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    FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XT225N(C). For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with the following manual. XT225D/XT225DC SERVICE MANUAL: LIT-11616-07-99 (4BE-28197-20) XT225H/XT225HC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-10-05 (4BE-28197-21) XT225N(C) SUPPLEMENTARY SERVICE MANUAL © 2000 by Yamaha Motor Corporation, U.S.A. First edition, October 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. PIN LIT-11616-14-42 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, itis imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This Policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal- ers and will appear in future editions of this manual where applicable. NOTE: * This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully * Designs and specifications are subject to change without notice. IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. a The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! EIGIINEM Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. “CAUTION: — A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: ANOTE provides key information to make procedures easier or clearer. HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL, This manual consists of chapters for the main categories of subjects. (See “SYMBOLS") Ast title ©: This is a chapter with its symbol on the upper right of each page. 2nd title @: This title appears on the upper of each page on the left of the chapter sym- bol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) 3rd title @: This is a final title MANUAL FORMAT Allof the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure @ is placed between a jine of asterisks “** with each pro- cedure preceded by “e”. IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol ©. «An encircled numeral © indicates a part name, and an encircled alphabetical letter data or an alignment mark @, the others being indicated by an alphabetical letter in a box ‘* A condition of a faulty component will precede an arrow symbol and the course of action required the symbol ©. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures, SYMBOLS The following symbols are not relevant to every vehicle. Symbols @ to @ indicate the subject of each chapter. @ General information ® Specifications @ Periodic checks and adjustments @ Engine © Carburetion © Chassis © Electrical system © Troubleshcoting Symbols @ to ® indicate the following. © Filling fluid @ Lubricant @ Special tool ® Tightening torque @ Wear limit, clearance @ Engine speed @ Electrical data Symbols ® to @ in the exploded diagrams indicate the types of lubricants and lubrication points. ® Engine oll © Gear oil ® Molybdenum disulfide oil ® Wheel bearing grease @ Lithium soap base grease @ Molybdenum disulfide grease Symbols @ to @ in the exploded diagrams indicate the following. @ Apply locking agent (LOCTITE®) @ Replace the part CONTENTS SPECIFICATIONS z GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS. CHASSIS SPECIFICATIONS... ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES....... ENGINE TIGHTENING TORQUES. CHASSIS TIGHTENING TORQUES. CABLE ROUTING...... PERIODIC INSPECTION AND ADJUSTMENT. ENGINE...coco Eee eer THROTTLE CABLE FREE PLAY ADJUSTMENT... ENGINE. z paneer ENGINE ASSEMBLY AND ADJUSTMENT. CLUTCH AND OIL PUMP. CYLINDER HEAD . CAMSHAFT AND TIMING CHAIN CHASSIS . . FRONT BRAKE. 26 ELECTRICAL. . CHECKING OF SWITCHES. 27 SWITCH CONNECTION AS SHOWN IN MANUAL......c CHECKING SWITCH FOR TERMINAL CONNECTION .... XT225N/XT225NC WIRING DIAGRAM GENERAL SPECIFICATIONS [SPEC SPECIFICATIONS GENERAL SPECIFICATIONS item Standard Limit Model code aBEV 4BEW (For California) Dimensions Overall length 2,070 mm (81.5 in) Overall width 805 mm (31.7 in) ‘Overall height 1,160 mm (45.7 in) Seat height 810 mm (31.9 in) Wheelbase 1,950 mm (53.1 in) Minimum ground clearance Minimum turning radius 285 mm (11.2 in) 1,900 mm (74.8 in) Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories) 121 kg (267 Ib) 108 kg (238 Ib) 183 kg (404 Ib) ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS |SPEC| Ttem Standard Limit Engine Engine type Air-cooled, 4-stroke, SOHC Displacement 223 om® Cylinder arrangement Forward inclined single cylinder Bore x stroke 70 x 58 mm (2.76 x 2.28 in) Camshaft cap inside diameter Camshaft journal diameter Camshaft-joumal-to-camshaft-cap clearance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A. Measurement B Measurement C Compression ratio 95:1 Engine idling speed 1,300 ~ 1,500 r/min Standard compression pressure 1,200 kPa (at sea level) (12.0 kgf/om?, 174 psi) at 1,000 r/min ‘Camshaft Drive system Chain drive (left) 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 24,960 ~ 24.980 mm (0.9827 ~ 0.9835 in) 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) 36.51 ~ 96.61 mm (1.497 ~ 1.441 in) 30.1 ~ 30.2 mm (1.185 ~ 1.189 in) 6.50 ~ 6.62 mm (0.256 ~ 0.261 in) 36.51 ~ 36.61 mm (1.437 ~ 1.441 in) 30.15 ~ 30.25 mm (1.187 ~ 1.191 in) 6.50 ~ 6.62 mm (0.256 ~ 0.261 in) 36.41 mm, (1.43 in) 30.0 mm (1.18 in) 36.41 mm, (1.43 in) 30.05 mm, (1.18 in) ENGINE SPECIFICATIONS |SPEC| Item Standard Limit Max. camshaft runout 0.03 mm (0.0012 in) —Se =o Timing chain Modelinumber of links Tensioning system Borg Wamer 92RH/104 Automatic Valve springs Inner springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt otrc* Intake Exhaust Winding direction (top view) Intake Exhaust 36.17 mm (1.42 in) 36.17 mm (1.42 in) 30.5 mm (1.20 in) 30.5 mm (1.20 in) 75.0 ~91.7N (7.50 ~ 9.17 kgf, 16.9 ~ 20.6 Ib) 75.0~91.7N (7.50 ~ 9.17 kgf, 16.9 ~ 20.6 Ib) Counterclockwise Counterclockwise C) 34.35 mm, (1.35 in) 34.35 mm, (1.35 in) 25°/1.6mm (25° (0.063 in) 25° /1.6mm (25° (0.063 in) ENGINE SPECIFICATIONS |SPEC| Ttem Standard Limit ‘Outer springs Free length Intake 36.63 mm (1.44 in) 34.80 mm (1.37 in) Exhaust 36.63 mm (1.44 in) 34,80 mm, (1.37 in) Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt a * Intake Exhaust Winding direction (top view) 32.0 mm (1.26 in) 32.0 mm (1.26 in) 128.5 ~ 157.9N (12.9 ~ 15.8 kgf, 28.9 ~ 35.5 Ib) 128.5 ~ 157.9N (12.9 ~ 15.8 kgf, 28.9 ~ 35.5 Ib) 2.5°/1.6mm (2.5° /0.063 in) 2.5°/1.6mm (25° (0.063 in) Intake Clockwise Exhaust Clockwise Piston Piston-to-cylinder clearance Diameter D Height H 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 69.960 ~ 69.975 mm (2.7543 ~ 2.7549 in) 5.0 mm (0.2 in) 0.15 mm (0.0059 in) ENGINE SPECIFICATIONS |SPEC| Item Standard Limit Piston pin bore (in the piston) Diameter 16.002 ~ 16.013 mm (0.6300 ~ 0.6304 in) | 16.043 mm, (0.6316 in) Offset Offset direction Piston pin Outside diameter Piston-pin-to-piston-pin-bore clear- ance Piston rings Top ring 2 pT Ring type Dimensions (B xT) End gap (installed) Ring side clearance 2nd ring [ \ Te bt Ring type Dimensions (B xT) End gap (installed) Ring side clearance Oil ring Dimensions (B x T) End gap (installed) 0.5 mm (0.0197 in) Intake side 15,991 ~ 16,000 mm (0.6296 ~ 0.6299 in) 0.002 ~ 0.022 mm (0.000079 ~ 0.000866 in) Barrel 1.2.x 2.8 mm (0.05 x 0.11 in) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.08 ~ 0.07 mm (0.0012 ~ 0.0028 in) Taper 1.2 x 2.8 mm (0.05 x 0.11 in) 0.15 ~ 0.30 mm (0.006 ~ 0.011 in) 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 2.5 x 2.8mm (0.10 x 0.11 in) 0.3 ~ 0.9 mm (0.01 ~ 0.04 in) 15.971 mm. (0.6288 in) 0.072 mm (0.0028 in) 0.55 mm (0.02 in) 0.12 mm (0.0047 in) 0.65 mm (0.025 in) 0.12 mm (0.0047 in) Clutch Clutch type. Clutch release method Operation Friction plates Thickness Plate quantity Wet, multiple disc Inner push, cam push Left-hand operation 2.9 ~ 3.1 mm (0.11 ~ 0.12 in) 6 2.8mm (0.110 in) ENGINE SPECIFICATIONS |SPEC| Tem) ‘Standard Limit Clutch plates Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Push rod bending limit 4.5 ~ 1.7 mm (0.06 ~ 0.07 in) 5 37.3 mm (1.47 in) 4 0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in) 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) 0.2mm (0.008 in) 35.3 mm (1.39 in) 0.5mm (0.02 in) Carburetors Model (manufacturer) x quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypess 1 Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level (below the line on the vac- uum chamber) BST34 (MIKUNI) x 1 3 ~5 mm (0.12 ~ 0.20 in) BEV 30 ABEW 20 (for California) #125 10 5DL27-1 0-4 #70 #2 0.85 #40 08 20 #65 08 #130 11.5 mm (0.45 in) CHASSIS SPECIFICATIONS |SPEC| CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type With tube Size 2.75-21-45P Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 Ib) 90 ~ 188 kg (198 ~ 404 Ib) ‘TW27 (BRIDGESTONE) C-6006 (CHENG SHIN) 125 kPa (1.25 kg/om?, 18 psi) 150 kPa (1.5 kg/om?, 22 psi) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 Ib) 90 ~ 197 kg (198 ~ 434 Ib) Min. tire tread depth Min. tire tread depth _ 1.0 mm (0.04 in) Rear tire Tire type With tube _ Size 120/80-18-62P Model (manufacturer) ‘TW30 (BRIDGESTONE) (©-6006 (CHENG SHIN) 150 kPa (1.5 kg/cm?, 21.8 psi) 175 kPa (1.75 kg/cm?, 25.4 psi) 1.0mm (0.04 in) Front brake Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake disc Diameter x thickness Min, thickness Max. deflection Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Single-dise brake Right-hand operation 2 ~ 5mm (0.08 ~ 0.20 in) DoT4 220 x 3.5 mm (8.66 x 0.14 in) 5.3 mm (0.21 in) 11 mm (0.43 in) 26.9 mm (1.06 and 22.2 mm (0.87 in) 3.0mm (0.12 in) 0.15 mm (0.0059 in) 0.8mm (0.08 in) CHASSIS SPECIFICATIONS |SPEC| Ttem Standard Limit Rear brake Brake type Leading, trailing - drum brake Operation Right-foot operation Brake pedal position 10 mm (0.39 in) oo Brake drum Inside diameter Lining thickness ‘Shoe spring free length 110 mm (4.33 in) 4mm (0.16 in) 50.5 mm (1.99 in) 111 mm (4.37 in) 1.5mm (0.06 in) Front suspension Suspension type Front fork type Front fork travel Spring Free length Spring rate (K1) Spring stroke (K1) Spring rate (K2) Spring stroke (K2) Optional spring available Standard enclosed gas/air pressure Fork oil Recommended oil ‘Quantity (each front fork leg) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Telescopic fork Coil spring/oil damper 225 mm (8.86 in) 594.7 mm (23.41 in) 3.4. Nimm (0.34 kgtimm, 19.4 Ibvin) 0 ~ 105 mm (0 ~ 4.13 in) 3.9 Nimm (0.39 kgf/mm, 22.27 Ib/in) 105 ~ 230 mm (4.13 ~ 9.06 in) No 2,000 kPa (20 kgf/cm?, 290 psi) Fork oil 10 W or equivalent 366 om? (12.9 Imp oz, 12.4 US oz) 140 mm (6.51 in) 582.8 mm (22.94 in) Steering Steering bearing type No,/size of steel balls (upper) Ball and taper roller bearing 19 pes./0.1875 in Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Swingarm (link suspension) Coil spring gas/oil damper 72 mm (2.83 in) 174 mm (6.85 in) 60.3 N/mm (6.03 kgtimm, 344.3 Ib/in) 0 ~ 87 mm (0 ~ 3.43 in) No CHASSIS SPECIFICATIONS |SPEC| Item Standard Limit Drive chain Model (manufacturer) 428V2 (DAIDO) Link quantity 120 Drive chain slack 85 ~ 45 mm (1.38 ~ 1.77in) ELECTRICAL SPECIFICATIONS |SPEC| ELECTRICAL SPECIFICATIONS Ttem Standard Limit Ignition coil Model (manufacturer) 2JN (YAMAHA) Minimum ignition spark gap 6 mm (0.24 in) Primary coil resistance 0.18 ~ 0.280 Secondary coil resistance 6.32 ~ 9.48 ko CDI CDI magneto model (manufacturer) CDI unit model (manufacturer) Pickup coil resistance Source coil resistance 4JG1 (YAMAHA) 3GX (YAMAHA) 803.6 ~ 836.4 Q/R-W 600 ~ 900 2/Br-G 472 ~ 708 QNY-G Charging system System type Model (manufacturer) Nominal output Stator coil resistance ‘AC magneto 4JG1 (YAMAHA) 14 V/12.1 A at 5,000 r/min 0.48 - 0.720 Rectifier regulator Regulator type Model (manufacturer) Semiconductor, short circuit ‘SH629A-12 (SHINDENGEN) No-load regulated voltage 141~14.9V Rectifier capacity 10A Withstand voltage 200V Battery Battery type GT6B-3 Battery voltage/capacity 12. V/6 AH Specific gravity 1.320 Bulbs (voltage/wattage x quantity) Headlight Tail/brake light Front tum signal light 12.V 60 Wi55 Wx 1 12V 8 Wi27 Wx14 12.V 27 WI8W x2 Rear tum signal light 1227 Wx2 Meter light 12V3.4Wx14 Electric starting system System type Constant mesh _ Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Armature coil resistance Commutator diameter Mica undercut 4JG (YAMAHA) 0.4 kW 40 mm (0.39 in) 5.52 ~ 8.28 N (552 ~ 828 gf, 19.9 ~ 29.8 02) 0.013 ~ 0.015 22 mm (0.87 in) 4.5 mm (0.06 in) 3.5mm (0.14 in) 21mm (0.83 in) =10- ELECTRICAL SPECIFICATIONS |SPEC| Item Standard Limit Starter relay Model (manufacturer) MSSF-651 (JIDECO) ‘Amperage 180A Coil resistance 3.52 ~ 5.282 eo Horn Horn type Plane Model (manufacturer) x quantity Max. amperage Performance Coil resistance GF-12 (NIKKO) x 4 15A 95 ~ 105 db/2 m 43-489 Turn signal relay Relay type Model (manufacturer) Self-cancelling device builtin Tum signal blinking frequency Wattage Full transistor FE246BH (DENSO) No 75 ~ 95 cyclesimin. 27Wx2+3.4W Fuses (amperage x quantity) Main fuse Reserve fuse 20Ax1 20Ax1 TIGHTENING TORQUES [SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Part name | "E24 cry, Tightening torque | parks size Nm [m-kgf ftlb Breather assembly Screw | M6) 2] 10 | 10 72 Tensioner Bot | M6 | 2/75 |075 54 Air fiter case Bot | M6 | 2] 10|10 72 Carburetor joint clamp Screw | M4) 2] 2 | 02 14 Air fiter case (front) Screw | M6) 1| 7 | 07 54 Air filter case (rear) Bot | M6) 2| 7 |o7 54 Exhaust pipe protector Screw | M6 | 3| 7 | 07 5.1 Muttler protector Screw | Me) 2| 7 | 07 54 Exhaust pipe and muffler link Bot | M8) 1| 20 | 20 14 crankcase 1 & 2 Bot | M6 | 7] 10 | 10 72 ICrankcase 1 & 2 Bot | M6 | 2] 10|10 72 ICrankcase 1 & 2 Bot | M6 | 2] 10|10 72 ICrankcase 1 & 2 Bot | M6 | 1] 10 | 10 72 ICrankcase cover 1 Bot | M6 |6| 10 | 10 72 ICrankcase cover 1 Bot | M6 | 2] 10|10 72 Ignition coil lead clamp Bot | M6 | 1] 10 | 10 72 ICrankcase cover 2 Bot | M6 | 2] 10 | 10 72 ICrankcase cover 3 Bot | M6 | 5 | 10 | 10 72 ICrankcase cover 3 Bot | M6 | 3| 10 |10 72 ICrankcase cover 3 Bot | M6 | 2] 10|10 72 Starter clutch assembly Bot__| Ms | 3 | 30 | 30 22 CHASSIS TIGHTENING TORQUES Part to be tightened Thread | Tightening torque | a narks size [Nm [mkgf] fib [Chift pedal assembly Me | 10 | 10 | 72 +12- CABLE ROUTING |SPEC| CABLE ROUTING @ Clutch cable @ Indicator light box lead @ Brake hose @ Main switch lead @ Throtle cable @® Speedometer cable @ Band ® Speedometer lead © Frontbrake switch lead @ Flasher light lead (left) @ Handebar switch lead (right) Pass the starter cable to the front of the clutch @ Handebar switch lead (left) cable and the throttle cable. Clutch switch lead Pass the throttle cable through the guide. @ Flasher light lead (right) Pass the brake hose through the guide. CABLE ROUTING |SPEC| Route the clutch switch load between the handle 1D Align the end of the brake master cylinder holder with the punch mark in the handlebar. crown and meter and through the head pipe [EJ Align the slit of clutch lever holder with the punch guide (left) ark on the handlebar. TH Clamp the flasher light lead (let), speedometer lead, lign the end of the handlebar switch (left) with ‘main switch lead and handlebar switch lead (eft) the punch mark on the handlebar. To headlight. [| Route the front brake switch lead and handlebar —_[K] Align the locating tape on the wirehamess with switch lead (right) between the handlebar crown the headlight stay. and speedometer, then through the head pipe Clamp the wirehamess. guide (left). 10° 14. CABLE ROUTING |SPEC| @ Speedometer cable @ Clutch cable © Cable holder @ Sidestand switch lead @ Brake hose @ Overflow hose @ Brake hose holder @ Hom lead © Cable guide ® Cable holder © Cable guide @ Rear brake switch lead @ Front brake switch lead @ Handle switch lead (right) @ Throttle cable @ Starter cable CABLE ROUTING |SPEC| Pass the handlebar switch lead (right) front brake —_[E] Fasten the flasher light lead (left) and sidestand switch lead, clutch switch lead, starter cable, switch lead with a plastic locking tie. throttle cable and clutch cable through the guide. Fasten the flasher light lead (left) with a plastic Fasten the front brake switch lead, clutch switch locking tie. lead and handlebar switch lead (right) with a Fasten the sidestand switch lead with a metal lastic locking tie. ‘clamp. fasten the wirehamess, throttle cable, clutch [HJ Fasten the sidestand switch lead with a plastic cable and starter cable with a plastic clamp. locking tie. 1D Fasten the wireharness with a plastic locking tie. [1] Guide (engine side) fasten the handlebar switch lead, clutch switch lead, front brake switch lead, starter cable, clutch cable and throttle cable with a plastic lock= ing tie. [Align the portion of the front brake hose marked ith white paint with the clamp. lamp the front brake hose. [Fasten the front brake hose and speedometer cable with a plastic locking tie. CABLE ROUTING |SPEC| [Fasten the flywheel magneto lead, pulser coil lead, battery lead (-), starter motor lead and rear brake switch leads with a plastic locking tie Fasten the flywheel magneto lead, pulser coil lead, battery lead (-) and starter motor lead with ‘a metal clamp. [B To engine. CABLE ROUTING |SPEC| @ Starter motor lead © Overtiow hose (for California only) © Battery lead (-) @ CDI unit lead @ Battery ‘@ Battery lead (+) @ Ground lead @ Starter relay © Pulser lead ] Fasten the flasher light lead (right) and taillight © Flywheel magnet lead lead with a plastic locking tie, @ Wirehamess Fasten the flywheel magneto lead, pulser coil @ Hom lead lead, battery lead (-), starter motor lead and © Diode wirehamess with a plastic locking ti. ® Canister (for Cali‘omia only) Align the white tape with the arrow mark. 1D] Fasten the clutch cable with a plastic locking tie. [E] Pass the canister hose through the guide (for California only), Fasten the canister hose (for California only) and wirehamess with a plastic clip. [G| Fasten the wireharness with a plastic clamp. Pass the canister hose through the guide (for California only). CABLE ROUTING |SPEC| (Fasten the starter motor lead with a metal clamp. Fasten the battery lead (+) with a plastic clamp. [Fasten the flasher light lead (right) and taillight lead with a locking tie. -19- CABLE ROUTING |SPEC| @ Wirehamess Fasten the flasher light lead (left) with a metal © Rectifier/regulator clamp. @ Flasher light lead (right) Fasten the relay lead, flasher light lead (left) and @ Tailibrake light lead sidestand switch lead with a plastic clip. © Flasher light lead (left) 1 Clamp the flywheel! magneto lead. © Sidestand switch lead [A] Fasten the flasher light lead (right) and tailight lead with a metal clamp. Fasten the tailight lead with a metal clamp. -20- THROTTLE CABLE FREE PLAY ADJUSTMENT PERIODIC INSPECTION AND ADJUSTMENT ENGINE THROTTLE CABLE FREE PLAY ADJUSTMENT Nove: — Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1. Check: « Throttle cable free play @ Out of specification — Adjust. Throttle cable free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Remove: * Side covers Seat Air scoops ¢ Fuel tank Refer to the “SEAT, FUEL TANK AND COVER’ section. 221 CHK THROTTLE CABLE FREE PLAY ADJUSTMENT | ADJ 3. Adjust « Throttle cable free play Adjustment steps: Note; When accelerating, throttle cable #1 @ is pulled and throttle cable #2 @ is pushed. First step: # Loosen the locknut @ on throttle cable #2. «Turn the adjuster @ in or out until all slack is removed from throttle cable #2. Second step: « Loosen the locknut © on throttle cable #1. « Turn the adjuster © in or out until the speci- fied free play is obtained. Turning in | Free play is increased. Tur gout | Free play is decreased. « Tighten the locknut, NoTe: — If the free play can not be adjusted here, adjust it at the throttle grip side of the cable. inal step: # Loosen the locknut @. «Tum the adjuster @ in or out until the speci- fied free play is obtained. Turning in | Free play is increased. Turing out | Free play is decreased. « Tighten the locknut, A WARNING After adjusting the free play, turn the han- dlebar to right and left, and make sure that the engine idling does not run faster. « Install the fuel tank, seat and the side covers. Bolts (fuel tank, air scoops, seat and side cover): ‘7 Nm (0.7 mekg, 5.1 ftelb) +22- ENGINE ASSEMBLY AND ADJUSTMENT | ENG ENGINE ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH AND OIL PUMP © Clutch spring @ Cuutch boss © Primary dive gear © Prossure plate Thrust washer ® Oil pump gear cover © Push plate @® Primary driven gear © Oil pump driven gear @ Push rod 1 @ Bal ® Oil pump © Clutch plate © Push rod 2 @ Gasket © Friction plate @ Push lover FRICTION PLATE THICKNESS: ‘CLUTCH SPRING MINIMUM | 2.90~ 3.10 mm (0.114 ~ 0.122 in) B| FREE LENGTH: : 35.3 mm (1.39 in) eee ‘CLUTCH PLATE WARPAGE | Lin: 0.2 mm (0.008 in) Tm (0.7 m=kg. 5.1 0-15) -23- ENGINE ASSEMBLY AND ADJUSTMENT | ENG “on CYLINDER HEAD @ Bolt @ Dowel pin @ Washer @ Grommet © Spark plug ® Cylinder head gasket @ Tappet cover (intake) ® Breather cover © O-ring ® O-ring © Bolt (oil check) ® O-ring © Tappet cover (exhaust) ® Cylinder head side cover Oxing © Cylinder head > ‘SPARK PLUG TYPE: DRBEA (N.G.K.), X24ESR-U (DENSO) ‘SPARK PLUG GAP: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) CYLINDER HEAD WARPAGE uit: 0.03 mm (0.0012 in) 22 Nm (2,2 m- kg, 16 ft-Ib) \ TONm (1.0m kg, 7.2 ft-lb) 20 Nm (2.0 m~ kg, 14 ft Ib) ENGINE ASSEMBLY AND ADJUSTMENT | ENG CAMSHAFT AND TIMING CHAIN @ Gasket © Timing chain tensioner @ Gasket @ Timing chain guide (intake side) @® Camshaft @Pin @ Cam sprocket Timing chain Timing chain guide (exhaust side) ‘SHAFT-TO-CAP CLEARANCE: 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) ‘CAMSHAFT RUNOUT LIMIT: 0.03 mm (0.0012 in) > -25- FRONT BRAKE CHAS| 5%) CHASSIS FRONT BRAKE @ Master cylinder cap @ Pad spring @ Diaphragm @ Caliper bracket @ Master cylinder kit @ Brake pads @ Master cylinder @ Piston, @ Holder (brake hose and meter cable) © Dust boot © Brake hose @ Piston seal © Brake caliper body © Brake disc © Rubber boot ® Cable holder "a ] BRAKE FLUID TYPE: pat 1.5Nm 7 Nm is) (0.15 m+ kg, 1.1 ft+ Ib)|] (0.7 m+ kg, 5.1 ft Ib), BRAKE PAD WEAR LIMIT: 0.8 mm (0.03 in) BRAKE DISC WEAR LIMIT: 3.0 mm (0.12 in) [27 Nm (2.7 m+ kg, 19 ft Ib) Nm (0.6 m+kg, 4.3 ft+Ib) (8.5 m-kg, 25 ft- Ib) AS 0.Nm (1.0 m= kg, 7.2 ft-1b) CHECKING OF SWITCHES ELECTRICAL CHECKING OF SWITCHES NOTI This section is written based on a general model. Check the switches for the continuity between the terminal to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, bracket switch, lighting switch etc.) The extreme left column indicates the switch positions and the top line indicates the colors of leads of connected with the terminals in the switch component. “O—©" indicates the terminals between which there is a continuity of electricity; ie, a closed circuit at the respective switch posi- tions. In this chart: “R and Br" and “B/W and B" are continuous with the “ON" switch position. R | Br [BW B ON | O+-0 | O+0 OFF LOCK, CHECKING SWITCH FOR TERMINAL CONNECTION Before checking the switch, refer to the con- ection chart as shown above and check for the correct terminal connection (closed circuit) by the color combination To explain how to check the switch, the main switch taken for example in the following, 227+ CHECKING OF SWITCHES 1. Disconnect the main switch coupler from. the wirehamess. “disconnect the main switch coupler by pulling the leads. Otherwise, leads may be pulled off the terminals inside the cou- pler. 2. Inspect whether any lead is off the termi- nal inside the coupler. If itis, repair it. NOTE: ss If the coupler is clogged with mud or dust, blow it off by compressed air. 3. Use the connection chart to check the color combination for continuity (a closed R_| Br |B B circuit). In this example, the continuity is ON | O-FO | O--O. as follows. Orr “R and Br’ and “BIW and B” are continu- LOCK ous with the “ON” switch position. Please note that there is no continuity (an open circuit) at all for the color combina- tions other than the above. 4. Check the switch component for the con- tinuity between “R and Br’ +28- CHECKING OF SWITCHES Checking steps: ‘« Tum the switch key to the “ON”, “OFF” and ‘LOCK’ several times. «# Set the pocket tester selector to the “Q x 1" le ‘* Connect the tester (+) lead to the “R” lead terminal in the coupler and the (-) lead to the “Br' lead terminal. NoTe: — Use thin probes for checking the continuity. Otherwise, the probes may contact other ter- minals inside the couplet. ‘¢ Check the continuity between “R” and “Br” at the switch position “ON” @, “OFF” @ and “LOCK” @. There must be continuity (the tester indicat- ing “0") at the “ON” switch position, and there must be no continuity (the tester indicating co") at “OFF” or “LOCK”. There is something wrong between “R” and “Br’ if there is no continuity at the "ON" posi- tion or if there is some continuity either at the

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