mSkg) 6. Down tube (right) 2 45 Nm (4. S Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.8 mSkg) 2. 4-8 . Engine bracket 3 40 Nm (4.0 mSkg) NOTE: S Align the punch mark a in the shift shaft with the slot b in the shift arm. Install: S engine assembly (from the right side of the motorcycle) 2.4 mSkg) 4. Bolts (front-lower) 4 40 Nm (4. 1.0 mSkg) 5.ENGINE REMOVAL EAS00192 ENG INSTALLING THE ENGINE 1.

Refer to “CARBURETORS” in CHATER 6.0 mSkg) M6 30 (4) 10 Nm (1.CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVERS ENG 18 Nm (1. Drain Refer to “CHANGING THE COOLANT” in CHAPTER 3. Refer to “CLEANING THE AIR FILTER” in CHAPTER 3. 4-9 .0 mSkg) M6 14 (12) 10 Nm (1.8 mSkg) 10 Nm (1. Stand the motorcycle on a level surface.0 mSkg) M6 23 (16) Order Job/Part Removing the cylinder head covers Q’ty Remarks Remove the parts in the order listed. WARNING Securely support the motorcycle so there is no danger of it falling over. Rider seat and fuel tank Air filter case Carburetors Cylinder head stay Coolant Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3.

0 mSkg) M6 23 (16) Order 1 2 3 4 5 6 7 Job/Part Spark plug caps Coolant hoses (to cylinder head) Chrome cylinder head covers Spark plugs Bolts (cylinder head covers) Cylinder head covers Gaskets (cylinder head covers) Q’ty 4 2 8 4 16 2 2 Disconnect Disconnect Remarks For installation.0 mSkg) M6 14 (12) 10 Nm (1.8 mSkg) 10 Nm (1.CAMSHAFTS ENG 18 Nm (1.0 mSkg) M6 30 (4) 10 Nm (1. reverse the removal procedure. 4-10 .

1 2 3 4 5 6 7 8 9 10 1 1 2 2 2 4 8 16 4 4 Refer to “REMOVING/INSTALLING THE CAMSHAFTS”. 4-11 .0 mSkg) 28 M6 40 (32) 12 Nm (1. reverse the removal procedure. Refer to “CYLINDER HEAD COVERS”.7 mSkg) M6 12 (2) Order Job/Part Removing the camshafts Cylinder head covers Crankcase cover plate Timing plug Cap bolts (tensioners) Timing chain tensioners Gaskets Timing chain guides (metal and rubber) Bolts (camshaft sprockets) Camshaft caps Camshafts (intake and exhaust) Camshaft sprockets Q’ty Remarks Remove the parts in the order listed.0 mSkg) M6 10 Nm (1.0 mSkg) M7 12 (8) 7 Nm (0. For installation.2 mSkg) M6 20 (4) 20 Nm (2.CAMSHAFTS CAMSHAFTS ENG 20 Nm (2.

Turn the crankshaft counterclockwise. Remove: S timing chain guide (exhaust side) 1 S camshaft caps (#2) 2 4-12 . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. Remove: S spark plugs S cylinder head cover S gasket (cylinder head cover) NOTE: Loosen each bolt 1/4 of a turn in a crisscross pattern. remove them. When piston #1 is at TDC on the compression stroke.CAMSHAFTS EAS00201 ENG REMOVING THE CAMSHAFTS Rear cylinder head 1. 4. align the “–” and “I” marks a with the stationary pointer b . Remove: S timing chain tensioner 2 S gasket 6. b. Align: S “–” and “I” marks on the generator rotor (with the stationary pointer on the crankcase cover) a. After all the bolts are loosened. Remove: S crankcase cover plate 1 S timing plug 2 3. Loosen: S cap bolt 1 5. 2.

9. loosen the camshaft cap bolts in stages and in a crisscross pattern. Remove: S intake camshaft S exhaust camshaft NOTE: To prevent the timing chain from falling into the crankcase. working from the outside in. NOTE: When loosening the camshaft cap bolts. 8. camshafts or camshaft caps. Remove: S camshaft sprocket bolts Hold the camshaft with a 22 mm wrench. 10. Remove: S camshaft sprockets 4-13 . Remove: S camshaft caps CAUTION: To prevent damage to the cylinder head. fasten it with a wire to it.CAMSHAFTS ENG 7. make sure that the camshaft lobes do not touch the valve lifters.

.e. Measure: S camshaft runout Out of specification ! Replace.CAMSHAFTS Front cylinder head ENG NOTE: When removing the front cylinder camshafts. Turn: S crankshaft NOTE: From the “–” and “I” marks. 360_ plus an additional 70_). 2. Camshaft lobe dimension limit Intake a 35. Camshaft runout Less than 0. However. Align: S “–” mark (with the stationary pointer) EB401401 CHECKING THE CAMSHAFTS 1.85 mm 3. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the camshaft. repeat the rear cylinder camshaft removal procedure.85 mm Exhaust a 35.03 mm 4-14 . note the following points.65 mm b 27.65 mm b 27. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Replace the camshaft. 2. turn the crankshaft counterclockwise 430_ (i. 1.

Camshaft-journal-to-camshaftcap clearance 0.054 mm a. c. Camshaft cap bolt 10 Nm (1. Remove the camshaft caps and then measure the width of the Plastigauge® 1 . 5. Within specification ! Replace the cylinder head and the camshaft caps as a set. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern. Camshaft journal diameter 24. Position a strip of Plastigauge® 1 onto the camshaft journal as shown.967 X 24.980 mm 4-15 . Install the dowel pins and camshaft caps. working from the inner caps out. Measure: S camshaft journal diameter a Out of specification ! Replace the camshaft. b. S Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®.CAMSHAFTS ENG 4. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). Measure: S camshaft-journal-to-camshaft-cap clearance Out of specification ! Measure the camshaft journal diameter.0 mSkg) d.020 X 0.

Check: S cap bolt S copper washer S spring S one-way cam S gasket S timing chain tensioner rod Damage/wear ! Replace the defective part(-s). Check: S one-way cam operation Rough movement ! Replace the timing chain tensioner housing. 1. AND TIMING CHAIN GUIDES The following procedure applies to all of the timing chains. 3. 1. EAS00211 CHECKING THE TIMING CHAIN TENSIONERS The following procedure applies to both of the timing chain tensioners. 4-16 . camshaft sprockets. 3.CAMSHAFTS EAS00209 ENG CHECKING THE TIMING CHAINS. 2. Check: S timing chain guide (exhaust side) S timing chain guide (intake side) S timing chain guide (top side) Damage/wear ! Replace the defective part(-s). Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and its respective camshaft sprockets as a set. Check: S timing chain tensioner Cracks/damage ! Replace. CAMSHAFT SPROCKETS. Check: S camshaft sprocket Damage/wear ! Replace the respective camshaft sprockets and the respective timing chain as a set. and timing chain guides. 2.

then the intake camshaft. Install: S intake camshaft S exhaust camshaft CAUTION: Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing. 4-17 . install the exhaust camshaft. install the rear cylinder camshafts. “IN” mark = intake camshaft “EX” mark = exhaust camshaft. align the “–” and “I” marks 1 on the generator rotor with the crankcase edge 2.CAMSHAFTS EAS00218 ENG INSTALLING THE CAMSHAFTS 1. NOTE: First. Then. Install the camshaft sprockets onto the camshafts. camshaft sprockets. S Make sure that the timing marks a (o: small hole) in the camshaft face up. b. NOTE: Make sure that the “REAR” marks a on the camshaft sprockets face away from the “IN” b and “EX” marks c on the camshafts. First. Rear cylinder 1. install the front cylinder camshafts and related parts. Refer to the camshaft sprocket installation steps below. Turn the crankshaft counterclockwise. CAUTION: Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. timing chain. Align: S “–” and “I” marks on the generator rotor (with the crankcase edge) a. NOTE: S Be sure to install the camshafts in the correct place as sown. b. When piston #1 is at TDC on the compression stroke. a. and timing chain tensioner.

f. exhaust camshaft cap #2. CAUTION: Do not turn the camshaft. S Remove the wire from the timing chain.CAMSHAFTS ENG S Be sure to keep the timing chain as tight as possible on the exhaust side. d. 2. #3. camshaft lobes. e.0 mSkg) g. NOTE: At this point. and finally #4. #1. do not install intake camshaft cap #2. Camshaft cap bolt 10 Nm (1. as damage could occur to the pistons and valves. Apply engine oil onto the camshaft bearing surfaces. Align the mark a on the camshaft with the mark b camshaft cap. and the timing chain guide (top side). NOTE: Cylinder #1 is at TDC when the small hole in the camshaft is aligned with the camshaft cap mark. NOTE: S The camshaft caps are numbered from right to left. Install intake and exhaust camshaft caps #1. S First. c. Install: S intake camshaft sprocket S exhaust camshaft sprocket (onto the camshafts) 4-18 . and finally #4. working from the inner caps out. and camshafts will result. tighten intake and exhaust camshaft cap bolts #3. Tighten the camshaft cap bolts. camshaft caps. Apply engine oil onto the threads of the camshaft cap bolts. CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head. and camshaft journals. S Tighten the camshaft cap bolts in stages and in a crisscross pattern.

f. and then finger tighten the camshaft sprocket bolts. NOTE: Align the “EX” mark hole in the exhaust camshaft sprocket with the thread hole in the camshaft. i. To remove the timing chain slack.CAMSHAFTS CAUTION: ENG Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve. j. NOTE: Align the “IN” mark a hole in the intake camshaft sprocket with the thread hole in the camshaft. Insert your finger into the timing chain tensioner hole and push the timing chain guide (intake side) in. b. 4-19 . g. Install the intake camshaft sprocket with the “REAR” mark facing out. If the camshaft cap marks and camshaft timing marks are not aligned. h. change the meshing position of the camshaft sprockets and timing chain. Turn the intake camshaft so that the camshaft timing mark 1 (o: small hole) is aligned with the camshaft cap mark 2 . k. d. Place the timing chain onto the exhaust camshaft sprocket. Turn the exhaust camshaft so that the mark (o: small hole) on the camshaft is aligned with the mark on the camshaft cap. Install the exhaust camshaft sprocket with the “REAR” mark facing out. When pushing the timing chain guide (intake side). To remove the timing chain slack. c. make sure that the camshaft cap marks and camshaft timing marks stay aligned. force the exhaust camshaft clockwise. and then finger tighten the camshaft sprocket bolts. a. e. Place the timing chain onto the intake sprocket. force the intake camshaft counterclockwise.

CAMSHAFTS 3.0 mSkg) 4. Install: S timing chain tensioner ENG a. c. Cap bolt 20 Nm (2. WARNING Always use a new gasket. washer 2 . washer 2 and spring 3 . Release the timing chain tensioner one-way cam 4 . Install the spring 3 . Timing chain tensioner bolt 12 Nm (1. S camshaft timing punch mark c (o: small hole) Make sure hat the punch marks in the camshafts are aligned with the marks d on the camshaft caps. Remove the cap bolt 1 . 4-20 . Check: S TDC mark a Make sure that the TDC mark on the generator rotor is aligned with the crankcase edge b. Out of alignment ! Adjust.2 mSkg) d. Install the timing chain tensioner 5 and gasket 6 onto the cylinder block. Turn: S crankshaft (several turns counterclockwise) 5. and cap bolt 1. Refer to the camshaft installation steps above. b.

0 mSkg) CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 360_ plus an additional 70_). note the following points.0 mSkg) S timing chain guide (exhaust side) 4 10 Nm (1. b.CAMSHAFTS 6. align the “–” mark a with the crankcase edge b . Tighten: S camshaft sprocket bolts ENG 20 Nm (2. 7. 1. Lubricate: S timing chain S camshaft sprockets S camshafts S valve pads Recommended lubricant Engine oil Front cylinder NOTE: When installing the front cylinder camshafts.e.0 mSkg) 8. Install: S exhaust camshaft S intake camshaft a. 4-21 . turn the crankshaft counterclockwise 430_ (i.. However. When piston #2 is at TDC on the compression stroke. From the “–” and “I” marks. repeat the rear cylinder camshaft installation procedure. Install: S camshaft caps “I-2” 1 S camshaft caps “E-2” 2 S timing chain guide (top side) 3 10 Nm (1.

2.CAMSHAFTS ENG c.7 mSkg) 4-22 . and then finger tighten the camshaft sprocket bolts. b. Refer to the camshaft sprocket installation steps below. c. Install: S timing mark accessing screw 1 S crankshaft end cover 2 7 Nm (0. Refer to “ADJUSTING THE VALVE CLEARANCE” in CHAPTER 3. Install the camshaft sprocket with the “FRONT” mark facing out. Install the camshaft sprockets onto the camshafts. Install: S intake camshaft sprocket S exhaust camshaft sprocket (onto the camshafts) a. Align the “–” mark a on the generator rotor with the crankcase edge b . NOTE: Make sure that the “FRONT” marks 1 on the camshaft sprockets face away from the “IN” 2 and “EX” marks 3 on the camshafts. d. Measure: S valve clearance Out of specification ! Adjust. Turn the intake and exhaust camshafts and align the camshaft timing marks c (o: big hole) with the camshaft cap marks d . Turn the camshafts by hand so that the camshaft timing marks (o: big hole) face up. 4. 3.

1 2 3 4 5 6 7 2 2 2 2 2 2 4 Refer to “INSTALLING THE CYLINDER HEADS”. Refer to “ENGINE REMOVAL”. 4-23 . reverse the removal procedure.0 mSkg) M10 30 Nm (3. Refer to “CAMSHAFTS”.CYLINDER HEADS CYLINDER HEADS ENG 30 Nm (3.0 mSkg) 28 30 Nm (3.0 mSkg) M8 22 (2) Order Job/Part Removing the cylinder heads Engine assembly Cylinder head covers Camshafts Lock pins Water jacket joints Oil delivery pipes Cylinder heads Timing chain dampers Gaskets (cylinder heads) Dowel pins Q’ty Remarks Remove the parts in the order listed. For installation.

Place a 400 X 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. S timing chain damper Damage/wear ! Replace. rotate the cylinder head several times. Cylinder head warpage Less than 0. c. Check: S cylinder head Damage/scratches ! Replace. 1. b. Eliminate: S carbon deposits (from the combustion chambers with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: S spark plug threads S valve seats 2. NOTE: To ensure an even surface. Measure the warpage. Measure: S cylinder head warpage Out of specification ! Resurface the cylinder head.03 mm a. If the limited is exceeded. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. S cylinder head water jacket 1 Mineral deposits/rust ! Eliminate. resurface the cylinder head as follows. Install: S dowel pins 1 S gasket (New) 2 S timing chain guide (exhaust side) 3 4-24 . d. EAS00235 INSTALLING THE CYLINDER HEADS Rear cylinder 1.CYLINDER HEADS EAS00230 ENG CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 3.

Install: S cylinder head 1 ENG 43 Nm (4.3 mSkg) S washers NOTE: S To prevent the timing chain 2 from falling into the crankcase.CYLINDER HEADS 2. 1. Install: S cylinders nuts 4-25 . note the following points. Front cylinder NOTE: When installing the front cylinder head. However. fasten it with a wire. S Install the timing chain guide (intake side) into the timing chain guide slot in the cylinder head. repeat the rear cylinder head installation procedure. S Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern.

VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS

ENG

Order

Job/Part Removing the valves and valve springs Engine assembly Camshafts Cylinder heads Valve pads Valve lifters Valve cotters Valve spring retainers Valve springs (inner/outer) Valves (intake/exhaust) Valve spring seats Oil seals Valve guides

Q’ty

Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL”. Refer to “CAMSHAFTS”. Refer to “CYLINDER HEADS”.

1 2 3 4 5 6 7 8 9

16 16 32 16 16/16 8/8 16 16 16

Refer to “REMOVING/INSTALLING THE VALVES”.

For installation, reverse the removal procedure.

4-26

VALVES AND VALVE SPRINGS
EAS00237

ENG

REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: S valve pad 1 S valve lifter 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Check: S valve sealing Leakage at the valve seat ! Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. a. Pour a clean solvent a into the intake and exhaust ports. b. Check that the valves properly seal. There should be no leakage at the valve seat 1.

3. Remove: S valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor YM-04019, 90890-04019 Attachment YM-01253-1, 90890-04114

4-27

VALVES AND VALVE SPRINGS
4. Remove: S upper spring seat 1 S valve springs 2 S oil seal 3 S lower spring seat 4 S valve 5

ENG

NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
EAS00239

CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: S valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a X Valve stem diameter b Out of specification ! Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 X 0.037 mm Limit: 0.08 mm Exhaust 0.025 X 0.052 mm Limit: 0.1 mm 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C in an oven.

4-28

VALVES AND VALVE SPRINGS

ENG

a. Remove the valve guide with a valve guide remover 1 .

b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 .

c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (6.0 mm): YM-4064-A, 90890-04064 Valve guide installer (6.0 mm): YM-04065-A, 90890-04065 Valve guide reamer (6.0 mm): YM-04066, 90890-04066

3. Eliminate: S carbon deposits (from the valve face and valve seat) 4. Check: S valve face Pitting/wear ! Grind the valve face. S valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve.

4-29

VALVES AND VALVE SPRINGS

ENG

5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 1.15 X 1.45 mm <Limit>: 0.7 mm 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always replace the oil seal. Valve stem runout <Limit>: 0.01 mm
EAS00240

CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: S carbon deposits (from the valve face and valve seat) 2. Check: S valve seat Pitting/wear ! Replace the cylinder head. 3. Measure: S valve seat width a Out of specification ! Replace the cylinder head. Valve seat width Intake: 0.9 X 1.1 mm <Limit>: 1.4 mm Exhaust: 0.9 X 1.1 mm <Limit>: 1.4 mm a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the valve seat and valve face contacted one another, the blueing will have been removed.

4-30

VALVES AND VALVE SPRINGS
4. Lap: S valve face S valve seat

ENG

NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

a. Apply a coarse lapping compound a to the valve face.

CAUTION:
Do not let the lapping compound enter the gap between the valve stem and the valve guide.

b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head.

d. Turn the valve unit the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression.

4-31

VALVES AND VALVE SPRING

ENG

j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length inner (IN, EX) 37.3 mm <Limit>: 35.3 mm outer (IN, EX) 39.45 mm <Limit>: 37.25 mm 2. Measure: S compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force (installed) inner (IN, EX) 4.57 X 5.37 kg outer (IN, EX) 10.1 X 11.9 kg 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit inner (IN, EX) 2.5_/1.6 mm outer (IN, EX) 2.5_/1.7 mm
EAS00242

CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: S valve lifter Damage/scratches ! Replace the valve lifters and cylinder head.

4-32

VALVES AND VALVE SPRING
EAS00245

ENG

INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: S valve stem end (with an oil stone)

2. Lubricate: S valve stem 1 S oil seal 2 New (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil

3. Install: S valve 1 S lower spring seat 2 S oil seal 3 New S valve spring 4 S upper spring seat 5 (into the cylinder head)

NOTE: Install the valve spring with the larger pitch a facing up.
b Smaller pitch

4. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor YM-04019, 90890-04019 Attachment YM-01253-1, 90890-04114
4-33

VALVES AND VALVE SPRINGS

ENG

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

CAUTION:
Hitting the valve tip with excessive force could damage the valve.

6. Install: S valve lifter 1 S valve pad 2 NOTE: S Apply molybdenum disulfide oil onto the valve lifter and valve pad. S The valve lifter must move smoothly when rotated with a finger. S Each valve lifter and valve pad must be reinstalled in its original position.

4-34

CLUTCH CLUTCH
CLUTCH MASTER CYLINDER

ENG

10 Nm (1.0 mSkg)

30 Nm (3.0 mSkg)

Order

Job/Part Removing the clutch master cylinder

Q’ty

Remarks Remove the parts in the order listed. NOTE: Before removing the master cylinder, drain the clutch fluid from the entire clutch system.

1 2 3 4 5 6 7 8 9 10

Rear view mirror Front remote controller Coupler (clutch switch) Clutch lever Holder (push rod) Union bolt Copper washers Clutch hose Master cylinder Clutch switch

1 1 1 1 1 1 2 1 1 1

Disconnect

Refer to “INSTALLING THE CLUTCH MASTER CYLINDER”.

For installation, reverse the removal procedure.
4-35

CLUTCH

ENG

Order

Job/Part Disassembling the clutch master cylinder Master cylinder cap Holder (diaphragm) Diaphragm Push rod Dust boot Circlip Washer Master cylinder kit

Q’ty

Remarks Disassemble the parts in the order listed.

1 2 3 4 5 6 7 8

1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.

4-36

CLUTCH
EAS00307

ENG

CAUTION:
Clutch components rarely require disassembly. Therefore, always follow these preventive measures: S Never disassemble clutch components unless absolutely necessary. S If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. S Never use solvents on internal clutch components. S Use only clean or new clutch fluid for cleaning clutch components. S Clutch fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt fluid immediately. S Avoid clutch fluid coming into contact with the eyes as it can cause serious injury. First aid for clutch fluid entering the eyes: S Flush with water for 15 minutes and get immediate medical attention.
EAS00308

CHECKING THE CLUTCH MASTER CYLINDER Recommended clutch component replacement schedule Piston seals Clutch hose Clutch fluid Every two years Every four years Every two years and whenever the clutch is disassembled

1. Check: S clutch master cylinder body 1 Cracks/damage ! Replace the clutch master cylinder. S clutch fluid delivery passage 2 (clutch master cylinder body) Obstruction ! Blow out with compressed air.

WARNING
Whenever a clutch master cylinder is disassembled, replace the piston seals.

4-37

CLUTCH

ENG

2. Check: S clutch master cylinder 1 S clutch master cylinder kit 2 Rust/scratches/wear ! Replace the clutch master cylinder and clutch master cylinder kit as a set. S clutch hose Cracks/damage/wear ! Replace.

EAS00309

ASSEMBLING THE CLUTCH MASTER CYLINDER

WARNING
S Before installation, all internal clutch components must be cleaned and lubricated with clean or new clutch fluid. S Never use solvents on internal clutch components as they will cause the piston seals to swell and distort. S Whenever a clutch master cylinder is disassembled, replace the piston seals. Recommended clutch fluid Brake fluid DOT 4

EAS00310

INSTALLING THE CLUTCH MASTER CYLINDER 1. Install: S clutch master cylinder 1

WARNING
S Install the clutch lever holder with the “UP” mark facing up. S Align the end of the clutch lever holder with the punch mark a in the handlebar. S First, tighten the upper bolt, then the lower bolt.

4-38

CLUTCH
2. Install: S copper washers (New) S clutch hose 1 S union bolt 2

ENG

30 Nm (3.0 mSkg)

WARNING
Proper clutch hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. NOTE: While holding the clutch hose, tighten the union bolt.

3. Install: S clutch push rod holder 1 S clutch lever 2 NOTE: Lubricate the clutch lever pivot bolt with lithium soap base grease. 4. Fill: S clutch master cylinder reservoir (with the specified amount of the recommended clutch fluid) Recommended clutch fluid Brake fluid DOT 4

WARNING
S Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. S Refill with the same type of clutch fluid that is already in the system. Mixing clutch fluids may result in a harmful chemical reaction, leading to poor clutch performance. S When refilling, be careful hat water does not enter the reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock.

4-39

CLUTCH
CAUTION:

ENG

Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reservoir is horizontal. 5. Bleed: S clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in CHAPTER 3. 6. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL” in CHAPTER 3. 7. Check: S clutch lever operation Soft spongy feeling ! Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in CHAPTER 3.

4-40

CLUTCH
CLUTCH RELEASE CYLINDER

ENG

12 Nm (1.2 mSkg)

25 Nm (2.5 mSkg)

Order

Job/Part Removing the clutch release cylinder

Q’ty

Remarks Remove the parts in the order listed. NOTE: Before removing the clutch release cylinder or the master cylinder, drain the clutch fluid from the entire clutch system. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “STARTER CLUTCH AND GENERATOR”.

Engine oil Middle gear case cover, shift pedal assembly, crankcase cover (left side) Rubber cover Clutch pipe clamps Union bolt Copper washers Clutch release cylinder

1 2 3 4 5

1 2 1 2 1

Refer to “INSTALLING THE CLUTCH RELEASE CYLINDER”. For installation, reverse the removal procedure.

4-41

CLUTCH

ENG

6 Nm (0.6 mSkg)

Order

Job/Part Disassembling the clutch rlease cylinder Oil seal Piston (release cylinder) Spring Piston seal

Q’ty

Remarks Disassemble the parts in the order listed.

1 2 3 4

1 1 1 1

Refer to “DISASSEMBLING THE CLUTCH RELEASE CYLINDER”.

CAUTION:
Never attempt to pry out the piston.
5

Air bleed screw

1 For assembly, reverse the disassembly procedure.

4-42

CLUTCH
EAS00313

ENG

DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove: S oil seal 1 S clutch release cylinder piston 2 S spring 3 S piston seal 4

a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder.

WARNING
S Cover the clutch release cylinder with a rag. Be careful not to get injured when the piston is expelled from the clutch release cylinder. S Never try to pry out the clutch release cylinder piston. b. Remove the clutch release cylinder piston seals.

EAS00314

CHECKING THE CLUTCH RELEASE CYLINDER Recommended clutch component replacement schedule Piston seals Clutch hose Clutch fluid Every two years Every two years Every two years and whenever the clutch is disassembled.

2. Check: S clutch release cylinder 1 S clutch release cylinder piston 2 Rust/scratches/wear ! Replace the clutch release cylinder and clutch release cylinder piston as a set.

4-43

Install: S piston seal 1 New S spring 2 S piston (release cylinder) 3 S oil seal 4 New EAS00315 INSTALLING THE CLUTCH RELEASE CYLINDER 1. Recommended brake fluid: DOT #4 S Replace the piston seal and oil seal whenever the clutch release and master cylinder are disassembled. 1. Refer to “CABLE ROUTING”.CLUTCH ENG 3. S During installation internal parts should be lubricated with new fluid. make sure that the pipe touches the projection a . ASSEMBLING THE CLUTCH RELEASE CYLINDER WARNING S All internal parts shoud be cleaned in new fluid only.5 mSkg) WARNING Proper clutch hose routing is essential to insure safe motorcycle operation. CAUTION: When installing the clutch hose onto the clutch release cylinder. 4-44 . Install: S copper washers (New) S clutch hose 1 S union bolt 2 25 Nm (2. Check: S spring 1 Wear/rust ! Replace the clutch release cylinder assembly.

Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in CHAPTER 3. CAUTION: Clutch fluid may damage painted surfaces or plastic parts. 4. 5. Refer to “CHECKING THE CLUTCH FLUID LEVEL” in CHAPTER 3. Mixing clutch fluids may result in a harmful chemical reaction. S When refilling. always clean up any spilt clutch fluid immediately. Therefore. be careful that water does not enter the reservoir.CLUTCH ENG 2. Fill: S clutch master cylinder reservoir (with the specified amount of the recommended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING S Use only the designated clutch fluid. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper level. Bleed: S clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in CHAPTER 3. leading to poor clutch performance. Check: S clutch lever operation Soft or spongy feeling ! Bleed the clutch system. 4-45 . make sure that the top of the reservoir is horizontal. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. NOTE: In order to ensure a correct reading of the clutch fluid level. 3. Other clutch fluids may cause the rubber seals to deteriorate. S Refill with the same type of clutch fluid that is already in the system. causing leakage and poor clutch performance.

1 2 3 4 5 For installation. For OCE.0 mSkg) Order Job/Part Removing the clutch cover Q’ty Remarks Remove the parts in the order listed. exhaust pipe (#4 cylinder) Horn leads Horn Crankcase cover (right side) Gasket Dowel pins Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “ENGINE REMOVAL”. 2 1 1 1 2 Disconnect for OCE. Engine oil Muffler assembly (right side). Stand the motorcycle on a level surface WARNING Securely support the motorcycle so there is no danger of it falling over. Refer to “INSTALLING THE CLUTCH”. 4-46 . reverse the removal procedure.CLUTCH CLUTCH COVER ENG 10 Nm (1.

Refer to “INSTALLING THE CLUTCH”. Refer to “INSTALLING THE CLUTCH”. Refer to “REMOVING/INSTALLING THE CLUTCH”.8 mSkg) M6 25 (6) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Removing the clutch Clutch spring plate Clutch spring Clutch spring seat Pressure plate Push rod #2 O-ring Ball Friction plates Clutch plates Nut Lock washer Clutch boss Retaining wire Clutch plate Q’ty 1 1 1 1 1 1 1 7 6 1 1 1 1 1 Remarks Remove the parts in the order listed.CLUCH CLUTCH ENG 70 Nm (7. 4-47 .0 mSkg) 8 Nm (0.

For installation. reverse the removal procedure. 4-48 .0 mSkg) 8 Nm (0.CLUTCH ENG 70 Nm (7.8 mSkg) M6 25 (6) Order 15 16 17 18 19 20 21 22 Job/Part Friction plate Spring plate Washer Clutch housing Push rod #1 Circlip Oil pump drive gear Dowel pins Q’ty 1 1 1 1 1 1 1 2 Remarks Refer to “INSTALLING THE CLUTCH”.

1.9 X 3. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set.CLUTCH EAS00275 ENG REMOVING THE CLUTCH 1. Straighten the lock washer tab. 90890-04086 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. loosen the clutch boss nut. NOTE: Measure the friction plate at four places. Friction plate thickness 2. Check: S friction plate Damage/wear ! Replace the friction plates as a set. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder 3 .8 mm 4-49 .1 mm <Limit>: 2. 2. Universal clutch holder YM-91042. 2.

Measure: S clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set. Damage ! Replace. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing.CLUTCH EAS00281 ENG CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. S clutch spring plate seat 3 EAS00284 CHECKING THE CLUTCH HOUSING 1. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. Check: S clutch plate Damage ! Replace the clutch plates as a set. Check: S clutch boss splines Damage/pitting/wear ! Replace the clutch boss. Check: S clutch spring plate 1 . Clutch plate warpage limit Less than 0. 2. 1.2 mm EAS00283 CHECKING THE CLUTCH SPRING PLATE 1. S clutch spring 2 . 4-50 .

S bearing 2 Damage/wear ! Replace. 2.0 mSkg) NOTE: While holding the clutch boss 2 with the universal clutch holder 3 . Check: S short clutch push rod 1 S O-ring 2 S ball 3 S long clutch push rod 4 Cracks/damage/wear ! Replace the defective part(-s). Check: S pressure plate 1 Cracks/damage ! Replace. tighten the clutch boss nut. Install: S clutch spring plate 1 S friction plate 2 S clutch plate 3 S wire circlip (New) 4 NOTE: Install the clutch spring plate with the “OUTSIDE” mark facing towards the clutch cover. Universal clutch holder YM-91042. Bend the lock washer tab along a flat side of the nut. EAS00300 INSTALLING THE CLUTCH 1. Tighten: S clutch boss nut 1 70 Nm (7. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 4-51 . 4. EAS00288 CHECKING THE CLUTCH PUSH RODS 1.CLUTCH EAS00286 ENG CHECKING THE PRESSURE PLATE 1. 90890-04086 3.

4-52 . Install: S long clutch push rod 1 S ball 2 S short clutch push rod 3 (along with a new O-ring 4 ) 8. 6. S Align the two slots a in the friction plates with the two punch marks b in the clutch housing.CLUTCH 5. Install: S friction plates S clutch plates ENG NOTE: S First. Install: S pressure plate 1 NOTE: Align the punch mark a in the clutch boss with the punch mark b in the pressure plate. install a friction plate and then alternate between a clutch plate and a friction plate. Lubricate: S long clutch push rod 1 S ball 2 S short clutch push rod 3 (with the recommended lubricant) Recommended lubricant Lithium soap base grease 7.

Install: S clutch spring plate seat 1 S clutch spring plate 2 S clutch spring plate retainer 3 S clutch spring plate bolts 4 8 Nm (0.CLUTCH ENG 9. 4-53 . Install: S clutch cover 1 10 Nm (1. 10.8 mSkg) NOTE: Tighten the clutch spring plate bolts in stages and in a crisscross pattern.0 mSkg) NOTE: Tighten the clutch cover bolts in stages and in a crisscross pattern.

1 1 NOTE: Loosen the bolts in a crisscross pattern. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. reverse the removal procedure.0 mSkg) M6 20 10 Nm (1. Refer to “ENGINE REMOVAL”. 2 3 4 Gasket Dowel pins Shift pedal link 1 2 1 Disconnect For installation. exhaust pipe (#2 cylinder) Middle gear case cover Q’ty Remarks Remove the parts in the order listed.0 mSkg) M6 M6 35 (3) 45 (3) Order Job/Part Removing the shift arm Engine oil Muffler assembly (left side).SHIFT SHAFT SHIFT SHAFT SHIFT ARM ENG 10 Nm (1. 4-54 .

For installation.0 mSkg) M6 18 Order Job/Part Removing the shift shaft and stopper lever (B) Shift shaft assembly Circlip Washer Torsion spring Stopper lever Return spring Q’ty Remarks Remove the parts in the order listed.SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER ENG 10 Nm (1. reverse the removal procedure. 1 2 3 4 5 6 1 1 1 1 1 1 Refer to “INSTALLING THE SHIFT SHAFT”. 4-55 .

Check: S stopper lever 1 Bends/damage ! Replace. 4-56 . EAS00330 CHECKING THE STOPPER LEVER 1. Check: S shift shaft 1 S shift lever 2 Bends/damage/wear ! Replace. Roller turns roughly ! Replace the stopper lever. S shift lever spring 3 Damage/wear ! Replace. Install: S shift shaft NOTE: S Install the stopper lever spring and stopper lever as shown. Install: S stopper lever spring 1 S stopper lever 2 2. S Hook the end of the shift lever spring onto the shift lever spring stopper 1 . EAS00333 INSTALLING THE SHIFT SHAFT 1.SHIFT SHAFT EAS00328 ENG CHECKING THE SHIFT SHAFT 1.

7 mSkg) M6 52 Nm (5. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “ENGINE REMOVAL”. 4-57 . shift pedal link Shift pedal assembly Crankcase cover (left side) Gasket Dowel pins Pickup coil lead.0 mSkg) M10 32 (2) M6 M6 45 (7) 60 (4) Order Job/Part Removing the stator coil Engine oil Muffler assembly (left side). stator coil lead Cable holder Pickup coil Q’ty Remarks Remove the parts in the order listed. Refer to “SHIFT SHAFT”. exhaust pipe (#2 cylinder) Middle gear case cover.2 mSkg) 30 (3) 10 Nm (1. 1 2 3 4 5 6 7 1 1 1 2 1/1 1 1 Refer to “CRANKCASE COVER (LEFT SIDE)”. Remove from the cable clamp.STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR STARTOR COIL ENG 7 Nm (0.

7 mSkg) M6 52 Nm (5.2 mSkg) 30 (3) 10 Nm (1.STARTER CLUTCH AND GENERATOR ENG 7 Nm (0.0 mSkg) M10 32 (2) M6 M6 45 (7) 60 (4) Order 8 9 Job/Part Plate (stater coil) Stater coil Q’ty 1 1 Remarks For installation. reverse the removal procedure. 4-58 .

4 mSkg) M6 M6 25 55 M8 25 (6) 130 Nm (13. 4-59 .0 mSkg) 24 Nm (2. reverse the removal procedure. Disconnect For installation.STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR ENG 10 Nm (1.0 mSkg) M12 48 Order Job/Part Removing the stater clutch and generator rotor Shafts Starter idler gears Rotor Woodruff key Starter wheel gear Starter clutch assembly Starter motor lead Starter motor Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 7 8 2 3 1 1 1 1 1 1 Refer to “REMOVING/INSTALLING THE GENERATOR”. Refer to “INSTALLING THE GENERATOR”.

2. Remove: S generator rotor bolt 1 S washer NOTE: S While holding the generator rotor with the sheave holder 2 . 90890-01362 Adopter YM-33282.STARTER CLUTCH AND GENERATOR EAS00346 ENG REMOVING THE GENERATOR 1. ! Replace 3. Check: S starter clutch gear’s contacting surfaces Damage/pitting/wear ! Replace the starter clutch gear. S Do not allow the sheave holder to touch the projection on the generator rotor. 90890-04089 EAS00350 CHECKING THE STARTER CLUTCH 1. loosen the generator rotor bolt. Sheave holder YS-01880. Check: S starter clutch rollers 1 Damage/wear ! Replace. 4-60 . 90890-01701 2. Remove: S generator rotor 1 (with the flywheel puller set 2 ) S woodruff key Flywheel puller set YU-33270. Check: S starter clutch idler gear 1 S starter clutch drive gear 2 S starter clutch gear Burrs/chips/roughness/wear the defective part(-s).

the starter clutch is faulty and must be replaced. S When installing the generator rotor. 2. If the starter clutch drive gear does not turn freely.STARTER CLUTCH AND GENERATOR 4.0 mSkg) NOTE: S While holding the generator rotor with the sheave holder 2 . Check: S starter clutch operation ENG a. S Do not allow the sheave holder to touch the projection on the generator rotor. When turning the starter clutch drive gear clockwise A . Sheave holder YS-01880. c. If the starter clutch drive gear and starter clutch do not engage. the starter clutch and the starter clutch drive gear should engage. make sure the woodruff key is properly seated in the key way of the crankshaft. b. Install: S starter wheel gear 1 S woodruff key 2 S generator rotor 3 S washer 4 S pin 5 S generator rotor bolt 6 NOTE: S Clean the tapered portion of the crankshaft and the generator rotor hub. Install the starter clutch 1 onto the generator rotor 2 and hold the starter clutch. tighten the generator rotor bolt. it should turn freely. 90890-01701 4-61 . the starter clutch is faulty and must be replaced. When turning the starter clutch drive gear counterclockwise B . Tighten: S generator rotor bolt 1 130 Nm (13. EAS00354 INSTALLING THE GENERATOR 1.

7 mSkg) 24 Nm (2. Refer to “ENGINE REMOVAL”. Refer to “CLUTCH”.0 mSkg) M6 30 (12) 10 Nm (1.2 mSkg) M6 12 10 Nm (1.0 mSkg) M6 25 (3) 12 Nm (1.4 mSkg) M8 95 10 Nm (1. Refer to “INSTALLING THE OIL PUMP”. Straighten For installation.0 mSkg) M6 16 Order Job/Part Removing the oil pan and oil pump Engine assembly Clutch assembly Circlip Idler gear (oil pump) Oil pan Dowel pins Gasket Oil level switch Oil pump assembly Dowel pins Oil pump pipe Bracket tabs Oil pipe Oil gallery pipe Oil filter Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. 4-62 .OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP ENG 17 Nm (1. 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 2 1 1 1 2 1 2 1 1 1 Refer to “REMOVING/INSTALLING THE OIL PAN”.

4-63 .OIL PAN AND OIL PUMP ENG Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Disassembling the oil pump Oil strainer Oil strainer housing Gasket Circlip Driven gear (oil pump) Gear housing Spring Relief valve Inner rotor Shaft Pin Outer rotor Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Disassemble the parts in the order listed. Refer to “ASSEMBLING THE OIL PUMP”.

For assembly. reverse the disassembly procedure. 4-64 .OIL PAN AND OIL PUMP ENG Order 13 14 Job/Part Dowel pins Oil pump housing Q’ty 2 1 Remarks Refer to “ASSEMBLING THE OIL PUMP”.

1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0 X 0.08 mm <Limit>: 0.12 mm <Limit>: 0. Check: S oil pump operation Unsmooth ! Repeat steps (1) and (2) or replace the defective part(-s). Check: S oil pump driver gear 1 S oil pump driven gear 2 S oil pump housing 3 S oil pump housing cover Cracks/damage/wear ! Replace the defective part(-s).17 mm Outer-rotor-to-oil-pump-housing clearance 0. EAS00364 CHECKING THE OIL PUMP 1. remove them. After all of the bolts are fully loosened.08 mm Oil-pump-housing-to-inner-rotorand-outer-rotor clearance 0.03 X 0. 2. Measure: S inner-rotor-to-outer-rotor-tip clearance A S outer-rotor-to-oil-pump-housing clearance B S oil-pump-housing-to-inner-rotor-and-outerrotor clearance C Out of specification ! Replace the oil pump. Remove: S oil lever switch 1 S oil pan 2 S gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time.08 mm 3.03 X 0. 4-65 . in stages and in a crisscross pattern.OIL PAN AND OIL PUMP EAS00362 ENG REMOVING THE OIL PAN 1.

EAS00367 CHECKING THE OIL GALLERY PIPES The following procedure applies to all of the oil gallery pipes. Check: S relief valve body S relief valve 1 S spring 2 Damage/wear ! Replace the defective part(-s). Install: S oil gallery pipe 1 S oil pipe 2 WARNING Always use new O-rings.OIL PAN AND OIL PUMP EAS00365 ENG CHECKING THE RELIEF VALVE 1. Obstruction ! Wash and blow out with compressed air. INSTALLING THE OIL GALLERY PIPES 1. Check: S oil strainer 1 S oil strainer housing 2 Damage ! Replace. Contaminants ! Clean with engine oil. Check: S oil gallery pipe 1 Damage ! Replace. EAS00368 CHECKING THE OIL STRAINER 1. 1. 2. Bend: S bracket tabs 1 4-66 .

Install: S oil pump 1 10 Nm (1.0 mSkg) CAUTION: After tightening the bolts. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. 3. 4-67 . Check: S oil pump operation Refer to “CHECKING THE OIL PUMP”. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5 S pin 6 S oil pump housing S screw NOTE: When installing the inner rotor. EAS00376 INSTALLING THE OIL PUMP 1. align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4 . make sure that the oil pump turns smoothly.OIL PAN AND OIL PUMP EAS00375 ENG ASSEMBLING THE OIL PUMP 1.

0 mSkg) S oil level switch 2 10 Nm (1.0 mSkg) S engine oil drain bolt WARNING Always use new copper washers. S Lubricate the oil level switch’s O-ring with engine oil. NOTE: S Tighten the oil pan bolts in stages and in a crisscross pattern. Install: S oil strainer housing 1 2. Install: S oil strainer cover 2 S relief valve NOTE: The arrow a on the oil strainer cover must point towards the rear of the engine. Install: S dowel pins S gasket (New) S oil pan 1 10 Nm (1. EAS00380 INSTALLING THE OIL PAN 1. 4-68 .OIL PAN AND OIL PUMP EAS00378 ENG INSTALLING THE OIL STRAINER 1.

Refer to “CLUTCH”.CRANKCASE CRANKCASE ENG 25 Nm (2. Refer to “OIL PAN AND OIL PUMP”. Refer to “STARTER CLUTCH AND GENERATOR”.7 mSkg) M6 13 (3) Order Job/Part Crankcase separation Engine assembly Cylinder head Water pump Clutch assembly Shift shaft.5 mSkg) M8 21 (4) 30 Nm (3. Refer to “CYLINDER HEADS”. Refer to “CLUTCH RELEASE CYLINDER”. Refer to “ENGINE REMOVAL”. Refer to “SHIFT SHAFT AND STOPPER LEVER”. Refer to “WATER PUMP” in CHAPTER 5. 4-69 . stopper lever Clutch release cylinder AC Magneto Oil pan and oil pump assembly Q’ty Remarks Remove the parts in the order listed.0 mSkg) M8 30 (3) 7 Nm (0.

4-70 .0 mSkg) M8 30 (3) 7 Nm (0.7 mSkg) M6 13 (3) Order 1 2 3 4 5 6 Job/Part Retainer (main axle bearing) Retainers (middle gear bearing) Middle driven gear assembly Shims Crankcase (upper) Crankcase (lower) Q’ty 1 2 1 2/4 1 1 Remarks Refer to “ASSEMBLING THE CRANKCASE”. reverse the removal procedure. For installation.5 mSkg) M8 21 (4) 30 Nm (3.CRANKCASE ENG 25 Nm (2. Refer to “DISASSEMBLING/ ASSEMBLING THE CRANKCASE”.

reverse the disassembly procedure.0 mSkg) M6 40 (6) 10 Nm (1. 4-71 .4 mSkg) M8 25 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Disassembling the crankcase Crankcase breather cover Crankcase breather spacer Rubber gaskets Oil pipe Drain plugs (cylinders) Oil pipe Bracket (timing chain damper) Circlip Oil pump drive shaft Idler gear (oil pump) Q’ty 1 1 2 1 4 1 1 1 1 1 Remarks Disassemble the parts in the order listed.8 mSkg) M8 22 24 Nm (2. For assembly.0 mSkg) M6 16 (4) 18 Nm (1.CRANKCASE ENG 10 Nm (1.

Remove: S crankshaft journal lower bearing (from the lower crankcase) NOTE: Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place. 4-72 . B 2. S The numbers embossed on the crankcase indicate the crankcase tightening sequence. S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). Tap only on reinforced portions of the crankcase.CRANKCASE A EAS00384 ENG DISASSEMBLING THE CRANKCASE 1. not on the crankcase mating surfaces. in stages and in a crisscross pattern. 3. Remove: S crankcase bolts A Upper crankcase B Lower crankcase NOTE: S Loosen each bolt 1/4 of a turn at a time. Work slowly and carefully and make sure that the crankcase halves separate evenly. remove them. Remove: S dowel pins S O-ring 4. After all of the bolts are fully loosened. Remove: S upper crankcase CAUTION: Tap on one side of the crankcase with a softface hammer.

4-73 . 5. 7. 2. 4. 6. Check: S crankcase Cracks/damage ! Replace. Check: S drain plugs (cylinders) 1 Cracks/wear/damage ! Replace. 3. S oil pipe (crankcase breather) 3 Blockage ! Blow out the passages with compressed air. Check: S idler gear (oil pump) 1 S shaft 2 Bends/wear/damage ! Replace. Check: S crankcase breather cover 1 S crankcase breather spacer 2 Cracks damage ! Replace. S union bolt 2 Blockage ! Blow out the passages with compressed air.CRANKCASE EAS00399 ENG CHECKING THE CRANKCASE 1. Check: S oil pipe 1 Blockage ! Blow out the passages with compressed air. Throughly wash the crankcase halves in a mild solvent. S oil delivery passages Obstruction ! Blow out with compressed air. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.

Install: S bracket (timing chain damper) 1 24 Nm (2.CRANKCASE EAS00417 ENG ASSEMBLING THE CRANKCASE 1.0 mSkg) 4-74 . Install: S crankcase breather assembly 4 10 Nm (1.4 mSkg) S oil pipe 2 18 Nm (1. 5. 3. Install: S drain plugs (cylinders) 2 4. Install: S oil pipe 1 S rubber gaskets 2 New S crankcase breather spacer 3 S crankcase breather cover 4 WARNING Always use new O-rings. Install: S shaft 1 S Idler gear (oil pump) 2 S circlip 3 New 2.8 mSkg) NOTE: Apply LOCTITER to the bracket bolt.

Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: S final drive assembly Refer to “MIDDLE GEAR”.0 mSkg) 4-75 . Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 9. make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand.CRANKCASE ENG 6. Install: S upper crankcase 1 (onto the lower crankcase 2 ) CAUTION: Before tightening the crankcase bolts. Install: S middle driven shaft bearing housing bolts NOTE: The bolt with the washer goes in the lower right hole a of the middle driven shaft bearing housing. 8. NOTE: The arrow on the final drive assembly must point towards the upper crankcase. 1215 90890-85505 Quick Gasket® ACC-11001-15-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Middle driven shaft bearing housing bolt 30 Nm (3. 10.

NOTE: S Tighten the bolts in the tightening sequence cast on the crankcase.4 mSkg) M6 bolt 12 Nm (1.0 mSkg) M8 bolt 24 Nm (2.2 mSkg) 12. Tighten: S upper crankcase bolts S lower crankcase bolts WARNING Always use new copper washers. CAUTION: S Apply LOCTITER on to the retainer screws. Install: S middle driven shaft bearing housing retainers 1 25 Nm (2. S After tightening the middle driven shaft bearing housing retainer screws.5 mSkg) S main axle bearing retainer 2 7 Nm (0. S Install the cable holder on bolts 22 and 32 . 4-76 .7 mSkg) WARNING Always use new screws. S Install the washers on bolts 2 and 4 X 8 . S Install copper washers on bolts 28 and 30 . be sure to stake them with a center punch.CRANKCASE A ENG 11. A Upper crankcase B Lower crankcase B M10 bolt 40 Nm (4.

1 2 3 4 5 1 4 1 2 8 Refer to “REMOVING/INSTALLING THE CRANKSHAFT”. 4-77 . reverse the removal procedure. For installation. Refer to “CRANKCASE”.CRANKSHAFT CRANKSHAFT ENG Order Job/Part Removing the crankshaft assembly Crankcase separation Balancer shaft Balancer shaft bearings Crankshaft Timing chains Main journal bearings Q’ty Remarks Remove the parts in the order listed.

Crankshaft-journal-to-crankshaftjournal-bearing clearance 0. crankshaft journals. Measure: S crankshaft runout Out of specification ! Replace the crankshaft. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. Clean the crankshaft journal bearings. c. EAS00395 CHECKING THE CRANKSHAFT 1. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. b. Remove: S balancer shaft 1 S crankshaft assembly 2 S crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. a. Measure: S crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification ! Replace the crankshaft journal bearings.03 mm 2. Place the upper crankcase upside down on a bench. and bearing portions of the crankcase.CRANKSHAFT EAS00387 ENG REMOVING THE CRANKSHAFT ASSEMBLY 1.038 mm <Limit>: 0. the crankshaft journal bearings must be installed in their original positions. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage.020 X 0. 3.1 mm CAUTION: Do not interchange the crankshaft journal bearings. 4-78 . Crankshaft runout Less than 0.

d. S Do not move the crankshaft until the clearance measurement has been completed. Put a piece of Plastigauge® 2 on each crankshaft journal. NOTE: S Align the projections a of the crankshaft journal lower bearings with the notches b in the crankcase.CRANKSHAFT ENG NOTE: Align the projections a of the crakshaft journal upper bearings with the notches b in the crankcase. 4-79 . Install the crankshaft journal lower bearings 3 into the lower crankcase and assemble the crankcase halves. NOTE: Do not put the Plastigauge® over the oil hole in the crankshaft journal. e.

CRANKSHAFT A ENG f. S Install the washers on bolts 2 and 4 X 8 . If the clearance is out of specification. h. Remove the lower crankcase and the crankshaft journal lower bearings.4 mSkg) M 6 bolt 12 Nm (1. Tighten the bolts to specification in the tightening sequence cast on the crankcase. S Install the coble holder on bolts 22 and 32 . Measure the compressed Plastigauge® width c on each crankshaft journal. select replacement crankshaft journal bearings. 4-80 . NOTE: S Install copper washers on bolts 28 and 30 .2 mSkg) g.0 mSkg) M 8 bolt 24 Nm (2. A Upper crankcase B Lower crankcase B M 10 bolt 40 Nm (4.

CRANKSHAFT ENG 4. if the crankcase “J” and crankshaft web “J1” numbers are “6” and “2” respectively. For example. Select: S crankshaft journal bearings (J1 X J4) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. then the bearing size for “J1” is: Bearing size for J1: J1 (crankcase) – J1 (crankshaft web) = 6 – 2 = 4 (green) CRANKSHAFT JOURNAL BEARING COLOR CODE 1 2 3 4 5 6 7 blue black brown green yellow pink red 4-81 . S If “J1 X J4” are the same. use the same size for all of the bearings. S “J1 X J4” refer to the bearings shown in the crankshaft illustration.

Balancer shaft journal-to-balancer shaft bearing clearance 0.048 mm CAUTION: S Do not interchange the balancer shaft bearings S To obtain the correct balancer shaft journal-to-balancer shaft journal bearing clearance and prevent engine damage. the balancer shaft journal bearings mst be installed in their original positions. 4-82 .020 X 0. Measure S balancer shaft journal-to-balancer shaft journal bearing clearance Out of specification ! Replace the balancer shaft journal bearings.03 mm 2. Measure S balancer shaft runout out of specification ! Replace the balancer shaft Balancer shaft runout Less than 0. Check: S balancer shaft journal surfaces S bearing surface S balancer shaft driven gear 1 S water pump drive gear 2 Scratches/wear ! Replace the balancer shaft 3.CRANKSHAFT ENG CHECKING THE BALANCER SHAFT 1.

NOTE: Align the projections a of the balancer shaft journal upper bearings with the notches b in the crankcase. c. NOTE: Do not put the Plastigauge® over the oil hole in the balancer shaft journal. S Do not move the balancer shaft until the clearance measurement has been completed. balancer shaft journals. Clean the balancer shaft journal bearings. 4-83 . and bearing portions of the crankcas.CRANKSHAFT ENG a. Put a piece of Plastigauge® 1 on each balancer shaft journal. Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase. b. d. NOTE: S Align the projections a of the balancer shaft journal lower bearings with the notches b in the crankcase. Place the upper crankcase upside down on a bench. Install the balancer shaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. e.

4 mSkg) M 6 bolt 12 Nm (1. select replacement balancer shaft journal bearings. Measure the compressed Plastigauge® width c on each balancer shaft journal. A Upper crankcase B Lower crankcase B M 10 bolt 40 Nm (4. NOTE: S Install copper washers on bolts 28 and 30 . S Install the coble holder on bolts 22 and 32 . h.2 mSkg) g. 4-84 . S Install the washers on bolts 2 and 4 X 8 .CRANKSHAFT A ENG f. If the clearance is out of specification.0 mSkg) M 8 bolt 24 Nm (2. Tighten the bolts to specification in the tightening sequence cast on the crankcase. Remove the lower crankcase and the balancer shaft journal lower bearings.

Select: S Balancer shaft journal bearings (P1 X P2) NOTE: The numgers A stamped into the balancer weight and the numbers 1 stamped into the lower creankcase are used to determine the replacement balancer shaft journal bearing sizes. then the bearing size for “P1” is: Bearing size for P1: P1 (crankcase) – P1 (balancer weight) = 6 – 2 = 4 (green) BALANCER SHAFT JOURNAL BEARING COLOR CODE 1 2 3 4 5 6 7 blue black brown green yellow pink red 4-85 .CRANKSHAFT ENG 4. For example. “P1 P2” refer to the bearings shown in the balancer shaft illustration. if the crankcase “P1” and balancer weight “P1” numbers are “6” and “2” respectively. use the same size for all of the bearings. If “P1 P2” are the same.

4-86 . Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. EAS00410 INSTALLING THE BALANCER SHAFT 1. fasten it with a wire. Install: S timing chain 1 (onto the crankshaft sprocket) S crankshaft assembly 2 NOTE: S Pass the timing chain through the timing chain cavity. 2. Install: S balancer shaft NOTE: Align the punch mark a in the balancer shaft drive gear with the punch mark b in the balancer shaft driven gear. S To prevent the timing chain from falling into the crankcase.CRANKSHAFT EAS00407 ENG INSTALLING THE CRANKSHAFT 1. S Be sure to install each crankshaft journal upper bearing in its original place.

Refer to “CRANKCASE”.6 mSkg) Order Job/Part Connecting rod and piston removal Crankcase separation Nuts (connecting rod caps) Connecting rod caps/plain bearings Connecting rods/pistons Piston pin clips Piston pins Pistons Piston rings Q’ty Remarks Remove th parts in the order listed. 1 2 3 4 5 6 7 8 4/8 4/4 8 4 4 12 4-87 . reverse the removal procedure.CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS ENG 36 Nm (3. Refer to “REMOVING/INSTALLING THE CONNECTING RODS AND PISTONS”. Refer to “INSTALLING THE PISTONS AND CONNECTING RODS”. For installation.

ONNECTING RODS AND PISTONS EAS00393 ENG REMOVING THE CONNECTING RODS AND PISTONS 1. 4-88 . Remove: S connecting rod bearings NOTE: Identify the position of each bearing very carefully so that it can be reinstalled in its original place. S Before removing the piston pin. If both areas are deburred and the piston pin is still difficult to remove. The following procedure applies to all of the cylinders and pistons. 2. NOTE: S Before removing the piston pin clip. deburr the piston pin clip’s groove and the piston’s pin bore area. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out. Piston pin puller YU-01304. cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Remove: S top ring S 2nd ring S oil ring NOTE: When removing a piston ring. 90890-01304 3. open the end gap with your fingers and lift the other side of the ring over the piston crown. S For reference during installation. remove it with the piston pin puller 4 . put an identification mark on each piston crown.

rebore or replace the cylinder. a 40 mm from the top of the cylinder NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. and replace the piston and piston rings as a set. and replace the piston and piston rings as a set. If out of specification. Measure: S piston-to-cylinder clearance a. Check: S piston wall S cylinder wall Vertical scratches ! Rebore or replace the cylinder. 4-89 .967 X 79. Then.016 mm 79. Measure cylinder bore “C” with the cylinder bore gauge. 2. find the average of the measurements. Wear limit Standard Cylinder 78. 1.CONNECTING RODS AND PISTONS EAS00260 ENG CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons.1 mm bore C C=X+Y 2 b.

25 mm 79.CONNECTING RODS AND PISTONS ENG c. rebore or replace the cylinder.50 mm d.15 mm f. Measure piston skirt diameter “P” with the micrometer. 4-90 . NOTE: Before measuring the piston ring side clearance.933 mm 79. b Piston size P Standard Oversize 2 Oversize 4 78. If out of specification. Measure: S piston ring side clearance Out of specification ! Replace the piston and piston rings as a set. e. EAS00264 CHECKING THE PISTON RINGS 1. If out of specification.069 mm <Limit>: 0. 4 mm from the bottom edge of the piston. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.055 X 0. eliminate any carbon deposits from the piston ring grooves and piston rings. Calculate the piston-to-cylinder clearance with the following formula.926 X 78. and replace the piston and piston rings as a set. replace the piston and piston rings as a set.

Oversize 2 Oversize 4 0. NOTE: The oil ring expander spacer’s end gap cannot be measured. Measure: S piston ring end gap Out of specification ! Replace the piston ring. replace all three piston rings.35 X 0.12 mm 2nd ring 0. Install: S piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown as shown.55 mm 2nd ring 0.02 X 0.8 mm Oil ring 0.CONNECTING RODS AND PISTONS ENG Piston ring side clearance Top ring 0.07 mm <Limit>: 0.50 mm <Limit>: 0.9 mm Piston ring oversize S Top and 2nd piston rings The size of the top and 2nd oversize piston rings is stamped on the top of each ring.12 mm 2.25 mm 0.06 mm <Limit>: 0. a 40 mm 3.50 mm 4-91 .20 X 0.35 mm <Limit>: 0. If the oil ring rail’s gap is excessive.3 X 0. Piston ring end gap Top ring 0.03 X 0.

Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0. Piston pin outside diameter 18. 1. Size Oversize 2 Oversize 4 Color Blue Red EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. Check: S pison pin Blue discoloration/grooves ! Replace the piston pin and then check the lubrication system.000 mm 3. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin.991 X 19. Calculate: S piston-pin-to-piston clearance Out of specification ! Replace the piston pin.007 mm 4-92 .0024 mm <Limit>: 0.CONNECTING RODS AND PISTONS ENG S Oil ring The expander spacer of the oil ring is colorcoded for size identificaton. 2.004 X 0.

CAUTION: Do not interchange the big end bearings and connecting rods. #3 cylinder. S Make sure that the “Y” mark 1 on the connecting rod faces towards the right side of the crankshaft at #2. crankshaft pins. the big end bearings must be installed in their original positions.039 mm The following procedure applies to all of the connecting rods. Put a piece of Plastigauge® on the crankshaft pin. d. threads. a. 4-93 . b.CONNECTING RODS AND PISTONS EAS00395 ENG CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Crankshaft-pin-to-big-endbearing clearance 0. NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage. S Make sure that the “Y” mark 1 on the connecting rod faces towards the left side of the crankshaft at #1. c. #4 cylinder. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. S Make sure that the characters 2 on both the connecting rod and connecting rod cap are aligned. and nut seats. Assemble the connecting rod halves. and bearing portions of the connecting rods. S Apply molybdenum disulfide grease onto the bolts. Measure: S crankshaft-pin-to-big-end-bearing clearance Out of specification ! Replace the big end bearings. Clean the big end bearings.021 X 0.

if the connecting rod “P1” and the crankshaft web “P1” numbers are “4” and “1” respectively. then the bearing size for “P1” is: Bearing size for “P1”: “P1” (connecting rod) – “P1” (crankshaft)= 4 – 1 = 3 (brown) 4-94 . Remove the connecting rod and big end bearings. g. be sure to use an F-type torque wrench. Refer to “INSTALLING THE CONNECTING RODS”. Apply continuous torque between 3. If the tightening is interrupted between 3. Select: S big end bearings (P1 X P2) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. Connecting rod nut 36 Nm (3.0 and 3.CONNECTING RODS AND PISTONS CAUTION: ENG e. Tighten the connecting rod nuts.0 and 3. For example. tighten the connecting rod nuts to the specified torque. select replacement big end bearings. If the clearance is out of specification.0 mSkg. Once you reach 3.6 mSkg.6 mSkg. S When tightening the connecting rod nuts.0 mSkg and start again. loosen the connecting rod nut to less than 3. Measure the compressed Plastigauge® width 1 on the crankshaft pin. S Without pausing. 2.6 mSkg) f. DO NOT STOP TIGHTENING until the specified torque is reached. S “P1” X “P2” refer to the bearings shown in the crankshaft illustration. Refer to “REMOVING THE CONNECTING RODS”.

Install: S piston 1 S piston pin 2 S piston pin clip (New) 3 NOTE: S Apply engine oil onto the piston pin. Install: S top ring 1 S 2nd ring 2 S lower oil ring rail 3 S upper oil ring rail 4 S oil ring expander 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 4 “Y” mark 5 “EX” exhaust side 6 “IN” intake side 7 Projection 3. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4-95 .CONNECTING RODS AND PISTONS ENG BIG END BEARING COLOR CODE 1 2 3 4 blue black brown green EAS00267 INSTALLING THE PISTONS AND CONNECTING RODS 1. 2.

2 and No. S The stamped “Y” mark 1 on the No. S Install each bearing in its original place. Install: S plain bearings 1 NOTE: S Align the projection a of the bearings with the notches b in the connecting rod cap.CONNECTING RODS AND PISTONS 4.4 connecting rods should face towards the right side of the crankcase. 6. A A Top view 2 Front 3 “Y” mark facing direction 4 Piston exhaust mark 5 Piston intake mark 4-96 .3 connecting rods should face towards the left side of the crankcase. Install: S connecting rod and piston assembly NOTE: S The stamped “Y” mark 1 on the No. 90890-05158 7.1 and No. Install: S Piston ring compressor 1 Piston ring compressor: YM-8037. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring ENG 5.

9.CONNECTING RODS AND PISTONS 8. 4-97 . S The projection 1 on the connecting rod cap should face toward the crankshaft web. Tighten: S nuts (connecting rod cap) 36 Nm (3.0 and 3.0 mSkg and start again.6 mSkg.6 mSkg) NOTE: S Apply Molybdenum disulfide grease to the rod cap bolt threads and nut surfaces. Once you reach 3.0 and 3. If the tightening is interrupted between 3. Apply continuous torque between 3. Install: S connecting rod cap ENG NOTE: Be sure that the characters on the side of the cap and connecting rod are aligned. loosen the nut to less than 3. CAUTION: S When tightening the nuts be sure to use an F-type torque wrench.0 mSkg DO NOT STOP TIGHTENING until final torque is reached. S Without pausing tighten to full torque specification.6 mSkg.

TRANSMISSION TRANSMISSION ENG 7 Nm (0. 1 2 3 4 5 6 7 8 9 10 1 1 1 1 2 2 3 1 1 1 Refer to “INSTALLING THE SHIFT FORKS”. Refer to “INSTALLING THE TRANSMISSION”. reverse the removal procedure. For installation. 4-98 . Refer to “CRANKCASE”.4 mSkg) M5 9 (3) Order Job/Part Removing the transmission Crankcase separation Drive axle assembly Main axle assembly Push rod support bearing Oil seal Bearing circlips Guide bars Shift forks Neutral switch Shift cam retainer Shift cam Q’ty Remarks Remove the parts in the order listed.7 mSkg) M6 13 (3) 4 Nm (0.

Refer to “MIDDLE GEAR”. 1 2 3 4 5 6 7 8 9 10 11 12 1 1 1 1 1 1 1 1 1 1 1 1 4-99 .TRANSMISSION ENG Order Job/Part Disassembling the transmission Middle drive pinion gear assembly Circlip Bearing 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle Plug 2nd wheel gear Washer Circlip Q’ty Remarks Remove the parts in the order listed.

4-100 .TRANSMISSION ENG Order 13 14 15 16 17 18 19 20 21 22 23 24 25 Job/Part 5th wheel gear Bearing Circlip Bearing Main axle 4th pinion gear Washer Circlip 2nd. 3rd pinion gear 5th pinion gear Washer Circlip Bearing Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks For installation. reverse the disassembly procedure.

3. Check: S oil seals 2 Damage/wear ! Replace. WARNING Do not attempt to straighten a bent shift fork guide bar. then rotate the inner race with your finger. S circlips 3 Bends/damage/looseness ! Replace. 4-101 . Check: S shift fork cam follower 1 S shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork. 2. EAS00402 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. Check: S bearings 1 Clean and lubricate the bearings. Bends ! Replace. 2. Rough movement ! Replace. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface. Check: S shift fork movement (on the shift fork guide bar) Rough movement ! Replace the shift forks and shift fork guide bar as a set.TRANSMISSION EAS00401 ENG CHECKING THE BEARINGS AND OIL SEALS 1. 1.

Drive axle runout limit 0. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s).08 mm 2. 4-102 . Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. S shift drum bearing 1 Damage/pitting ! Replace. 6. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Main axle runout limit 0. S shift drum segment 2 Damage/wear ! Replace.TRANSMISSION EAS00422 ENG CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S transmission gear movement Rough movement ! Replace the defective part(-s).08 mm 3. EAS00425 CHECKING THE TRANSMISSION 1. Measure: S drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s). Check: S circlips Damage/bends/looseness ! Replace. 4. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum.

shaft. EAS00428 INSTALLING THE TRANSMISSION 1. 4-103 . 3. Install: S shift forks 1 S shift fork guide bars 2 NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”. and bearing throughly. Check: S transmission Rough movement ! Repair. Install: S shift cam 1 S shift cam retainer 2 7 Nm (0.4 mSkg) NOTE: Apply grease to the neutral switch. 2. Install: S main axle assembly 1 S drive axle assembly 2 NOTE: S Make sure that the bearing circlips 3 are inserted into the grooves in the lower crankcase.TRANSMISSION EAS00426 ENG INSTALLING THE SHIFT FORKS 1. WARNING Always use a new O-ring.7 mSkg) NOTE: S Apply LOCTITER #648 to the shift cam retainer screws. S The bearing pin 4 are inserted into the grooves in the lower crankcase. NOTE: Oil each gear. S Rotate the shift cam to the neutral position. 2. “C”. Install: S neutral switch 1 4 Nm (0. “L”.

Refer to “DISASSEMBLING/ ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY”. 4-104 .MIDDLE GEAE MIDDLE GEAE ENG 90 Nm (9.0 mSkg) 30 Nm (3. Refer to “CRANKCASE”. Refer to “TRANSMISSION”.0 mSkg) 110 Nm (11. 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 2 1 1 1 1 1 1 1 Refer to “DISASSEMBLING/ ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY”.0 mSkg) Order Job/Part Removing the middle gear Crankcase separation Drive axle assembly Nut Washer Universal joint (yoke) Dust seal Middle driven gear housing Shims O-ring Bearing Collapsible collar Spacer Bearing Middle drive shaft Retainer Q’ty Remarks Remove the parts in the ordr listed.

MIDDLE GEAR ENG 90 Nm (9.0 mSkg) 110 Nm (11.0 mSkg) 30 Nm (3. reverse the removal procedure.0 mSkg) Order 14 15 16 17 18 19 20 21 Job/Part Thrust washer Middle drive pinion gear Damper cam Damper spring Spring seat Bearing Nut Bearing Q’ty 1 1 1 1 1 1 1 1 Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE MDDLE DRIVE SHAFT ASSEMBLY”. For installation. 4-105 .

4-106 .MIDDLE GEAR EAS00434 ENG MIDDLE DRIVE DISASSEMBLING THE SHAFT ASSEMBLY 1. Loosen the middle drive shaft nut with the middle drive shaft nut wrench 4 . Remove: S middle drive shaft nut 1 S bearing 2 S middle drive shaft 3 a . Middle drive shaft nut wrench YM-04054. b. remove the spring retainers. 3. Damper spring compressor YM-33286. 90890-04090 2. Remove: S spring retainers 1 NOTE: While compressing the spring with a damper spring compressor 2 . Remove the middle drive shaft nut and bearing.Secure the middle drive shaft holder in a vice. Straighten the stake. 90890-04054 c.

NOTE: It may be necessary to lightly tap the universal joint driven yoke with a center punch. With a pipe of the proper diameter positioned deneath the universal joint driven yoke as shown. 1. Remove the circlips 1 .MIDDLE GEAR EAS00437 ENG DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following procedure should only be performed if the middle drive gear or middle driven shaft bearing(-s) has to be replaced. loosen the middle driven shaft nut. e. c. b. 4-107 . Separate the universal joint yokes. press the bearing into the pipe. Remove: S universal joint a. Check: S damper cam surface Scratches/wear ! Replace the damper cam. 2. Repeat the above steps to remove the opposite side’s bearing. 90890-04062 EB414400 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. d. Check: S spring Cracks/damage ! Replace. 2. Universal joint holder YM-04062. Place the universal joint in a press. Loosen: S middle driven shaft nut NOTE: While holding the universal joint driven yoke with the universal joint holder 1 .

3.MIDDLE GEAR EAS00439 ENG CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: S universal joint movement Rough movement ! Replace the universal joint. Check: S middle driven gear Galling/pitting/wear ! Replace the middle driven shaft assembly. 2. Tighten: S middle drive shaft nut 110 Nm (11 mSkg) NOTE: Lock the threads on the middle drive shaft nut by staking them with a center punch 1 . 4. Check: S O-ring S oil seal Damage ! Replace the defective part(-s). Check: S bearings Damage/pitting ! Replace the middle drive shaft bearing housing assembly. EAS00441 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. 4-108 .

90890-04090 EAS00443 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following points are critical when assembling the middle gears: S The collapsible collar must be replaced whenever the middle driven shaft assembly is removed from the middle driven shaft bearing housing. Install: S spring retainers 1 ENG NOTE: While compressing the spring with a damper spring compressor 2 . S If there is insufficient preload on the bearings. In addition to torquing the middle driven shaft nut to specification. 2. S When performing this procedure for the first time. allowing oil to leak past the seal. the middle driven shaft can move slightly. be sure to have at least one extra collapsible collar on hand. tighten the middle driven shaft nut. Install: S bearing outer race (into the middle driven shaft bearing housing) WARNING Do not press the bearing outer race. always press the bearing inner race carefully. Damper spring compressor YM-33286.MIDDLE GEAR 2. 1. and then install the spring retainers. While holding the universal joint driven yoke with the univesal joint holder 1 . During installation. Tighten: S middle driven shaft nut 90 Nm (9. 4-109 . you must also check the spinning torque (bearing preload).0 mSkg) CAUTION: Apply LOCTITER on to the middle driven shaft nut.

install a new collapsible collar. and repeat steps (1) – (3).MIDDLE GEAR CAUTION: ENG Tighten the middle driven shaft nut in small increments. Measure: S middle driven gear spinning torque (with the beam-type torque wrench) Under specification ! Repeat steps (2) and (3). requiring replacement of the collapsible collar and reassembly of the middle driven shaft assembly. If the spinning torque specification is exceeded. checking the torque it takes to keep the middle driven gear turning in the middle driven shaft bearing housing – not the torque it takes to start it turning. Repeat these steps until the proper spinning torque is obtained. Universal joint holder YM-04062.04X0.5 Nm (0. 90890-04062 3. tighten the middle driven shaft nut slightly and check the spinning torque again.05 mSkg) 4. This will result in a change in the standard spinning torque. Install: S universal joint driven yoke/cross joint (into the universal joint drive yoke) CAUTION: Do not hammer the universal joint drive yoke or the collapsible collar may be distorted. S If the spinning torque is not high enough.4X0. remove the middle driven shaft assembly. Middle driven gear spinning torque 0. 4-110 . CAUTION: S Never exceed the standard spinning torque.

MIDDLE GEAR ENG 5. ALIGNING THE MIDDLE GEAR 1. so check each bearing carefully. Slide the universal joint driven yok assembly back and forth on the bearings. 4-111 . NOTE: The bearings must be inserted far enough into the universal joint driven yoke assembly so that circlips can be installed. Press each bearing into the universal joint driven yoke assembly with a socket of the proper size. If a needle is out of place. Select: S middle drive gear shim(-s) NOTE: Select the proper middle drive gear shim(-s) whenever the crankcase or the middle gears are replaced. 6. Install: S bearings (onto the universal joint driven yoke/cross joint) CAUTION: Then needles can easily fall out of their races. the yoke will not go all the way onto the bearings.

If the left crankcase is stamped “45”. 5. 4.60 mm. 1. the calculated shim thickness of 0. Shim sizes are supplied in the following thicknesses: Middle drive pinion shim Thickness (mm) 0. If the middle drive gear is stamped “06” ( a positive number (+ 06) is implied since only the negative (–) designations are stamped alongside the numbers). then: “B” = 42 + 0. 8.30 mm and two 0. Then calculated shim thickness is 0. Therefore.61 mm is rounded off to 0.30 mm shims or one 0. therefore round off to the hundredths digit of the calculated thickness and select the appropriate shim(-s) with the following chart. Shims can only be selected in 0.MIDDLE GEAR ENG Example Shim thickness = Distance “A” – Distance “B” A = 43 + a B = 42 + b a.45 = 0.30 0.50 4-112 .61 mm c.06 – 42. 6 7. 9 Rounded value 0 5 10 d.06 NOTE: All stamped numbers are in hundredths of a millimeter. two 0.15 mm shims. Using the above example.45 = 42.06 = 43.15 mm shims as selected from the shim thickness chart below.61 mm. Hundredths digit 0.05 mm increments. 2 3.15 0. then: “A” = 43 + 0.45 Therefore: T=A–B = 43. you may choose either four 0. b.

Push in the middle driven shaft bearing housing and then tighten the bolts to specification.MIDDLE GEAR EAS00450 ENG ADJUSTING THE MIDDLE GEAR BACKLASH 1. Loosen: S middle driven shaft bearing housing bolts 3. Install: S middle gear backlash tool Middle gear backlash tool 90890-04080 2. Turn: S universal joint drive yoke NOTE: While carefully tightening the middle driven shaft bearing housing bolts in stages and in a crisscross pattern. Measure: S crankcase-to-middle-driven-shaft-bearinghousing clearance (with a thickness gauge) 4-113 . one thread turn at a time only. 5. Tighten: S middle driven shaft bearing housing bolts CAUTION: Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too little middle gear backlash and damage the middle gears.05 X 0. Then. as stated below. turn the universal joint drive yoke back and forth until the dial gauge reads 0. repeat all of the previous steps. when measured with a thickness gauge 1 . NOTE: S Tighten the middle driven shaft bearing housing bolts carefully.08 in). S Clearance between the crankcase and the middle driven shaft bearing housing should be approximately 2 mm (0. 6.12 mm. loosen them until the crankcase-to-middledriven-shaft-bearing-housing clearance is within specification. If the bolts are overtightened. Remove: S shim(-s) 4.

the clearance between the crankcase and the middle driven shaft bearing housing is 0. Middle drive gear shim Thickness (mm) 0. Thus. 9 Rounded value 0 5 10 Shims are supplied in the following thicknesses. Therefore.10. S After tightening the bearing retainer screws.MIDDLE GEAR 7. b. 6. 0. 0. you should use one 0. For example. 0. 1. Select: S shim(-s) 1 ENG a. stake them with a center punch. therefore round off to the hundredths digit of the calculated thickness and select the appropriate shim(-s) with the following chart. 4-114 . Tighten: S middle driven shaft bearing housing bolts 30 Nm (3 mSkg) 11. 0. 2 3. Hundredths 0. Install: S shim(-s)R 10. Shims can only be selected in 0. 0.5 mSkg) WARNING Always use new screws. Install: S bearing retainers 1 25 Nm (2.42 mm.20. the chart instructs you to round off the 2 to 0. Loosen: S middle driven shaft bearing housing bolts 9. 12.50 8. CAUTION: S Apply LOCTITER on to the retainer screws.40.05 mm increments. 4.30. Measure: S middle gear backlash Out of specification ! Refer to “MEASURING THE MIDDLE GEAR BACKLASH”.40 mm shim. 5. 7 8.15.

COOL 5 .

. . WATER PUMP . . . . . . . THERMOSTAT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .COOL CONTENTS COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5-6 5-7 5-7 5-8 5-9 5-11 5-11 5-13 5-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHECKING THE RADIATOR . . . . 5-2 INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP . . 5-3 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE WATER PUMP . . . . . .

COOL .

RADIATOR COOL COOLING SYSTEM RADIATOR 2 Nm (0. Coolant 1 2 3 4 5 6 7 Steering head side covers Lower radiator bolts Radiator hose clamps (upper and lower) Thermo unit lead Fan lead Radiator Fan motor 2 2 2 1 1 1 1 Loosen Disconnect Disconnect For installation.2 mSkg) M6 12 (3) 7 Nm (0. Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3. fuel tank Q’ty Remarks Remove the parts in the order listed.7 mSkg) M6 40 (2) Order Job/Part Removing the radiator Rider seat. reverse the removal procedure. Refer to “CHANGING THE COOLANT” in CHAPTER 3. 5-1 .

95 X 1. Install the radiator cap tester 1 to the radiator cap.25kgf/cm2. 0.RADIATOR EAS00455 COOL CHECKING THE RADIATOR 1.95 X 1. Check S radiator fan Damage ! Replace.25 bar) a. Refer to “COOLING SYSTEM” in chapter 8. 5-2 . 2. Check: S radiator fins Obstruction ! Clean. 90890-01325 b. Damage ! Repair or replace. Apply the specified pressure for ten seconds and make sure that there is no drop in pressure. Check: S radiator hoses S radiator pipes Cracks/damage ! Replace. Malfunction ! Check and repair. flathead screwdriver. NOTE: Straighten any flattened fins with a thin. 4. 3. Radiator cap opening pressure 95 X 125 kPa (0. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Radiator cap tester YU-24460-01. Apply compressed air to the rear of the radiator.

2. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Refer to “CHECKING THE RADIATOR”. 5-3 . Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. Check: S cooling system Leaks ! Repair or replace any faulty part.RADIATOR EAS00456 COOL INSTALLING THE RADIATOR 1. 3.

Refer to “REMOVING THE RADIATOR”.0 mSkg) 10 Nm (1. Refer to “CHANGING THE COOLANT” in CHAPTER 3. Disconnect 1 2 3 4 5 6 1 2 1 2 1 1 Loosen Disconnect 5-4 .0 mSkg) 10 Nm (1. Refer to “CLEANING THE AIR FILTER” in CHAPTER 3.0 mSkg) Order Job/Part Removing the thermostat Rider seat. fuel tank Coolant Air filter case Steering head side covers Overflow hose Bolts (radiator cap assembly) Coolant pipe (right) Thermostatic hose clamp (lower) Thermo switch lead Thermostat Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in CHAPTER 3.0 mSkg) 10 Nm (1.THERMOSTAT THERMOSTAT COOL 10 Nm (1.

0 mSkg) 10 Nm (1.THERMOSTAT COOL 10 Nm (1. 5-5 . reverse the removal procedure.0 mSkg) Order 7 Job/Part Radiator cap pipe Q’ty 1 Remarks For installation.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.

THERMOSTAT THERMOSTAT HOUSING COOL 23 Nm (2. reverse the disassembly procedure.0 mSkg) Order 1 2 3 4 5 6 Job/Part Disassembling the thermostat Thermostat stay Thermostat housing cover O-ring (housing cover) Thermostatic valve Thermo switch Thermostat housing Q’ty 1 1 1 1 1 1 Remarks Disassemble the parts in the order listed.3 mSkg) 10 Nm (1. 5-6 . For assembly. Refer to “ASSEMBLING THE THERMOSTAT”.

5 X 83. Thermostat full opening range 8 mm at 95 _C a. 2. Slowly heat the water. 5-7 . Check: S thermostat 1 Does not open at 80. c. While stirring the water. e. Check the opening range of the thermostat valve after keep the water around 95 _C in 5 X 6 minuts. Suspend the thermostat in a container filled with water. 1 Thermometer 2 Water 3 Thermostat 4 Container A Closes B Opens NOTE: S Do not put the thermostat directly to the bottom of the container 4 . A faulty thermostat could cause serious overheating or overcooling. d. b. observe the thermometer’s indicated temperature. Place a thermometer in the water. Install: S thermostat housing 1 S thermostat 2 S O-ring (New) 3 S thermostat housing cover 4 NOTE: Install the thermostat with its breather hole a facing up.THERMOSTAT EAS00462 COOL CHECKING THE THERMOSTAT 1. replace it. EAS500464 ASSEMBLING THE THERMOSTAT 1. Check S thermostat housing cover 1 S thermostat housing 2 Cracks/damage ! Replace. S If the accuracy of the thermostat is in doubt.5_C ! Replace.

Install: S thermo switch 1 COOL 75Nm (0. 3. Refer to “CHECKING THE RADIATOR”. 2. Replace any part that was dropped or subjected to a strong impact. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap.THERMOSTAT 2. Check: S cooling system Leaks ! Repair or replace any faulty part. EAS00466 INSTALLING THE THERMOSTAT 1. 5-8 .75 mSkg) CAUTION: Use extreme care when handing the thermo switch and temperature sender.

Loosen 1 2 3 4 5 6 7 8 9 Radiator hose clamp (lower) Bolts (water pump inlet pipe) Water pump cover O-ring Water pump inlet pipe O-ring Water pump housing Gasket Dowel pins 1 2 1 1 1 1 1 1 2 Refer to “INSTALLING THE WATER PUMP”.0 mSkg) 10 Nm (1. Refer to “CHANGING THE COOLANT” in CHAPTER 3. 5-9 . reverse the removal procedure.0 mSkg) M6 14 M6 M6 30 (2) 80 (3) Order Job/Part Removing the water pump Coolant Q’ty Remarks Remove the parts in the order listed.WATER PUMP WATER PUMP COOL 10 Nm (1.0 mSkg) M6 25 (4) 10 Nm (1. For installation.

reverse the disassembly procedure. 5-10 . For assembly.WATER PUMP COOL Order 1 2 3 4 5 6 7 8 9 10 Job/Part Disassembling the water pump Circlip Driven gear Gear stopper pin Circlip Impeller Bearing Oil seal Water pump seal Damper rubber Slip ring Q’ty 1 1 1 1 1 1 1 1 1 1 Remarks Disassemble the parts in the order listed. Refer to “ASSEMLING THE WATER PUMP”. Refer to “DISASSEMBLING/ ASSEMBLING THE WATER PUMP”.

WATER PUMP EAS00470 COOL DISASSEMBLING THE WATER PUMP 1. Check S water pump housing cover 1 S water pump housing 2 2. Remove: S water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. Remove: S rubber damper holder 1 Srubber damper 2 (from the impeller. Check S impeller 1 S rubber damper 2 S rubber damper holder 3 Cracks/damage/wear ! Replace. 2. EAS00474 CHECKING THE WATER PUMP 1. 5-11 . with a thin. flat-head screwdriver) NOTE: Do not scratch the impeller shaft. 3. Remove: S bearing 1 S oil seal 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing.

7. Check: S water pump driven gear Pitting/wear ! Replace. 5-12 . Check: S bearing Roughness ! Replace. 5.WATER PUMP COOL 3. Check: S water pump inlet pipe S radiator outlet hose Cracks/damage/wear ! Replace. Check: S water pump seal 1 S oil seal 2 Cracks/damage/wear ! Replace. 4.

Mechanical seal installer 3 90890-04078 Middle driven shaft bearing driver 4 90890-04058 Yamaha bond No. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller. Install: S water pump seal 1 New CAUTION: Never lubricate the water pump seal surface with oil or grease.WATER PUMP EAS00476 COOL ASSEMBLING THE WATER PUMP 1. apply Yamaha bond No. NOTE: S Install the water pump seal from the special tools. apply tap water or coolant onto its outer surface.15 mm 1 Straightedge 2 Impeller 3. Measure: S tilt Out of specification ! Repeat step 1. Tilt limit 0. S Before installing the water pump seal. 1215 to the water pump housing 2 . Install: S rubber damper 1 S rubber damper holder 2 NOTE: Before installing the rubber damper. 1215 90890-85505 A push down. 2. 5-13 .

S Make sure that the side of the bearing with the number faces up. 5-14 . 7. Install: S circlip 1 EAS00478 INSTALLING THE WATER PUMP 1. Install: S key S water pump driven gear NOTE: Align the slot a in the water pump driven gear with the pin b .WATER PUMP 4. Install: S oil seal S bearing 1 COOL NOTE: S Install the oil seal and bearing from the inside of the water pump housing. Install: S water pump housing 1 WARNING Always use a new gascket. Install: S impeller 1 S circlip 2 6. 5. S Gently tap the bearing into place until it is flush with the water pump housing.

Install: S O-ring (New) S water pump housing cover 1 10 Nm (1. 5-15 . NOTE: Before installing the water pump inlet pipe 2 . 3. Refer to “CHECKING THE RADIATOR”. apply a thin coat of lithium soap base grease onto the O-rings. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Check: S cooling system Leaks ! Repair or replace the faulty part.WATER PUMP COOL 2. 4.0 mSkg) S O-ring (New) S water pump inlet hose 2 WARNING Always use a new O-ring. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. 5.

COOL .

CARB 6 .

. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL COCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARB CONTENTS CARBURETORS CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION . . . . . . . . . . . . 6-1 6-6 6-8 6-10 6-10 6-11 6-14 6-15 6-15 6-16 6-16 6-16 6-17 6-18 . . AIR INDUCTION SYSTEM . AIR CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . .

CARB .

6-1 .CARBURETORS CARB CARBURETORS CARBURETORS Order Job/Part Removing the carburetors Rider seat. 1 2 3 4 5 6 7 8 9 Air induction box Fuel hose Drain hose Throttle position sensor lead Carburetour heater lead Throttle cables Air vent hoses Clamps (carburetor joints) Carburetor assembly 1 1 2 1 1 2 2 4 1 Disconnect Disconnect Disconnect Disconnect Loosen For installation. Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3. fuel tank Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure.

CARBURETORS CARB Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Separating the carburetors Choke knob Choke knob bracket Choke lever TPS Throttle stop screw Bracket Connecting bolt Bracket Carburetor heater Bracket Fuel feed pipe Breather hose Synchronization rod Bracket Q’ty 1 2 2 1 1 1 4 1 4 1 2 1 1 1 Remarks Remove the parts in the order listed. 6-2 .

reverse the disassembly procedure.CARBURETORS CARB Order 15 16 Bracket Carburetors Job/Part Q’ty 1 4 Remarks For assembly. 6-3 .

. NOTE: The remaining steps should be followed for all four of the carburetors.CARBURETORS CARB Order Job/Part Disassembling the carburetor Q’ty Remarks Disassemble the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 11 12 Starter plunger holder O-ring Starter plunger assembly Coasting enrichment cover Spring Diaphragm Vacuum chamber cover Spring Vacuum piston Plastic screw Spring Plastic bushing 6-4 1 1 1 1 1 1 1 1 1 1 1 1 Refer to “ASSEMBLING THE CARBURETORS”.

reverse the disassembly procedure. 6-5 .CARBURETORS CARB Order 13 14 15 16 17 18 19 20 21 22 23 24 Job/Part Jet needle Float chamber cover Gasket Float pin Float Needle valve Holding screw (valve seat) Valve seat Main jet Main jet holder Pilot jet Needle jet Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 Remarks For assembly.

b. Check: S needle valve 1 S needle valve seat 2 Damage/obstruction/wear ! Replace the needle valve. Check: S float chamber body Dirt ! Clean. Blow out all of the passages and jets with compressed air. a. 5. 6. Check: S O-ring 3 Damage/wear ! replace the needle valve. Wash the carburetor in a petroleumbased solvent. 3. needle valve seat and O-ring as a set. 7. Check: S fuel passages Obstruction ! Clean. Check S float chamber rubber gasket 1 Cracks/damage/wear ! Replace. Check: S float Damage ! Replace. Do not use any caustic-carburetorcleaning solution. 2. needle valve seat and O-ring as a set. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 4.CARBURETORS EAS00486 CARB CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 6-6 .

9. S rubber diaphragm 2 Cracks/tears ! Replace. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S pilot jet 4 S pilot screw 5 Bends/damage/wear ! Replace. Check: S fuel feed pipes S hose joint Cracks/damage ! Replace. 6-7 . 11.CARBURETORS CARB 8. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder Cracks/damage ! Replace. Tightness ! Replace the piston valve. Blow out the jets with compressed air. 10. Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down. Blow out the pipes with compressed air. Check: S piston valve 1 Damage/scratches/wear ! Replace. Obstruction ! Clean. Obstruction ! Clean. 12.

0 X 9. CAUTION: S Before assembling the carburetors.CARBURETORS CARB 13. Obstruction ! Clean.0 mm 6-8 . EAS00489 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors. Check: S fuel feed hoses S fuel hoses Cracks/damage/wear ! Replace. Blow out the hoses with compressed air. Install: S piston valve holder 2. 1. 3. wash all of the parts in a petroleum-based solvent. Float height 8. Measure: S float height a Out of specification ! Adjust. Install: S needle jet 1 S pilot jet S main jet NOTE: Align the slot a on the needle jet with the projection b on the carburetor body. S Always use a new gasket.

e. replace them both. If either the needle valve seat or needle valve is worn. 6. Install: S connecting bracket NOTE: After installing the connecting bracket check that the throttle cable lever and starter plunger link operate smoothly.CARBURETORS CARB a. 5. d. Check the float height again. If both the needle valve seat and needle valve are fine. Install: S coasting enricher diaphragm 1 S coasting enricher spring 2 S coasting enricher cover 3 NOTE: Align the tab a on the coasting enricher diaphragm with the recess b in the carburetor body. inspect the needle valve seat and needle valve. f. 4. Hold the carburetor upside down. Install: S piston valve S piston valve spring S vacuum chamber cover 1 NOTE: Align the tab a on the vacuum chamber cover with the recess in the carburetor body. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float. NOTE: The float arm should rest on the needle valve without depressing it. If the float height is not within specification. 6-9 . adjust the float height by bending the float tang 1 . c. b.

Adjust: S engine idling speed Engine idling speed 950 X 1. Adjust: S throttle cable free play Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in CHAPTER 3. 3. 90890-01312 d. EAS00495 MEASURING AND ADJUSTING THE FUEL LEVEL 1.050 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in CHAPTER 3. 6-10 . Fuel level (above the edge of body b ) 13. Measure: S fuel level a Out of specification ! Adjust. b. 2. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Stand the motorcycle on a level surface.0 X 14. Adjust: S carburetor synchronization Refer to “SYNCHRONIZING THE CARBURETORS” in CHAPTER 3. Fuel level gauge YM-01312-A.0 mm a.CARBURETORS EAS00493 CARB INSTALLING THE CARBURETORS 1. Loosen the fuel drain screw 3 . Install the fuel level gauge 1 to the fuel drain pipe 2 .

g. f. f. EAS00502 CHECKING AND ADJUSTING THROTTLE POSITION SENSOR THE NOTE: Before adjusting the throttle position sensor. e. Disconnect the throttle position sensor coupler. Repeat steps (a) to (f) until the fuel level is within specification. NOTE: The fuel level readings should be equal on both sides. Remove the carburetor assembly. Measure the fuel level again. replace them as a set. 2. Tester positive lead ! Blue 1 Tester negative lead ! Black 2 c. Out of specification ! Replace the throttle position sensor. 1. Throttle position sensor maximum resistance 4 X 6 kΩ at 20_C (Blue X Black) 6-11 . Connect the pocket tester (Ω 1 k) to the throttle position sensor. Check: S throttle position sensor (with it installed on the carburetor) a. d. Measure the fuel level on both sides of the carburetor assembly.CARBURETORS CARB e. Hold the fuel level gauge vertically next to the edge of body 4 . the engine idling speed should be properly adjusted. Check the needle valve seat and needle valve. If either is worn. Install the carburetor assembly. Check the throttle position sensor maximum resistance. b. adjust the float level by slightly bending the float tang 1 . Adjust: S fuel level a. c. b. If both are fine.

Throttle position sensor maximum resistance 4 X 6 kΩ at 20_C (Blue X Black) e. Out of specification or the resistance changes abruptly ! Go to step 2. While slowly opening the throttle. Tester positive lead ! Yellow 3 Tester negative lead ! Black 2 e. Remove the throttle position sensor from the carburetor. Check: S throttle position sensor (with it removed from the carburetor) a. NOTE: Check mainly that the resistance changes gradually when turning the throttle. Connect the pocket tester (Ω throttle position sensor. Throttle position sensor resistance 0. check that the throttle position sensor resistance is within the specified range. 6-12 . Out of specification ! Replace the throttle position sensor. c. While slowly opening the throttle. Tester positive lead ! Yellow 3 Tester negative lead ! Blue 1 f.6 X 5. Tester positive lead ! Blue 1 Tester negative lead ! Black 2 d. since the readings (from closed to wide-open throttle) may differ slightly from those specified. b. Connect the pocket tester (Ω 1 k) to the throttle position sensor. The slot is worn or broken 4 ! Replace the throttle position sensor. check that the throttle position sensor resistance is within the specified range. Check the throttle position sensor maximum resistance. Connect the pocket tester (Ω 1 k) to the throttle position sensor’s coupler.7 kΩ at 20_C (Yellow X Black) 2. Disconnect the throttle position sensor coupler.CARBURETORS CARB 1 k) to the d. The resistance does not change or it changes abruptly ! Replace the throttle position sensor.

Loosen the throttle position sensor screws 4 g.15) Example If the maximum resistance = 5 kΩ. Adjust the throttle position sensor angle so that the measured resistance is within the specified range. Disconnect the throttle position sensor coupler. since the readings (from closed to wide -open throttle) may differ slightly from those specified. Tester positive lead ! Yellow 3 Tester negative lead ! Blue 1 h. then the throttle position sensor’s maximum resistance when the throttle is fully closed should be: 5 kΩ (0. Lift the carburetor assembly slightly out of the intake manifolds.6 X 5. 6-13 .CARBURETORS CARB NOTE: Check mainly that the resistance changes gradually when turning the throttle. Adjust: S throttle position sensor angle a. f. After adjusting the throttle position sensor angle.7 kΩ at 20_C (Yellow X Blue) 3.13 – 0. Connect the pocket tester (Ω 1 k) to the throttle position sensor. b. Measure the throttle position sensor maximum resistance. d. Tester positive lead ! Blue 1 Tester negative lead ! Black 2 c. tighten the throttle position sensor screws.15) = 650 – 750 Ω e. Throttle position sensor resistance 0. Connect the pocket tester (Ω 100) to the throttle position sensor. Throttle position sensor resistance 583 X 875 Ω (Yellow X Blue) i. Throttle position sensor maximum resistance (throttle is fully closed) = Maximum resistance (0.13 – 0. Calculate the throttle position sensor maximum resistance when the throttle is fully closed.

welding equipment. keep gasoline away from fire. Place a container under the end of the fuel hose. b. Fuel flows ! Fuel pump is OK Fuel does not flow ! Replace the fuel pump c. Start the engine and check if fuel flows from the fuel hose 1 . Check: S fuel pump a. lighted cigarettes). Fuel stops flowing ! Fuel pump is OK Fuel flows ! Replace the fuel pump WARNING S Gasoline and its vapors are highly flammable and explosive. Stop the engine and check if the fuel stops flowing from the fuel hose 1 .CARBURETORS EAS00504 CARB CHECKING THE FUEL PUMP 1.g. Therefore. 6-14 .. sparks or open flames (e. S Failure to check for gasoline leaks may result in fire or explosion.

2. Check: S fuel cock operation a.CARBURETORS EAS00505 CARB CHECKING THE FUEL COCK 1. Check that the fuel cock lever is positioned to “ON” or “RES”. 3. Check: S fuel lock Cracks/damage/wear ! Replace. Place a container under the end of the fuel hose. EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock. Fuel flows ! Fuel cock is OK Fuel does not flow ! Replace the fuel cock 6-15 . check its operation. Suck on the end of the vacuum hose. 1.

When there is negative pressure around the exhaust port. (FLOW) 6-16 . this valve is opened in order to allow fresh air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600_ to 700_C. VIEW 1. Normally. When the throttle is rapidly closed. This is to reduce the output of the hydrocarbons. negative pressure is generated and the valve closes in order to prevent after-burning. (NO FLOW) VIEW 1.AIR INDUCTION SYSTEM EB601000 CARB AIR INDUCTION SYSTEM(AIS) AIR INJECTION This system burns the unburned exhaust gases by injecting fresh air (secondary air) at the exhaust port. VIEW 2. AIR CUT-OFF VALVE The air cut-off valve is operated by intake gas pressure through the diaphragm. (NO FLOW) When decelerating (the throttle closes). (FLOW) During normal operation the valve is open. A From the air filter B To the reed valve C To the carburetor joint VIEW 2. the valve will close. the reed valve opens and the secondary air flows into the exhaust port.

AIR INDUCTION SYSTEM EAS00509 CARB AIR INDUCTION SYSTEM DIAGRAMS 1 2 3 4 5 Reed valve Air cleaner Air cutoff valve Carburetor joint (cylinder #2) Carburetor joint (cylinder #4) A B C D E F To cylinder #1 To cylinder #2 To cylinder #3 To cylinder #4 To carburetor joint (#2) To carburetor joint (#4) 6-17 .

6-18 . Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace.AIR INDUCTION SYSTEM EAS00510 CARB CHECKING THE AIR INDUCTION SYSTEM 1. 2. S pipes Cracks/damage ! Replace. Check: S air cutoff valve Cracks/damage ! Replace.

CHAS 7 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS . . CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . REMOVING THE REAR WHEEL . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT BRAKE CALIPERS . REAR BRAKE MASTER CYLINDER . . . . . . . . . . CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS . . . REMOVING THE REAR BRAKE MASTER CYLINDER . . . . REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AND REAR BRAKES . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3 7-4 7-4 7-6 7-7 7-8 7-10 7-10 7-11 7-14 7-14 7-15 7-15 7-15 7-16 7-16 7-17 7-18 7-20 7-23 7-25 7-28 7-28 7-29 7-30 7-32 7-34 7-36 7-38 7-38 7-40 7-41 7-43 7-46 7-50 7-50 7-51 7-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL AND BRAKE DISC . . FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS . . REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FENDER . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE CALIPERS . . . . . . . . INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . .CHAS CONTENTS CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER . CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE ASSEMBLY . . REMOVING THE HANDLEBAR . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD . . . . . . . . . FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD . . . . . 7-56 7-56 7-58 7-58 7-59 7-61 7-61 7-63 7-63 7-64 7-66 7-66 7-68 7-68 7-69 7-70 7-70 7-72 7-72 7-73 7-74 7-74 7-74 7-77 7-78 7-78 7-79 7-80 7-81 7-81 7-83 7-83 7-85 7-86 7-87 . . . . . . . . ADJUSTING THE RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE ASSEMBLY AND DRIVE SHAFT . . . . . . . . . . . . REMOVING THE LOWER BRACKET . . . . . . . . . . CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS . . . . . . . . . . . . HANDLEBAR . . .CHAS INSTALLING THE FRONT FORK LEGS . . . . . . . . INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHAFT DRIVE . . . . . . . . . . . . . . MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE . . . . . . . . . . . . . . . . CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND INSTALLING THE RING GEAR BEARINGS . . STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE . . . . . . . . . . . . REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . FINAL DRIVE ASSEMBLY AND DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR . . INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . 7-55 HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . .

. . . . . . . . . . 7-91 INSTALLING THE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . .CHAS CHECKING THE DRIVE SHAFT . . 7-91 . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS .

2 3 4 Pinch bolt(front wheel axle) Front wheel axle Front wheel 7-1 .8 mSkg) 23 Nm (2. 1 1 1 Loosen Elevate the front wheel.3 mSkg) M8 25 (6) 19 Nm (1.9 mSkg) 40 Nm (4.3 mSkg) M8 25 (6) Order Job/Part Removing the front wheel and brake discs Q’ty Remarks Remove the parts in the order listed. Stand the motorcycle on a level surface. Place a suitable stand under the engine. WARNING Securely support the motorcycle so there is no danger of it falling over.FRONT WHEEL AND BRAKE DISCS EAS00514 CHAS CHASSIS FRONT WHEEL AND BRAKE DISCS 25 Nm (2.5 mSkg) 78 Nm (7.0 mSkg) 23 Nm (2. 1 Front brake calipers/brackets (left and right) 2/2 NOTE: Do not depress the brake lever when the wheel is off of the motorcycle as the brake pads will be forced shut.

7-2 .5 mSkg) 78 Nm (7.8 mSkg) 23 Nm (2.FRONT WHEEL AND BRAKE DISCS “ CHAS 25 Nm (2. reverse the removal procedure.0 mSkg) 23 Nm (2.9 mSkg) 40 Nm (4.3 mSkg) M8 25 (6) Order 5 6 7 8 Job/Part Collars Brake disc cover (left) Brake discs Brake disc cover (right-with weight) Q’ty 2 1 2 1 Remarks Refer to “INSTALLING THE FRONT WHEEL”. For installation.3 mSkg) M8 25 (6) 19 Nm (1.

reverse the disassembly procedure. 1 2 3 Oil seals Bearings Spacer 2 2 1 For assembly. 7-3 .FRONT WHEEL AND BRAKE DISCS EAS00518 CHAS FRONT WHEEL Order Job/Part Disassembling the front wheel Q’ty Remarks Disassemble the parts in the order listed.

WARNING Do not attempt to straighten a bent wheel axle. Check: S wheel axle Roll the wheel axle on a flat surface. Bends ! Replace. 2. EAS00525 CHECKING THE FRONT WHEEL 1. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.FRONT WHEEL AND BRAKE DISCS EAS00521 CHAS REMOVING THE FRONT WHEEL 1. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 7-4 . Loosen S front wheel axle 1 . 2. Elevate: S front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 3. Remove: S brake caliper S brake caliper bracket NOTE: Do not squeeze the brake lever when removing the brake calipers. 4. WARNING Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. Check: S tire S front wheel Damage/wear ! Replace.

place a rag 2 between the screwdriver and the wheel surface. CAUTION: Do not contact the wheel bearing center race 2 or balls 3 . 7-5 . Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel. d.5 mm 4. S oil seals Damage/wear ! Replace.0 mm Front wheel lateral runout limit 0. 5. b. Contact should be made only with the outer race 4 . Remove the wheel bearings with a general bearing puller. Clean the outside of the front wheel hub. NOTE: Use a socket 1 that matches the diameter of the wheel bearing outer race and oil seal. Install the new wheel bearings and oil seals in the reverse order of disassembly. Replace: S wheel bearings (New) S oil seals (New) a. Check: S wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. c.FRONT WHEEL AND BRAKE DISCS CHAS 3. Front wheel radial runout limit 1.

Brake disc thickness limit (minimum) Front: 4. Check: S brake disc Damage/galling ! Replace. Remove the brake disc.15 mm a. e. turn the handlebar to the left or right to ensure that the front wheel is stationary. 3. Out of specification ! Replace.5 mm 4. b. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.5 mm Rear: 6. Measure the deflection 2 X 3 mm b below the edge of the brake disc. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. 1. 2. Remove the brake caliper. Rotate the brake disc by one bolt hole. Hold the dial gauge 1 at a right angle against the brake disc surface. Before measuring the front brake disc deflection. d.15 mm Rear: 0. b. Brake disc deflection limit (maximum) Front: 0.FRONT WHEEL AND BRAKE DISCS EAS00531 CHAS CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. Measure: S brake disc thickness a Measure the brake disc thickness at a few different locations. c. c. Adjust: S brake disc deflection a. Place the motorcycle on a suitable stand so that the wheel is elevated. Install the brake disc. 7-6 .

f.9 mSkg) CAUTION: Before tightening the wheel axle nut.0 mSkg) S brake caliper 2 25 Nm (2. If out of specification.3 mSkg) LOCTITE® d. Install: S brake caliper bracket 1 40 Nm (4. 1. e.5 mSkg) WARNING Make sure that the brake hose is routed properly. 7-7 . S Tighten the brake disc bolts in stages and in a crisscross pattern. If the brake disc deflection cannot be brought within specification. repeat the adjustment steps until the brake disc deflection is within specification. 3.8 mSkg) 19 Nm (1. push down hard on the handlebar several times and check if the front fork rebounds smoothly. Measure the brake disc deflection. EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 4. replace the brake disc.FRONT WHEEL AND BRAKE DISCS CHAS Brake disc bolt 23 Nm (2. Install: S brake disc 1 S brake disc cover 2 NOTE: S Apply LOCTITE® 648 to the threads of the brake disc bolts. Tighten: S wheel axle 1 S wheel axle pinch bolt 2 78 Nm (7. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2.

The spot where all the marks come to rest is the front wheel’s heavy spot “X”. b. Remove: S balancing weight (-s) NOTE: Place the front wheel on a suitable balancing stand. e. put an “X” mark at the bottom of the wheel. When the front wheel stops. Repeat steps (b) through (d) several times until all the marks come to rest at the same spot. 7-8 . adjust: S front wheel static balance a. g. Turn the front wheel 90_ so that the “X1” mark is positioned as shown. NOTE: Start with the lightest weight.FRONT WHEEL AND BRAKE DISCS EAS00549 CHAS ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire. c. put an “X2” mark at the bottom of the wheel. Spin the front wheel. d. S Adjust the front wheel static balance with the brake discs installed. Find: S front wheel’s heavy spot a. wheel or both. When the wheel stops. 2. f. 1. 3. the front wheel static balance should be adjusted. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. Release the front wheel.

rebalance it.FRONT WHEEL AND BRAKE DISCS CHAS b. d. Repeat steps (b) and (c) until the front wheel is balanced. Turn the front wheel 90_ so that the heavy spot is positioned as shown. If the heavy spot does not stay in that position. c. 7-9 . b. install a heavier weight. Turn the front wheel and make sure that it stays at each position shown. Check: S front wheel static balance a. 4. If the front wheel does not remain stationary at all of the positions.

Stand the motorcycle on a level surface. Ride seat 1 2 3 4 5 Antenna.8 mSkg) 48 Nm (4. WARNING Securely support the motorcycle so there is no danger of it falling over.8 mSkg) 23 Nm (2. trunk and saddlebags Antenna lead Tail/brake and flasher lights lead coupler Passenger footrests (left and right) Side covers (left and right) Rear fender assembly 1 1 2 2 1 Disconnect For installation. Refer to ”SADDLEBAGS” in CHAPTER3. 7-10 Refer to ”RIDER AND PASSENGER SEATS” in CHAPTER 3.3 mSkg) Order Job/Part Removing the rear fender Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. .REAR WHEEL AND BRAKE DISC EAS00551 CHAS REAR WHEEL AND BRAKE DISC REAR FENDER 48 Nm (4.

0 mSkg) 23 Nm (2.0 mSkg) 150 Nm (1. 1 2 3 4 5 1 1 1 1 1 NOTE: Do not depress the brake pedal when removing the rear brake caliper.REAR WHEEL AND BRAKE DISC EAS00560 CHAS REAR WHEEL AND BRAKE DISC 40 Nm (4. Loosen 6 7 8 Pinch bolt Rear wheel axle nut Washer 1 1 1 7-11 .3 mSkg) Order Job/Part Removing the rear wheel and brake disc Muffler (right) Saddlebag guide bar (left and right) Side cover (right) Exhaust pipe Rear brake caliper Q’ty Remarks Remove the parts in the order listed.5 mSkg) 40 Nm (4.

Place a suitable stand under the engine.5 mSkg) 40Nm (4.0mSkg) 23 Nm (2. reverse the removal procedure.3 mSkg) Order 9 Job/Part Rear wheel axle Q’ty 1 Remarks NOTE: S Elevate the rear wheel.REAR WHEEL AND BRAKE DISC CHAS 40Nm (4. S Move the wheel to the right to separate it from the final gear case. 7-12 . 10 11 12 13 14 Washer Rear brake caliper bracket Rear wheel Collar Brake disc 1 1 1 1 1 For installation.0mSkg) 150 Nm (1.

reverse the disassembly procedure.REAR WHEEL AND BRAKE DISC CHAS Order 1 2 3 4 5 6 7 8 9 10 Job/Part Disassembling the rear wheel Oil seal Bearing Collar Oil seal Bearing Circlip Clutch hub Hub dust seal Damper O-ring Q’ty 1 1 1 1 1 1 1 1 6 1 Remarks Disassemble the parts in the order listed. For assembly. 7-13 .

Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to “FRONT WHEEL AND BRAKE DISCS”. 2. 3. Remove: S wheel axle nut 2 S washer S wheel axle 3 Move the rear wheel to the right to separate it from the final drive housing. Measure: S rear wheel radial runout S rear wheel lateral runout Refer to “FRONT WHEEL AND BRAKE DISCS”. Remove: S brake caliper 1 NOTE: Do not depress the brake pedal when removing the brake caliper. Check: S tire S rear wheel Damage/wear ! Replace. 2. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in CHAPTER 3. Loosen: S pinch bolt 1 4. Remove: S rear wheel EAS00565 CHECKING THE REAR WHEEL 1. 7-14 . NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 5.REAR WHEEL AND BRAKE DISC EAS00562 CHAS REMOVING THE REAR WHEEL 1. 3.

3 mSkg) 40 Nm (4. Adjust: S rear wheel static balance Refer to “FRONT WHEEL AND BRAKE DISCS”.REAR WHEEL AND BRAKE DISC EAS00567 CHAS CHECKING THE REAR WHEEL DRIVE HUB 1. the rear wheel static balance should be adjusted.0 mSkg) EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire. S rear wheel drive hub dampers Damage/wear ! Replace. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2.0 mSkg) 23 Nm (2. EAS00572 INSTALLING THE REAR WHEEL 1. Check: S rear wheel drive hub Cracks/damage ! Replace. 1. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. wheel or both. 7-15 . Tighten: S wheel axle nut S pinch bolt S brake caliper bolts 150 Nm (15.

FRONT AND REAR BRAKES EAS00577 CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS 25 Nm (2.5 mSkg) Order 1 2 3 Job/Part Removing the front brake pads Brake caliper retaining bolts Brake caliper Brake pads Q’ty 2 1 2 Remarks Remove the parts in the order listed Refer to “REPLACING THE FRONT BRAKE PADS”. reverse the removal procedure. For installation. 7-16 .

7-17 . 6 Brake caliper 1 For installation. S Replace the brake pads as a set if either is found to be worn to the wear limit. NOTE: S When the brake pads have to be replaced install a new brake pad spring.FRONT AND REAR BRAKES REAR BRAKE PADS CHAS 40 Nm (4.0 mSkg) Order 1 2 3 4 5 Job/Part Removing the rear brake pad Brake pad cover Retaining clips Retaining pins Brake pad spring Brake pads Q’ty 1 2 2 1 2 Remarks Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PADS”. reverse the removal procedure.

always clean up any spilt fluid immediately. the entire brake system must be disassembled. Therefore. First aid for brake fluid entering the eyes: S Flush with water for 15 minutes and get immediate medical attention. S If any connection on the hydraulic brake system is disconnected. 1. Remove: S brake hose holder 1 S brake caliper 2 7-18 .FRONT AND REAR BRAKES EAS00579 CHAS CAUTION: Disc brake components rarely require disassembly. S Brake fluid may damage painted surfaces and plastic parts. Therefore. always follow these preventive measures: S Never disassemble brake components unless absolutely necessary. properly filled. it is not necessary to disconnect the brake hose or disassemble the brake caliper. and bled after reassembly. EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. cleaned. NOTE: When replacing the brake pads. S Avoid brake fluid coming into contact with the eyes as it can cause serious injury. S Never use solvents on internal brake components. drained. S Use only clean or new brake fluid for cleaning brake components.

Tighten the bleed screw.FRONT AND REAR BRAKES CHAS 2. e. a. Bleed screw 6 Nm (0. Remove: S brake pads 1 (along with the brake pad shims) 3. Put the other end of the hose into an open container. Install: S brake pad shims (onto the brake pads) S brake pads NOTE: Always install new brake pads.6 mSkg) d. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Connect a clear plastic hose 1 tightly to the bleed screw 2 . c. b. 7-19 . Install new brake pads.6 mm 4. Install new brake pad shims onto the new brake pads. and a brake pad spring as a set. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Brake pad wear limit 0. brake pad shims.

5 mSkg) 6. EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads. Remove: S brake pad cover 1 S brake caliper 2 2. 7. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3.FRONT AND REAR BRAKES CHAS 5. Remove: S brake pad clips 1 S brake pad pins 2 S brake pad spring 3 7-20 . Install: S brake caliper retaining bolt 25 Nm (2. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. 1. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. it is not necessary to disconnect the brake hose or disassemble the brake caliper. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

Remove: S brake pads 1 CHAS 4. c. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Put the other end of the hose into an open container. b. Bleed screw 6 Nm (0. NOTE: The arrow mark a of the brake pad spring must point in the direction of disc rotation. Install new brake pads and a new brake pad spring. Tighten the bleed screw. 7-21 .6 mSkg) e. a. Brake pad wear limit 0.5 mm 5.FRONT AND REAR BRAKES 3. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads and a brake pad spring as a set. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Connect a clear plastic hose 1 tightly to the bleed screw 2 .

FRONT AND REAR BRAKES 6. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. Install: S brake pad pins S brake pad clips S brake pad cover S brake caliper CHAS Brake caliper bolt 40 Nm (4. 8. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3.0 mSkg) 7. 7-22 . Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

NOTE: Before removing the master cylinder. reverse the removal procedure.0 mSkg) 30 Nm (3. 1 2 3 4 5 6 7 8 Rear view mirror Brake lever Union bolt Brake hose Copper washers Master cylinder bracket Master cylinder Front brake switch 1 1 1 1 2 1 1 1 Refer to “REMOVING/INSTALLING THE FRONT BRAKE MASTER CYLINDER”.FRONT AND REAR BRAKES EAS00584 CHAS FRONT BRAKE MASTER CYLINDER 10 Nm (1. drain the brake fluid from the entire brake system.0 mSkg) New Order Job/Part Removing the front brake master cylinder Q’ty Remarks Remove the parts in the order below. 7-23 . For installation.

reverse the disassembly procedure.FRONT AND REAR BRAKES EAS00585 CHAS Order Job/Part Disassembling the front brake master cylinder Master cylinder cap Holder (diaphragm) Master cylinder diaphragm Dust boot Circlip Master cylinder kit Q’ty Remarks Disassemble the parts in the order listed. 1 2 3 4 5 6 1 1 1 1 1 1 For assembly. 7-24 .

NOTE: Before removing the master cylinder. drain the brake fluid from the entire brake system.FRONT AND REAR BRAKES EAS00586 CHAS REAR BRAKE MASTER CYLINDER 30 Nm (3.3 mSkg) Order Job/Part Removing the rear brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 7 Rear brake switch Brake hose Copper washer Brake pedal assembly Master cylinder Cotter pin Washer 1 1 1 1 1 1 1 Disconnect Disconnect Refer to “REMOVING/INSTALLING THE REAR BRAKE MASTER CYLINDER”.0 mSkg) New 52 Nm (5.2 mSkg) 23 Nm (2. 7-25 .

FRONT AND REAR BRAKES CHAS 30 Nm (3. reverse the removal procedure.0 mSkg) New 52 Nm (5. For installation. 7-26 .2 mSkg) 23 Nm (2.3 mSkg) Order 8 9 10 11 Job/Part Clevis pin Reservoir hose Reservoir tank cover Reservoir tank Q’ty 1 1 1 1 Remarks Unhook from the clamps.

FRONT AND REAR BRAKES EAS00587 CHAS Order Job/Part Disassembling the rear brake master cylinder Dust boot Circlip Brake pedal push rod Master cylinder kit Cap (reservoir tank) Diaphragm Reservoir tank Q’ty Remarks Disassemble the parts in the order listed. 1 2 3 4 5 6 7 1 1 1 1 1 1 1 For assembly. reverse the disassembly procedure. 7-27 .

place a container under the master cylinder and the end of the brake hose. 7-28 . place a container under the master cylinder and the end of the brake hose. drain the brake fluid from the entire brake system.FRONT AND REAR BRAKES EAS00588 CHAS REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder. 1. Remove: S brake pedal assembly 1 2. Remove: S brake switch 1 2. Remove: S union bolt 1 S copper washers 2 S brake hoses 3 NOTE: To collect any remaining brake fluid. EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER 1. Remove: S joint bolt 1 S copper washers 2 S brake hose 3 NOTE: To collect any remaining brake fluid.

FRONT AND REAR BRAKES A EAS00592 CHAS A CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. A Front B Rear A B 2. A Front B Rear 3. Check: S front brake master cylinder reservoir 1 Cracks/damage ! Replace. Check: S rear brake fluid reservoir 1 Cracks/damage ! Replace. S front brake master cylinder reservoir diaphragm 2 Damage/wear ! Replace. 7-29 . Check: S brake master cylinder kit 1 Damage/scratches/wear ! Replace. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. 1. S rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. S brake fluid delivery passages 2 (brake master cylinder body) Obstruction ! Blow out with compressed air. 4.

7-30 . leads). NOTE: Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts (e. all internal brake components should be cleaned and lubricated with clean or new brake fluid.FRONT AND REAR BRAKES CHAS 5. EAS00598 INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation. Check: S brake reservoir hose 1 Cracks/damage/wear ! Replace. Install: S brake master cylinder 1 10 Nm (1. Recommended brake fluid DOT 4 1. cables. Install: S copper washers 1 (New) S brake hose 2 S union bolt 3 30 Nm (3. tighten the upper bolt.. S First. wire harness.g.0 mSkg) NOTE: S Install the brake master cylinder holder with the “UP” mark facing up. 2. S Align the end of the brake master cylinder holder with the punch mark a on the handlebar. S Never use solvents on internal brake components.0 mSkg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. then the lower bolt. Correct if necessary. Refer to “CABLE ROUTING”.

FRONT AND REAR BRAKES CHAS 3. CAUTION: Brake fluid may damage painted surfaces and plastic parts. S Refill with the same type of brake fluid that is already in the system. S When refilling. 6. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. always clean up any spilt brake fluid immediately. Therefore. 5. be careful that water does not enter the reservoir. leading to poor brake performance. Mixing brake fluids may result in a harmful chemical reaction. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. 7-31 . causing leakage and poor brake performance. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Other brake fluids may cause the rubber seals to deteriorate. 4.

CAUTION: Brake fluid may damage painted surfaces and plastic parts.FRONT AND REAR BRAKES EAS00610 CHAS INSTALLING THE REAR BRAKE MASTER CYLINDER 1. be careful that water does not enter the reservoir. Other brake fluids may cause the rubber seals to deteriorate. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Mixing brake fluids may result in a harmful chemical reaction. leading to poor brake performance. causing leakage and poor brake performance. 4. Refer to “CABLE ROUTING”. S Refill with the same type of brake fluid that is already in the system. Therefore.0 mSkg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. S When refilling. 2. always clean up any spilt brake fluid immediately. Fill: S brake fluid reservoir (to the maximum level mark a ) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Install: S copper washers 1 (New) S brake hose 2 30 Nm (3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3. 3. 7-32 .

7-33 . Brake pedal position (below the top of the rider footrest) 100 mm 6. Adjust: S rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in CHAPTER 3.FRONT AND REAR BRAKES CHAS 5. Adjust: S brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in CHAPTER 3.

5 6 Front brake calipers Brake caliper brackets 2 2 For installation. drain the brake fluid from the entire brake system. NOTE: Before removing the brake caliper. 1 2 3 4 Brake hose holders Union bolts Copper washers Brake hoses 2 2 4 2 Refer to “INSTALLING THE FRONT BRAKE CALIPERS”.0 mSkg) 40 Nm (4. reverse the removal procedure.FRONT AND REAR BRAKES EAS00613 CHAS FRONT BRAKE CALIPERS 30 Nm (3.0 mSkg) 25 Nm (2.5 mSkg) Order Job/Part Removing the front brake calipers Q’ty Remarks Remove the parts in the order listed. NOTE: Put the brake hose end into a container and pump out the brake fluid carefully. 7-34 .

reverse the disassembly procedure.6 mSkg) Order Job/Part Disassembling the front brake caliper Air bleed screw Caliper pistons Caliper piston seals Q’ty Remarks Disassemble the parts in the order listed. 1 2 3 1 8 4 Refer to “DISASSEMBLING THE FRONT BRAKE CALIPERS For assembly.FRONT AND REAR BRAKES CHAS 6 Nm (0. 7-35 .

For installation.0 mSkg) Order Job/Part Removing the rear brake caliper Q’ty Remarks Remove the parts in the order listed. NOTE: Before removing the master cylinder. 4 Rear brake caliper 1 7-36 . NOTE: Put the brake hose end into a container and pump out the brake fluid carefully. 1 2 3 Union bolt Copper washers Brake hose 1 2 1 Refer to ”INSTALLING THE REAR BRAKE CALIPER”. reverse the removal procedure.0 mSkg) 40 Nm (4.FRONT AND REAR BRAKES EAS00616 CHAS REAR BRAKE CALIPER 30 Nm (3. drain the brake fluid from the entire brake system.

FRONT AND REAR BRAKES EAS00617 CHAS 6 Nm (0. Refer to “REAR BRAKE PADS”.6 mSkg) Order 1 2 3 4 5 Job/Part Disassembling the rear brake caliper Brake pads cover Brake pads Air bleed screw Caliper pistons Caliper piston seals Q’ty 1 2 1 4 8 Remarks Disassemble the parts in the order listed. 7-37 . Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”. For assembly. reverse the disassembly procedure.

NOTE: Before disassembling either brake caliper. Repeat the previous steps to force out the other side pistons from the brake caliper. Secure the one brake caliper piston with a piece of wood a b. Remove the brake caliper piston seals. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. c. d. 7-38 . 1. EAS00629 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper. drain the brake fluid from the entire brake system. drain the brake fluid from the entire brake system. Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper. WARNING Never try to pry out the brake caliper pistons. 2. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a.FRONT AND REAR BRAKES EAS00625 CHAS DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.

d. WARNING S Never try to pry out the brake caliper pistons. S Do not loosen the bolts 4 . Secure the right side brake caliper pistons with a piece of wood 3 b. Remove the brake caliper piston seals. Remove: S union bolt 1 S copper washers 2 S brake hose CHAS NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. c. 7-39 .FRONT AND REAR BRAKES 1. 2. Blow compressed air into the brake hose joint opening a to force out the left side pistons from the brake caliper. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a. Repeat the previous steps to force out the right side pistons from the brake caliper.

FRONT AND REAR BRAKES EAS00632 CHAS CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every two years Every two years and whenever the brake is disassembled A B 1. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air. S brake calipers 3 Cracks/damage ! Replace. S brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. 7-40 . Check: S brake caliper brackets 1 Cracks/damage ! Replace. A Front B Rear 2. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. replace the brake caliper piston seals. WARNING Whenever a brake caliper is disassembled.

S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. WARNING S Before installation. replace the brake caliper piston seals. Install: S brake caliper bracket 40 Nm (40 mSkg) S brake caliper 1 (temporarily) S copper washers (New) S brake hose 2 S union bolt 3 30 Nm (30 mSkg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Recommended brake fluid DOT 4 1. all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Whenever a brake caliper is disassembled. Remove: S brake caliper 7-41 . Refer to “CABLE ROUTING”. 2.FRONT AND REAR BRAKES EAS00638 CHAS INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. CAUTION: When installing the brake hose onto the brake caliper 1 . make sure that the brake pipe a touches the projection b on the brake caliper.

Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Mixing brake fluids may result in a harmful chemical reaction. Therefore. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. leading to poor brake performance. be careful that water does not enter the reservoir. 7-42 . Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. causing leakage and poor brake performance.FRONT AND REAR BRAKES CHAS 3. Install: S brake pads S brake pad shim 25 Nm (2. 6.5 mSkg) S brake caliper Refer to “REPLACING THE BRAKE PADS”. always clean up any spilt brake fluid immediately. Other brake fluids may cause the rubber seals to deteriorate. S When refilling. CAUTION: Brake fluid may damage painted surfaces and plastic parts. 4. S Refill with the same type of brake fluid that is already in the system. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Refer to “CABLE ROUTING”. all internal brake-components should be cleaned and lubricated with clean or new brake fluid. Install: S brake caliper 1 (temporarily) S copper washers (New) S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. 2. Recommended brake fluid DOT 4 1. replace the brake caliper piston seals. make sure that the brake pipe a touches the projection b on the brake caliper. Remove: S brake caliper 7-43 . CAUTION: When installing the brake hose onto the brake caliper 1 . Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system.FRONT AND REAR BRAKES CHAS 7. S Whenever a brake caliper is disassembled. INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation.

S Refill with the same type of brake fluid that is already in the system. 4. causing leakage and poor brake performance. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. leading to poor brake performance. Other brake fluids may cause the rubber seals to deteriorate.0 mSkg) S brake caliper Refer to “REPLACING THE BRAKE PADS”. Therefore. Fill: S brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. be careful that water does not enter the reservoir. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. 5. Install: S brake pads S brake pad springs S brake pins S retaining clips 40 Nm (4. CAUTION: Brake fluid may damage painted surfaces and plastic parts.FRONT AND REAR BRAKES CHAS 3. always clean up any spilt brake fluid immediately. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3. S When refilling. Mixing brake fluids may result in a harmful chemical reaction. 7-44 . Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. 6.

FRONT AND REAR BRAKES CHAS 7. 7-45 . Check: S brake pedal operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3.

FRONT FORK EAS00647 CHAS FRONT FORK 10 Nm (1. Refer to “HANDLEBAR”. Front brake calipers (left and right) Front wheel Front cowling Handlebar Refer to “FRONT AND REAR BRAKES”. 7-46 .0 mSkg) Order Job/Part Removing the front fork Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT COWLING” in CHAPTER 3. Refer to “FRONT WHEEL”.0 mSkg) 20 Nm (2. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.

0 mSkg) 20 Nm (2.FRONT FORK CHAS 10 Nm (1. Loosen. reverse the removal procedure.0 mSkg) Order 1 2 3 4 5 6 7 8 Upper bracket Job/Part Q’ty 1 2 2 2 4 2 2 2 Remarks Refer to “CHECKING THE STEERING HEAD” in CHAPTER 3. Upper fork covers Upper fork cover spacers Upper fork cover washers Front fork pinch bolts (lower) Front fork legs Brake hose guides Lower fork covers For installation. Refer to “REMOVING/INSTALLING THE FRONT FORK LEGS”. 7-47 .

4 5 6 7 8 9 10 Dust seal Retaining clip Bolt/gasket Damper rod/rebound spring Inner tube Oil seal Seal spacer 1 1 1/1 1/1 1 1 1 Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”.3 mSkg) 20 Nm (2. Drain the fork oil.0 mSkg) Order 1 2 3 Job/Part Disassembling the front fork Cap bolt O-ring Fork spring Q’ty 1 1 1 Remarks Disassemble the parts in the order listed. 7-48 .FRONT FORK EAS00648 CHAS 23 Nm (2. Pump the fork tube several times to remove the fork oil.

For assembly.FRONT FORK CHAS 23 Nm (2. reverse the disassembly procedure.0 mSkg) Order 11 12 13 14 Job/Part Outer tube bushing Inner tube bushing Oil flow stopper Outer tube Q’ty 1 1 1 1 Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”.3 mSkg) 20 Nm (2. 7-49 .

FRONT FORK EAS00649 CHAS REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Remove: S damper rod bolt NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 . 90890-01294 T-Handle YM-01326. 4. 90890-01326 7-50 . WARNING Securely support the motorcycle so that there is no danger of it falling over. loosen the damper rod bolt. 1. support the front fork leg. NOTE: Place the motocycle on a suitable stand so that the front wheel is elevated. 2. 1. 2. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. Remove: S front fork leg EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Remove: S upper bracket Refer to “STEERING HEAD” 3. Damper rod holder YM-01300-1. Stand the motorcycle on a level surface. Loosen: S lower bracket pinch bolt 1 WARNING Before loosening the upper and lower bracket pinch bolts.

c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. S oil flow stopper 2 Damage ! Replace. EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. 2. Measure: S spring free length a Over the specified limit ! Replace. A damaged oil seal or bushing must be replaced. as the oil flow stopper will be damaged. 7-51 . Hold the front fork leg horizontally. Spring free length limit 573 mm 3. Securely clamp the brake caliper bracket in a vise with soft jaws. Check: S damper rod 1 Damage/wear ! Replace. Remove: S inner tube CHAS a. S Avoid bottoming the inner tube into the outer tube during the above procedure. Obstruction ! Blow out all of the oil passages with compressed air. b.FRONT FORK 3. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 1. CAUTION: S Excessive force will damage the oil seal and bushing.

NOTE: S When assembling the front fork leg. Install: S damper rod 1 CAUTION: Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal S Before assembling the front fork leg. 1. S When disassembling and assembling the front fork leg. which are particularly sensitive to foreign material.FRONT FORK CAUTION: CHAS S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction. 4. make sure that all of the components are clean. Be careful not to damage the inner tube. EAS00658 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 7-52 . WARNING S Make sure that the oil levels in both front fork legs are equal. Check: S cap bolt O-ring Damage/wear ! Replace. S Uneven oil levels can result in poor handling and a loss of stability. do not allow any foreign material to enter the front fork.

Install: S outer tube bushing 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight YM-33963. 7-53 . cover the top of the front fork leg with a plastic bag a to protect the oil seal during installation. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 5W or equivalent 3. 90890-01374 5.0 mSkg) NOTE: While holding the damper rod with the damper rod holder and T-handle. S Apply fork oil onto the outer surface of the inner tube. Install: S washer S oil seal 1 (with the fork seal driver weight and adapter) CAUTION: Make sure that the numbered side of the oil seal faces up. tighten the damper rod bolt. Tighten: S damper rod bolt LOCTITE® 204 20 Nm (2. S Before installing the oil seal.FRONT FORK CHAS 2. 90890-01326 4. 90890-01367 Adapter YM-8020. apply lithium soap base grease onto its lips. Damper rod holder YM-01300-1. NOTE: S Before installing the oil seal. 90890-01294 T-handle YM-01326.

apply grease onto the O-ring. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0. 7. S After filling. Install: S oil seal clip 1 CHAS NOTE: Adjust the oil seal clip so that it fits into the outer tube groove. Install: S spring 1 S cap bolt 2 NOTE: S Install the spring with the smaller pitch facing down. keep it upright. slowly pump the front fork leg up and down to distribute the fork oil.553 L Front fork leg oil level (from the top of the inner tube. S Temporarily tighten the cap bolt. 7-54 . and without the fork spring) 117 mm Recommended oil Yamaha fork and shock oil 5W or equivalent NOTE: S While filling the front fork leg.FRONT FORK 6. S Before installing the cap bolt. with the inner tube fully compressed. 9. Install: S dust seal 1 (with the fork seal driver weight) 8.

7. Tighten S cap bolt 3 23 Nm (2. 3.0 mSkg) 4. 2. Adjust: S spring preload Refer “ADJUSTING THE FRONT FORK” in CHAPTER 3.0 mSkg) 6. Install: S front fork leg Temporarily tighten the lower bracket pinch bolts. 7-55 . NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. remove S upper bracket 5. Install S upper fork cover 1 S upper bracket 2 10 Nm (1. 1. Install: S upper bracket Temporarily tighten the steering stem nut.FRONT FORK EAS00662 CHAS INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.3 mSkg) WARNING Make sure that the brake hoses are routed properly. Tighten S lower bracket pich bolt 20 Nm (2.

0 mSkg) M6 25 32 Nm (3. 7-56 . WARNING Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface.8 mSkg) M8 25 (4) 10 Nm (1.HANDLEBAR EAS00664 CHAS HANDLEBAR 28 Nm (2. 1 2 3 4 Plastic locking ties Front brake master cylinder Handlebar switch (right) Throttle grip 4 1 1 1 Refer to “FRONT AND REAR BRAKES”. Refer to ”INSTALLING THE HANDLEBAR”.2 mSkg) Order Job/Part Removing the handlebar Q’ty Remarks Remove the parts in the order listed .

0 mSkg) M6 25 35 Nm (3. For installation. reverse the removal procedure. Disconnect Refer to “INSTALLING THE HANDLEBAR”.3 mSkg) M8 25 (4) 10 Nm (1.5 mSkg) Order 5 6 7 8 9 10 11 Job/Part Clutch master cylinder Clutch switch coupler Handlebar switches (left) Grip (left) Handlebar bracket (upper) Handlebar Handlebar bracket (lower) Q’ty 1 1 1 1 2 1 2 Remarks Refer to “CLUTCH” in CHAPTER 4. 7-57 .HANDLEBAR CHAS 23 Nm (2.

3. Install: S handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. EAS00668 CHECKING THE HANDLEBAR 1. 7-58 . 2. Check: S handlebar 1 Bends/cracks/damage ! Replace. b. Stand the motorcycle on a level surface. Slide the handlebar grip over the left end of the handlebar. WARNING Securely support the motorcycle so that there is no danger of it falling over. Remove: S left handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip. Remove: S throttle cable housing 1 S throttle grip 2 3.HANDLEBAR EAS00666 CHAS REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. 2. and gradually push the grip off the handlebar. WARNING Securely support the motorcycle so that there is not danger of it falling over. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

tighten the bolts on the front side of the handlebar holder.HANDLEBAR CHAS c. 3. NOTE: Align the match marks a on the handlebar with the upper surface of the lower handlebar holders. EAS00672 INSTALLING THE HANDLEBAR 1. Wipe off any excess rubber adhesive with a clean rag. Install: S handlebar 1 S upper handlebar holders 2 28 Nm (2. Stand the motorcycle on a level surface. adjust the handlebar position. WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. If there is any contact with the fuel tank. WARNING Securely support the motorcycle so that there is no danger of it falling over. Install: S throttle grip 1 S throttle cables 7-59 .8 mSkg) CAUTION: S First. 2. S Turn the handlebar all the way to the left and right. then on the rear side.

5. Installing the throttle cable 2 on cruise control rotor No.HANDLEBAR CHAS a.4 b. when installing.2 d. 6 Throttle grip 7 Carburetor 8 Cruise control actuator 4. Install: S brake master cylinder Refer to “FRONT AND REAR BRAKES”. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm Cruise control cable free play 1 X 2 mm 7-60 . Install: S right handlebar switch NOTE: Align the pins a on the right handlebar switch with the holes b in the handlebar. Adjust: S throttle cable free play S cruise control cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in CHAPTER 3. 7. Installing the throttle cable 1 on cruise control rotor No.3 c.1 WARNING Pay attention to the mark on throttle cable 1 X 4 and throttle rotor 5 . Installing the throttle 3 on cruise control rotor No. Install: S left handlebar switch NOTE: Align the mating surfaces of the left handlebar switch with the punch mark a on the handlebar. Installing the throttle cable 4 on cruise control rotor No. 6.

front forks Leads (to the front cowling body) Chrome flasher bracket cover 7-61 .STEERING HEAD EAS00676 CHAS STEERING HEAD 130 Nm (13. Refer “FRONT COWLING” in CHAPTER 3. WARNING Securely support the motorcycle so that there is no danger of it falling over. 52 Nm (5. Disconnect 1 1 2 Handlebar Front cowling Front wheel. fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3.0 mSkg) 1st. Refer to“FRONT FORK”. Rider seat.3 mSkg) Order Job/Part Removing the steering head Q’ty Remarks Remove the parts in the order listed.2 mSkg) 3 Nm (0. Stand the motorcycle on a level surface. 2nd. Refer to “HANDLEBAR”.

2 mSkg) 3 Nm (0. 2nd. For installation.3 mSkg) Order 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job/Part Flasher light bracket assembly Brake hose joint Brake hose guide Steering stem nut Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut Bearing cover Bearing (upper) Bearing races Lower bracket Bearing (lower) Rubber seal Q’ty 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 Remarks Refer to “REMOVING THE LOWER BRAKET/INSTALLING THE STEERING HAND”. reverse the removal procedure.0 mSkg) 1st. 52 Nm (5. 7-62 .STEERING HEAD CHAS 130 Nm (13.

Stand the motorcycle on a level surface. 90890-01403 WARNING Securely support the lower bracket so that there is no danger of it falling. EAS00682 CHECKING THE STEERING HEAD 1. WARNING Securely support the motorcycle so that there is no danger of it falling over. Remove: S upper ring nut 1 S lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench. 2. Wash: S bearing Recommended cleaning solvent Kerosine 2. 7-63 .STEERING HEAD EAS00679 CHAS REMOVING THE LOWER BRACKET 1. Exhaust and steering nut wrench 90890-01268 Ring nut wrench YU-33975. then remove the upper ring nut with the ring nut wrench. Check: S bearing 1 S bearing races Damage/pitting ! Replace.

the steering head pipe could be damage. replace the dust seal.STEERING HEAD 3. Install a new dust seal and new bearing races. c. NOTE: S Always replace the bearing balls and bearing races as a set. S Whenever the steering head is disassembled. Lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium soap base grease 2. 7-64 . Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. CAUTION: If the bearing race is not installed properly. b. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to “INSPECTING THE STEERING HEAD” in chapter 3. 4. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. EAS00683 INSTALLING THE STEERING HEAD 1. Replace: S bearing balls S bearing races CHAS a. Check: S upper bracket S lower bracket (along with the steering stem) Bends/cracks/damage ! Replace.

Install: S upper bracket S steering stem nut CHAS NOTE: Temporarily tighten the steering stem nut.STEERING HEAD 3. 4. Install: S front fork legs Refer to “FRONT FORK”. 7-65 . NOTE: Temporarily tighten the upper and lower bracket pinch bolts.

8 mSkg) 50 Nm (5. . Refer to “ENGIEN REMOVAL” in CHAPTER 4.0 mSkg) 50 Nm (5. Rear fender and rear wheel Muffler 1 2 3 4 5 Bolt (shock absorber-frame) Bolt (shock absorber-relay arm) Rear shock absorber Bolt (connecting arm-relay arm) Bolt (connecting arm-swingarm) 7-66 Refer to “REAR WHEEL AND BRAKE DISC”.9 mSkg) 48 Nm (4. 1 1 1 1 1 1 Refer to “REAR SHOCK ABSORBER ASSEMBLY”.REAR SHOCK ABSORBER ASSEMBLY EAS00685 CHAS REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5. Stand the motorcycle on a level surface.0 mSkg) Order Job/Part Removing the rear shock absorber assembly Q’ty Remarks Remove the parts in the order listed. WARNING Securely support the motorcycle so there is no danger of it falling over.

REAR SHOCK ABSORBER ASSEMBLY CHAS 59 Nm (5.0 mSkg) 50 Nm (5. 7-67 .8 mSkg) 50 Nm (5.9 mSkg) 48 Nm (4.0 mSkg) Order 6 7 8 Job/Part Connecting arms Bolt (relay arm -frame) Relay arm Q’ty 2 1 1 Remarks For installation. reverse the removal procedure.

S bolts Bends/damage/wear ! Replace. Check: S relay arm Cracks/damage ! Replace. 2. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 7-68 . 3. Check: S connecting arms Cracks/damage ! Replace. S bushings Damage/wear ! Replace. 2. Check: S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. WARNING Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface.REAR SHOCK ABSORBER ASSEMBLY EAS00690 CHAS REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Remove: S rear shock absorber assembly EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 1.

0 mSkg) Relay-arm-to-frame-nut 3 50 Nm (5. lift up the swingarm. S Install the connecting arm front bolt from the right. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 2.0 mSkg) NOTE: S When installing the rear shock absorber assembly. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 1 59 Nm (5.9 mSkg) Rear shock absorber assembly lower nut 2 50 Nm (5.REAR SHOCK ABSORBER ASSEMBLY EAS00698 CHAS INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. 7-69 .

Refer to “REAR SHOCK ABSORBER ASSEMBLY”.2 mSkg) (4) 16 Nm (1.0 mSkg) 42 Nm (4. Rear fender and rear wheel Rear shock absorber 1 2 3 4 5 Speedometer sensor Final gear case Drive shaft Brake hose holder Speedometer sensor leads 1 1 1 3 1 Refer to “REAR WHEEL AND BRAKE DISC”. Unhook from the cable guide.SWINGARM EAS00701 CHAS SWINGARM SWINGARM 100 Nm (10. Stand the motorcycle on a level surface.6 mSkg) Order Job/Part Removing the swingarm Q’ty Remarks Remove the parts in the order listed. WARNING Securely support the motorcycle so there is no danger of it falling over. 7-70 .

SWINGARM CHAS 100 Nm (10.6 mSkg) Order 6 7 Job/Part Pivot shafts (right and left) Swingarm Q’ty 2 1 Remarks Refer to “REMOVING THE SWINGARM”. reverse the removal procedure.2 mSkg) (4) 16 Nm (1.0 mSkg) 42 Nm (4. 7-71 . For installation.

c. Check: S swingarm Bends/cracks/damage ! Replace. If swingarm vertical movement is not smooth or if there is binding. WARNING Securely support the motorcycle so that there is no danger of it falling over. check the spacers and bearings.0 mSkg) Left pivot bolt 100 Nm (10. Check the swingarm vertical movement B by moving the swingarm up and down. If the swingarm side play is out of specification. Check the tightening torque of the swingarm pivot bolts and locknut. Locknut 100 Nm (10. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Stand the motorcycle on a level surface.SWINGARM EAS00702 CHAS REMOVING THE SWINGARM 1. 7-72 .7 mSkg) b. Check: S swingarm side play A S swingarm vertical movement B a. 2.0 mSkg) Right pivot bolt 7 Nm (0. Check the swingarm side play A by moving the swingarm from side to side. EAS00708 CHECKING THE SWINGARM 1. Swingarm side play (at the end of the swingarm) 0 mm d. check the spacers and bearings.

Lubricate: S drive shaft splines Recommended lubricant Lithium soap base grease 2. Check: S left pivot bolt S right pivot bolt Damage/wear ! Replace.SWINGARM CHAS 2. EAS00712 INSTALLING THE SWINGARM 1. 3. Lubricate: S bearings S spacers S oil seals Recommended lubricant Molybdenum disulfide grease 7-73 . Check: S spacers 1 S oil seals 2 S bearings 3 S universal joint boot 4 Damage/wear ! Replace.

Improper gear lash C. The symptoms are quite subtle and difficult to distinguish from normal operating noises. 7-74 .A locked-up condition of the shaft drive mechanism or no power transmitted from the engine to the rear wheel A.Damaged gear teeth D. a high-pitched whine. If there is reason to believe these components are damaged. Bearing damage B.) 2. Seizure due to lack of lubrication G.A rolling “rumble” noticeable at low speeds. or sustained speeds (This must not be confused with engine surging or transmission-related movements. B and C may be extremely difficult to diagnose.SHAFT DRIVE SHAFT DRIVE TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: A Symptoms B CHAS Possible Causes 1. deceleration.Broken drive shaft E.A Pronounced hesitation of jerky movement during acceleration.Small foreign objects lodged between moving parts NOTE: Causes A. remove them for individual inspection. or a “clunk” from a shaft drive component or area 3. Broken gear teeth F.

The noise increases with rear wheel speed. acceleration. causing loss of control of the motorcycle and possible injury to the rider. too little gear lash CAUTION: Insufficient gear lash is extremely destructive to the gear teeth. This noise must be distinguished from normal motorcycle operation. A slight “clunk” evident at low speed operation. Diagnosis: Possible wheel bearing damage b. A rolling “rumble” during coasting. Investigate any unusual noises. NOTE: A small amount of metal particles in the oil is normal. stop riding immediately to minimize gear damage. c.SHAFT DRIVE CHAS Inspection notes 1. 7-75 . Diagnosis: Possible incorrect reassembly. 2. but does not increase with higher engine or transmission speeds. Check: S drained oil Drained oil contains a large amount of metal particles ! Check the bearing for seizure. This condition could result in a locking of the shaft drive assembly. Diagnosis: Possible broken gear teeth WARNING Stop riding immediately if broken gear teeth are suspected. If a test ride following reassembly indicates this condition. or deceleration. A whining noise that varies with acceleration and deceleration. The following noises may indicate a mechanical defect: a.

7-76 . Place the motorcycle on a suitable stand so that the front wheel is elevated and then spin the front wheel.SHAFT DRIVE EAS00716 CHAS Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section exist. Refer to “REAR WHEEL AND BRAKE DISCS”. Is the wheel bearing damaged? NO YES Rear wheel bearings and shaft drive bearings are probably not damaged. check following points. Remove and check the drive shaft components. Remove the rear wheel. Refer to “FRONT WHEEL AND BRAKE DISCS”. Repeat the test or remove and check the components. NO Place the motorcycle on a suitable stand so that the rear wheel is elevated and then spin the rear wheel. Is the wheel bearing damaged? YES Replace the wheel bearing. Is the wheel bearing damaged? YES NO Replace the rear wheel bearing.

NOTE: A small amount of metal particles in the final drive oil is normal. may result from the application of a rust preventive coating or excessive seal lubrication. Drain: S final drive oil (from the final drive housing) Refer to “CHANGING THE FINAL DRIVE OIL” in CHAPTER 3. Check: S final drive oil Large amount of metal particles ! Check for bearing seizure. Thoroughly clean the entire motorcycle and then completely dry it.SHAFT DRIVE EAS00717 CHAS CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 1. S Always clean the motorcycle and recheck the area where the leak is thought to originate from. 3. Oil leak ! Repair or replace the faulty part(-s). Apply a leak-locating compound or dry powder spray to the shaft drive. 2. b. c. 1 Oil seal 2 O-ring 3 Forward NOTE: S What may appear to be an oil leak on a new or fairly new motorcycle. Check: S shaft drive housing (for oil leaks) a. 7-77 . Test ride the motorcycle long enough to locate a leak.

Rear fender and rear wheel 1 2 3 Speedometer sensor Final gear assembly Drive shaft 1 1 1 For installation.FINAL DRIVE ASSEMBLY AND DRIVE SHAFT EAS00718 CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 42 Nm (4. reverse the removal procedure. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.2 mSkg) Order Job/Part Removing the final drive assembly and drive shaft Q’ty Remarks Remove the parts in the order listed. Refer to “REAR WHEEL AND BRAKE DISC”. 7-78 .

5 mm a. Measure: S ring gear backlash Out of specification ! Adjust. Ring gear backlash 0. Final gear backlash band YM-01230. Record the reading on the dial gauge. 90890-01230 3 Dial-gauge-plunger contact point d. e. f. Drain: S final drive oil (from the final drive assembly) 4. Install a bolt 1 of the specified size. 7-79 . Gently rotate the gear coupling from engagement to engagement. and bolt.2 mm 1. Install the special tool 2 and dial gauge 3 . Finger tighten the bolt until it stops the ring gear from moving. 2. Secure the final drive assembly in a vise.FINAL DRIVE ASSEMBLY AND DRIVE SHAFT EAS00719 CHAS MEASURING THE RING GEAR BACKLASH 1. 100 mm c. special tool. 14 mm NOTE: Do not overtighten the bolt. b.1 X 0. Remove: S final drive oil drain bolt 3. Remove the dial gauge. into the final drive oil filler hole.

3. loosen each nut 1/4 of a turn. and dial gauge. S Do not damage the joint surface of the final gear case. Remove: S final gear housing rim 1 S ring gear 2 S ring gear shim(-s) 3 S thrust washer 4 3. 2. Adjust: S ring gear backlash a. Use the following chart to select the suitable shim(-s) and thrust washer. EAS00720 ADJUSTING THE RING GEAR BACKLASH 1. remove them and the bolts. special tool. Remove: S ring gear bearing housing nuts S ring gear bearing housing bolts NOTE: Working in a crisscross pattern. j. Repeat steps (d) to (h) three more times (for a total of four measurements). Thinner shim ! Ring gear backlash is increased. After all of the nuts are fully loosened. h. If any of the readings are over specification. Rotate the final drive pinion gear 90_. Thicker shim ! Ring gear backlash is decreased. i. Reinstall the bolt.FINAL DRIVE ASSEMBLY AND DRIVE SHAFT CHAS g. 7-80 . adjust the ring gear backlash. Remove S ring gear bearing housing 1 Remove the ring gear bearing housing off the final gear case by using a flat head screw driver at grooves a . CAUTION: S Do not use a driver at any other part than .

0.2.2 mm for every 0. Remove: S ring gear bearing housing (along with the ring gear) Refer to “ADJUSTING THE RING GEAR BACKLASH”. c.4. Install: S ring gear bearing housing (along with the ring gear) EAS00722 ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE 1 Remove: S ring gear 1 S stopper bolt 2 S stopper bolt shim(-s) 3 4 ring gear bearing housing 7-81 .30. 1. reduce the thrust washer thickness by 0. 1. 1.2 mm. If it is necessary to reduce the ring gear backlash by more than 0. Measure: S ring-gear-to-stopper-bolt clearance a Out of specification ! Adjust.2 mm.2 mm decrease of ring gear shim thickness.2 mm for every 0.40. Ring-gear-to stopper-bolt clearance 0. If it is necessary to increase the ring gear backlash by more than 0. increase the thrust washer thickness by 0.3 X 0.2 mm increase of ring gear shim thickness. Ring gear shims Thickness (mm) 0. 2.0 EAS00721 MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE 1.6.6 mm 1 Ring gear 2 Stopper bolt 3. 2.FINAL DRIVE ASSEMBLY AND DRIVE SHAFT CHAS b. 0.8.50 Thrust washers Thickness (mm) 1.

30. 0. 0. 0.20.40. 3. repeat the above procedure.10.9 mSkg) S ring gear 3 4 Ring gear bearing housing CAUTION: Apply LOCTITE® onto the stopper bolt. Measure: S ring-gear-to-stopper-bolt clearance NOTE: If the ring-gear-to-stopper-bolt clearance is out of specification. Install: S stopper bolt shim(-s) 1 S stopper bolt 2 9 Nm ( 0.15. 7-82 . 0. 0.50 2.FINAL DRIVE ASSEMBLY AND DRIVE SHAFT CHAS Select: stopper bolt shim(-s) Stopper bolt shims thickness (mm) 0.

7-83 . remove them. loosen each bolt 1/4 of a turn. 1 1 1 1 1 1 3 4 5 6 7 8 9 Bearing housing Dust cover Shim(s) Thrust washer Self-locking nut (gear coupling) Gear coupling Bearing retainer (final drive shaft) Refer to “DISASSEMBLING THE FINAL DRIVE ASSEMBLY/ALIGHING THE FINAL DRIVE PINION GEAR AND RING GEAR”.9 mSkg) 23 Nm (2.0 mSkg) 42 Nm (4.FINAL DRIVE EAS00723 CHAS FINAL DRIVE ASSEMBLY 23 Nm (2.2 mSkg) Order Job/Part Disassembling the final drive assembly Nuts (bearing housing) Bolts (bearing housing) Q’ty Remarks Disassemble the parts in the order listed 1 2 NOTE: Working in a crisscross pattern.0 mSkg) 110 Nm (11.3 mSkg) 110 Nm (11.0 mSkg) 9 Nm (0. After all the bolts are loosened.3 mSkg) 40 Nm (4.

0 mSkg) 42 Nm (4.0 mSkg) 110 Nm (11.3 mSkg) 110 Nm (11.9 mSkg) 23 Nm (2. For assembly. 7-84 .3 mSkg) 40 Nm (4.FINAL DRIVE CHAS 23 Nm (2.2 mSkg) Order 10 11 12 13 14 Job/Part Shim(s) Final drive shaft assembly Final drive shaft roller bearing Ring gear stopper Shim(s) Q’ty 1 1 1 Remarks Refer to “REMOVING AND INSTALLING THE RING GEAR BEARINGS”.0 mSkg) 9 Nm (0. reverse the disassembly procedure.

Remove: S self-locking nut S gear coupling (with the special tool 1 ) Final drive shaft holder YM-01229. After all of the nuts are fully loosened. remove them and the bolts. 4. NOTE: Lightly tap on the end of the final drive pinion gear with a soft hammer. 90890-01229 3. Remove: S ring gear bearing housing nuts S ring gear bearing housing bolts NOTE: Working in a crisscross pattern. loosen each nut 1/4 of a turn. 7-85 . To loosen the bearing retainer. Remove: S bearing retainer (with the special tool 1 ) Final drive shaft bearing retainer wrench YM-04050. 90890-04050 CAUTION: The bearing retainer has left-hand threads. Remove: S final drive pinion gear WARNING Always use new bearings.FINAL DRIVE EAS00724 CHAS DISASSEMBLING THE FINAL DRIVE ASSEMBLY 1. 2. turn it clockwise. CAUTION: The final drive pinion gear should only be removed if ring gear replacement is necessary.

3. NOTE: The removal of the final drive pinion gear bearing is a difficult procedure and is rarely necessary. b. Remove: S collar 1 S oil seal 2 S bearing 3 (With an appropriate press tool 4 and an appropriate support for the final drive housing) 2. Install the inner race onto the final drive pinion gear. 7-86 . c. Remove: S bearing 1 a. Heat the final gear case to approximately 150_C. Remove the bearing outer races with an appropriately shaped punch 2 . Install the bearing outer races with a socket or appropriate tool that matches the diameter of the races. Install: S bearing (New) 1 a. Heat the final gear case to approximately 150_C. c. b. Remove the inner race from the final drive pinion gear. 4. Check: S bearing Damage ! Replace.FINAL DRIVE EAS00725 CHAS REMOVING AND INSTALLING THE RING GEAR BEARINGS 1.

EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE: Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: S final drive housing S any bearing 1.(86 + b /100) 7-87 . 1 Final drive pinion gear shim 2 Ring gear shim 3 Thrust washer b. but Yamaha recommends installing a new one. Position the final drive pinion gear and the ring gear with shims 1 and 2 . Calculate the respective thicknesses from information marked on the final drive housing and the drive pinion gear.FINAL DRIVE CHAS 5. Select: S final drive pinion gear shim(-s) 1 S ring gear shim(-s) 2 a. To find final drive pinion gear shim thickness “A”. Install: S collar 1 S oil seal 2 (New) S bearing 3 (with an appropriate press tool 4 and press) NOTE: The bearing can be reused. use the following formula: Final drive pinion gear shim thickness A = (87 + a /100) .

To find ring gear shim thickness “B”.40 0. to be divided by 100 and added to 45 d = a numeral usually on the outside of the ring gear bearing housing.(86 + 50/100) = (87 + 0. round off to the hundredths digit.(86 + 0.51 mm.51 Therefore. f = the ring gear bearing thickness constant 7-88 .40”. Shim sizes are supplied in the following thicknesses. Thus. to be divided by 100 and added to “86” Example: If the final drive pinion gear is marked “+01” and the final drive housing is marked “50”: A = (87 + 1/100) . to be divided by 100 and added to “35. Final drive pinion gear shims Thickness (mm) 0. you should use a 0.50-mm final drive pinion gear shim.01 .50 Since the final drive pinion gear shims are only available in 0.10-mm increments.05) = 87. Hundredths 0. 0. to be divided by 100 and added to “87” b = a numeral on the final drive housing. 3. the calculated final drive pinion gear shim thickness is 0. 8.51 mm.50 = 0. to be divided by 100 and added to 3 e = a numeral (positive or negative) on the inside of the ring gear. 2. the calculated final drive pinion gear shim thickness is 0. The chart instructs you to round off the 1 to 0.30. 7. use the following formula: Ring gear shim thickness B = (45 + c /100) + (3 + d /100) [(35.01) . 6.FINAL DRIVE CHAS Where: a = a numeral (positive or negative) on the ring gear. 1. 4 5.86. 9 Rounded value 0 10 In the example above.40 + e /100) + f] Where: c = a numeral on the final drive housing. c.

00: B = (45 + 51/100) + (3 + 35/100) .86 . you should use a 0.51 mm.35 + 13] = 48. the ring gear is marked “-05”.10-mm increments. To tighten the bearing retainer. Hundredths 0.35) .5/ 100) + 13] = (45 + 0. and “f” is 13. Bearing retainer wrench YM-04050.51 + 3.40 . 2.0. 0. 1. The chart instructs you to round off the 1 to 0. 6.[35. the calculated ring gear shim thickness is 0.05) + 13] = 48.86 . 2. 9 Rounded value 0 10 In the example above. 7.50-mm ring gear shim.[35. round off the hundredths digit. the calculated ring gear shim thickness is 0.50 Since the ring gear shims are only available in 0. Ring gear shims Thickness (mm) 0.30. 3. Shim sizes are supplied in the following thicknesses. turn it counterclockwise.FINAL DRIVE CHAS Ring gear bearing thickness “f” 13 mm Example: If the final drive housing is marked “51” the ring gear bearing housing is marked “35”.40 .51) + (3 + 0.35 = 0.51-mm. 8. 4 5.35 -[(35. 0.51 Therefore.40.48. 90890-04050 7-89 . Install: S shims (as calculated) S final drive pinion gear S bearing retainer 110 Nm (11.0 mSkg) (with the bearing retainer wrench) CAUTION: The bearing retainer has left-hand threads. Thus.[(35.05) + 13] = 45.0.40 .

Measure the width of the flattened Plastigauge® 1 . If the ring-gear-to-thrust-washer clearance is within specification. 4. d.1 X 0.2 mm f. Remove the ring gear bearing housing (along with the ring gear). Install: S ring gear bearing housing (along with the ring gear. Install the ring gear bearing housing and tighten the bolts and nuts to specification. b. Place four pieces of Plastigauge® between the original thrust washer and the ring gear.0 mSkg) Ring gear bearing housing nut 23 Nm (2. Measure: S ring-gear-to-thrust-washer clearance a. install the ring gear bearing housing (along with the ring gear). Ring-gear-to-thrust-washer clearance 0.FINAL DRIVE CHAS 3. e. Ring gear housing bolt 40 Nm (4. 7-90 . Install: S gear coupling 110 Nm (11. 6. but without the thrust washer) 5. Remove the ring gear bearing housing. c. 90890-01229 CAUTION: Apply LOCTITE® to the self-locking nut.3 mSkg) NOTE: Do not turn the final drive pinion gear and ring gear while measuring the ring-gear-to-thrustwasher clearance with Plastigauge®. Adjust: S ring gear backlash Refer to “MEASURING THE RING GEAR BACKLASH” and “ADJUSTING THE RING GEAR BACKLASH”.0 mSkg) S self-locking nut (with the special tool 1 ) Coupling gear/middle shaft tool YM-01229.

6. 20 S Repeat the measurement steps until the ringgear-to-thrust-washer clearance is within the specified limits. 1.2 mm EAS00727 CHECKING THE DRIVE SHAFT 1. Select the suitable thrust washer from the following chart. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2.4. Ring-gear-to-thrust-washer clearance 0. select the correct thrust washer as follows. Apply: S sealant (onto both final drive housing mating surfaces) Quickgasket® ACC-11001-15-01 Yamaha bond No.FINAL DRIVE CHAS g.1 X 0. If the ring-gear-to-thrust-washer clearance is out of specification. EAS00728 INSTALLING THE DRIVE SHAFT 1.1215 90890-85505 3. 1. Install: S drive shaft (to the final drive pinion gear) 7-91 .2. Thrust washers Thickness (mm) 1. h.8. Check: S drive shaft splines Damage/wear ! Replace the drive shaft. 1.

Install: S rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. 5. Tighten: S final bearing housing nuts 42 Nm (4.FINAL DRIVE 4.2 mSkg) 6. 7-92 . Install: S drive shaft CHAS NOTE: Align the drive shaft splines with the driven yoke to the universal joint.

– + ELEC 8 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 CIRCUIT DIAGRAM . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . 8-2 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . . . . . . . . . . . . . 8-5 8-5 8-5 8-7 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . 8-32 COOLING SYSTEM . . . . . . . . . . . 8-8 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 CIRCUIT DIAGRAM . .ELEC CONTENTS ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . 8-26 8-26 8-27 8-28 SIGNAL SYSTEM . . . . . . . . . . . . 8-2 SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . 8-39 TROUBLESHOOTING . . . ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . 8-13 8-13 8-14 8-15 8-18 8-20 8-21 8-22 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 8-3 CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . 8-23 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40 FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 8-43 8-44 8-45 8-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . 8-24 LIGHTING SYSTEM . . TROUBLESHOOTING . . . . . . . . . . . . . . . . TYPES OF BULBS . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ELEC CARBURETOR HEATING SYSTEM . . . . . . . . . . . . . . . . . . CRUISE CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLE SHOOTING . . . FUEL METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 AUDIO SYSTEM CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . CRUISE CONTROL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . 8-62 8-62 8-64 8-65 8-66 8-72 8-75 8-77 8-80 8-82 8-84 8-86 . . . . . . . . . . . . . . . . . . . . . . . . 8-48 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . 8-53 CRUISE CONTROL SYSTEM . . . . . . . . . “SET”/“RES” INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL COMPONENTS EAS00729 ELEC ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Front brake switch Clutch switch Thermo unit Fuel sender TPS (throttle position sensor) Ignition coil Spark plug Ignitor unit 9 10 11 12 13 14 15 16 Battery Fuse (main) Starter relay Speed sensor Neutral switch Oil level switch Pickup coil Sidestand switch 17 18 19 20 21 22 23 24 25 26 Rear brake switch Flasher relay Starting circuit cut-off relay Rectifier/ regulator Horn 2 Fan motor Thermo switch Main switch Brake light relay (blue) Cruise control relay (white) for EUR for OCE 8-1 .

set the pocket tester to “0” and to the “Ω 1” range.g. 8-2 . S When checking for continuity.. switch back and forth between the switch positions a few times. main switch. Pocket tester 90890-03112 NOTE: S Before checking for continuity. replace the switch. between brown/blue and red. CAUTION: Never insert the tester probes into the coupler terminal slots 1 . If the continuity reading is incorrect.SWITCHES EAS00730 ELEC SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. The terminal connections for switches (e. and between blue/yellow and blue/black when the switch is set to “ON”. a closed circuit at the respective switch position). check the wiring connections and if necessary. The example illustration on the left shows that: There is continuity. taking care not to loosen or damage the leads. Always insert the probes from the opposite end of the coupler. NOTE: “ ” indicates a continuity of electricity between switch terminals (i.e. engine stop switch) are shown in an illustration similar to the one on the left.. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration.

proper connections. Incorrect continuity reading ! Replace the switch. and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Improperly connected ! Properly connect. Damage/wear ! Repair or replace the switch.SWITCH INSPECTION EAS00731 ELEC SWITCH CONTINUITY INSPECTION Check each switch for damage or wear. for EUR 1 2 3 4 5 6 Dimmer switch Horn switch Turn signal switch Pass switch Clutch switch Main switch 7 8 9 10 11 12 Front brake switch Gruise control switch “CANCEL” switch Engine stop switch Start switch Light switch 8-3 13 14 15 16 17 Emargency stop switch Side stand switch Neutral switch Rear brake switch Oil level switch .

SWITCH INSPECTION ELEC for OCE 1 2 3 4 5 6 Dimmer switch Horn switch Turn signal switch Pass switch Clutch switch Main switch 7 8 9 10 11 12 Front brake switch Gruise control switch “CANCEL” switch Engine stop switch Start switch Emargency stop switch 8-4 13 14 15 16 Side stand switch Neutral switch Rear brake switch Oil level switch .

S Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. bulb socket or both. CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Damage/wear ! Repair or replace the bulb.CHECKING THE BULBS AND BULB SOCKETS EAS00732 ELEC BULBS AND CHECKING THE BULB SOCKETS Check each bulb and bulb socket for damage or wear. Incorrect continuity reading ! Repair or replace the bulb. and also for continuity between the terminals. Remove: S bulb 8-5 . Improperly connected ! Properly connect. S Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out. proper connections. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. bulb socket or both. S Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb. The majority of these bulbs can be removed from their respective socket by turning them counterclockwise.

thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. and check the continuity. S Avoid touching the glass part of the headlight bulb to keep it free from oil. If the headlight bulb gets soiled. 8-6 . otherwise it may be pulled out of the terminal in the coupler. the life of the bulb and the luminous flux will be adversely affected. otherwise the transparency of the glass. c. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 2 . a.CHECKING THE BULBS AND BULB SOCKETS WARNING ELEC Since the headlight bulb gets extremely hot. b. set the pocket tester to “0” and to the “Ω 1” range. replace the bulb. keep flammable products and your hands away from the bulb until it has cooled down. and check the continuity. Never pull the lead. If either of the readings indicate no continuity. CAUTION: S Be sure to hold the socket firmly when removing the bulb. Check: S bult (for continuity) (with the pocket tester) No continuity ! Replace. 2. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 3 . Pocket tester 90890-03112 NOTE: Before checking for continuity.

a.CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. Install a good bulb into the bulb socket. Check the bulb socket for continuity. b. Connect the pocket tester probes to the respective leads of the bulb socket. note the following. c. replace the bulb socket. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. however. 8-7 . If any of the readings indicate no continuity.

IGNITION SYSTEM DAS00734 ELEC IGNITION SYSTEM CIRCUIT DIAGRAM 4 5 6 13 14 15 23 25 28 65 Main switch Battery Fuse (main) Ignitor Ignition coil Spark plug Engine stop switch Fuse (ignition) Pick up coil Neutral switch 8-8 .

Ignition coil resistance 7. Pickup coil resistance 8. Refer to “CHECKING THE BATTERY” in CHAPTER 3. 8-9 . Spark plug cap resistance 6. Main and ignition fuses 2. Ignition spark gap 5. Dynamic spark tester YM-34487 Ignition checker 90890-60754 Pocket tester YU-03112. Main and ignition fuses S Check the main and ignition fuses for continuity. Battery 3. S Are the main and ignition fuses OK? YES NO Replace the fuse(-s). Neutral switch 11. it is of the correct type. EAS00741 3. and its gap within specification? YES NO Re-gap or replace the spark plug. S Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUGS” in CHAPTER 3. Engine stop switch 10. Open-circuit voltage 12. Spark plugs S The following procedure applies to all of the spark plugs.IGNITION SYSTEM EAS00737 EAS00739 ELEC TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). remove the following part(-s): 1) Rider and passenger seats 2) Side cover (left and right) 3) Front cowling S Troubleshoot with the following special tool(-s).8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals.9 mm S Is the spark plug in good condition. Check: 1. Battery S Check the condition of the battery. Starting circuit cut-off relay (diode) 12. 90890-03112 EAS00738 2. S Recharge or replace the battery. Spark plugs 4.8 X 0. Main switch 9. 1. S Check the condition of the spark plug. Standard spark plug DPR8EA-9 (NGK) X24EPR-U9 (DENSO) Spark plug gap 0. Wiring connections (of the entire ignition system) NOTE: Before troubleshooting. Refer to “CHECKING THE FUSES” in CHAPTER 3. S Check the spark plug type.

S Connect the pocket tester (Ω 1k range) to the spark plug cap as shown. Ignition spark gap S The following procedure applies to all of the spark plugs. Ignition coil resistance S The following procedure applies to all of the ignition coils. Spark plug cap resistance S The following procedure applies to all of the spark plug caps. Primary coil resistance 3. S Remove the spark plug cap. S Measure the secondary coil for the specified resistance. S Disconnect the spark plug cap from the spark plug. S Measure the ignition spark gap a . S Connect the pocket tester (Ω 1) to the ignition coil as shown. S Connect the ignition checker/dynamic spark tester 1 as shown. 8-10 . EAS00747 6.8 mm S Is there a spark and is the spark gap within specification? NO YES The ignition system is OK. S Measure the spark plug cap resistance. S Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.57 X 4. Tester positive probe ! red/black Tester negative probe ! orange (gray) Minimum ignition spark gap 0. 2 Spark plug cap S Set the main switch to “ON”.83 Ω at 20_C S Connect the pocket tester (Ω 1k) to the ignition coil as shown. Tester posltlve probe ! red/black Tester negative probe ! spark plug lead 5.IGNITION SYSTEM EAS00743 ELEC 4. Spark plug cap resistance 10 kΩ at 20_C S Is the spark plug cap OK? YES NO Replace the spark plug cap. EAS00745 S Measure the primary coil resistance. S Disconnect the ignition coil leads from the wire harness.

the readings in the above chart will be reversed. Refer to “CHECKING THE SWITCHES”. S Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler as shown. Neutral switch S Check the neutral switch for continuity.71 X 14. EAS00749 Continuity 8. EAS00748 9.49 kΩ at 20_C S Is the ignition coil OK? YES NO Replace the ignition coil. Main switch S Check the main switch for continuity. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Is the engine stop switch OK? YES NO Replace the right handlebar switch. Tester positive probe – green/yellow 1 Tester negative probe – black 2 10. Pickup coil resistance 189 X 231 Ω at 20_C (between gray and black) S Is the pickup coil OK? YES NO Replace the pickup coil. S Connect the pocket tester (Ω 100) to the pickup coil terminal as shown. Tester positive probe ! blue/yellow 1 Tester negative probe ! light green 2 Tester positive probe ! light green 1 Tester negative probe ! blue/yellow 2 No continuity S Measure the pickup coil resistance. 8-11 NOTE: When you switch the tester’s positive and negative probes. S Are the tester readings correct? YES NO Replace the starting circuit cut-off relay. S Is the neutral switch OK? YES NO Replace the neutral switch. . S Is the main switch OK? YES NO Replace the main switch. Refer to “CHECKING THE SWITCHES”.IGNITION SYSTEM EAS00750 ELEC Secondary coil resistance 10. EAS00751 7. S Check the starting circuit cut-off relay for continuity. EAS00753 12. Starting circuit cut-off relay (diode) S Disconnect the starting circuit cut-off relay coupler from the wire harness. Engine stop switch S Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”.

IGNITION SYSTEM EAS00754 ELEC 13. S Is the ignition system’s wiring properly connected and without defects? NO Properly connect or repair the ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. Wiring S Check the entire ignition system’s wiring. 8-12 . YES Replace the ignitor unit.

ELECTRIC STARTING SYSTEM EAS00755 ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 4 5 6 7 8 10 11 23 24 25 26 49 65 Main switch Battery Fuse (main) Starter relay Starter motor Starting circuit cutoff relay Diode Engine stop switch Start switch Fuse (ignition) Side stand switch Clutch switch Neutral switch 8-13 .

the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed).ELECTRIC STARTING SYSTEM EAS00756 ELEC STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed). the neutral relay is open so current cannot reach the starter motor. The neutral relay prevents the starter motor from operating when neither of these conditions has been met. When at least one of the above conditions has been met the neutral relay is closed and the engine can be started by pressing the start switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Fuse (main) 3 Main switch 4 Fuse (ignition) 5 Engine stop switch 6 Starting circuit cutoff relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 8-14 . S The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). In this instance.

Start switch 12. Starter motor S Connect the battery positive terminal 1 and starter motor lead 2 with a jumper lead 3 . Battery 3. 90890-03112 EAS00738 2. EAS00758 3.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. Battery S Check the condition of the battery. Engine stop switch 8. Wiring connections (of the entire starting system) NOTE: S Before troubleshooting. 8-15 . Open-circuit voltage 12.ELECTRIC STARTING SYSTEM EAS00757 EAS00739 ELEC TROUBLESHOOTING The starter motor fails to turn. S Recharge or replace the battery. S Are the main and ignition fuses OK? YES NO WARNING S A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead. therefore make sure that no flammable gas or fluid is in the vicinity. Starter relay 6. Main and ignition fuses 2. Neutral switch 9. Pocket tester YU-03112. Starting circuit cut-off relay 5. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Check: 1. Main and ignition fuses S Check the main and ignition fuses for continuity. otherwise the jumper lead may burn. Main switch 7. Clutch switch 11. Sidestand switch 10. Starter motor 4. 1. remove the following part(-s): 1) Rider and passenger seats 2) Fuel tank 3) Front cowling S Troubleshoot with the following special tool(-s). Replace the fuse (-s). Refer to “CHECKING THE FUSES” in CHAPTER 3. S This check is likely to produce sparks. S Does the starter motor turn? YES NO Repair or replace the starter motor.

Refer to “CHECKING THE SWITCHES”. S Is the neutral switch OK? YES NO Replace the neutral switch. Engine stop switch S Check the engine stop switch for continuity. EAS00750 S Does the starting circuit cut-off relay have continuity between blue and black? YES NO Replace the starting circuit cut-off relay. S Is the engine stop switch OK? YES NO Replace the right handlebar switch. S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown. EAS00761 7. 8-16 . Refer to “CHECKING THE SWITCHES”.ELECTRIC STARTING SYSTEM EAS00759 ELEC 4. Battery positive terminal ! red/black 1 Battery negative terminal ! black/yellow 2 Tester positive probe ! blue 3 Tester negative probe ! black 4 S Does the starter relay have continuity between red and black? YES NO Replace the starter relay. Starter relay S Disconnect the starter relay coupler from the wire harness. Neutral switch S Check the neutral switch for continuity. EAS00749 6. Main switch S Check the main switch for continuity. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Is the main switch OK? YES NO Replace the main switch. EAS00751 5. Refer to “CHECKING THE SWITCHES”. S Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay coupler as shown. Battery positive terminal ! blue 1 Battery negative terminal ! red/white 2 Tester positive probe ! red 3 Tester negative probe ! black 4 8.

Wiring S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Sidestand switch S Check the sidestand switch for continuity. Start switch S Check the start switch for continuity. 8-17 .ELECTRIC STARTING SYSTEM EAS00752 ELEC 9. EAS00763 10. EAS00766 12. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? YES NO Replace the sidestand switch. EAS00764 11. Refer to “CHECKING THE SWITCHES”. S Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK? NO Properly connect or repair the starting system’s wiring. S Is the start switch OK? YES NO Replace the right handlebar switch. Clutch switch S Check the clutch switch for continuity. S Is the clutch switch OK? YES NO Replace the clutch switch. Refer to “CIRCUIT DIAGRAM”.

ELECTRIC STARTING SYSTEM STARTER MOTOR 7 Nm (0. Refer to “REMOVING THE ENGINE” in CHAPTER 4. 8-18 . 1 2 Starter motor lead Starter motor/O-ring 1 1/1 For installation.7 mSkg) ELEC M5 110 (2) 10 Nm (1. reverse the removal procedure.0 mSkg) M6 M6 25 (1) 55 (1) Order Job/Part Removing the starter motor Exhaust pipe assembly Q’ty Remarks Remove the parts in the order listed.

0 mSkg) M6 M6 25 (1) 55 (1) Order 1 2 3 4 5 Job/Part Disassembling the starter motor Front bracket Washer kit Rear bracket Washer kit Brush seat/Brush #1 Q’ty 1 1 2 1 1/1 Remarks Disassemble the parts in the order listed. NOTE: Be sure to remove the installation nut on brush #1 first.ELECTRIC STARTING SYSTEM ELEC 7 Nm (0.7 mSkg) M5 110 (2) 10 Nm (1. 8-19 . Refer to “ASSEMBLING THE STARTER MOTOR”. 6 Armature coil 1 For assembly reverse the disassembly procedure.

Measure: S mica (insulation) undercut a Out of specification ! Scrape the mica (insulation) to the proper measurement with a hacksaw blade which has been grounded to fit the commutator.7 mm NOTE: The mica (insulation) of the commutator must be undercut to ensure proper operation of the commutator. Check: S commutator Dirt ! Clean with 600 grit sandpaper. Commutator wear limit 27 mm 3. Measure: S armature coil resistances (continuity and insulation) Out of specification ! Replace the starter motor. Armature coil continuity resistance 0.025 Ω at 20_C Armature coil insulation resistance Above 1MΩ at 20_C c. Measure the armature coil resistances. Check the continuity resistance 1 and mica (insulation) resistances 2 with a pocket tester. 90890-03112 b. Pocket tester YU-03112. 4. Measure: S commutator diameter a Out of specification ! Replace the starter motor. 8-20 . If any resistance is out of specification.ELECTRIC STARTING SYSTEM EAS00770 ELEC CHECKING THE STARTER MOTOR 1. a. Mica (insulation) undercut 0. 2.015 X 0. replace the starter motor.

2. 8. EAS00772 ASSEMBLING THE STARTER MOTOR 1. Brush length wear limit 5 mm 6. Measure: S brush spring force Fatigue/out of specification ! Replace the brush springs as a set. Install: S washers 1 S armature coil 2 S o-ring 3 S rear bracket 4 NOTE: To prevent damaging the brushes during installation push down on the brush springs. Check: S bearing 1 S oil seal 2 S bushing 3 Damage/wear ! Replace the defective part(-s). Check: S gear teeth Damage/wear ! Replace the gear. Measure: S brush length a Out of specification ! Replace the brushes as a set.ELECTRIC STARTING SYSTEM ELEC 5. Install: S brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the rear cover. Brush spring force 570 X 920 N 7. 8-21 .

Install: S bolts 1 7 Nm (0. Install: S o-ring 1 New S washers 2 S front bracket 3 S o-ring 4 New ELEC NOTE: Align the match marks a on the yoke with the match marks b on the brackets. 4. 8-22 . Install: 10 Nm (1.0 mSkg) S starter motor Refer to “AC MAGNETO AND STARTER CLUTCH” in CHAPTER 4.ELECTRIC STARTING SYSTEM 3.7 mSkg) INSTALLATION 1.

CHARGING SYSTEM YP804000 ELEC CHARGING SYSTEM CIRCUIT DIAGRAM 1 3 5 6 AC magneto Rectifire/ reguretor Battery Fuse (main) 8-23 .

Check: 1. Stator coil resistance S Remove the generator cover. Tester positive probe ! white 1 Tester negative probe ! white 2 Tester positive probe ! white 3 Tester negative probe ! white 1 NO S Clean the battery terminals. Main fuse 2.CHARGING SYSTEM EAS00774 EAS00775 ELEC TROUBLESHOOTING The battery is not being charged.8 V or more at 20_C S Is the battery OK? YES . EAS00776 1. Charging voltage S Connect the engine tachometer to the spark plug lead of cylinder #1. S Recharge or replace the battery. Charging voltage 14 V at 5. S Is the charging voltage within specification? NO YES The charging circuit is OK. Refer to “CHECKING THE FUSES” in CHAPTER 3. Engine tachometer YU-08036-A. 8-24 2. Battery S Check the condition of the battery.000 r/min NOTE: Make sure that the battery is fully charged. 90890-03113 Pocket tester YU-03112. Main fuses S Check the fuses for continuity. remove the following part(-s): 1) Rider and passenger seats 2) Side cover (left) S Troubleshoot with the following special tool(-s). S Connect the pocket tester (20 V DC) to the battery as shown. EAS00739 4. S Measure the charging voltage. S Connect the pocket tester (Ω 1) to the stator coils as shown. Open-circuit voltage 12. Charging voltage 4. Stator coil resistance 5.000 r/min. 90890-03112 EAS00738 3. S Are the fuses OK? YES NO Replace the fuse (-s). Battery 3. Tester positive probe ! battery positive terminal Tester negative probe ! battery negative terminal S Start the engine and let it run at approximately 5. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Wiring connections (of the entire charging system) NOTE: S Before troubleshooting.

CHARGING SYSTEM S Measure the stator coil resistances. S Is the charging system’s wiring properly connected and without defects? YES Replace the rectifier/regulator. 8-25 . Refer to “CIRCUIT DIAGRAM”. Stator coil resistance 0. Wiring S Check the wiring connections of the entire charging system.279 X 0.341 Ω at 20_C S Is the stator coil OK? YES NO Replace the stator coil assembly. NO Properly connect or repair the charging system’s wiring. EAS00779 ELEC 5.

LIGHTING SYSTEM EB804000 ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM 4 5 6 20 34 45 Main switch Battery Fuse (main) Light switch Fuse (headlight) Dimmer switch 58 61 75 77 78 79 High beam indicator light Ilumination light Tail/ brake light Headlight Front turn signallight (left) Front turn signallight (right) 8-26 .

Refer to “CHECKING THE FUSES” in CHAPTER 3. remove the following part(-s): 1) Rider and passenger seats 2) Side cover (left and right) 3) Front cowling S Troubleshoot with the following special tool(-s). S Recharge or replace the battery. 2. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Light/dimmer switch 5. Pocket tester YU-03112. Replace the left handlebar switch. S Is the lighting system’s wiring properly connected and without defects? NO Properly connect or repair the lighting system’s wiring. Main switch S Check the main switch for continuity. EAS00785 4. Battery S Check the condition of the battery.LIGHTING SYSTEM EAS00782 EAS00739 ELEC TROUBLESHOOTING Any of the following fail to come on: headlight. Main and headlight fuses S Check the main and headlight fuses for continuity. WAS00739 5. and meter light. Main and headlight fuses 2. Refer to “CIRCUIT DIAGRAM”. high beam indicator light. Light/dimmer switch S Check the light/dimmer switch for continuity. 90890-03112 EAS00738 3. 8-27 Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE SWITCHES”. taillight. Battery 3. Open-circuit voltage 12. Check: 1. Refer to “CHECKING THE SWITCHES”. EAS00787 1. Main switch 4. . S Is the light/dimmer switch OK? YES NO The light/dimmer switch is faulty.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. S Is the main switch OK? YES NO Replace the main switch. S Are the main and headlight fuses OK? YES NO YES Replace the fuse (-s). Wiring S Check entire lighting system’s wiring. Wiring connections (of the entire charging system) NOTE: S Before troubleshooting. Refer to “CHECKING THE LIGHTING SYSTEM”.

”. 1. 2. Headlight buld and scocket S Check the headlight bulb and socket for continuity. Vollage S Connect the pocket tester (20 V) to the meter light coupler (wire harness side) as shown. NO The wiring circuit from the main switch to the headlight coupler (wire harness side) is faulty and must be repaired. Tester positive probe ! blue 1 Tester negative probe ! black 2 ”. S Set the dimmer switch to “ ” or “ ”. 1. S Is the voltage within specification? YES This circuit is OK. Meter light bulb and socket S Check the meter light bulb and socket for continuity. Headlight Tester positive probe ! yellow 1 or green 2 Tester negative probe ! black 3 High beam indicator light Tester positive probe ! yellow 4 Tester negative probe ! black 5 Headlight coupler (headlight side) Meter light coupler (wire harness side) 8-28 . socket or both 2. The meter light fails to come on. S Are the headlight bulb and socket OK? YES NO Replace the headlight bulb. EAS00789 2. S Measure the voltage (12 V) of green 2 (yellow 1 ) on the headlight coupler (headlight side). Voltage S Connect the pocket tester (20 V DC) to the headlight and high beam indicator light couplers as shown. A When the dimmer switch is set to “ B When the dimmer switch is seto to “ S Set the main switch to “ON”. The headlight and the high beam indicator light fail to come on. S Are the meter light bulb and socket OK? YES NO Replace the meter light bulb.LIGHTING SYSTEM EAS00788 ELEC CHECKING THE LIGHTING SYSTEM 1. socket of both.

S Is the voltage within specification? YES This circuit is OK. EAS00790 3. yellow 3 on the tail/brake light coupler (tail/brake light side). yellow 3 Tester negative probe ! black 2 for EUR for OCE 8-29 . S Are the tail/brake light bulb and socket OK? YES NO Replace the tail/brake light bulb. NO The wiring circuit from the main switch to the meter light coupler (wire harness side) is faulty and must be repaired. S Is the voltage within specification? YES This circuit is OK. The tail/brake light fails to come on.LIGHTING SYSTEM S Set the main switch to “ON”. S Measure the voltage (12 V) of blue 1 on the meter light coupler (wire harness side). socket or both. Voltage S Connect the pocket tester (20 V DC) to the tail/brake light coupler (wire harness side) as shown. NO The wiring circuit from the main switch to the tail/brake light coupler (tail/brake light side) is faulty and must be repaired. S Measure the voltage (12 V) of blue/red 1 . Tester positive probe ! blue/red 1 . 2. Tail/brake light bulb and socket S Chek the tail/brake light bulb and socket for continuity. ELEC S Set the main switch to “ON”. 1.

SIGNAL SYSTEM EB806000 ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM 8-30 .

SIGNAL SYSTEM 4 5 6 9 10 18 23 25 35 38 40 41 42 43 46 47 52 54 55 56 59 60 65 68 75 77 78 ELEC Main switch Battery Fuse (main) Oil level switch Starting circuit cutoff relay Front brake switch Engine stop switch Fuse (ignition) Fuse (signal) Brake light relay Rear brake switch Horn 2 Horn 1 Flasher relay Horn switch Turn signal switch Oil level indicator light Over drive indicator light Neutral indicater light Fuel level indicator light Turn indicator light (left) Turn indicator light (right) Neutral switch Fuel sender unit Tail/ brake light Front turn signal light (left) Front turn signal light (right) 8-31 .

8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. 2. brake light or indicator light. 2. Main. The horn fails to sound. S Are the main. 1. Refer to “CIRCUIT DIAGRAM”. signal and ignition fuses S Check the main. Main switch 4. 90890-03112 EAS00738 3. Refer to “CHECKING THE SIGNALING SYSTEM”. signal and ignition fuses OK? YES NO Replace the fuse (-s). signal and ignition fuses 2. Battery 3. 8-32 . Refer to “CHECKING THE FUSES” in CHAPTER 3. Wiring connections (of the entire signal system) NOTE: S Before troubleshooting. Main switch S Check the main switch for continuity. signal and ignition fuses for continuity. Main. Voltage S Connect the pocket tester (20 V DC) to the horn lead (at the horn terminal) as shown. S Is the signaling system’s wiring properly connected and without defects? YES Check the condition of each of the signal system’s circuits. Wiring S Check the entire signal system’s wiring. Battery S Check the condition of the battery. Pocket tester YU-03112. S Is the main switch OK? YES NO Replace the main switch. S Recharge or replace the battery. EAS00739 CHECKING THE SIGNAL SYSTEM 1. Check: 1. Open-circuit voltage 12. S The horn fails to sound. 1. Refer to “CHECKING THE SWITCHES”. EAS00795 4. Horn switch Refer to “CHECKING THE SWITCHES”.SIGNAL SYSTEM EAS00794 EAS00749 ELEC TROUBLESHOOTING S Any of the following fail to come on: turn signal light. Refer to “CHECKING THE BATTERY” in CHAPTER 3. YES NO Replace the left handlebar switch. EAS00796 NO Properly connect or repair the signal system’s wiring. remove the following part(-s): 1) Rider seat 2) Side covers (left and right) 3) Fuel tank 4) Front upper cowling S Troubleshoot with the following special tool(-s).

socket or both. Tail/brake light bulb and socket. S Measure the voltage (12 V) of the black/ white connector at the horn terminal. S Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn terminal is faulty and must be repaired. 1. EAS00797 NO Replace the horn. S Are the tail/brake light bulb and socket OK? YES NO Replace the tail/brake light bulb. 4. Voltage S Connect the pocket tester (20 V DC) to the tail/brake light coupler (wire harness side) as shown. Horn S Disconnect the black/red connector at the horn terminal. S Does the horn sound? S Set the main switch to “ON”. 2. 3. S Measure the voltage (12 V) of pink 1 at the horn terminal.SIGNAL SYSTEM Tester positive probe ! black/white 1 Tester negative probe ! ground ELEC Tester positive probe ! pink 1 Tester negative probe ! ground S Set the main switch to “ON”. The tail/brake light fails to come on. S Is the voltage within specification? YES Repair or adjust the horn. S Check the tail/brake light bulb and socket for continuity. 8-33 3. Refer to “CHECKING THE SWITCHES”. . Voltage S Connect the pocket tester (20 V DC) to the horn at the black terminal as shown. YES NO Replace the brake switch. 2. Brake switch S Check the brake switch for continuity. S Set the main switch to “ON”. S Connect a jumper lead 1 to the horn terminal and ground the jumper lead. S Is the brake switch OK? YES NO Replace the horn.

Turn signal switch S Check the turn signal switch for continuity. S Is the turn signal switch OK? YES NO Replace the left handlebar switch. The turn signal light. Refer to “CHECKING THE SWITCHES”. socket or both. NO The wiring circuit from the main switch to the tail/brake light coupler (wire harness side) is faulty and must be repaired. S Measure the voltage (12 V) of yellow 1 on the tail/brake light coupler (wire harness side). Turn indicator light bulb and socket S Check the turn signal light bulb and socket for continuity. 2. Voltage ELEC S Connect the pocket tester (20 V DC) to the flasher relay coupler (flasher relay side) as shown. S Are the turn signal light bulbs and socket OK? YES NO Replace the turn signal light bulb. turn indicator light or both fail to blink. S Measure the voltage (12 V) of brown 1 at the flasher relay coupler (wire harness side). 1. S Set the main switch to “ON”. Tester positive probe ! brown/white 1 Tester negative probe ! ground EAS00799 3. Voltage S Connect the pocket tester (20 V DC) to the flasher relay coupler (wire harness side) as shown. 4. Tester positive probe ! brown 1 Tester negative probe ! ground S Set the main switch to “ON”. S Is the voltage within specification? YES NO The wiring circuit from the main switch to the flasher relay coupler (wire harness side) is faulty and must be repaired.SIGNAL SYSTEM Tester positive probe ! yellow 1 Tester negative probe ! black 2 3. S Pull in the brake lever or push down on the brake pedal. S Is the voltage within specification? YES This circuit is OK. 8-34 .

S Measure the voltage (12 V). S Is the voltage within specification? YES This circuit is OK.SIGNAL SYSTEM S Set the main switch to “ON”. 2. S Are the neutral indicator light bulb and socket OK? YES NO Replace the neutral indicator light bulb. S Is the voltage within specification? YES NO The wiring circuit from the main switch to the meter light bulb coupler (wire harness side) is faulty and must be repaired. Neutral indicator light bulb and socket S Check the neutral indicator light bulb and socket for continuity. S Measure the voltage (12 V) of the chocolate 1 or dark green 2 on the turn signal light connector (wire harness side). S Set the turn switch to “ ” or “ ”. 1. Neutral switch S Check the neutral switch for continuity. S Set the main switch to “ON”. NO The wiring circuit from the turn signal switch to the turn signal light connector (wire harness side) is faulty and must be repaired. 5. S Is the voltage within specification? YES NO The flasher relay is faulty and must be replaced. 3. Voltage S Connect the pocket tester (20 V DC) to the meter light bulb coupler (wire harness side) as shown. socket or both. S Measure the voltage (12 V) on brown/white 1 at the flasher relay coupler (wire harness side). A Rear turn signal light B Turn signal indicator light EAS00800 ELEC 4. Refer to “CHECKING THE SWITCHES”. 8-35 . The neutral indicator light fails to come on. S Is the neutral switch OK? YES NO Replace the neutral switch. Tester positive probe ! brown 1 Tester negative probe ! ground Left turn signal light Tester positive probe ! chocolate 1 Tester negative probe ! ground Right turn signal light Tester positive probe ! dark green 2 Tester negative probe ! ground B A S Set the main switch to “ON”. Voltage (rear) S Connect the pocket tester (20 V DC) to the turn signal light connector (wire harness side) as shown.

Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. Tester positive probe ! light green 1 Tester negative probe ! ground ELEC 2. S Check the engine oil level switch for continuity. Engine oil level switch S Drain the engine oil and remove the engine oil level switch from the oil pan.6 Ω at 20_C S Is the resistor resistance within specification? YES NO Replace the starting circuit cut-off relay.SIGNAL SYSTEM 4. EAS00750 EAS00802 5. S Is the voltage within specification? YES This circuit is OK. Refer to “CHECKING THE SWITCHES”. S Are the oil level indicator light bulb and socket OK? YES NO Replace the oil level indicator light bulb. S Set the transmission within neutral. Engine stop switch S Check the engine stop switch for continuity. 1. Voltage S Connect the pocket tester (20 V DC) to the neutral switch coupler (wire harness side) as shown. NO The wiring circuit from the neutral switch to neutral switch coupler (wire harness side) is faulty and must be repaired. Oil level indicator light bulb and socket S Check the oil level indicator light bulb and socket for continuity. S Measure the voltage (12 V). 8-36 . Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? YES NO Replace the right handlebar switch. 6. Tester positive terminal ! black/red 1 Tester negative terminal ! brack/white 2 S Set the main switch to “ON”. The oil level indicator light fails to come on.4 – 9. 4. 3. S Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler (wire harness side) as shown. S Is the engine oil level switch OK? YES NO Replace the engine oil level switch. socket or both. S Measure the resistor for the specified resistance.

Tester positive probe ! red/brack 1 Tester negative probe ! ground ELEC Tester positive probe ! green/red 1 Tester negative probe ! black 2 S Check: Does the fuel sender have continuity? YES S Set the main switch to “ON”. Voltage The wiring circuit from the main switch to the meter light coupler (wire harness side) is faulty and must be repaired. S Set the main switch to “ON”. 2. S Disconnect the fuel sender coupler from the wire harness. S Connect the pocket tester (20 V DC) to the fuel sender coupler (wire harness side) as shown. Fuel level indicator light bulb and socket S Check: Do the fuel level indicator light bulb and socket have continuity? YES NO Replace the fuel level indicator light bulb. 8-37 . socket of both. NO 3. NO The wiring circuit from the main switch to the fuel sender coupler (wire harness side) is faulty and must be repaired. Fuel sender S Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank. S Is the voltage within specification? YES This circuit is OK. the NO fuel EAS00803 6. S Measure the voltage (12 V). S Connect the pocket tester (Ω 1) to the fuel sender as shown. 1. Voltage S Connect the pocket tester (20 V DC) to the meter light coupler (wire harness side) as shown. The fuel level indicator light fails to come on.SIGNAL SYSTEM 5. S Measure the voltage (12 V). S Is the voltage within specification? YES This circuit is OK. Tester positive probe ! green/white 1 Tester negative probe ! ground Replace sender.

2. Voltage S Connect the pocket tester (20 V DC) to the meter light bulb coupler (wire harness side) as shown. S Is the voltage within specification? YES This circuit is OK. S Is the neutral switch OK? YES NO Replace the neutral switch. 8-38 .SIGNAL SYSTEM 7. Tester positive probe ! brown 1 Tester negative probe ! white/green 2 ELEC S Set the main switch to “ON”. NO The wiring circuit from the main switch to the meter light coupler (wire harness side) and meter light coupler to over drive switch are faulty and must be repaired. 3. Refer to “CHECKING THE SWITCHES”. S Set the transmission 5th gear. S Are the over drive indicator light bulb and socket OK? YES NO Replace the over drive indicator light bulb. The over drive indicator light fails to come on. Neutral switch S Check the neutral switch for continuity. socket or both. 1. S Measure the voltage (12 V). Over drive indicator light bulb and socket S Check the over drive indicator light bulb and socket for continuity.

COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM ELEC Main switch Battery Fuse (main) Thermo switch Noise filter Fan motor Fues (fan motor) Fuse (signal) Engine overheat indica tor light 67 Thermo unit 4 5 6 30 31 32 33 35 53 8-39 .

S Are the main. Radiator fan motor 5. remove the following part(-s). EAS00749 3. Main. Main. Radiator fan motor S Disconnect the rediator fan motor coupler (wire harness side). S The engine overheat indicator light fails to come on when the engine is hot. Thermo switch 6. and radiator fan motor fuses OK? YES NO Replace the fuse (-s). Refer to “CHECKING THE SWITCHES”. Water temperature warning light bulb and socket 8. Wiring connections (the entire cooling system) NOTE: S Before troubleshooting. Battery S Check the condition of the battery. signal. Main switch S Check the main switch for continuity. signal. Battery positive lead ! blue 1 Battery negative lead ! black 2 1.8 V or more at 20_C 8-40 . 2. Main switch 4. EAS00809 4. 1) Rider and passenger seats 2) Side covers (left and right) 3) Fuel tank S Troubleshoot with the following special tool(-s). Check: 1. S Is the main switch OK? YES NO Replace the main switch. and rediator fan motor fuses 2. Open-circuit voltage 12. 90890-03112 EAS00738 S Is the battery OK? YES NO S Clean the battery terminals. turn signal. S Recharge or replace the battery. EAS00739 S Does the rediator fan motor turn? YES NO The radiator fan motor is faulty and must be replaced. turn signal. and radiator fan motor fuses for continuity.COOLING SYSTEM EAS00808 ELEC TROUBLESHOOTING S The radiator fan motor fails to turn. Pocket tester YU-03112. and radiator fan motor fuses S Check the main. S Connect the battery (12 V) as shown. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Refert to “CHECKING THE FUSES” in CHAPTER 3. Battery 3. Thermo unit 7.

Test step 1 Coolant temperature Thermo switch 0 – 98_C More than 105 ± 3_C 105 to 98_C Less than 98_C Continuity NO 2 YES 3* 4* YES NO Steps 1 & 2: Heating phase Steps 3* & 4*: Cooling phase 8-41 . radiator fan on S Does the thermo switch operate properly as described above? S Does the rediator fan motor turn? YES NO Replace the thermo switch. If the thermo switch is dropped.8 mSkg) Three bond sealock® 10 S Thermo switch circuit open. S Check the thermo switch for continuity at the temperaures indicated below. Thermo switch 8 Nm (0. 6. then let it cool down to the specified temperature. replace it. S Connect the pocket tester (Ω 1) to the thermo switch 1 as shown. S Slowly heat the coolant. Engine overheat indicator light bulb and socket S Check the engine overheat indicator light bulb and socket for continuity. socket or both. radiator fan off S Thermo switch circuit closed. WARNING S Handle the thermo switch with special care. Thermo switch S Remove the thermo switch from the thermostat housing. S Never subject the thermo switch to strong shocks. S Place a thermometer 3 in the coolant.COOLING SYSTEM EAS00811 ELEC 5. S Immerse the thermo switch in a container filled with coolant 2 . S Are the engine overheat indicator light bulb and socket OK? YES NO Replace the engine overheat indicator light bulb.

If the temperature sender is dropped. S Immerse the temperature sender in a container filled with coolant 2 . 8. Temperature sender 23 Nm (2. Check the thermo unit sender for continuity at the temperaures indicated below. S Is the cooling system’s wiring properly connected and without defects? YES This circuit is OK. 8-42 . S Place a thermometer 3 in the coolant. replace it. S Connect the pocket tester (Ω 10) to the thermo unit 1 as shown. Thermo unit S Remove the thermo unit sender from the radiator.3 mSkg) Three bond sealock® 10 S Does the thetmo unit operate properly? YES NO Replace the thermo unit sender. S Never subject the temperature sender to strong shocks. S Slowly heat the coolant. NO Properly connect or repair the cooling system’s wiring. Wiring S Check the entire cooling system’s wiring.COOLING SYSTEM EAS00812 EAS00813 ELEC 7. Refer to “CIRCUIT DIAGRAM”. Temperature sender resistance 80_C: 47 – 53 Ω 100_C: 26 – 30 Ω WARNING S Handle the temperature sender with special care.

FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM ELEC 4 5 6 10 12 13 23 25 Main switch Battery Fuse (main) Starting circuit cutoff relay Fuel pump Ignitor Engine stop switch Fuse (ignition) 8-43 .

FUEL PUMP SYSTEM EB808010 ELEC FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay. 1 2 3 4 5 6 7 8 Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump 8-44 . fuel pump. engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fuel pump.

Refer to “CHECKING THE SWITCHES”. 90890-03112 EAS00738 3. Main.FUEL PUMP SYSTEM EAS00816 EAS00749 ELEC TROUBLESHOOTING If the fuel pump fails to operate: Check: 1. Main and ignition fuses 2. remove the following part(-s): 1) Rider seat 2) Side cover (left) 3) Fuel tank Troubleshoot with the following special tool(-s). Main switch S Check the main switch for continuity. . Battery positive terminal ! red/black 1 Battery negative terminal ! blue/red 2 Tester positive probe ! red/black 3 Tester negative probe ! blue/black 4 2. 8-45 S Does the starting circuit cut-off relay have continuity between red/black and blue/black? YES NO Replace the starting circuit cut-off relay.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. Refer to “CHECKING THE FUSES” in CHAPTER 3. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. EAS00739 5. Battery S Check the condition of the battery. S Are the main and ignition fuses OK? YES NO Replace the fuse (-s). S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown. EAS00750 NO the main 4. Engine stop switch 5. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Fuel pump 7. Starting circuit cut-off relay (the fuel pump relay) 6. Engine stop switch S Check the engine stop switch for continuity. S Is the main switch OK? YES Replace switch. Pocket tester YU-03112. S Is the engine stop switch OK? YES NO Replace the right handlebar switch. and ignition fuses S Check the main and ignition fuses for continuity. Refer to “CHECKING THE SWITCHES”. Main switch 4. Open-circuit voltage 12. S Recharge or replace the battery. EAS00759 1. Wiring connections (the entire fuel system) NOTE: S Before troubleshooting. Battery 3.

FUEL PUMP SYSTEM EAS00817 ELEC 6. Fuel pump resistance 4 – 30 Ω at 20_C S Is the fuel pump OK? YES Replace pump. Refer to “CIRCUIT DIAGRAM”. Wiring S Check the entire fuel pump system’s wiring. 8-46 . NO Properly connect or repair the fuel system’s wiring. S Is the fuel system’s wiring properly connected and without defects? YES Replace the ignitor unit. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. EAS00818 NO the fuel 7. Tester positive probe ! blue/black 1 Tester negative probe ! black 2 S Measure the fuel pump resistance. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown.

Therefore. the fuel pump is OK. If fuel does not flow. Battery positive lead ! blue/black 1 Battery negative lead ! black 2 d. and keep away from open flames. sparks. S If you do accidentally spill gasoline. If fuel flows out of the fuel hose. S If gasoline touches the engine when it is not. wipe it up immediately with dry rags. 1. replace the fuel pump. Fill the fuel tank. a fire may occur. Put the end of the fuel hose into an open container. or any other source of fire. 8-47 . c.FUEL PUMP SYSTEM EAS00819 ELEC CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. b. make sure that the engine is completely cool before performing the following test. Check: S fuel pump operation a. S Do not smoke. Connect the battery (12 V) to the fuel pump coupler as shown. Be extremely careful and note the following points: S Stop the engine before refuelling.

CARBURETOR HEATING SYSTEM CABURETOR HEATING SYSTEM ELEC 4 5 6 36 37 Main switch Battery Fuse (main) Fuse (carburetor heater) Carburetor heater relay 39 65 70 71 72 73 Thermo switch Neutral switch Carburetor heater #1 Carburetor heater #2 Carburetor heater #3 Carburetor heater #4 8-48 .

Check: 1. Refer to “CHECKING THE SWITCHES”. Battery 3. Main switch 4. . Battery S Check the condition of the battery. 90890-03112 EAS00738 3. Main and carburetor heater fuses 2. S Is the carburetor heater relay OK? YES NO Replace the carburetor heater relay. Open-circuit voltage 12. Carburetor heater 8. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE BATTERY” in CHAPTER 3. Carburetor heater relay 6. Battery positive terminal ! brown 1 Battery negative terminal ! light green 2 Tester positive probe ! brown 3 Tester negative probe ! black/white 4 2. Thermo switch 7. S Connect the pocket tester (Ω 1) and battery (12 V) to the carburetor heater relay coupler as shown. S Recharge or replace the battery. S Are the main and carbretor heater fuses OK? YES NO Replace the fuse (-s). Neutral switch S Check the neutral switch for continuity. EAS00822 1. Refer to “CHECKING THE FUSES” in CHAPTER 3. Main. remove the following part(-s): 1) Rider and passenger seats 2) Fuel tank Troubleshoot with the following special tool(-s). EAS00751 NO the main 4. Carburetor heater relay S Disconnect the carburetor heater relay coupler from the wire harness. Wiring connections (of the entire carburetor heating system) NOTE: Before troubleshooting. Neutral switch 5. and carbretor heater fuses S Check the main and carbretor heater fuses for continuity. Main switch S Check the main switch for continuity.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. Pocket tester YU-03112. S Is the main switch OK? YES Replace switch. EAS00739 5.CARBURETOR HEATING SYSTEM EAS00821 EAS00749 ELEC TROUBLESHOOTING The carburetor heating system fails to operate. S Is the neutral switch OK? YES NO Replace the neutral switch. 8-49 S Check the carburetor heater relay for no continuity.

S Connect the pocket tester to the (Ω 1) to the thermo switch as shown. 8. Carburetor heater S Remove the carburetor heating element from the carburetor.CARBURETOR HEATING SYSTEM EAS00825 ELEC 6. Tester positive probe ! black/white 1 Tester negative probe ! black/yellow 2 The following procedure applies to all of the carburetor heating elements. 7. S Connect the pocket tester to the carburetor heating element as shown. Wiring S Check the entire carburetor heating system’s wiring. Tester positive probe ! heating element 1 Tester negative probe ! heating element body 2 B/W B/Y S Check the thermo switch for continuity at the temperatures indicated below. 20_C S Measure the carburetor heater resistance. 8-50 . Thermo switch S Remove the thermo switch from the thermo switch plate. S Is the carburetor heating system’s wiring properly connected and without defects? NO Properly connect or repair the carburetor heating system’s wiring. Carburetor heating element resistance 6 X 12 Ω at 20_C 26_C S Is the carburetor heating element OK? YES NO Replace the carburetor heating element. Refer to “CIRCUIT DIAGRAM”. EAS00826 A COOL DOWN B HEAT UP S Does the thermo switch operated properly? YES NO Replace the thermo switch.

AUDIO SYSTEM AUDIO SYSTEM ELEC 4 5 6 17 Main switch Battery Fuse (main) Fuse (back up) 8-51 .

AUDIO SYSTEM ELEC 80 81 82 83 84 85 86 87 88 89 Fuse (audio) MCU Speaker (front) Speaker (front) Speaker (rear) Rear remoto controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) 8-52 .

1 2 3 4 5 6 7 8 9 10 ELEC Battery Fuse (main) Main switch Fuse (back up) Fuse (audio) Main control unit Front remoto controller Rear remoto controller Front speakers Rear speakers 11 12 13 14 15 16 17 18 19 FM / AM antenna Tape deck Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Front headset (option) Rear headset (option) CD changer (option) 8-53 . front/rear speakers. and main control unit (MCU). tape deck.AUDIO SYSTEM AUDIO SYSTEM CIRCUIT OPERATION The audio system circuit consists of the front/rear remote controllers.

If the coupler is twisted when connecting. If the coupler is twisted when disconnecting. Connect: S Front remote control coupler (to the main control unit) S Tape deck coupler (to the main control unit) CAUTION: When connecting a coupler. 8-54 . the inner pins may be damaged. be sure to push on the coupler as shown. and pull it out straight. the inner pins may be damaged. Disconnect: S Front remote control coupler (from the main control unit) S Tape deck coupler (from the main control unit) CAUTION: When disconnect a coupler. INSTALL 1. be sure to align projection 1 with indent 2 and push inward straightly.AUDIO SYSTEM ELEC REMOVAL 1.

1. 5. Wiring connections S Check the wiring (blue/green) of MCU X front remote controller. 4. S Check the wiring. Pocket tester YU-03112. S Connect the pocket tester (20 V DC) to the MCU 18P connector as shown. S Check the ground. Fuse S Check the main back up and audio fuse for continuity. 3. All AUDIO system does not operation. MCU back up S Disconnect the MCU 18P connector from the wire harness. 90890-03112 1. Back up Tester positive probe ! red/green 1 Tester negative probe ! ground Audio Tester positive probe ! brown/white 2 Tester negative probe ! ground NO MCU S Measure the voltage (12 V) on the MCU 18P connector. 8-55 . 2. Ground 3. Refer to “checking the connection”. S Is the main back up and audio fuse OK? YES NO Replace the fuses. remove the following part(-s): 1) Front cowlling 2) Trunk S Troubleshoot with the following special tool(-s). Front remote Controller / Display S Is the ground lead OK? YES NO Correct the ground lead. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting. Fuses 2. S Is the voltage within specification? YES NO Correct the wiring. S Is the MCU connector OK? YES Correct the connector. MCU coupler ELEC S Check the connection of MCU 18P connector. MCU 4. Ground lead S Check the ground lead 1 .AUDIO SYSTEM AUDIO SYSTEM does not operation Check: 1. Refer to “CHECKING THE FUSES” in CHAPTER 3.

2. NO Correct the MCU X front remote controller wiring. NO Correct the MCU X antenna wiring. Radio does not sound. S Is the cassette deck moved? YES NO Replace the cassette deck. 1. Casset deck S Check the cassette deck operation. Wiring connections S Check the wiring (gray) of MCU X cassette deck 13P DIN wiring. 3. 8-56 . ELEC S Is the MCU X cassette deck 13P wiring properly connected and without defected? YES Replace the MCU. Wiring connections S Check the wiring of MCU X antenna. 2.AUDIO SYSTEM S Is the MCU X front remote controller wiring properly connected and without defects? YES Replace the MCU. NO Correct the MCU X cassette deck 13P wiring. S Is the MCU X antenna wiring properly connected and without defected? YES Replace the MCU. Casset deck does not sound. 1.

NO Set up the “FADE” switch.AUDIO SYSTEM Speaker does not sound Check: 1. 1) to the Front left Tester positive prove ! red/white 1 Tester negative prove ! gray 2 Front right Tester positive prove ! red/black 1 Tester negative prove ! blue/black 2 Rear left Tester positive prove ! blue/green 1 Tester negative prove ! pink/black 2 Rear right Tester positive prove ! red/yellow 1 Tester negative prove ! brown/black 2 S Measure the speaker resistance. “FADE” switch S “FADE” switch set up near front or rear. Pocket tester YU-03112. Front or rear speaker does not sound. 1. 1) Front cowling 2) Trunk S Troubleshoot with the following special tool(-s). Does not sound of the speaker. S Remove the speaker. remove the following part(-s). Out put mode 2. S Change the out put mode “HS” ! “SP”. S Connect the pocket tester (Ω speaker as shown. 2. S “FADE” switch set up OK? YES Replace the MCU. Out put mode.6 Ω at 20_C S Is the speaker resistance within specification? YES NO Replace the speaker. 90890-03112 1. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting. Speaker 3. Speaker ELEC 3. 1.4 X 4. 8-57 . Speaker resistance 3.

NO Correct the MCU 18P connector. remove the following part(-s). Front head set does not sound 1. Wiring connections SCheck the wining of head set. S Check the pocket tester (Ω 1) to the head set wiring as shown. 1) Front cowling 2) Trunk S Troubleshoot with the following special tool(-s). MCU 18P connector S Check the MCU 18P connector. S Is the MCU 18P connector OK? YES Replace the MCU. Rear head set 4. Wiring connections S Check the wiring of MCU X wire harness X speaker wiring. Front head set 3. S Change the out put mode “SP” ! “HS”. Refer to “CHECKING THE CONNECTION”. All speaker does not sound 1. Left Tester positive prove ! 3 Tester negative prove ! 2 Right Tester positive prove ! 5 Tester negative prove ! 2 8-58 . Out put mode. Pocket tester YU-03112.AUDIO SYSTEM 2. NO Correct the MCU X wire harness X speaker wiring. 90890-03112 1. S Is the MCU X wire harness X speaker wiring properly connected and without defected? YES Replace the MCU. Out put mode 2. 4. 2. ELEC Headset does not sound Check: 1. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting.

AUDIO SYSTEM ELEC S Check the head set wiring for continuity. S Check the head set wiring for continuity. Left Tester positive prove ! 3 Tester negative prove ! 2 Right Tester positive prove ! 5 Tester negative prove ! 2 1) to the S Is the MCU X 5P DIN cable X head set wiring properly connected and without defected OK? YES Replace the MCU. NO Correct the MCU X 5P DIN cable X head set wiring. Rear remote controller volume S Check the rear remote controller volume 1 out put level. Rear head set does not sound 1. 3. Wiring connections S Check the wiring of MCU X 5P DIN cable X head set (red). S Is the head set wiring OK? YES NO Correct the head set wiring. 2. 8-59 . 2. S Is the rear remote controller volume out put level OK? YES NO Adjust the rear remote controller volume out put level. Wiring connections S Check the wiring of head set. S Is the head set wiring OK? YES NO Correct the head set wiring. S Connect the pocket tester (Ω head set as shown.

Wiring connections S Check the head set wiring. S Connect the pocket tester (Ω head set wiring as shown. S Is the head set wiring OK? YES Replace the MCU. NO Correct the head set wiring. NO S Check the head set wiring for continuity. 2. Wiring connections S Check the wiring of MCU X 5P DIN cable X head set (white). Intercom volume out put level YES NO Adjust the Intercom volume out put level. 4. Left Tester positive prove ! 3 Tester negative prove ! 2 Right Tester positive prove ! 5 Tester negative prove ! 2 8-60 1) to the . Correct the MCU X 5P DIN cable X head set wiring. ELEC Mike Tester positive prove ! 1 Tester negative prove ! 4 S Is the MCU X 5P DIN cable X head set wiring properly connected and without defected? YES Replace the MCU.AUDIO SYSTEM 2. Intercom does not used 1.

Wiring connections S Check the MCU X front remote controller 13P wiring (blue). 8-61 . NO Correct the Wire harness X rear remote controller wiring. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting.AUDIO SYSTEM Front remote controller does not operation Check: 1. 90890-03112 1. Pocket tester YU-03112. 90890-03112 1. S Is the wire hamess X rear remote controller wiring properly connected and without defected? YES Replace MCU or rear remoto controller. remove the following part(-s): 1) Front cowling 2) Trunk S Troubleshoot with the following special tool(-s). remove the following part(-s): 1) Front cowling 2) Trunk S Troubleshoot with the following special tool(-s). Pocket tester YU-03112. ELEC Rear remote controller does not operation Check: 1. S Is the MCU X front remote controller 13P wiring properly connected and without defected? YES Repalce MCU or front remoto controller NO Correct the MCU X front remote controller 13P wiring. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting. Wiring connections S Check the wire harness X rear remote controller wiring.

CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM ELEC 8-62 .

CRUISE CONTROL SYSTEM (4 (5 (6 ( 14 ( 18 ( 21 ( 22 ( 35 ( 38 ( 40 ( 49 ( 57 ( 62 ( 63 ( 64 ( 66 ( 75 ( 90 ( 91 ( 92 ( 93 ( 94 Main switch Battery Fuse (main) Ignition coil Front brake switch Cruise control switch “CANCEL” switch Fuse (signal) Brake light relay Rear brake switch Clutch switch Speedometer/ Fuel meter Cruise control light (MAIN) Cruise control light (SET) Cruise control light (RES) Speed sensor Tail/ brake light Cruise control unit Vacuum pump Fuse (cruise control) “CRUISE” switch Cruise control relay ELEC 8-63 .

CRUISE CONTROL SYSTEM CRUISE CONTROL CIRCUIT OPERATION 1 2 3 4 5 6 7 8 9 10 ELEC Battery Main fuse Main switch Signal fuse Cruise control fuse “CRUISE” switch Cruise contrl relay “ON” indicator light “SET” indicator light “RES” indicator light 11 12 13 14 15 16 17 18 19 20 Cruise contrl unit Vacuum pump Cruise contrl switch Rear brake switch Cancel switch Clutch switch Front brake switch Rear brake light switch Front brake light switch Brake lamp relay 21 22 23 24 Brake light To ignition coil Speed sensor Speedometer 8-64 .

CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM COMPONENTS 1 2 3 4 5 6 ELEC Speed sensor Battery Fuse Main switch Fuse Indicators 7 Front brake switch 8 Cruise control switch /cancel 9 10 11 12 13 14 switch Clutch switch Cruise control unit Rear brake switch Vacuum pump Vacuum autuator Throttle cable joint 15 16 17 18 19 20 Air Carburetor (s) Throttle valve Air/ Fuel mixture “CRUISE” switch Ignition coil 8-65 .

Refer to “CHECKING THE FUSES” in CHAPTER 3. main. 4. “CRUISE” switch S Disconnect the “CRUISE” switch connector. 2. “CRUISE” switch 5. Main switch S Check the main switch for continuity. remove the folling part (-s): 1) seat 2) under cowl (left and right) 3) upper cowl S Troubleshoot with the following special tool (-s). Tester positive prove ! red/blue 1 Tester negative prove ! brown/red 2 or yellow/black 3 EAS00738 1. S Are the control fuses OK? YES Replace (-s). S Check the “CRUISE” switch for continuity. battery 3. the NO fuse S Is the “CRUISE” switch OK? YES NO Replace the “CRUISE” switch. and cruise control fuses S Check the control fuses for continuity. signal.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals S Recharge or replace the battery. 8-66 . signal and cruise control 2.CRUISE CONTROL SYSTEM EAS00781 EAS00739 ELEC TROUBLESHOOTING Check: 1. Refer to “CHECKING THE SWITCHES”. Open-circuit voltage 12. EAS00749 Pocket tester 90890-03112 3. Battery S Check the condition of the battery. S Is the main switch OK? YES NO Replace the main switch. cruise control relay 6. Refer to “CHECKING AND CHARGING THE BATTERY” in CHAPTER 3. wiring (of the entire charging system) NOTE: S Before troubleshooting. main switch 4. Main.

Tester positive probe ! yellow/black 1 Tester negative probe ! black 2 S Does the cruise control relay have continuity between brown/red and yellow/red? YES NO Replace the relay unit. S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit terminal as shown. NO Properly connect or repair the cruise control system’s wiring. Battery positive terminal ! yellow/red Battery negative terminal ! black 3 Tester positive prove ! brown/red 2 Tester negative prove ! yellow/red 4 1 ELEC CHECKING THE CRUISE CONTROL SYSTEM Detecting an abnormality with the motorcycle stopped 1. Cruise control relay. Cruise control indicator light bulb and socket S Check the cruise control indicator light bulb and socket for continuity. S Are the cruise control indicator light bulb and socket OK? YES NO Replace the cruise control indicator light bulb. 1. S Is the cruise control system’s wiring properly connected and without defects? YES Check the condition of each of the cruise control system’s circuits. 8-67 . socket or both. The cruise control indicator light fail to come on. S Measure the voltage (12V) of blue 1 on the meter assembly coupler (wire harness side). 6. 2. S Set the cruise switch to “ON”. Wiring S Check the entire cruise control system’s wiring. S Set the main switch to “ON”. S Is the voltage within specification? YES This circuit is OK. Refer to “CIRCUIT DIAGRAM”. Voltage S Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.CRUISE CONTROL SYSTEM 5. NO The wiring circuit from the cruise control relay to the meter assembly coupler is faulty and must be repaired. S Disconnect the relay from the coupler. Refer to “CHECKING THE CRUISE CONTROL SYSTEM”.

CRUISE CONTROL SYSTEM 2. Voltage S Connect the pocket tester (DC 20 V) to the “SET”/“RES” indicator light couplers (wire harness side) as shown. S Are the “SET”/“RES” indicator light bulb and socket OK? YES NO YES Replace the “SET”/ “RES” indicator light bulb.“RES” and “ON” indicator lights go out after approximaterly 1. The cruise control system can not be set. S Is it correct? NO The “SET” and “RES” indicator light(s) flashes. Tester positive prove ! pink/white or pink/black 1 Tester negative prove ! black 2 S Set the main switch to “ON”. The ”ON” indicator light stays on. S Is the resistance with specification? YES NO The cruise control switch is faulty. Replace the right handlebar switch. 1. Refer to “SELFDIAGNOSIS”. S Measure the voltage (12 V) of yellow/black 1 on the meter assembly couplers (wire harness side). S Connect the pocket tester (Ω x 1) to the coupler. (The “SET” indicator light does not come on) 1. 8-68 S When set the cruise control switch to “SET. the resistance reading 0 Ω to ∞ Ω. “SET” indicator light Tester positive probe ! yellow/black 1 Tester negative probe ! green/blue 2 “RES” indicator light Tester positive probe ! yellow/black 1 Tester negative probe ! orang/blue 3 3. “SET”/“RES” indicator light bulb and socket S Check the “SET”/“RES” indicator light bulb and socket for continuity. . Cruise control switch S Disconnect the right handlebar switch coupler from the wire harness. This circuit is OK. S Is the voltage within specification? YES NO The wiring circuit from the cruise control relay to the meter light coupler is faulty and must be repaired. S The cruise control. S Set the “CRUISE” switch to “ON”. Check ELEC S Set the main switch to “ON” and the “CRUISE” switch to “ON”. “SET” and “RES” indicator lights come on. DEC”. S The “SET”. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. socket or both.4 second (to check for a burned bulb). Detecting and abnormality during operation 1. The “SET”/“RES” indicator light will show any an abnormality of the cruise control system. 2.

the voltage reading is 12 V to 0 V. Tester positive prove ! yellow/black 1 or green/white 2 Tester negative prove ! black 3 Replace the speed Replace the cruise control unit. S Are the switches OK? YES NO Replace the faulty switch(es). front brake. Replace the right handlebar switch. Cruise control unit ELEC S Disconnect the coupler from the cruise control unit. . Engine warning light is flashing (Fault code 4) Refer to “SELF-DIAGNOSIS”. rear brake and clutch switch. b. rear brake or clutch switches). S Check the switches for continuity. “SET” and/or “RES” indicator light is flashing (Fault code 4) Refer to “SELF-DIAGNOSIS”. 4. S Is the speed sensor OK? NO (Faulty) YES (Normal) 3. Refer to “CHECKING THE SWITCHES”.CRUISE CONTROL SYSTEM 2. Tester positive prove ! yellow/green 1 Tester negative prove ! yellow/blue 2 S Set the main switch to “ON” and the “CRUISE” switch to “ON”. S When operating the cancel switches (“CANCEL. 2. Vacuum hose S Check the vacuum hose for clogging and/ or damage. Front brake. sensor. Set speed can not be cancelled by cansel switches (“CANCEL”. S Check the “CANCEL” switch for continuity.” front brake. S Is the “CANCEL” switch OK? YES NO The “CANCEL” switch is faulty. rear brake and/or clutch switches) 1. 8-69 S Is the vacuum hose OK? YES NO Repair or replace the vacuum hose. “CANCEL” switch S Disconnect the right handlebar switch coupler from the wire harness. S Is the voltage with specification? YES NO The wiring circuit is faulty and must be repaired. S Connect the pocket tester (DC20V) to the coupler. Speed sensor S Check the following items. 2. 1) Speedometer is faulty operation a.

2. Throttle cable free play S Check the throttle cable free play a . control unit. 8-70 . S Is the actuator diaphram staying? YES NO Actuator diaphram and/or vacuum hose are faulty. Replace as required. Free Play a : 1 X 2 mm S Is the throttle cable free play OK? YES NO Adjust the free play. Throttle cable joint ELEC S Check the throttle cable joint operation by operating the actuator manualy. and check if the throttle valve opens.CRUISE CONTROL SYSTEM 5. Replace the cruise Repair or replace the throttle cables. 3. Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY in CHAPTER 3. 3. Cruise control system can not be set (“SET” indicator light come on) 1. S Is the throttle cables OK? YES NO S Is the throttle cable joint OK? YES NO Repaire or replace the throttle cable joint. Throttle cables S Checke the throttle cables and throttle housing condition. Vacuum actuator S Disconnect the vacuum hose at the vacuum pump and operate the actuator manualy and play the open end of the hose by a finger.

S Connect the pocket tester (Ω x 1) to the connector. The cruise control switch is faulty. 5. 1. Tester positive prove ! pink/black 1 Tester negative prove ! black 2 S When set the cruise control switch to “RES. S Connect the battery (12 V) as shown. Cruise control switch S Disconnect the right handlebar switch connector from the wire harness. Replace the right handlebar switch. Vacuum pump 2 S After operating the actuator. Cruising speed can not be increased or resume can not be operated by cruise control switch. Vacuum pump 1 S Reconnect the vacuum hose and disconnect the vacuum pump connector. Speed sensor ELEC 4.CRUISE CONTROL SYSTEM 4. b. S Is the actuator operating? YES NO Replace the vacuum pump. leave it approximetely 5 seconds and check if the actuator diaphragm stays or returns. Engine warning light is flashing (Fault code 4) Refer to “SELF-DIAGNOSIS”. YES NO 8-71 . stop the vacuum pump by disconnecting the battery lead from the 4 terminals. NO Replace the vacuum pump. a. 5. Vehicle speed fluctuate during the cruising S Check the following items. Battery positive terminal ! red 1 Battery negative terminal ! blue/black 2 blue/white 3 blue/red 4 1. In this condition. Replace the cruise control unit. 1) Speedometer is faulty operation. S Is the speed sensor OK? NO (Faulty) Replace the speed sensor. the resistance reading 0 Ω to ∞ Ω. YES (Normal) Replace the cruise control unit. S Is the resistance with specification? S Is the actuator diagram stying? YES Replace the cruise control unit. “SET” and/or “RES” indicator light is flashing (Fault code 4) Refer to “SELF-DIAGNOSIS”. ACC”.

Use of the function allows the self diagnosis about the following: 1. 3. 2) Turn the rear wheels. 4) Use the engine stop switch and stop the engine. the “SET” and “RES” indicator lights will be remained on. NOTE: When the cruise control system is not failure. 8-72 . 3) Turn off the main switch. 2) Set the “CRUISE” switch to the “ON” position. 3) Start the engine. 1) Start the engine. Trouble diagnosis of the throttle drive system. Then the indicator light will be lit and the cruise control system will enter the self diagnosis mode. Trouble diagnosis of the cancel switch signal. Trouble diagnosis of the brake light signal.CRUISE CONTROL SYSTEM ELEC SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL SYSTEM The cruise control system has a self diagnosis function. 5) Wait for 10 seconds. 2. 4) Push the “CRUISE” switch to “OFF”. Exiting the self diagnosis mode Perform any one of the four steps shown below. Operating procedure for the self diagnosis mode 1) Turn on the main switch. The system will then exit the self diagnosis mode. 6) Push the cruise control switch to the “SET” and “RES” alternatively three times (total of 6 times) within 2 seconds while pressing the cancel switch. 1) The “SET” and “RES” indicator lights will then blink alternatively three times.

If the “SET” indicator light is not extinguished after any one of these switches is operated. 2) Operate the cancel. Trouble diagnosis of the cancel switch signal 1) The “SET” indicator light is lit. it mean that the relevant switch is in failure. Example: If the cancel switch is operated and the “SET” indicator light is not extinguished. it means that the cancel switch is in failure. 8-73 .CRUISE CONTROL SYSTEM ELEC 14 15 16 17 18 19 Rear brake switch Concel switch Clutch switch Front brake light switch Rear brake light switch Front brake light switch 1. rear brake. front brake. and clutch switches.

5 seconds later.CRUISE CONTROL SYSTEM ELEC 2. it means that the vacuum pump is in failure. If noise is heard from the vacuum pump but the throttle is not operating. Check the closing throttle for noises and operation. If no noises are heard from the vacuum pump. 2) Operate the following front brake and rear switches. 12 Vacuum pump 13 Vacuum actuator 14 Throttle cable joint 17 Throttle valve 8-74 . Trouble diagnosis of the brake light signal 1) The “RES” indicator light is lit. The throttle will be then opened fully in approx. it means that the throttle cable is in failure. Example: If the front brake switch is operated and the “RES” indicator light is not extinguished.5 seconds and kept fully open for 3 seconds. 3. 2. Trouble diagnosis of the throttle drive 1) Push the cruise control switch to ”RES”. If the RES indicator light is not extinguished after either of these switches is operated. it means that the relevant switch is in failure. The throttle will be fully closed approx. 2. it means that the front brake switch is infailure.

000 r/min) Fault code [4] – Blinks in Light on Fault code [9] Speed sensor Emergency stop switch Illegality pulse Disconnected Short-circuit Disconnected 8-75 . Fuel meter 3. However. if there is a malfunction. Engine warning light 2. it comes on for 1. 1. In the XVZ13TF. Light on Fault code [3] S Displays the condition code on the engine indicator light. when the main switch is turned on the “Engine trouble indicator light” in the speedometer comes on tor 1. the following items are monitored and the condition codes are displayed on the engine trouble indicator light (irrespective of whether the engine is running or not). NOTE: The XVZ13TF features a self-diagnosing system. (However. S Operate the speed limiter Blinks in Light on (5. goes off and then begins flashing. ENGINE TROUBLE INDICATOR LIGHT When the main switch is turned to “ON”. it is on while the engine is running. “SET”/“RES” indicator light 1.4 seconds.SELF-DIAGNOSIS SELF-DIAGNOSIS ELEC The XVZ13TF features a self-diagnosing system for following displays.) Display condition code Item Condition Response When When engine engine is is stationary running Throttle position sensor (TPS) Disconnected Short-circuit Locked S Enables the motorcycle to run so that the ignition timing is fixed when the throttle is Blinks in fully opened.4 seconds then goes off.

. . . . . . . . . .5 seconds 0. Light off (seconds) .SELF-DIAGNOSIS Display order on the engine warning light When one item being monitored ELEC 1 2 3 4 Light on (seconds) . . . . . . . . . 0. . . . . . . . . 0.5 seconds Fault code 3 seconds Light on Light off Repetition When more than one item is being monitored 1 2 3 4 5 Light on (seconds) . . . . . Number of blinks . . .5 seconds Fault code [4] 3 seconds Fault code [3] Light on Light off Repetition 8-76 . . . . . . . . . . . Light off (seconds) . . . . . . . Number of blinks .5 seconds 0. Light off (seconds) . . Light off (seconds) . . . . . . . Number of blinks . . .

EB812401 2. speed sensor 3. 1. Refer to “CIRCUIT DIAGRAM”. throttle position sensor 2. Wire harness S Check the wire harness for continuity. Pocket tester 90890-03112 EAS00836 1. Throttle position sensor CIRCUIT DIAGRAM Replace the ignitor unit.SELF-DIAGNOSIS EAS00835 ELEC TROUBLESHOOTING The tachometer starts to display the selfdiagnosis sequence. Check: 1. Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in chapter 6. S Is the wire harness OK? YES NO Repair or replace the wire harness. emergency stop switch NOTE: S Before troubleshooting. 13 Ignitor unit 29 Throttle position sensor 8-77 . remove the following part(-s): 1) rider seat 2) fuel tank 3) air filter case S Troubleshoot with the following special tool(-s). Throttle position sensor S Check the throttle position sensor for continuity. S Is the throttle position sensor OK? YES NO Replace the throttle position sensor.

8-78 . Speed sensor CIRCUIT DIAGRAM EB812401 ELEC 2. Emergency stop switch CIRCUIT DIAGRAM 13 Ignitor unit 27 Emergency stop switch 1. Speedometer S Check the speedometer operation. NO Replace the speed sensor. S Is the wire harness OK? YES NO Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM”. 3. Wire harness 13 Ignitor unit 66 Speed sensor S Check the wire harness for continuity. 1. S Is the speedometer OK? YES Replace the ignitor unit. Refer to “CIRCUIT DIAGRAM”.SELF-DIAGNOSIS 2. Wire harness S Check the wire harness for continuity. S Is the wire harness OK? YES NO Repair or replace the wire harness.

50_. Tester positive prove ! black/white 1 Tester negative prove ! black 2 50_ S When turn the emergency stop switch approx.SELF-DIAGNOSIS EB812401 ELEC 2. S Connect the pocket tester (Ω 1) to the emergency stop switch coupler as shown. Emergency stop switch S Remove the emergency stop switch. NO Replace the emergency stop switch. the resistance reading is 0 Ω to ∞ Ω. S Is the emergency stop switch OK? YES Replace the ignitor unit. 8-79 .

. . . . . . . . .SELF-DIAGNOSIS 2. . . . . .5 seconds Light on Light off Repetition 8-80 . . . . . 0.5 seconds Number of blinks . . . . . . .5 seconds 2 Light off . . . . . . . 0. . FUEL METER The fuel meter is indicated the fault displays as follows S Fuel sender S Fuel thermistor Fuel meter display sequence Fuel sender 1 2 3 4 5 ELEC Light on . .5 seconds Light off . . . . 0. . . 3 seconds 1 cycle 3 times repetition Light on Light off Repetition 1 Light on . . . . 8 times Light off . . . . 0. . . . . . . . . .

SELF-DIAGNOSIS Fuel thermistor 1 2 3 4 5 ELEC Light on . . . . . . . . . 0. . . . 0. . . . . . . . . . . . 8 times Light off . . . . . . . 3 seconds 1 cycle 3 times repetition Light on Light off Repetition 1 Light on . . .5 seconds Light off . . . . . . . . . . . . . . .5 seconds 2 Light off .5 seconds Light on Light off Repetition 8-81 . . . 0. .5 seconds Number of blinks . . . . . . 0.

fuel thermistor NOTE: S Before troubleshooting. 2. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the fuel sender OK? YES Replace the fuel meter. S Is the wire harness OK? YES NO Repair or replace the wire harness. fuel 1. Pocket tester 90890-03112 EAS00836 1. Refer to “SIGNAL SYSTEM”. fuel sender 2.SELF-DIAGNOSIS EAS00835 ELEC TROUBLESHOOTING The tuel meter starts to display the selfdiagnosis sequence. Fuel sender CIRCUIT DIAGRAM 57 Fuel meter 68 Fuel sender unit (thermistor) 57 Fuel meter 68 Fuel sender unit 8-82 . remove the following part (-s): 1) rider seat 2) fuel tank 3) air filter case S Troubleshoot with the following special tool (-s). EB812401 2. Fuel sender S Check the fuel sender for continuity. Check: 1. Fuel thermistor CIRCUIT DIAGRAM NO Replace the sender unit.

S After 1. S When set the main switch to on. the fuel level indicator light comes on. S Is the wire harness OK? YES NO Repair or replace the wire harness. Wire harness S Check the wire harness for continuity. EB812401 ELEC 2. Refer to “CIRCUIT DIAGRAM”. NO The fuel thermistor is faulty. the fuel level indicator light goes off. Fuel thermistor S Check the fuel thermistor operation. S Is the fuel thermistor OK? YES Replace the fuel meter. Replace the fuel sender unit.4 second. 8-83 .SELF-DIAGNOSIS 1.

. . Light off (seconds) . . “SET”/“RES” INDICATOR LIGHT When the main switch is turned to “ON”. . Number of blinks .SELF-DIAGNOSIS ELEC 3. the following items are monitored and the condition codes are displayed on the “SET”/“RES” indicator light at same time (irrespective of whether the engine is running or not). . . Rear brake switch or Clutch switch Speed sensor Ignition coil Cruise control switch Disconnected Short-circuit Disconnected Shart-circuit Disconnected Short-circuit Illegality palse Illegality pulse Disconnected Short-circuit Disconnected Blinks in Blinks in Blinks in Blinks in Blinks in Blinks in Blinks in Blinks in 3 4 5 6 Display order on the “SET/“RES” indicator light 1 2 3 4 Light on (seconds) . . Front brake switch.5 seconds 0. .5 seconds Fault code 3 seconds Light on Light off Repetition 8-84 . . Display condition Item Condition When engines is stationary Blinks in Blinks in When engine is running Blinks in Blinks in Fault code 1 2 Cruise control unit Vacuum pump Concel switch. 0. . . . . Light off (seconds) .

. . Fault code 3 seconds A Light on B Light off 8-85 .ELEC Fault code A 1 B A 2 B A 3 B A 4 B A 5 B A 6 B 1 2 3 4 0. .5 seconds Number of blinks .5 seconds 0. .

cancel switch. S Is the wire harness OK? YES NO Repair or replace the wire harness. front brake switch. Refer to “CIRCUIT DIAGRAM”. Cruise control unit Replace the cruise control unit. Vacuum pump S Check the vacuum pump for continuity. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. NO Replace the vacuum pump. front brake switch. rear brake switch and clutch switch S Check the switches for continuity. 2. rear brake switch or clutch switch 1. S Is the wire harness OK? YES NO Repair or replace the wire harness. ignition coil 6. 2. Check: 1. Wire harness S Check the wire harness for continuity. 3. vacuum pump 3. remove the following part (-s): 1) rider seat 2) fuel tank 3) air filter case S Troubleshoot with the following special tool (-s): Pocket tester 90890-03112 1. 90 Cruise control unit 91 Vacuum pump 8-86 . S Is the vacuum pump OK? YES Replace the cruise control. Cancel switch. EB812401 2.SELF-DIAGNOSIS EAS00835 ELEC TROUBLESHOOTING The “SET”/“RES” indicator light starts to display the self-diagnosis sequence. cruise control switch NOTE: S Before troubleshooting. S Are the switches OK? YES Replace the cruise control unit. Refer to “CRUISE COUTROL SYSTEM”. Vacuum pump CIRCUIT DIAGRAM 1. rear brake switch or clutch switch 4. NO Repair or replace the faulty switch (es). front brake switch. cruise control unit 2. Cancel switch. speed sensor 5. Refer to “CRUISE CONTROL SYSTEM”.

SELF-DIAGNOSIS CIRCUIT DIAGRAM ELEC 18 Front brake switch 22 “CANCEL” switch 40 Rear brake switch 49 Clutch switch 90 Cruise control unit 8-87 .

Refer to “CRUISE CONTROL SYSTEM”. S Is the speed sensor OK? YES Replace the cruise control unit. 90 Cruise control unit 8-88 . Speed sensor CIRCUIT DIAGRAM 5. S Is the wire harness OK? YES NO Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM”. Speed sensor S Check the speed sensor operation. Ignition coil CIRCUIT DIAGRAM ELEC 66 Speed sensor 90 Cruise control unit 1. EB812401 2.SELF-DIAGNOSIS 4. NO 14 Ignition coil Replace the speed sensor. Wire harness S Check the wire harness for continuity.

NO Replace the ignition coil. Engine condition S Start the engine and check the engine condition from the idling to full opening the throttle. S Is the cruise control switch OK? YES Replace the cruise control unit. Cruise control switch 6. Wire harness ELEC S Check the wire harness for continuity. Tester positive prove ! pink/white 1 pink/black 2 Tester negative prove ! black 3 S Check the cruise control switch for continuity. Refer to “CIRCUIT DIAGRAM”. S Connect the pocket tester (Ω 1) to the coupler. S Is the engine condition OK? YES Replace the cruise control unit. Cruise control switch 1. Refer to “CIRCUIT DIAGRAM”. 2. S Is the wire harness OK? YES NO Repair or replace the wire harness. Wire harness S Check the wire harness for continuity. 2. S Is the wire harness OK? YES NO Repair or replace the wire harness. Replace the right handlebar switch.SELF-DIAGNOSIS 1. S Disconnect the rihgt handlebar switch coupler from the wire harness. 8-89 . NO The cruise control switch is faulty.

SELF-DIAGNOSIS CIRCUIT DIAGRAM ELEC 8-90 .

TRBL SHTG 9 .

. SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . 9-3 ENGINE . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 UNSTABLE HANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9-4 9-4 9-4 9-4 9-4 OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . 9-3 CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR . . . . . . . . . . 9-3 9-3 9-3 9-3 FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRBL SHTG CONTENTS TROUBLESHOOTING STARTING PROBLEMS . . . . . . . . . . 9-5 MALFUNCTION . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 LEAKAGE OIL . . . . . . . . . . . . 9-1 9-1 9-1 9-2 9-2 9-2 9-2 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 FUEL SYSTEM . . . . . . . . . . . SHIFTING IS DIFFICULT . . . . . . ENGINE . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . . . . . . 9-4 FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY . . HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9-6 9-6 9-6 9-6 9-6 9-6 9-6 . . . HORN DOES NOT SOUND . . . . . .TRBL SHTG FAULTY SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

however. worn or fatigued piston ring S Seized piston ring S Seized or damaged piston Air filter S Improperly installed air filter S Clogged air filter element Crankcase and crankshaft S Crankcase and crankshaft S Improperly assembled crankcase S Seized crankshaft FUEL SYSTEM Fuel tank S Empty fuel tank S Clogged fuel filter S Clogged fuel strainer S Clogged fuel tank drain hose S Clogged rollover valve S Clogged rollover valve hose S Deteriorated or contaminated fuel Fuel pump S Faulty fuel pump S Faulty fuel pump relay Fuel cock S Clogged or damaged fuel hose Carburetor(-s) S Deteriorated or contaminated fuel S Clogged pilot jet S Clogged pilot air passage S Sucked-in air S Damaged float S Worn needle valve S Improperly installed needle valve seat S Incorrect fuel level S Improperly installed pilot jet S Clogged starter jet S Faulty starter plunger S Improperly adjusted starter cable 9-1 . It should be helpful. Refer to the relative procedure in this manual for checks.as a guide to basic troubleshooting. and replacement of parts.TROUBLESHOOTING EAS00844 TRBL SHTG TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of trouble. STARTING PROBLEMS ENGINE Cylinder(-s) and cylinder head (-s) S Loose spark plug S Loose cylinder head S Damaged cylinder head gasket S Worn or damaged cylinder S Incorrect valve clearance S Improperly sealed valve S Incorrect valve-to-valve-seat contact S Incorrect valve timing S Faulty valve spring S Seized valve S Piston(-s) and piston ring(-s) S Improperly installed piston ring S Damaged. adjustments.

damaged or incorrect fuse S Improperly installed fuse Spark plug(-s) S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Starting system S Faulty starter motor S Faulty starter relay S Faulty starting circuit cut-off relay S Faulty starter clutch TRBL SHTG Ignition system S Faulty ignitor unit S Faulty pickup coil S Broken generator rotor woodruff key S Switches and wiring S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring S Faulty neutral switch S Faulty start switch S Faulty sidestand switch S Faulty clutch switch S Improperly grounded circuit S Loose connections Ignition coil(-s) S Cracked or broken ignition coil S Broken or shorted primary or secondary coils S Faulty spark plug lead EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder(-s) and cylinder head(-s) S Incorrect valve clearance S Damaged valve train components Air filter S Clogged air filter element FUEL SYSTEM Carburetor(-s) S Faulty starter plunger S Loose or clogged pilot jet S Loose or clogged pilot air jet S Damaged or loose carburetor joint S Improperly synchronized carburetors S Improperly adjusted engine idling speed (throttle stop screw) S Improper throttle cable free play (at the flange of the throttle grip) S Flooded carburetor S Faulty air induction system ELECTRICAL SYSTEMS Battery S Improperly charged battery S Faulty battery S Spark plug(-s) S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Ignition coil(s) S Broken or shorted primary or secondary coils S Faulty spark plug lead S Cracked or broken ignition coil Ignition system S Faulty ignitor unit S Faulty pickup coil S Broken generator rotor woodruff key 9-2 .TROUBLESHOOTING ELECTRICAL SYSTEMS Battery S Improperly charged battery S Faulty battery Fuse(-s) S Blown.

clogged or disconnected carburetor air vent hose S Clogged or leaking air duct FUEL SYSTEM Carburetor(-s) S Faulty diaphragm S Incorrect fuel level S Loose or clogged main jet Fuel pump S Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to “CLUTCH DRAGS”. ENGINE Air filter S Clogged air filter element S Air intake system S Bent. SHIFT PEDAL DOES NOT MOVE S Shift shaft S Improperly adjusted shift rod S Bent shift shaft. S Shift drum and shift fork(-s) S Foreign object in the shift drum groove S Seized shift fork S Bent shift fork guide bar Transmission S Seized transmission gear S Foreign object between transmission gears S Improperly assembled transmission EAS00852 JUMPS OUT OF GEAR Shift shaft S Incorrect shift pedal position S Improperly returned stopper lever Shift fork(-s) S Worn shift fork Shift drum S Incorrect axial play S Worn shift drum groove Transmission S Worn gear dog FAULTY CLUTCH CLUTCH SLIPS S Clutch S Improperly assembled clutch S Improperly assembled clutch master cyinder S Improperly assembled clutch release cylinder S Incorrect clutch fluid level S Damage clutch hose S Loose or fatigued clutch spring S Loose union bolt S Worn friction plate S Worn clutch plate S Damage clutch release cylinder Engine oil S Incorrect oil level S Incorrect viscosity (low) S Deteriorated oil CLUTCH DRAGS S Clutch Air in hydraulic clutch system S Unevenly tensioned clutch springs S Warped pressure plate S Bent clutch plate S Swollen friction plate S Bent clutch push rod S Damaged clutch boss S Burnt primary driven gear bushing S Damaged clutch release cylinder S Match marks not aligned Engine oil S Incorrect oil level S Incorrect viscosity (high) S Deteriorated oil 9-3 .TROUBLESHOOTING EAS00849 TRBL SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”.

TROUBLESHOOTING EAS00855 TRBL SHTG OVERHEATING ENGINE S Clogged coolant passages Cylinder head(-s) and piston(-s) S Heavy carbon buildup Engine oil S Incorrect oil level S Incorrect oil viscosity S Inferior oil quality FUEL SYSTEM Carburetor(-s) S Incorrect main jet setting S Incorrect fuel level S Air leak at carburetor joint Air filter S Clogged air filter element ELECTRICAL SYSTEMS Spark plug(-s) S Incorrect spark plug gap S Incorrect spark plug heat range Ignition system S Faulty ignitor unit COOLING SYSTEM Coolant S Low coolant level Radiator S Damaged or leaking radiator S Faulty radiator cap S Bent or damaged radiator fins Water pump S Damaged or defective water pump Thermostat S Thermostat stays closed CHASSIS Brake(-s) S Dragging brake EAS00856 OVERCOOLING COOLING SYSTEM Thermostat S Thermostat stays open EAS00857 POOR BRAKING PERFORMANCE Disc brake S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper kit S Faulty brake caliper seal S Loose union bolt S Damaged brake hose S Oil or grease on the brake disc S Oil or grease on the brake pad S Incorrect brake fluid level 9-4 .

deformed or damaged outer tube S Damaged fork spring S Worn or damaged outer tube bushing S Bent or damaged damper rod S Incorrect oil viscosity S Incorrect oil level EAS00862 UNSTABLE HANDLING Handleber S Bent or improperly installed handlebar Steering S Improperly installed upper bracket S Improperly installed lower bracket (improperly tightened ring nut) S Bent steering stem S Damaged ball bearing or bearing race Tire(-s) S Uneven tire pressures (front and rear) S Incorrect tire pressure S Uneven tire wear Swingarm S Worn bearing or bushing S Bent or damaged swingarm S Rear shock absorber assembly S Faulty rear shock absorber spring S Leaking oil or gas Front fork leg(-s) S Uneven oil levels (both front fork legs) S Uneven fork spring tension (both front fork legs) S Broken fork spring S Bent or damaged inner tube S Bent or damaged outer tube Wheel(-s) S Incorrect wheel balance S Deformed cast wheel S Damaged wheel bearing S Bent or loose wheel axle S Excessive wheel runout Frame S Bent frame S Damaged steering head pipe S Improperly installed bearing race 9-5 .TROUBLESHOOTING EAS00861 TRBL SHTG FAULTY FRONT FORK LEGS LEAKING OIL S Bent. damaged or rusty inner tube S Cracked or damaged outer tube S Improperly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod bolt S Damaged damper rod bolt copper washer S Cracked or damaged cap bolt O-ring MALFUNCTION S Bent. deformed or damaged inner tube S Bent.

damaged or incorrect fuse HORN DOES NOT SOUND S Improperly adjusted horn S Damaged or faulty horn S Faulty main switch S Faulty horn switch S Faulty battery S Blown. damaged or incorrect fuse S Faulty wire harness HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Incorrect ground S Faulty main switch S Faulty light switch S Headlight bulb life expired TURN SIGNAL BLINKS SLOWLY S Faulty flasher relay S Faulty main switch S Faulty turn signal switch S Incorrect turn signal bulb TURN SIGNAL REMAINS LIT S Faulty flasher relay S Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY S Incorrect turn signal bulb S Faulty flasher relay S Burnt-out turn signal bulb 9-6 .TROUBLESHOOTING EAS00866 TRBL SHTG FAULTY SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Incorrect ground S Poor contacts (main or light switch) S Burnt-out headlight bulb TURN SIGNAL DOES NOT LIGHT S Faulty turn signal switch S Faulty flasher relay S Bumt-out turn signal bulb S Incorrect connection S Damaged or defective wire harness S Incorrect ground S Discharged battery S Blown.

XVZ13TF (for EUR) WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 AC magneto Condenser Rectifire/ regurator Main switch Battery Fuse (main) Starter relay Starter motor Oil level switch Starting circuit cutoff relay Diode Fuel pump Ignitor Ignition coil Spark pulg CYCLELOCK (option) Fuse (back up) Front brake switch Handlebar switch (right) Light switch Cruise control switch “CANCEL” switch Engine stop switch Start switch Fuse (ignition) Side stand switcn Emargency stop switch Pick up coil Throttle position sensor Thermo switch Noise filter Fan motor Fuse (fan motor) Fuse (head light) Fuse (signal) Fuse (caburetor heater) Carburetor heater relay Brake light relay Thermo switch Rear brake switch 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Horn 2 Horn 1 Flasher relay Handlebar switch (left) Dimmer switch Horn switch Turn signal switch “PASS” switch Clutch switch Meter assembly Engine trouble indicator light Oil level indicator light Engine overheat indicator light Over drive indicator light Neutral indicater light Fuel level indicator light Speedometer/ Fuel meter High beam indicator light Turn indicator light (left) Turn indicator light (right) Ilumination light “ON” indicator light (MAIN) “SET” indicator light (SET) “RES” indicator light (RES) Neutral switch Speed sensor Thermo unit Fuel sender unit Carburetor heater ground Carburetor heater #1 Carburetor heater #2 Carburetor heater #3 Carburetor heater #4 License light Tail/ brake light Auxiliary light Headlight Front turn signal light (left) Front turn signal light (right) .

. . R/ Y . . G/W ... P/ L . .. . . Y/ B . . . . G . L/B .. . Br/ R . O/L . . P/ W . . Black Brown Chocolate Dark green Green Gray Blue Light green O . . Ch . . . .. . W/ R .. . .. . .. Br/ W . B/ R . . B/ L . . .. Y . .. . . B/ Y . Lg .. R. Green / Blue Green / Red Green / White Green / Yellow Blue/ Black Blue/ Green Blue/ Red Blue/ White L/Y . L/R . P/ B .. Black/ White Black/ Yellow Brown/ Black Brown/ Blue Brown/ Red Brown/ White Brown/ Yellow Green / Black G/L . . .. . Sb . Y/ L . . . G/B . . . . W . L/W . . . . .. .. . . Red/ White Red/ Yellow White/ Green White/ Red White/ Yellow Yellow/ Black Yellow/ Green Yellow/ Blue Y/ R . Br/ Y . . . Dg . . Br/ B . R/ G ... . . . Orange Pink Red Sky blue White Yellow Black/ Blue Black/ Red B/ W .. L/G . . .. Blue/ Yellow Orange / Blue Pink/ Black Pink/ Blue Pink/ White Red/ Black Red/ Green Red/ Blue R/ W . . . . .. R/ L . ... G/Y . Gy . L . . .. P . Br . Y/ G .. . R/ B . W/ G ..MCU CUISE CONTROL UNIT “CRUISE” SWITCH 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 Fuse (audio) MCU Speaker (front) Speaker (front) Speaker (rear) Rear remote controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Cruise control unit Vacuum pump Fuse (cruise control) “CRUISE” switch Cruise control relay D. . . . .. . . G/R ... W/ Y . . Br/ L .C OUTLET COLOR CODE B . Yellow/ White .. Yellow/ Red Y/ W . . .

XVZ13TFL (for OCE) WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 AC magneto Condenser Rectifire/ regurator Fuse (back up) Main switch Fuse (main) Battery Starter relay Starter motor Oil level switch Starting circuit cutoff relay Diode Fuel pump Ignitor Ignition coil Spark plug Front brake switch Handlebar switch (right) Cruise control switch “CANCEL” switch Engine stop switch Start switch Fuse (ignition) Side stand switch Emargency stop switch Pick up coil Throttle position sensor Thermo switch Noise filter Fan motor Fuse (fan motor) Fuse (head light) Fuse (signal) Fuse (carburetor heater) Carburetor heater relay Brake light relay Thermo switch Rear brake switch 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Horn 2 Horn 1 Flasher relay Handlebar switch (left) Dimmer switch Horn switch Turn signal switch “PASS” switch Clutch switch Meter assembly Engine trouble indicator light Oil level indicator light Engine overheat indicator light Over drive indicator light Neutral indicator light Fuel level indicator light Speedometer/ Fuel meter High beam indicator light Turn indicator light (left) Turn indicator light (right) Ilumination light “ON” indicator light (MAIN) “SET” indicator light (SET) “RES” indicator light (RES) Neutral switch Speed sensor Thermo unit Fuel sender unit Carburetor heater ground Carburetor heater #1 Carburetor heater #2 Carburetor heater #3 Carburetor heater #4 License light Tail/ brake light Headlight Front turn signal light (left) Front turn signal light (right) .

B/ Y . . L/Y . . . . Lg . .... . Br/ L . . Br/ Y .. Gy ... . . . . Y/ R . B/ L . R/ W .. . . Y/ W . P/ B . Dg . . . L/R . . .. . Brown/ Black Brown/ Blue Brown/ Red Brown/ White Brown/ Yellow Green / Black Green / Blue Green / Red Green / White G/Y .. . Y .. Y/ G . . B/ R . . Br/ R .. . . W/ L . Br .. .. . Y/ L . L/G .MCU CUISE CONTROL UNIT “CRUISE” SWITCH 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 Fuse (audio) MCU Speaker (front) Speaker (front) Speaker (rear) Rear remote controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Cruise control unit Vacuum pump Fuse (cruise control) “CRUISE” switch Cruise control relay D... R/ Y . ... L/W . B/ W . . . . . . L/B . . . . . . P/ L ... .. Green / Yellow Blue/ Black Blue/ Green Blue/ Red Blue/ White Blue/ Yellow Orange / Blue Pink/ Black Pink/ Blue P/ W . R/ L .. .C OUTLET COLOR CODE B . G . . . R/ B . . W . . .. . Br/ W . . . . R/ G . W/ R . . . G/R . . O/L . G/B ... White/ Yellow Yellow/ Black Yellow/ Green Yellow/ Blue Yellow/ Red Yellow/ White . . G/W . . Black Brown Chocolate Dark green Green Gray Blue Light green Orange P . Pink/ White Red/ Black Red/ Green Red/ Blue Red/ White Red/ Yellow White/ Green White/ Blue White/ Red W/ Y . . . .. . Pink Red Sky blue White Yellow Black/ Blue Black/ Red Black/ White Black/ Yellow Br/ B . Sb . Ch . .. Y/ B .. . G/L . . . W/ G . L . . O .. . R. . . .. . . .

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