EB000000

FZS600 SERVICE MANUAL ©1997 by Yamaha Motor Co., Ltd. First edition, December 1997 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter 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 ar subject to change without notice.

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

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.

YP002000

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 Chapter3, “Periodic Inspections 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 descrided sequentially. 1 4 3

2

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.

3

4
1 General information

5

6

7

8

Specifications Periodic inspection and adjustment Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting Symbols 10 to 17 indicate the following.
2 3 4 5 6 7 8 9

9

10

11

12

Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Symbols 18 to 23 in the exploded diagrams
10 11 12 13 14 15 16 17

indicate the types of lubricants and lubrication points.
13 14

15

16

17

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 Symbols 24 to 25 in the exploded diagrams
18 19 20 21 22 23

indicate the following:
24 Apply locking agent (LOCTITE®) 25 Use new one

24

25

INDEX
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 .

. . . . . . . . . . . . . OIL SEALS AND O-RINGS . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-4 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . MODEL CODE . . . . . . . . . . . . . . . CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS .GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . .

GEN INFO .

This information will be needed to order spare parts. EB100020 1 MODEL CODE The model code label 1 is affixed to the frame. 1-1 .MOTORCYCLE IDENTIFICATION EB100000 GEN INFO GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head.

EB102020 lip lip spring oil grease GASKETS. remove all dirt. Other brands may be similar in-function and appearance. During reassembly. always keep mated parts together. mud. 2. EB102010 REPLACEMENT PARTS 1. This will speed up assembly and allow for the correct installation of all parts. Refer to the “SPECIAL TOOLS” section. During disassembly.IMPORTANT INFORMATION EB102000 GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Mated parts must always be reused or replaced as an assembly. cylinders. oil seal lips and O-rings must be cleaned. Before removal and disassembly. This includes gears. pistons and other parts that have been “mated” through normal wear. replace all gaskets. properly oil all mating parts and bearings and apply grease onto the oil seal lips. Use oil and grease recommended by Yamaha for all lubrication jobs. When disassembling. 5. 2. 3. clean all of the parts and place them in trays in the order of disassembly. but inferior in quality. OIL SEALS AND O-RINGS 1. 1-2 . 4. seals and O-rings. All gasket surfaces. dust and foreign material. Use only the proper tools and cleaning equipment. Keep all parts away from any source of fire. Use only genuine Yamaha parts for all replacements. When overhauling the engine.

bend the lock tabs along a flat of the bolt or nut. After the bolt or nut has been tightened to specification. After removal. 4 Shaft 1-3 . check all circlips carefully and replace damaged or distorted circlips. When installing oil seals. replace all lock washers/ plates 1 and cotter pins. When installing a circlips 1 . Always replace piston pin clips after one use. Before reassembly. if appropriate. EB102040 BEARINGS AND OIL SEALS 1.IMPORTANT INFORMATION EB102030 GEN INFO OR LOCK WASHERS/PLATES AND COTTER PINS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. Oil bearings liberally when installing. apply a light coat of lithium soap base grease onto the oil seal lips. 1 Oil seal CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1 Bearing EB102050 CIRCLIPS 1. is positioned opposite the thrust 3 that the circlip receives. make sure that the sharp-edged corner 2 .

clean the terminals. 4. Disconnect: S lead S coupler S connector 2. S When checking the wire harness. couplers. 3. Check: S lead S coupler S connector Moisture !Dry with an air blower. moisture. S As a quick remedy. use a contact revitalizer available at most part stores.CHECKING THE CONNECTIONS EB103000 GEN INFO CHECKING THE CONNECTIONS Check the leads. Rust/stains ! Connect and disconnect several times. rust. etc. 1-4 . 5. Connect: S lead S coupler S connector NOTE: Make sure that all connections are tight. Check: S continuity (with a pocket tester) Pocket tester 90590-03112 NOTE: S If there is no continuity. 1. and connectors for stains. NOTE: If the pin 2 on the terminal is flattened. bend in up. Check: S all connections Loose connection ! Connect properly. perform steps 1 to 3.

90890-01325 -01352 Radiator cap tester 1 Adaptor 2 These tools are used for checking the cooling system. 90890-01312 Fuel level gauge 1 This gauge is used to measure the fuel level in the float chamber.SPECIAL TOOLS EB104000 GEN INFO SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Tool No. 1-5 . refer to the list provided below to avoid any mistakes. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. 90890-01362 -01382 Flywheel puller 1 Crank shaft protector 2 These tools are used for removing the rotor and starter clutch. 90890-01460 -01326 Damper rod holder 1 T-handle 2 These tool ar used for holding the damper rod when removing or installing the damper rod. When placing an order. 90890-01367 -01381 Fork seal driver weight Fork seal driver attachment (ø41 mm) These tools are used when installing the forkseal. 90890-01268 Tool name/Usage Ring nut wrench Illustration This tool is used to loosen and tighten the steering ringnut. 90890-01304 Piston pin puller This tool is used to remove the piston pin.

90890-01399 Tool name/Usage Special thickness gauge GEN INFO Illustration This tool is used to measure the valve clearance. 90890-03133 Engine tachometer This tool is needed for detecting engine rpm. 90890-01401 Spark plug wrench This tool is used for removing or installing the spark plug. 90890-01701 Sheave holder This tool is used for holding the magneto rotor. 90890-03081 Compression gauge This tool is used to measure the engine compression 90890-03094 Vacuum gauge This tool is used to measure the synchronizing the carburetors.SPECIAL TOOLS Tool No. 1-6 . 90890-01469 Oil filter wrench This tool is used for removing or installing the oil filter. 90890-01403 Ring nut wrench This tool is used to tighten the steering ring nut. 90890-03112 Pocket tester 1 These instruments are invaluable for checking the electrical system. 90890-03153 -03139 Oil pressure gauge Oil pressure adaptor H These tools are used to measure the engine oil pressure.

0 mm) This tool is used to rebore the new valve guide. 90890-03158 Carburetor angle driver This tool is used to adjust the pilot screw.SPECIAL TOOLS Tool No. 90890-04101 Valve lapper This tool is used for removing and installing the valve lifter and for lapping the valve. 90890-04113 Valve guide reamer (4. 90890-04112 Valve guide installer (4. 90890-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder. 90890-03141 Timing light Tool name/Usage GEN INFO Illustration This tool is necessary for checking ignition timing.0 mm) This tool is used to remove the valve guides. 90890-04019 -04114 Valve spring compressor 1 Valve spring compressor attachment 2 These tools are used when removing or installing the valve and the valve spring. 90890-04111 Valve guide remover (4.0 mm) This tool is needed to install the valve guides properly. 90890-06754 Ignition checker 1 This instrument is necessary for checking the ignition system components. 90890-04086 Clutch holding tool This tool is used for holding the clutch boss. 1-7 .

1-8 .1215 GEN INFO Illustration This sealant (bond) is used for crankcase mating surface. 90890-85505 Tool name/Usage Yamaha bond No.SPECIAL TOOLS Tool No. etc.

SPEC 2 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 ENGINE . . 2-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CHASSIS . . . 2-25 . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 LUBRICATIONS AND LUBRICANT TYPES . . . 2-20 LUBRICATION DIAGRAMS . . . . . . 2-22 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC .

415 mm 130 mm 2.5 L 1.6 mm 12 : 1 1.900 mm 210 kg Liquid cooled 4-stroke. DOHC Forward inclined parallel 4-cylinder 599 cm3 62.080 mm 710 mm 1.7 L 3.550 kPa/400 r/min (15.5 kgf/cm2) Electric starter Wet sump FZS600 Periodic oil change With oil filter replacement Total amount Radiator capacity Total amount (including all routes) Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount 2.0 49.170 mm 790 mm 1.GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and 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 API STANDARD: SE or higher grade ACEA STANDARD: G4 or G5 5DM1 2.5 L 2-1 .95 L Dry type element Regular unleaded gasoline 18 L 3.5 L 2.

846) 37/19 (1.708) Chain drive 48/15 (3. multiple-disc Spur gear 82/48 (1.5 kg/cm2.8 kg/cm2. rider. passenger.200) Constant mesh 6-speed Left foot operation 37/13 (2. 2.25 bar) 280 kPa (2. 2.947) 34/22 (1.25 bar) 280 kPa (2.25 kg/cm2.8 bar) front rear front rear front rear Tire pressure: Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear High-speed riding front rear *Load is the total weight of cargo.190) 29/27 (1.333) 25/21 (1.25 bar) 250 kPa (2.GENERAL SPECIFICATIONS Model 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 ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Chassis: Frame type Caster angle Trail Tire: Type Size Manufacturer Type BSR 33/4 MIKUNI FZS600 SPEC CR9E.8 kg/cm2.545) 28/21 (1.7 X 0. and accessories.8 mm Wet. 2-2 . 2.25 kg/cm2.8 bar) 225 kPa (2.074) Double cradle 24_ 88 mm Tubeless 110/70ZR 17 (54W) 160/60ZR 17 (69W) BRIDGESTONE/DUNLOP BRIDGESTONE/DUNLOP BT-57F/D207F BT-57R/D207J 187 kg 0 X 90 kg 225 kPa (2. CR8E/U27ESR-NU24ESR-N NGK/DENSO 0.25 kg/cm2.5 bar) 90 X 187 kg 225 kPa (2. 2. 2. 2.

4 W 12V 1.C.GENERAL SPECIFICATIONS Model Brake: Front brake Rear brake type operation type operation FZS600 Dual disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link suspension) Coil spring/Oil damper Coil spring/Gas-oil damper 120 mm 120 mm T.4 W 12V 1.4 W 12V 1. wattage quantity: Headlight Brake/tail light Front turn signal light Rear turn signal light License light Meter light Indicator light Neutral indicator light High beam indicator light Oil level warning light Turn indicator light Fuel level warning light Engine temperature warning light 2-3 .C.4 W 12V 1.I. (digital) A.4 W LED 1 1 1 2 1 SPEC Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight bulb type: Bulb voltage. magneto GT12B-4 12V 10 AH Halogen bulb 12V 60 W/55 W 2 12V 21W/5W 2 12V 21 W 2 12V 21 W 2 12V 5 W 2 12V 2 W 3 12V 1.

1 mm 0.03 mm SSS SSS SSS SSS Face Width Seat Width Margin Thickness “A” head dia.6 mm 0. valve seat. Camshaft to cap clearance Cam dimensions: Intake “A” “B” “C” Exhaust “A” “B” “C” Camshaft runout limit Cam chain: Cam chain type/No.5 mm 3.960 X 3.9 X 1.95 mm 7.55 mm 24.56 X 2. IN EX IN EX IN EX IN EX IN EX IN EX 23.6 mm SSS 92RH2010J/130 Automatic 0.MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head: Warp limit Cylinder: Bore size Taper limit Out of round limit Camshaft: Drive method Cam cap inside dia. “B” face width “C” seat width “D” margin thickness Stem outside dia.20 mm 0.967 X 22. Guide inside dia.000 X 23.012 mm SSS SSS SSS SSS 1.6 X 0.012 mm 4.95 mm 3.9 X 24.6 X 0.975 mm 4.40 mm 1.00 X 62.25 mm 0.6 mm 1.09 mm 0.85 mm 25.9 mm 7.990 mm 3.5 mm 32. valve guide: Valve clearance (cold) IN EX Valve dimensions: Standard SSS 62.05 mm 7.1 mm 0.042 mm 4.07 mm SSS SSS SSS 0.021 mm 23.975 X 3.21 X 0.08 mm 32.05 mm 62.000 X 4.1 mm 20.042 mm 2-4 .9 X 1.9 X 21.020 X 0.980 mm 0.8 mm 3.7 mm 24.4 mm 24.11 X 0.1 mm 1.1 mm 0.75 X 32.85 mm 32.054 mm 32.000 X 4.8 mm 0.40 mm 0.4 X 7.1 mm 7.30 mm SPEC Limit 0.5 mm 0.56 X 2.0 X 25. of links Cam chain adjustment method Valve.935 mm 4.45 X 32. Camshaft out side dia.95 X 25.65 X 7.01 mm SSS SSS Chain drive (center) 23.

Green 48.07 mm SSS SSS SSS SSS SSS SSS Barrel 0.09 mm 34.020 X 0.9 X 1.50 mm 0.025 X 0.055 mm 1.8 2.MAINTENANCE SPECIFICATIONS Item Stem-to-guide clearance Stem runout limit Valve seat width Valve spring: Free length Set length (valve closed) Compressed pressure Tilt limit Direction of winding Piston: Piston clearance Piston size “D” Measuring point “H” Piston off-set Piston off-set direction Piston pin bore inside dia.262 mm 0.5 mm SSS SSS 2.7 mm 0.6 kg) SSS Clockwise 0.03 mm 0. Brown 4.3 mm 0.6 mm 1.5 mm 0.066 mm 1.025 X 0.037 mm 0. Blue 2.960 X 61.08 mm 0.2 mm 0.1 mm SSS SSS 0.0 mm SSS 0.35 mm 0.975 mm 5 mm 0. Pink SSS SSS 0.043 mm 1.5 mm 134 X 156 N (13.010 X 0.066 mm 0.25 X 0.9 X 1.020 X 0.1 mm 40.043 X 0.050 mm 61.5 2. Black 3.1 mm 0.1 mm 0.025 X 0.10 X 0.8 X 298.30 mm 0.5 mm In side 17. Black 2. Piston rings: Top ring: Type Dimensions (B T) End gap (installed) Side clearance (installed) 2nd ring: Type Dimensions (B T) End gap (installed) Side clearance (installed) Oil ring: End gap (installed) Connecting rod: Oil clearance Color code (corresponding size) Crankshaft: Crankshaft width “A” Assembly width “B” Runout limit “C” Big end side clearance “D” Big end radial clearance “E” Small end free play “F” Journal oil clearance Color code (corresponding size) IN EX IN EX IN/EX IN/EX IN/EX IN/EX IN/EX Standard 0.08 mm SSS SSS SSS 0. Green 4.08 mm 0.8 2.8 mm SSS 0.4 mm 296.991 X 17.160 X 0.8 mm 0.002 X 17.1 mm SSS SSS 0.013 mm 16. Piston pin outside dia.052 mm SSS 0.40 mm 0.4 X 15.32 X 0. Yellow 5.000 mm SPEC Limit 0.6 mm 37.3 mm 0.15 X 0. Brown 3.6 mm 0.04 mm 1.5_/1.075 mm Taper 0.043 X 0.08 mm SSS 2-5 .

screw push SSS SSS SSS Guide bar SSS 5DM1 00 #115 #80 5D86 P-O #130 0.7 X 33.J) (B.1) (P.1 mm SSS SSS 34.05 X 0.1) (G.L) (with special tool) 2-6 .1) (B.2) (B.250 r/min 30.06 mm 1 pcs 1.3) (P.J) (M.05 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS (M.0 0.V) (F.3 mm 0.02 mm SSS 0.S.9 X 2.94 X 3. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Fuel level Engine idle speed Intake vacuum Standard 2.2) (TH.1 mm 8 pcs SSS 34.005 X 0.9 0.06 mm 8 pcs SSS 2.3 kPa (230 X 250 mmHg) SPEC Limit SSS SSS 2.8 #110 4.8 mm SSS SSS SSS SSS 0.P.8 2 1.S) (G.5 0.8 0.P.J.5 mm 1.13 mm 0.J) (P.S.041 mm Inner push.9 #12.D.O) (P.N) (N.A.2 mm SSS SSS 0.3 mm 0.02 mm 0.94 X 3.150 X 1.P.9 mm 6 pcs SSS 0.A.J) (J.6 0.S) (V.MAINTENANCE SPECIFICATIONS Item Clutch: Friction plate thickness Quantity Wear limit Friction plate thickness Quantity 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 Transmission: Main axle deflection limit Drive axle deflection limit Shifter: Shifter type Guide bar bending limit Carburetor: I.

09 mm 0.673) Size Plane 30 15 Plane 30 16 S3-29-40-7.8 X 1.15 mm 0.22 L Single suction centrifugal pump 82/48 48/49 (1.2 kg/cm2) 450 X 550 kPa (4.4 mm 27 mm 95 X 125 kPa (0.08 mm 80 X 120 kPa (0.6 L 0.25 kg/cm2) 0.MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance “A” or “B” Side clearance Bypass valve setting pressure Relief valve operating pressure Pressure check location Cooling system: Radiator core size: Width Height Thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity From low to full level Water pump: Type Reduction ratio Item Bearings and oil seals: Big end bearing Crankshaft bearing Crankshaft oil seal Water pump bearing Water pump oil seal Main axle bearing (left) Main axle bearing (right) Drive axle bearing (left) Drive axle bearing (right) Drive axle oil seal Shift shaft oil seal Standard Paper type Trochoid type 0.5L HS BWF26-44R SD-12-28-7-1 HS Ball 6204DLA8NUR 83B285SH2C3 22 56 83424ASH2CS41 20NQ3315NE 20 33 SD7-35-52-8 VS SD-12-22-5 HS SSS SSS SSS SSS SSS SSS SSS SSS SSS 16 15 2-7 .03 X 0.5 kg/cm2) Main gallery SPEC Limit SSS SSS 0.95 X 1.03 X 0.61 L 0.15 mm SSS SSS SSS 320 mm 161.5 X 5.

0 7 0.4 Remarks .0 10 1.2 63 6.4 10 1.3 43 4.0 24 2.2 24 2.C magneto cover Drive sprocket cover Drive sprocket cover Part name Bolt Nut – Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Union bolt Bolt Bolt Bolt – Bolt Screw Bolt Screw Nut Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Screw 2-8 SPEC Thread size M6 M9 M10 M6 M5 M7 M7 M6 M6 M11 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M20 M14 M10 M6 M20 M6 M5 M6 M6 M6 M8 M8 M6 M8 M6 M6 M6 M6 M5 y Q’ty 24 12 4 8 8 8 4 2 2 1 2 2 3 1 3 4 2 2 4 4 1 3 2 14 1 1 2 1 1 8 4 3 6 8 1 12 21 1 6 2 5 5 4 Tightening torque Nm mSkg 10 1.0 12 1.0 10 1.7 10 1.0 4 0.0 17 1.7 2 0.0 10 1.0 10 1.0 20 2.4 7 0.0 35 3.3 20 2.9 See NOTE 24 2.0 10 1.7 10 1.0 10 1.8 10 1.7 10 1.0 9 0.0 12 1.0 10 1.1 7 0.7 10 1.0 10 1.0 7 0.2 Cap case to air filter case Air filter case Air filter cover to air clearance Exhaust pipe Exhaust joint Crankcase Crankcase Crankcase Breather plate Oil seal stopper plate A.5 13 1.2 10 1.3 10 1.4 12 1.0 20 2.0 1 0.0 8 0.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE g Part to be tightened Camshaft cap Cylinder head Spark plug Cylinder head cover Cylinder head side cover Connecting rod cap Camshaft sprocket Timing chain tensioner case Timing chain guide (intake side) Timing chain tensioner cap Pipe 2 Pipe 3/Pipe 4 Thermostat cover Conduction assembly Radiator Joint Water pump Water pump housing Radiator cover Pipe 5/Pipe 6 Roter housing Oil pump assembly Strainer housing Strainer cover Oil cooler Oil drain bolt Delivery pipe Delivery pipe holder Oil filter element Carburetor joint 1.2 10 1.0 10 1.

C magneto roter Stator coil Pickup coil Starter motor Neutral switch Oil level sensor Thermo switch (fan motor) Thermo switch (warning light) Part name Bolt – Bolt Screw Bolt Bolt Screw Bolt Screw Nut Nut Bolt Bolt Bolt Nut Bolt Screw Bolt Bolt Screw Bolt Screw Bolt – – Thread size M6 M16 M6 M6 M10 M8 M6 M18 M5 M8 M18 M6 M6 M6 M6 M6 M5 M12 M6 M5 M6 M6 M6 M16 PT1/8 Q’ty y 7 2 10 1 1 3 6 1 2 1 1 1 1 2 2 1 1 1 3 2 2 2 2 1 1 SPEC Remarks Tightening torque Nm mSkg 12 1.0 30 3.8 NOTE: After tightening to 15 Nm (1.5 16 1.7 10 1.0 4 0.4 130 13.2 8 0. tighten another 90_.0 4 0.C magneto cover) Starter clutch assembly Starter clutch outer Pressure plate Clutch boss Push lever Push rod adjuster Drive sprocket Shift drum retainer Shift arm Shift fork guide bar retainer Shift pedal adjuster Stopper lever Side plate 2 A.0 10 1.6 70 7.0 5 0.0 7 0.2 7 0.8 12 1.4 7 0.3 8 0.0 10 1.0 10 1.0 5 0. Crankcase tightening sequence Lower crankcase Upper crankcase 2-9 .7 80 8.8 70 7.0 8 0.7 23 2.MAINTENANCE SPECIFICATIONS Part to be tightened g Starter cover Oil gallery Clutch cover Clamp (A.5 10 1.0 10 1.5 mSkg).

5 mm SSS SSS SSS radial lateral radial lateral Drive chain: Type/manufacturer No.7 kg/mm) 0 X 50 mm No 1200 kPa (12 kg/cm2) SSS SSS Cast wheel 17 MT3. of links Chain free play 2-10 .5 mm SSS SSS SSS 1 mm 0.75 kg/mm) 14 N/mm (1.4 kg/mm) 0 X 70 mm 70 X 120 mm No 475 cm3 121 mm Fork oil 10W or equivalent 50 mm 177 mm 168 mm 147 N/mm (14.5 N/mm (0.00 Aluminum SSS SSS 50VA7/DAIDO 110 30 X 40 mm SSS 319 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 1 mm 1 mm SSS SSS SSS 1 mm 0.00 Aluminum SSS SSS Cast wheel 17 MT5.9 mm 200 mm 7.MAINTENANCE SPECIFICATIONS CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring Rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade Rear suspension: Shock absorber travel Spring free length Fitting length Spring Rate (K1) Stroke (K1) Optional spring Enclosed gas/air pressure (STD) Swingarm: g Swingarm free play limit-end Swingarm free play limit-side Front wheel: Type Rim size Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout limit Standard Angular bearing SPEC Limit SSS 120 mm 323 mm 315.

1 mm DOT No.2 mm 0.15 mm 0. Caliper cylinder inside dia. Brake fluid type Brake lever and brake pedal: Brake pedal position (N) Clutch lever free play (lever end) Throttle i free play Th l grip f l Item Bearings and oil seals: Pivot shaft bearing Front wheel bearing (left) Front wheel bearing (right) Rear wheel bearing (left) Rear wheel bearing (right) Rear wheel oil seal (right) Clutch hub bearing Clutch hub oil seal Standard Dual 298 4 mm SSS 5.5 mm 0.5 mm 0.5 mm 12. thickness Disc deflection limit Pad thickness Inner Pad thickness Outer Master cylinder inside dia.7 mm 38.6 mm 10 X 15 mm 3 X 5 mm Size TA2428Z/24 31 28 6203LLU/2A 17 40 12 6203 LLU/2A 17 40 12 6204 2RS 20 47 14 6204 2RS 20 47 14 SD-28-47-7-1 62062RS 30 62 16 MHSA-40-62-8-B SPEC Limit SSS SSS 0.5 mm SSS SSS SSS SSS SSS SSS 0.4 36.4 Single 245 5 mm SSS 5.5 mm 5.MAINTENANCE SPECIFICATIONS Item Front disc brake: Type Disc outside dia.5 mm SSS SSS SSS SSS SSS SSS 2-11 . Caliper cylinder inside dia. thickness Disc deflection limit Pad thickness inner Pad thickness outer Master cylinder inside dia.5 mm 14 mm 30. Brake fluid type Rear disc brake: Type Disc outside dia.2 mm 27 mm DOT No.5 mm 5.

8 1.0 7 0.7 1.7 7 0.0 1.3 30 3.MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS g Part to be tightened Upper bracket and inner tube Upper bracket and steering stem Handlebar under holder Handlebar upper holder Under bracket and inner tube Ring nut (steering stem) Master cylinder bracket Master cylinder cap Brake hose union bolt Grip end Cowling stay Cowling bracket Front fender Engine bracket (front) Engine mount (front) Engine mount (rear upper) Engine mount (rear under) Engine bracket (rear) Pivot shaft Rear shock absorber (upper) Rear shock absorber and relay arm Relay arm and rear shock absorber bracket Relay arm and connecting rod Connecting rod and rear arm Chain guide Chain case Fuel tank (front) Fuel tank (rear) Fuel tank bracket (rear) Cap Fuel cock Fuel sender Ignition coil Seat lock Roter Rear fender and frame Taillight bracket and rear fender Tail cover and Taillight bracket Tail cover and frame Rear turn signal light Taillight Thread size M8 M22 M10 M8 M10 M25 M6 M4 M10 M10 M8 M6 M6 M8 M10 M10 M10 M8 M16 M10 M10 M10 M12 M12 M6 M6 M6 M6 M6 M5 M6 M5 M6 M6 M6 M6 M6 M5 M6 M6 M6 1.25 1.0 10 1.3 7 0.7 7 0.4 Remarks NOTE 2-12 .0 1.25 1.0 1.25 1.0 1.0 SPEC Tightening torque Nm mSkg 30 3.0 – – 10 1.7 7 0.25 1.25 1.3 11.25 1.5 1.25 1.7 6 0.8 1.0 1.5 11.7 33 3.0 1.8 7 0.5 33 3.7 7 0.4 7 0.7 7 0.25 1.0 1.7 4 0.0 7 0.0 1.5 55 5.0 40 4.25 1.0 40 4.5 40 4.0 1.25 1.4 7 0.0 0.7 7 0.3 55 5.0 1.7 4 0.0 48 4.0 110 11.25 1.25 1.0 0.0 0.25 1.0 1.2 30 3.0 1.8 48 4.7 33 3.8 1.0 2 0.5 55 5.0 1.25 1.0 1.0 23 2.7 10 1.8 48 4.0 1.0 0.7 7 0.25 1.7 4 0.25 1.6 7 0.

0 117 11.25 1.8 56 5.25 1.7 20 2.25 1. Align the slots both ring nut and install the lock washer. 2-13 .6 23 2.0 30 3. then finger tighten the ring nut (center).5 1.0 NOTE: 1.25 1.25 1.25 1.3 60 6.3 55 5. tighten the ring nut (lower) approximately 18 Nm (1.4 19 1. 2.0 1.3 6 0.6 40 4.6 23 2.5 28 2.25 1.25 1.25 1. Final.0 1.0 40 4. 3.25 1.0 1.25 1. then loosen the right nut completely.9 67 6. tighten the ring nut (lower) approximately 52 Nm (5.0 6 0.5 1.3 28 2.2 mSkg) by using the torque wrench.25 1.25 1.0 23 2.25 SPEC Remarks Tightening torque Nm mSkg 4 0.0 mSkg) by using the torque wrench. First.0 1.0 16 1. hold the ring nuts (lower and center) and tighten the ring nut (upper) 110 Nm (11.3 23 2.25 1.25 1.8 mSkg) by using the torque wrench.25 1.MAINTENANCE SPECIFICATIONS g Part to be tightened Side cover and frame Garb bar Front wheel axle Front wheel axle pinch bolt Front brake caliper Front brake disc Front brake caliper bleed screw Compression bar Rear wheel sprocket Drive chain puller nut Rear brake caliper and caliper bracket Rear wheel axle nut Rear brake hose union bolt Rear brake caliper bleed screw Rear brake disc Sidestand Bracket footrest and frame Rear master cylinder and bracket Footrest bracket and footrest Footrest bracket (rear) and frame Center stand nut Footrest bracket and exhaust pipe Footrest bracket (rear) and muffler Thread size M6 M8 M16 M8 M8 M8 M7 M8 M10 M8 M10 M18 M10 M7 M8 M8 M8 M8 M10 M8 M10 M8 M10 1.7 30 3. Second.8 23 2.6 20 2.

87 X 2.36 X 0.000 r/min 0.C.250 r/min 50_/4.500 r/min TPS and electrical type 189 X 231 Ω Y-L J4T085/MITSUBISHI J0313/DENSO 1.53 Ω at 20_C 12 X 18 kΩ at 20_C Resin type 10 kΩ A.MAINTENANCE SPECIFICATIONS ELECTRICAL Item Voltage Ignition system: Ignition timing (B.T.44 Ω at 20_C/W-W Semi conductor-short circuit type SH650-12/SHINDENGEN 14.I.T.1 X 14. magneto F4T359 /MITSUBISHI 12 V 18 A at 5.C.D.320 Constant mesh type SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 2-14 .C.9 V SH650-12/SHINDENGEN 18 A 200 V 1.) Advance type T.: Pickup coil resistance T. unit model/manufacturer Ignition coil: Model/manufacturer Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Standard output Stator coil resistance Voltage regulator: Type Model/manufacturer No load regulated voltage Rectifier: Model/manufacture Capacity Withstand voltage Battery: Specific gravity Electric starter system: Type Standard 12 V 10_/1.C.I.D.C.) Advanced timing (B.

7 kW 0.0015 X 0.8 X 10.MAINTENANCE SPECIFICATIONS Item Starter motor: Model/manufacturer I.0025 Ω at 20_C 10 mm 7.4 W 4JH/SOMIC 4YR/NIPPON SEIKI 4 X 10 Ω 90 X 100 Ω 5DM/DENSO 3LN/NIPPON THERMOSTAT Fuse SPEC Limit SSS SSS SSS SSS 4 mm SSS 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 2-15 .15 X 1.2 N (780 X 1.25 Ω at 20_C Full transistor type FE246BH/DENSO No Yes 75 X 95 cyl/min 21 W 2 + 1.D.0 A 105 X 120 db/2 m 1.18 X 4. Mica undercut (depth) Starter relay: Model/manufacturer Amperage rating Coil winding resistance Horn: Type Quantity Model manufacturer Maximum amperage Performance Coil winding resistance Flasher relay: Type Model/manufacturer Self cancelling device Hazard flasher device Flasher frequency Wattage Oil level gauge: Model/manufacture Fuel gauge: Model/manufacture Sender unit resistance -full -empty Electric fan: Model/manufacturer Thermostat switch: Model/manufacture Circuit breaker: Type Standard SM-13/MITSUBA SM-13 0.62 Ω at 20_C Plane type 1 pcs YF-12/NIKKO 3.020 gf) 28 mm 0.7 mm MS5F-631 /JIDECO 100 A 4. number Output Armature coil resistance Brush overall length Brush spring pressure Commutator dia.

MAINTENANCE SPECIFICATIONS Item Amperage for individual circuit: Main Headlight Signal Ignition Fan Back up Reserve Standard 30 A 20 A 20 A 20 A 10 A 5A 30 A 20 A 10 A 5A SPEC limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 2-16 .

Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.0 5.5 8. tightening torque specifications require clean.5 13.6 1. tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. dry threads.0 22 mm 2-17 . Unless otherwise specified. A (Nut) 10 mm 12 mm 14 mm 17 mm 19 mm A: Width across flats B: Thread diameter B (Bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm 6 15 30 55 85 130 mSkg 0.5 3. To avoid warpage.GENERAL TIGHTENING TORQUE SPECIFICATIONS EB201000 SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Components should be at room temperature.

6th pinion Drive axle 1 X 4th wheel gear Push lever Push rod Shift cam Shift fork guide bar Shift shaft Starter idrer gear shaft 1 Neutral switch O-ring Push rod Push rod 1 O-ring Shift pedal Shift shaft Water pump O-ring Cylinder head cover gasket Shift cam plug Breather plate Crankcase Taper plug Bearing plate SPEC Symbol Coolant Silicon Yamaha bond No. profile Valve stem (IN. EX) Valve stem end (IN. 1215 Yamaha bond No. piston pin Connecting rod bolt Camshaft journal. 1215 2-18 . EX) Cylinder head tightening nut mounting surface Valve lifter Camshaft cap Water pump seal Water pump shaft Radiator hose Oil pump Relief valve O-ring Oil cooler O-ring Oil filter Oil level gauge Starter moter O-ring Starter idrer gear Main axle 5.LUBRICATION POINT AND LUBRICATION TYPES LUBRICATION POINT AND LUBRICATION TYPES ENGINE Lubrication Point Oil seal lips Bearing Crankshaft journal Connecting rod big end and small end Piston.

LUBRICATION POINT AND LUBRICATION TYPES CHASSIS Lubrication Point Steering bearing and bearing race (upper and lower) Pivot shaft Rear arm bearing Rear arm oil seal Rear arm cover oil seal lips Relay arm bearing Relay arm oil seal Rear shock absorber (upper/lower) Front wheel oil seal Speed sensor oil seal Rear wheel oil seal Clutch damper oil seal Clutch and rear wheel Throttle cable inner surface Starter cable inner surface and lever pivot Rear brake pedal shaft Shift pedal shaft Side stand sliding surface Rear foot rest pivot bolt SPEC Symbol 2-19 .

COOLING SYSTEM DIAGRAMS EB203000 SPEC COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 Engine outlet hose Engine outlet hose Carburetor inlet hose Carburetor outlet hose Water pump Coolant drain bolt Water pump outlet hose 8 Radiator outlet hose 9 Radiator 10 Radiator inlet hose 3 2 10 1 1 4 3 6 5 9 5 7 8 6 2-20 .

COOLING SYSTEM DIAGRAMS 1 2 3 4 5 Radiator Water pump outlet hose Oil cooler inlet hose Oil cooler outlet hose Carburetor outlet hose SPEC 2-21 .

LUBRICATION DIAGRAMS EB204000 SPEC LUBRICATION DIAGRAMS 1 2 3 4 5 6 7 Oil nozzle (main nozzle) Oil nozzle (drive axle) Projection Oil filter Relief valve Oil strainer Oil pump 1 2 3 4 7 6 5 4 2-22 .

LUBRICATION DIAGRAMS 1 2 3 4 Main axle Drive axle Camshaft Oil delivery pipe SPEC 1 2 3 4 2-23 .

LUBRICATION DIAGRAMS 1 Camshaft 2 Crankshaft SPEC 1 2 2-24 .

B Pass the brake hose out side of the speed sensor lead. 1 2 3 4 5 7 8 A B 6 7 2-25 . then use a plastic clamp to fasten them. clutch cable and starter cable.CABLE ROUTING EB205000 SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 Throttle cable Clutch cable Handlebar switch (right) Starter cable Main switch Brake hose Speed sensor lead Headlight lead 9 Handlebar switch (left) A Use a plastic clamp to fasten together the handlebar switch lead (left).

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Main switch lead Starter cable Handlebar switch lead (left) Clutch cable Rectifier/ regulator Horn lead Box Air guide plate Starter cable Flasher leray 11 12 13 14 15 16 17 18 19 20 Battery Starting circuit cut-off relay Battery positive (+) lead Seat lock cable AC magneto lead Starter motor lead Air filter drain hose Sidestand switch Neutral switch Oil level switch 21 22 23 24 25 26 27 28 29 30 31 SPEC Speed sensor lead Horn Starter relay Fuse box To front brake switch To battery negative (–) lead To starter relay AC magneto coupler Pickup coupler Sidestand switch coupler Oil level / neutral switch coupler 2-26 .

then hold the clamp to the frame bracket. sidestand switch lead and oil level/ neutral switch lead. AC magneto lead. 2-27 . SPEC D Use a steel holder to fasten together the AC magneto lead. Position the band end to out side of chassis. C Use a plastic locking tie to fasten the starter motor lead. AC magneto lead. sidestand switch lead and oil level / neutral switch lead to the frame bracket. sidestand lead and oil level/ neutral switch lead. starter motor lead. clutch cable and starter cable to the frame. B Use a plastic band to fasten together wireharness. E Use a plastic clamp to fasten the horn lead and air guide plate to the frame.CABLE ROUTING A Use a plastic clamp to fasten the handlebar switch lead (left). main switch lead. Cut off the excess end of the tie.

2-28 .P. headlight lead handlebar switch (right) and speed sensor lead. lead Handlebar switch lead (right) 10 11 12 13 14 15 16 17 18 Throttle cable Brake hose Headlight lead Speed sensor lead Main switch lead Reservoir tank Cross tube Reservoir tank over flow hose Swingarm bracket SPEC A Use a plastic clamp to fasten together the throttle cables.S. B Use a plastic locking tie to fasten the handlebar switch (right) and brake hose to the right front fork inner tube.CABLE ROUTING 1 2 3 4 5 6 7 8 9 Battery negative (–) lead Rear brake switch lead Battery Reservoir tank hose Air filter Fuel tank breather hose Fuel tank drain hose T.

E Pass the battery negative (–) lead inside of the reservoir hose. headlight lead. D Pass the reservoir tank over flow hose. then insert it right side of the box. fuel tank breather hose and fuel tank drain hose through the cable holder. handlebar switch lead (right) and speed sensor lead. SPEC 2-29 .CABLE ROUTING C Pass the main switch lead under the throttle cables.

S lead Fuel sender.CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Throttle cable Handlebar switch lead (right) Headlight lead Speed sensor lead Carburetor heater hose Reservoir tank hose Fuel pump Fuel filter T.P. coupler 11 12 13 14 15 16 17 18 19 20 Battery negative (–) lead Battery Rear brake reservoir tank Rear brake switch lead Seat lock cable Ignitor Rear turn signal light lead (right) Taillight lead Rear turn signal light lead (left) Starter motor lead 21 22 23 24 25 26 27 28 29 30 SPEC Starter relay Starting circuit cut-off relay Flasher relay Fuel pump lead coupler Ignition coil Clutch cable Ground lead Starter cable Fan motor lead Rectifier/ regulator lead 2-30 .

Pass the reservoir hose left side of thermo stat housing. Use a plastic band to fasten the high tension cord #3. Pass the carburetor inlet hose under the high tension cord #2. then connecte each coupler in the box. then bend the rear SPEC D E F G turn signal light lead and clamp it. handlebar switch lead (left). handlebar switch lead (right) and speed sensor lead through front side of the box.CABLE ROUTING 31 32 33 34 35 36 37 A Starter cable Clutch cable Handlebar switch lead (left) Main switch lead To taillight Rear fender Clamp Pass the wireharness under the starter relay. #4. #4. Do not fasten the high tension cord #4 with locking tie. headlight lead. B Pass the rectifier / regulator lead. fan motor lead. C Align the connector position of rear turn signal light leads (left and right). main switch lead. 2-31 .

SPEC .

CHK ADJ 3 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . 3-25 CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . .CHK ADJ CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . 3-21 ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 CHECKING THE BRAKE HOSES . . . . . . . . . . 3-11 ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 ADJUSTING THE FRONT BRAKE . . 3-31 ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . 3-48 REPLACING THE HEADLIGHT BULBS . . . . . . . . . . 3-26 CHECKING THE COOLING SYSTEM . . . . . . . . . . . 3-42 ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . 3-16 MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . 3-36 CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . . . 3-42 LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . 3-33 ADJUSTING THE SHIFT PEDAL . . 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 CHASSIS . . . . . . . 3-36 CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . 3-33 BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE . . . . . . . . . 3-43 CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . 3-5 ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . 3-30 CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 FRONT COWLING/SEAT/SIDE COVER/FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 LUBRICATING THE CENTER STAND . . . . . . . . . . . . . . . . . 3-14 CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . 3-26 CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . 3-38 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . 3-38 CHECKING THE TIRES . . . . . . . . . . . . . . . . . . 3-13 ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . 3-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . .

CHK ADJ .

000 km or 24 months (whichever comes first).INTRODUCTION / PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 CHK ADJ PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. S Cehck operation. S Check chain slack.000 km or 6 months (whichever comes first) √ 7500 EVERY 12. S Check valve clearance. S Check condition.000 km) 6. S Replace if necessary. Correct if necessary. Check air pressure. runout and for damage. 7 * Front brake √ √ √ 8 * Rear brake √ √ √ 9 * Wheels √ √ 10 * Tires √ √ 11 * Wheel bearings S Check bearing for looseness or damage. Make sure that the rear wheel is properly aligned.000 km or 24 months (whichever comes first). S Make sure that all nuts. S Check condition. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. S Clean. S Check operation.000 km and after washing the motorcycle or riding in the rain 14 * Steering bearings √ √ 15 * Chassis fasteners Sidestand / centerstand √ √ √ √ 16 * 3-1 .) S Correct accordingly. √ √ 12 * Swingarm √ √ 13 Dirve chain Every 1. regap or replace if necessary. S S S S Check tread depth and for damage. All service technicians should be familiar with this entire chapter. S Replace if necessary. S Correct if necessary. √ 2 3 4 5 6 * Fuel filter Spark plugs √ √ * Valves Air filter Clutch 26000Miles Every 42. S Lubricate with molybdenum disulfide grease every 24. ITEM CHECKS AND MAINTENANCE JOBS 1 * Fuel line S Check fuel hoses and vacuum hose for cracks or damage. (See NOTE. bolts and screws are properly tightened. S Check swingarm pivoting point for play. Replace if necessary. S Check balance. S Check bearing play and steering for roughness. S Check operation.000 km or 42 months (whichever comes first) √ √ √ √ √ S Clean or replace if necessary. S Replace brake pads if necessary. EB301000 PERIODIC MAINTENANCE/LUBRICATION INTERVALS INITIAL (1.) S Correct accordingly. (See NOTE.000 km or 12 months (whichever comes first) √ √ NO. these preventive maintenance procedures will ensure more reliable vehicle operation. S Replace brake pads if necessary. S Check operation S Adjust or replace cable. If followed. S Replace if necessary. S Rebalance or replace if necessary. S Lubricate and repair if necessary. S Tighten if necessary. fluid level and vehicle for fluid leakage. S Adjust if necessary. S Clean and lubricate. S Correct accordingly. S Adjust if necessary. S Lubricate with lithium soap base grease every 24. a longer service life and reduce the need for costly overhaul work. fluid level and vehicle for fluid leakage.

ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1. S Check operation and for oil leakage.PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ EVERY 6. synchronization and starter operation. S Change coolant every 24. 3-2 . they should be serviced by a Yamaha dealer. S Check coolant level and vehicle for coolant leakage.000 km) 17 18 * * Sidestand switch Front fork Rear shock absorber assembly Rear suspension relay arm and connecting arm pivoting points Carburetors S Check operation. 3.000 km or 12 months (whichever comes first) √ √ √ NO. Check the brake fluid level regularly and fill as required. 2. S Check oil level and vehicle for oil leakage. S Replace shock absorber assembly if necessary. (Warm engine before draining. S Change.) S Replace. S Check engine idling speed. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas. When disassembling the master cylinder or caliper cylinder. √ √ √ 21 * √ √ 22 Engine oil Engine oil filter cartridge √ √ √ √ √ 23 24 * Cooling system √ √ *Since these items require special tools. S Correct accordingly.000 km or 24 months (whichever comes first). √ 19 * 20 * 15000 S Check operation.000 km or 24 months (whichever comes first). Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.000 km or 6 months (whichever comes first) √ √ √ 12. Replace the brake hose every four years or if cracked or damaged. S Adjust if necessary. S Check operation and shock absorber for oil leakage. S Replace if necessary. S Brake fluid replacement 1. S Correct if necessary. always replace the brake fluid. data and technical skills. S Lubricate with molybdenum disulfide grease every 24. S Correct if necessary.

reverse the removal procedure. NOTE: Disconnect the couplers.3 mSkg) Order 1 2 3 4 5 6 7 Job name/Part name Removing the front cowling View mirror (left/right) Inner panel (left/right) Cowling stay (left/right) Head light lead Front flasher light lead (left/right) Front cowling Head light assembly Q’ty 1/1 1/1 1/1 2 2/2 1 1 Remarks Remove the parts in the order listed.FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK FRONT COWLING/SEAT/SIDE COVER/FUEL TANK FRONT COWLING CHK ADJ 33 Nm (3. 3-3 . For installation.

3-4 . 1 2 3 4 5 6 7 8 9 1 1 1 NOTE: 1 Disconnect the couplers. 1 1 1/1 1 1 For installation. side cover and fuel tank Seat Fuel tank Fuel sender lead Fuel tank breaser hose Fuel tank drain hose Fuel hose Side cover (left/right) Grab bar Tail cover Q’ty Remarks Remove the parts in the order listed. SIDE COVER AND FUEL TANK CHK ADJ 19 Nm (1.4 mSkg) Order Job name/Part name Removing the seat.FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK SEAT. reverse the removal procedure.0 mSkg) 4 Nm (0.9 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.

at room temperature.21 X 0.11 X 0. SIDE COVER AND FUEL TANK” in chapter 3) 2. Remove: S spark plug cap S spark plug S magneto cover 5. 1. NOTE: S Valve clearance adjustment should be made on a cold engine. Drain the coolant (Refer to “COOLANT REPLACEMENT” in chapter 3) 3.ADJUSTING THE VALVE CLEARANCE EB303001 CHK ADJ ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. Valve clearance (cold) Intake valve 0. the piston must be at top dead center (TDC) on the compression stroke. Remove: S radiator (Refer to “RADIATOR” in chapter 5) 4.20 mm Exhaust valve 0. S When the valve clearance is to be measured or adjusted.30 mm 3-5 . Measure: S valve clearance Out of specification ! Adjust. Remove: S front cowling S seat S fuel tank (Refer to “FRONT COWLING SEAT.

align the TDC mark a on the generator rotor with the mark b on the crankcase. S Measure the valve clearance in the following sequence. For each cylinder. b. When piston #1 is at TDC on the compression stroke. Measure the valve clearance with a thickness gauge 1 . 1 b NOTE: S If the valve clearance is incorrect. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.ADJUSTING THE VALVE CLEARANCE CHK ADJ a a. Turn the crankshaft counterclockwise. turn the crankshaft counterclockwise as specified in the following table. Valve clearance measuring sequence Cylinder #1 ! #2 ! #4 ! #3 A Front d. c. C Cylinder D Combustion cycle #2 Cylinder #4 Cylinder #3 Cylinder 180_ 360_ 540_ 6. starting with cylinder #1 at TDC. B Degrees that the crankshaft is turned counterclockwise. 3-6 . Remove: S carburetor Refer to “CARBURETION” in chapter 6. record the measured reading.

Valve pad thickness range Nos.ADJUSTING THE VALVE CLEARANCE CHK ADJ 7. fasten a wire to the timing chain to retrieve it if it falls into the crankcase. 10. Adjust: S valve clearance a. NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. 120 X 240 120 X 2. S When removing the timing chain and camshafts. Select the proper valve pad from the following table. Remove: S camshaft 1 NOTE: S Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chapter 4.05 mm increments 3-7 . Remove the valve lifter 1 and the valve pad 2 .40 mm Available valve pads 25 thickness in 0. Remove: S timing chain tensioner bolt 1 S timing chain tensioner assembly 2 8. Remove: S timing chain guide 1 S timing chain guide (upper) 2 S camshaft cap 3 9. b.

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. 3-8 . Round off the original valve pad number according to the following table. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.48 mm) Rounded value = 150 d. The point where the column and row intersect is the new valve pad number.ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: S The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. c. Last digit 0 or 2 5 8 Rounded valve 0 5 10 EXAMPLE: Original valve pad number = 148 (thickness = 1. NOTE: The new valve pad number is only an approximation.

32 1.12 1.73 X 0.37 0.38 X 0.42 0.98 X 1.97 0.82 0.92 0.18 X 1.93 X 0.20 mm Installed is 150 Measured clearance is 0.37 0.20 0.33 X 1.98 X 1.62 0.25 mm Replace 150 pad with 160 pad EXHAUST Measured clearance # INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 120 125 120 125 130 120 125 130 135 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 125 130 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 150 155 160 155 160 165 160 165 170 165 170 175 Specification 175 180 185 180 185 190 185 190 195 190 195 200 195 200 205 200 205 210 205 210 215 210 215 220 215 220 225 220 225 230 225 230 235 230 235 240 235 240 240 160 165 170 175 180 190 195 200 205 210 215 220 225 230 235 240 165 170 175 180 185 195 200 205 210 215 220 225 230 235 240 170 175 180 185 190 200 205 210 215 220 225 230 235 240 175 180 185 190 195 205 210 215 220 225 230 235 240 180 185 190 195 200 210 215 220 225 230 235 240 185 190 195 200 205 215 220 225 230 235 240 190 195 200 205 210 220 225 230 235 240 195 200 205 210 215 200 205 210 215 220 205 210 215 220 225 210 215 220 225 230 215 220 225 230 235 exa ! 0.02 0.53 X 0.32 1.63 X 0.30 0.31 X 0.08 X 0.23 X 1.22 1.03 X 0.68 X 0.37 1.78 X 0.87 0.03 X 0.07 0.78 X 0.13 X 1.20 0.21 X 0.43 X 1.62 0.27 1.23 X 0.33 X 1.72 0.17 0.00 X 0.30 X 1.32 0.07 0.28 X 0.28 X 1.42 0.57 0.11 X 0.33 X 0.82 0.58 X 0.11 X 0.63 X 0.13 X 1.38 X 1.42 1.00 X 0.43 X 0.53 X 0.52 0.88 X 0.21 X 0.73 X 0.18 X 0.17 1.77 0.47 0.03 X 1.02 1.23 X 1.17 1.68 X 0.47 225 230 235 240 230 235 240 235 240 240 EXAMPLE: VALVE CLEARANCE: 0.12 1.48 X 0.18 X 1.27 1.38 X 0.28 X 1.08 X 0.30 mm Installed is 175 Measured clearance is 0.10 0.97 0.58 X 0.87 0.37 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 EXAMPLE: VALVE CLEARANCE: 0.27 0.21 X 0.93 X 0.83 X 0.08 X 1.07 1.43 X 0.92 0.35 mm Replace 175 pad with 185 pad 3-9 .33 X 0.32 0.77 0.08 X 1.13 X 0.ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE Measured clearance # CHK ADJ INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 145 150 155 160 165 120 125 130 135 140 145 150 155 160 165 170 120 125 130 135 140 145 150 155 160 165 170 175 Specification 130 135 140 145 150 155 160 165 170 175 180 185 135 140 145 150 155 160 165 170 175 180 185 190 140 145 150 155 160 165 170 175 180 185 190 195 145 150 155 160 165 170 175 180 185 190 195 200 150 155 160 165 170 175 180 185 190 195 200 205 155 160 165 170 175 180 185 190 195 200 205 210 160 165 170 175 180 185 190 195 200 205 210 215 165 170 175 180 185 190 195 200 205 210 215 220 170 175 180 185 190 195 200 205 210 215 220 225 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 235 185 190 195 200 205 210 215 220 225 230 235 240 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 240 170 175 180 185 190 195 200 205 210 215 220 225 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 240 exa ! 0.67 0.48 X 0.83 X 0.22 0.02 1.52 0.88 X 0.07 1.47 0.22 1.10 0.57 0.67 0.02 0.72 0.

If the valve clearance is still out of specification. timing chain and camshaft caps. Install the exhaust and intake camshafts. Install the new valve pad 1 and the valve lifter 2 . S Lubricate the camshaft bearings. Note the following points.2 mSkg) 3-10 . Install: S AC magneto cover Bolt (AC magneto cover): 12 Nm (1. S Rotate the crankshaft counterclockwise several turns to seat the parts. repeat all of the valve clearance adjustment steps until the specified clearance is obtained. f. Install: S all removed parts NOTE: For installation. S First. camshaft lobes and camshaft journals. S Install the valve lifter and the valve pad in the correct place. S Align the camshaft marks a with the camshaft cap marks. NOTE: S Apply molybdenum disulfide grease to the valve pad. Measure the valve clearance again. a CAUTION: The camshaft caps must be tightened evenly or damage to the cylinder head.0 mSkg) NOTE: S Refer to “CAMSHAFT” in chapter 4. reverse the removal procedure. S The valve lifter must turn smoothly when rotated by hand. 12. h. camshaft caps and camshafts will result. S Lubricate the valve lifter with molybdenum disulfide oil. install the exhaust camshaft. 11. g.ADJUSTING THE VALVE CLEARANCE CHK ADJ e. Camshaft cap bolt 10 Nm (1. 13. Install: S timing chain guide (exhaust side) S timing chain guide (upper) S timing chain tensioner Refer to “CAMSHAFT” in CHAPTER 4.

3 mSkg) EB303010 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors. 5. NOTE: Place the motorcycle on a suitable stand. Remove: S cap 3. the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.250 r/min 3-11 . #1) Vacuum gauge 90890-03094 Engine tachometer 90890-03113 4. Engine idling speed 1. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Start the engine and let it warm up for several minutes. Install: S vacuum gauge 1 S engine tachometer 2 (to the spark plug lead of cyl. Stand the motorcycle on a level surface. Check: S engine idling speed Out of specification ! Adjust.ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS 14. Install: S cylinder head cover S spark plugs CHK ADJ Bolt (cylinder head cover): 10 Nm (1. 2. 1.150 X 1.0 mSkg) Spark plug: 13 Nm (1.

Install: S cap 3-12 . 0. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same.SYNCHRONIZING THE CARBURETORS CHK ADJ 6. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. c. Check: S engine idling speed Out of specification ! Adjust. 9. NOTE: After each step.4 in Hg).3 kPa (230 X 250 mm Hg) NOTE: The difference in vacuum pressure between two carburetors should not exceed 1. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. b.33 kPa (10 mm Hg. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm 10. rev the engine two or three times. Vacuum pressure at engine idling speed 30. each time for less than a second.7 X 33. 7. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same. and check the synchronization again. Adjust: S carburetor synchronization a. Stop the engine and remove the measuring equipment. 8.

Engine idling speed 1. Direction b ! Idling sped is decreased. 2. 5. #1) Engine tachometer 90890-03113 3. 1. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Adjust: S engine idling speed a. Turn the throttle stop screw 2 a or b until the specified idling speed is obtained. Install: S engine tachometer (to the spark plug lead of cyl. Start the engine and let it warm up for several minutes. the air filter should be clean. Turn the pilot screw 1 in or out until it is lightly seated. b. Carburetor angle driver: 90890-03158 Pilot screw: 2 turns out c. Direction a ! Idling speed is increased. Turn the pilot screw out by the specified number of turns.250 r/min 4. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm 1 3-13 .ADJUSTING THE ENGINE IDLING SPEED EB303020 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed. the carburetor synchronization should be adjusted properly.150 X 1. and the engine should have adequate compression. Check: S engine idling speed Out of specification ! Adjust.

throttle cable #1 1 is pulled and throttle cable #2 2 is pushed. d. Adjust: S throttle cable free play Carburetor side NOTE: When the motorcycle is accelerating. use the adjusting nut on the handlebar side. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable. Direction a ! Throttle cable free play is increased. c. Check: S throttle cable free play a Out of specification ! Adjust. the engine idling speed and carburetor synchronization should be adjusted properly. a. Tighten the locknut. 3-14 b a b a . Loosen the locknut 3 on throttle cable #2. Direction b ! Throttle cable free play is decreased. b. Loosen the locknut 1 . Turn the adjuster 6 a or b until the specified free play is obtained.ADJUSTING THE THROTTLE CABLE FREE PLAY EB303032 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm 2. Remove: S bracket S ignition coil S fuel pump 3. Turn the adjuster 4 a or b to take up any slack on throttle cable #2. b. 1. c. Handlebar side a. Direction b ! Throttle cable free play is decreased. e. Tighten the locknuts. Direction a ! Throttle cable free play is increased. Loosen the locknut 5 on throttle cable #1.

clean the spark plug and gasket surface. Measure: S spark plug gap 3 (with a specification ! Regap.ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS CHK ADJ After adjusting the throttle cable free play. Check: S electrode 1 Damage/wear ! Replace the spark plug. Normal color is a medium-to-light tan color. 3.8 mm 7. 4. Install: S fuel pump S ignition coil S bracket EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 3-15 . Check: S spark plug type Incorrect ! Change. turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. Remove: S spark plug CAUTION: Before removing the spark plugs. Disconnect: S spark plug cap 2. Spark plug gap 0.3 mSkg) NOTE: Before installing the spark plug. Spark plug type (manufacturer) CR8E (NGK) U24ESR-N (DENSO) 4. S insulator 2 Abnormal color ! Replace the spark plug. Install: S spark plug Spark plug 13 Nm (1. 5. blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. Clean: S spark plug (with a spark plug cleaner or wire brush) 6.7 X 0. 1.

#1) Timing light 90890-03141 Engine tachometer 90890-03113 3. Remove: S engine tachometer S timing light 5. Install: S timing light 1 S engine tachometer 2 (to the spark plug lead of cyl. warm it up for several minutes. 4. and then let it run at the specified engine idling speed. 1. Connect: S spark plug cap CHK ADJ EB303053 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing.150 X 1. Make sure that all connections are tight and free of corrosion.CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 8. Engine idling speed 1. Install: S timing plug 3-16 . Check: S ignition timing a. Incorrect firing range ! Check the ignition system. Remove: S timing plug 1 2. Check that the stationary pointer a is within the firing range b on the generator rotor. Start the engine. NOTE: The ignition timing is not adjustable.250 r/min b. check the wiring connections of the entire ignition system.

5. use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. Remove: S spark plug CAUTION: Before removing the spark plugs. Install: S compression gauge 1 Compression gauge 90890-03081 6. 1. Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Same as without oil Diagnosis Piston wear or damage ! Repair. and piston crown for carbon deposits. and then turn it off. Start the engine. 2. warm it up for several minutes. Refer to “ADJUSTING THE VALVE CLEARANCE”. Below the minimum pressure ! Squirt a few measure again. 3. valve surfaces. 3-17 . NOTE: Insufficient compression pressure will result in a loss of performance. Piston ring(-s). Check: S valve clearance Out of specification ! Adjust. S Refer to the following table. Disconnect: S spark plug cap 4. Measure: S compression pressure Above the maximum pressure ! Inspect the cylinder head. valves cylinder head gasket or piston possibly defective ! Repair.MEASURING THE COMPRESSION PRESSURE EB303060 CHK ADJ MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders.

crank the engine until the reading on the compression gauge stabilizes.0 kg/cm2) Minimum 1. 1 bar). To prevent sparking. With the throttle wide open. Install: S spark plug Spark plug 13 Nm (1.MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ Compression pressure (at sea level) Standard 1. S Make sure that the motorcycle is upright. 3-18 . NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2.500 kPa (15. Let the engine idle for a few minutes.3 mSkg) 8. 7. 3.200 kPa (12. ground all spark plug leads before cranking the engine. NOTE: S Place the motorcycle on a suitable stand.0 kg/cm2) a. Turn the main switch to “ON”. b. Check: S engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b . Stand the motorcycle on a level surface. Below the minimum level mark ! Add the recommended engine oil to the proper level. Connect: S spark plug cap EB303070 CHECKING THE ENGINE OIL LEVEL 1. 2.

EB303081 CHANGING THE ENGINE OIL 1. NOTE: Before checking the engine oil level. Therefore. warm it up for several minutes.CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ TEMP SAE 10W-30 SAE 10W-30 SAE 10W-30 Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. Remove: S engine oil filler cap 1 S engine oil drain bolt 2 (along with the gasket) 4. Start the engien. do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled “ENERGY CONSERVING II” b or higher. 5. 2. API standard ! SE or higher grade ACEA standard ! G4 or G5 CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. S Do not allow foreign materials to enter the carankcase. 2 3-19 . warm it up for several minutes. and then turn it off. Check the engine oil level again. wait a few minutes until the oil has settled. and then turn it off. perform the following procedure. Start the engine. 4. 3. If the oil filter cartridge is also to be replaced. Place a container under the engine oil drain bolt. Drain: S engine oil (completely from the crankcase) 5.

Remove the oil filter cartridge 1 with an oil filter wrench 2 . Check: S engine oil drain bolt gasket Damage ! Replace. warm it up for several minutes. 11. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.3 mSkg) 3 8. c. Fill: S crankcase (with the specified amount of the recommended engine oil) 1 Quantity Total amount 3.7mSkg) 6.5 L Without oil filter cartridge replacement 2. Start the engine. Tighten the new oil filter cartridge to specification with an oil filter wrench. Install: S engine oil filler cap 10. Oil filter cartridge 17 Nm (1. and then turn it off.5 L With oil filter cartridge replacement 2. Install: S engine oil drain bolt 1 43 Nm (4. Check: S engine (for engine oil leaks) 12.7 L 9. 3-20 .CHANGING THE ENGINE OIL CHK ADJ a. Oil filter wrench 90890-01469 b. Apply a thin coat of engine oil onto the Oring 3 of the new oil filter cartridge. 7. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.

the engine oil will have a higher viscosity. causing the engine oil pressure to increase. warm it up for several minutes. and then turn it off. CAUTION: When the engine is cold. 10. Install: S oil pressure gauge 1 S adapter 2 Oil pressure gauge 90890-03153 Adapter 90890-03139 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 450 kPa (4. 3. Therefore. be sure to measure the engine oil pressure after warming up the engine. 2. Start the engine. Remove: S oil gallery bolt 1 The engine. muffler and engine oil are extremely hot.5 kg/cm2) Engine speed Approx.000 r/min Engine oil temperature 115_C Out of specification ! Adjust. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper level. Engine oil pressure Possible cause Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Leaking oil passage Faulty oil filter Oil viscosity too high 2 Below specification Above specification 3-21 . 4.MEASURING THE ENGINE OIL PRESSURE EB303090 CHK ADJ MEASURING THE ENGINE OIL PRESSURE 1.

Clutch cable free play (at the end of the clutch lever) 10 X 15 mm Handlebar side Engine side 2. Loosen the locknuts 3 . c.MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY 6. Engine side a. a b c d 3-22 . Check: S clutch cable free play a Out of specification ! Adjust.8 mSkg) EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Loosen the locknut 1 . Install: S oil gallery bolt CHK ADJ 8 Nm (0. Tighten the locknut. c. Tighten the locknuts. Direction d ! Clutch cable free play is decreased. Direction b ! Clutch cable free play is decreased. Adjust: S clutch cable free play Handlebar side a. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Turn the adjusting bolt 4 in direction c or d until the specified clutch cable free play is obtained. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable. b. Direction a ! Clutch cable free play is increased. use the adjusting nut on the engine side. b. Direction c ! Clutch cable free play is increased.

3-23 . Install: S air filter element S air filter case cover CAUTION: Never operate the engine without the air filter element installed. 4. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Check: S air filter element Damage ! Replace.CLEANING THE AIR FILTER ELEMENT EB303130 CHK ADJ CLEANING THE AIR FILTER ELEMENT 1. Remove: S air filter case cover 1 S air filter element 2 3. Clean: S air filter element Apply compressed air to the outer surface of the air filter element. Operating the engine without the air filter element will also affect the carburetor turning. leading to poor engine performance and possible overheating. Remove: S Seat S Fuel tank S Cover 1 2. 5.

1. 6.CLEANING THE AIR FILTER ELEMENT/ CHK CHECKING THE CARBURETOR JOINTS AND IN TAKE MANIFOLDS/ ADJ CHECKING THE FUEL HOSES AND FUEL FILTER NOTE: When installing the air filter element into the air filter case cover. NOTE: S Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. 3. Install: S fuel tank S seat 3-24 . 3. Remove: S seat S fuel tank 2. S fuel filter 2 Damage/dirt ! Replace. be sure their sealing surfaces are aligned to prevent any air leaks. Remove: S seat S fuel tank 2. Refer to “CARBURETOR” in chapter 6. Check: S carburetor joint 1 S intake manifold 2 Cracks/damage ! Replace. 1. Install: S cover S fuel tank S seat EB303171 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the carburetor joints and intake manifolds. Install: S fuel tank S seat EB303181 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. Check: S fuel hose 1 Cracks/damage ! Replace.

0 mSkg) Exhaust pipe and muffler 6 20 Nm (2. Check: S tightening torque Exhaust pipe ring nut 4 10 Nm (1. 1. CAUTION: Make sure that the crankcase breather hose is routed correctly. 3. Remove: S seat S fuel tank S carburetor 2. 2.0 mSkg) Muffler and footrest bracket (rear) 7 30 Nm (3.0 mSkg) Exhaust pipe and footrest bracket 5 20 Nm (2. Install: S carburetor S fuel tank S seat EB303200 3 4 4 4 1 1 1 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. Loose connection ! Connect properly.0 mSkg) 7 2 5 6 3-25 . Check: S crankcase breather hose 1 Cracks/damage ! Replace. S gasket 3 Exhaust gas leaks ! Replace.CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EB303190 CHK ADJ CHECKING THE CRANKCASE BREATHER HOSE 1.

Soft water may be used if distilled water is not available.CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EB303220 CHK ADJ CHECKING THE COOLANT LEVEL 1. Remove: S side cover (right) 3. 5. wait a few minutes until it settles. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S water jacket outlet joint 4 S water jacket inlet joint 5 S oil cooler inlet hose 6 S oil cooler outlet hose 7 Cracks/damage ! Replace. 4. CAUTION: a b S Adding water instead of coolant lowers the antifreeze content of the coolant. Refer to “COOLING SYSTEM” in chapter 5. 3. S Make sure that the motorcycle is upright. and then turn it off. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level marks b . 6. 2. Remove: S seat S fuel tank 2. Install: S fuel tank S seat 3-26 . Start the engine. Stand the motorcycle on a level surface. check and correct the antifreeze concentration of the coolant. Install: S side cover (right) EB303230 7 6 CHECKING THE COOLING SYSTEM 1. If water is used instead of coolant. S Place the motorcycle on a suitable stand. warm it up for several minutes. Check: S coolant level NOTE: Before checking the coolant level. Below the minimum level mark ! Add the recommended coolant to the proper level. S Use only distilled water.

Disconnect: S coolant reservoir hose 1 3. while still pressing down turn it counterclockwise. open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly rotate the radiator cap counterclockwise towrd the detent to allow any residual pressure to escape. 5. Check: S copper washer 1 (coolant drain bolt water pump) Damage ! Replace.CHANGING THE COOLANT EB303240 CHK ADJ CHANGING THE COOLANT 1. do not remove the radiator cap when the engine is hot. Remove: S coolant drain bolt (water pump) 1 (along with the copper washer) 6. and then remove it. press down on the radiator cap. which could cause serious injury. Remove: S seat S fuel tank 2. 8. When the hissing sound has stopped. Remove: S radiator cap A hot radiator is under pressure. Scalding hot fluid and steam may be blown out. Install: S coolant drain bolt (water pump) 10 Nm (1. The following procedure applies to all of the coolant drain bolts and copper washers. Therefore. Drain: S coolant (from the engine and radiator) 7. Drain: S coolant (from the coolant reservoir) 4. When the engine has cooled.0 mSkg) 3-27 .

quickly wash it away with water and then with soap and water. immediately wash them with water. If water is used instead of coolant. S Do not mix different types of antifreeze. thoroughly wash them with water and consult a doctor. Coonect: S coolant reservoir hose 10. check.95 L Coolant reservoir capacity 0. S If coolant is swallowed. and if necessary. CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant.CHANGING THE COOLANT CHK ADJ 9. Soft water may be used if distilled water is not available. 11. correct the antifreeze concentration of the coolant. S If coolant splashes in your eyes. 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 Quantity Total amount 1. S If coolant comes into contact with painted surfaces. S Use only distilled water. S If coolant splashes on your clothes. Install: S radiator cap 3-28 . induce vomiting and get immediate medical attention.22 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care.61 L From minimum to maximum level mark 0.

wait a few minutes until it settles. Start the engine. and then turn if off. Fill: S coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. warm it up for several minutes. Check: S coolant level Refer to “CHECKING THE COOLANT LEVEL”. 15. Install: S coolant reservoir cap 14.CHANGING THE COOLANT CHK ADJ 12. Install: S fuel tank S seat 3-29 . 16. NOTE: Before checking the coolant level.

NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 Position #1 Position #4 Distance a is the largest. make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial. Brake pedal position (below the top of the rider footrest) 36. b.6 mm 2. Direction a ! Brake pedal is raised. Adjust: S brake pedal position a b c a.ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHK ADJ CHASSIS ADJUSTING THE FRONT BRAKE 1. Direction b ! Brake pedal is lowered. Distance a is the smallest. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. While pushing the brake lever forward. EB304010 ADJUSTING THE REAR BRAKE 1. 3-30 . turn the adjusting dial 1 until the brake lever is in the desired position. 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. After adjusting the brake lever position. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. Loosen the locknut 1 .

Before the vehicle is operated. EB304020 CHECKING THE BRAKE FLUID LEVEL 1. bleed the brake system. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. 3. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Tighten the locknut 1 to specification. c. A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. make sure that there is no brake drag. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. inspect and. NOTE: S Place the motorcycle on a suitable stand.ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ After adjusting the brake pedal position. 2. A B Recommended brake fluid DOT4 A Front brake B Rear brake 3-31 . check that the end of the adjusting bolt 2 is visible through the hole c . if necessary. CAUTION: After adjusting the brake pedal position. Therefore. S Make sure that the motorcycle is upright. Stand the motorcycle on a level surface. the air must be removed by bleeding the brake system.

Other brake fluids may cause the rubber seals to deteriorate. Check: S rear brake light operation timing Incorrect ! Adjust. a b 3-32 . be careful that water does not enter the reservoir. Direction b ! Brake light comes on later. CAUTION: Brake fluid may damage painted surfaces and plastic parts. 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. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Therefore. S Refill with the same type of brake fluid that is already in the system. EB304050 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. Direction a ! Brake light comes on sooner. NOTE: In order to ensure a correct reading of the brake fluid level. causing leakage and poor brake performance. always clean up any spilt brake fluid immediately. Mixing brake fluids may result in a harmful chemical reaction. S When refilling. make sure that the top of the reservoir is horizontal. leading to poor brake performance. Adjust: S rear brake light operation timing a. 2.CHECKING THE BRAKE FLUID LEVEL / ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ S Use only the designated brake fluid. 1. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

1. 3.CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHK ADJ CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. S If bleeding is difficult. 4. S When bleeding the hydraulic brake system. Refer to “FRONT AND REAR BRAKES” in chapter 7. Check: S brake hose Activate the brake several times. Remove: S reservoir cap S diaphragm 1 NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. 3-33 . it may be necessary to let the brake fluid settle for a few hours. Brake fluid leakage ! Replace damaged hose. Check: S brake hose clamp Loose connection ! Tighten. Check: S brake hose Cracks/damage/wear ! Replace. make sure that there is always enough brake fluid before applying the brake. EB304071 BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the hydraulic brake system whenever: S the system was disassembled. S brake operation is faulty. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. Ignoring this precaution could allow air to enter the hydraulic brake system. 1. 2. S the brake fluid level is very low. S a brake hose was loosened or removed. considerably lengthening the bleeding procedure. Hold the motorcycle upright and apply the brake.

check the brake operation. h. S Tighten both locknuts. j. i. Refer to “CHECKING THE BRAKE FLUID LEVEL”. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). e. c. 2. b. Direction a ! shift pedal is raised. d. 3-34 . This will release the tension and cause the brake lever to contact the throttle grip of the brake pedal to fully extend. Tighten the bleed screw and then release the brake lever or brake pedal. Check: S shift pedal position The end 1 of the shift pedal is above the shift rod. Slowly apply the brake several times. Rear After bleeding the hydraulic brake system. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. Loosen the bleed screw. Tighten the bleed screw to specification. Direction b ! pedal is lowered. Bleed: S hydraulic brake system a.) Incorrect ! Adjust.BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL Front CHK ADJ 2. Place the other end of the hose into a container. Adjust: S shift pedal position a. f. Loosen both locknuts 2 . Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. Bleed screw 6 Nm (0. Turn the shift rod 3 in direction a or b to obtain the correct shift pedal position. EB304080 a b ADJUSTING THE SHIFT PEDAL 1. g. Fill the reservoir to the proper level. b. (The angle a should be approximately 90_.6 mSkg) k. Add the recommended brake fluid to the proper level.

Adjust: S drive chain slack a. Check: S drive chain slack a Out of specification ! Adjust. Loosen: S wheel axle nut 1 5. keep the drive chain slack within the specified limits. 1. NOTE: Both wheels should be on the ground without rider on the motorcycle. Securely support the motorcycle so that there is no danger of it falling over. 3. adjust both sides evenly. CAUTION: A drive chain that is too tight will overload the engine and other vital parts. 3-35 . Direction a ! Drive chain is tightened. and one that is too loose can skip and damage the swingarm or cause an accident. Drive chain slack 30 X 40 mm 4. 2. Direction b ! Drive chain is loosened. a b NOTE: S To maintain the proper wheel alignment. Loosen both locknuts 1 .ADJUSTING THE DRIVE CHAIN SLACK EB304090 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. S Push the rear wheel forward to make sure that there is no clearance between the swingarm end plates and the ends of the swingarm. Stand the motorcycle on a level surface. Turn both adjusting nuts 2 in direction a or b until the specified drive chain slack is obtained. b. Therefore. Rotate the rear wheel several times and check the drive chain to locate its tightest point.

Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. and the use of a coarse brush can damage these O-rings. Therefore. certain solvents. high-pressure washing.7 mSkg) Locknut 16 Nm (1. Tighten the wheel axle nut to specification. Looseness or binding ! Adjust the steering head. Stand the motorcycle on a level surface. If the drive chain is not maintained properly. Securely support the motorcycle so that there is no danger of it falling over. Wheel axle nut 117 Nm (11. Steam cleaning. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. use only kerosine to clean the drive chain. Remove: S handlebar S upper bracket 3-36 . the drive chain should be serviced.6 mSkg) EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ c. Therefore. 2. especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate. 3. it will wear out rapidly. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EB304130 CHECKING AND ADJUSTING THE STEERING HEAD 1.

CHECKING AND ADJUSTING THE STEERING HEAD 1 2 3 4 CHK ADJ 4. Ring nut wrench 90890-01403 Lower ring nut (initial tightening torque) 52 Nm (5.8 mSkg) d. Remove the lock washer 1 . NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b . g. 8 7 6 a b 3-37 . Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . b. Do not overtighten the lower ring nut. Check the steering head for looseness or binding by turning the front fork all the way in both directions. then tighten it to specification. If any binding is felt. Install the rubber washer 6 . hold the lower ring nut and tighten the upper ring nut until their slots are aligned.2 mSkg) c. Install the lock washer 8 . Refer to “STEERING HEAD AND HANDLEBAR” in chapter 7. If necessary. Loosen the lower ring nut completely. e. Lower ring nut (final tightening torque) 18 Nm (1. f. Adjust: S steering head a. and the rubber washer 3 . NOTE: Set the torque wrench at a right angle to the ring nut wrench. h. then align the slots of both ring nuts. Finger tighten the upper ring nut 7 . Install the upper ring nut 7 . remove the lower bracket and inspect the upper and lower bearings. the upper ring nut 2 .

EB304160 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. Adjust: S spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. 2. 1.CHECKING ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ 5. Install: S upper bracket S handlebar Steering stem nut 110 Nm (11. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. Securely support the motorcycle so that there is no danger of it falling over. Refer to “FRONT FORK” in chapter 7. 4.0 mSkg) Handlebar upper holder bolt 23 Nm (2.0 mSkg) Upper bracket pinch bolt 30 Nm (3. Hold the motorcycle upright and apply the front brake. 3. Check: S inner tube Damage/scratches ! Replace. Check: S operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.3 mSkg) EB304140 CHECKING THE FRONT FORK 1. 3-38 . S oil seal Oil leakage ! Replace. Unsmooth operation ! Repair.

NEVER OVERLOAD THE MOTORCYCLE. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo.ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES adjusting position CHK ADJ a b a. Align the desired position on the adjusting ring with the stopper. Direction b ! Spring preload is decreased (suspension is softer). Minimum Standard Maximum Adjusting positions 1 4 9 EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. Direction a ! Spring preload is increased (suspension is harder). Turn the adjusting ring 1 in direction a or b. S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. b. an accident or an injury. Measure: S tire pressure Out of specification ! Regulate. S Operation of an overloaded motorcycle could cause tire damage. rider passenger and accessories) and the anticipated riding speed. 1. 3-39 .

6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator 3 2 1 A B 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. use great care and replace the tube as soon as possible with a good quality replacement. S Patching a punctured tube is not recommended. S To avoid pinching the tube. passenger and accessories It is dangerous to ride with a worn-out tire. 2. Minimum tire tread depth 1. rider. replace the tire immediately. S When using a tube tire.25 kg / cm2) 225 kPa (2. make sure that the wheel rim band and tube are centered in the wheel groove. Check: S tire surface Damage/wear ! Replace the tire.50 kg / cm2) 280 kPa (2.CHECKING THE TIRES Basic weight (with oil and a full fuel tank) Maximum load Cold tire pressure Up to 90 kg load* 90 kg maximum load* High speed riding CHK ADJ 210 kg 187 kg Front tire 225 kPa (2.25 kg / cm2) Rear tire 250 kPa (2. When the tire tread reaches the wear limit. be sure to install the correct tube.80 kg / cm2) 280 kPa (2. S Always replace a new tube tire and a new tube as a set. If it is absolutely necessary to do so.80 kg / cm2) *: total of cargo. A Tire B Wheel Tube wheel Tubeless wheel Tube tire only Tube or tubeless tire 3-40 .25 kg / cm2) 225 kPa (2.

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.. Ltd. EB304180 CHECKING THE WHEELS The following procedure applies to both of the wheels. NOTE: For tires with a direction of rotation mark 1 : S Install the tire with the mark printing in the direction of wheel rotation. Front tire Manufacturer BRIDGESTONE DUNLOP Size Type 110 / 70-ZR17 BT57F (54 W) 110 / 70-ZR17 D207F (54 W) Rear tire Manufacture BRIDGESTONE DUNLOP Size Type 160 / 60-ZR17 BT57R (69 W) 160 / 60-ZR17 D207J (69 W) After mounting a new tire. Check: S wheel Damage/out-of-round ! Replace. The front and rear tires should always be by the same manufacturer and of the same design. Never attempt to make any repairs to the wheel. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. 1. NOTE: After a tire or wheel has been changed or replaced. 3-41 . always balance the wheel. the tires listed below have been approved by Yamaha Motor Co. for this model. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle.CHECKING THE TIRES/ CHECKING THE WHEELS CHK ADJ S After extensive tests.

Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Recommended lubricant Lithium soap base grease EB304240 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 / LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTER STAND/ LUBRICATING THE REAR SUSPENSION EB304200 CHK ADJ CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. Recommended lubricant Lithium soap base grease EB304220 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Check: S cable sheath Damage ! Replace. Recommended lubricant Lithium soap base grease LUBRICATING THE CENTER STAND Lubricate the pivoting point and metal-to-metal moving parts of the center stand. Recommended lubricant Molybdenum disulfide grease 3-42 . 2. Replace damaged cable sheaths and cables as soon as possible. Check: S cable operation Unsmooth operation ! Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device. DB304210 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts parts of the levers and pedals. 1.

Therefore. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. S Charge batteries in a well-ventilated area. S DO NOT SMOKE when charging or handling batteries. The MF battery should be charged as explained in the charging method illustrations. always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. CAUTION: S This is a sealed battery. take special care when charging the battery. beaten egg or vegetable oil. Therefore. If the battery is overcharged.g. sparks or open flames (e. Get immediate medical attention. lighted cigarettes). charging amperage and charging voltage for a MF battery are different from those of conventional batteries. the electrolyte level will drop considerably.. S EYES – Flush with water for 15 minutes and get immediate medical attention. S Keep batteries away from fire. welding equipment. First aid in case of bodily contact: External S SKIN – Wash with water. S Charging time. Internal Drink large quantities of water or milk followed with milk of magnesia.CHECKING AND CHARGING THE BATTERY EB305020 CHK ADJ ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. 3-43 . S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. S KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

b. 3. Connect a digital voltmeter to the battery terminals. the voltage when the positive terminal is disconnected). disconnect the negative lead 1 . S No charging is necessary when the opencircuit voltage equals or exceeds 12. then the positive lead 2 . Tester positive lead Tester negative lead battery positive terminal battery negative terminal NOTE: S The charge state of a MF battery can be checked by measuring its open-circuit voltage (i. it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte..0 V d. Therefore.5 hours e. Charge of the battery = 20 X 30 % 5. Charge: S battery (refer to the appropriate charging method illustration) 3-44 . Check the charge of the battery. the charge of the battery has to be checked by measuring the voltage at the battery terminals.e. Example c. Disconnect: S battery leads (from the battery terminals) CAUTION: First. as shown in the charts and the following example. Remove: S battery 4. Remove: S seat 2. Open-circuit voltage = 12.CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed.8 V. Charging time = 6. Check: S battery charge a. 1.

disconnect the battery charger and let the battery cool before reconnecting it. 3-45 . A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. be careful not to overcharge the battery. S Make sure that the battery vent is free of obstructions. do not plug in the battery charger until the battery charger leads are connected to the battery. S Never remove the MF battery sealing caps.CHECKING AND CHARGING THE BATTERY CHK ADJ Do not quick charge a battery. Therefore. the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. (If charging has to be done with the battery mounted on the motorcycle. disconnect the negative lead from the battery terminal. be sure to turn off the battery charger. S Before removing the battery charger lead clips from the battery terminals. S If the battery becomes hot to the touch at any time during the charging process. be sure to remove it from the motorcycle. S If it is impossible to regulate the charging current on the battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. wait 30 minutes after charging is completed before measuring the open-circuit voltage. S When charging a battery.) S To reduce the chance of sparks. Hot batteries can explode! S As shown in the following illustration. S Do not use a high-rate battery charger. S Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted.

If the current does not exceed the standard charging current after 5 minutes. charging will be insufficient.Charging is complete.CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Measure the open-circuit voltage prior to charging.8 V or more --. the battery will be over-charged. If there is any change in the amperage. Monitor the amperage for 3 X 5 minutes to check if the standard charging current is reached. Connect a charged and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. 12. readjust the voltage to obtain the standard charging current. Under 12. CHK ADJ NOTE: Voltage should be measured 30 minutes after the machine is stopped.7 V or less --. 3-46 .Replace the battery.0 V --. (If the setting is lower.Recharging is required. 12.) YES NO By turning the charging voltage adjust dial. Adjust the voltage so that the current is at the standard charging level. If too high. set the charging voltage at 20 X 24 V. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. NO YES Set the time according to the charging time suitable for the open-circuit voltage. If charging requires more than 5 hours. it is advisable to check the charging current after a lapse of 5 hours. replace the battery. NOTE: Set the charging voltage at 16 X 17 V. Refer to “Battery condition checking steps”.

7 V or less --.CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging. 3-47 . YES Make sure that the current is higher than the standard charging current written on the battery. NOTE: Set the charging time at 20 hours (maximum). Connect a charger and AMP meter to the battery and start charging. 12. 12. Under 12. CHK ADJ NOTE: Voltage should be measured 30 minutes after the machine is stopped. Charging method using a constant-current type charger This type of battery charger cannot charge the MF battery. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. A variable voltage charger is recommended.Replace the battery.Charging is complete.0 V --. NO Charge the battery until the battery’s charging voltage is 15 V.Recharging is required. This type of battery charger cannot charge the MF battery.8 V or more --. Charge the battery until the battery’s charging voltage is 15 V.

always turn the main switch to “OFF” when checking or replacing a fuse. If the pocket tester indicates “∞”. CAUTION: To avoid a short circuit. 1”. Connect the pocket tester to the fuse and check it for continuity. 3-48 . Remove: S seat 2. Install: S seat EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses. NOTE: Se the pocket tester selector to “Ω Pocket tester 96890-03112 b. Check: S fuse a. 8. Loose connection ! Connect properly. 1. replace the fuse.CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. connect the positive lead 1 . then the negative lead 2 . Check: S battery terminals Dirt ! Clean with a wire brush. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First. Lubricate: S battery terminals Recommended lubricant Dielectric grease 10. 9.

Turn on the switches to verify if the electrical circuit is operational. 1. 4. Disconnect: S headlight lead 1 3-49 . Install a new fuse of the correct amperage rating. Turn off the ignition. check the electrical circuit. Install: S seat EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. d. Replace: S blown fuse CHK ADJ a. b. If the fuse immediately blows again. c.CHECKING THE FUSES/ REPLACING THE HEADLIGHT BLUBS 3. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system. Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Reserve fuse Amperage rating 30 A 20 A 20 A 20 A 5A 30 A 20 A 10 A Quantity 1 1 1 1 1 1 1 1 Never use a fuse with an amperage rating other than that specified. cause the lighting and ignition systems to malfunction and could possibly cause a fire.

5. otherwise the transparency of the glass. 4. 3-50 . Remove: S headlight bulb 2 Since the headlight bulb gets extremely hot. keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil. Install: S headlight bulb holder 6. If the headlight bulb gets soiled. Connect: S headlight lead EB305061 a b a b a a b b ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights.REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS CHK ADJ 2. Turn the adjusting screw 1 3 in direction a or b . Direction b ! Headlight beam is lowered. Install: S headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder. Remove: S headlight bulb holder 1 3. Adjust: S headlight beam (vertically) a. thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 1. Direction a ! Headlight beam is raised. the life of the bulb and the luminous flux will be adversely affected.

Turn the adjusting knob 2 4 in direction a or b .ADJUSTING THE HEADLIGHT BEAMS CHK ADJ 2. Adjust: S headlight beam (horizontally) a. Direction b ! Headlight beam moves o the right. Left headlight 2 Direction a ! Headlight beam moves to the right. 3-51 . Right headlight 4 Direction a ! Headlight beam moves to the left. Direction b ! Headlight beam moves to the left.

CHK ADJ .

ENG 4 .

. . . . . . . . . . . . . . . . . . . . . 4-11 INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENG CHAPTER 4 OVERHAULING THE ENGINE REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 DRIVE SPROCKET AND EXHAUST PIPE . 4-3 ENGINE BRACKET AND ENGINE . . . . . . . . . . . . . . . . . . . . . 4-28 INSTALLING THE PISTON AND CYLINDER . . . . 4-34 CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 LEADS AND HOSES . . . . . . . . . . . . 4-19 CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 REMOVING THE CLUTCH . . . 4-20 CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CHECKING THE TIMING CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 INSTALLING THE VALVES . . 4-25 REMOVING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 REMOVING THE VALVES . . 4-16 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . 4-35 CHECKING THE CLUTCH SPRING PLATE . . . . . . . . . . . 4-15 INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 INSTALLING THE CLUTCH . . . . . . . . . . . . 4-35 CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT SPROCKETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . 4-22 CHECKING THE CAMSHAFT CAP . . . . . 4-11 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . 4-36 CHECKING THE CLUTCH PUSH RODS . 4-5 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . 4-31 CLUTCH . . . 4-35 CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . 4-26 CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 CYLINDERS AND PISTONS . . 4-31 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 CLUTCH . . . . . . . . . . . . . . . . 4-7 REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . 4-6 CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL . . . . . . . . . CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . 4-41 4-41 4-42 4-43 4-44 4-44 4-45 4-46 4-46 4-47 4-47 4-48 4-50 4-50 4-50 4-51 4-51 4-51 4-52 4-52 4-52 4-54 4-56 4-56 4-57 4-59 4-60 4-61 4-61 4-61 4-66 4-68 4-69 4-72 4-73 4-74 4-75 4-75 4-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . OIL STRAINER . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE AC MAGNETO . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS . REMOVING THE AC MAGNETO . . . . . . . . . . . INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT DRUM AND SHIFT FORKS . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS . . CHECKING THE OIL NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC MAGNETO ROTOR . . . . . . . . . INSTALLING THE CRANKSHAFT . . . . . . . . . . . INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY . . . . . . CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENG AC MAGNETO AND STARTER CLUTCH . . . . . . . REMOVING THE OIL PAN . . . OIL PAN AND OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH . . . . . . . . . . . . STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refer to “CARBURETOR” section in chapter 6. Refer to “CHANGING THE ENGINE OIL” section in capter 3. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. 1 4 1 4-1 1 2 3 Exhaust pipe assembly Exhaust pipe gasket Oil filter . Refer to “RADIATOR” section in chapter 5.REMOVING THE ENGINE ENG OVERHAULING THE ENGINE REMOVING THE ENGINE DRIVE SPROCKET AND EXHAUST PIPE 25 Nm (2.5 mSkg) 70 Nm (7.7 mSkg) Order Job name/Part name Removing the drive sprocket and exhaust pipe Drain the coolant Drain the engine oil Front cowling Fuel tank Battery negative terminal Radiator Carburetor Starter motor Q’ty Remarks Remove the parts in the order listed.0 mSkg) 10 Nm (1.0 mSkg) 17 Nm (1. Refer to “STARTER MOTOR” section in chapter 8.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.

For installation. reverse the removal procedure.5 mSkg) 70 Nm (7.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.REMOVING THE ENGINE ENG 25 Nm (2.7 mSkg) Order 4 5 6 7 8 9 Job name/Part name Shift arm Drive sprocket cover Drive chain sprocket gasket Dowel pin Lock washer Drive sprocket/Drive chain Q’ty 1 1 1 2 1 1/1 Remarks Refer to “INSTALLING THE ENGINE” section. 4-2 .0 mSkg) 10 Nm (1.0 mSkg) 17 Nm (1.

2 mSkg) 12 Nm (1.2 mSkg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed.REMOVING THE ENGINE LEADS AND HOSES ENG Engine right side Engine left side 12 Nm (1. Magneto/sidestand/neutral/engine oil 1/1/1/1 level switch lead 1 Ground lead 4 Plug cap 1 Crankcase breather hose 1 Cover 1 Water pump outlet hose 1 Radiator outlet hose 1 Engine outlet hose 1 Engine outlet hose For connecting. 4-3 . reverse the disconnection procedure.

REMOVING THE ENGINE
ENGINE BRACKET AND ENGINE

ENG

33 Nm (3.3 mSkg)

55 Nm (5.5 mSkg)

33 Nm (3.3 mSkg)

55 Nm (5.5 mSkg)

33 Nm (3.3 mSkg)

Order

Job name/Part name Removing the engine bracket and engine Engine mounting bolt (front left) Engine mounting bolt (front right) Engine bracket (front) Engine mounting bolt (rear upper) Engine bracket (rear right) Engine mounting bolt (rear lower) Engine

Q’ty

Remarks Remove the parts in the order listed.

1 2 3 4 5 6 7

1 1 1 1 1 1 1

Refer to “INSTALLING THE ENGINE” section.

For installation, reverse the removal procedure.

4-4

REMOVING THE ENGINE
EB400700

ENG

INSTALLING THE ENGINE 1. Install: S bolt 1 S bolt 2 S bolt 3 S bolt 4 S engine bracket 5 S engine bracket 6 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. Bolt 1 55 Nm (5.5 mSkg) Bolt 2 55 Nm (5.5 mSkg) Bolt 3 55 Nm (5.5 mSkg) Bolt 4 55 Nm (5.5 mSkg) Engine bracket 5 33 Nm (3.3 mSkg) Engine bracket 6 10 Nm (10 mSkg) 3. Install: S shift arm 1 NOTE: S Align the punch mark a in the shift shaft with the slot in the shift arm. S Align the bottom edge of the shift pedal b with the mark a on the frame-to-swingarm bracket. Shift arm bolt 10 Nm (1.0 mSkg)

4-5

CAMSHAFT CAMSHAFT
CYLINDER HEAD COVERS

ENG

10 Nm (1.0 mSkg)

9 Nm (0.9 mSkg)

Order

Job name/Part name Removing the cylinder head cover Front cowling Seat and fuel tank Drain the coolant Radiator Carburetor Exhaust pipe Plug cap Cylinder head side cover Cylinder head cover Cylinder head cover gasket

Q’ty

Remarks Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3.

Refer to “RADIATOR” section in chapter 5. Refer to “CARBURETOR” section in chapter 6. Refer to “REMOVING THE ENGINE” section. 4 1 1 For installation, reverse the removal procedure.

1 2 3

4-6

CAMSHAFT
CAMSHAFT

ENG

10 Nm (1.0 mSkg)

10 Nm (1.0 mSkg)

20 Nm (2.0 mSkg)

13 Nm (1.3 mSkg)

10 Nm (1.0 mSkg)

Order 1 2 3 4 5 6 7 8 9 10

Job name/Part name Removing the camshafts Spark plug Magneto cover Timing chain guide (upper) Timing chain tensioner assembly Timing chain guide (exhaust side) Camshaft cap Dowel pin Camshaft (intake) Cmashaft (exhaust) Camshaft sprocket

Q’ty 4 1 1 1 1 4 12 1 1 2

Remarks Remove the parts in the order listed.

Refer to “REMOVING/INSTALLING THE CAMSHAFT” section.

For installation, reverse the removal procedure.

4-7

CAMSHAFT
EB401102

ENG

REMOVING THE CAMSHAFTS 1. Remove: S magneto cover 2. Align: S “T” mark on the magneto rotor (with the stationary pointer on the crankcase) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark a with the stationary pointer b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.

3. Remove: S timing chain guide (top side) 1 4. Loosen: S camshaft sprocket bolts 2

2

5. Loosen: S timing chain tensioner cap bolt 1 6. Remove: S timing chain tensioner 2

7. Remove: S timing chain guide (exhaust side) 1 S camshaft caps 2 NOTE: For reference during installation, put identification marks on each camshaft cap.

4-8

CAMSHAFT
2 3

ENG

CAUTION:
To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in. 8. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3 .

1

EB401401

CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft.

!

2. Measure: S camshaft lobe dimensions A and B Out of specification ! Replace the camshaft. Camshaft lobe dimension limit Intake A 32.7 mm B 24.95 mm Exhaust A 32.4mm B 24.9 mm 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout Less than 0.03 mm

4-9

CAMSHAFT

ENG

4. Measure: S camshaft-journal-to-camshaft-cap clearance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-tocamshaft-cap clearance 0.08 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge® 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. S Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 mSkg) a. Remove the camshaft caps and then measure the width of the Plastigauge® 1.
EB401421

1

CHECKING THE TIMING CHAIN, CAMSHAFT SPFROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2. Check: S camshaft sprocket More than 1/4 tooth a wear ! Replace the camshaft sprockets and the timing chain as a set.
a b 1 2

1 / 4 tooth Correct Timing chain roller Camshaft sprocket

3. 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).

4-10

2. Check: S timing chain tensioner Cracks/damage ! Replace.CAMSHAFT EB401430 ENG CHECKING THE TIMING CHAIN TENSIONER 1. Check: S cap bolt 1 S copper washer 2 S ball 3 S spring 4 S ball 5 S one-way cam 6 S gasket S timing chain tensioner rod 7 Damage/wear ! Replace the defective part(-s). working from the inner caps out. 2. S Do not install the designated camshaft cap bolts 4 at this stage. 4-11 . Check: S one-way cam operation Rough movement ! Replace the timing chain tensioner housing. EB401702 1 INSTALLING THE CAMSHAFTS 1. Install: S dowel pins 1 S intake camshaft caps 2 S exhaust camshaft caps 3 NOTE: Install the camshaft cap with the arrow mark a pointing towards the right side of the engine. Install: S exhaust camshaft 1 S intake camshaft 2 (with the camshaft sprockets temporarily tightened) NOTE: Install the camshafts with their punch marks facing up. 3. Install: S camshaft cap bolts NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern. 2 2 3 3 4 4 2 3.

and springs 3 b. Camshaft cap bolt 10 Nm (1. c. Install: S timing chain guide (exhaust side) 6. 5. make sure that marks a and b are aligned. Install the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. and camshafts will result.CAMSHAFT CAUTION: ENG The camshaft cap bolts must be tightened evenly or damage to the cylinder head. When piston #1 is at TDC on the compression stroke. NOTE: S When installing the camshaft sprockets. “I”: Intake side “E”: Exhaust side “E” C “I” C CAUTION: Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. camshaft caps. washer 2 . After the crankshaft is turned several full turns and piston #1 is at TDC. start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side. Remove the cap bolt 1 . Install: S timing chain tensioner 5 3 2 1 4 6 a. Release the timing chain tensioner oneway cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain tensioner housing. align the “T” mark a on the magneto rotor with the stationary pointer b on the crankcase. b.0 mSkg) 4. c. S Make sure that the match marks c are parallel with the edge of the cylinder head. d. Install: S intake camshaft sprocket S exhaust camshaft sprocket a. 4-12 . Turn the crankshaft counterclockwise. Install the timing chain tensioner and gasket 6 onto the cylinder block.

Tighten: S camshaft sprocket bolts d d c c CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possiblity of the bolts coming loose and damaging the engine.0 mSkg) 7. Camshaft sprocket bolt 24 Nm (2. S camshaft punch marks c Make sure that the punch marks on the camshafts are aligned with the embossed marks d on the camshaft cap. Turn: S crankshaft (several full turns counterclockwise) 8.4 mSkg) 10. Refer to the installation steps above.0 mSkg) d. Out of alignment ! Adjust. Cap bolt 20 Nm (2. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.CAMSHAFT ENG Always use a new gasket. Check: S “T” mark a Make sure that the “T” mark on the magneto rotor is aligned with the stationary pointer b on the crankcase. 9. 4-13 . Timing chain tensioner bolt 10 Nm (1. and cap bolt 1 . Install the springs 3 . Measure: S valve clearance Out of specification ! Adjust. washer 2 .

5 mSkg) 20 Nm (2. 4-14 .CYLINDER HEAD CYLINDER HEAD ENG 35 Nm (3.0 mSkg) Order Job name/Part name Removing the cylinder head Camshaft Union bolt Copper washer Oil delivery pipe Cylinder head Cylinder head gasket Dowel pin Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. Refer to “CAMSHAFT”section. 1 2 3 4 5 6 2 4 1 1 1 2 Refer to “REMOVING/INSTALLING THE CYLINDER HEAD” section. For installation.

3.05 mm a. c. EB402403 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. b. S cylinder head water jacket Mineral deposits/rust ! Eliminate. Place a 400 X 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.CYLINDER HEAD EB402101 ENG REMOVING THE CYLINDER HEADS 1. Measure: S cylinder head warpage Out of specification ! Resurface the cylinder head. remove them. S Loosen each nut 1/2 of a turn at a time. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. resurface the cylinder head as follows. Check: S cylinder head Damage/scratches ! Replace. 4-15 . If the limited is exceeded. rotate the cylinder head several times. Cylinder head warpage Less than 0. Measure the warpage. Eliminate: S carbon deposits (from the combustion chambers with a pounded scraper) NOTE: Do not use a sharp instument to avoid damaging or scratching: S spark plug threads S valve seats 2. 1. After all of the nuts are fully loosened. d. Remove: S cylinder head nuts NOTE: S Loosen the nuts in the proper sequence as shown. NOTE: To ensure an even surface.

Cylinder head nut First 20 Nm (2. THE CAM- 4-16 . S Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.CYLINDER HEAD EB402702 ENG INSTALLING THE CYLINDER HEAD 1. Install: S gasket (New) 1 S dowel pins 2 NOTE: The “UP” mark a on the gasket must face up.5 mSkg) 3. Install: S exhaust camshaft S intake camshaft Refer to “INSTALLING SHAFTS”. Install: S cylinder head NOTE: S Apply engine oil onto the threads of the cylinder head nuts. 2.0 mSkg) Second 35 Nm (3.

Refer to “CYLINDER HEAD” section. 4-17 . reverse the removal procedure. Refer to “CAMSHAFT” section. 1 2 3 4 5 6 7 8 9 4 4 8 4 4 2 2 4 4 Refer to “REMOVING/INSTALLING THE VALVES” section.VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS ENG Order Job name/Part name Removing the valves and valve springs Camshaft Cylinder head Valve lifter Adjusting pad Valve cotters Upper spring seat Valve spring Valve (intake) Valve (exhaust) Oil seal Lower spring seat Q’ty Remarks Remove the parts in the order listed. For installation.

Check that the valves properly seal. 2. Remove: S valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Pour a clean solvent a into the intake and exhaust ports. There should be no leakage at the valve seat 1 .. valve seats). Remove: S upper spring seat 1 S valve spring 2 S oil seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. Check: S valve sealing Leakage at the valve seat ! Check the valve face.g. b. valve seat. make sure that the valves properly seal. Remove: S valve lifter 1 S valve pad NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. Refer to “CHECKING THE VALVE SEATS”. and valve seat aidth.VALVES AND VALVE SPRINGS EB403100 ENG REMOVING THE VALVES The following procedure applies to all of the valves and related components. a 1 3. valves. 4-18 . NOTE: Before removing the internal parts of the cylinder head (e. Valve spring compressor 90890-04019 Attachment 90890-04114 4. 1. valve springs. a.

0 mm) 90890-04111 Valve guide installer (ø4. NOTE: After replacing the valve guide. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . and to maintain the correct fit. Eliminate: S carbon deposits (from the valve face and valve seat) 4-19 .08 mm Exhaust Limit: 0. a.1 mm 2.VALVES AND VALVE SPRINGS EB403400 ENG a CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. b. Measure: S valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification ! Replace the valve guide. heat the cylinder head to 100_C (212_C) in an oven.0 mm) 90890-04112 Valve guide reamer (ø4. After installing the valve guide. c. reface the valve seat. 1. b Valve-stem-to-valve-guide clearance Intake Limit: 0. Valve guide remover (ø4. Replace: S valve guide NOTE: To ease valve guide removal and installation. bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-to-valveguide clearance.0 mm) 90890-04113 3. Remove the valve guide with a valve guide remover 1 .

9 X 1. When installing a new valve. Check: S valve face Pitting/wear ! Grind the valve face. always replace the oil seal. 3. Valve margin thickness 0.1 mm (Limit 1. 1.6 mm) Exhaust:0.VALVES AND VALVE SPRINGS ENG 4.6 mm) 4-20 . 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Measure: S valve seat width a Out of specification ! Replace the cylinder head. Valve seat width Intake: 0. S valve stem end Mushroom shape of diameter larger than the body of the valve stem ! Replace the valve.04 mm EB403410 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and vlve seats.5 mm a 6. If the valve is removed or replaced. always replace the valve guide. Valve stem runout Limit 0.1 mm (Limit 1. Check: S valve seat Pitting/wear ! Replace the cylinder head. Measure: S valve stem runout a Out of specification ! Replace the valve.9 X 1. Eliminate: S carbon deposits (from the valve face and valve seat) 2.

d. j. f. h. reface and lap the valve seat. 4-21 . Press the valve through the valve guide and onto the valve seat to make a clear pattern. If the valve seat width is out of specification. Where the valve seat and valve face contacted one another. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. c. be sure to clean off all of the lapping compound from the valve face and valve seat. e. Measure the valve seat width a again. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: For the best lapping results. Press the valve through the valve guide and onto the valve seat to make a clear impression. Apply molybdenum disulfide oil onto the valve stem. Turn the valve until the valve face and valve seat are evenly polished. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide. Install the valve into the cylinder head. a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. lightly tap the valve seat while rotating the valve back and forth between your hand. Measure the valve seat width.VALVES AND VALVE SPRINGS ENG a. b. then clean off all of the lapping compound. d. the valve seat and valve face should be lapped. Install the valve into the cylinder head. Apply a coarse lapping compound a to the valve face. c. After every lapping procedure. b. g. 4. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. the blueing will have been removed. i. Install the valve into the cylinder head.

4 X 15. Measure: S valve spring free length a Out of specification ! Replace the valve spring. 4-22 . b Installed length Compressed spring force Intake and exhaust spring 13. 1.09 mm (Limit 37.VALVES AND VALVE SPRINGS EB403420 ENG CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. 1. Measure: S compressed spring force a Out of specification ! Replace the valve spring. Check: S valve lifter Damage/scratches ! Replace the valve lifters and cylinder head.8 mm EB403430 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. Spring tilt limit Intake and exhaust spring 1.5 mm) 2. a Valve spring free length (intake and exhaust) Spring 40.6 kg at 34.5 mm a 3.

Dirt/obstruction ! Wash the pipe(-s) and then blow it out with compressed air. EB403700 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. Install: S valve 1 S lower spring seat 2 S oil seal 3 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. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . and check the camshafts (Refer to “CHECKING THE CAMSHAFTS”. 1. Deburr: S valve stem end (with an oil stone) 2.VALVES AND VALVE SPRINGS EB403440 ENG 1 2 2 2 CHECKING THE CAMSHAFT CAP 1. Lubricate: S valve stem 1 S oil seal (with the recommended lubricant) 1 5 Large a Recommended lubricant Molybdenum disulfide oil 3. 4-23 . 2. S camshaft bearing surfaces 2 Damage/pitting/scratches ! Replace the camshaft case and camshaft caps as a set. Check: S camshaft case S camshaft caps 1 Cracks/damage ! Replace th camshaft case and camshaft caps as a set.).). b Smaller pitch 4 3 Small b 2 4. Check: S oil delivery pipes 1 Damage ! Replace the defective part(-s). and check the camshafts (Refer to “CHECKING THE CAMSHAFTS”.

6.VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04019 Attachment 90890-04114 5. To secure the valve cotters 1 onto the a valve stem. Install: S valve pad 1 S valve lifter 2 NOTE: S Apply molybdenum disulfide oil onto the valve lifter and valve pad. 4-24 . lightly tap the valve tip with a soft-face hammer. S Each valve lifter and valve pad must be reinstalled in its original position. CAUTION: Hitting the valve tip with excessive force could damage the valve. S The valve lifter must move smoothly when rotated with a finger.

1 2 3 4 5 6 7 8 9 10 1 2 1 1 2 4 8 4 4 4 Refer to “INSTALLING THE PISTON AND CYLINDER” section. For installation. Refer to “REMOVING THE CYLINDER AND PISTONS/INSTALLING THE PISTON AND CYLINDER” section.0 mSkg) Order Job name/Part name Removing the cylinder and pistons Cylinder head Water jacket joint O-ring Cylinder Cylinder gasket Dowel pin O-ring Piston pin circlip Piston pin Piston Piston ring set Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD” section.CYLINDER AND PISTON CYLINDER AND PISTON ENG 10 Nm (1. reverse the removal procedure. 4-25 .

Check: S piston wall S cylinder wall Vertical scratches ! Rebore or replace the cylinder. S For reference during installation. put an identification mark on each piston crown. 1 20 mm from the top of the cylinder NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Remove: S top ring S 2nd ring S oil ring NOTE: When removing a piston ring.CYLINDER AND PISTON EB404101 ENG 1 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. deburr the piston pin clip’s groove and the piston’s pin bore area. 1. EB404405 4 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. Measure: S piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. remove it with the piston pin puller 4 . If both areas are deburred and the piston pin is still difficult to remove. and replace the piston and piston rings as a set. 4-26 . find the average of the measurements. S Before removing the piston pin. open the end gap with your fingers and lift the other side of the ring over the piston crown. 1. Piston pin puller 90890-01304 2. 2. cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. NOTE: S Before removing the piston pin clip. Then. Remove: S piston pin clip 1 S piston pin 2 S piston 3 2 CAUTION: Do not use a hammer to drive the piston pin out.

Piston-to= cylinder clearance cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0. piston and piston rings as a set. P a Piston size P Standard 61. replace the cylinder. eliminate any carbon deposits from the piston ring grooves and piston rings.00 X 62.CYLINDER AND PISTON ENG Wear limit 62.07 mm f.020 X 0. piston and piston rings as a set. e.960 X 61. replace the cylinder. If out of specification. c.050 mm <Limit>: 0.025 X 0.020 X 0.1 mm Standard Cylinder 62. NOTE: Before measuring the piston ring side clearance. Measure: S piston ring side clearance 1 Out of specification ! Replace the piston and piston rings as a set.055 mm <Limit>: 0. Calculate the piston-to-cylinder clearance with the following formula.1 mm 4-27 .01 bore “C” X+Y “C” = 2 b. Measure piston skirt diameter “P” with the micrometer. If out of specification. a 5 mm from the bottom edge of the piston. replace the piston and piston rings as a set. If out of specification. EB404410 CHECKING THE PISTON RINGS 1.075 mm <Limit>: 0. Piston ring side clearance Top ring 0.975 d.1 mm 2nd ring 0.

Piston pin outside diameter 16.35 mm EB404421 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins.000 mm a 4-28 . Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin.15 X 0. 1. Install: S piston ring 1 (into the cylinder) a ENG NOTE: Level the piston ring in the cylinder with the piston crown as shown.6 mm 2nd ring 0. NOTE: The oil ring expander spacer’s end gap cannot be measured.30 mm <Limit>: 0.40 mm <Limit>: 0. If the oil ring rail’s gap is excessive. Check: S piston pin Blue discoloration/grooves ! Replace the piston pin and then check the lubrication system. a 20 mm 3.7 mm Oil ring 0.CYLINDER AND PISTON 2.1 X 0. Measure: S piston ring end gap Out of specification ! Replace the piston ring. Piston ring end gap Top ring 0. replace all three piston rings.991 X 17.25 X 0. 2.

Install: S gasket (New) 1 S dowel pins 2 4. 1. Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0. 4 5 3 2.011 X 0. 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 face up. S Before installing the piston pin clip. S Make sure that the “EX” mark a on the piston faces towards the exhaust side of the engine. 3.CYLINDER AND PISTON b ENG 3. cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.013 mm <Limit>: 0. Calculate: S piston-pin-to-piston clearance Out of specification ! Replace the piston pin. Install: S piston 1 S piston pin 2 S piston pin clip (New) 3 a NOTE: S Apply engine oil onto the piston pin.023 mm EB404701 1 2 INSTALLING THE PISTON AND CYLINDER The following procedure applies to all of the pistons and cylinders. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4-29 .

e. install pistons #2 and #3. c. S Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. Install: S cylinder 1 S O-ring 2 NOTE: S First.CYLINDER AND PISTON d c ENG 5. Install the piston ring compressor 1 to pistons #1 and #4. Install a piston ring compressor 1 to piston #2 and #3. f. Install pistons #2 and #3 onto the cylinder. b. Remove the piston ring compressor. Remove the piston ring compressor. d. Piston ring compressor: 90890-04044 4-30 . Offset: S piston ring end gaps a b c d e Top ring Lower oil ring rail Upper oil ring rail 2nd ringe Oil ring expander e b a 1 6. 2 2 a. Install pistons #1 and #4 onto the cylinder.

Refer to “CHANGING THE ENGINE OIL” section in chapter 3. 1 2 3 4 5 Clutch cover Clutch cover gasket Dowel pin Drive sprocket cover Clutch cable 1 1 2 1 1 For installation. 4-31 .CLUTCH CLUTCH CLUTCH COVER ENG 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Removing the clutch cover Drain the engine oil Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure.

Refer to “REMOVING/INSTALLING THE CLUTCH” section.8 mSkg) Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Removing the clutch Compression spring Pressure plate Short clutch push rod O-ring Ball Long clutch push rod Friction plate Clutch plate Fricition plate (large) Clutch spring plate Nut Q’ty 6 1 1 1 1 1 8 8 1 1 1 Remarks Remove the parts in the order listed. 4-32 . Refer to “INSTALLING THE CLUTCH” section.0 mSkg) 8 Nm (0.CLUTCH CLUTCH ENG 70 Nm (7.

Refer to “INSTALLING THE CLUTCH” seciton. Refer to “INSTALLING THE CLUTCH” section.CLUTCH ENG 70 Nm (7. 4-33 .8 mSkg) Order 12 13 14 15 16 17 18 19 Job name/Part name Lock washer Clutch boss Thrust washer Spacer Bearing Clutch housing Thrust washer Spacer Q’ty 1 1 1 1 1 1 1 1 Remarks Refer to “REMOVING/INSTALLING THE CLUTCH” section. For installation.0 mSkg) 8 Nm (0. Refer to “REMOVING/INSTALLING THE CLUTCH” section. reverse the removal procedure.

Straighten the lock washer tab. NOTE: Measure the friction plate at four places. Measure: S clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification ! Replace the clutch plates as a set. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder 3 . 2.94 X 3.1 mm 4-34 . EB405400 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. Friction plate thickness 2. loosen the clutch boss nut.CLUTCH EB405100 ENG 2 REMOVING THE CLUTCH 1.06 mm <Limit>: 2. 3 Universal clutch holder 3 90890-04086 3. Check: S friction plate Damage/wear ! Replace the friction plates as a set. 2. 1 Clutch plate warpage limit Less than 0. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. 1. 2. Remove: S spacer 1 S bearing 2 NOTE: Insert two M6-mm bolts 3 into the spacer and then remove the spacer by pulling on the bolts.8 mm EB405410 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates.

Check: S clutch housing dogs 1 Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. 1.9 mm <Limit>: 34. Check: S bearing 2 Damage/wear ! Replace the clutch housing. EB405440 CHECKING THE CLUTCH HOUSING 1. Check: S clutch spring plate seat Damage ! Replace. Check: S clutch spring plate Damage ! Replace. 2. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: S clutch spring Damage ! Replace the clutch springs as a set. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set.CLUTCH EB405420 ENG a CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 2 4-35 . 2. Clutch spring free length 34.3 mm EB405430 CHECKING THE CLUTCH SPRING PLATE 1.

Check: S pressure plate 1 Cracks/damage ! Replace. Long clutch push rod bending limit 0. S bearing 2 Damage/wear ! Replace. 4-36 . 2.CLUTCH EB405450 ENG CHECKING THE CLUTCH BOSS 1.3 mm 1 EB405701 1 2 INSTALLING THE CLUTCH 1. Check: S clutch boss splines 1 Damage/pitting/wear ! Replace clutch boss. EB405480 CHECKING THE CLUTCH PUSH RODS 1. Measure: S long clutch push rod bending limit 1 Out of specification ! Replace the long clutch push rod. Install: S bearing 1 S spacer 2 NOTE: Install the spacer with the two screw holes facing towards the clutch boss. the NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. Check: S O-ring 1 S short clutch push rod 2 S long clutch push rod 3 S ball 4 Cracks/damage/wear ! Replace the defective part(-s). EB405450 CHECKING THE PRESSURE PLATE 1.

friction plate (large of inside dia. Install: S long clutch push rod S ball S short clutch push rod (along with a new O-ring 4 ) 6. Lubricate: S long clutch push rod 1 S ball 2 S short clutch push rod 3 S O-ring 4 (with the recommended lubricant) Recommended lubricant Lithium soap base grease 5. b.) and clutch plate. alternate between long and short clutch springs.0 mSkg) 1 3 2 NOTE: While holding the clutch boss with the universal clutch holder 2 .8 mSkg) NOTE: S When installing the clutch springs.CLUTCH 2. Install: S pressure plate 1 S clutch springs 2 S clutch spring bolts 3 8. Install: S friction plates 1 S clutch plates 2 a. Install a clutch spring plate. Install a friction plate and clutch plate. Lubricate: S friction plates 1 S clutch plates 2 (with the recommended lubricant) 1 2 Recommended lubricant Engine oil 7. Install a friction plate and then alternate between a clutch plate and a friction plate. 8. Universal clutch holder 90890-04086 3. 4. Tighten: S clutch boss nut 1 ENG 70 Nm (7. 4-37 . c. Bend the lock washer 3 tab along a flat side of the nut. tighten the clutch boss nut. S Tighten the clutch spring bolts in stages and in a crisscross pattern.0 Nm (0.

4-38 . Install: S clutch cover 1 ENG 12 Nm (1.CLUTCH 9.2 mSkg) NOTE: Tighten the clutch cover bolts in stages and in a crisscross pattern.

Refer to “REMOVING THE ENGINE” section. 4-39 . Refer to “OIL PUMP” section. For installation. 1 2 3 4 5 Collar Shift shaft Shift lever spring Stopper lever SHift lever spring 1 1 1 1 1 Refer to “INSTALLING THE SHIFT SHAFT” section. reverse the removal procedure.SHIFT SHAFT SHIFT SHAFT ENG Order Job name/Part name Removing the shift shaft Oil pump Drive sprocket cover Q’ty Remarks Remove the parts in the order listed.

Check: S shift shaft 1 S shift lever 2 Bends/damage/wear ! Replace. Install: S stopper lever 1 S stopper lever spring 2 S shift shaft lever NOTE: S Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss. 1 2 4-40 . Install: S shift shaft 1 NOTE: S Lubricate the oil seal lips with lithium soap base grease. S Hook the end of the shift lever spring onto the shift lever spring stopper 2 . 1 2 3 4 EB408700 2 INSTALLING THE SHIFT SHAFT 1. S shift lever spring 3 S stopper lever spring 4 Damage/wear ! Replace. 2.SHIFT SHAFT EB408400 ENG CHECKING THE SHIFT SHAFT 1. S Mesh the stopper lever with the shift drum segment assembly.

1 2 3 4 5 Stator/pickup coil lead Cover Generator cover Dowel pin Stator coil 1/1 1 1 2 1 For installation.0 mSkg) 12 Nm (1. reverse the removal procedure.AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH STATOR COIL ENG 5 Nm (0.2 mSkg) Order Job name/Part name Removing the stator coil Seat Fuel tank Q’ty Remarks Remove the parts in the order listed.5 mSkg) 10 Nm (1. 4-41 . Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3.

4-42 .AC MAGNETO AND STARTER CLUTCH STARTER CLUTCH ENG 12 Nm (1.0 mSkg) Order Job name/Part name Removing the starter clutch Generator cover Starter clutch cover Dowel pin Gasket Starter clutch assembly Wood ruff key Starter wheel gear Shaft (Primary) Starter idle gear (primary) Shaft (Secondary) Starter idle gear (secondary) Shaft drive gear Q’ty Remarks Remove the parts in the order listed.2 mSkg) 80 Nm (8. 1 2 3 4 5 6 7 8 9 10 11 1 2 1 1 1 1 1 1 1 1 1 Refer to “REMOVING/INSTALLING THE STARTER CLUTCH” section. For installation. reverse the removal procedure.

0 mSkg) Order 1 2 3 Job name/Part name Removing the generator roter Bolt/washer Rotor Woodruff key Q’ty 1/1 1 1 Remarks Remove the parts in the order listed.AC MAGNETO AND STARTER CLUTCH AC MAGNETO ROTOR ENG 130 Nm (13. Refer to “REMOVING/INSTALLING THE AC MAGNETO” section. reverse the removal procedure. For installation. 4-43 .

Sheave holder: 90890-01701 4-44 . Remove: S starter clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time. 2.AC MAGNETO AND STARTER CLUTCH EB410100 ENG REMOVING THE STARTER CLUTCH 1. loosen the AC magneto rotor bolt 1 . remove them. Remove: S starter clutch bolt 1 NOTE: S While holding the magneto rotor 2 with the sheave holder 3 . After all of the bolts are fully loosened. Remove: S Bolt (AC magneto rotor) 1 S Washer NOTE: While holding the AC magneto rotor 2 with a sheave holder 3 . in stages and in a crisscross pattern. remove the starter clutch bolt. Remove: S starter clutch 1 (with the flywheel puller set 2 ) Flywheel puller set 90890-01362 REMOVING THE AC MAGNETO 1. Sheave holder 90890-01701 3.

AC MAGNETO AND STARTER CLUTCH
2. Remove: S AC magneto rotor 1 S Woodruff key

ENG

NOTE: Use a flywheel puller 2 to remove the AC magneto rotor 1 . Flywheel puller: 90890-01362
EB410401

2

CHECKING THE STARTER CLUTCH 1. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 S starter clutch gear 3 Burrs/chips/roughness/wear ! Replace the defective part(-s).
1

3

2. Check: S starter clutch operation a. When turning the starter clutch drive gear clockwise a , the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. b. When turning the starter clutch drive gear counterclockwise b , it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.

4-45

AC MAGNETO AND STARTER CLUTCH

ENG

INSTALLING THE AC MAGNETO 1. Install: S Woodruff key 1 S AC magneto rotor 2 S Bolt (AC magneto rotor) NOTE: S Clean the tapered portion of the crankshaft and the AC magneto rotor. S When installing the AC magneto rotor, make sure that the woodruff key is properly seated in the key way of the crankshaft. 2. Tighten: S Bolt (magneto rotor) Bolt (AC magneto rotor): 130 Nm (13.0 mSkg) NOTE: While holding the AC magneto rotor 1 with a sheave holder 2 tighten the AC magneto rotor bolt 3 . Sheave holder: 90890-01701

EB410710

INSTALLING THE STARTER CLUTCH 1. Install: S starter clutch 1 NOTE: S While holding the generator rotor 1 with the sheave holder 2 , tighten the starter clutch bolt. Sheave holder 90890-01701 Starter clutch bolt 80 Nm (8.0 mSkg)

4-46

OIL PAN AND OIL STRAINER OIL PAN AND OIL STRAINER
OIL STRAINER

ENG

7 Nm (0.7 mSkg)

43 Nm (4.3 mSkg) 12 Nm (1.2 mSkg)

10 Nm (1.0 mSkg)

63 Nm (6.3 mSkg)

Order

Job name/Part name Removing the oil strainer Engine

Q’ty

Remarks Remove the parts in the order listed. Refer to “REMOVING THE ENGINE” section.

1 2 3 4 5 6 7 8 9

Oil level warning switch/O-ring Oil pan Dowel pin Oil pan gasket Relief valve/O-ring Oil strainer Oil strainer housing Oil bypass valve Oil cooler/O-ring

1/1 1 2 1 1/1 1 1 1 1/1

Refer to “INSTALLING THE OIL PAN” section.

Refer to “INSTALLING THE OIL STRAINER” section. Refer to “INSTALLING THE ADAPTOR” section. For installation, reverse the removal procedure.

4-47

OIL PAN AND OIL STRAINER
OIL PUMP

ENG

10 Nm (1.0 mSkg)

Order

Job name/Part name Removing the oil pump Clutch Oil pump assembly Oil pump gasket Dowel pin

Q’ty

Remarks Remove the parts in the order listed. Refer to “CLUTCH” section.

1 2 3

1 1 1

Refer to “INSTALLING THE OIL PUMP” section. For installation, reverse the removal procedure.

4-48

OIL PAN AND OIL STRAINER

ENG

7

Order 1 2 3 4 5 6 7

Job name/Part name Disassembling the oil pump Oil pump rotor housing Dowel pin Inner rotor/outer rotor Dowel pin Oil pump shaft assembly Oil pump cover Washer

Q’ty 1 2 1/1 1 1 1 1

Remarks Disassembly the parts in the order listed.

Refer to “ASSEMBLING THE OIL PUMP” section.

For assembly, reverse the disassembly procedure.

4-49

OIL PAN AND OIL STRAINER
EB411100

ENG

REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
EB411401

CHECKING THE OIL PUMP 1. Check: S oil pump drive gear 1 S oil pump driven gear 2 S oil pump housing 3 S oil pump housing cover 4 Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: S inner-rotor-to-outer-rotor-tip clearance A S outer-rotor-to-oil-pump-housing clearance B S oil-pump-housing-to-inner-rotor-and-outer-rotor clearance C Out of specification ! Replace the oil pump.
1 Inner rotor 2 Outer rotor 3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance 0.03 X 0.09 mm Limit 0.15 mm Outer-rotor-to-oil-pumphousing clearance 0.03 X 0.08 mm Limit 0.15 mm Oil-pump-housing-to-innerrotor-and-outer-rotor clearance 0.03 X 0.08 mm Limit 0.15 mm 3. Check: S oil pump operation Unsmooth ! Repeat steps (1) and (2) or replace the defective part(-s).
EB411410

CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective part(-s).

4-50

OIL PAN AND OIL STRAINER
EB411430

ENG

CHECKING THE OIL STRAINER 1. Check: S oil strainer 1 Damage ! Replace. Contaminants ! Clean with engine oil.

EB411470

CHECKING THE OIL NOZZLE 1. Check: S oil nozzle 1 S check ball 2 Damage/wear ! Replace the oil nozzle. S O-ring 3 Damage/wear ! Replace. S oil nozzle passage Obstruction ! Blow out with compressed air.
EB411701

ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil

7

5 6

6 4

2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S washer S pin 3 S inner rotor 4 S outer rotor 5 S dowel pin 6 S oil pump housing 7

7.0 Nm (0.7 mSkg)

NOTE: When installing the inner rotor, align the pin a in the oil pump shaft with the groove b on the inner rotor 1 . 3. Check: S oil pump operation Refer to “CHECKING THE OIL PUMP”.

b a

4-51

Install: S dowel pins S gasket (New) S oil pan 1 S oil level switch 2 S engine oil drain bolt Always use new copper washers. make sure that the oil pump turns smoothly. 2.OIL PAN AND OIL STRAINER EB411710 ENG INSTALLING THE OIL PUMP Install: 10 Nm (1. d c EB411720 INSTALLING THE OIL STRAINER 1.0 mSkg) S oil pump 1 CAUTION: b After tightening the bolts. Install: S oil strainer cover 1 NOTE: The arrow on the oil strainer cover must point towards the rear of the engine. EB411730 INSTALLING THE OIL PAN 1. 4-52 . Install: S oil strainer housing 1 10 Nm (10 mSkg) LOCKTITE® NOTE: The arrow on the oil strainer housing must point towards the front of the engine. NOTE: Align the projection a on the oil pump shaft with the slot b on the water pump shaft. NOTE: Align the arrow c on the oil pump with the arrow d on the crankcase.

OIL PAN AND OIL STRAINER ENG NOTE: S Tighten the oil pan bolts in stages and in a crisscross pattern.7 mSkg) 4-53 . Oil pan bolt 12 Nm (1. S Lubricate the oil level switch’s O-ring with engine oil.2 mSkg) Oil level switch bolt 7 Nm (0.

CRANKCASE CRANKCASE ENG 24 Nm (2. Refer to “CYLINDER HEAD” section. Refer to “OIL PUMP” section.0 mSkg) 24 Nm (2. 1 2 3 Oil seal stopper plate Neutral switch lead Neutral switch 4-54 1 1 1 . Refer to “REMOVING THE ENGINE” section. Refer to “CAMSHAFT” section.4 mSkg) Order Job name/Part name Disassembling the crankcase Engine Camshaft Cylinder head Cylinder.2 mSkg) 10 Nm (1. piston Clutch Oil pump Shift shaft Magneto rotor Starter clutch Oil strainer Water pump Q’ty Remarks Disassembly the parts in the order listed. Refer to “OIL PAN AND OIL STRAINER” section.4 mSkg) 12 Nm (1. Refer to “AC MAGNETO AND STARTER CLUTCH section. Refer to “CLUTCH” section in chapter 4. Refer to “SHIFT SHAFT” section. Refer to “WATER PUMP” section in chapter 5. Refer to “CYLINDER AND PISTON” section.

reverse the disassembly procedure. For assembly.2 mSkg) 10 Nm (1.4 mSkg) 12 Nm (1.0 mSkg) 24 Nm (2. 4-55 .4 mSkg) Order 4 5 6 7 8 9 Job name/Part name O-ring Upper crankcase Dowel pin Oil seal Oil jet O-ring Q’ty 1 1 1 1 1 1 Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE CRANKCASE” section.CRANKCASE ENG 24 Nm (2.

remove them. Check: S crankcase Cracks/damage ! Replace. Tap only on reinforced portions of the crankcase. 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. Remove: S lower crankcase CAUTION: Tap on one side of the crankcase with a soft-face hammer. 5. 3. Remove: S dowel pins S oil jet 6. S oil delivery passages Obstruction ! Blow out with compressed air.CRANKCASE EB412100 ENG A DISASSEMBLING THE CRANKCASE 1. Work slowly and carefully and make sure that the crankcase halves separate evenly. After all of the bolts are fully loosened. Place the engine upside down. Remove: S lower crankcase bolts 1 X 20 B lower crankcase 4. not on the crankcase mating surfaces. 3. S The numbers embossed on the crankcase indicate the crankcase tightening sequence. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Remove: S crankcase bolts 1 X 15 A Upper crankcase NOTE: S Loosen each bolt 1/4 of a turn at a time. B 2. 4-56 . EB412420 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. in stages and in a crisscross pattern. 2. S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).

Install: S crankshaft journal lower bearings 1 (into the lower crankcase) a b NOTE: S Align the projections a on the crankshaft journal lower bearings with the notches b in the crankcase. S Install each crankshaft journal lower bearing in its original place. 4-57 . Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Install: S dowel pin 4.CRANKCASE EB412742 ENG ASSEMBLING THE CRANKCASE 1. 6. make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. Install: S upper crankcase 1 (onto the lower crankcase 2 ) CAUTION: 2 Before tightening the crankcase bolts. 5. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. 3. Set the shift drum assembly and transmission gears in the neutral position. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No.

CRANKCASE A ENG 7. S Tighten the bolts in increasing numerical order. A Upper crankcase B Lower crankcase M8 bolt 24 Nm (2. S Install washers on bolts 1 X 12 . S Install the cable holder on bolt #35.4 mSkg) M6 bolt 12 Nm (1.2 mSkg) B 4-58 . Install: S upper crankcase bolts S lower crankcase bolts NOTE: S Lubricate the bolt threads with engine oil.

Refer to “CRANKCASE” section.CRANKSHAFT CRANKSHAFT ENG 10 Nm (1.0 mSkg) Order Job name/Part name Removing the crankshaft Disassembly the crankcase Timing chain guide (intake side) Crankshaft assembly Oil seal Timing chain Crankshaft journal bearing Q’ty Remarks Remove the parts in the order listed. 4-59 . 1 2 3 4 5 1 1 1 1 12 Refer to “REMOVING/INSTALLING THE CRANKSHAFT ASSEMBLY” section. reverse the removal procedure. For installation.

reverse the removal procedure.5 mSkg) + 90_ Order 1 2 3 4 5 Job name/Part name Removing the connecting rod Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod big end bearing Q’ty 8 8 4 4 8 Remarks Remove the parts in the order listed.CRANKSHAFT CONNECTING ROD ENG 15 Nm (1. 4-60 . For installation. Refer to “INSTALLING THE CONNECTING RODS” section. Refer to “REMOVING/INSTALLING THE CONNECTING RODS” section.

CRANKSHAFT EB412110 ENG 1 REMOVING THE CRANKSHAFT ASSEMBLY 1. Measure: S crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification ! Replace the crankshaft journal bearings.03 mm 2. 2 EB412121 REMOVING THE CONNECTING RODS 1. Remove: S connecting rods 1 S big end bearings 2 NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. 1 2 EB412401 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Crankshaft runout Less than 0. 3. Remove: S crankshaft assembly 1 S crankshaft journal upper bearing 2 (from the upper crankcase) S timing chain guide (intake side) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. 4-61 . Measure: S crankshaft runout Out of specification ! Replace the crankshaft.

and bearing portions of the crankcase. a b a. NOTE: Do not put the Plastigauge® over the oil hole in the crankshaft journal. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves.08 mm CAUTION: Do not interchange the crankshaft journal bearings. the crankshaft journal bearings must be installed in their original position. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the crankcase. crankshaft journals. 4-62 . S Do not move the crankshaft until the clearance measurement has been completed.025 X 0. 2 a b NOTE: S Align the projections a of the crankshaft journal lower bearings with the notches b in the crankcase. c.CRANKSHAFT ENG Crankshaft-journal-to-crankshaft-journal-bearing clearance 0. Clean the crankshaft journal bearings. Put a piece of Plastigauge® 2 on each crankshaft journal. d.043 mm Limit 0. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. b. e. To obtain the correct crankshaft journal-to-crankshaft-journal-bearing clearance and prevent engine damage. Place the upper crankcase upside down on a bench.

S If “J1 X J6” are the same. B C g. Measure the compressed Plastigauge® width C on each crankshaft journal.4 mSkg) M6: 12 Nm (1. S “J1 X J6” refer to the bearings shown in the crankshaft illustration. select replacement crankshaft journal bearings. Remove the lower crankcase and the crankshaft journal lower bearings. If the clearance is out of specification. Select: S Crankshaft journal bearings (J1 X J6) 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. h. 4-63 .2 mSkg) A Upper crankcase B Lower crankcase NOTE: Lubricate the crankcase bolt threads (M8) and (M6) with engine oil. Tighten the bolts to specification in the tightening sequence cast on the crankcase.CRANKSHAFT A ENG f. use the same size for all of the bearings. 4. Crankcase bolt M8: 24 Nm (2.

Put a piece of Plastigauge® 1 on the crankshaft pin. Measure: S crankshaft-pin-to-big-end-bearing clearance Out of specification ! Replace the big end bearings. then the bearing size for “J1” is: A Bearing size for J1: J1 (crankcase) – J1 (crankshaft web) + 1 = 6 – 2 + 1 = 5 (yellow) CRANKSHAFT JOURNAL BEARING COLOR CODE 1 1 2 3 4 5 6 blue black brown green yellow pink 1 1 5.043 X 0. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage. 1 b a CAUTION: Do not interchange the big end bearings and connecting rods. b. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. a. crankshaft pins. and bearing portions of the connecting rods. Clean the big end bearings. 1 4-64 . the big end bearings must be installed in their original positions.08 mm The following procedure applies to all of the connecting rods.CRANKSHAFT ENG For example. Crankshaft-pin-to-big-endbearing clearance 0. if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively.066 mm Limit 0. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. c.

f. S Apply molybdenum disulfide grease onto the bolts. Select: S big end bearings (P1 X P4) 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. 11 ftSlb) + (turn the nut another 90_) Refer to “INSTALLING THE CONNECTING RODS”.5 mSkg. S “P1” X “P4” refer to the bearings shown in the crankshaft illustration. A 4-65 . select replacement big end bearings. threads.CRANKSHAFT ENG c NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed. e 6. Measure the compressed Plastigauge® width e on the crankshaft pin. g. S Make sure that the characters d on both the connecting rod and connecting rod cap are aligned. Remove the connecting rod and big end bearings. Nut (connecting rod): 15 Nm (1. If the clearance is out of specification. Refer to “REMOVING THE CONNECTING RODS”. e. and nut seats. Tighten the connecting rod nuts. S Make sure that the “Y” mark c on the connecting rod faces towards the left side of the crankshaft.

S Be sure to reinstall each big end bearing in its original place. Lubricate: S crankshaft pins S big end bearings S connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. Install: S big end bearings 1 S connecting rods 2 S connecting rod caps 3 (onto the crankshaft pins) NOTE: S Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.CRANKSHAFT ENG For example. 4-66 . S Make sure that the characters on both the connecting rod and connecting rod cap are aligned. Lubricate: S bolt threads S nut seats (with the recommended lubricant) 3 Recommended lubricant Molybdenum disulfide grease 2. if the connecting rod “P1” and the crankshaft web “P1” numbers are “4” and “1” respectively. S Make sure that the “Y” marks a on the connecting rods face towards the left side of the crankshaft. then the bearing size for “P1” is: Bearing size for P1: P1 (connecting rod) – P1 (crankshaftweb) = 4 – 1 = 3 (brown) BIG END BEARING COLOR CODE 2 1 blue 2 black 3 4 brown green 2 2 EB412700 2 INSTALLING THE CONNECTING RODS 1.

Tighten the connecting rod nuts. note that the angle from one corner to another is 60_. CAUTION: S Do not use a torque wrench to tighten the nut to the specified angle. Tighten: S Nuts (connecting rod) Nut (connecting rod): 15 Nm (1. e. d. Tighten the nut further to reach the specified angle (90_). NOTE: When using a hexagonal nut. S Tighten the nut until it is at the specified angles. Replace the bolt with a new one and perform the procedure again.CRANKSHAFT ENG 4. do not loosen the nut and then retighten it. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3. 4-67 . Clean the connecting rod bolts and nuts. Always install new bolts and nuts. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. When the nut is tightened more than the specified angle. c.5 mSkg) + (turn the nut another 90_) a. b. Align: S bolt heads 1 (with the connecting rod caps) 5.

Install: S timing chain 1 (onto the crankshaft sprocket) S crankshaft assembly 2 NOTE: S Pass the timing chain through the timing chain cavity.CRANKSHAFT EB412720 ENG INSTALLING THE CRANKSHAFT 1.0 mSkg) 4-68 . Install: S crankshaft journal upper bearings 1 (into the upper crankcase) a b NOTE: S Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. 2. 3. S Be sure to install each crankshaft journal upper bearing in its original place. fasten it with a wire. S To prevent the timing chain from falling into the crankcase. Install: S timing chain guide 1 10 Nm (1.

1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 1 1 1 1/1 1 Refer to “INSTALLING THE TRANSMISSION” section. 4-69 . Refer to “INSTALLING THE TRANSMISSION” section.TRANSMISSION TRANSMISSION ENG Order Job name/Part name Removing the transmission Disassembly the crankcase Main axle assembly Circlip Bearing Bearing Drive axle assembly Circlip Nozzle Bearing Plate washer Oil seal/collar Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKCASE” section. reverse the removal procedure. For installation.

TRANSMISSION

ENG

Order
1 2 3 4 5 6 7 8 9
10 11 12 13

Job name/Part name Disassembling the transmission 1st wheel gear 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear 2nd wheel gear Washer Circlip Drive axle 2nd pinion gear 6th pinion gear

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks Disassembly the parts in the order listed.

4-70

TRANSMISSION

ENG

Order
14 15 16 17 18

Job name/Part name 3rd/4th pinion gear Circlip Washer 5th Main axle

Q’ty 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

4-71

TRANSMISSION
EB413422

ENG

CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1) Out of specification ! Replace the main axle. Main axle runout limit 0.02 mm 2. Measure: S drive axle runout (with a centering device and dial gauge 1) Out of specification ! Replace the drive axle. Drive axle runout limit 0.02 mm

3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s). S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s).

4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(-s).

Transmission gear reassembling point: Press the 2nd pinion gear 1 into the main axle 2 , as shown in the illustration.

4-72

TRANSMISSION
EB413710

ENG

INSTALLING THE TRANSMISSION 1. Install: S oil baffle plate 1 S crankcase breather hose 2 NOTE: Insert the metal clamp 3 on the crankcase breather hose into the slots 4 in the crankcase.

2. Install: S main axle assembly 1 S drive axle assembly 2 S oil seals S circlips S lock washer

NOTE: S Make sure that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase. S The main axle bearing pin 5 must face towards the front of the crankcase and the drive axle bearing pin 6 must face towards the rear of the crankcase. 3. Check: S transmission Rough movement ! Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.

4-73

SHIFT DRUM AND SHIFT FORKS
SHIFT DRUM AND SHIFT FORKS

ENG

10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg)

Order

Job name/Part name Removing the shift drum and shift forks Disassembly the crankcase Transmission Shift fork guide bar retainer Shift drum retainer Shift fork guide bar 1 Shift fork C Shift fork guide bar 2 Shift fork L Shift fork R Shift drum

Q’ty

Remarks Remove the parts in the order listed. Refer to “CRANKCASE” section. Refer to “TRANSMISSION” section.

1 2 3 4 5 6 7 8

1 1 1 1 1 1 1 1

Refer to “INSTALLING THE SHIFT FORKS AND SHIFT DRUM” section.

For installation, reverse the removal procedure.

4-74

SHIFT DRUM AND SHIFT FORKS
EB413400

ENG

2 1

CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: S shift fork cam follower 1 S shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork.

2. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface. Bend ! Replace.

Do not attempt to straighten a bent shift fork guide bar.

3. Check: S shift fork movement (on the shift fork guide bar) Rough movement ! Replace the shift forks and shift fork guide bar as a set.

EB413410

1 2

CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum. S shift drum segment 1 Damage/wear ! Replace. S shift drum bearing 2 Damage/pitting ! Replace.
EB413701

INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: S shift drum assembly 1

4-75

SHIFT DRUM AND SHIFT FORKS
2 3

ENG

2. Install: S shift fork guide bars 1 S shift fork “L” 2 S shift fork “C” 3 S shift fork “R” 4
1

1

NOTE: S The embossed marks on the shift forks should face towards the left side of the engine and be in the following sequence: “L”, “C”, “R”. S The grooved side of the shift fork guide bar should face towards the right side of the engine. 3. Install: S shift drum retainer 1
10 Nm (1.0 mSkg)

LOCKTITER S shift fork guide bar retainer 2
10 Nm (1.0 mSkg)r

4-76

COOL 5 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP . . . . . . . INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .COOL CHAPTER 5 COOLING SYSTEM RADIATOR . INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE WATER PUMP . . . . . . . . . . . . 5-1 5-2 5-3 5-4 5-6 5-7 5-7 5-8 5-9 5-9 5-9 . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . .

COOL .

Refer to “CHANGING THE COOLANT” section in chapter 3.RADIATOR COOL COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg) Order Job name/Part name Removing the radiator Seat Fuel tank Drain the coolant Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. 1 2 3 4 5 Fan motor leads Radiator outlet hose Radiator inlet hose Radiator Fan 1 1 1 1 1 For installation. Refer to “FRONT COWLING/SEAT/SIDE COVER/FUEL TANK” section in chapter 3. NOTE: Disconnect the coupler. 5-1 .

Install the radiator cap tester 1 and adapter 2 to the radiator cap 3 . Refer to “COOLING SYSTEM” in chapter 8. Apply the specified pressure for ten seconds and make sure that there is no drop in pressure. Check: S radiator fan Damage ! Replace. Malfunction ! Check and repair.95 X 1. Check: S radiator hoses S radiator pipes Cracks/damage ! Replace. NOTE: Straighten any flattened fins with a thin. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Apply compressed air to the rear of the radiator. flathead screwdriver. Check: S radiator fins Obstruction ! Clean. Radiator cap opening pressure 95 X 125 kPa (0. 4. 2. 3.25 kg/cm2) a. Radiator cap tester 90890-01325 Adapter 90890-01352 b. Damage ! Repair or replace. 5-2 .RADIATOR EB500010 COOL CHECKING THE RADIATOR 1.

a. Check: S cooling system Leaks ! Repair or replace any faulty part.0 kg/cm2) of pressure. Measure the indicated pressure with the gauge. Attach the radiator cap tester 1 to the radiator.RADIATOR EB500020 COOL INSTALLING THE RADIATOR 1. 2. Radiator cap tester: 90890-01325 b. Apply 100 kPa (1. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. c. 5-3 .

Refer to “CHANGING THE COOLANT” section in chapter 3. NOTE: Disconnect the lead.0 mSkg) Order Job name/Part name Removing the thermostat Seat Fuel tank Drain the coolant Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. NOTE: Disconnect the coupler. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. 5-4 . 1 2 3 4 5 6 7 8 9 Thermo switch lead (engine temperature) Thermo switch lead (fan motor) Reservoir tank hose Carburetor inlet hose Engine outlet hose Engine outlet hose Radiator inlet hose Thermostat housing Ground read 1 1 1 1 1 1 1 1 1 For installation.THERMOSTAT THERMOSTAT COOL 10 Nm (1.

5-5 .8 mSkg) 10 Nm (1.3 mSkg) 8 Nm (0. For assembly.THERMOSTAT COOL 23 Nm (2. reverse the disassembly procedure. Refer to “ASSEMBLING THE THERMOSTAT” section.0 mSkg) Order 1 2 3 4 5 6 Job name/Part name Disassembling the thermostat Thermo switch (fan motor) Thermo switch (engine temperature) Thermostat housing cover O-ring Thermostat Thermostat housing Q’ty 1 1 1 1 1 1 Remarks Disassembly the parts in the order listed.

b. A faulty thermostat could cause serious overheating or overcooling. Check: S thermostat 1 Does not open at 80.5_ 95_C 2. Refer to “CHECKING THE RADIATOR”.5 X 83. replace it.5_X83.5_C ! Replace. 5-6 . Check: S thermostat housing cover O-ring S thermostat inlet pipe O-ring S thermostat inlet pipe S water pump outlet pipe Damage ! Replace. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. d. 4. While stirring the water. 3. c. observe the thermometer’s indicated temperature. Thermometer Water Thermostat Container A Closes B Opens 1 2 3 4 1 3 4 2 NOTE: If the accuracy of the thermostat is in doubt. Check: S thermostat housing cover 1 S thermostat housing 2 Cracks/damage ! Replace. Place a thermometer in the water. Suspend the thermostat in a container filled with water. a. 8 mm 80. Slowly heat the water.THERMOSTAT EB502021 COOL 1 CHECKING THE THERMOSTAT 1.

THERMOSTAT EB502030 COOL ASSEMBLING THE THERMOSTAT 1. 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 3.3 mSkg) S thermo switch (engine temperature) 2 8 Nm (0.8 mSkg) CAUTION: Use extreme care when handling the thermo switch and temperature sender. Refer to “CHECKING THE RADIATOR”. 3. EB502040 INSTALLING THE THERMOSTAT 1. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. 5-7 . 2. 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. Install: S thermo switch (fan motor) 1 23 Nm (2.

reverse the removal procedure. Refer to “REMOVING THE ENGINE” section in chapter 4.WATER PUMP WATER PUMP COOL 10 Nm (1. For installation. 5-8 . drive chain cover Q’ty Remarks Remove the parts in the order listed.0 mSkg) 10 Nm (1. Refer to “CHANGING THE COOLANT” section in chapter 3. 1 2 3 4 5 6 7 Radiator outlet hose Water pump outlet hose Water pump outlet pipe Water pump housing cover O-ring Water pump assembly O-ring 1 1 1 1 1 1 1 Refer to “REMOVING/INSTALLING THE WATER PUMP” section.0 mSkg) Order Job name/Part name Removing the water pump Drain the coolant Shift arm.

Check: S bearing 1 Roughness ! Replace. 3. Remove: S water pump housing 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. Check: S water pump inlet pipe S radiator outlet hose Cracks/damage/wear ! Replace.WATER PUMP EB503020 COOL REMOVING THE WATER PUMP 1. EB503052 INSTALLING THE WATER PUMP 1. Check: S water pump seal 1 S oil seal 2 Cracks/damage/wear ! Replace. 4. Check: S water pump housing cover S water pump housing 1 S impeller 2 2 2. EB503032 1 CHECKING THE WATER PUMP 1. Install: S water pump housing Always use a new O-ring 5-9 .

Check: S cooling system Leaks ! Repair or replace any faulty part. Refer to “CHECKING THE RADIATOR”. 2.0 mSkg) 3. 7. 6. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. S Before installing the water pump housing. Water pump housing cover bolt 10 Nm (1. Install: S water pump housing cover 1 S water pump outlet pipe 2 Always use a new gasket and O-rings. NOTE: Before installing the water pump outlet pipe.0 mSkg) 4. 5-10 . Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. Install: S shift arm 1 10 Nm (1. 5.WATER PUMP COOL a b NOTE: S Align the slot a on the impeller shaft with the projection b on the oil pump shaft. apply a thin coat of lithium soap base grease onto the O-rings. apply a thin coat of lithium soap base grease onto the O-ring. Install: S gasket S dowel pins S drive chain sprocket cover 1 10 Nm (1.0 mSkg) NOTE: Align the slot a on the shift arm 1 with the punch mark b on the shift shaft 2 .

CARB 6 .

. . . . . . . . . . . . 6-9 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 ASSEMBLING THE CARBURETORS . . . . . 6-8 MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARB CHAPTER 6 CARBURETORS CARBURETORS . . 6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARB .

CARBURETORS CARB CARBURETORS CARBURETORS AIR FILTER CASE Order Job name/Part name Removing the air filter case Seat. fueltank and sidecovers Q’ty Remarks Remove the parts in the order listed. 6-1 . Drain the coolant 1 2 3 4 5 Air filter case (left/right) Battery negative lead Battery positive lead Battery Stay 1/1 1 1 1 1 For installation. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. reverse the removal procedure. Refer to “CHANGING THE COOLANT” section.

6-2 .CARBURETORS CARBURETORS CARB Order Job name/Part name Removing the carburetors Throttle position sensor lead Air filter joint screw Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable Q’ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 4 4 1/1 1 1 2 For installation. reverse the removal procedure. NOTE: Disconnect the coupler.

#1. 6-3 . #4 Refer to “ASSEMBLING THE CARBURETERS” section. #3. #2.CARBURETORS CARB Order 1 2 3 4 5 6 7 8 9 10 11 12 Job name/Part name Disassembling the carburetors Starter plunger link Carburetors assembly Vacuum chamber cover Piston valve spring Piston valve Needle kit Float chamber Float chamber gasket Float pin Float Needle valve assembly Main jet Q’ty 1 4 1 1 1 1 1 1 1 1 1 1 Remarks Disassembly the parts in the order listed.

For assembly. 6-4 . reverse the disassembly procedure.CARBURETORS CARB Order 13 14 15 16 17 Job name/Part name Main jet holder Needle jet Pilot jet Pilot screw set Starter plunger kit Q’ty 1 1 1 1 1 Remarks Refer to “ASSEMBLING THE CARBURETORS” section.

Check: S needle valve 1 S needle valve seat 2 Damage/obstruction/wear ! Replace the needle valve. Check: S carburetor body S float chamber S main jet holder Cracks/damage ! Replace. b. Do not use any caustic-carburetor-cleaning solution. 2. needle valve seat and O-ring as a set. 3. 1. 5. Blow out all of the passages and jets with compressed air. a. Wash the carburetor in a petroleumbased solvent. 4. 6-5 . 7. needle valve seat and O-ring as a set.CARBURETORS EB600031 CARB CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 6. Check: S float chamber rubber gasket 2 Cracks/damage/wear ! Replace. Check: S O-ring 3 Damage/wear ! Replace the needle valve. Check: S float chamber body 1 Dirt ! Clean. Check: S float 1 Damage ! Replace. Check: S fuel passages Obstruction ! Clean.

Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S pilot jet 4 S pilot screw 5 S starter plunger 6 Bends/damage/wear ! Replace. 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. 11. 10. Obstruction ! Clean. Check: S fuel feed pipes S hose joint Cracks/damage ! Replace. Obstruction ! Clean. S rubber diaphragm 2 Cracks/tears ! Replace. Check: S piston valve 1 Damage/scratches/wear ! Replace. Check: S fuel hoses Cracks/damage/wear ! Replace. 9. 12. Blow out the hoses with compressed air. 6-6 . Blow out the jets with compressed air. Obstruction ! Clean. 13. Tightness ! Replace the piston valve.CARBURETORS CARB 8.

CAUTION: S Before assembling the carburetors.CARBURETORS EB600041 CARB ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. Install: S O-ring (New) S washer S pilot screw spring S pilot screw 1 Pilot screw 2 turns out 2.5 mm) Standard clip position: No. S Always use a new gasket. Install: S jet needle 1 S washer 2 (0. S Align the tab on the piston valve diaphragm with the recess in the carburetor body. 6-7 . Install: S piston valve S jet needle kit 1 S jet needle holder 2 S piston valve spring 3 S vacuum chamber cover NOTE: S Insert the end of the piston valve spring onto the spring guide on the vacuum chamber cover.5 mm) S ring 3 S clip 4 S washer 5 (0. 3 Groove 3. 1. wash all of the parts in a petroleumbased solvent.

and #4 between the spring 10 and synchronizing screw 11 . tighten the connecting bolts while pushing down the carburetor assembly with an even force. Adjust: S engine idling speed Engine idling speed 1.CARBURETORS CARB 4.250 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. S Install the throttle arm 9 onto carburetors #1. 6-8 . S After tightening the connecting bolts. EB600051 INSTALLING THE CARBURETORS 1. check that the throttle cable lever and starter plunger link operate smoothly.150 X 1. S Place the carburetor assembly on a surface plate with the intake manifold side down. Adjust: S throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Install: S fuel feed joints 1 S hose joints 2 S spacer 3 S connecting bolt 4 S starter plunger link 5 S throttle cable holder 6 S spacer 7 S connecting bolt 8 NOTE: S Do not tighten the connecting bolts yet. Adjust: S carburetor synchronization Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3. S Install the starter plunger link onto each starter plunger. #2. 3. 2. Then.

Hold the fuel level gauge vertically next to the float chamber. Install the fuel level gauge 1 to the fuel drain pipe 2 . If either is worn. b. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. 6-9 . NOTE: Fuel level readings should be equal on both sides of the carburetor assembly. Fuel level gauge 90890-01312 3 2 d.5 mm a. Check the needle valve seat and needle valve. Measure: S fuel level a Out of specification ! Adjust Fuel level (above the float chamber mating surface) 4. g.CARBURETORS EB600062 CARB MEASURING AND ADJUSTING THE FUEL LEVEL 1. Adjust: S fuel level a. f. c. If both are fine. Repeat steps (a) to (f) until the fuel level is within specification. Loosen the fuel drain screw 3 . c. Measure the fuel level again. f. d. Install the carburetor assembly. replace them as a set. Remove the carburetor assembly. e. e. 2. b. adjust the float level by slightly bending the float tang 1 . Measure the fuel level a .

Check the throttle position sensor maximum resistance. Connect the pocket tester (Ω 1k) to the throttle position sensor. Connect the pocket tester (Ω 1k) to the throttle position sensor. 1. b. Refer to the adjustment procedure below. Check: S throttle position sensor a. Tester positive lead ! YELLOW 3 Tester negative lead ! BLACK/BLUE 2 f.5 X 6. Disconnect the throttle position sensor coupler. e. Tester positive lead ! BLUE 1 Tester negative lead ! BLACK/BLUE 2 c. check that the throttle position sensor resistance is within the specified range. Out of specification ! Replace the throttle position sensor. Turn the main switch to “ON”. Out of specification ! Replace the throttle position sensor. Install the throttle position sensor onto the carburetor. 6-10 . Adjust: S throttle position sensor angle a. adjust its angle according to the RPM which is displayed on the tachometer. S When installing the throttle position sensor. the engine idling speed should be properly adjusted.5 kΩ at 20_C (BLUE — BLACK/BLUE) d. Throttle position sensor maximum resistance 3.5 kΩ at 20_C (YELLOW — BLACK/BLUE) 2. While slowly opening the throttle. Throttle position sensor resistance 0 X 5 ± 1.CARBURETORS EB600070 CARB CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor.

c.CARBURETORS CARB b. tighten the throttle position sensor screws. Loosen the throttle position sensor screws 1 . e. 2 NOTE: To exit the throttle position sensor adjustment mode. d. Tachometer Reading 5000 rpm 1 3 0 rpm 2 10000 rpm 3 Throttle position sensor angle Correct Incorrect Incorrect Adjustment direction —— a b f. Adjust the throttle position sensor angle according to the following table: NOTE: The angle of the throttle position sensor is indicated by the RPM which is displayed on the tachometer. start the engine or turn the main switch to “OFF”. NOTE: After reconnecting the throttle position sensor coupler. Reconnect the throttle position sensor coupler. After adjusting the throttle position sensor angle. 6-11 . the tachometer switches to the throttle position sensor adjustment mode. Disconnect the throttle position sensor coupler.

CARB 6-12 .

CHAS 7 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 ASSEMBLING THE FRONT FORK LEGS . . . . . . 7-11 CHECKING AND REPLACING THE REAR WHEEL SPROCKET . . . 7-27 FRONT BRAKE CALIPERS . . . . . . . . . . . 7-1 FRONT WHEEL . . . . . . . . . . . . . . . 7-15 REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . 7-26 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 DISASSEMBLING THE FRONT FORK LEGS . . 7-14 FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 FRONT AND REAR BRAKES . . . . . . . . . . . . . . . 7-12 ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . .CHAS CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 7-45 INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . 7-33 DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 REMOVING THE REAR BREAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 DISASSEMBLY THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 CHECKING THE HANDLEBAR . . . . . 7-47 HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . 7-34 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . 7-8 BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 REMOVING THE FRONT WHEEL . . . . 7-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . 7-16 REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . 7-48 REMOVING THE HANDLEBAR . . . 7-7 REAR WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . 7-18 FRONT BRAKE MASTER CYLINDER . . . . 7-29 REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . 7-14 REAR BRAKE PADS . . . . . . . . . . 7-3 CHECKING THE BRAKE DISCS . . . . . . . . . 7-51 . . . . . . . . . . . . . . . . . 7-37 FRONT FORK . 7-31 DISASSEMBLING THE FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . 7-10 REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 INSTALLING THE REAR WHEEL . . . . . . . . 7-8 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . INSTALLING THE DRIVE CHAIN . . . . . . . . .CHAS STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET . . . . . . SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . 7-53 7-53 7-55 7-55 7-56 7-57 7-59 7-59 7-60 7-61 7-61 7-62 7-64 7-65 7-66 7-67 7-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND RELAY ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 .7 mSkg) 20 Nm (2.3 mSkg) Order Job name/Part name Removing the flont wheel and brake discs Wheel axle pinch bolt Brake hose horder (left/right) Brake caliper (left/right) Wheel axle Front wheel assembly Speed sensor unit Collar Brake disc (left/right) Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. For installation.0 mSkg) 23 Nm(2.0 mSkg) 67 Nm (6. 1 2 3 4 5 6 7 8 1 1/1 1/1 1 1 1 1 1/1 NOTE: Loosen Refer to “REMOVING/INSTALLING THE FRONT WHEEL” section.FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC 40 Nm(4.

7-2 . For assembly.FRONT WHEEL AND BRAKE DISC FRONT WHEEL CHAS Order 1 2 3 4 Job name/Part name Disassembling the front wheel Oil seal Bearing Spacer Bearing Q’ty 1 1 1 1 Remarks Disassembly the parts in the order listed. reverse the disassembly prodedure.

Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. Remove: S Wheel axle S Speed sensor unit 1 CAUTION: Push the front wheel rearward and remove the speed sensor unit 1 from the front wheel. Elevate: S front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Remove: S wheel axle pinch bolt S brake hose holder (left/right) 3. 7-3 . Refer to “CHECKING THE TIRES” and ”!CHECKING THE WHEELS” in chapter 3. 5. Check: S tire S front wheel Damage/wear ! Replace. EB700400 CHECKING THE FRONT WHEEL 1.FRONT WHEEL AND BRAKE DISC EB700102 CHAS REMOVING THE FRONT WHEEL 1. Measure: S wheel axle runout Wheel axle runout <Limit> 0. 2. Remove: S left brake caliper S right brake caliper NOTE: Do not squeeze the brake lever when removing the brake calipers. 4. 2.25 mm Do not attempt to straighten a bent wheel axle.

Contact should be made only with the outer race 7 . b. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. 7-4 . S oil seals Damage/wear ! Replace. d. Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0. NOTE: Use a socket 8 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. place a rag 2 between the screwdriver and the wheel surface. NOTE: To prevent damaging the wheel. CAUTION: Do not contact the wheel bearing center race 5 or balls 6 . Check: S wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. 5. c.FRONT WHEEL AND BRAKE DISC 2 1 CHAS 3. Clean the outside of the front wheel hub.5 mm 4. Replace: S wheel bearings (New) S oil seals (New) a. Remove the oil seals 1 with a flat-head screwdriver. Remove the wheel bearings 3 with a general bearing puller 4 .

Before measuring the front brake disc deflection. Out of specification ! Replace. Measure the deflection 2 X 3 mm below the edge of the brake disc. 3.5 mm Rear: 4. Remove the brake caliper. If out of specification. If the brake disc deflection cannot be brought within specification. Place the motorcycle on a suitable stand so that the wheel is elevated. 2. Measure: S brake disc thickness b Measure the brake disc thickness at a few different locations. Rotate the brake disc by one bolt hole. Brake disc thickness limit (minimum) Front: 3.3 mSkg) d.15 mm a. replace the brake disc. 7-5 . Measure the brake disc deflection. Measure: S brake disc deflection a Out of specification ! Correct the brake disc deflection or replace the brake disc. NOTE: Tighten the brake disc bolts 1 in stages and in a crisscross pattern. turn the handlebar to the left or right to ensure that the front wheel is stationary. b. c. d. Adjust: S brake disc deflection a. Remove the brake disc.FRONT WHEEL AND BRAKE DISC EB700414 CHAS CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. b. 1. Check: S brake disc Damage/galling ! Replace. Install the brake disc. Hold the dial gauge at a right angle against the brake disc surface. Brake disc deflection limit (maximum) Front: 0. repeat the adjustment steps until the brake disc deflection is within specification. e. f.5 mm 4. e.2 mm Rear: 0. Brake disc bolt LOCKTITER 23 Nm (2. c.

push down hard on the handlebar several times and check if the front fork rebounds smoothly. 4. Install: S Speed sensor unit NOTE: Make sure that the speed sensor unit and the wheel hud are installed with the two projections a meshed into the two slots b respectively. 7-6 . Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: S wheel axle S wheel axle pinch bolt S brake caliper bolts Wheel axle 67 Nm (6.0 mSkg) Brake caliper bolt 40 Nm (4. 3.7 mSkg) Wheel axle pinch bolt 20 Nm (2. Install: S front wheel NOTE: Make sure that the slot a in the speed sensor unit fits over the stopper on the outer tube b .0 mSkg) Make sure that the brake cable is routed properly.FRONT WHEEL AND BRAKE DISC EB700722 CHAS INSTALLING THE FRONT WHEEL 1. CAUTION: Before tightening the wheel axle nut.

Remove: S balancing weight(-s) X1 B NOTE: Place the front wheel on a suitable balancing stand. Turn the front wheel 90_ so that the “X1” mark is positioned as shown A . If the heavy spot does not stay in that position. When the front wheel stops. e. 7-7 . When the wheel stops. X NOTE: Start with the lightest weight. c. b. rebalance it. f. g. Check: S front wheel static balance a. Repeat steps (b) through (d) several times until all the marks come to rest at the same spot. 4. Turn the front wheel and make sure that it stays at each position shown. wheel or both. 3. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. put an “X2” mark at the bottom of the wheel B . d. put an “X1” mark at the bottom of the wheel. Release the front wheel. b. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X” C . the front wheel static balance should be adjusted. Spin the front wheel b.FRONT WHEEL AND BRAKE DISC A EB700901 CHAS ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire. S Adjust the front wheel static balance with the brake discs installed. Turn the front wheel 90_ so that the heavy spot is positioned as shown D . Repeat steps (b) and (c) until the front wheel is balanced. 1. install a heavier weight. If the front wheel does not remain stationary at all of the positions. Adjust: S front wheel static balance C D a. Find: S front wheel’s heavy spot a. c. 2. d.

REAR WHEEL.7 mSkg) 40 Nm (4. BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL CHAS REAR WHEEL. reverse the removal procedure. Refer to “REMOVING/INSTALLING THE REAR WHEEL” section. 7-8 .0 mSkg) Order 1 2 3 4 5 6 7 8 Job name/Part name Removing the rear wheel Brake caliper Nut Washer Wheel axle Washer Drive chain puller (left) Drive chain puller (right) Rear wheel assembly Q’ty 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. BRAKE DISC AND REAR WHEEL SPROCKET 117 Nm (11. For installation.

0 mSkg) 23 Nm (2. 1 2 3 4 5 6 7 8 1/1 1 1 1 6 1 1 1 For instalation. reverse the removal procedure.3 mSkg) Order Job name/Part name Removing the brake disk and rear wheel sprocket Collar (left/right) Brake disc Rear wheel sprocket Collar Drive hub damper Rear wheel drive hub Oil seal Bearing Q’ty Remarks Remove the parts in the order listed. 7-9 .REAR WHEEL. BRAKE DISC AND REAR WHEEL SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET CHAS 60 Nm (6.

For assembly. reverse the disassembly procedure. BRAKE DISC AND REAR WHEEL SPROCKET DIASSEMBLY THE REAR WHEEL CHAS Order 1 2 3 4 Job name/Part name Disassembling the rear wheel Oil seal Bearing Collar Bearing Q’ty 1 1 1 1 Remarks Disassembly the parts in the order listed. 7-10 .REAR WHEEL.

7-11 . that there is no danger of it falling over. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. BRAKE DISC AND REAR WHEEL SPROCKET EB701100 CHAS REMOVING THE REAR WHEEL 1. Remove: S left collar 1 S rear wheel drive hub 2 S rear wheel drive hub damper 3 S right collar EB701400 CHECKING THE REAR WHEEL 1. Remove: S wheel axle nut 3 S wheel axle 4 S rear wheel NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. 5. Securely support the motorcycle so. Loosen: S locknut 1 S adjusting nut 2 4.REAR WHEEL. 3 2 1 1 3. 2. Stand the motorcycle on a level surface. Remove: S brake caliper 1 NOTE: Do not depress the brake pedal when removing the brake caliper. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to “FRONT WHEEL AND BRAKE DISC” 2. Check: S tire S rear wheel Damage/wear ! Replace.

Replace: S rear wheel sprocket 1 a.7 mSkg) Brake caliper bolt 40 Nm (4. Clean the rear wheel drive hub with a clean cloth. BRAKE DISC AND REAR WHEEL SPROCKET CHAS 3. Install the new rear wheel sprocket. EB701440 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. especially the surfaces that contact the sprocket. Bent teeth ! Replace the rear wheel sprocket. Check: S rear wheel sprocket More than 1/4 tooth a wear ! Replace the rear wheel sprocket. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2.REAR WHEEL. EB701711 INSTALLING THE REAR WHEEL 1. b. Measure: S rear wheel radial runout S rear wheel lateral runout Refer to “FRONT WHEEL AND BRAKE DISC”. S correct b S drive chain roller 1 S rear wheel sprocket 2 2. Remove the self-locking nuts and the rear wheel sprocket.0 mSkg) 7-12 . Rear wheel sprocket self-locking nut 60 Nm (6. c.0 mSkg) NOTE: Tighten the self-locking nuts 2 in stages and in a crisscross pattern. Tighten: S wheel axle nut S brake caliper bolts Wheel axle nut 117 Nm (11.

the rear wheel static balance should be adjusted. 1.REAR WHEEL. wheel or both. BRAKE DISC AND REAR WHEEL SPROCKET EB701900 CHAS ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire. 7-13 . S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. Adjust: S rear wheel static balance Refer to “FRONT WHEEL AND BRAKE DISC”.

0 mSkg) Order 1 2 3 4 5 Job name/Part name Removing the front brake pads Brake caliper Brake pads clip Brake pad pin Brake pad spring Brake pad Q’ty 1 2 1 1 2 Remarks Remove the parts in the order listed. reverse the removal procedure.FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS CHAS 40 Nm (4. Refer to “REPLACING THE FRONT BRAKE PADS” section. For installation. 7-14 .

7-15 .0 mSkg) 40 Nm (4. For instalation. reverse the removal procedure.FRONT AND REAR BRAKES REAR BRAKE PADS CHAS 10 Nm (1.0 mSkg) Order 1 2 3 4 Job name/Part name Removing the rear brake pads Caliper Brake pad pin Brake pad/shim Brake pad spring Q’ty 1 2 2/2 1 Remarks Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PADS” section.

S Brake fluid may damage painted surfaces and plastic parts. and bled after reassembly. First aid for brake fluid entering the eyes: S Flush with water for 15 minutes and get immediate medical attention. NOTE: When replacing the brake pads. S Use only clean or new brake fluid for cleaning brake components. S If any connection on the hydraulic brake system is disconnected. Remove: S brake hose holder 1 S speedometer cable guide 2 S brake caliper 3 2. always clean up any spilt fluid immediately. properly filled. S Never use solvents on internal brake components. always follow these preventive measures: S Never disassemble brake components unless absolutely necessary. it is not necessary to disconnect the brake hose or disassemble the brake caliper. drained. Remove: S brake pad clips 1 S brake pad pins 2 S brake pad spring 3 7-16 . Tehrefore. 1. cleaned. the entire brake system must be disassembled.FRONT AND REAR BRAKES EB702100 CHAS CAUTION: Disc brake componets rarely require disassembly. S Avoid brake fluid coming into contact with the eyes as it can cause serious injury. EB702112 REPLACING THE FRONT BRAKES PADS The following procedure applies to both brake calipers. Therefore.

b. Install: S brake pad spring S brake pad pins 1 S brake pad clips 2 S brake caliper 40 Nm (4. Connect a clear plastic hose 1 tightly to the bleed screw 2 . brake pad shims. and a brake pad spring as a set. 7-17 . Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. 8.5 mm 5. Put the other end of the hose into an open container. 7. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads. 6 Nm (0. Install new brake pad shims onto the new brake pads.6 mSkg) d. e. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. Tighten the bleed screw. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. 6.0 mSkg) NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. Remove: S brake pads 1 (along with the brake pad shims) 4. a. Brake pad wear limit 0. c. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.FRONT AND REAR BRAKES CHAS 3. Install new brake pads and a new brake pad spring.

a. 7-18 . Put the other end of the hose into an open container. 6 Nm (6 mSkg) d. Install a new brake pad shim 3 onto each new brake pad 4 . Brake pad wear limit 0. Install S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. brake pad shims.5 mm 5. Connect a clear plastic hose 1 tightly to the bleed screw 2 .FRONT AND REAR BRAKES EB702113 CHAS REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads. Remove: S brake pad pins 1 3. Remove: S brake caliper 1 2. it is not necessary to disconnect the brake hose or disassemble the brake caliper. and a brake pad spring as a set. c. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Install new brake pads and a new brake pad spring. 1. Remove: S brake pads 2 (along with the brake pad shims) S brake pad spring 4. Tighten the bleed screw. e. b.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.0 mSkg) 40 Nm (4.0 mSkg) 7.FRONT AND REAR BRAKES 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7-19 . Install: S brake pad pins 1 S brake caliper CHAS 10 Nm (1. 8. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system.

0 mSkg) Order Job name/Part name Removing the front brake master cylinder Drain the brake fluid Brake lever Brake switch lead Brake switch Union bolt Copper washer/brake hose Master cylinder bracket Master cylinder Q’ty Remarks Remove the parts in the order listed. For installation. 1 2 3 4 5 6 7 1 2 1 1 2/1 1 1 Refer to “REMOVING/ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER” section.FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER CHAS 10 Nm(1. 7-20 .0 mSkg) 30 Nm(3. reverse the removal procedure.

reverse the disassembly procedure. 1 2 3 4 1 1 1 1 For assembly.FRONT AND REAR BRAKES CHAS Order Job name/Part name Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring Q’ty Remarks Disassembly the parts in the order listed. 7-21 .

reverse the removal procedure.0 mSkg) 4 Nm(0.3 mSkg) Order Job name/Part name Removing the rear brake master cylinder Side cover (right) Drain the brake fluid Master cylinder bolt Union bolt Copper washer/brake hose Clip/hose Cotter pin Pin Washer Master cylinder Q’ty Remarks Remove the parts in the order listed.FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER CHAS 30 Nm(3. For installation. 1 2 3 4 5 6 7 8 2 1 2/1 2/1 1 1 1 1 Refer to “REMOVING/ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER” section.4 mSkg) 23 Nm(2. 7-22 .

reverse the disassembly procedure. 7-23 . 1 2 3 4 1 1 1 1 For assembly.FRONT AND REAR BRAKES CHAS Order Job name/Part name Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring Q’ty Remarks Disassembly the parts in the order listed.

1. Remove: S union bolt 2 S copper washers 3 S brake hoses 4 NOTE: To collect any remaining brake fluid. 7-24 . Disconnect: S brake switch coupler 1 (from the brake switch) 2. drain the brake fluid from the entire brake system. place a container under the master cylinder and the end of the brake hose. place a container under the master cylinder and the end of the brake hose. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: To collect any remaining brake fluid. Remove: S side cover right 2.FRONT AND REAR BRAKES EB702210 CHAS REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Befor disassembling the front brake master cylinder. EB702220 REMOVING THE REAR BRAKE MASTER CYLINDER 1.

Check: S brake master cylinder kit 1 Damage/scratches/wear ! Replace. 4. Check S front brake master cylinder diaphragm 1 Damage/wear ! Replace. 7-25 . A Front B Rear 2.FRONT AND REAR BRAKES A B EB702242 CHAS C D CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S rear brake fluid reservoir 1 Cracks/damage ! Replace. 5. Check: S brake master cylinder Damage/scratches/wea ! Replace. C Front D Rear 3. Check: S brake hoses 1 Cracks/damage/wear ! Replace. S rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.

FRONT AND REAR BRAKES EB702270 CHAS ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER S Before installation. Refer to “CABLE ROUTING”. make sure that the brake pipe touches the projection a on the brake master cylinder.0 mSkg) S union bolt 3 a Proper brake hose routing is essential to insure safe motorcycle operation. causing leakage and poor brake performance. Recommended brake fluid DOT 4 1. Other brake fluids may cause the rubber seals to deteriorate. tighten the union bolt as shown. S Never use solvents on internal brake components. 7-26 . leading to poor brake performance. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 S Use only the designated brake fluid. Mixing brake fluids may result in a harmful chemical reaction. wire harness. Install: S copper washers (New) 1 S brake hose 2 30 Nm (3. all internal brake components should be cleaned and lubricated with clean or new brake fluid.g. S Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts (e. be careful that water does not enter the reservoir. CAUTION: When installing the brake hose onto the brake master cylinder. NOTE: S While holding the brake hose. S When refilling. 2. S Refill with the same type of brake fluid that is already in the system. Correct if necessary. leads). cables.

make sure that the brake pipe touches the projection a on the brake master cylinder. Refer to “CABLE ROUTING”. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Fill: S brake fluid reservoir (to the maximum level mark a ) Recommended brake fluid DOT 4 7-27 . Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.0 mSkg) S union bolt 3 CAUTION: When installing the brake hose onto the brake master cylinder.FRONT AND REAR BRAKES CAUTION: CHAS Brake fluid may damage painted surfaces and plastic parts. Install: S copper washers (New) 1 S brake hose 2 30 Nm (3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. always clean up any spilt brake fluid immediately. 4. 2. 3. EB702292 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. 5. Therefore. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. Proper brake hose routing is essential to insure safe motorcycle operation.

S Refill with the same type of brake fluid that is already in the system. Therefore.6 mm 6.FRONT AND REAR BRAKES CHAS S Use only the designated brake fluid. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. 4. 3. causing leakage and poor brake performance. THE REAR Brake pedal position (below the top of the rider footrest) 36. always clean up any spilt brake fluid immediately. 5. Adjust: S brake pedal position a Refer to “ADJUSTING BRAKE” in chapter 3. Mixing brake fluids may result in a harmful chemical reaction. 7-28 . Adjust: S rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LICHT SWITCH” in chapter 3. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Other brake fluids may cause the rubber seals to deteriorate. be careful that water does not enter the reservoir. S When refilling. leading to poor brake performance. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. CAUTION: Brake fluid may damage painted surfaces and plastic parts.

reverse the removal procedure. 1 2 3 4 1 2 1 1 Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS” section. 7-29 . For installation.FRONT AND REAR BRAKES FRONT BRAKE CALIPERS CHAS 40 Nm(4.0 mSkg) Order Job name/Part name Removing the front brake calipers Drain the brake fluid Union bolt Copper washer Brake hose Brake caliper assembly Q’ty Remarks Remove the parts in the order listed.0 mSkg) 30 Nm(3.

FRONT AND REAR BRAKES CHAS Order Job name/Part name Disassembling the front brake calipers Clip Pad pin Brake pad spring Brake pad Bleed screw kit Brake caliper piston Dust seal Piston seal Q’ty Remarks Disassembly the parts in the order listed. reverse the disassembly procedure. For assembly. 7-30 . Refer to “DISASSEMBLING THE FRONT BRAKE CALIPER” section. 1 2 3 4 5 6 7 8 2 1 1 2 1 4 4 4 Refer to “REPLACING THE FRONT BRAKE PADS” section.

1 2 3 4 1 2 1 1 Refer to “ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER” section.0 mSkg) Order Job name/Part name Removing the rear brake caliper Drain the brake fluid Union bolt Copper washer Brake hose Rear brake caliper Q’ty Remarks Remove the parts in the order listed.FRONT AND REAR BRAKES REAR BRAKE CALIPER CHAS 30 Nm(3. revers the removal procedure. For installation. 7-31 .0 mSkg) 40 Nm(4.

For assembly. reverse the disassembly procedure.FRONT AND REAR BRAKES CHAS 10 Nm (1. Disassembling the rear brake caliper Pad pin 2 Pad spring 1 Brake pad assembly/shim 2/2 Bleed screw kit 2 Brake caliper piston 2 Dust seal 2 Piston seal 2 7-32 . Refer to “DISASSEMBLING THE REAR BRAKE CARIPER” section.0 mSkg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Remarks Disassembly the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PAD” section.

Repeat the previous steps to force out the right side pistons from the brake caliper. c. NOTE: Before disassembling either brake caliper. d. Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper. 1. S Do not remove the plugs 4 . Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a. Secure the right side brake caliper pistons with a piece of wood a b. drain the brake fluid from the entire brake system. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2.FRONT AND REAR BRAKES EB702317 CHAS DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 7-33 . Remove the brake caliper piston seals. S Never try to pry out the caliper pistons.

EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads Piston seals Brake fluid If necessary Every two years Every two years and whenever the brake is disassembled. S Never try to pry out the brake caliper pistons. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a. 1. Secure the right side brake caliper piston with a piece of wood a b. 2. d. c.FRONT AND REAR BRAKES EB702322 CHAS DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. drain the brake fluid from the entire brake system. Remove the brake caliper piston seals. Brake hoses Every four years 7-34 . Repeat the previous steps to force out the right side piston from the brake caliper. Blow compressed air into the brake hose joint opening b to force out the left side piston from the brake caliper. S Do not loosen the bolts 3 .

Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. Recommended brake fluid DOT 4 1. S brake calipers 3 Cracks/damage ! Replace. Install: S brake caliper 1 (temporarily) S copper washers (New) 2 S brake hose 3 30 Nm (30 mSkg) S union bolt 4 Proper brake hose routing is essential to insure safe motorcycle operation. EB702374 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. S brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. replace the brake caliper piston seals. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. replace the brake caliper piston seals. all internal brake components should be cleaned and lubricated with clean or new brake fluid. A Front B Rear 2. S Before installation. 7-35 . Check: S brake caliper brackets 1 Cracks/damage ! Replace. S Whenever a brake caliper is disassembled. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air. Whenever a brake caliper is disassembled.FRONT AND REAR BRAKES A CHAS B 1. Refer to “CABLE ROUTING”.

always clean up any spilt brake fluid immediately. 7-36 . Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. make sure that the brake pipe a touches the projection a on the brake caliper. Install: S brake pads S brake spring S brake caliper pins S brake caliper clips S brake caliper S brake hose holder Refer to “REPLACING THE BRAKE PADS”. 2. Other brake fluids may cause the rubber seals to deteriorate. Mixing brake fluids may result in a harmful chemical reaction. Brake caliper bolt 40 Nm (40 mSkg) 4. Remove: S brake caliper 3. S When refilling. leading to poor brake performance. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 S Use only the designated brake fluid. CAUTION: Brake fluid may damage painted surfaces and plastic parts.FRONT AND REAR BRAKES CAUTION: CHAS When installing the brake hose onto the brake caliper. S Refill with the same type of brake fluid that is already in the system. be careful that water does not enter the reservoir. Therefore. causing leakage and poor brake performance.

0 mSkg) S union bolt 3 1 3 2 Proper brake hose routing is essential to insure safe motorcycle operation. Recommended brake fluid DOT 4 1. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. EB702378 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER S Before installation. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort.FRONT AND REAR BRAKES CHAS 5. 6. CAUTION: When installing the brake hose onto the brake caliper. S Whenever a brake caliper is disassembled. 7-37 . Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. all internal brake components should be cleaned and lubricated with clean or new brake fluid. 7. Refer to “CABLE ROUTING”. replace the brake caliper piston seals. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. Install: S brake caliper 1 (temporarily) S copper washers (New) S brake hose 2 30 Nm (3. make sure that the brake pipe a slot the projection a on the brake caliper. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

always clean up any spilt brake fluid immediately. leading to poor brake performance. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Install: S brake pad spring S brake pads S brake pad pins S brake caliper S brake hose holder Refer to “REPLACING THE BRAKE PADS”. S Refill with the same type of brake fluid that is already in the system. Therefore.0 mSkg) 4. Fill: S brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 S Use only the designated brake fluid. causing leakage and poor brake performance. S When refilling. 7-38 .0 mSkg) Brake caliper bolt 40 Nm (4. 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.FRONT AND REAR BRAKES CHAS 2. be careful that water does not enter the reservoir. Mixing brake fluids may result in a harmful chemical reaction. Brake caliper pad pin 10 Nm (1. 5. Remove: S brake caliper 3. CAUTION: Brake fluid may damage painted surfaces and plastic parts.

Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7-39 .FRONT AND REAR BRAKES CHAS 6. Check: S brake pedal operation Soft or spongy feeling ! Bleed the brake system. 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

7 mSkg) Order Job name/Part name Removing the front fork Front wheel Front brake calipers Q’ty Remarks Remove the parts in the order listed.0 mSkg) 7 Nm (0. Refer to “FRONT AND REAR BRAKES” section. 1 2 3 4 5 Front fender Bolt (upper bracket) Cap bolt Bolt (lower bracket) Front fork assembly (left/right) 1 2 2 2 NOTE: Loosen NOTE: Loosen NOTE: Loosen 1/1 Refer to “REMOVING/INSTALLING THE FRONT FORK LEGS” section. reverse the removal procedure.0 mSkg) 30 Nm (3. For installation. 7-40 .FRONT FORK FRONT FORK CHAS 30 Nm (3. Refer to “FRONT WHEEL AND BRAKE DISCS” section. Refer to “REMOVING/ INSTALLING THE FRONT FORK LEGS” section.

Refer to “ASSEMBLING THE FRONT FORK LEGS” section.0 mSkg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Disassembling the front fork Cap bolt O-ring Spacer Washer Front fork spring Dust seal Oil seal clip Bolt Gasket Damper rod/rebound spring Inner tube/Inner tube bushing Oil seal Washer Q’ty 1 1 1 1 1 1 1 1 1 1/1 1 1 1 Remarks Disassembly the parts in the order listed.FRONT FORK CHAS 23 Nm (2. 7-41 .3 mSkg) 15 6 7 12 13 14 10 11 9 8 30 Nm (3. Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS” section.

0 mSkg) Order 14 15 Job name/Part name Outer tube bushing Oil flow stopper Q’ty 1 1/1 Remarks Refer to “ASSEMBLING THE FRONT FORK LEGS” section.3 mSkg) 15 6 7 12 13 14 10 11 9 8 30 Nm (3. For assembly. reverse the disassembly procedure. 7-42 .FRONT FORK CHAS 23 Nm (2.

2. Damper rod holder 90890-01460 T-Handle 90890-01326 7-43 . 1. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 2. Remove: S damper rod bolt NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 . 3.FRONT FORK EB703100 CHAS REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. support the front fork leg. Remove: S front fork leg EB703110 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. loosen the damper rod bolt. Loosen: S upper bracket pinch bolt 1 S cap bolt 2 S lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts. 1.

Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. Measure: S spring free length a Over the specified limit ! Replace. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. Hold the front fork leg horizontally. 1. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. Remove: S inner tube CHAS a. S Avoid bottoming the inner tube into the outer tube during the above procedure. EB703401 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. do not allow any foreign material to enter the front fork. b. which are particularly sensitive to foreign material. Securely clamp the brake caliper bracket in a vise with soft jaws. Check: S damper rod 1 Damage/wear ! Replace. Spring free length limit 319 mm 3. S When disassembling and assembling the front fork leg. CAUTION: S Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. Obstruction ! Blow out all of the oil passages with compressed air.FRONT FORK 3. CAUTION: S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction. as the oil flow stopper will be damaged. c. 7-44 . 2. S oil flow stopper Damage/wear ! Replace.

Damper rod holder 90890-01460 T-handle 90890-01326 7-45 . 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 2.FRONT FORK CHAS 4. EB703700 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. S Make sure that the oil levels in both front fork legs are equal. Check: S cap bolt O-ring Damage/wear ! Replace. Tighten: S damper rod bolt 1 30 Nm (3. Lubricate: S inner tube’s outer surface Recommended lubricant Fork oil 10 W or equivalent 3. make sure that all of the components are clean. 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.0 mSkg) NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3 . 1. Be careful not to damage the inner tube. NOTE: S When assembling the front fork leg. tighten the damper rod bolt. S Uneven oil levels can result in poor handling and a loss of stability.

Install: S outer tube bushing 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 5. NOTE: S Before installing the oil seal. with the inner tube fully compressed and without the fork spring) 121 mm 7-46 . S Apply fork oil onto the outer surface of the inner tube. faces up. Install: S washer S oil seal 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 CAUTION: Make sure that the numbered side of the oil seal.475 L Yamaha fork and shock oil 10 W or equivalent. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0. Front fork leg oil level a (from the top of the inner tube. Install: S oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 6.FRONT FORK CHAS 4. apply lithium soap base grease onto its lips. 7. Install: S dust seal 1 (with the fork seal driver weight) 1 Fork seal driver weight 90890-01367 8.

1. keep it upright. S After filling. 9. S Temporarily tighten the cap bolt. S Before installing the cap bolt.3 mSkg) Upper bracket pinch bolt 30 Nm (3.0 mSkg) Cap bolt 23 Nm (2. slowly pump the front fork leg up and down to distribute the fork oil. Tighten: S lower bracket pinch bolt 1 S cap bolt 2 S upper bracket pinch bolt 3 Lower bracket pinch bolt 30 Nm (3. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt NOTE: S Install the spring with the smaller pitch facing up. 2. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts.FRONT FORK CHAS NOTE: S While filling the front fork leg. apply grease onto the O-ring. 7-47 . NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.0 mSkg) Make sure that the brake hoses are routed properly. EB703710 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

7-48 .HANDLEBAR HANDLEBAR CHAS 10 Nm (1. Refer to “INSTALLING THE HANDLEBAR” section.7 mSkg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Removing the handle bar Master cylinder bracket Master cylinder assembly Throttle cable housing cover Handle bar switch (right) Throttle cable housing Throttle cable Grip end Grip assembly Clutch cable Clutch switch Handle bar switch (left) Starter cable Grip end Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE HANDLEBAR” section.7 mSkg) 23 Nm (2.0 mSkg) 7 Nm (0.3 mSkg) 7 Nm (0.

Refer to “INSTALLING THE HANDLEBAR” section.7 mSkg) Order 14 15 16 17 Job name/Part name Grip (left) Clutch lever holder Upper handlebar holder Handle bar Q’ty 1 1 2 1 Remarks Refer to “REMOVING THE HANDLEBAR” section.3 mSkg) 7 Nm (0.HANDLEBAR CHAS 10 Nm (1. For installation. 7-49 . reverse the removal procedure.7 mSkg) 23 Nm (2.0 mSkg) 7 Nm (0.

Remove: S throttle cable housing 1 S throttle grip 2 NOTE: While removing the throttle cable housing. Slide the handlebar grip over the left end of the handlebar. Stand the motorcycle on a level surface. 7-50 . Check: S handlebar 1 Bends/cracks/damage ! Replace. Securely support the motorcycle so that there is no danger of it falling over. Stand the motorcycle on a level surface. 2. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. c. 1 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. 2. Install: S handlebar grip a. Do not touch the handlebar grip until the rubber adhesive has fully dried. 3. Wipe off any excess rubber adhesive with a clean rag. and gradually push the grip off the handlebar. 1 EB704400 CHECKING THE HANDLEBAR 1.HANDLEBAR EB704100 CHAS REMOVING THE HANDLEBAR 1. Do not attempt to straighten a bent handlebar as this may dangerously weaken it. pull back the rubber cover 3 . 3.

Install: S left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. tighten the bolts on the front side a of the handlebar holder. NOTE: S The upper handlebar holders should be installed with the arrows facing forward. Securely support the motorcycle so that there is no danger of it falling over. adjust the handlebar position. Install: S master cylinder bracket 1 NOTE: Align the mating surfaces of the master cylinder bracket with the punch mark (right handlebar switch side) a on the handlebar. S Align the match marks b on the handlebar with the upper surface of the lower handlebar holders.0 mm of clearance a between the handlebar grip and the left grip end. If there is any contact with the fuel tank. 3.HANDLEBAR EB704701 CHAS INSTALLING THE HANDLEBAR 1. Install: S clutch lever holder S handlebar grip 1 S left grip end 2 NOTE: There should be 1.3 mSkg) b CAUTION: S First. 5. 7-51 . then on the rear side. 2. Install: S handlebar 1 S upper handlebar holders 2 23 Nm (2. S turn the handlebar all the way to the left and right. 4. Stand the motorcycle on a level surface.

Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm 7-52 . NOTE: S Align the projection a on the throttle cable housing with the hole b in the handlebar. 7. 8. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Install: S right grip end S right handlebar switch 1 Make sure that the throttle grip operates smoothly. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 9. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.HANDLEBAR CHAS 6. Install: S throttle grip 1 S throttle cable housing 2 S throttle cables 3 NOTE: Apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar. NOTE: S Align the projection a on the right handlebar switch with the hole b in the handlebar.

Refer to “HANDLEBAR” section. 7-53 . 1 1 1 1 Refer to “REMOVING THE LOWER 1 BRACKET/INSTALLING THE STEER1 ING HEAD” section.2 mSkg) 18 Nm (1.8 mSkg) Order Job name/Part name Removing the lower bracket Front cowling Fuel tank Front wheel Front fork Handle bar Main switch lead coupler Brake hose joint/cover Steering stem nut Upper bracket Lock washer Ring nut (upper) Rubber washer 1 Ring nut (lower) Q’ty Remarks 1 2 3 4 5 6 7 8 Remove the parts in the order listed.STEERING HEAD STEERING HEAD LOWER BRACKET CHAS 110 Nm (11.0 mSkg) 1st 2nd 52 Nm (5. Refer to “FRONT COWUNG/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3 Refer to “FRONT WHEEL” section. 1 NOTE: 1/1 Disconnect the coupler. Refer to “FRONT FORK” section.

7-54 . reverse the removal procedure.2 mSkg) 18 Nm (1.8 mSkg) Order 9 10 11 12 13 Job name/Part name Lower bracket Ball race cover Ball bearing Rubber washer 1 Ball bearing Q’ty 1 1 1 1 1 Remarks Refer to “INSTALLING THE STEERING HEAD” section.STEERING HEAD CHAS 110 Nm (11. For installation.0 mSkg) 1st 2nd 52 Nm (5.

Replace: S bearing balls S bearing races a. then remove the upper ring nut with the ring nut wrench. 2. Exhaust and steering nut wrench 90890-01268 Securely support the lower bracket so that there is no danger of it falling. Wash: S bearing balls S bearing races Recommended cleaning solvent Kerosine 2. Remove: S upper ring nut S lower ring nut 1 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench 2 . EB705401 CHECKING THE STEERING HEAD 1. Securely support the motorcycle so that there is no danger of it falling over. Check: S bearing 1 S bearing race 2 Damage/pitting ! Replace. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. Stand the motorcycle on a level surface. 3.STEERING HEAD EB705102 CHAS REMOVING THE LOWER BRACKET 1. 7-55 .

4 3 2 1 7-56 . S Whenever the steering head is disassembled. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3.STEERING HEAD CHAS b. c. Install: S upper bracket S steering stem nut NOTE: Temporarily tighten the steering stem nut. NOTE: S Always replace the bearing balls and bearing races as a set. CAUTION: If the bearing race is not installed properly. EB705700 INSTALLING THE STEERING HEAD 1. Install: S front fork legs Refer to “FRONT FORK”. Check: S upper bracket S lower bracket (along with the steering stem) Bends/cracks/damage ! Replace. 3. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. 4. replace the dust seal. 4. the steering head pipe could be damaged. Lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium soap base grease 2. Install a new dust seal and new bearing races.

0 mSkg) 40 Nm (4.REAR SHOCK ABSORBER AND RELAY ARM REAR SHOCK ABSORBER AND RELAY ARM CHAS 48 Nm (4.8 mSkg) Order Job name/Part name Removing the rear shock absorber assembly and relay arm Side covers Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3 Refer to “REAR WHEEL. 7-57 . Rear wheel 1 2 3 4 5 6 7 Self-locking nut/washer Bolt Self-locking nut/washer Bolt Self-locking nut/bolt Rear shock absorber assembly Self-locking nut 1/1 1 1/1 1 1/1 1 1 = 120 mm = 40 mm Refer to “REMOVING/ INSTALLING THE REAR SHOCK ABSORBER” section.0 mSkg) 48 Nm (4.8 mSkg) 40 Nm (4. BRAKE DISK AND REAR WHEEL SPROCKET” section.

8 mSkg) 40 Nm (4. reverse the removal procedure.0 mSkg) 48 Nm (4.REAR SHOCK ABSORBER AND RELAY ARM CHAS 48 Nm (4.8 mSkg) Order 8 9 10 11 12 13 14 15 16 17 18 19 Job name/Part name Bolt Relay arm Self-locking nut/washer Bolt Connecting plate Spacer Spacer Spacer Oil seal Bearing Bearing Bearing Q’ty 1 1 1/1 1 2 1 2 1 2 2 1 1 = 80 mm Remarks = 120 mm For installation. 7-58 .0 mSkg) 40 Nm (4.

S Do not tamper or attempt to open the rear shock absorber. High heat can cause an explosion due to excessive gas pressure. or both are damaged. read and make sure you understand the following information. Before handling the rear shock absorber. To release the gas pressure. If the rear shock absorber. S Do not deform or damage the rear shock absorber in any way. EB706111 DISPOSING OF A REAR SHOCK ABSORBER a. 7-59 . S Do not subject the rear shock absorber to an open flame or any other source of high heat. drill a 2 X 3 mm hole through the gas cylinder at a point 15 X 20 mm from its end as shown 1 . The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. Wear eye protection to prevent eye damage from released gas or metal chips.REAR SHOCK ABSORBER AND RELAY ARM EB706101 CHAS HANDLING THE REAR SHOCK ABSORBER This rear shock absorber contain highly compressed nitrogen gas. damping performance will suffer. Gas pressure must be released before disposing of a rear shock absorber.

Remove: S rear shock absorber assembly upper bolt 1 S rear shock absorber assembly NOTE: Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm. Stand the motorcycle on a level surface. then the positive lead 2 . 5. hold the swingarm so that it does not drop down. 7-60 .REAR SHOCK ABSORBER AND RELAY ARM EB706204 CHAS REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. 3. Remove: S battery 4. Remove: S side covers S connecting plate bolt 1 S rear shock absorber assembly lower bolt 2 NOTE: While removing the rear shock absorber assembly lower bolt. 2. Disconnect: S battery leads (from the battery terminals) CAUTION: First. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. disconnect the negative lead 1 . Securely support the motorcycle so that there is no danger of it falling over.

7-61 . Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm (4. lift up the swingarm. EB706701 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1.REAR SHOCK ABSORBER AND RELAY ARM EB706401 CHAS CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. S rear shock absorber oil leaks ! Replace the rear shock absorber assembly. then the negative lead 2 . 3. S Install the connecting arm front bolt from the right.0 mSkg) Relay-arm-to-frame-nut 48 Nm (4.0 mSkg) Rear shock absorber assembly lower nut 40 Nm (4. S dust seals Damage/wear ! Replace. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 2. Connect: S battery leads (to the battery terminals) CAUTION: First. S bolts Bends/damage/wear ! Replace. S spring Damage/wear ! Replace the rear shock absorber assembly.8 mSkg) NOTE: S When installing the rear shock absorber assembly. S bushings Damage/wear ! Replace. connect the positive lead 1 . Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly.

7 mSkg) Order Job name/Part name Removing the swingarm and drive chain Rear wheel Q’ty Remarks Removing the parts in the order listed. BRAKE DISC AND REAR WHEEL SPROCKET” section. Refer to “REAR SHOCK ABSORBER AND RELAY ARM” section. Refer to “REAR WHEEL.5 mSkg) 23 Nm (2.SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN CHAS 115 Nm (11.3 mSkg) 7 Nm (0. Refer to “REMOVING THE ENGINE” section in chapter 4 Rear shock absorber assembly Relay arm Rear wheel sprocket 1 2 3 4 5 6 7 8 9 Drive chain guard Brake hose holder Caliper bracket Compression bar Drive chain guide Pivot shaft Swingarm Drive chain Cover 7-62 1 2 1 1 1 1 1 1 2 .

5 mSkg) 23 Nm (2.SWINGARM AND DRIVE CHAIN CHAS 115 Nm (11. 7-63 . reverse the removal procedure.3 mSkg) 7 Nm (0.7 mSkg) Order 10 11 12 Spacer Bearing Washer Job name/Part name Q’ty 1 2 2 Remarks For installation.

7-64 . washers. and dust covers. bearings. If swingarm vertical movement is not smooth or if there is binding.SWINGARM AND DRIVE CHAIN EB707100 CHAS NOTE: Before removing the drive sprocket. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Pivot shaft nut 115 Nm (11. Check the tightening torque of the pivot shaft nut. 2. hold the swingarm so that it does not drop down. Check the swingarm vertical movement B by moving the swingarm up and down. 3. Check: S swingarm side play S swingarm vertical movement B A a. check the spacers.5 mSkg) b. Stand the motorcycle on a level surface. Check the swingarm side play A by moving the swingarm from side to side. If the swingarm side play is out of specification. check the spacers. and dust covers. Swingarm side play (at the end of the swingarm) 1 mm d. measure the drive chain slack and the length of a ten-link section of the drive chain. drive chain. Remove: S side covers S connecting plate bolt 1 S rear shock absorber assembly lower bolt 2 NOTE: When removing the rear shock absorber assembly lower bolt. bearings. c. washers. Securely support the motorcycle so that there is no danger of it falling over. and rear wheel. EB707111 REMOVING THE SWINGARM 1.

SWINGARM AND DRIVE CHAIN EB707400 CHAS CHECKING THE SWINGARM 1. 2. 3. 5. Bends ! Replace. Check: S swingarm Bends/cracks/damage ! Replace. 7-65 . Check: S pivot shaft Roll the pivot shaft on a flat surface. Check: S connecting arms 6 S relay arm 7 Damage/wear ! Replace. Check: S dust covers 1 S spacer 2 S washers 3 S oil seals 4 Damage/wear ! Replace. S bearings 5 Damage/pitting ! Replace. Wash: S pivot shaft S dust covers S spacer S washers S bearings Recommended cleaning solvent Kerosine 4. Do not attempt to straighten a bent pivot shaft.

4. Wipe the drive chain with a clean cloth. Check: S O-rings 1 Damage ! Replace the drive chain. Put the drive chain in kerosine and remove any remaining dirt. S drive chain rollers 2 Damage/wear ! Replace the drive chain. b. Remove the drive chain from the kerosine and completely dry it. benzine). and solvents will deteriorate the O-rings. use only kerosine to clean the drive chain. Check: S drive chain Stiffness ! Clean and lubricate or replace. S drive chain side plates 3 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain. certain solvents (e. Clean: S drive chain a.. c. A coarse brush can also damage the Orings.g. S Perform this measurement at two or three different places. 7-66 . or a coarse brush to clean the drive chain. 3. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. steam.SWINGARM AND DRIVE CHAIN EB707410 CHAS CHECKING THE DRIVE CHAIN 1. Therefore. gasoline. 2. High-pressure methods could force dirt or water into the drive chain’s internals. Never use highpressure water or air. Ten-link drive chain section limit (maximum) 150 mm NOTE: S While measuring the ten-link section. push down on the drive chain to increase its tension. S Measure the length between drive chain roller 1 and 11 as shown. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain.

Lubricate: S drive chain CHAS Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Install: S drive chain S swingarm 1 S relay arm 2 S left connecting plate 3 S right connecting plate 4 Swingarm pivot shaft nut 115 Nm (11.5 mSkg) Relay arm nut 48 Nm (4. 3.8 mSkg) NOTE: Install the swingarm bolt 5 from the left. Install: S rear shock absorber assembly S rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” and “REAR WHEEL”. 7-67 . b Correct 1 Drive chain roller 2 Drive chain sprocket EB707700 INSTALLING THE SWINGARM 1.8 mSkg) Connecting plate nut 48 Nm (4. Check: S drive sprocket S rear wheel sprocket More than 1/4 tooth a wear ! Replace the drive chain sprockets as a set. Bent teeth ! Replace the drive chain sprockets as a set.SWINGARM AND DRIVE CHAIN 5. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Molybdenum disulfide grease 2.

Adjust: S drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. CAUTION: Never install a new drive chain onto worn drive chain sprockets. tighten the drive sprocket nut. Drive chain slack 30 X 45 mm EB707710 INSTALLING THE DRIVE CHAIN 1. and one that is too loose can skip and damage the swingarm or cause an accident. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2.0 mSkg) NOTE: While applying the rear brake. Drive chain slack 30 X 45 mm CAUTION: A drive chain that is too tight will overload the engine and other vital parts. 7-68 . Install: S drive chain 1 S drive sprocket 2 S washer 3 S drive sprocket nut 4 70 Nm (7.SWINGARM AND DRIVE CHAIN CHAS 4. 5. Therefore. this will dramatically shorten the drive chain’s life. keep the drive chain slack within the specified limits. Adjust: S drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3.

– + ELEC 8 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SWITCH POSITION AND TERMINAL CONNECTION . . . . . . . . . . . . 8-25 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 CIRCUIT DIAGRAM . . . . . . . 8-5 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38 SIGNAL SYSTEM CHECK . . . . . . . . . . 8-33 SIGNAL SYSTEM . . . . . . . 8-23 CHARGING SYSTEM . . . . . 8-25 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 CIRCUIT DIAGRAM . . . . . . . . . . . 8-2 CHECKING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . 8-61 SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56 FUEL PUMP CIRCUIT OPERATION . . . . . . . . .ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 STARTER MOTOR . . . . 8-13 STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . 8-56 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SWITCH CONNECTION AS SHOWN IN THIS MANUAL . . . . . 8-36 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 8-26 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 CIRCUIT DIAGRAM . . . . . 8-6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 TROUBLESHOOTING . . . . . . . . . . . . . 8-52 FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELEC .

ELECTRICAL COMPONENTS
EB800000

ELEC

ELECTRICAL
ELECTRICAL COMPONENTS
1 2 3 4 5 6

Main switch Fuel sender Rear brake switch Battery Ignitor unit Starter relay

7 8 9 10 11 12

Starting circuit cut-off relay Flasher relay Sidestand switch Neutral switch Oil level gauge Ignition coil

13 14 15 16 17

Rectifier/ Regulator Thermo switch (warning light) Thermo switch (fan motor) Horn Diode

8-1

CIRCUIT DIAGRAM CIRCUIT DIAGRAM

ELEC

8-2

CIRCUIT 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

ELEC

A.C. magneto Rectifier regulator Main switch Battery Fuse (back up) Fuse (main) Starter relay Starter motor Starting circuit cut-off relay Fuel pump relay Ignitor unit Ignition coil Spark plug Pickup coil Throttle position sensor Neutral switch Speed sensor Fuel sender Thermo switch (warning light) Diode Fuel pump Sidestand switch Speedometer Tachometer Fuel meter Fuel level warning light Engine temperature warning light Neutral indicator light Oil level warning light

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

High beam indicator light Turn indicator lights Meter lights Clutch switch Oil level switch Flasher relay Horn Pass switch Dimmer switch Horn switch Turn switch Front turn signal lights Rear turn signal lights Head light Tail/ Brake light Auxiliary light Fan motor Thermo switch (fan motor) Fuse (fan) Fuse (head) Rear brake switch Fuse (signal) Front brake switch Lights switch Engine stop switch Starter switch Fuse (ignition) Alarm (option)

NOTE: S Starter switch is closed while the button (switch) is pushed. S Sidestand switch is closed while the side stand is upped. S Clutch switch is closed while the clutch lever is pulled. S Brake switch is closed while the brake is applied.

COLOR CODE B Br Ch Dg G L Lg O Sb P R Black Brown Chocolate Dark green Green Blue Light green Orange Sky blue Pink Red Y W B/L B/R B/Y Br/L Br/W G/R G/W G/Y L/B Yellow White Black/Blue Black/Red Black/Yellow Brown/Blue Brown/White Green/Red Green/White Green/Yellow Blue/Black L/Y L/W L/R R/B R/Y R/W Y/B Y/R W/B W/G Blue/Yellow Blue/White Blue/Red Red/Black Red/Yellow Red/White Yellow/Black Yellow/White White/Black White/Green

8-3

CHECKING SWITCHES
YP-N

ELEC

CHECKING SWITCHES
CHECKING STEPS Using pocket tester, check switches for continuity between their terminals to determine whether they are correctly connected. Replace the switch component if any of the combinations does not produce the correct reading. Pocket tester: 90890-03112 NOTE: S Turn the switch to the “ON”, “OFF” positions several times. S Adjust the pocket tester to correct “0” position before checking switches. S Set the pocket tester selector to “X1” Ω.

SWITCH CONNECTION AS SHOWN IN THIS MANUAL This manual contains connection charts, like the one shown on the left, showing the terminal connections of switches (e.g. the main switch, handlebar switch, brake switch, lighting switch etc.) The column on the extreme left indicates the different switch positions, the top line indicates the colors of the leads connected to the terminals on the switch. ” indicates terminals between which “ there is continuity, i.e. a closed circuit, in the given switch position. In this chart: “Br and R” have continuity with the switch in the “ON” position.

8-4

CHECKING SWITCHES
YP******

ELEC

SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault ! Repair or replace.

* indicates coupler positions.

8-5

EB802000

CIRCUIT DIAGRAM

IGNITION SYSTEM

8-6 12 13 14 3 Main switch 16 22 4 Battery 6 Fuse (main) 54 11 Ignitor unit 56 Ignition coil Spark plug Pickup coil Neutral switch Sidestand switch Engine stop switch Fuse (ignition)

IGNITION SYSTEM

ELEC

IGNITION SYSTEM
EB802010

ELEC

TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main and ignition) 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side cover (left) S Use the following special tool(s) for troubleshooting.

8. Engine stop switch 9. Neutral switch 10. SIdestand switch 11. Diode (starting circuit cut-off relay) 12. Pickup coil resistance 13. Wiring connection (the entire ignition system)

Ignition checker: 90890-06754 Pocket tester: 90890-03112

EB802011

1. Fuses (main and ignition) S Remove the fuses. S Connect the pocket tester (Ω X 1) to the fuses. S Check the fuses for continuity. CONTINUITY
EB802012

NO CONTINUITY

Replace the fuses.

2. Battery S Check the battery condition. Refer to “BATTERY INSPECTION” in CHAPTER 3. Open-circuit voltage: 12.8 V or more at 20_C CORRECT :

INCORRECT

S Clean the battery terminals. S Recharge or replace the battery.

8-7

CR8E/U27ESR-N. Minimum spark gap: 6. Refer to “SPARK LUG INSPECTION” in CHAPTER 3. S Check the spark plug gap.IGNITION SYSTEM : ELEC EB802013 3. Spark plugs S Check the spark plug condition. S Connect the ignition checker 1 as shown. Ignition spark gap S Disconnect the spark plug cap from the spark plug.0 mm OUT OF SPECIFICATION OR NO SPARK MEETS SPECIFICATION The ignition system is not faulty. Standard spark plug: CR9E. : 8-8 . U24ESR-N NGK/NIPPONDENSO Spark plug gap: 0. S Check the ignition spark gap a . S Crank the engine by pushing the starter switch.7 X 0. and increase the spark gap until a misfire occurs. 4.8 mm CORRECT EB802014 INCORRECT Repair or replace the spark plugs. S Check the spark plug type. 2 Spark plug cap S Turn the main switch to “ON”.

Spark plug cap resistance: 10 kΩ at 20_C OUT OF SPECIFICATION Replace the spark plug cap. 1k) to the S Check if the spark plug cap has the specified resistance. Secondary coil resistance: 12 X 18 kΩ at 20_C BOTH MEET SPECIFICATION : OUT OF SPECIFICATION Replace the ignition coil. Spark plug cap resistance S Remove the spark plug cap. Tester (+) lead ! Red/Black terminal Tester (–) lead ! Orange (Gray) terminal S Check if the primary coil has the specified resistance. Primary coil resistance: 1.53 Ω at 20_C S Connect the pocket tester (Ω ignition coil. 1k) to the Tester (+) lead ! spark plug lead 1 Tester (–) lead ! spark plug lead 2 S Check if the secondary coil has the specified resistance. S Connect the pocket tester (Ω 1) to the ignition coil. S Connect the pocket tester (Ω spark plug cap. Ignition coil resistance S Disconnect the ignition coil connector from the wire harness. 8-9 .87 X 2.IGNITION SYSTEM : ELEC EB802015 5. MEETS SPECIFICATION EB802016 6.

S Check for continuity as follows: Red/White 1 – Red/Black 2 NO CONTINUITY Replace the right handlebar switch. Engine stop switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Neutral switch terminal 1 – Ground 8-10 .IGNITION SYSTEM : ELEC EB802017 7. CONTINUITY EB802018 8. CONTINUITY EB802019 9. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. Neutral switch S Disconnect the neutral switch/lead from the neutral switch.

IGNITION SYSTEM ELEC NO CONTINUITY Replace the main switch. S Check for continuity as follows: Blue/Yellow 1 – Light green 2 8-11 . S Check for continuity as follows: Black 1 – Black 2 NO CONTINUITY Replace the sidestand switch. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. Diode (starting circuit cut-off relay unit) S Remove the relay unit from the wire harness. CONTINUITY EB80201A 10. CONTINUITY 11.

POOR CONNECTION Properly connect the ignition system. Tester (+) lead ! Yellow terminal 1 Tester (–) lead ! Blue terminal 2 S Check if the pickup coil has the specified resistance.IGNITION SYSTEM Tester  lead!Blue/Yellow 1 Continuity Tester lead!Light green 2 Tester lead!Blue/Yellow 1 No Tester lead!Light green 2 Continuity Replace the relay unit. CORRECT Replace the ignitor unit. Refer to “CIRCUIT DIAGRAM”. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. 13. S Connect the pocket tester (Ω 100) to the pickup coil terminal. Wiring connection S Check the connections of the entire ignition system. Pickup coil resistance: 189 X 231 Ω at 20_C (Yellow – Blue) MEETS SPECIFICATIONS EB80201D OUT OF SPECIFICATION Replace the pickup coil. CORRECT EB80201C ELEC INCORRECT 12. 8-12 .

EB803000 CIRCUIT DIAGRAM ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM 8-13 3 4 6 7 Main switch Battery Fuse (main) Starter relay 8 9 16 22 33 54 55 56 Starter motor Starting circuit cut-off relay Neutral switch Sidestand switch Clutch switch Engine stop switch Start switch Fuse (ignition) ELEC .

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

Main switch 7. CONTINUITY EB802012 NO CONTINUITY Replace the fuses. Wiring connection (the entire starting system) Pocket tester: 90890-03112 EB802011 1. Fuses (main and ignition) 2.8 V or more at 20_C CORRECT : INCORRECT S Clean the battery terminals. Sidestand switch 10.ELECTRIC STARTING SYSTEM EB803020 ELEC TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Start switch 12. Battery 3. Starting circuit cut-off relay 5. Refer to “BATTERY INSPECTION” in CHAPTER 3. 2. Fuses (main and ignition) S Remove the fuses. S Check the fuses for continuity. S Connect the pocket tester (Ω X 1) to the fuses. Neutral switch 9. Battery S Check the battery condition. Diode (starting circuit cut-off relay) 13. 8. Open-circuit voltage: 12. Starter motor 4. Engine stop switch NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side cover (left) S Use the following special tool(s) for troubleshooting. Clutch switch 11. Starter relay 6. 8-15 . S Recharge or replace the battery.

Starting circuit cut-off relay (relay unit) S Remove the relay unit from the wire harness. DOES NOT MOVE Repair or replace the starter motor. so be sure that no flammable gas or fluid is in the vicinity.ELECTRIC STARTING SYSTEM : : ELEC EB803021 3. Battery (+) terminal ! Red/Black terminal 1 Battery (–) terminal ! Black/Yellow terminal 2 Tester (+) lead ! Blue/White terminal 3 Tester (–) lead ! Black terminal 4 NO CONTINUITY S Check the starting circuit cut-off relay for continuity. S Connect the pocket tester (Ω X 1) and battery (12 V) to the relay unit terminals. otherwise the jumper lead may burn. 8-16 . S Check the operation of the starter motor. CONTINUITY Replace the starting circuit cut-off relay. MOVES EB803023 4. S A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead. S This check is likely to reduce sparks. Starter motor S Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 :.

6. Battery (+) terminal ! Red/White terminal 3 Battery (–) terminal ! Blue/White terminal 4 Tester (+) lead ! Red terminal 3 Tester (–) lead ! Black terminal 4 S Check the starter relay for continuity.ELECTRIC STARTING SYSTEM : ELEC EB803024 5. S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY : 8-17 . S Connect the pocket tester (Ω X 1) and battery (12 V) to the relay unit coupler terminals. Starter relay S Disconnect the relay unit coupler from the wire harness. Main switch S Disconnect the main switch couplers from the wire harness. CONTINUITY EB802017 NO CONTINUITY Replace the starter relay.

CONTINUITY : 8-18 . CONTINUITY EB802019 8. S Check for continuity as follows: Red/White 1 – Red/White 2 NO CONTINUITY Replace the right handlebar switch. Neutral switch S Disconnect the neutral switch/lead from the neutral switch.ELECTRIC STARTING SYSTEM : ELEC EB802018 7. S Check for continuity as follows: Neutral switch terminal 1 – Ground NO CONTINUITY Replace the neutral switch.Engine stop switch S Disconnect the right handlebar switch coupler from the wire harness.

CONTINUITY EB803025 10. CONTINUITY : 8-19 . Clutch switch S Disconnect the clutch switch coupler from the wire harness. S Check for continuity as follows: Black/Yellow 1 – Blue/Yellow 2 NO CONTINUITY Replace the clutch switch. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. S Check for continuity as follows: Black 1 – Black 2 NO CONTINUITY Replace the sidestand switch.ELECTRIC STARTING SYSTEM : ELEC EB80201A 9.

ELECTRIC STARTING SYSTEM : ELEC EB803027 11. Diode (starting circuit cut-off relay) S Remove the relay unit from the wire harness. Start switch S Disconnect the right handlebar switch coupler from the wire harness. Tester (+) lead!Black/ Yellow 1 Continuity Tester (–) lead !Light green 2 Tester (+) lead !Light green 1 No Tester (–) lead !Black/ Yellow 2 Continuity CORRECT : 8-20 . S Check for continuity as follows: Black/Yellow 1 – Light green 2 INCORRECT Replace the relay unit. CONTINUITY EB803026 12. S Check for continuity as follows: Blue/White 1 – Black 2 NO CONTINUITY Replace the right handlebar switch.

Refer to “CIRCUIT DIAGRAM”.ELECTRIC STARTING SYSTEM : ELEC EB803028 13. 8-21 . Wiring connection S Check the connections of the entire starting system. POOR CONNECTION Properly connect the starting system.

1 2 3 4 5 6 Starter motor disassembly Front bracket Washers Rear bracket Shims Brush holder/Brush Armature ass’y Disassembly the parts in order.ELECTRIC STARTING SYSTEM EB803030 ELEC STARTER MOTOR Order 1 2 Job name/Part name Starter motor removal Starter motor Starter motor lead Q’ty 1 1 Remarks Remove the parts in order. 8-22 . 1 1 2 1 1/1 1 Reverse the disassembly procedure for assembly. Reverse the removal procedure for installation.

Armature coil continuity resistance 1 : 0. Inspect: S Commutator Dirty ! Clean it with #600 grit sandpaper. 8-23 . Brush spring force: 780 X 1.ELECTRIC STARTING SYSTEM ELEC CHECKING THE STARTER MOTOR 1.020 g 3. Inspection steps: S Connect the pocket tester for the continuity 1 and insulation 2 checks. Inspect: S Armature coil resistances (insulation/continuity) Defects ! Replace the starter motor.0015 X 0.0025 Ω at 20_C Armature coil insulation resistance 2 : More than 1 MΩ at 20_C S If the resistance is incorrect. Brush length wear limit: 4 mm 2. Measure: S Brush spring force Fatigue/out of specification ! Replace as a set. S Measure the armature coil resistances. 4. Measure: S Brush length a Out of specification ! Replace. replace the starter motor.

ELECTRIC STARTING SYSTEM ELEC 5. Commutator wear limit: 27 mm 6. 8-24 . Measure: S Commutator diameter a Out of specification ! Replace the starter motor. Measure: S Mica undercut a Out of specification ! Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator. Mica undercut: 0.7 mm NOTE: The mica insulation of the commutator must be undercut to ensure proper operation of the commutator.

CHARGING SYSTEM EB804000 ELEC CHARGING SYSTEM CIRCUIT DIAGRAM AC magneto Rectifier/regulator Battery Fuse (main) 8-25 1 2 4 6 .

Fuse (main) 2. Wiring connections (the entire charging system) Engine tachometer: 90890-03113 Pocket tester: 90890-03112 EB802011 1. S Recharge or replace the battery. S Connect the pocket tester (Ω X 1) to the fuses. 4. S Check the fuses for continuity. CONTINUITY EB802012 NO CONTINUITY Replace the fuses. 2. Charging voltage NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Side cover (left) S Use the following special tool(s) for troubleshooting. Refer to “BATTERY INSPECTION” in CHAPTER 3. 8-26 . Open-circuit voltage: 12. Fuses (main) S Remove the fuses.8 V or more at 20_C CORRECT : INCORRECT S Clean the battery terminals. Stator coil resistance 5.CHARGING SYSTEM EB803020 ELEC TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Battery 3. Battery S Check the battery condition.

S Check the terminal voltage. S Connect the pocket tester (DC 20 V) to the battery.5 V up NOTE: Use a fully charged battery. Tester (+) lead ! Battery (+) terminal Tester (–) lead ! Battery (–) terminal S Measure the battery terminal voltage. OUT OF SPECIFICATION 8-27 . Charging voltage S Connect the engine tachometer to the spark plug lead. Stator coil resistance S Remove the generator cover.CHARGING SYSTEM : ELEC EB804011 3. Charging voltage = measured voltage-terminal voltage: 0. 4.2 X 2.36 X 0.44 Ω at 20_C BOTH MEET SPECIFICATION : Replace the stator coil1assembly.000 r/min. S Connect the pocket tester (Ω stator coils. Stator coil resistance: 0. S Start the engine and accelerate to about 5. OUT OF SPECIFICATION EB804012 MEETS SPECIFICATION The charging circuit is not faulty. 1) to the Tester (+) lead ! White terminal 1 Tester (–) lead ! White terminal 2 Tester (+) lead ! White terminal 1 Tester (–) lead ! White terminal 3 S Measure the stator coil resistance.

Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION Properly connect the charging system.CHARGING SYSTEM : ELEC EB804015 5. Wiring connections S Check the connections of the entire charging system. CORRECT Replace the rectifier/regulator. 8-28 .

EB805000 CIRCUIT DIAGRAM LIGHTING SYSTEM 8-29 3 4 6 30 32 37 38 Main switch 43 Battery 44 Fuse (main) 45 High beam indicator light 49 Meter light 53 Pass switch Dimmer switch Headlight Tail/brake light Auxiliary light Fuse (head) Lights switch LIGHTING SYSTEM ELEC .

S Connect the pocket tester (Ω X 1) to the fuses. Open-circuit voltage: 12. 8-30 . Lights switch (for Europe) NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side cover (left) 4) Front cowling assembly S Use the following special tool(s) for troubleshooting. CONTINUITY EB802012 NO CONTINUITY Replace the fuses. TAILLIGHT.LIGHTING SYSTEM EB803020 ELEC TROUBLESHOOTING IF THE HEADLIGHT. Fuses (main and head) S Remove the fuses. 5. Battery S Check the battery condition. S Check the fuses for continuity.8 V or more at 20_C CORRECT : INCORRECT S Clean the battery terminals. Fuses (main and head) 2. Pass switch (for Europe and Australia) 7. Battery 3. AUXILIARY LIGHT AND/OR METER LIGHT FAIL TO COME ON: Procedure Check: 1. Main switch 4. S Recharge or replace the battery. HIGH BEAM INDICATOR LIGHTS. Wiring connections (the entire lighting system) Pocket tester: 90890-03112 EB802011 1. Refer to “BATTERY INSPECTION” in CHAPTER 3. Dimmer switch 6. 2.

S Check for continuity as follows: Red 1 – Brown/Blue 2 Blue/Red 1 – Blue 2 NO CONTINUITY Replace the main switch. Lights switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Red/Yellow 1 – Blue 2 S Turn the lights switch to “ON”. Main switch S Disconnect the main switch couplers from the wire harness. CONTINUITY EB805011 4.LIGHTING SYSTEM : ELEC EB802017 3. CONTINUITY : 8-31 . S Turn the lights switch to “ON” or “PO”. Replace the right handlebar switch. S Check for continuity as follows: Red/Yellow 1 – Blue 2 Red/Yellow 1 – Blue/Black 2 NO CONTINUITY The lights switch is faulty.

Pass switch S Disconnect the left handlebar switch coupler from the wire harness. Replace the left handlebar switch. Refer to “CIRCUIT DIAGRAM”. S Turn the pass switch to “ON”. POOR CONNECTION Properly connect the lighting system. Refer to “LIGHTING SYSTEM CHECK”. CONTINUITY EB805013 7. S Check for continuity as follows: Blue/Black 1 – Yellow 2 CONTINUITY The dimmer switch is faulty. EB805012 NO CONTINUITY 6. S Turn the dimmer switch to “HI”. 8-32 . Replace the left handlebar switch.LIGHTING SYSTEM : ELEC 5. Dimmer switch S Disconnect the left handlebar switch couplers from the wire harness. CORRECT Check the condition of each of the lighting system’s circuits. Wiring connections S Check the connections of the entire lighting system. S Check for continuity as follows: Red/Yellow 1 – Yellow 2 NO CONTINUITY The pass switch is faulty.

Turn the light switch to “ON”. NO CONTINUITY Replace the bulb and/or bulb socket. If the headlight and the high beam indicator light fail to come on: 1. Headlight: Tester (+) lead ! Black/Yellow lead 1 or Black/Blue lead 2 Tester (–) lead ! Black lead 3 High beam indicator light: Tester (+) lead ! Yellow lead 4 Tester (–) lead ! Black lead 5 B Meter connector Headlight connector S S S S Turn the main switch to “ON”.LIGHTING SYSTEM EB805020 ELEC LIGHTING SYSTEM CHECK 1. “Black/Blue” and “Yellow” leads on the bulb socket connector. Voltage S Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers. Turn the dimmer switch to “LO” or “HI”. Check the voltage (12 V) of the “Black/Yellow”. B When the dimmer switch is ON “HI”. This circuit is not faulty. CONTINUITY 2. repair it. Bulb and bulb socket. 8-33 . S Check the bulb and bulb socket for continuity. MEETS SPECIFICATION OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. A When the dimmer switch is on “LO”.

S Check the voltage (12 V) of the “blue” lead on the bulb socket connector. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. If the meter light fails to come on: 1. Bulb and bulb socket S Check the bulb and bulb socket for continuity. Bulb and bulb socket S Check the bulb and bulb socket for continuity. S Turn the main switch to “ON”. S Turn the light switch to “ON” or “PO”. If the taillight fails to come on: 1. MEETS SPECIFICATION The circuit is not faulty. Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black terminal 2 1 2 NO CONTINUITY Replace the bulb and/or bulb socket. repair it. NO CONTINUITY 8-34 . Tester (+) lead ! Blue terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (20 V) to the bulb socket coupler. CONTINUITY 2. EB805022 3. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector.LIGHTING SYSTEM EB805021 ELEC 2.

Tester (+) lead ! Blue/Red terminal 1 Tester (–) lead ! Black terminal 2 Replace the bulb and/or bulb socket. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. S Turn the lights switch to “ON” or “PO”. MEETS SPECIFICATION This circuit is not faulty. NO CONTINUITY S Turn the main switch is “ON”. repair it. OUT OF SPECIFICATION ELEC The wiring circuit from the main switch to the bulb socket connector is faulty. Bulb and bulb socket S Check the bulb and bulb socket for continuity. 8-35 . MEETS SPECIFICATION This circuit is not faulty. If the auxiliary light fails to come on: 1. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. EB805023 4. CONTINUITY 2. S Turn the lights switch to “ON” or “PO”. repair it. S Check the voltage (12 V) of the “Blue/Red” lead on the bulb socket connector. S Check the voltage (12 V) of the “Blue” lead on the bulb socket connector.LIGHTING SYSTEM S Turn the main switch to “ON”.

SIGNAL SYSTEM EB806000 ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM 8-36 .

SIGNAL SYSTEM 3 4 6 16 18 20 25 26 28 29 31 34 35 36 39 40 41 42 44 50 51 52 55 Main switch Battery Fuse (main) Neutral switch Fuel sender Diode Fuel meter Fuel level warning light Neutral indicator light Oil level warning light Turn indicator light Oil level switch Flasher relay Horn Horn switch Turn switch Front turn signal light Rear turn signal light Tail/ brake light Rear brake switch Fuse (signal) Front brake switch Start switch ELEC 8-37 .

8 V or more at 20_C CORRECT : INCORRECT S Clean the battery terminals. Wiring connection (the entire signal system) NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side covers (left and right) 4) Front cowling assembly S Use the following special tool8s) for troubleshooting. 8-38 . Battery 3. BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON: IF THE HORN FAILS TO SOUND: Procedure Check: 1. S Connect the pocket tester (Ω fuses. Fuses (main and signal) S Remove the fuses. Pocket tester: 90890-03112 EB802011 1. Refer to “BATTERY INSPECTION” in CHAPTER 3. S Check the fuses for continuity. Battery S Check the battery condition.SIGNAL SYSTEM B806010 ELEC TROUBLESHOOTING IF THE TURN SIGNAL LIGHT. Fuses (main and signal) 2. Main switch 4. CONTINUITY EB802012 2. Open-circuit voltage: 12. 1) to the NO CONTINUITY Replace the fuses. S Recharge or replace the battery.

S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB806011 4. Main switch S Disconnect the main switch coupler from the wire harness. CORRECT Check the condition of each of the signal system’s circuits.SIGNAL SYSTEM : ELEC EB802017 3. 8-39 . Wiring connections S Check the connections of the entire signal system. Refer to “SIGNAL SYSTEM CHECK”. POOR CONNECTION Properly connect the signal system. Refer to “CIRCUIT DIAGRAM”.

S Turn the main switch to “ON”. Horn S Disconnect the “Pink” lead at the horn terminal. S Check the voltage (12 V) of the “Brown” lead at the horn terminal. Tester (+) lead ! Brown lead 1 Tester (–) lead ! Frame ground NO CONTINUITY Replace the left handlebar switch. S Turn the main switch to “ON”. 8-40 . OUT OF SPECIFICATION The wiring circuit from the main switch to the horn terminal is faulty. If the horn fails to sound: 1. S Connect a jumper lead 1 to the horn terminal and ground the jumper lead. Horn switch S Disconnect the left handlebar switch coupler from the wire harness. MEETS SPECIFICATION 3. repair it. Voltage S Connect the pocket tester (DC 20 V) to the horn lead.SIGNAL SYSTEM EB806020 ELEC SIGNAL SYSTEM CHECK 1. S Check for continuity as follows: Pink 1 – Black 2 CONTINUITY 2. S Disconnect the “Black/White” lead at the horn terminal.

If the brake light fails to come on: 1. Bulb and bulb socket S Check the bulb and bulb socket for continuity. CONTINUITY : Replace the bulb and/or bulb socket. Voltage S Connect the pocket tester (DC 20 V) to the horn at the “Pink” terminal. Tester (+) lead ! Brown lead 1 Tester (–) lead ! Pink S Turn the main switch to “ON”. EB806022 OUT OF SPECIFICATION Replace the horn. S Check the voltage (12 V) of the “Pink” lead at the horn terminal. MEETS SPECIFICATION Adjust or replace the horn.SIGNAL SYSTEM ELEC HORN SOUNDS The horn is not faulty. 2. HORN DOES NOT SOUND 4. NO CONTINUITY 8-41 .

S Check the voltage (12 V) of the “Yellow” lead on the bulb socket connector. S Disconnect the rear brake switch coupler from the wire harness. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. MEETS SPECIFICATION This circuit is not faulty. S The brake lever is pulled in or the brake pedal is pressed down. 8-42 . repair it.SIGNAL SYSTEM : ELEC 2. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. S Check for continuity as follows: Brown 1 – Green/Yellow 2 Black 3 – Black 4 A B A Front brake switch B Rear brake switch NO CONTINUITY CONTINUITY Replace the brake switch. 3. Tester (+) lead ! Yellow terminal 1 Tester (–) lead ! Black terminal 2 S Turn the main switch to “ON”. Brake switch S Disconnect the front brake switch leads.

Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler. MEETS SPECIFICATION : OUT OF SPECIFICATION The wiring circuit from the main switch to the flasher relay connector is faulty. S Check for continuity as follows: Brown/White 1 – Chocolate 2 Brown/White 1 – Dark green 3 Replace the bulb and/or bulb socket. NO CONTINUITY NO CONTINUITY Replace the left handlebar switch. 8-43 .SIGNAL SYSTEM EB806023 ELEC 3. If the turn signal light and/or turn indicator light fails to blink: 1. CONTINUITY 3. CONTINUITY 2. repair it. S Check the voltage (12 V) of the “Brown” 1 lead at the flasher relay terminal. Turn switch S Disconnect the left handlebar switch couplers from the wire harness. Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Frame ground S Turn the main switch to “ON”. Bulb and bulb socket S Check the bulb and bulb socket for continuity.

Tester (+) lead ! Brown/White terminal 1 Tester (–) lead ! Frame ground S Turn the main switch to “ON”. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler. MEETS SPECIFICATION This circuit is not faulty. S Turn the turn switch to “L” or “R”. repair it. replace it. MEETS SPECIFICATION 5. S Check the voltage (12 V) of the “Chocolate” lead or “Dark green” lead on the bulb socket connector. A B 1 2 At the flasher light (left): Tester (+) lead ! Chocolate lead 1 Tester (–) lead ! Frame ground At the flasher light (right): Tester (+) lead ! Dark green lead 2 Tester (–) lead ! Frame ground S Turn the main switch to “ON”.SIGNAL SYSTEM : ELEC 4. OUT OF SPECIFICATION The wiring circuit from the turn switch to the bulb socket connector is faulty. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. 8-44 . S Check the voltage (12 V) on the “Brown/White” 1 lead at the flasher relay terminal. S Turn the turn switch to “L” or “R”. A Flasher light B Turn indicator light OUT OF SPECIFICATION The flasher relay is faulty.

If the neutral indicator light fails to come on: 1. CONTINUITY 3. Bulb and bulb socket S Check the bulb and bulb socket for continuity. S Check for continuity as follows: Sky blue 1 – Light green 2 Tester (+) lead ! Sky blue 1 Continuity Tester (–) lead ! Light green 2 Tester (+) lead ! Light green 1 No Tester (–) lead ! Sky blue 2 Continuity INCORRECT Replace the diode. NO CONTINUITY NO CONTINUITY Replace the neutral switch.SIGNAL SYSTEM EB806024 ELEC 4. S Check for continuity as follows: Neutral switch terminal 1 – Ground Replace the bulb and/or bulb socket. Diode S Remove the diode from the wire harness. Neutral switch S Disconnect the neutral switch lead from the neutral switch. CORRECT : 8-45 . CONTINUITY 2.

Replace the bulb and/or bulb socket. If the oil level warning light fails to come on: 1. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket coupler. S Check the voltage (12 V). 5. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Frame ground 1 S Turn the main switch to “ON”. CONTINUITY 2. S Connect the pocket tester (Ω 100) to the starting circuit cut-off relay coupler terminals.SIGNAL SYSTEM : ELEC 4. NO CONTINUITY 8-46 . EB806025 OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. repair it. S Check the resistor for the specified resistance. Tester (+) terminal ! Black/Red terminal 1 Tester (–) terminal ! White/Black 2 OUT OF SPECIFICATION 8 Ω at 20_C MEETS SPECIFICATION : Replace the starting circuit cut-off relay. MEETS SPECIFICATION This circuit is not faulty. Bulb and bulb socket S Check the bulb and bulb socket for continuity.

Oil level switch S Drain the engine oil and remove the oil level switch from the oil pan. Tester (+) lead ! Black/Red terminal 1 Tester (–) lead ! Frame ground NO CONTINUITY ELEC S Check the oil level switch for continuity. 4.SIGNAL SYSTEM 3. S Check for continuity as follows: White/Black 1 – Black 2 Tester (+) lead ! White / Black 1 Tester (–) lead ! Black 2 Tester (+) lead ! Black 1 Tester (–) lead ! White / Black 2 INCORRECT Continuity No Continuity Replace the relay unit. Diode (starting circuit cut-off relay) S Remove the relay unit from the wire harness. S Connect the pocket tester (Ω 1) to the oil level switch. CONTINUITY Replace the oil level switch. CORRECT : 8-47 .

S Check for continuity as follows: Blue/White 1 – Black 2 ELEC NO CONTINUITY Replace the right handlebar switch. Start switch S Disconnect the right handlebar switch coupler from the wire harness. CONTINUITY 6. repair it. MEETS SPECIFICATION This circuit is not faulty.SIGNAL SYSTEM 5. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. 8-48 . S Check the voltage (12 V). Tester (+) lead ! Brown lead 1 Tester (–) lead ! Black/Red lead 2 2 1 S Turn the main switch to “ON”.

Tester (+) lead ! Green/Red terminal 1 Tester (–) lead ! Black terminal 3 S Check the fuel sender for continuity. OUT OF SPECIFICATION NO CONTINUITY ELEC Replace the bulb and/or bulb socket. S Disconnect the fuel sender coupler from the wire harness. Bulb and bulb socket S Check the bulb and bulb socket for continuity. If the fuel level warning light fails to come on or the fuel meter fails to operate: 1. S Connect the pocket tester (Ω 1) to the fuel sender. Tester (+) lead ! Green terminal 2 Tester (–) lead ! Black terminal 3 S Measure the fuel sender resistance. NOTE: Before reading the meter. Fuel sender resistance 4 : 4 X 10 Ω at 20_C 5 : 90 X 100 Ω at 20_C MEETS SPECIFICATION 3. Replace the fuel sender. S Connect the pocket tester (Ω 1) to the fuel sender. Float position Float “UP” 1 Float “DOWN” 2 Needle moves “F” “E” 8-49 DOES NOT MOVE Replace the fuel meter. stay put the float for more than three minutes respectively at “UP” or “DOWN”. CONTINUITY 2. S Connect the fuel sender to wireharness. . S Check the fuel gauge needle moves “F” or “E”. S Move the float to “UP” 1 or “DOWN” 2 . Fuel meter S Drain the fuel and remove the fuel sender from the fuel tank. S Turn the main switch to “ON”.SIGNAL SYSTEM 6. Fuel sender S Drain the fuel and remove the fuel sender from the fuel tank.

repair it. MEETS SPECIFICATION This circuit is not faulty. S Check the voltage (12 V). Tester (+) lead ! Brown terminal 1 Tester (–) lead ! Green/Red terminal 2 ELEC 1 2 S Drain the fuel. 8-50 . OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. S Turn the main switch to “ON”. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector.SIGNAL SYSTEM 3.

EB807000 CIRCUIT DIAGRAM COOLING SYSTEM 8-51 3 4 6 19 Main switch Battery Fuse (main) Thermo switch (warning light) 27 46 47 48 51 Engine temperature warning light Fan motor Thermo switch (fan) Fuse (fan) Fuse (signal) COOLING SYSTEM ELEC .

1) to the NO CONTINUITY Replace the fuse(s). Thermo switch NOTE: S Remove the following part(s) before troubleshooting. S Check the fuses for continuity. 6. Refer to “BATTERY INSPECTION” in CHAPTER 3. Fuses (main. Open-circuit voltage: 12. Main switch 4. Battery 3. S Recharge or replace the battery. signal and fan) S Remove the fuses.COOLING SYSTEM EB807010 ELEC TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN: IF THE WATER TEMPERTATURE METER FAILS TO MOVE.8 V or more at 20_C CORRECT : INCORRECT S Clean the batery terminals. WHEN THE ENGINE IS WARM: Procedure Check: 1. Wiring connections (the entire cooling system) Pocket tester: 90890-03112 EB802011 1. signal and fan) 2. Fan motor 5. Fuses (main. CONTINUITY EB802012 2. Battery S Check the battery condition. Voltage 8. Engine temperature warning light 7. S Connect the pocket tester (Ω fuses. 8-52 . 1) Seat 2) Fuel tank 3) Front cowling assembly S Use the following special tool(s) for troubleshooting.

COOLING SYSTEM : ELEC EB802017 3. replace it. MOVES : The fan motor is faulty. S Connect the battery (12 V) as shown. S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. Battery (+) lead ! Black terminal 1 Battery (–) led ! Black terminal 2 DOES NOT MOVE S Check the operation of the fan motor. CONTINUITY EB807011 4. Main switch S Disconnect the main switch coupler from the wire harness. 8-53 . Fan motor S Disconnect the fan motor coupler.

S Immerse the thermo switch in coolant 2 . Tests 1 & 2. While heating the coolant use a thermometer 3 to record the temperatures. engine temperature) S Remove the thermo switch from the thermostatic valve housing. it must be replaced. Cool-down tests f: Continuity : No continuity 98_C 105_C BAD CONDITION A THERMO SWITCH “ON” B THERMO SWITCH “OFF” Replace the thermo switch. GOOD CONDITION : 8-54 . Should it be dropped. Heat-up tests Tests 3* & 4*. Thermo switch (fan. S Connect the pocket tester (Ω 1) to the thermo switch 1 .COOLING SYSTEM : ELEC EB802017 5. Test step 1 2 3* 4* Water temperature Thermo switch 0 X 105_C More than 105_C 105 to 98_C Les than 98_C Good condition  f f  Handle the thermo switch with special care. Never subjct it to strong shocks or allow it to be dropped. S Check the thermo switch for continuity.

CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. Refer to “CIRCUIT DIAGRAM. Tester (+) lead ! Brown lead 1 Tester (–) lead ! Green/White lead 2 2 1 S Turn the main switch to “ON”. CORRECT Properly connect the cooling system. 7.COOLING SYSTEM : ELEC 6. POOR CONNECTION 8. Engine temperature warning light S Check the bulb and bulb socket for continuity. 8-55 . repair it. This circuit is not faulty. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Wiring connections S Check the connections of the entire cooling system. MEETS SPECIFICATION EB807014 OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty. S Check the voltage (12 V).

EB808000 CIRCUIT DIAGRAM FUEL PUMP SYSTEM FUEL PUMP SYSTEM 8-56 3 4 6 10 11 21 54 56 Main switch Battery Fuse (main) Fuel pump relay Ignitor unit Fuel pump Engine stop switch Fuse (ignition) ELEC .

FUEL PUMP SYSTEM EB808010 ELEC FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay. fuel pump. 1 2 3 4 5 6 7 8 Battery Fuse (main) Main switch Fuse (ignition) Engine stop switch Ignitor unit Fuel pump relay Fuel pump 8-57 . engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fuel pump.

8 V or more at 20_C CORRECT : INCORRECT S Clean the battery terminals. CONTINUITY EB802012 2. S Recharge or replace the battery. 5. S Connect the pocket tester (Ω fuses. S Check the fuses for continuity. Wiring connections (the entire fuel system) Pocket tester: 90890-03112 EB802011 1. 8-58 . Engine stop switch NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side cover (left) S Use the following special tool(s) for troubleshooting. Open-circuit voltage: 12. Battery S Check the battery condition. Battery 3. 1) to the NO CONTINUITY Replace the fuse(s). Main switch 4. Fuel pump resistance 7. Fuses (main and ignition) S Remove the fuses. Fuel pump relay (starting circuit cut-off relay) 6. Fuses (main and ignition) 2. Refer to “BATTERY INSPECTION” in CHAPTER 3.COOLING SYSTEM EB808020 ELEC TROUBLESHOOTING IF THE FUEL PUMP FAILS TO OPERATE: Procedure Check: 1.

CONTINUITY EB803023 5. CONTINUITY EB802018 4. 1 8-59 . Fuel pump relay (starting circuit cut-off relay) S Remove the relay unit from the wire harness. S Check for continuity as follows: Red/White 1 – Red/White 2 NO CONTINUITY Replace the right handlebar switch. S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit terminals.FUEL PUMP SYSTEM : ELEC EB802017 3. Main switch S Disconnect the main switch coupler from the wire harness. Engine stop switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch.

6. 7. Replace the ignitor unit.FUEL PUMP SYSTEM Battery (+) terminal ! Red/Black terminal 1 Battery (–) terminal ! Blue/Red terminal 3 Tester (+) lead ! Red/Black terminal 1 Tester (–) lead ! Blue/Black terminal 3 S Check the fuel pump relay for continuity.8 X 2. Fuel pump resistance: 1.6 Ω at 20_C MEETS SPECIFICATION EB808022 Replace the fuel pump. S Connect the pocket tester (Ω 1) to the fuel pump coupler terminals. CONTINUITY EB808021 ELEC NO CONTINUITY Replace the starting circuit cut-off relay. Refer to “CIRCUIT DIAGRAM”. Wiring connections S Check the connections of the entire fuel pump system. CORRECT POOR CONNECTION Properly connect the fuel pump system. Tester (+) lead ! Black/Blue terminal 1 Tester (–) lead ! Black terminal 2 OUT OF SPECIFICATION S Check if the fuel pump has the specified resistance. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. 8-60 .

Battery (+) lead ! Black terminal 1 Battery (–) lead ! Black terminal 2 d. If not. or any other source of fire. Fill up the fuel tank. S Take care not to spill gasoline.FUEL PUMP SYSTEM EB808030 ELEC FUEL PUMP TEST Gasoline is extremely flammable and under certain circumstances there can be danger of an explosion or combustion. Make sure that the engine is completely cool before performing the following test. Check: S Fuel pump operation a. Put the end of the fuel hose into an open container. 8-61 . b. the fuel pump is good. sparks. If fuel flows out from the fuel hose. S Do not smoke and keep away from open flames. If you do accidentally spill some. there is a danger of combustion. S If gasoline touches the engine when the engine is still hot. replace the fuel pump assembly. c. Connect the battery (12 V) to the fuel pump coupler terminals. Be extremely careful and note the following points: S Stop the engine before refuelling. wipe it up immediately with dry rags. 1.

3 seconds While the engine is stopped..000 r/min Display order on the tachometer 1. D Displays the condition code on the tachometer. Fail to the throttle position sensor Revolusion Tachometer display Engine speed Second 1 0 r / min.. Display condition code 3. 2. 8-62 .2.3 seconds 2 Display condition code. the following items are monitored and the condition codes are displayed on the tachometer (irrespective of whether the engine is running or not). When the main switch is turned to “ON”.5 seconds 3 Engine speed.3 seconds 2 Display condition code..3 seconds While the engine is stopped.2....5 seconds 3 Engine speed... the engine speed 3 is shown as 0 r/min.SELF-DIAGNOSIS SELF-DIAGNOSIS ELEC The YZF600R features self-diagnosis. the engine speed 3 is shown as 0 r/min. Item Throttle position sensor (TPS) Condition Disconnected Short-circuit Locked Response D Enables the motorcycle to run so that the ignition timing is fixed when the throttle is fully opened.000 r/min Speed sensor Disconnected short-circuit Wheel IC fails to pulse 4.... D Displays the condition code on the tachometer. Fail to speed sensor Revolusion Tachometer display Engine speed Second 1 0 r / min..

8-63 . BAD CONDITION Replace the TPS. NO CONTINUITY Repair or replace the wire harness. Replace the ignitor unit. Pocket tester: 90890-03112 1. TPS S Check the TPS for continuity. CONTINUITY 2. S Refer to “THROTTLE POSITION SENSOR (TPS) ADJUSTMENT AND INSPECTION” in CHAPTER 6. Wire harness S Check the wire harness for continuity. GOOD CONDITION.SELF-DIAGNOSIS TROUBLESHOOTING The tachometer starts to display the self-diagnosis sequence. ELEC NOTE: Use the following special tool in this troubleshooting. Throttle position sensor (TPS) CIRCUIT DIAGRAM 11 Ignitor unit 15 Throttle position sensor (TPS) 1. Refer to “CIRCUIT DIAGRAM”.

SELF-DIAGNOSIS 2. Replace the speed sensor. Speed sensor CIRCUIT DIAGRAM ELEC 11 Ignitor unit 17 Speed sensor 1. CONTINUITY NO CONTINUITY Repair or replace the wire harness. Refer to “CIRCUIT DIAGRAM”. 8-64 . Wire harness S Check the wire harness for continuity.

TRBL SHTG 9 .

. . . . . . . . . . . POOR MEDIUM-AND HIGH-SPEED PERFORMANCE . . . . . . . . . FAULTY LIGHTING AND SIGNAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRBL SHTG CHAPTER 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEAKAGE . . . . POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FZS600’98 WIRING DIAGRAM 9-1 9-1 9-1 9-2 9-2 9-2 9-2 9-2 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-5 9-5 9-5 9-5 9-5 9-5 9-5 9-5 9-5 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR MEDIUM-AND HIGH-SPEED PERFORMANCE . POOR ENGINE IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . HORN DOES NOT SOUND . . . . . . . . . . . . . . . FAULTY CLUTCH PERFORMANCE . . . . . . . FLASHER BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS-OUT-OF GEAR . . BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . OVERHEATING . . . . . . . . . . . . . . . . . . . . . POOR BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPPING . . . OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR ENGINE IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER REMAINS LIT . . . . . . . . . . . . . . FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION . . . . . . . OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLASHER BLINKS SLOWLY . . . . . . . . FUEL SYSTEM . . . . . .

TRBL SHTG .

Refer to the relative procedure in this manual for inspection. however. It should be helpful. adjustment and replacement of parts. as a guide to troubleshooting.STARTING FAILURE/HARD STARTING EB900000 TRBL SHTG TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank S Empty S Clogged fuel filter S Clogged fuel strainer S Clogged fuel tank drain hose S Clogged roll-over valve S Clogged roll-over valve breather hose S Deteriorated or contaminated fuel Fuel cock S Clogged fuel hose Carburetor S Deteriorated or contaminated fuel S Clogged pilot jet S Clogged pilot air passage S Sucked-in air S Deformed float S Worn needle valve S Improperly sealed valve seat S Improperly adjusted fuel level S Improperly set pilot jet S Clogged starter jet S Faulty starter plunger S Improperly adjusted starter cable Air filter S Clogged air filter element Fuel pump S Faulty fuel pump S Faulty fuel pump relay ELECTRICAL SYSTEM Spark plug S Improper plug gap S Worn electrodes S Wire between terminals severed S Improper heat range S Faulty spark plug cap Ignition coil S Faulty spark plug lead S Broken body Full-transistor system S Faulty ignitor unit S Faulty pickup coil Switch 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 Starter motor S Faulty starter motor S Faulty starter relay S Faulty circuit cut-off relay S Faulty starter clutch 9-1 .

electrical system.STARTING FAILURE/HARD STARTING/POOR ENGINE IDLE SPEED PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head S Loose spark plug S Loose cylinder head or cylinder S Faulty cylinder head gasket S Worn. (Fuel system. compression system and valve train) Carburetor S Faulty diaphragm S Improperly adjusted fuel level S Clogged or loose main jet Air filter S Clogged air filter element Fuel pump S Faulty fuel pump 9-2 . damaged or seized cylinder S Improperly sealed valve S Improper valve-to-valve seat contact S Improper valve timing S Faulty valve spring EB901000 TRBL SHTG Piston and piston ring S Improperly installed piston ring S Worn. fatigued or broken piston ring S Seized piston ring S Seized or damaged piston Crankcase and crankshaft S Improperly seated crankcase S Seized crankshaft POOR ENGINE IDLE SPEED PERFORMANCE POOR ENGINE IDLE SPEED PERFORMANCE Carburetor S Improperly returned starter plunger S Loose pilot jet S Clogged pilot air jet S Improperly synchronized carburetors S Improperly adjusted idle speed (throttle stop screw) S Improper throttle cable free play S Flooded carburetor Electrical system S Faulty battery S Faulty spark plug S Faulty ignitor unit S Faulty pickup coil S Faulty ignition coil Valve train S Improperly adjusted valve clearance Air filter S Clogged air filter element EB902000 POOR MEDIUM-AND HIGH-SPEED PERFORMANCE POOR MEDIUM-AND HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”.

SHIFT PEDAL DOES NOT MOVE Shift shaft S Improperly adjusted shift pedal link S Bent shift shaft Shift cam. shift fork S Groove jammed with impurities S Seized shift fork S Bent shift fork guide bar JUMPS-OUT-OF GEAR Shift shaft S Improperly adjusted shift lever position S Improperly returned stopper lever Shift fork S Worn shift fork EB904000 Transmission S Seized transmission gear S Jammed impurities S Incorrectly assembled transmission Shift cam S Improper thrust play S Worn shift cam groove Transmission S Worn gear dog FAULTY CLUTCH PERFORMANCE CLUTCH SLIPPING Clutch S Improperly adjusted clutch cable S Loose clutch spring S Fatigued clutch spring S Worn friction plate/clutch plate S Incorrectly assembled clutch CLUTCH DRAGGING Clutch S Warped pressure plate S Unevenly tensioned clutch springs S Bent push rod S Broken clutch boss S Burnt primary driven gear bushing S Bent clutch plate S Swollen friction plate S Match marks not aligned Engine oil S Improper oil level S Improper viscosity (low) S Deterioration Engine oil S Improper oil level S Improper viscosity (high) S Deterioration 9-3 .FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE EB903000 TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”.

damaged or rusty inner tube S Damaged or cracked outer tube S Damaged oil seal lip S Improperly installed oil seal S Improper oil level (too high) S Loose damper rod holding bolt S Broken cap bolt O-ring S Loose drain bolt S Damaged drain bolt gasket 9-4 . deformed or damaged inner tube S Bent or deformed outer tube S Damaged fork spring S Worn or damaged slide metal S Bent or damaged damper rod S Improper oil viscosity S Improper oil level OIL LEAKAGE S Bent.OVERHEATING/OVERCOOLING/ POOR BRAKING/FAULTY FRONT FORK LEGS EB905000 TRBL SHTG OVERHEATING OVERHEATING Ignition system S Improper spark plug gap S Improper spark plug heat range S Faulty ignitor unit Fuel system S Improper carburetor main jet setting S Improper fuel level S Clogged air filter element Cooling system S Faulty cooling fan S Faulty thermo stat S Faulty thermo switch S Improper coolant level (low) S Faulty radiator S Faulty radiator cap S Faulty water pump Compression system S Heavy carbon build-up Engine oil S Improper oil level S Improper oil viscosity S Inferior oil quality Brake S Brake drag OVERCOOLING OVERCOOLING S Faulty cooling fan EB906000 S Faulty thermo stat S Faulty thermo switch POOR BRAKING POOR BRAKING EFFECT Disc brake S Worn brake pad S Worn disc S Air in brake fluid S Leaking brake fluid S Faulty cylinder cup kit S Faulty caliper seal kit S Loose union bolt S Broken brake hose S Oily or greasy brake disc/brake pad S Improper brake fluid level EB907000 FAULTY FRONT FORK LEGS MALFUNCTION S Bent.

faulty rectifier/regulator) S Incorrect connection S Improperly grounded S Poor contacts (main or light switch) FLASHER DOES NOT LIGHT S Improperly grounded S Discharged battery S Faulty turn switch S Faulty flasher relay S Faulty wire harness S Loosely connected coupler S Burnt-out bulb S Faulty fuse FLASHER BLINKS SLOWLY S Faulty flasher relay S Faulty main and/or turn switch S Improper bulb BULB BURNT OUT S Improper bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded S Faulty main and/or light switch S Bulb life expired FLASHER REMAINS LIT S Faulty flasher relay S Burnt-out bulb FLASHER BLINKS QUICKLY S Improper bulb S Faulty flasher relay S Burnt-out bulb HORN DOES NOT SOUND S Faulty battery S Faulty fuse S Faulty main and/or horn switch S Improperly adjusted horn S Faulty horn S Broken wire harness 9-5 .UNSTABLE HANDLING/ FAULTY LIGHTING AND SIGNAL SYSTEMS EB908000 TRBL SHTG UNSTABLE HANDLING UNSTABLE HANDLING Handlebar S Improperly installed or bent Steering S Improperly installed handlebar crown S Bent steering stem S Improperly installed steering shaft (improperly tightened ring nut) S Damaged ball bearing or bearing race Swingarm S Worn bearing or busing S Bent or damaged Rear shock absorber S Faulty spring S Oil and gas leakage Tire S Uneven tire pressures on both sides S Incorrect tire pressure S Uneven tire wear Front fork S Uneven oil levels on both sides S Uneven spring tension S Broken spring S Twisted front fork Wheel S Incorrect wheel balance S Deformed cast wheel S Damaged bearing S Bent or loose wheel axle S Excessive wheel runout Frame S Bent S Damaged steering head tube S Improperly installed bearing race EB909000 FAULTY LIGHTING AND SIGNAL SYSTEMS HEADLIGHT DOES NOT LIGHT S Improper bulb S Too many electric accessories S Hard charging (broken stator coil wire.

TRBL SHTG .

Y . . . . . . R/B . . . L/B . B/W ... . . . .. Black/Blue Black/Red Black/ Black/Yellow Brown/Blue Brown/White Green/Red G/W . . .. .C. R/Y . .. . .. . .. ... . W . Br/W . B/R . L/R . . . Y/R . . . Brown Ch . . .. . R. . Gray L . Green/White Green/Yellow Blue/Black Blue/Red Blue/White Blue/Yellow Red/Black R/W . Black Br .. . W/R . . .. Dark green G . . . Sb . . G/Y . . L/Y . W/B .. Br/L . . .. . Pink Light green Orange Red Sky blue White Yellow B/L . . magneto Rectifier/ regulator Main switch Battery Fuse (back up) Fuse (main) Starter relay Starter motor Starting circuit cut-off relay Fuel pump relay Ignitor unit Ignition coil Spark plug Pick up coil Throttle position sensor Neutral switch speed sensor Fuel sender Thermo switch (engine temperature) Diode Fuel pump Sidestand switch Speedometer Tachometer Fuel meter Fuel level warning light Engine temperature warning light Neutral indicator light Oil level warning light High beam indicator light Turn indicator light Meter light Clutch switch Oil level switch Flasher relay Horn Pass switch Dimmer switch Horn switch Turn switch Front turn signal light Rear turn signal light Headlight Tail/ Brake light Auxiliary light Fan motor Thermo switch (fan motor) Fuse (fan) Fuse (head) Rear brake switch Fuse (signal) Front brake switch Light switch Engine stop switch Starter switch Fuse (ignition) Alarm (option) COLOR CODE B .. .. . . L/W . . .. .. Blue P . . . O . G/R . . Lg . . Red/White Red/Yellow White/Black White/Green White/Red Yellow/Black Yellow/Red . . . . Chocolate Dg . . . B/Y . .FZS600 ’98 WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 A. Y/B . W/G . Green Gy .

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