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EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR


SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.

CAUTION:
NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage


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

EB002000

HOW TO USE THIS MANUAL


MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See Illustrated symbols)
1st title 1 :

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

2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper right corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by
a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to
the exploded diagram and the job instruction chart.

6
3

8
5
4

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the


top right of each page and indicate the subject of
each chapter.
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting

CHK
ADJ
5

10

11

12

13

14

Illustrated symbols 10 to 17 are used to identify


the specifications appearing in the text.
10
11
12
13
14
15
16
17

15

16

17

18

19

20

21

24

22

23

25

Can be serviced with engine mounted


Filling fluid
Lubricant
Special tool
Torque
Wear limit, clearance
Engine speed
, V, A

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

Apply engine oil


Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply lightweight lithium-soap base grease
Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply locking agent 24
and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Replace

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2
3
4

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

PERIODIC CHECKS AND ADJUSTMENTS


INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 16
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

CHASSIS
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

GENERAL SPECIFICATIONS

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item

Standard

Model code:

XVS1100: 5PB2

Basic weight:
With oil and a full fuel tank

275 kg

Tire:
Type
Size
Manufacturer
Type

front
rear
front
rear
front
rear

Maximum load-except motorcycle:

With tube
110/90-18 61S
170/80-15M/C 77S
DUNLOP
DUNLOP
K555F
K555
200 kg

SPEC

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item

Standard

Camshaft:
Drive method
Cam cap inside diameter
Camshaft outside diameter
Shaft-to-cap clearance
Cam dimensions

Intake

Exhaust

Camshaft runout limit

A
B
C
A
B
C

Limit

Chain drive (left & right)


25.000  25.021 mm
24.96  24.98 mm
0.020  0.061 mm






39.112  39.212 mm
32.093  32.193 mm
7.162 mm
39.112  39.212 mm
32.127  32.227 mm
7.162 mm


39.012 mm
31.993 mm
7.012 mm
39.012 mm
32.027 mm
7.012 mm
0.03 mm

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS
Item
Front suspension:
Front fork travel
Fork spring free length
Fitting length
Collar length
Spring rate
Stroke

Standard

(K1)
(K2)
(K1)
(K2)

Optional spring
Oil capacity
Oil level
Oil grade
Rear suspension:
Shock absorber travel
Spring free length
Fitting length
Spring rate
Stroke
Optional spring

(K1)
(K1)

Limit

140 mm
356.9 mm
319.4 mm
183 mm
4.41 N/mm (0.9 kg/mm)
6.37 N/mm (1.3 kg/mm)
0  77.5 mm
77.5  140 mm
No
0.464 L
108 mm
Fork oil 10W or equivalent


350 mm











50 mm
179.5 mm
163 mm
117.7 N/mm (12 kg/mm)
0  50 mm
No








Tightening torques
g
Part to be tightened
Brake caliper and bracket

Tightening
torque

Thread size
M10

Remarks

Nm

mkg

ftlb

27

2.7

20

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL
Item

Standard

Limit

Ignition coil:
Model/manufacturer
Primary winding resistance
Secondary winding resistance

F6T541 /MITSUBISHI
3.57  4.83 at 20_C
10.7  14.5 k at 20_C

SSS
SSS
SSS

Charging system:
Type
Model/manufacturer
Nominal output
Stator coil resistance/color

A.C. magneto
F4T654 /MITSUBISHI
14 V 305 W at 5,000 r/min
0.36  0.44 at 20_C/White White

SSS
SSS
SSS
SSS

Constant mesh type

SSS

SM-13/MITSUBA
0.6 kW
0.026  0.034 at 20_C
10 mm
7.65  10.01 N (780  1021 g)
28 mm
0.7 mm

SSS
SSS
SSS
5 mm
SSS
27 mm
SSS

MS5F-421 /JIDECO
180 A

SSS
SSS

Electric starter system:


Type
Starter motor:
Model/manufacturer
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating

CABLE ROUTING

SPEC

EB206000

CABLE ROUTING
Clutch cable
Starter cable
Handlebar switch lead (left)
Handlebar switch lead (right)
High tension code
Throttle cable
Fuel hose (fuel cock-filter)
Fuel breather hose (fuel tank-roll
over valve) (for CAL)
9 Fuse box
10 Alarm connector
11 Fuel pump lead
1
2
3
4
5
6
7
8

Speed sensor lead


Sidestand switch lead
Neutral switch lead
Pickup coil lead
To engine
A.C. magneto lead
Ventilation hose
Sensing hose (AIS-carburetor
joint)
20 Fuel hose (carburetor-fuel pump)
21 Clip
22 Brake hose
12
13
14
15
16
17
18
19

23
24
25
26
27
28
29
30
31

Heat protector
Speed meter lead
Wireharness
Purge hose (carburetor-solenoid valve) (for CAL)
Fitting plate
Fuel hose (inlet) (fuel filter-fuel
pump)
Fuel hose (outlet) (carburetorfuel pump)
Alarm connector lead
Wireharness

CABLE ROUTING
27

A Fasten the handlebar switch


lead (left and rihgt) to the handlebar with plastic locking tie and
cut the end of tie.
B Fasten the mainharness with a
plastic clamp at the back of the
cable guide.
C Clamp the wireharness with the
hook of frame side.

SPEC

D When installing the pipe of G When connecting the sensing


throttle cable press it inside.
hose (carburetor joint-AIS) with
E Clamp the fuel hoses to the
a nozzle.
frame with the clamp.
H Push the sensing hose inside of
F Change the fuel hose (fuel cock
the LID and not bend the sensing
side) and fuel hose (carburetor
hose.
side) between guide of frame I Push the wireharness inside of
and clamp. (carburetor side is
the side cover.
upper)

CABLE ROUTING
J Position the all connectors inside O Route the clutch cable through
of the connector cover.
the cable guide.
K Through the wireharness of so- P Position the throtlle cable and
lenoid valve between AIS duct
starter cable as shown and
and fuel hose (for CAL).
clamp them with holder.
L Fasten the alarm lead with a Q Fasten the handlebar switch
plastic band on the LID.
leads (left and right) under the
M Fasten the sidestand switch lead
handle crown with a plastic
to the bracket of LID with plastic
band. Set the band at four
locking tie.
notches and install it no slacking.
N Fasten the lead with locking tie R Route the each hoses through the
near the side cover.
frame guide and do not pinch it.

SPEC

S When installing the fitting plate,


do not pinch the each hoses and
wireharness.
T Wher install the AIS push the
wireharness to space of rearside.

CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11

Battery
Battery positive (+) lead
Starter motor positive lead
Speedmeter lead
Fuel hose (carburetor-fuel pump)
High tension code
Main switch lead
Throttle cable
Brake hose
Handlebar switch lead (right)
Headlight lead

12 Ignition coil
13 Breather hose
14 Purge hose (carburetor-solenoid
15
16
17
18
19
20
21

valve) (for CAL)


Rear brake switch
Reserve hose
Air filter drain hose
Delay relay
Battery negative () lead
Starter motor positive (+) lead
Oil level switch lead

22
23
24
25
26
27
28
29
30
31
32

SPEC

Rear brake switch lead


Carburetor heater connecter
Light reduce relay
Rectifier/ regulator
Stay. 1
Down tube
frame
Stay. 2
Battery box
Carburetor heater lead
Light reduce lelay lead

CABLE ROUTING
33
34
35
36
37
38
39
40
41

Flasher relay
Handlebar switch lead (left)
Silencer
Throttle position sensor lead
Carburetor heater lead
Thermo switch lead
Starting circuit cut-off relay
Horn
Rectifire/ regulator and light (reduce relay) lead

A Clamp the battery positive (+)


lead to the battery with battery
band.
B Connect the battery negative ()
lead and push it in to the space
between battery box and battery.
C Push the wireharness into the
space between frame and starter motor relay.

SPEC

D Route the rectifire / regulator


lead, wireharness and starter
motor positive (+) lead through
the out of frame bracket and fasten them to the frame with a plastic locking tie. The place to fix
must be between 0 mm and
10 mm from the top of the
diverging point of the lead on the
harness side whitch connected
the battery negative () lead.

CABLE ROUTING
E Connect the purge hose (carburetor side-solenoid valve side)
with joint, knob is out side of frame.
F Route the front turn signal / position light lead and headlight lead
through the rear of headlight
body hole.
G Connect the ignition coil lead at
red tape to the right side.
H Knob of clip is rearside of body.

SPEC

I Fasten the rear brake switch M Fasten the rear brake switch lead
lead to the rear brake switch
and master cylinder reservoir
bracket with a plastic locking tie
hose to the down tube with a plasand cut of the end, inside of frame.
tic locking tie, and cut the end of
J Fasten the wireharness, starter
locking tie and position is inside of
motor positive (+) lead and batframe.
tery negative () lead to the N About 20 mm from bead end.
frame with a plastic locking tie.
O Locate the band to forward of
K From the engine.
down tube.
L About 70 mm
P Route the rectifire/regulator lead
and carburetor heater lead
through inside of battery box hole
to outside it and connect them.

10

CABLE ROUTING
Q To rear brake.
R Fasten the rear brake switch
lead with a band to down tube.
(four point)
S Cutting part at the edge of the
band.
T About 30_  45_

SPEC

U Fasten the oil level sensor lead V Clamp the handlebar switch lead
with a locking tie to battery box.
(right) to the frame with a holder.
Fix to the battery box with the
The part to open and shut is outband. To fix, algin the band to the
side of the body.
bottom of the boxs hole while fix- W Arrange the throttle position sening the lead to the back of the box
sor connector, carburetor heater
(inside the body). The cutting part
connector and thermo switch
at the edge of the band comes to
connector between the starting
the front side of the body.
circuit cut off relay and high tension code.
X Put the light reduce relay lead,
carburetor heater lead into the
bottom of the groove.

11

CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11

Brake hose
Throttle cable
Master cylinder reservoir hose
High tension code
Purge hose (carburetor-solenoid
valve) (for CAL)
Rear brake switch lead
Fuel hose (carburetor-fuel pump)
Delay relay
Battery negative () lead
Battery negative () lead connector
Battery

12
13
14
15
16
17
18
19
20
21
22

Battery positive (+) lead


Taillight lead
Starter relay
Starter motor positive (+) lead
Fuel tank breather hose (fuel
tank-roll over valve) (for CAL)
Outlet
Inlet
Ventilation hose
Starter cable
Sensing hose (AIS-carburetor
joint)
Fuel hose (fuel cock-fuel filter)

12

23
24
25
26
27
28
29
30
31
32
33
34
35
36

SPEC

Throttle position sensor lead


Carburetor heater lead
Tappet cover
Clutch cable
Thermo switch lead
Wireharness
Frame
Igniter unit
LID. 2
Mud guard
Fuel filter
LID.
Ignitor unit lead
Speed meter lead connecter

CABLE ROUTING
A Clamp the throttle cables with E Position the steel band end to
the holder. Position the end of
right side.
clip downword.
F Route the battery positive (+)
B Route the rear brake switch lead
lead through the slit of the batunder the master cylinder resertery box.
vor hose.
G Clamp the igniter unit lead to the
C Position the band end of right
frame with a holder.
side bracket.
H To the rear fender.
D Position the steel band end to
forward.

13

SPEC

I Connect the wireharness to the


ignitar unit through the hole of
LID. 2.
J Route the fuel tank breather
hose under the fuel filter and
connect it (fuel tank sideroll over
valve side) with a joint. Position
the end of clip outside.

CABLE ROUTING
K Position the mark on the steel O Clamp the clutch cable and startband to forward.
er cable with a holder.
L Fasten the wireharness with a
Position the end of holder down
band on the tool box plate.
side.
M Fasten the wireharness to the P Route the igniter lead through
frame with a plastic locking tie.
the igniter plate hole to the wirePosition the locking tie front of
harness.
the holder.
Q To the wireharness.
N Route the wireharness outside R Clamp the taillight lead with mud
of the guide on the frame.
guard clamp.

14

SPEC

S Clamp the taillight lead with a


holder on the mud guard.
T Position the locking tie upward.
U The front direction of the level
body.

CABLE ROUTING
1
2
3
4
5
6
7

Throttle cable
Starter cable
Clutch cable
Handlebar switch lead (left)
Headlight lead
Brake hose
Handlebar switch lead (right)

A Route the handlebar switch


lead (right) rear side of the
throttle cable.

15

SPEC

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS

CHK
ADJ

EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTS


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

PERIODIC MAINTENANCE/LUBRICATION INTERVALS


NOTE:
 The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
 From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING ( 1,000 km)
NO
NO.

ITEM

CHECK OR MAINTENANCE JOB

Fuel line

 Check fuel hoses for cracks or damage.

Fuel filter

 Check condition.

Spark plugs

 Check condition.
 Clean and regap.

10

20

30

40

ANNUAL
CHECK

Valves

Air filter element

Clutch

Front brake

 Check valve clearance.


 Adjust

 Clean.

Rear brake

Brake hose

 Check operation.
 Adjust.

 Check operation, fluid level and vehicle for fluid


leakage. (See NOTE)

 Check operation, fluid level and vehicle for fluid


leakage. (See NOTE)

 Check for cracks or damage.


 Replace. (See NOTE)

Tires






12 *

Wheel bearings

 Check bearing for looseness or damage.

13 *

Steering bearings

Every 4 years

 Check runout, spoke tightness and for damage.


 Tighten spokes if necessary.

11

Whenever worn to the limit

Wheels

10 *

Whenever worn to the limit

 Replace brake pads.


9

 Replace.

 Replace brake pads.


8

 Replace.
4

Check tread depth and for damage.


Replace if necessary.
Check air pressure.
Correct if necessary.

 Check bearing play and steering for roughness.

 Lubricate with lithium-soap-based grease.

14 *

Chassis fasteners

 Make sure that all nuts, bolts and screws are


properly tightened.

15

Sidestand

 Check operation.
 Lubricate.

16 *

Sidestand switch

 Check operation.

Every 20,000 km

16

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS

CHK
ADJ

ODOMETER READING ( 1,000 km)


NO
NO.

ITEM

17 *

Front fork

18 *

Rear shock
absorber assembly

CHECK OR MAINTENANCE JOB

10

20

30

40

 Check operation and for oil leakage.

 Check operation and shock absorber for oil leakage.

 Lubricate the pivoting points with molybdenum


disulfide grease.

ANNUAL
CHECK

19 *

Carburetors

 Check starter (choke) operation.


 Adjust engine idling speed and synchronization.

20

Engine oil

 Change.

21

Engine oil filter


element

 Replace.

22

Final gear oil

 Check oil level and vehicle for oil leakage.

 Change.

23

Moving parts and


cables

 Lubricate.

24 *

Lights, signals
and switches

 Check operation.
 Adjust headlight beam.

EAU03541

NOTE:
 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
 Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.

17

REPLACING THE HEADLIGHT BULB

CHK
ADJ

ELECTRICAL SYSTEM
EAS00182

REPLACING THE HEADLIGHT BULB


1. Disconnect:
 connector 1
2. Remove
 headlight bulb cover 2

3. Remove:
 headlight bulb holder 1
4. Remove:
 headlight bulb 2

WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
5. Install:
 headlight bulb (New)
Secure the new headlight bulb with the headlight bulb holder.

CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
 headlight bulb holder
7. Install:
 headlight bulb cover
8. Connect:
 leads

18

ADJUSTING THE HEADLIGHT BEAM

CHK
ADJ

EAS00184

ADJUSTING THE HEADLIGHT BEAM


1. Adjust:
 headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a or
b.
Direction a  Headlight beam is raised.
Direction b  Headlight beam is
lowered.
2. Adjust:
 headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction a or
b.
Direction a  Headlight beam moves to
the right.
Direction b  Headlight beam moves to
the left.

19

AIR INDUCTION SYSTEM

CARBURETION
AIR INDUCTION SYSTEM
AIR INDUCTION SYSTEM DIAGRAMS

1
2
3
4
A
B
C
D
E

Reed valve
Air filter
Orifice
Carburetor joint (near cylinder)
To the front cylinder head
To the rear cylinder head
To the orifice
To the carburetor joint (rear cylinder)
To the air cut-off valve

NOTE:
The orifice 3 should be installed with the arrow
mark facing the air cut-off valve side.

20

CARB

AIR INDUCTION SYSTEM

Order
1
2
3
4
5
6
7
8
9

Job name/Part name

Qty

Removeing the air induction system


Side cover
Air filter
Air filter to air cut valve hose
Air cut valve
Vacuume hose 2
Orifice
Vacuum hose 1
Reed valve case to rear cylinder head
pipe
Reed valve case to rear cylinder head
pipe

CARB

Remarks
Remove the parts in the order listed.

1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.

21

AIR INDUCTION SYSTEM

CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM


1. Check:
 hoses
Loose connection  Connect properly.
Cracks/damage  Replace.
 pipes
Cracks/damage  Replace.

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

3. Measure:
 reed valve bending a
Out of specification  Replace the reed
valve.
Maximum reed valve bending
0.4 mm
1 Surface plate

4. Check:
 air cutoff valve
Cracks/damage  Replace.

5. Check:
 air cleaner
Cracks/damage  Replace.
Clogged  Clean.

22

FRONT AND REAR BRAKES

CHAS

CHASSIS
FRONT AND REAR BRAKES
FRONT BRAKE CALIPERS

6 Nm (0.6 mkg)

30 Nm (3.0 mkg)

27 Nm (2.7 mkg)

Order

1
2
3
4
5
6

Job name/Part name

Qty

Removing the front brake calipers


Brake fluid
Brake hose holder
Union bolt
Copper washers
Brake hose
Retaining bolt
Brake caliper assembly

Remarks
Remove the parts in the order listed.
Drain

1
1
2
1
2
1

Refer to REMOVING/INSTALLING
THE FRONT BRAKE CALIPERS.

For installation, reverse the removal


procedure.

23

STEERING HEAD

CHAS

STEERING HEAD

1st
2nd

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

110 Nm (11.0 mkg)

7 Nm (0.7 mkg)

Order

Job name/Part name

Qty

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

Removing the lower bracket

WARNING
Securely support the motorcycle so
that there is no danger of it falling over.

1
2
3
4
5
6
7
8

Front fork legs


Handlebar
1
Headlight lens unit

Leads (in the headlight body)


Front turn signal/position light (left/right) 1/1
1
Headlight body
1/1
Brake hose joint/holder
1
Upper bracket
1
Lock washer
1
Upper ring nut

24

Refer to FRONT FORK.


Refer to HANDLEBAR.
Disconnect

STEERING HEAD

1st
2nd

CHAS

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

110 Nm (11.0 mkg)

7 Nm (0.7 mkg)

Order
9
10
11
12
13
14
15

Job name/Part name


Rubber washer
Lower ring nut
Bearing cover
Lower bracket
Bearing (upper)
Rubber seal
Bearing (lower)

Qty
1
1
1
1
1
1
1

Remarks
Refer to REMOVING THE LOWER
BRACKET/INSTALLING THE
STEERING HEAD.

For installaiton, reverse the removal


procedure.

25