YAMAHA KJ9005(6)* SERVICE MANDAL OpnNOTICE ‘This manual was written by the Yamaha Motor Company primarily for use by Yamaha deat- rs and their qualified mechanics. Its not possible to put an entire mechanic's education into ‘one manual, $0 it ig assumed that persons using tFis book to perform maintenance and repairs on Yamaha motorcycles have a basic understending of the mechanical concepts and procedures inherent in motoreyele repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use andlor unsafe. Yamaha Motor Company, Ld. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be for- warded to all Authorized Yamaha dealers and will, where applicable, appear in future edi- tions ofthis manu PARTICULARY IMPORTANT INFORMATION ‘This material is distinguished by the following notation “The Safety Alen Symbol means ATTENTION! BECOME ALERT! YOUR a SAFETY IS INVOLVED! FREUEUNINEY Fell to follow WARNING instructions could result in severe injury or death to the motoreycle operate, @ bystander, or a person inspecting Or repairing the motorcycle. (RENUHIONRY A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle, Nore: NOTE 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. (Seo “llustrated sym bois") settle O: ‘This ie chapter with its symbol on the upper right of each page. 2nd title @: ‘This ttle appoars on the upper of ach page on the lat of the chapter ‘symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) ardtitle @: “This is a final tte. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The Information has baen compiled to provide the mechani: with an easy to read, handy refer tence that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. {A sot of particularly important procedure @ is placed between teach procedure preceded by "®”. IMPORTANT FEATURES ‘+ Data and a special tool are framed in @ box preceded by a rolevant symbol @ An encircled numeral © indicates a part namo, and an encircled alphabetical letter data or ‘an alignment mark @, the others boing indicated by an alphabotical lator in a box @. «+ Acondition ofa faulty component will precede an arrow symbol and the course of action ‘required the symbol ©. EXPLODED DIAGRAM. Each chapter provides exploded dlagrams before each dsassombly section for ease in identi- tying corcect disassembly and assembly procedures. 1 of asterisks “¥“withILLUSTRATED SYMBOLS. (Refer to the illustration) Illustrated symbols @ to @ are designed as thumb tabs to indicate the chapter's num ber and content. © Genera information @ Specfcatons {@ Peri inspection and adlustmont @Trousteshooting Iustrated symbols © 10 ® are used to identity the specifications appearing in tho text @ Filing tis DLupr Iustrted symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply engine oil (@ Apply gear oi! {© Apply molyadenum disulfide oi {@ Apply whee! bearing groase © AppW lightweight ithium-so9p base grease @ App molybdenum dsutide grease Aoply locking agent (LOCTITE®) @ Use tew oneINDEX GENERAL INFORMATION er SPECIFICATIONS a SPEC iY, PERIODIC INSPECTION AND ae ADJUSTMENT SKE ENGINE OVERHAUL ae CARBURETION oe CHASSIS LE ELECTRICAL TROUBLESHOOTING | TRBL > fils sHTG KeCONTENTS CHAPTER 1. GENERAL INFORMATION (MOTORCYCLE IDENTIFICATION. aot VEHICLE IDENTIFICATION NUMBER (For E, AUS and NZ) cnn FRAME SERIAL NUMBER (Except for E, AJS and NZ). + ENGINE SERIAL NUMBER. . 1 IMPORTANT INFORMATION... PREPARATION FOR REMOVAL. a ALL REPLACEMENT PARTS xo GASKETS, OIL SEALS, AND O-RINGS... LOCK WASHERS/PLATES AND COTTER FINS. BEARINGS AND OIL SEALS. . CIRCLIPS. SPECIAL TOOLS 1 FOR TUNE UP nn +4 FOR ENGINE SERVICE... 15 FOR CHASSIS SERVICE ws cn 8 FOR ELECTRICAL COMPONENTS. vines CHAPTER 2. SPECIFICATIONS 2A GENERAL SPECIFICATIONS. [MAINTENANCE SPECIFICATIONS ENGINE. - CHASSIS... ELECTRICAL EXCLUSIVE SPECIFICATION, HOW TO USE THE CONVERSION TABLE. 221 (GENERAL TORQUE SPECIFICATIONS... 221 LUBRICATION POINT AND GRADE OF LUBRICANT. sn 92D ENGINE 2.22 CHASSIS : 2.23LUBRICATION DIAGRAMS on. : ‘CABLE ROUTING. CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION... PERIODIC MAINTENANCE/LUBRICATION INTERVALS SSIDE COVER, FUEL TANK AND COWLING, REMOVAL... i INSTALLATION... i ENGINE - \VALVE CLEARANCE ADJUSTMENT. CARBURETOR SYNCHRONIZATION. IDLING SPEED ADJUSTMENT. THROTTLE CABLE ADJUSTMENT. ‘SPARK PLUG INSPECTION wo IGNITION TIMING CHECK. oe ‘COMPRESSION PRESSURE MEASUREMENT ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT CLUTCH ADJUSTMENT. AIR FILTER CLEANING. FUEL LINE INSPECTION.. CHASSIS. FRONT BRAKE LEVER POSITION ADJUSTMENT. REAR BRAKE ADJUSTMENT. [BRAKE FLUID LEVEL INSPECTION. [BRAKE PAD INSPECTION BRAKE LIGHT SWITCH ADJUSTMENT. BRAKE HOSE INSPECTION. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)... FINAL GEAR OIL LEVEL INSPECTION. FINAL GEAR OIL REPLACEMENT... ‘STEERING HEAD INSPECTION FRONT FORK INSPECTION wn REAR SHOCK ABSORBER ADJUSTMENT... 24TIRE INSPECTION, WHEEL INSPECTION = “aa2 CABLE INSPECTION AND LUBRICATION. vrcornnnens B42 LEVER AND PEDAL LUBRICATION. 343 SSIDESTAND LUBRICATION ...cccsccennsnnnnnrnrrnn 43 (CENTERSTAND LUBRICATION co vn M8 REAR SUSPENSION LUBRICATION enn 848, ELECTRICAL. BATTERY INSPECTION FUSE INSPECTION... HEADUGHT BEAM ADJUSTMENT. HEADLIGHT BULB REPLACEMENT... DIGITAL CLOCK ADJUSTMENT. CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL... FUEL TANK AND COWLINGS.. ENGINE OIL, fe BATTERY LEADS AR FILTER CASE ‘ALS (AIR INDUCTION S¥STEW. ‘CARBURETOR... HOSES AND LEADS: CLUTCH CABLE. SHIFT PEDAL. STARTER MOTOR... ‘AC. GENERATOR EXHAUST PIPE. ‘O1L COOLER DRIVE SHAFT RUBBER BOOT ENGINE REMOVAL. ENGINE DISASSEMBLY. ‘CYLINDER HEAD COVER, CAMSHAFT AND CYLINDER HEAD. CYLINDER AND PISTON PICKUP COIL sense CLUTCH (OIL PAN AND OIL PUMP. ‘SHIFT SHAFT. MIDDLE GEAR... CRANKCASE DISASSEMBLY. SHIFT FORK AND SHIFT CAM .. TRANSMISSION,(CRANKSHAFT AND STARTER CLUTCH VALVE wnt CONNECTING ROD... — OL PUMP, INSPECTION AND REPAIR.. CYLINDER HEAD... — VALVE AND VALVE GUIDE. VALVE SEAT. VALVE SPRING VALVE LIFTER CAMSHAFT wows a TIMING CHAIN, SPROCKET AND CHAIN GUIDE TIMING CHAIN TENSIONER. CYLINDER AND PISTON... PISTON RING. PISTON PIN, 2 : CRANKSHAFT AND CONNECTING ROD OILPUMP = PRIMARY DRIVE, STARTER DRIVES cure —— ‘TRANSMISSION AND SHIFTER, SHIFT SHAFT AND STOPPER LEVER. OILET NOZZLE RELIEF VALVE, OIL PIPE AND STRAINER OIL COOLER . CRANKCASE BEARING AND OIL SEAL... CIRCLIP AND WASHER ws - MIDDLE GEAR SERVICE, REMOVAL... DISASSEMBLY. INSPECTION. REASSEMBLY INSTALLATION GEAR LASH MEASUREMENT GEAR LASH ADJUSTMENT, MIDDLE ORIVE GEAR AND DRIVEN GEAR POSITIONING... ENGINE ASSEMBLY AND ADJUSTMENT. ‘OIL PUMP. : CONNECTING ROD. —— VALVE. : (CRANKSHAFT AND STARTER CLUTCH TRANSMISSION ——— SHIFT FORK AND SHIFT CAM Ah 45 aa a7 449 a4 450 454 454 “487 458 60 461‘CRANKCASE ASSEMBLY. MIDDLE GEAR SHAFT... SHIFT SHAFT. OIL PAN AND Olt. PUMP... CLUTCH AND PICKUP COIL PISTON AND CYLINDER wn CYLINDER HEAD AND CAMSHAFT... TIMING CHAIN TENSIONER . CYLINDER HEAD COVER... ENGINE REMOUNTING, CHAPTER 5. CARBURETION DISASSEMBLY. INSPECTION. ASSEMBLY... INSTALLATION FUEL LEVEL ADJUSTMENT... ‘TPS (THROTTLE POSITION SENSOR) AD.USTMENT ‘AND INSPECTION. ALS. (AIR INDUCTION SYSTEM... ‘AIR INJECTION ‘AIR CUT VALVE. ‘ALS. (AIR INDUCTION SYSTEM) DIAGRAMS. a ‘ALS. (AIR INDUCTION SYSTEM) INSPECTION nnn 5-14 ‘ALLS. (AIR INDUCTION SYSTEM) ADJUSTMENT... CHAPTER 6. CHASSIS INSPECTION INSTALLATION wc STATIC WHEEL BALANCE ADJUSTMENT. REAR WHEEL. REMOVAL. INSPECTION INSTALLATION STATIC WHEEL BALANCE ADJUSTMENT.FRONT AND REAR BRAKE..... ‘BRAKE PAD REPLACEMENT. CALIPER DISASSEMBLY 00 MASTER CYLINDER DISASSEMBLY. INSPECTION AND REPAIR CALIPER ASSEMBLY oso | MASTER CYLINDER ASEM FRONT FORK. REMOVAL. DISASSEMBLY. INSPECTION. ‘ASSEMBLY... INSTALLATION STEERING HEAD AND HANDLEBAR REMOVAL. INSPECTION. INSTALLATION REAR SHOCK ABSORBER AND SWINGARM, HANDLING NOTES. NOTES ON DISPOSAL. REMOVAL INSPECTION... INSTALLATION... ‘SHAFT DRIVE. ‘TROUBLESHOOTING REMOVAL. FINAL DRIVE GEAR CASE. DRIVE SHAFT... INSTALLATION. CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS. (CHECKING OF CONNECTIONS. IGNITION SYSTEM... CIRCUIT DIAGRAM. ‘TROUBLESHOOTING é TREL [fs SHTGELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM, STARTING CIRCUIT OPERATION. ‘TROUBLESHOOTING STARTER MOTOR, CHARGING SYSTEM. CIRCUIT DIAGRAM... ‘TROUBLESHOOTING .. LUGHTING SySTEM CIRCUIT DIAGRAM: ‘TROUBLESHOOTING UGHTING SYSTEM CHECK SIGNAL SYSTEM CIRCUIT DIAGRAM. TROUBLESHOOTING . SIGNAL SYSTEM CHECK cnurnnnnon oat FUEL PUMP SYSTEM... CIRCUIT DIAGRAM... FUEL PUMP CIRCUIT OPERATION... se TROUBLESHOOTING ... — 755 FUEL PUMP TEST. — 758 ‘CARBURETOR HEATER SYSTEM. 758 159 760 CIRCUIT DIAGRAM. ‘TROUBLESHOOTING ‘TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS... CIRCUIT DIAGRAM, ‘TROUBLESHOOTING CHAPTER 8. TROUBLESHOOTING ‘STARTING FAILURE/HARD STARTING., FUEL SYSTEM ou ELECTRICAL SYSTEM... COMPRESSION SYSTEM. POOR IDLE SPEED PERFORMANCE... 82 POOR IDLE SPEED PERFORMANCE... 82POOR MEDIUM AND HIGH SPEED PERFORMANCE... POOR MEDIUM AND HIGH SPEED PERFORMANCE. FAULTY GEAR SHIFTING... HARD SHIFTING, SHIFT PEDAL DOES NOT MOVE. JUMP-OUT GEAR CLUTCH SLIPPING/ORAGGING CLUTCH SLIPPING, CLUTCH DRAGGING OVERHEATING se OVERHEATING. : FAULTY BRAKE POOR BRAKING EFFECT FRONT FORK Oll. LEAKAGE AND FRONT FORK MALFUNCTION... OIL LEAKAGE MALFUNCTION... INSTABLE HANDLING... INSTABLE HANDLING... FAULTY LIGHTING AND SIGNAL SYSTEM... HEADLIGHT DARK. : BULB BURNT OUT. FLASHER DOES NOT LIGHT. FLASHER WINKS SLOWER, FLASHER KEEPS ON vos FLASHER WINKS QUICKER. HOIN IS INOPERATIVE. XJ900S(G) ‘95 WIRING DIAGRAM 83 33 23 son ceGEN MOTORCYCLE IDENTIFICATION | jNFO [OM] GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (For E, AUS and NZ) The vehicle identification number ® is stamped into the right side of the steering head. © {IvAdPsTo Sao00TO" (AUS, NZ) ore, —__ ‘The vehicle Identification number fs used to Identfy your motoreyele and may be used to register your motorcycle withthe lice ing authority in your state. FRAME SERIAL NUMBER. (Except for E, AUS and NZ} The fame serial number @ is stamped into the right side ofthe steering head. ‘Starting serial number: "aKM-000701 {7.000101 (CH, A Nove: —___ ‘The frst three digits of these numbers are for model identifications; the remaining digits are the unit production number. ENGINE SERIAL NUMBER ‘The engine serial number @ Is stamped into crankcase, “Starting serial number: ‘ac-000701 ‘akM-023101 (E) 4°R.000101 (CH, A 4°5.000101 (AUS, NZ) Nove: —____ 1 The frst three digits ofthese numbers ore for model identification; the remaining digits are the unit production number. ‘= Designs and specifications are subject to chenge without notice.IMPORTANT INFORMATION (REN [am IMPORTANT INFORMATION PREPARATION FOR REMOVAL ‘Remove all dirt, mud dust, and foreign ‘material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS". ‘3When disassombling the machine Keep ‘mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been “mated” through normal ‘wear, Mated parts must be reused as an assembly or replaced. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all Parts are correctly reinstalod, '5Keop away from fire. ALL REPLACEMENT PARTS: 1.Use only genuine Yamaha parts for all replacements. Use oil and/or grease rec ‘ommended by Yamaha for assembly and ‘adjustment. Other brands may be simi In funetion and appearance, but inferior in ‘ualty. GASKETS, OIL SEALS, AND O-RINGS “LAI gackots, goals and O-rings should be feplicod when an engine is overhauled All caskets surfaces, oil seal lips and O: rings must be cleaned. 2.Properly oll all mating parts and bearing ‘uring reassembly. Apply grease to the oll seal lips.IMPORTANT INFORMATION [NEO cas] ‘LOCK WASHERS/PLATES AND COTTER PINS “LAI ock washers/plates @ and cotter pins ‘must be replaced when they are removed. Loc tabs} should be bent along the bolt CF rut flats) after the bolt or nut has been propery tightened. BEARINGS AND OIL SEALS. “Linstall the bearings) and oil seals) with ‘their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seals), apply a light coating of light- ‘weight lithium base greasa to the seal il the bearings liberally when Do not use comprossedair to opin the boar” ings dry. This causes damage to the bear- Ing surfaces, Deering incurs “LAI cirlips should be Inspected carefully reassembly. Always replace pis: 1. When installing a ciclips (©, make sure thatthe sharp edged comer (@'is positioned opposite tothe thrust @ it recsives. See the sectional view. @ statEN SPECIAL TOOLS. [SEN ee SPECIAL TOOLS ‘The proper special tools are necessary for ‘complete and accurate tune-up and assem: bly. Using the correct special too! will help prevent damage caused by the use of improper tools or improvised techniques. ‘The shape and part number used for the special too! differ by country, 0 two types are provided. FOR TUNE UP Fofer to the list provided to avoid errors when glacing an order. 7 inductive tachometor PIN. 80880-03113 The teot ie sed for dotocting engine rpm 2 ‘inductive timing light > ome a, This tool is necessary for checking ignition ming. a [Compression gavae PN. 9c690-03081 acepter PIN: 9c390-04082 This gauge Is used to measure the engine 7 Vacuum gouge oo ‘0 03004 this gauge is roeded for carourtor synchro- nization 5 Fusi evel gouge PIN. 9c980-01312 \ \ This gauge is used to measure the fu lvel in tne oat chamber. Carburetor angle driver PIN. 80690-03158 This tool is used to adjust the pilot serow. This teot ie used to moasure the exhaustGEN sPeciat Toots | NEO |S FOR ENGINE SERVICE J apr adusting too! PIN: 90880-06125 This tot le necessary to rapace valve acjus- ing pads. 2 Piston pin puller PIN. 20890-01204 This too is used to remove the piston pin. 3 Universal clutch holder IN: 30890-04088 tS This too! Ie used to hold the clutch when removing o nstaling the eluteh boss locknut Valve soring compressor . PN, 80890-04018 . This too! is needed to remove and intall the] valve asomblis, = tachmant PIN. 90880:01243 © sed to remove and install the combi é Valve guide remover (6.0 en PIN. ot890-04064 & This tools used to romave the valve guides, 7 ave guide inetator (6.0 me) IN; 90890-04085 This too! is needed to instal propery Valve guide raamer (6.0 mm) PIN, 90890-02085, PP This too! is used 10 rebore the new vave| auido a ave seat cuter PIN-YMISTO@3SPECIAL TOOLS [EO os 1] YAMAHA Bond No. 1218 PIN, 20890-85808 —> Fe This sealant (one ie used for erankease met ing surfaces, 7 Damper spring compressor PIN: 9c990-04000 i -this tcol is needed to disassemble ond rons smb the middle goar damper. 7 [Universe joint holder PIN. s0g90-04082 eE This tools used when dissssemblingisssom: ling the Ujaint and aduting gear lash, 3 date gear bcklash root PIN. 9c890-08000 Se ory This tools neaced whon measuring gear lash. rn Piston ring compressor IN: c0g00-04008, Tis tool is used to compress piston sings when installing the eyinder. ee SX \a ‘Use four pieces of these to hold the pistons uring evindor instalation, 6 Oi ker wrench PIN. sogo0-01428 ©) This tool is used to remove and instal th ol iter FOR CHASSIS SERVICE Francie PN 80860-01326 Hrs too! is used to loosen and tighten the ron fork damper rod holding bolt ail [Fron fork ytindr complete holder (27 mm) PIN 90890-01388, @ ‘this tel 1 used to looten and tighten the ont ferk demper rod holding bok.SPECIAL TOOLS Lie | em) 3 Fork see divor weight IN. 80680-01387 Thiatool is used when instaling the fork es 2 Fork seal driver attachment (att) Pn seo sD his tools used wen installing the fork sea 3 aor Pres aa KP? Tis tool is used to loosen and tighten the] steering ring nut Final goar backlash band PIN. soeo0-01230 a tools needed when measuring geet lah, 7 TMidale and fina gor holding too! a This too is used when measuring goar lsh Final driveshaft bearing retainer wrench Fret This wot ie used to remove and inetll the boarirg retainer FOR ELECTRICAL COMPONENTS 7 ignition checker PIN: e0680:0675¢ this instrument is necessary for checking the ignition system components z Pocket tester IN, 80@60-05112 This instrument is invalunbie for checking the]GENERAL SPECIFICATIONS [SPEC] UO" SPECIFICATIONS GENERAL SPECIFICATIONS Moder TaB00S NT aKM-TOTTOT [Frame starting number: aKM-OODIOT Dimensions Overall iength 2.230 mm Overall with 735 ram Overal height +1300 mm Seat height 795 mm Wheelbase 1.505 mm Minimum ground clearance 130 mm Minimum turning recs 300 mm asic weight ‘With oan fl fuel tank 265 ko Fagine - Engine type Aircooled t-stoke, OOHC Cylinder arrangement Forwardinlined parallel tcvlinder Dispiacament 892 em’ Borexstoke 685% 60.5 mm Compression ratio 0 Compression pressure (STD) 1200 KPa (12 kglem’, 12 bar) at 390 rimin Starting system Electriostarer Tubrieation system Tw sump Oil ype or grade: Engine ll SAEZOW40 type SE motor cl Final goa i: | SAEBOAPI“GL4" Hypoid Gear Oi ‘Giteapaciy= - - Engine ol Periodieollenange aa With ol iter placement Bau Total amount aa Final gear case ol “Total amount oat ine — iv i stement— Fue Type Regular unleaded gosotine Fuel tank capacity aL Fuel reserve amount BLGENERAL SPECIFICATIONS [SPEC] U"™ Wiodel 18005 Carburetor Type / quantity Bosra Manufacturer MIKUNI ‘Spark plug Type DPREA-xK24EPR-UD Manufacturer NGKINIPFONDENSO Spark plug oap 08-09 mm Cutch type Wet mail dse Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio ‘Transmission type ‘Spur gear 8758 (1.672) Shaft dive 4638X19118X32/11 (8.717) Constant mesh -speed Operation | Left foot operation Gear ratio ast 36/16 (2.188) 2nd | 30/20 (1.500) 3rd 30/26 (1.184) ath 22/30 (0.833) sth___| 26/32 (0.813) _ Chassis ———— Frame type Double cradio Coster angle ar Trail 321mm Tire Type Tubeless Size front | 120/70-17 av rear | 150/70-17 09 Manufacturer front | METZLE/BRIDGESTONE/DUNLOP rear _| METZLER/BRIDGESTONE/DUNLOP- Type front | MES3/Ge01/KS05F ear__| MEssA'Gs02/K505 __| “Tite pressure co1d Ura ~ ‘Maximum load-except motorcycle 205 kg Loading condition Ax 0-909 front | 225 kPa (2.25 kglom?, 2.25 bar) roar | 250 kPa (25 kg/em?, 25 bar) Loading condition 8 90 ~ 208 ig front | 250 kPa (2.5 kglem, 25 bar) 230 4a (29 kgler?, 2.9 bar) | Braker Front brake type ‘operation Rear brake ‘ype ‘operation Dual dise brake Right hand operation Single dise brake Right foo! oporat 22GENERAL sPeciFicaTions [SPEC) U=* Model 3008 Suspension Front suspension ‘Telescopic fork Rear suspension ‘Swingarm (lik suspension) ‘Shock absorber: Front shock absorber Coll spring / Oil dampor Rear shock absorber Coilgee spring / Oil ‘Whee! travel T Front wheel travel 140 mm Rear whee trav nomm Electrica: lgrition syste TCA (digital) Generator system | AC. generator Battery type | yirxiess: Battery capacity wv 12AH Headlight ype: ‘Quartz bulb thalogent ‘Bulb wattage x quantity Headlight r2veow/55W Auxiliary fight ravawer Tail brake light 12 V5W/21Wx2 Flasher light wv2iWx4 Licence tight 12V5Wx2 Meter light 1RV34Wx4 Inicator ight NEUTRAL. vavs4we1 TURN 12V34Wx2 OILLEVEL, wV34Wxt HIGH BEAM. 12V34Wxt FUEL rv a4WxtMAINTENANCE sPEciFicaTioNs [SPEC] U"* MAINTENANCE SPECIFICATIONS ENGINE Moder T 9005 yi rend ] Warp limit 0.03 mm 2 ‘Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam dimensions Intake ~ pa a Exhaust ~ ea cca ‘camshaft runout limit Cylinder Bore size 68.49 ~ 68.54 mm “Taper limit | 0.05 mm (ut of round tit | 0.01 mm | Camshare Drive method Chain drive (center) 26,000 = 26.021 mm 24967 ~ 24.980 mm 0.020 ~ 0.054 mm 26:75 ~ 26.85 mm 21975 - 28075 mm 8.75 ~885 mm 36.75 ~ 96.85 mm 21975 - 28075 mm 875 ~885 mm 0.03 mm ‘MAINTENANCE SPECIFICATIONS [SPEC] U™ 9005 Tam chal — ‘Cam chain type / No. of links SILENT-CHAIN/150 Gam chain adjustment method Automatic Valve, vaive seat, valve guide: Valve clearance (cold) N 0.11015 mm x. 0.16 ~ 020 mm Valve dimensions: Jw Me m4 . ements a.MAINTENANCE SPECIFICATIONS iar Ts — Baa & — [zsronm I “lo btn a ing ctookwse feses " Fx | cmctn er spring care » |eum | Seesmn eanratitnveciod ow (sagem & [Samm compensa pressure ‘asta wn [er setep om ftetoaiiy rete Re | 2ercr me & | zen _ Vda Dinetion of winlng countrdockse meee " ae ee a ton tcyndr clearance 003-005 mm con cineMAINTENANCE SPECIFICATIONS ISPEC| Wodel 9005 ay Measuring point "H” Oversize 2nd ah Piston offset Piston off sot direction Piston pin bore inside diametor Piston pin outside 545 =6B.5O mM 55mm 69mm 625mm 05mm IN side 16.002~ 16.013 mm 18.990 ~ 16.000 mm Piston rings! Top rings Type Dimensions (8 xT) End gap (installed) Side clearance (installed) 2nd rng Type Dimensions (8 xT) End gap (installed) Side clearance Dimensions (BT) End gap (instlled) | Barre! [12x25 mm 0.10 -0.25mm 0.926 ~0.080 mm Taper 123.1 mm 0.30 - 0.45 mm 0.02 ~ 006 mm 25%28mm 02-07 mm | Connecting oe: Oil clearance 0,026 ~0.055 mmISPEC| MAINTENANCE SPECIFICATIONS Wodel 9005 Crankshate ® ~ & —F ‘Assembly width “8” 240.8 - 212.0 mm unout limit "C* 0.03 mmm Big end side clearance "D" 0.160 - 0262 mm Big end radial clearance “E* 0.016 ~ 0040 mm Journal oll clearance 0.020 ~ 0052 mm Color code (corresponding size) @ Blue @ Black @ Brown ® Green OYellow ‘utah: Friction pate thickness 29-3.1mm Quantity 8 Friction plate wear limit 28mm Clutch plate thickness 19-21 mm Quantity 7 ‘Warp tim 0.05 mm, Clutch spring free length 518mm Quantity 6 Minimum tength 50mm Clutch release method (Outer pul, rack & pinion pull “Transmission: Main axle defletion limit ‘Shifter ype Carburetor - 1D. mark Main jot (mg) | #100 Main air et man [4725 Jet needa Gn | spT32 Noodle jt wa [02 Pilot air jet (easy | #120 Pilot outlet (0 | 10 Pilot jot ea [ans Bypass 1 wen los Bypass 2 (ar2) [os Bypass 3 (rs) [os Pilot screw es) | te Valve seat size ws [isMAINTENANCE SPECIFICATIONS SPEC] Oo ‘Model 9005 ‘Savior at Tes) [0 Throttle valve size my | #15 Fuel level uy |6-7mm Engine idle speed Intake vacuum 30.3 ~ 22.9 kPa (280 ~ 250 mma) bration system: Oil filter type Paper type i pump type Trochoid type Tip clearance 0.03 ~ ¢.09 mm ‘Side clearance 0.03 ~ 08mm Bypass valve setting pressure Relief valve operating pressure Oil pressure thot) 120 ~ 150 KPa(1.2 ~ 1.6 kg/cm, 1.2 ~ 1.6 bar) 540 - 650 KPa (5.4 ~ 6.6 kg/cm, 6.4 ~ 6.6 bar) 80 kPa (0.8 kglom?, 0.8 bat) at 1,000 efmin Shaft drive: ‘Middle gear backlash Final gear backlash 01-02 mm. 01-02 mm. ‘Crankease tightening sequence: Ccrankease (upper Crankease (lower) x: MB bolt: 24 Nem (2.4m + kg) (5: MG bolt: 12 Nm (1.2 m+ kg)MAINTENANCE SPECIFICATIONS [SPEC] U™® ‘ode X08 ‘Lubrication chart Presse foo Slashes Relat ave]Tightening torques [Camshaft cap [Cylinder head (cam chain) [Cylinder head (exhaust pipe) it gallery bolt Spark plug [Cylinder heed [Cylinder head cover [Cylinder (cam chain) [Cylinder [Cylinder head [Connecting rod [cam sprocket Guide stopper Chain guide intake) Oit pump sprocket Oi pump Oil itr housing Oil delivery pipe Drain Bott Oil level switch Oi fiter [carburetor joint Air filter case Exhaust pipe Muffet and stay Exhaust pipe blind plug (CO test) Exhaust pipe and stay Exhaust pipe and muffier Pipe 2,3 and cowling stay Air cut valve and cowling stay [crankcase crankcase [crankcase Bearing holder Oil battle plate Oil battle plate Shift shaft lever cover Drive axle bearing housing [clutch cover MAINTENANCE spEciFicaTions [SPEC] U"* | Partto be tightened Pertname torque _| remarks Tien [kg “at 70 | 10 sud bot «| sos} a Sue bot e|sli| a = 1 | 8 | 08 = a | w]e Nut nlala| ~a@ Bot 2 | 10 | 10 Suxdbot 1/8 fos] ~a Nut 1 | 20 | 20 Nut «| | 10 Nut 8 | 37 | 37 | «amy Bott 4 | 2 | 26 sero 1] 7 | o7 Bot 1 | 2 | 20 Bot 1] 2} 12 Bole a|2| 2 Union bot 1 | 6 | 50 for | mi | 2 | a2 | 32 Pug | ma | 1 | as | a3 sot | xe | 2 | 10 | 10 — | mola |w|a wor | ve | a | 2 | 12) cor | ne | 1 | 10 | 10 na | wa | 8 | 20 | 20 sot | mo | 2 | 25 | 25 por | ne | 4 | 7 | 07 por | mmo | 1 | 25 | 25 cor | we | 2 | 2 | 20 Reed valve brackat and cowling stey| sot | ve | 4 | 10 | 10 wot | we | 2 | 7 | 07 scew | ve | 2 | 7 | 07 swdbot | mio | 12 | 2 | 20) tot | me | 19 | | 24) aot | me | | 2) 12) a scow | ma | 4 | 25 | 25 |stoke sow | ms | 7 | 8 | 08 scew | we | 1| 8 |os| -@ wor | ms | 0 | 2 | 12 aot | me | 3 | 12] 12 sot_| me_| 0 | [12MAINTENANCE sPEciFications |SPEC| 0 Tarionng Pantoberighoned | partname "284 | ay | torque | Remarks Tim [mg eiacraabe say we weap 2 Generator bering housing or | we |e | | 10 Pie sopoer or | me | 1 | 1 | ro |Ueefck H¥.v0 cain guide er | we | 2 | w| 10 each sping som | we | 6 | 8 | 08 catch boos na | wao | 1 | 7 ie dvs pion ge x | ame | 1 | a0 | ov [Usetock ota ont wa | ma] 1 | 0 | 80 ida criven bearing housing | ton | Me | 4 | oe | 25 Shit pedal adjster wa | owe | 2 | wo | 10 shit arm vor | ome | 7 | wo | 0 Shit am bearing holder sow | we | 2 | 0 | 10 Sacco ut ef aime | 4 | 0 | Final gear bearing housing Bok mio | 2 | 2 | 23 Fe ear bearing housing wa | we | 6 | zs | 2s Final gear oil filler bott Plug wa | 1 | 23 | 23 inna og | ame | 4 | a | a3 Fal rv bstng retainer wes | 1 | to | 1 Final gar swcvot | two | 4 |e | Firat gor cee seabot | wo | ¢ | 9 | 09 Finet gor cove ond swingarm wa | ano | 4 | a | a2 IA. generar to | Me | 2 | a | 2s AC generator sa | me |i | mf 2s) a Pcp cot bate sow | we | 2 | @ | os ming pate cor fame | 1 | | as | yawn ster motor sot | ome | 1 | 7 | a7 \YAMARA, | Starter motor and crankcase: Bolt M6 1 2 | Neate sno | 1MAINTENANCE SPECIFICATIONS: spec] oo cHassis ‘Model xaa8005 ‘Steering avstor ‘Steering bearing type. _ Ball bearing Front suspension: Front fork travel 40. mm Fork spring free length 505 mm Spring rate (Kt) | 5:0 Nm (0.5 kg/mm) (K2) | 8.0mm (0.9 kg/mm) ‘Stroke Kn |o-s0mm (2) | 80~ 149mm Options spring No. il capacity 44h om! Oil level 133mm Oil grade Fork oil W or equivalent Roar suspension: - ‘Shock absorber travel 50mm ‘Spring fre longth 177 mm Fitting length 161.5 mm (157.5 ~ 165.5 mn) Spring rate (1) | 186.0 Nim (15.5 kgirme) Stroke (cy |0~ 50mm Optional spring No. ‘Swingarm! ~ Free play limit end 1mm side | 1mm Front wheat ‘i Type cast whee! Fim sizo 17 XMT3.00 Fim material | Aluminum im runout limit radial | 1mm lateral | 0.5 mm Fear wheal Type Cast whee! Rim size 7 XMT4.00 Rim materia ‘Alurioum im runout limit radial | 1mm lateral | 05 mm Front disc brake! — Type Dual Disc outside diameter thickness 320x 4mm Dise deflection limit 0.15 mm Pad thickness inner | 6.1mm <08mm> Pad thickness outer __| 6.1mmMAINTENANCE SPECIFICATIONS [SPEC] U"* Wider TaR00S mie Dare mee}. | Mester cylinder inside diameter 18.67 mn Caliper ylinder inside diameter 302mm Caliper cylinder inside ciameter s33mm Brake fuld type Doras Fear cise brats Type Single Dise outside diameter thickness 267%5 mm Dise deflection iit 0.15 mm Pad thickness inner | 5.5mm Limits <05 mm Pad thickness outer | 5.5mm Limits <05 mm ‘Master cylinder inside diameter tem Caliper eylinder inside diameter 42.85 mm Brake fluid type por #4 Brake lover & brake pods q ‘Brake lever fae play (at ever pivot) | omm. Brake pedal position 20mm Broke pedal free play omm Clutch lever free play (at lever end) 10-15 mm “Thyotte cable foo play 3-5mmMAINTENANCE SPECIFICATIONS SPEC) o Remarks Tightening torques Tahtening Part to be tightened Theead size | _toraue Nim | mg Chassis: Handle crown and inner tube wax12s | 2 | 30 Handle erawn and steering stem raxtas | 10 | 119 Handle crown and handlebar (upper) Mex125 | 23 | 23 Steering stom and ring nut nosxio | 3 | 18 ‘Seo “NOTE” Front master cylinder and cap mavor | 2 | 02 Front master cylinder and brackat wex10 | 9 | 09 Front brake hose and union bolt mioxias | a | 30 Cowling and cowling stay exo | o7 | oor Cowling and frame eon | o7 | oor Coving and windscreen Msxos | o7 | oo7 Cowling and inner panel nsxoe | 4 | 04 Cowling and headlight Mexia | 7 | 07 Cowling stay and frame wex125 | 1 | 16 meio | 7 | 07 Cowling stay and metor meio | 7 | 07 Cowling stay and front flasher light mizxizs | 13 | 13 Meter and meter cable mixio | 3 | 03 Brake hose holder and front fork meio | 7 | o7 Engine mount (ront-upperfiower) mioxi2s | as | 48 (rear-uppertower) nmoci2s | a | 43. Down tube and frame mmio<125 | @ | a9 Engine stay (Tront) and frame wex125 | 2 | 30 Engine stay (rear and frame wex12s | 2% | 30 Pivot shaft let) and frame Marx15 | 10 | 100 Pivot shaft (right) and frame noxxis | 7 | 07 Pivot shaft (right) and locknut ua2x15 | 10 | 100 Relay arm and frame miox125 | | 48 Relay arm and connecting rod izc125 | a | 48 Connecting rod and rear arm mix12 | a | 48 Rear shock absorber and frame mioxi2s | 0 | 40 Rear shock absorber and relay arm miox125 | as | 48 Fuel cock and fuel tank mexio | 7 | o7 Fuel sender and fuel tank nsxon | 4 | 04 Rear fender and frarme mexio | 7 | 07 Tailight mexio | 7 | o7 Rear fonder cover and side cover msxos | 4 | 04 Side cover and framo sos | « | 04 Rear fender stay and framo mexro__| 1 | 10MAINTENANCE SPECIFICATIONS [SPEC] U™™ Part to be tightened Thread size Rear brake reservoir tank and rear ender | WBx10 | 7 | 7 Rear flasher light and rear fender | maxis | 4 | os Reflector bracket and rear fender maxar | 3 | 03 Rear fender and flap maxaz | 3 | 03 Battery cover and frame Mexto | 7 | 07 Footrest bracket and frame wex125 | 90 | 30 Rear footrest and frame maxis | 30 | 30 Roar master cylinder and bracket maxi25 | 30 | 30 Brake hose and union bolt mioxi2s | 2 | a0 Shift pedal maxi2s | 30 | 30 Brake pedal and brake shaft mexio | @ | os Mainstand bolt and nut mioxi2s | 6 | 56 Front wheel axle muxts | 9 | 59 Rear wheel axle and nut miex1s | 105 | 105 Front brake caliper and front fork miox:25 | 35 | 35 | Rear brake caliper and caliper bracket mioxi25 | a5 | a5. Dise brake and hub (frontiear) mexio | 2 | 20 | + Front brake calipar and bleed screw = | x0 | 6 | 08. Rear broke caliper and bleed screw wex125 | 6 | 06 ‘Speedometer cable and gear unit mixio | 3 | 03 Front whee! axle pinch bolt wexi25 | 19 | 19 Rear wheel axle pinch bolt mexi25 | 16 | 16 Front brake caliper retaining bolt Mexi25 | 22 | 22 Front fender end front fork wexio | 9 | 09 Rear brake hose and hose joint mioxio | 1 | 16 Reer brake caliper and hose joint mioxio_| 30 | 30 Nore: ‘UFirt, tighten the ring nut approximately 82 Nm (52 m= kg) by using the torque wrench, then loosen the ring nut ono turn. 2.Retightan the ring nut to specification,MAINTENANCE SPECIFICATIONS [SPEC] U= ELECTRICAL | Vonage: ‘wodel = Ignition Tanition system: Advanced timing (BT.D.C.) ‘Advancer type ‘ean 08 at 1,000 rimin 40" at 5,000 rin Electrical type ine soa 1 in [rer Pickup coll resistance / color “.C:.unit model / manufecturee 446 ~ 545 2 at 20°C / White/Red - White/Green} J4T05 YMITSUBISH! Tanition cot ‘Model manufacturer ‘Minimum spark gap Primary winding resistance J0312,J0314)NIPPONDENSO emm 197 ~ 253.0020 Secondary winding resistance 12 18ka atzve ‘Spark plug cap: Type Resin type Resistance 10a. Charging system: TT Type AC. generator Model / manufacturer ‘B3GINPPONDENSO Nominal output 14.33 A at 6,000 riminMAINTENANCE SPECIFICATIONS [SPEC] U" Xa9008 i é Engines 10 Rotor ool resistance 276 -305.0.2t 200 ‘Stator coil sistance 019-021 2at20¢ Brush overall length 13.7 mm “Wear limi <4] mm Spring force 520-5809 Voltage regulator: Type ‘Semi-conducto, field control type ‘Model / menufscturer BSGINIPPONDENSO [No load regulated voltage 142 ~148V Fecifier ‘Model manufacturer BaG/NIPPONDENSO Withstand vottage 200 Battery - Specific gravity 1.320 Fleciie starter systor Type Constant mesh type Starter motor: “Model manufacturer DB¢DTINPPONDENSO Output os kw ‘Armature coil resistance 0.013 ~ 0015 Qat 20° Brush overall length 12mm Limit <85mm> Spring force 650 ~ 950.9 Commutator diameter 28mm “Wear lenis <2 mm> Mica undercut 06 mm Starter swite: ‘Model / manufacturer MSBF/JICECO Amperage rating 100 Coil winding resistance 4.18 ~ 4.62.0 0t 20°CMAINTENANCE SPECIFICATIONS SPEC} Moder xa9005 Harn: Type ‘Quantity ‘Mode! manufacturer Maximum amperage Flasher relay: Plane type 1 YE-12INIKKO. 258 Model manufacturer Sender unit resistance full empty Type Fall transistor type Model / manufacturer FE246BH/NIPPONDENSO Self canceling device | No Flasher frequency 175 ~ 95 cyeleimin Wattage | 21w2 134. Oil level switche - Model manufacturer 4H7/NPPONDENSO Fuel gauge: ~ AKMUNIPPONDENSO 4-100a20c 90 - 100.0 at 20°C ‘Starting crcut cut of rola: ‘Model/ manufecturor Coil winding resistance SIGNAL IGNITION ‘cLock Reserve Reserve ‘3ENIOMRON 2025 ~247.50.3t 20°C Yes Fuse 30Axt AxI 20Ax1 waxt waxt 2Ax1 woAxtEXCLUSIVE SPECIFICATION |SPE EXCLUSIVE SPECIFICATION ‘The following specifications are exclusive forthe below listed countries. For specifications other than below, please refer to the General and maintenance specifica- tions. For Spain (Model cod RM Engine starting number “aKW-G2STOT Vehicle identification number: “SVAAKMSO%SA023107 For Switzerland, Austria Model code! [Par Engine starting number: [aPR-000707 4 Frame starting number: [aPR-000707 | (Carburetor: LD. mark 4PROO Ignition system: ‘Advanesr type Ek unt modolmantacturer JeTosomrsusish For Australia Mode code a Engine sang Raber 5 001 Veil dntfenion sure IYAAPSTONSAGOOTO Ft ve Unlaed faontyHOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS SPEC} o* HOW TO USE THE CONVERSION TABLE {All specification data inthis manual is listod in Sland METRIC UNITS. Use this table to convert METRIC unit data to IMP unit data, GENERAL TORQUE SPECIFICATIONS “This chart specifies torque for standard fas- teners with standard 1.8.0. pitch threads. Torque specifications for special compo- nents or assemblies are included in the ‘applicable sections of this book. To avoid S warpage, tighten multi-fastener assemblies METRIC = MULTIPLIER wp in a crisscross fashion, in progressive stm x 00097 = tin Sages, ut al torque Is reached. Unless 2mm x 003937 |= 04in ‘thence speci, torque specications fall for clean, dry threads. Components Sane ae ‘should be at room temperature. TEE TOHP oT me pan (Re frome fois, fesse Ine ee ee [ee rey & a LY fer oars [ron oe ee 4 Hd ic ‘Ac Distance across flats: fm fess, |e 6: Outide tend domator | —— enor Jor anrnar Genet one joumer Jest [oonee [en a | 3 | Sena some, litte [om Jere as iy | (wor {rcen [eae [entmesay_| Tin [ ka ame jem —|55997 Jin wan | eam] 6 | 068 | Bow [fee [prion [neous | consigrede | 64°Ci+32 | Fahrenheit "F) T2nm | 8mm 15 15 Tamm | 10mm | 30 3.0 a7mm | mm 5 5S 18mm | 14mm. 85 85 Zmm | wemm | 130 13.0i LUBRICATION POINT AND GRADE OF LUBRICANT |SPEC} LUBRICATION POINT AND GRADE OF LUBRICANT. ENGINE Tubrication Point Oilseal lips ‘O-ring Piston surface toni Grnksha in Cranlahat ourabig ond Connecting rod blunt Connoating rod small ond - ‘Middle drive shaft (drive damper camidriven damper cam) ie dive goa Teaver ea Camaha ear obal url | Valve stom (IN, EX) Valve stom ond NB Valier | AAASIAAMIRMAMd Add ddd ddd ag adidadiees {il pump rotor linner/outen, Housing Oil strainer assembly Tle g a ‘Starter idle gear ‘Starter idle goar shaft ‘Starter clutch (outerrollen) ‘Grankoase cover (pull rod hole) Primary dive gearfdamper ‘Transmission gear (wheel/pinion) ‘Axle (rainjarive) Pull rod (bearingiwasher) Shiftcam Shit forkgulde bar ‘Shift shaft assembly surfaceLUBRICATION POINT AND GRADE OF LUBRICANT SPEC] o= chassis Tubrication Paint ‘Symbot Steering bearing (upperiiower) I Front wheel oll seal (ightiew) Rear who ol sal {Clutch hub oll seat Clutch hub fiting area Roar brake pedal shaft Shift padal Center stand sliding surface ‘Side stand siding surface Tube guide (throttio grip) inner surface ‘luich cable end (lever side) Brake ever bolt, sliding surface Clutch lever bol, sliding surface Roar footrest pivot Roar shock absorber (upper) Roar shock absorber (ower - ol sealh Connecting rod bearing (on the swingarm) Ha ‘Swingarm pivot Bearing ‘Swingarm pivot oil seal Relay arm bearing inner) | Drive shait (final gear Drive shaft (middle gear side) gagedLUBRICATION DIAGRAMS |SPEC] U=™ ke) OMeLUBRICATION DIAGRAMS |SPEC| O=* Qotrnoze Starter clutch @Main ante dive axe @Shift guide bar_—__Wanicarion oincrams [SPEC Deanaian Sennen Suainace Sommeunecanon anaes ‘@Shift guide bar ‘@diveaxte @Main axe @Midate rive shatcaste ROUTING [SPEC] O=™ CABLE ROUTING Ome Bana Flasher lead @Hor © Thermo switch {© Heasignt coupler B coming stay ‘assembly coupler [Clamp the meter lad tothe comling stay [E]Clamp tho horn fed tothe inne fork tube 60 me from the handle crown, [c]Pase the ft and right fashor leds through the cowing stay gude wie Tbjclamp the horn ead tote ane fork tube 20 mm from the under racket [ElWhen connecting the nom las, make sure thatthe lead points down: ‘wards from the connector so tet water cannot got inside when [B.ciame the brake hoses tothe iner fork tube. [EiCiamp the wire hares to the sowing staycaBLE ROUTING |SPEC| v=] (OFuse box [Bi clamp the fuel eendor wie hanass tothe side cover stay. ignitor unit Become hgh #4, tothe upper par, and the #2 cord to @Fual sender lead ‘the lower par 1 position, @hacheable [©.Clmp the igh tnsion core bred Cute cable and sensing hi @ciamp [Game te hgh enon cork 4:9 and #40 he clamp on the Band athe marked postions accordingly. cl Ooi (@ Fear brake switch leadCABLE ROUTING [SPEC] U=™ [Ectemp the brake noses othe Inner vube IF.clamp the brake hoses tothe guide wie [GlAter connecting the loft and right flasher leads, clamp them tothe cowlng stay. Con- ‘eet the harmo switch lead the plug with ‘ahite tape affixed to [EiCiamp the auxiliary light lead and wire har. ress tothe cowling stay, [clamp the flasher lead and thermo switch lead to the cowing stay. [Postion the sparkplug cap so that Inward [Pass the drain hoses forthe tank and drat hose for the after case through the ‘amp. [TP aes the betory © load under the cross pipe ‘and sacute ta the side ofthe batery G ter ‘mina [iClanp the rear brake witch lead to the back stay acingcaBiE RouTING [SPEC] 0 ‘@Dandteder switch et @Sidestand awit lead [E)Giamp the high tension cord (#3 and #2) ‘Doitteve switch be [E.Clip both ends ofthe ual howe. @Spood meter [E]Clamp ths wire hamose inside the seat all @Startormotor lead Point the clamp end so tht is facing downwards. [T)pase to fisher looa [Elctamp the wire harness and tho fuel purnp lead. Position the fue, through the guide wire behind the wire harass. he erss pipe, then clamp it tothe > pie. Pass the tart motor lead inside tho tab on the rear fende'and then inside the bracket on the rear shock absorber.‘switch lead through the inner part of the ear arm. Clamp the side stand switch load andthe of level ste lead wath the engine clam. (@Pull the ol lvel switch Toad backwards ‘slightly so that te not slack. [BPass the thote postion sensor le tho high tension cords #1 and #2. + Eithor one ofthe high tension cords 1) and 3m be uppermost. ord (a) outside the fuel hose and ther hoa. cord (#1) ouside the fuel hose, Sather hose and thrattle postion sensor inside CABLE ROUTING Dart atthe marked poston, andthe high en. S01 cord #2 tothe lower pa. |BlPostion the sparkplug cap so that tis facing Inward. [BiClamp the oft handlebar switch leed, main ‘Starter eable an trot cables peedometor cable tothe lft of the heaalight and pass through the guide wire which secures the cowting stay guide wire, Draka Hose elder, fencer bracket guide wire ‘ndealiper. Clamp the part ofthe wire harness which has wht tape affixed to onto the cowling say When inctaling tho cowlng, make sure that the speedometer cable isnot pinched between the headlight end the cowting,Front right (Hah) Toad o @Aunilary ight lend {Thermo swe lead the wire ‘wire, lth the throttle wire underneath, [B\Clamp the AC generatr lee, fuel hose and air iter case den hose, [EiPase the wice harness through the guide on the roar fender, [D)Pase the rer Fashor leads underneath te point ight instal. [BPass the left and right ear flasher leads through the guide hole Inthe rear fonder. (E.Conect th leads and clamp them to the frame atthe guide hole{Glciemp the wire harness to the rar fonder at the tb. te couplor forthe wice harness outside look wire outside the roar (iPass the wice harness underneath the point the rear fonder and uel Install, then pass It above the fra the bracket ofthe rear shock absorber CABLE ROUTING {SPEC} TlPass te starter motor load under the wire mess and fuel hoe [ela the portion of ‘marked wth white ts aster the ground tarminal and the ignition oil together. WClame the wire harness, main switch lead ind eater abe. me the handlabar switch lead tothe han 10 wire harnessINTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS [apy | QR PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ‘This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, i followed, will ensure more reli fable vehicle operation and a longer service life. The need for costly overhaul work will be Greatly reduced. This information applies to vehicles already in service as well as new vehi- les that are being prepared for sale. All service technicians should be farnliar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION INTERVALS ee i aan Soria oo [9 [scm zi o-|—6 Sal RT imum Aki oneeay i ° 2 a Seo oS ote | Ein ot rm engine befor dang o o o_| esansct iar —[ rae 3. o int neat Renney 240000734 ah eose | O. ° a Sosanrnht FOE om fea Soaps a Fa a memo [Saree A rn [Stone eons 5 = een ° [| ° Paes [Seca Tom oe Serato | Seca 2¢0wtmenes= | © c ra Chakri gp oy os a a renaeronuese [meatus ewan ° ° ° a ° ° ° Sarg at? | ot optan Caner rns | —O—| | 0 ‘eden wlth oerng aePERIODIC MAINTENANCE/LUBRICATION INTERVALS [NSF ‘NOTE: Brake figid replacement. ‘When disassembling the master cylinder or caliper eylinder, replace the brake fluid. Nor: ‘mally check the brake fui level and add the fluid as required, 2.0n the inner parts of the master cylinder and caliper cylinder, replace the ol seals every ‘wo years ‘3.Roplace the brako hoses every four years, or if eracked or damaged.ie ia ac lon ‘SIDE COVER, FUEL TANK AND COWLING REMOVAL Remove: + Seat 2.Remove: = Talleover © Remove: {= Grab bars (loft and right) © 1 Side covers (left and right) © Remove: = Bolt® feo + Paw @ + Damper rubber © '5.Tum the fuel cock @ to “OFF. BDis:onnect: ‘+ Fuel sender coupler @ ‘+ Fuel hose @ Avoid spilling fuel on the hot engine.INSP’ SIDE COVER, FUEL TANK AND COWLING Cy Nore, Place a rag under the fuel hose to avord Windscreen © += Rubter plugs + Inner cover @ ‘Remove: + Botts 10Disconnect: + Flasher light lead (front), Remover «+ Flasher light front) © 12bisecaneet: ‘+ Head ight lead, 13Remove: + Cowlingso coven ve raw aD comne _____scoven rut ro comune | INSTALLATION Reverse the REMOVAL" procedure. Note the following points ns: = Fucl tank. 2insall: 1 Side covers: instal: = Seat Nove, Insert the lobes on the front of tho seat into the bracket on the frame, thon push down the seat end,VALVE CLEARANCE apsustmenr | NSP Q ENGINE VALVE CLEARANCE ADJUSTMENT Nove ++ Tho valve clearance should be adjusted when the engine is cool tothe touch, + Tho piston must be at Top Dead Center (EDC) on compression stroke to check oF adjust the valve clearance. Remove: + Seat + Fuel tank + Coming Refer to “SIDE COVER, FUEL TANK AND cOMLING” 2.Disconnect = Broater hose ® + Drain hose @ S.Loosen: # Screws @ ‘4 Disconnect: ‘= Hose air fter case - air cut valve) @ {from sir fiter case) 5 Remove: + Air iter case ©VALVE CLEARANCE ADJUSTMENT Disconnect rottle cables © 1 Stator choke cable @ T.Disconnect: rburetor heater coupler © ‘ye hose ® (throttle positon sensor) couplor © Loosen: «= Sorews (carburotor- joint) @ 9.Ror «= Carburetor assembly 1ORemove: + Oil cooler © Refer to “ENGINE REMOVAL" in CHAP- TERS When removing the union bolt ®, be sure to secure the hexagonal part @ to stop it tuniog, Ti.Remove: «= Spark plug caps @ Remé 1a Remove: ‘= Cynder head cover @vaavecaanee asrnenr RET QR] var ctenance ri 14. Remove: += Timing plate cover @ Valve clearance (cold): Intake vaive: 046 ~ 020mm Checking steps: ‘¢Turn the crankshaft counterclockwise with a wrench, ‘@Align he TOC mark @ withthe align mark © whan #1 piston is at TOC on compres sion stroke, Nove: ‘TDC on compression stroke ean be found when the cam lobes are opposite each other as shown, re the valve clearence using @ gauge. Nore: + Record the measured reading the clear ance is incorrect ‘ + Measure the valve clearance in the follow: o ing sequence, B® BZD == sa [onaVALVE CLEARANCE ADJUSTMENT | ADJ] INSP Front & feTum the crankshaft by the number of degrees indicated below counterciock- wise from #1 cylinder TOC. Crankshaft counterclockwise turning angle Boo RPT Gyinder eumber \Combustion W cylinder 70 degrees, ‘#4 Cylinder [360 degrees Cylinder 540 degrees, 16Adjust: + Valve clearance Adjustment steps: ‘eFosition the valve Ii exhaust) opposite ‘Attach the tappet adjusting tool ©. Tappet adjusting tool: P/N 90880-04125, Nove; —__ ‘Make sure the tool only contacts the iter @,not the pad. ‘@Siowly turn the tappet adjusting tool so ‘that the pads can be romoved. ‘@Remove the pads from the liters. Use 2 small screwdriver and a pair of tweezers for removal. Note pad numbers. feselect the proper valve adjusting pad from the following chert.INSP VALVE CLEARANCE ADJUSTMENT el = ae 21 ao $3505 520m on n|.0.06|) ayn alto rea eS | elas ela ala Ta £2 20 a Gn 0 ela jn aon so, Se ae Ove CLEARANCE (ct [285|280|295| 200] 305[9%0] 315320] on ann soles eee xa: mate i280 Peso sain Monsured eorsce 0.23 mm be lselo sui Replace 20 pd vith 260 pad staf Pod number (example) Bee fed No 200 20 en Bs Pra No. 280-280 mn Aina ial pad wth number down, —_ Sap — es Beles a alrn oe ralae sec aal aera ease ln mle 2 9 Pca ll ae ih oleae Baas elem ala olla a lal ce ss ssa ios lS [210215 20] 2282301296] 240) 25s aoe 503s s,s 208 (0 ln sa ac rosa 24 0 al le loa a Le aT 22 m7 lol ga 125702 aloo an a Pa a VALVE CLEARANCE (col a setae 016-020 ees Example rataed 250 (so ‘Measured clearance 50:2 mm "ass feplce 250 pa with 268 ped Bass. 3f fed mabe (examp BE) Pad No. 260250 mm /320] Pad No, 265 = 2.65 mm Avaye al pad wih number downVALVE CLEARANCE ADJUSTMENT Pad range 'No.200 ~ | 2.00 mm ~ No, 320 | 320 mm_ Pads are stepped in 0.05 mm inere- ments NOTE: ‘Thictneas of each pad ls marked on the pad {ace that contacts the valve lifter (not the ‘eRound off the fund original pad number mn increment. redths digit of the ‘to the nearest 0.05 Hundredths digit] Rounded value Oor2 ° 5 (NOT ROUNDED OFF) 8 0 EXAMPLE: Original pad number ~ 248 (2.48 mm) Rounded off cigit = 250, NOTE: Pads can only be selected In 0.05 mm incre mets. ‘SLosete the previously installed pad num ber on the chart, Locate the measured vave clearance on tt the chart. The point where these coordinates intersect is the new pad number. Note: Use the new pad number asa guide only the number must be vor ified. ‘install the new pad side down, with the numbered ‘eRamove the adjusting too.INSP, VALVE CLEARANCE ADJUSTMENT | ADJ ‘@Racheck the valve clearance, ‘01f the clearance is incorrect, repeat all of tho clearance adjustment steps until the specified clearance is obtained. Hinata: + All tenioved parts Nore: —____ Install all removed pars In reversed order ‘of thelremoval. Note the following point, rBinstall: + Timing plate cover ‘Screw (timing plate coveri: ‘Sm (0.8m kg) 1B.nstall: + Cylinder heed cover, + Spark plugs Bolt (eylinder head cover): ON (1.0 m= kg) ‘Spark plug: BN (1.8 m+ kg) ‘When installing the union bot, be sure to the hexagonal part to stop it turning, ‘Nut (oll cooler toNm(t Bolt oll cooler ‘32.Nm (3.2m kohINSP’ (CARBURETOR SYNCHRONIZATION nS ‘CARBURETOR SYNCHRONIZATION carburetors Nore, Place the motoroyele on is centerstand ra Centerstand is equipped. if not, place a suit fable stand under the motoreyele. Remove: = Seat 1 Fuel tank. Refer to “SIDE COVER, FUEL TANK AND COWLING® s.attac: = Adeptors = Vacuum gauge © Tinduetive tachometer ® (to #1 spark plug lead) a Vacuum gauge: ‘90890-03094 Adapter: ‘90890-05060 Inductive tachometer: "90890-03113 4Start the engine and let it warm up for ‘sovoral minutes. .Check ‘+ Encine idling speed Outof specification -» Adjust. Ffor to “IDLING SPEED ADJUSTMENT". Lay] re og seme ‘950 ~ 1,050 r/min GAdust + Carburetor synchronization Adjustment stops: ‘eSynchronize carburetor #1 to carburetor {#2 by turning synchronizing serew © until both gauges read the same. ‘eRace the engine for loss than a second, ‘wo oF thew times and check the synchro- ization againINSP, CARBURETOR SYNCHRONIZATION INSET Q ‘@Repeat the above aa to synchronize Carburetor #4 to carburetor #3 by turning Synchronizing serew @ until both gauges read the same. ‘apeat the same stops to synchronize car buretor #2 to carburetor #3 by tuming ‘synchronizing screw @ until both gauges ead tho same. ‘Vacium pressure at ile speed: 903 ~ 329 kPa (230 ~ 250 mm Hg) Nove: ‘The diference between both carburetors should be 1.33 kPa (10 mm Hg) or ess 7.Cheek + Engine idling speed Out of specification + Adjust. ‘Stop the engine and detach the measur. ing equipment, 8Agjust: + Throtie cable tree play. fefer to “THROTTLE CABLE ADJUST- MENT. Free play, 3-5mm At throttle grip flange 10.nstalt + Fuel tank Seat Refer to "SIDE COVER, FUEL TANK AND cowUNa’.puna seeeo ansusruenr [NSP] QR a 6 IDLING SPEED ADJUSTMENT Nore; —___ ‘The carburetor synchronization should be ‘adjusted properly before adjusting the idling speed. {Start the engine and let i warm up for several minutes. Zatch: ‘Inductive tachometer 3.check ‘= Engine idling speed Outof specification ~» Adjust. ie=¥] Fae tog spon: ‘950 ~ 1,050 r/min 4Adust + Engine iting speed Adjustment stops: ‘eTurn the pilot sorew © until itis Hightly sectod. ‘eum out the pilot sorew for the specified umber of turns Z] Carburetor angle driver: | ‘90890-03158 Plot sorew: 1/2 turns out Tun the throttle stop screw @ in or out ‘nl specified idling speed is obtained. “Turning in > ldling speed increased. ‘Turning out ~ Idling speed decreased.Renae eo annem agave seep AniusMenT (INSE] aa mony Tt aie ss Free play: 3- 3mm ‘AC throttle grip flange ‘THROTTLE CABLE ADJUSTMENT ore: Engine idling speed ond carburetor ayn chroniztion should be adjusted properly bofore adjusting tho throttlo cable free play. ‘check «+ Throtie cable free play @ Out of specification + Adjust. Free play: 3- 5mm At throttle grip lange 2memeve: os Fuel tank Refor to “SIDE COVER, FUEL TANK AND cowuNe®. 1 Airfiter caso Refer to “VALVE CLEARANCE ADJUST- MENT. 3.Adjust 1 Throtle cable free play Adjustment steps: Nove; When sccelerating, tote cable #1 © 6 pulled and throtte cable #2 © is pushed.‘THROTTLE CABLE ADJUSTMENT INSP ADJ First step: ‘@Locsen the locknut @ on throttle cable #2. {Tum the adjuster @ in or out unt all slack is ramoved from throttle cable #2. Second step: {© Loosen the locknut @ on throttle cable #1 ‘Tum the adjuster @ in or out until the specified free play is obtained, Turing out > Free play is decreased. (eTighton the locknuts wore; Itthe free play can ot be adjusted here, ‘adjust it at the throttle grip side of the cable Final step: ‘eLooson the locknut ©. ‘eTum the adjuster ® in or out until the specified free play is obtained, ‘Turning in — Free play is increased, ‘Turning out ~> Free play is decreased, Tighten the locknut. ‘tien the handlobor to the right and lot, making sure that the engine Idling speed does not change. Ansa: «+ Aicfter case Ro’er to “VALVE CLEARANCE ADJUST- MENT". + Fuel tank seat Re’r to “SIDE COVER, FUEL TANK AND COWLNG*SPARK PLUG INSPECTION NSS Q ‘SPARKPLUG INSPECTION Remove: += Spark plug caps + Spark plugs plug, ue compressed air to clean the eylin- dor head cover areas to prevent dirt from falling into the engine. 2inspat * Spars plug type Incorrect -» Replace. 5K X2HEPR-U9 (NIPPONDENSO}) Binspect: ‘Electrode © WeartDamage -> Replace, ‘Insulator @ ‘Abnarmal color - Replace. Normal color is a medivmtoslight tan color. Clean += Spart plug (with spark plug cleaner or wire brush) ‘sMeasure: + Spart plug gap @ Uso a wire gauge. (Out of specification -» Re-gap. ‘Spark plug gap: 080.9 mm instal: # Spark plug Spark plan: ‘1BNm (18m +g) Nore: —___. Before installing @ spark plug, clean the gasket surface and plug surface.IGNITION TIMING CHECK | ADJ | Q IGNITION TIMING CHECK Nove: —___ Carburetor synchronization, engine il speed and throttle cable free play should adjusted property before checking the ii tion tining. Remove: = Timing plate cover © attach: 1 Timing ight © 1 Inductive tachometer © {to the #1 spark plug lead) 3.Checke ‘Ignition timing ‘Checking stops: ‘eStart the engine and lot it warm up for ‘several minutes, Let the engine run atthe spocrfied speed. [ray] Baan specs ‘950 ~ 1,050 r/min ‘eVieually check the align mark @ to verify it is within the required fring range ® indi- ceated on the timing pate. Incorrect firing range -> Check timing plate andlor pickup assembly.IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT “insta: += Timing plate cover COMPRESSION PRESSURE MEASUREMENT Nore: Insufficignt compression pressure will result in performance loss. 1.chece «Valve clearance Out cf specification -» Adjust. Refer to "VALVE CLEARANCE ADJUST- MENT" 2Start the engine and let it warm up for 4 Remove: «= Spart plug caps 1 Spart plugs CAUTION: Before completely removing the spa plug, use compressed airto clean the cy dor head cover areas to prevent dirt from falling into the engine. Sattac: + Comaression gouge O [Ay “ssaasenr ‘90880-03081 Adapter:COMPRESSION PRESSURE MEASUREMENT bo Q ‘eMessure: = Compression pressure ‘Above the maximum pressure: Inspect the eylinder head, valve surfaces, {anc platon croven for carbon deposits Bolow the minimum pressure: Squirt a fow drops of oil into the affected cylinder and moasure again. «+ Rofer tothe table below. “Compression pressure (with ol applied into cylinder) Reading [Diagnosis Higher than | Worn or damaged pistons Repair Detective ring), valves, cylinder head gasket or plston is possible ~> Repair [Se] Se rere aan ‘Minimum 1,000 kPa (10 kg/m, 10 bar) ‘Maximum 11.400 kPa (14 kg/em, 14 ber) Measurement stops: ‘©Crank over the engine with the throttle wice-open until the reading on the com- pression gauge stabilizes. POE Belore cranking the engine, ground all sparkplug leads to prevent sparking. ‘@Ropeat the previous steps for the othor ceylinders. NOTE: ‘The difference of compression pressure between the highest and lowest cylinder ‘compression readings should be 100 KPa (1 kalom, thar) or less.COMPRESSION PRESSURE MEASUREMENT/ [INSP CSRS uTeerumeneNT, INSP] Qk instal + Sparkplugs += Sparkplug caps Spark plug: ‘BN (1 mk) [ENGINE OIL LEVEL INSPECTION Nore; Position the rotoroyele sraight up when Inepecting the oll level ‘TPlace the motorcycle on Nore: Place the motoreycle on Tis centorstand if Ceenterstand is equipped. If not, place a sult able stand under the motorcycle 2inspoce += Oil oval Oil lvl should be betwo and maimum @ marks. il leva low -» Add oil to proper love. lovel surface, maximum ® Recommended o (" ‘SAE 20040 type SE motor oll Nore: —____ Recomrrended oll olassification: API Ser Vice “SE", “SF* and “SG" type or equiva lent (e9."SESE", “SFSE-CC", “SFSE 80" ete ‘=Do net add “any chemical additives. Engine oil also lubricates the clutch and ‘additives could cause clutch slippage. + Do not allow foreign material to enter the nkease,ENGINE OIL LEVEL INSPECTION/ [INSP ENGINE OIL REPLACEMENT | ADJ) 3.Start the engine and let It warm up for ‘several minutes. ‘4510p the engine and inspect the cil level ‘once again. Nove, —___ Wait'a Tow minutes unt the ot settles ‘before inspecting the il love [ENGINE OL REPLACEMENT 1.Start the engine and let it warm up for ‘several minutes 2.Stop the engine and place an oil pan ‘under the dain bolt. + Oil filler plug * Drain bolt © Drain the erankoase of ts oi ‘4ifthe oil fiteris to be replaced during this ‘il change, remove the following pars ‘and reinstall them. Replecement steps: foriove the ol filter © using the ol iter wrench @. (5A amass” A | “soose eee ‘eApply engine oil to the O-ring @ of the ‘new oil filter. ore, —___ Make sure the Oring © is positioned cor rectlyENGINE on rerLacement [INST | QR feTighton the olf iter using the oil filter ‘wrench [J Oil fitter: 17 Ne (1.7 mg) Sinsta: «= Drainbott Drain bolt: '43.Nen (4.3 m+ kg) Nore: Chock ‘he gasket (Grain plug) damaged, replace it with a new one. rit ‘= Crantease Refer to “ENGINE OIL. LEVEL INSPEC- TION’. il quantity: Total amount: pe ae Periodic ol char 32. With ot fiter replacement: 34 Tins + Oilfiler plug ‘Warm up the engine for a fow minutes, then stop the engine. siinspect: ‘Engine (for ol leaks) 2 Olltevel 10.Check: + Oil pressure Checking steps: {Slightly loosen the oil gal festartthe engine and ko starts to seep from the il gallery bolt. If ro oil comes out after one minute, turn the engine off soit wil not seize. aENGINE OIL REPLACEMENT/CLUTCH ADJUSTMENT | ‘ABs | QR doll pump ‘eStart the engine after solving the prob. emis} and racheck the oil pressure. ‘Tighten the oil gallery bot to specifica- tion. Hlery bolt: ‘BN (0.8 m = kg) ‘CLUTCH ADJUSTMENT Check: ‘Clutch cabie free play ® Outof specification > Adjust. 2Adust # Chach cable free play ‘Adjustment stops: ‘@Loosen the locknutis) ©, ‘©Tuin the adjusters) @ in or out until the specified free play is obtained. Turing in > Free play is increased. Turning out > Free play is decreased. (Tighten the locknutts. Bi dndieber side gine sideamrutencicanine [NSF] QR ‘AIR FILTER CLEANING Remove Seat 1 Fuol tank Rofer to “SIDE COVER, FUEL TANK AND COWLING". 2Remove: 1 Air iter case cover ‘S.Remove: Air filter element engine damage ‘without the fiter element will affect carbu- rotor tuning with subsequent poor perfor- ‘mance and possible engine overheating. Anspect + Airfiter element Damage -> Replace, 5Clean: | Airfiter element Biovr out the dust in the outer surface of ‘the element with compressed ait instal: Air fiter element 1 Air filter case cover sure its sealing surface matches the sealing surface ofthe case so there isn Tinstal: + Fuol tank i seat Rofer to "SIDE COVER, FUEL TANK AND COWLING".FUEL LINE INSPECTION Di5| Ba FUEL LINE INSPECTION “Lnspect: + Fualhose ©FRONT BRAKE LEVER POSITION ADJUSTMENT/ [INSP REAR BRAKE ADJUSTMENT | Niss| © 7 IN CHASSIS FRONT BRAKE LEVER POSITION ADJUSTMENT Adjust «= Brake lever position (distance @ from handle grip to front brake lover) Aajustment steps: Push the brake lever forward. (9Turn the adjuster © in or out “Turing in ~ Distance Is smaller. Turning out” > Distance is largest. ‘@Align the mark @ on the adjuster with the ‘mark Bon the lover ‘Make sure that the brake does not drag after acjusting it system, This air must bleeding the brake syster motoreyee Is operated. Air in the system ‘will cause greatly diminished braking capacity and can resut in loss of control ‘and an accident. Inspect and bleed the sys tom if recessary. REAR ERAKE ADJUSTMENT check + Broke pedal height @ ut of specification > Adjust. ‘Brake pedal height: 30 mm Bolow top of footrestREAR BRAKE ADJUSTMENT INSP Q 2aAdust ‘= Broke pedal height ‘Adjustment stops: ‘@Locsen the locknutts) ©. ‘eum the adjuster(s) @ in or out until the spesified pedal height is obtained. Turing in > Pedal height is down. ‘Turning out > Pedal height is up. ‘check the adjuster end through ‘The adjuster end ® must be visible within this hole. ‘STigiten the locknat D, ‘will ause greatly diminished braking capa- bility and can result In loss of control and ‘an accident. Inspect and bleed the system i necessary. BAdust «Broke light switch Roler to “BRAKE LIGHT SWITCH ADJUSTMENT.INSP Q BRAKE FLUID LEVEL INSPECTION | Ap. 'BRAKEFLUID LEVEL INSPECTION Nore: Position the motorevele Inspecting the fuidleval Int up when 1.Place the motoreyele ona level surface. Nove: Place the motoreyele on its conterstand a Conterstand is equipped. If not, place sult- able stand under the motorcycle. inspect: + Fluid level Frontbrake Rear bake Nore: When inepocting the fluid level in te reser voir on the handlebar, make sure the mas- tor cylinder top is horizontal Brake ‘luid may corrode painted surfaces fr plastic parts. Always clean up spilled fluid immediately. se only the daignated qaliy Wad Denon, the rar sols may etre fate casing losage and poor ale per formence oll wth the same type of ul Ming fats may rau a hora ehecl feoton lating to poo brake perforINSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT {= Be careful that water doos no enter the master cylinder when refiling. Water will ‘significantly lower the boiling point of the fluc and could cause vapor lock. BRAKE FLUID LEVEL INSPECTION/BRAKE PAD INS] Q ‘BRAKE PAD INSPECTION ‘Activate the brake lever or brake pedal inspect += Brats pad (front) += Brate pad (rear) Wear indicator @ almost contacting the brate diac —» Replace brake pad asa set. Refer to “FRONT AND REAR BRAKE" in CHAPTER 6. Front Rew BRAKE LIGHT SWITCH ADJUSTMENT Nore: —___ ‘The brake Tight ewitch a operated by move mentof the brake pedal Proper adjustment is achieved when the brake light comes on just before the brake Dbogins to tako effect. 1.cheok «Brake light operation timing Incorrect > AdjustBRAKE LIGHT SWITCH ADJUSTMENT/ [INSP BRAKE HOSE INSPECTION | ADJ Q 2Adjust: 1+ Brake light operating timing ‘Adjustment steps: ‘¢Hoid the main body © of the switch with Your hand so that it does not rotate, and turn the adjuster @ in or out until the ‘operating timing is correct, ‘Turning in > Brake light on tater. ‘Turning out > Brake ight on sooner. BRAKEHOSE INSPECTION inspect: «= Brake hoses Cracks Wear/Damage ~+ Replace, 2.check = Brake hose clamp Loosen -> Tighten. Hold the motorcycle on upright position ‘and apply the tront or rear brake, Acheck + Brake hoses Activate the brake lever or pedal several times. Fluid leakage -» Replace the hose. Rofer to “FRONT AND REAR BRAKE" in CHAPTER 6.INSP Q AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) | ADJ ‘AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) += The system has been disassembled. TA brake hose has been loosened or removed. «+ The brake fluid has been very low. 1 The brake operation has boon faulty. ‘loss of braking performance may occur if ‘the brake system is not property bled. Blood: = Brake system {ir Heeding stops: ‘a.Add proper brake fluid to the reservoir. binstall the diaphragm. Be careful not to ‘spit any Mid or allow the reservoir to overiow. ‘Connect a clear plastic hose © tightly to the caliper bleed screw . Bont Rear ‘Placa the other end ofthe hose into con- taner. ‘eSlomly apply the brake lever or pedal sev- ral times. {Pull the lever in oF push down on the peta, Hold the lever or pedal in position. @.Loosen the bleed screw and allow the lever or pedal to travel towards its limit Tighten the bleed seraw when the lever have disappeared from the fluid. i. Tighton the blood serow. Bleed screw: Nm (0.6 m~ ko)AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ [INSP FINAL GEAR OIL LEVELINSPECTION | Apsy | QR 10 let the brake fluid sette for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap peared, Add brake fluid to proper level. Refer to “BRAKE FLUID LEVEL INSPEC- TION’. Check the operation of the brake after bleeding the brake system. FINAL GEAR OIL LEVEL INSPECTION ove: Position the motoroyele straight up when ecting the oil level. {Place the motoreycle ona level surface. Nove: —___ Place the motoreycte on is conterstand a ‘centerstand fs equipped. ifnot, place a suit fable stand under the engine, Remove = Oilfiler bot © Binspect: = Oillevel Oil level should be up to bottom brim @ of hoe. Dil evel low -> Add oil to proper vel Recommended ol ‘SAE 80 API “GL-4” Hypoid gear oil "GL-4" ig a qualty and additive rating, “Gl 5° or “GLO” rated hypoid gear oils may also be used. ‘instar + ilfilr bolt Oi filler bolt: -23.Nen (23 m + kg)FINAL GEAR OIL REPLACEMENT/ ‘STEERING HEAD INSPECTION FINAL GEAR OIL REPLACEMENT ‘Place an oll pan under the final gear case. 2Remove: + Oilfiler bott 2 drain plug D Drain the final gear case ofits ol lst: plug Dian pig aN 3g) Check the gasket (Grain plug). Wr damaged, ‘oplaceitwith a new one. Ai = Fina goar case ‘Oil quantity: , oz Refer to “FINAL GEAR OL LEVEL INSPEC- Ton". ‘STEERING HEAD INSPECTION PRUNE ‘Securely support The motoreyele 50 there {sno danger of t falling over. 1 Place the motoreycle on a level place. 2.Elevate the front wheel by placing 2 sult ‘able stand under the exhaust pipe. 3.Chexk «= Stoering assembly bearings Grasp the bottom of the front forks and ‘gently rack the fork assembly back and for Looseness +> Adjust the stooring head.srezrING Heap wspection [ABs | QR “4Remove: + Handebar S.Loosen «= Pinch bolts © Remove: Nut + Upper bracket @ Agius «+ Stoeting head Adjustment steps: ‘eRemeove the spacial washer O, ring nut © upper) and rubber washer ©. feLoosan the ring nut lower! @. {Tighten the ring nut (lower using the ring ut wrench @. Set the torque wrench To the fing nut ‘wrench so that they form aright angle. [p> Seasons ‘sobgo ova Ting nut (lower! Ginitial tightening): ‘52 Nem (52 m= kg) ‘@Loosen the ring nut lower! @ completely, ‘then retighten It to specification. POE Do not overtighten ing nut lower! (final tightening: ‘New (1.8. kg)STEERING HEAD INSPECTION bead Q ‘eCheck the steering heed by turing it lock to lock. If it binds, remove the steering stem assembly and inspect the steering bearings Refer to “STEERING HEAD AND HANDLE- BAR" in CHAPTER 6. Install the rubber washer @. stl the fing aut (upper) @- ‘eFingor tighten the fing nut (upper) ®, then align the slots of both ring nuts. if necassary, hold the ring nut (lower) and tighten the ring nut (upper) until thelr siots are aligned, ‘install the lock washer ©. ore; —___ Make eur the Took washor tabs it correct in thes. Binet: ++ Upper bracket ‘Handlebar Nat "110 Nm (11.0 m + ka) Pinch bolt (upper bracket): '30 Nm (3.0 m« kg) Pinch bolt {handlebar holder}: 231Nm (23 m+ kg)FRONT FORK INSPECTION/ [INSP REAR SHOCK ABSORBER ADJUSTMENT | ADJ Qa FRONT FORK INSPECTION FOUN ‘Securely support {Is no denger of it faling over. Place the motoreyele on a lovel place 2.Check + Inner tube ‘Scratches/Damage -> Replace. += Oil sen! Excessive oil leakage ~> Replace. ‘Hold the motoreyele in an upright post ton and apply the front brake 4.check: ‘= Operation Pump the front fork up and down for sev- eral tines. Unsrrooth operation -> Repair. Referto “FRONT FORK" in CHAPTER 6, REAR SHOCK ABSORBER ADJUSTMENT A WARNIN ‘Securely support the motoreyele so there ‘sno dangor of it ali Spring preload Adjust: + Spring preload NOTE: ———— Use thi spacial wrench end extension bar included in the owners too! kit to adjustREAR SHOCK ABSORBER ADJUSTMENT/ [INSP TST, [NSETQR Adjustment steps: + Turn tho adjuster © in or out Tuning lower number > ‘Spring preload is softer. Turing higher number > ‘Spring preload is harder. ‘Adjuster position: ‘Stendard: 4 Minimum: 1 Maximum: 7 "Never turn the adjuster beyond the max ‘mum or minimum setting. ‘TIRE INSPECTION “Measure: ‘Tre pressure Outof specification > Adjust. PRUNE inflation pressure should be checked fané adjusted when the temperature of the tie equals the ambient air temp ture. Tire lflation pressure must be adjusted according to total weight of ‘cargo, rider, passenger, and accessories (faring, saddlebags, ete if approved for ‘this model, and vehicle speed. oper loading of your motorcycle is important for the handling, braking, and other performance and safety characterls- tics of your motorcycle. Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motoreycle, and dis tribute the weight evenly from side to side. Properiy adjust the suspension for ‘your load, and check the condition and pressure of your tres.ine wspecrion [Ay | QR jo Aa) (NEVER OVERLOAD YOUR MOTORCYCLE ‘Make sure the total weight of the cargo, rider, passenger, and accessories (airing, ‘seddiebags, ete. if approved for this modell ‘does not exceed the maximum load of the ‘motoreyele, Operation of an overloaded motorcycle could cause tire damage, an accident, or ‘even injury. Base ware and | 205 Nita cn | Maximum |toad*: ne Cold tire ‘ront Rear | pressure: om asim | aoe upto wta |p zstglen| astutlen, ier 250K» | 2904s soko - Max | 2 Seen, | tte Seen |e 250xe | 200 Pa igh speed astatlon,|aatetlen, riding 25 bar) ‘29 bar) * Load isthe total weight of earg, rider, pas: nae and accessories. 2inspest «Tire surfaces WearDamage -> Replace. ‘Minimum tre tread depth: (ront and rear: poe) Tread depth @Side walt Weer indicatorriremseecrion [Ase | QR RII It is dangerous To vide with @ worn-out tire. When a tire tread begins to show lines, replace the tire immediately. 1+Do not use tubeless tires on a whee! designed for tube type tires only. Tire fail- ture and personal injury may result from sudden deflation, Gre BWheot “Tube type wheel — Tube type tre only Tues type wheel ‘Tube type oF tubeless tire. + Be sure to install the correct tube when Using tube type tires. ‘After extensive toate, the tres mentioned below have been approved by Yamaha ‘Motor Co., Ltd. for this model. No guaran ‘tee for handling characteristics can be ven Ifa tire combinations other than the ‘approved is used on this motorcycle, The front and rear tires should always be of the nufacture and design. Manufacturer | Size Type |MeTZELER | 120/70-17 sev| MESS BRIDGESTONE | 120/70-17 58v | _G601 DUNLOP | 120/70-17 58 | KSOSF REAR Wanufacturer | Sze Type METZELER | 150/70-17 63 | MESSA [BRIDGESTONE | 150/70-17 68 | —G602 DUNLOP | 150/70-17 8] _K505 Fer mouning «Wa Was om tars nets the eo ne torso eae cmewenieure Sass tn enWHEEL INSPECTION/ [INSP CABLE INSPECTION AND LUBRICATION | aps | QR ‘WHEEL INSPECTION “inspect: = Wheets Damage/Bends -> Roy Nove: ‘Always Balance the wheal when @ We oF "whe! has been changed or replaced Never attempt to" make any repair to the wheel ‘CABLE INSPECTION AND LUBRICATION Damaged cable sheaths may caus corre” sion and interfere with the cable move- ‘ment. Replace damaged cables as soon as. possible. “Lnspeet = Cable sheath Damage -» Ropiace. 2.check += Cable operation Unsmooth operation -» Lubricate. Recommended lubricant ‘SAE 20W40 motor of! snd up and pour few drops of lubricant into the cable sheath.LEVER AND PEDAL LUBRICATION/SIDE: ‘CENTERSTAND LUBRICATION/REAR SUSPENSION LUBRICATION INSP ADJ STAND LUBRICATION/ LEVER AND PEDAL LUBRICATION LLubriate levers and pedals at ther pivoting points. ‘Recommended lubricant: ‘SAE 20W40 motor cil a S| SIDESTAND LUBRICATION LLubreate the sidestand at pivoting points. Recommended lubricant: Lithium soap base grease ‘CENTERSTAND LUBRICATION Lubricate the centerstand at points Recommended lubricant ‘ithium soap base grease REAR SUSPENSION LUBRICATION. Lubricate the rear suspension at pivoting points S pivoting Recommended lubricant: ‘Molybdenum disulfide greasesarrenr sezcron [RST ELECTRICAL BATTERY INSPECTION Nove; Since the MF battery is a sealed type bat tory, its not possible to measure the spe- cifle gravity of the electroiyie in order to check tre state of charge of the battery ‘Therefore the charge of the battery has 10 bbe checked by measuring the voltage at the battery terminals CHARGING METHOD + This is a sealed type battery. Never remove the sealing caps. If the sealing caps have been removed, the balancing will not be maintained, and battery per- formance will deteriorate. ‘Never add water, as this will atfect the chemical reaction in the battery and ‘cause oss of performance. ‘Charging. time, charging current and charging voltage for the MF battery are siffernt from general type batteries. ‘The MF battery should bo charged as ‘explained in “CHARGING METHOD". ‘the battery le overcharged, the electro Iyte level will drop considerably. There- fore, take epacial care whon charging the battery. “+ Never use an electrolyte other than speci- fied. The specific gravity of the MF bat: ‘ery electrolyte is 1.32 at 20°C, whereas the specifi gravity of a general type bat- tery dectrolyt is 1.28. If electrolyte with «8 specific gravity lower than 1.32 is used, the concentration of sulfuric acid wil decrease, resulting in poor battery perfor- ‘mance. If an electrolyte with a specific ‘gravity higher than 1.32 Is used, the bat- tery plates will corrode and battery ite willbe shortened,BATTERY INSPECTION Battery electrolyio Te ‘+ Avsld bodily contact with electrolyte as it ‘can cause severe burns or permanent aye injury. «+ Wear protective eye gear when handling or working near batteries. ‘Antidote (EXTERNAL): «SKIN - Flush with water. EVES - Flush with water for 15 minutes and get immediate medical attention. ‘Antidote (INTERNAL): += Drink large quantities of water or milk fol- low with milk of magnesia, beaten egg. ‘oF vegetable oil. Get immediate medical attention, Batteries gonerate explosive hydrogen gas. ‘Always follow the following proventive {+ Charge batteries in a well-ventilated area. 1 Keep batteries away from fire, sparks, oF ‘open flames (e.g, welding equipment, lighted cigarettes, ete) + D0 NOT SMOKE when charging or han- ing batteries. KEE? BATTERIES AND ELECTROLYTE OUT (OF REACH OF CHILDREN. ‘Remove «Side cover (sight) Refer to "SIDE COVER, FUEL TANK AND COWLING". 2Remove: Cover ‘.Diconnect: = Battery leads Disconnect the negative load © frst, then the positive lead ©. ‘Remove: ‘= BatteryBATTERY INSPECTION ‘Chace INSP ADs ‘= Battery condition Battery condition checking stops: ‘eConneet 9 digital vometer to the battery terminal, Testor () lead — Battery (+) terminal Tester (-} lead —> Battery (-) terminal Nove: ‘The chargo state of an MF battery can be checked by measuring the open circuit volt- ‘age (ie. when the positive terminalis dis- ‘connected. Open-circuit voltage | Charging time ta2avertioher | Nefaranais ‘Chock the condition of the battery using the charts Example: ‘©Opan circuit voltage = 12.0V fecharging time ~ 65 hours ‘Charge condition ofthe baton {@Charging method of MF batteries sift is impossible to set the standard ‘charging current, be careful not to over charge + When charging the battery, be sure to remove It from the motorcycle. (if charg- ing has to be done with the battery ‘mounted on the motoreycle for some rea~ son, be sure to disconnect the wire at the negative terminal) + Never remove the sealing caps of an MF battery += Take care that the charging clips are In a full contact with the terminal and that they are not shorted. (A corroded clip of, the charger may cause the battery to gen- crate heat at the contact area. A woak clip spring may cause sparks.BATTERY INSPECTION NSE Qa “= Bafere removing the clips from the bat- ‘tery terminals, be sure to turn off the power switch ofthe charger. «+ The open-ciruit voltage variation of the ME battory after charging ie shown below. As shown in the figure, the open- cireait voltage stabilizes about 30 min- tutes after charging has been completed, ‘Therefore, to check the condition of the battery after charging, wait 30 minutes ‘before measuring the open-circuit volt- aveBATTERY INSPECTION nee Q (Charging method using a variable-current(voltagel type cherger ‘am meter [ Measure the open circuit] Yong snoua te mamas 50 n= voltage prior to charging, | mms" he mac r ‘Connect a chargar and | te te canona vtaga TT AMP meter tothe battery | U0 he By tuming the charging vol- age adust dial, set the charg- ing velage at 20 - 25 v. r ‘Adjust the voltage so. that ‘Monitor the amperage for 3-5 ceutrant i at standard charg: [-YES. ‘minutes t0 check if tha stan- ing tv. dard ehorging eurtent is hed. No Set th timer according tothe HF current does charging time suitable for the not exceed stan ‘open circuit volte. ord chorging Refer to “Battery coneition current after 5 ‘checking stops” minutes replace the bat In case that charging requires more than 5 hours, its advisable to check the charging current after a lapse of § hours. f there is any ‘change in the amperage, readjust the voltage to obtain the standard charging current. n ‘Messure the battery open-citcut voltage ater having let the battery unused for more than 30 minutes. 12.8 v or more ~~ Charging # complete 12.7 vor less -— Recharging is required Under 12.0 v —- Replace the battory. a8 and start charging, ie once r ves higher than the standard |_NO charging current writen fn the bettoryearreny inspecTion [NS Q ‘Charging method using a constant-voltage type charger ‘Meseure the open-cteut | Verago moa voltage prior to charging, | the mahi ones ‘Connect @ charger and AMP meter to the bat- tery, and start charging ‘Make sure the current ves higher then the stardard No charging current written fon the battry. ‘Charge the battery untl the battery's So i type of battery charger cannot charging voltago i 16 volts ‘charge the MF battery. A variable owe voltage charger is recormmended, ‘Check the open-circuit vohage ator having laf tho battory for 30 ‘minutes ater charging Under 12 v—Replace the battery {Charging method using a constant current type chargor ‘This type of battery charger cannot chargo the MF batty.INSP BATTERY INSPECTION/FUSE INSPECTION Binspect ‘= Battey terminal Dirty + Clean with a wire brush. Poor sonnection -» Correct. Note ‘Aftar daaning the torminale, groaso them lightly. instal: = Battery Connect: + Battery leads 9insta: + Side 2over (eight) Rote: o “SIDE COVER, FUEL TANK AND COWLNG". FUSE INSPECTION checking or replacing the fuse. Otherwise, shor elroult may occu ‘Remove: + Side cover ‘right Rofer to “SIDE COVER, FUEL TANK AND COWUING™INSP FUSE INSPECTION | ADJ inspect, + Fusae Inspection steps: ‘eCornect the pockot tester to the fuse and chek i for continuity. NOTE: Sot the tester selector to "OT" Valeo ] (01f the tester indicates =, replace the fuse. 3.Replace: ‘= Blown fuse Replacement steps: ‘eTurs off the ignition ‘Install « new fuse of propor amperage. {@Turn on the switches t0 verify operation of ralatd electrical devices. ‘elf the fuse immediately blows agi ‘choxk the electrical circuit. Description | Amperage | Quantity Maia 208, 1 | Head “15a 7 Signal 208 1 Ignition 0A 7 Glock T0A 1 Nover use a fuse with a rating other than spectied. Never use other materials in place of fuse. An improper fuse may cause extensive damage to the electrical system, malfunction of lighting and igni- tion and possibly cause. ‘instar: + Side cover (right) Refar to “SIDE COVER, FUEL TANK AND ‘COWLING.HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT HEADLIGHT BEAM ADJUSTMENT 1 Adjuce «+ Headlight beam (vertically) Turn he adjuster @ in or out. [Tursing in > Headlight beam higher. Turning out > Headlight beam lower. 2Adiust: ‘+ Headight beam (horizontally) Turn he adjuster @ in or out. Turning in > Headlight beam to the ight Turning out > Headlight beam to the let. HEADUGHT BULB REPLACEMENT ‘disccanect: = Headight ead © 2Remove: cover LUnhook: ‘= Bulb holder © ‘Remove: = Bub® mm jammable producls and your hands ‘away from the bulb while tis on, as it will bbe hot, Do not touch the bulb until it has ‘cooled down,HEADLIGHT BULB REPLACEMENT/ [INSP DIGITAL CLOCK ADJUSTMENT | ADJ Cy ‘inst: “= Bulb (new) Secure the new bulb withthe bulb holder. with a cloth moistened with aleohol or lac- {quer thinner. ‘Hook «= Bulb holder Tinstall: = Cover 8.Cornect + Headlight esd DIGITAL CLOCK ADJUSTMENT + Digital clock ® Digital clock adjustment steps: Tum the main switch to "ON". ‘©The time (hour) setting can be made by pushing or holding the "H” switch @. fe The time (minute) setting can be made by pushing or holding the “M™ switeh @. Nove; —_____ When getting the clock after Te power source is cut by a removed battery, et, first set the time for 1:00 AM, then, go'on to setitfor the correct time.ENGINE Removat | ENG | yp) ENGINE OVERHAUL ENGINE REMOVAL ‘Securely support the motoreycla 60 there Is no danger oft fll ‘order to remove the following components: + Cylinder head + Cylinder Piston clutch + Oil cooler Fofer to "SIDE COVER, FUEL TANK AND COWLING® in CHAPTER 3. ENGINE O1L Dra: + Engine oll Rote to "ENGINE ll. REPLACEMENT” in (CHAPTER 3, BATTERY LEADS Disconnect: + Batiory leads Disconnect the Tagative lead © first and then disconnect the positive lead ©.enaine removat | ENG | Gp ‘AIR FILTER CASE ‘Romeve: # Airfiter case Rofer to “VALVE CLEARANCE ADJUST: MENT in CHAPTER 3. ‘ALLS. (AIR INDUCTION SYSTEM) Remeve: ‘ALS. (AIR INDUCTION SYSTEM) Refer to “VALVE CLEARANCE ADJUST- MENT" in CHAPTER 3. ‘CARBURETOR Remeve: + Carouretor Refer to “CARBURETOR” in CHAPTER 5, + Carburetor joint HOSES AND LEADS 3.Disconnect: «= Breather hose TAC. generator coupler Pickup coll coupler Remove: = Bands‘SReriove: «Side stand switch lead © from the clamp. = Clurch cable Removal steps: ‘eLocson the locknut ©. Tum the adjuster @ enough to free the clutch cable, ‘@Unhook the cable end @ + Cable stay © SHIFT PEDAL, ‘Remove: = Bok 2.isconneet: = Shitarm @ ‘STARTER MOTOR. ‘1Wisconnect = Starter motor lead D 2Remove: = Starter motor @encine removat | ENG | Gp] ‘AG. GENERATOR ‘Remo AC. generator © EXHAUST PIPE ‘Loosen: + Bote 2Remove: + Muffler @ 3.Remove: = Bolt, Nuts + Exhaust pipe @ + Gasket ‘OW COOLER ‘emove: + Olt cooler D When removing the union bolt ©, be eure to secure the hexagonal part @ to stop it turning. 2.Remove: + Oil iter housing © += Oil pipe @Encine Removat | ENG | yp DRIVE SHAFT RUBBER BOOT “Peel back: += Rubber boot © ENGINE REMOVAL ‘suitable stand under the frame and 2.Remove: ‘= Motnting bolt (front) 1+ Engine stay (front) © 2 Down tube (right) @ Cross tube front) Mounting bolt (rear - upper) ® {= Mounting bolt (rear- lower) © + Engine stay (rear) Remove: ‘Engine assembly (from the right side of the motorcycle) Cover the front Tender with a rug to pre vent seratchingENGINE DISASSEMBLY | ENG on ENGINE DISASSEMBLY CYLINDER HEAD COVER, CAMSHAFT AND CYLINDER HEAD OTE With the engine mounted, the cylinder heed cover, camshaft and cylinder head can be maintained by removing the following parts: ‘Fuel tank + Carburetor in a eresoross pattern 14 ‘urn each, Remove them aftr all are loos. ened. 2Remove: ‘Timing plate cover © 3.Alig: = "TDC" mack (with stationary pointer) Nove: — «= Turn tho crankshaft counterclockwise ond align the "TDC" mark @ with the align ‘mark @ when #1 piston is at TDC on com- pression stroke. +The #1 piston is in compression stroke ‘TDC when the cam lobes are turned away {rom each other, as shown.ENGINE pisassemsty | ENG| ogy “ALooeen: ‘= Bolts (cam sprockets) B.Loosen: «Tensioner bolt Remove: «Timing chain tensioner ® Remove: « Chain guide (exhaust side) © 8Romove: Carrshatt caps (intake) Carrshaft caps (exhaust) + Dowel pins ore: —_____ Remove the camahali ap bolts ino cries ‘cross pattern from the outside working inwards. Remove: «Camshaft (intake @ and exhaust @) Nore: —__ Attach @ wire @ to the timing chain to pre= vent trom falling into the crankcase.ENGINE DisassemsLy | ENG | Gp] «+ Start by loosening each nut 1/2 turn until all aro loose. 11.Remove: + Cylinder hoad + Gasket (cylinder head) © Dowel pins @ + Oxings @ CYLINDER AND PISTON piston can be maintained by removing the following parts: Ful Remove = Nut 2 Washer te Weleda ellENGINE piIsassemeLy | ENG | tw “2Remeve: = Cylinder «Gasket (oylinder) + Dowel pins @ ‘3Remnove: «= Piston pin clips © 1 Piston pins @ J Pistons @ Nore: —__ «=: Bofaré removing the piston pin clip, the crankease with a clean rag to prevent the piston pia lip from falling into the crankcase cavity, + Put identification marks on each piston head for reference during reinstallation. ‘= Before removing the piston pin, deburr ‘the clip groove and pin hole ares. If the piston pin groove is deburred and piston pin ig stl dificult to remove, use the pis tonpin puller ®. [3 Psisae, [7 |_suao0-ors0e 4.Remove: {+ Oilet nozzles © {with O-ring)ENGINE DISASSEMBLY PicKUP Con Remove + Bolt (ting plate) © Timing plate ® Ping® + Picku coll base © Working in a crisscross pattom, loosen the bolts 1/4 turn each. Remove them afterall are loosened. Remove: + Clutch pull ever shaft @ SGear@ENGINE DisAssemBLy | ENG wo ‘Remove: «= Bolts (clutch spring) © = Clutch springs © + Pressure plato @ tPullrod @ 2 Washer @ + Friction plates ® 1 Clute plates © + Oil guide plates @ 6.Loosen: «Nut lutch boss) ® wore: Loosen the nat (clutch boss) © while hole ing the clutch boss @ with the universal clutch holder ‘Universal olutoh holdor: "90890-04086 Remove: 4 Nut clutch boss) © + Lock washer @ S cluten bose @ = Thrust plate @ * Spacer © = Bearing © {+ Cluteh housing @ + Oil pump drive sprocket @ = Collar @ + Waster © CO1L PAN AND ONL PUMP. Nore, —____ With tag engine mounted, the oll pan, ol fr tor and oil strainer can be maintained by removing the following par + Exheust pipeENGINE pisassemeLy | ENG | yp] “Remove + Oi ove switch © + il pan ® 2 Gasket + Dowelpins Nove: Loosen the bolts in @ ofsscross pation T# turn each. Remove them afterall are loos ened. 2Remove: + Oil pup assembly S.Disconnect: = Neutral switch toad @ Remove: «+ Neutra switch @ SHIFT SHAFT Remove ‘Shift shaft lever cover © saskot = Dowel pins 2Remove: = Covers aRomove: «= Shift shaft © 2 Washoe 1 Shift lever @ + Spring 1 Stopper lever ® Nore: Roleasethe shit'arm @ from the dram pine “while puling out the shift shaft assemblyENGINE DISASSEMBLY | ENG +n] MIDDLE GEAR| “Loosen: «= Bolts (crankcase) © 2Remove: ‘+ Midale driven shaft assombly © shim aRemove: += Bearing holder © 1 Mico drive shatt assembly © J shim@ (CRANKCASE DISASSEMBLY ‘Remove: « Crankease cover (right) © 2Remove: «= Bolts (crankcase) Nove, ‘sLoosen the bolts 1/4 turn each and remove them afterall are loosened. Remove the bolts starting with the high fest numbered one. «The embossed numbers in the crankcase designate the crankcase tightening sequence. Place the engine upside down. ‘Rerrove: + Crarkcase (lower) peer easeENGINE DISASSEMBLY ENG |‘) Remove: «+ Main journal bearing (from ower crankcase) Nove: —____ Identity Sach plain bearing position very ‘carefully so that it can be reinstalled in ts crigina place. ‘SHIFT FORK AND SHIFT CAM. Remove: = Guide bars (shit fork) 1 Shift fork "2 shift fork “C* = Shift fork “L @ 2Remove: = Bearing holder © * shift cam assembly @ENGINE DISASSEMBLY | ENG on) TRANSMISSION Remove: «Main axle assembly @ {Middle drive shaft assembly holder @ Bearing © 2Remove: = Boaving housing © 1 Drive axle gear (5TH) 1 rive axle assembly @ ‘CRANKSHAFT AND STARTER CLUTCH 1.Streighten: « Loctwasher tab @ 2.Romove: + Bolt 1 Shaft (idle gear) © {ale gear @ 1 Stator clutch shat ® 1 Staner clutch ©ENGINE DisassemaLy | ENG| “p| “Remove: «Crankshaft assembly © $ Oil seal @ = Plug ‘Timing of THYAO chain @ 5Romove: + Timing chain guide tintake sido) © + Chain guide (H¥-VO chain) @ VALVE Nore, —___ With che engine mounted, the valve and camshaft ean be maintained by removing the following parts: = Fueltanie 1 Contr cowiings Air fiter case {Carburetor SAIS. assembly + Oil cooler Cylinder head Nore —___ “The valve sealing should be checked before emoving the intemal parts (valve, valve spring, valve seat etc) of the cylinder ‘Remove: + Liters + Pads ® Nore: Idontiy ‘each Titer @ and pad © position very carefully s0 that they can be rei stalled in their original place.EnciNe pisassematy | ENG| gp 2.check += Valve seating Leakage ot valve seat > Inspect the valve face, valve seat and the valve seat width Refer to "VALVE SEAT". Checking steps: ‘ePour é clean solvent @ into the intake and exhaust parts. ‘echeckthe valve seating, ‘There should be no leakage at the valve seat @. 3 Remove = Valve cotters © ove: ‘Attach the valve spring compressor @ and ‘attachment @ between the valve spring fetainer and cylinder head to remove the valve cottars. Valve spring compressor: ‘90890-04019. ‘Attachment: ‘90890-01263 4 Remove: + Valve retainer © Spring saat © svaive® ‘gach pan positon very carefully 60 that it can be reinstalled in its orginal place.encine pisassematy | ENG | Gp ‘CONNECTING ROD “Remove: ‘= Connecting rod ‘ Boarings connecting rod} wore; ‘dentiy cach bearing position vary careful 80 that t can be reinstalled in its original place. on PUMP “URemove: ++ Oil stiner + Oil steiner cover @ + Chain cover J chain ® = Bolt® racket © Pump cover © Inner rotor Pump shaft Pin ‘Outer rotorINSPECTION AND REPAIR | ENG en) INSPECTION AND REPAIR: +'Carson deposit {from combustion chamber) Use rounded seraper. ore; Do not use a sharp instrument to avoid ‘dameging or scratching + Spark plug threads. {Valve seat inspect = Cylinder head a Messuce: 2 = Cylinder head warpage 7 Outof specification -> Resurtace. ‘ylinder head warpage: 7 {Less than 0.03 mm Worpage measurement and resurfacement stops: ‘eHold a straight edge @ and a thickness ‘gauge © to the eylinder head. ‘eiMeasure the warpage. ‘eit t3e warpage is out of specification, resurface the cylinder head. ‘ePlace a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head Using a figure-eight sending pattern. NOTE: Rotate the head several timer to avoid removing too much material from one siINSPECTION AND REPAIR | ENG | Gp) VALVE AND VALVE GUIDE 1LMessure + Storn-to-guide clearance CTs I we ‘Stem to-guide clearance ve guide inside diameter @ — Valve stem diameter (Out of specification + Replace valve ‘ide. ‘Limit 0.08 mm Exhaust 10.025 ~ 0.052 mm ‘Limit 0.10 mm 2.Replace: + Valve guide Replacement steps: ian oven to 100 to ease guide removal and installation and tom intorforenco fit. ‘@Remove the valve guide using the valve ‘guide remover ©. ‘install the valve guide (new) using the valve guide installer @ and valve guide remover ©. ‘@After installing the valve guide, bore the valve guide using the valve guide roamer @ to obtain proper stem-to-guide clear Valve guide remover (6.0 mm) 040s Valve guide roamer (6.0 mm: ‘90890-04068insPECTION AND REPAIR | ENG | %qp| wore —___ Reface the valve seat after replacing the valve guide. ‘2etiminate ‘= Carton deposit {from valve face) inspect: 1 Valve face Pitting Wear -> Grind the face. «+ Valve stem end Mushroom shape or diameter larger than rest of stem -» Replace. Measure oe + Margin thickness © Out of speciation -» Replace. / 6 Measure: + Runout (valve stom) Out of specification > Replace. ‘Runout limits ‘O01 mm NoTE: «Always replace the guide ithe valve replaced «Always replace the oll seal ifthe valve is removed.INSPECTION AND REPAIR ENG VALVE SEAT 1.Eliminat: «= Carben deposit {from valve face and valve seat) 2inspest: 1 Valve soat Pitting Wear -» Reface valve seat ‘3.Moasure: = Valve soat wiath © Out o specification -+ Reface valve seat Valve seat Intake: Exhaust: Measurement steps: ‘@Apply the Mechanic's blueing dye (Dyker) @ to the valve face. intallthe valve into the cylinder head. ‘ePress the valve through the valve guide ‘and nto the valve seat to make a clear patter. ‘@Masure the valve seat width, Where the valve seat and valve face made contact, blueing will have been removed. fei the valve seat is too wide, 00 narrow, ‘or the seat is not contered, the valve seat ‘must be refaced, “4Reface: + Valve seat Use 31, 45° and 60" valve seat cuter. A Valve seat cutter: ‘YE9TO43-C.INSPECTION AND REPAIR ENG ‘on ‘When twisting The cutter, Keep an even downward pressure (4 ~ 5 kg) to prevent ‘chatter marks ‘Gut sections as follows: Gestion ater x 7 e o . © oo | | fata sto: | Bivate sat conrad on valve face but it i Isto wie ! ae sat eters] — Deed osu TFist ns Use 31’ cutter | To reduce valve seat wy |seconar wt 1m Secor F [Valve seat is in the middie of the valve ; oe butte too narow | ate sat etter ext] Desed vent 1 |To achieve a uniform : >, Uso [45° cutter | valve seat width of \s ome cr ——]_vsive seats too narow and neat valve margin. [Vatve seat euttar eat Desired result iF Ist cutter |To conter the seat Use land to achieve its [Second [width of 1.0mm 45" cutterINSPECTION AND REPAIR | ENG | gp TB Valve seat is too narrow and its located near tho bottom edge ofthe valve face. i Voive seat cuter sot] — Desired rest I cuter | To center th | [a cuter [To canter the se » Use land increase te ‘second: | Sun seater Sia: + Valve foe {Valve seat Note After relacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping stops: ‘@Apply 8 coarse la the valve face. ‘compound @ to je sure no compound enters the gap betweenthe valve stem and guide. a ier ne mare Nove: ‘To obtain the best lapping rosul, Tightly fap the valve seat while rotating the valve back and forth between your hand. ‘®Apply 2 fine lapping compound to the valve fece and repeat the above stops.wsrecron vo eran [ENG |e NOTE: ——— Be sure To clean off all compound from the valve face and valve seat after every lap: ping operation. ‘eApply the Mechanic's blueing dye (Dyker) 6 tothe valve face. ‘install the valve into the cylinder head. ‘ePress tho valve through the valve guide ‘and onto the valve seat to mak a clear patter. (@Mezsuro tho valve soat width © again. If the valve seat width is out of specifica- tion, reface and lap the valve seat. ‘VALVE SPRING “Measure: + Free length (valve spring) @ Outof specification -» Replace. Free length (valve spring): Taner (intake exhaust "37.40 men Outer (intake/exhaust): ‘39.85 mm 2Measure: = Compressed force (valve spring) ® Gutof specification > Replace. ® bostales length Compressed force: Tner(intake/exhaust) 6.35 ~ 7.45 kg at 31.8 mm Outer (intake/exhaust) 124 = 141 kg at 3.8mm 26 a.Measure: = Spring tit @ Out of specification -> Replace. ‘Spring tt tm: Taner (intake /exhaust 8 mm Outer (intake/exhaust UmmINSPECTION AND REPAIR VALVE LIFTER, “inspect: = Valve ifters Seratcres/Damage -» Replace both lifters ‘and cylinder head. ‘CAMSHAFT ‘Unspect: + Cam lobes PittingScratches/Biue discoloration -> Replace. 2Measure: ‘Cam lobes length ® and Out of specification > Replace. ‘Gam lobes length limit: intake: '36.75 mm 27.978 mm Exhaust: @ 36.75 mm ®27975mm aMeasuc: ‘= Runout (camshaft) Out of specification -» Replace. unout camshattl: Less than 0.03 mm ‘4Moasure: = Comstattto-cap clearance Out of specification > Measure bearing ‘ameter (camshaft) ‘Camshaf-to-cap clearance: ‘0.020 = 0.054 mmINSPECTION AND REPAIR | ENG wo ‘Measurement steps: feinstall the camshaft onto the cylinder head. ‘ePosition a strip of Plastigaugt ‘the camshaft ‘Install the dowel pins and camshaft caps. Bolts (camshaft cap) ‘ON (1.0 m- kg) NOTE: « Tigiten the bolts camshaft cap) © onto ‘eRemove the camshaft caps and measure ‘the width ofthe Plastigauge® ©. ut of specification -> Replace the cam- shaft Within specification -» Replace cylinder hhaad and camshaft caps as a set. Bearing diameter (camshaft ‘24.967 = 24.980 mm ‘TIMING CHAIN, SPROCKET AND CHAIN StiffCracks + Roplaco chain and sprocket ase cet.nsrscnon mo reran [ENG] 2inspect = Cam sprockets Wear/Damage -> Replace cam sprocket and timing chain 0s sot @ vetoc B correc ORoller @ Sprociet 3inspect: ‘Timing chain guide (exhaust) «= Timing chain guide (intake) «= Timing chain guide (upper) ‘WearfDamage -» Replace. TIMING CHAIN TENSIONER 1.Cheeks + One-way cam operation ‘Unsmooth operation > Replace. inspect + Allpars Damage/Wear -+ Replace. CYLINDER AND PISTON ‘Lnspee + Cylinder and Piston walls Vertical scratches > Rebore or replace cylinder and piston. 2Measue: + Piston to-cylinder clearance ‘®Measure the cylinder bore °C" with eyl- Inder bore gauge Nove: “Measura the cylinder bore "G" In parallel and at right angles tothe crankshatt. Then, Find the average of the measurements.INSPECTION AND REPAIR | ENG en) Gylinderbore"C" | 6849-6854 mm |*R” =(Maximum D,D, or DD = (Minimums Dy D, oF DD (617 oxt of specification, rebore or replace the eylinder, and replace the piston and piston rings as set 2nd step: ‘eMeasure the piston skirt diameter “P* witha micrometer. @55 mm rom the piston botom ede. Piston size P ‘Standard | 68.45 ~ 68.50 mm Oversize2 8.0mm Oversize & 68.5 mm ‘81f 0x4 of specication, replace the piston ‘and piston rings as a set. ard stp: ‘eColcslate the piston-to-ylinder clearance with following formula Piston-to-eylinder clearance Griinder Dore “C" Phiton skirt diameter “P” Aq Piston-to-eylindor clearance: ‘0183 ~ 0.08 mm ‘ctimits:0.1!mm ‘e1f out of specification, rebore or replace tho oylinder, and replace the piston and piston rings assetINSPECTION AND REPAIR | ENG te PISTONRING Measure = Side clearance ‘Out of specifieation -+ Replace piston and Fings as a sot deposits from the pis ton ring grooves and rings before measur ing the sie cloaranco. ‘Side clearance: ‘Top ring: ‘0.028 = 0.080 mm 2nd ring: ‘0.02 ~ 0.06 mm 2Posiion: «= Pistonsing (into cylinder) Nore: Push tha ring withthe piston crown 60 0 ‘the ring willbe ata right angle to the eylin- ‘3 Measure: + End gup Out of specification -> Replace. Note: You cannot measure the end gap on the expander spacer of the oll control ring. If the oil control ring rails show excessive 9p, replace all three rings. End gap: “Top ring: (0770025 mm 2nd ting 0.30 = 0.45 mm Ollring: 0.20 0.70 mmINSPECTION AND REPAIR a PISTON PIN “Unspec: «Piston pin Blue discoloration/Grooves > Replace, then inspect lubrication systern. 2Measure += Piston pin-to-pston clearance Measurement steps: ‘eMeasure the piston pin outside diameter ®. If out of specifestion, replace the piston pin ‘Outsk 158 ‘diameter (piston pink: 30 ~ 16.000 mm ‘eMeasure the piston inside diamotor B. ‘eCalculate the piston pin-o-piston clear ‘ance with following formula: Piston pin-to-piston clearance = Bare size (piston pin) @— Outside diameter (piston pin) © ‘e1f tof specification, replace the piston. Piston pin-to-piston clearance 0.002" 0.023 mm ‘Limits: 0.07 mr ‘CRANKSHAFT AND CONNECTING ROD Measure: ‘+ Runcut(erenksheft) ‘Out of specification -» Replace. Runout Lees than 0.03 mmINSPECTION AND REPAIR | ENG wo Binspest: + Main journal surfaces + Crankpin surfacos ‘= Boaring surfaces ‘WaarSeratehes -» Replace. 3Measure: ‘= Oil clearance (main journal) Out of specification > Replace ‘Oil clearance: 0.820 ~ 0.052 mm ance may not be obtained causing engine damage. ‘@Clean the bearings, main journals and bearing portions of the crankcase. ‘Place the crankcase (upper) on a bench in ‘an upside down position. felnstal the uppor half of the bearings © ‘and the erankshaft into the crankcase (upper. Nore; tthe projection @ of the bearing with the notsh @ in the crankcase. ut @ piece of Plastigauge® @ on each ‘main journal. Nove: Do not put the Plastigauge™ over the oll !hole inthe main journal of the crankshaft, ‘Sinstal the lower half ofthe bearings into the crankcase (lower) and assemble the crankzase halves.INSPECTION AND REPAIR co) ‘+ Align the projection of the bearing with the notch inthe erankease, '+Do not move the crankshaft until the oil ance ‘completed. ‘eTighton the bolt to specification in the tightaning sequence cast on the crank: BJ Uppercase 24.Nen (2.4 m + kg) ‘Me: 421Nm (1.2 m kg) Blower case Nore — + Lubricate the threads of bolts (Ma) with engine oil «= Lubricato the threads of bolts (M6) with engine ol ‘@emave the crankcase (lower) and lower half ofthe bearing,INSPECTION AND REPAIR | ENG wo ‘eMoasure the compressed Plastigauge” width © on each main journal If oil clearance is out of specification, selecta replacement bearing. A.Measure: ‘Oil clesrance (crank pin) Out of specification > Replace bearing. ‘Oil clearance: 0.026 ~ 0.055 mm ‘Measurement steps: “CAUTION! Do not interchange the bearings and con ‘necting rod. They must be installed in thelr ‘original positions, or the correct oil clear- ‘ance may not be obtained causing engine 1 bearings, orank pins end be ing portions of the connecting rods. ‘instal the upper half of the bearing into ‘the connecting rod and lower half of the baring into the connecting rod cap. Nore: —__ Align the projection @ of the bearing with the notch © of tho cap and connecting rod ‘ePut @ piece of Plastigauge® @ on the crank pin. ‘eAssomble the connecting rod halves. NoTE: + Do noi move the connecting rod or eran shaft until the oll clearance measurement thas been comploted ‘Apply molybdenum disulfide grease to the bats, threads and nut seats. ‘Mako sure the “Y" marks © on the con: necting rods face the lft side ofthe erank- shat. «+ Mako sure thet the letters @ on both com: ‘ponents align to form a perfect characte.INSPECTION AND REPAIR | ENG | yp] ‘eTighien the nuts. Nat ‘37 New (3.7 m+ kg) SCRUTIONS + Be sure to usa an Fype torqu when tightening the nuts. 1 When you reach 3.0 m kg, keep tighten- ing until the final torque is obtained. ‘Apply continuous torque until the speci- fled torque is obtained. Refer to “ENGINE ASSEMBLY AND ADJUSTMENT” — "CONNECTING ROD" feRomove the connecting rods and bear- ings. feMeasure the compressed Pi width © on each crank pin W cil clearance is out of specification, select a replacement bearing 5Sebet «Main journal bearing (J ~ J) 1 Crank pin bearing (P,~ P) ge Selection of bearings: Example 1: Main journal bearing ‘011 “J.” on the crankcase is “6” and "2" on mnkweb, then the bearing size for 6224 (Green) BEARING COLOR CODE 7 Blue 2 Black | 3 Brown 4 Green 5 Yellow |INSPECTION AND REPAIR | ENG | yp ‘Example 2: Crank pin bearing ‘elf “P\" on the connecting rod is "4" and "1" on the erankweb, then the bearing size for “Pi: Bearing size of P: ‘Connecting rod P, ~ Crankeweb P, = 42153 (Brown) ‘BEARING COLOR CODE 7 Blue 2 Black a Brown | 4 ‘Green on puNP “Unspect: ‘Drive gear (oil pump ©) {= Driven gear (oil pump @) ‘+ Pump housing © ‘Pump housing cover @ ‘WoarfCracks/Damage -> Replace. = Tip clearar (between the inner rotor @ and the outer rotor @) + Side cloarance ® (between the outer rotor @ and the pump housing @) Out oF specification > Replace the cil ump assembly. AY Tip clearance:INSPECTION AND REPAIR ENG ‘3.Chock: ‘= Oil pump operation Unsmooth > Repeat steps 1 and 2 or repkce defective parts. PRIMARY DRIVE “Lnspect + Geer teeth (primary drive) 1 Geer teeth (primary driven) ‘Wear/Damage -» Replace both gears. Excessive noises duting operation -> Forlace both gears STARTER DRIVES Lnspect: «= Gear tooth (starter idle O) 2 Gear teeth (starr drive ©) 1 Gear teeth (starter whoo! @) ‘BurrsiChips/Roughness/Wear > Replace. 2.Cheeks «Starter clutch operation ‘Clutch operation checking steps: feinezall the starter wheel gear @ to the starter clutch @, and hold the starter clutch, ‘eWren turing the startor wheel gear clockwise Uf, the starter clutch and the ‘wheel gear should be engaged. If rot. the starter clutch is faulty. Replace feWnen turning the starter wheol gear counterclockwise [El the starter wheel ‘gear should turn freely. not, the starter clutch is faulty. Replace itINSPECTION AND REPAIR ENG ‘on! cLuTCH “Lnspect + Friction plate DamagelWesr > Replace friction plates asad, 2Measire: * Friction plate thickness (Out of specification —» Replace friction plates as a set Measure at four points S.inspect = Clutch plate Damage ~> Replace clutch plates as a set Measure: ‘= Clutch plate warpage Out of specification > Replace clutch plate zs a sot Use e surface plate and feclor gauge ©. Seaan | S.inspoct: + Clutch spring Damage -» Replace springs as 0 satINSPECTION AND REPAIR | ENG | Gyp| ‘EMessure: + Free length (clutch spring) © ‘Outof specification -» Replace spring as a Free length (clutch spring): ‘Samm ‘Limit! 50.0 mm inspect + Dogs {on the clutch housing) Piting’Wear/Damage > Deburr or replace + Clutch housing bearing ‘Wear/Damage -» Replace clutch housing. Nore: —____ Piting on the clutch housing dogs will cause erratic operation, Binspect + Clutch boss splines Pitting?Wear/Damage > Replace clutch bose. Nore: —__ iting on the clutch boss splines will suse erratic operation. S.inspect 1 Prossure plate @ Crasks/Damage > Replace. ‘= Bearing © Wear/Damage -» Replace. tonspect: + Gear teeth (pull lever pinion gear) + Gear teeth (pull rod) ‘WoarfDamage -> Replace aso set.INSPECTION AND REPAIR | ENG [Sn ‘inspect: + Bearing (pull rod) © WeartDamage -> Replace, ‘TRANSMISSION AND SHIFTER, inspect: « Shift fork cam follower @ «= Shift fark paw! @ Scoring/Bends)Wear/Damage + Replace. inspect += Guide bar Roll the guide baron a flat surface. Bends» Replace. 3.check «Shift fork movement (on its guide bar) Unsmooth operation > Replace the fork and guide bar. Atnspoct: «= Shift cam grooves Wear?Damage/Scratches -> Replace. + Shift cam sogment © Damage/Wear -» Replace, + Shift cam bearing © PitingDamage — Roplace,INSPECTION AND REPAIR ENG ‘S.Measure: + Axle runout (main and drive) Usea centering device and dial gauge ©. Outof specification > Replace. Runout limit ‘0.08 mm Binspoct: + Goar tooth Blue discoloration/itting Wear > Replace. + Mated dogs Rounded edges/Cracks/Missing portions = Foplace, 7.Checks ‘= Prover gear engagement (each gear) (10 ts counter part) Incorrect -» Reassemble. ++ Geer movernent Foughness > Replace. Transmission gear reassembling point: Press the bearing @ in the main axle @ as shown. ‘When you have Finished pressing the bear ing ©, make sure that the Sth pinion rotates smoothly. Bunspect: = Girelps Damage/Loosenese/Bends > Replace.INSPECTION AND REPAIR | ENG ‘SHIFT SHAFT AND STOPPER LEVER ‘Lnspece: = Shift erat @ = Shift ever @ «Return spring (shift arm) @ BondsWear/Damage > Replace. 2inspect: = Stopper lever @ Roller turns roughly ~» Replace. ‘BendsDamage -» Replace. S.nspect: ' Return spring (shift shaft) © + Return spring (stopper lever) @ WearDamage -> Replace. OWLETNOZZLE 1.check: + Oitjet nozzles O toring = Check oall @ Damage/Wear ~+ Replace ol jet nozzle ‘assembly. + Oil jet passage ‘Clogged ~» Blow outwith compressed aie. RELIEF VALVE, OIL PIPE AND STRAINER Check: + Rolie valve body © Valve ® = Spring 1 Spring seat Loring Damage/Wear + Replace. 2.Cheoke + Oil dolivery pipe Damage -+ Replace. Contamination -> Wash and blow out the passage.INSPECTION AND REPAIR | ENG | yp] Binspect + Oil srainer Damage — Replace. OWL cooLeR “UGheck + Oit cooler © nlethose (oll cooler! 2 Outist hose (oi cooler) CCracks/Wear/Damage -» Replace. CRANKCASE {Thoroughly wash the ease halves in mild solvant 2.Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. inspect: = Crarkease ‘Cracks/Damage ~> Replace. + Oil delivery passages Clogged -» Blow out with compressed alr. BEARING AND OIL SEAL ‘Lnspect: «= Boatings Clean and lubricate, then rotate inn with finger. Roughnass ~» Replace, 2inspect + Oil seals Damage/Wear -> Replace. CIRCUP AND WASHER inspect: + Cicips + Washers Damage/Looseness/Bends ~+ Replace.MIDDLE GEAR SERVICE [ ENG | Gp) MIDDLE GEAR SERVICE Spring mice driven shat {@ Bearing housing assonbly @shin Boring Dortseat Middle rive shor Universe joie ‘SHINS: 0.15 mm SHINS JoA0mm 0.20:mm [020mm 050mm a SON BO MTG! TON (TO Mig)MIDDLE GEAR service | ENG a] REMOVAL ‘Remove: + Middle driven shaft assembly + Midcle drive shaft assembly Refer to “ENGINE DISASSEMBLY". DISASSEMBLY O. [Middle driven shaft assembly ‘URemave: a = Universal joint Removal stops: ‘@Remave the ciccips ©. ‘9Place the U joint in a press. whan ‘eWitha suitable diameter pipe beneath tho yoke, prass the bearing into the pipe as shown, Nore; It may be necessary to lightly tap the yore with @ punch, ‘@Repeat the stops for the opposite bearing ‘@Remave the yoke. ore: Itmay be necessary to lightly tap the vos with a punch, attach: = Universal joint holder © (Onto the universal joint yoke. [p> wacala = ‘90690-04062 3.Loo8en: «+ Nut (middle driven shaft) ©miopte ear service | ENG| Yop “4Romove: «Nut (middle driven shat) Washer @ Tole 3) 2 Oil seal @ = Boarirg housing assembly @ += Driven pinion gear ® ‘ Midale driven shat = O-ring ® ‘Always replace the collapable collar when ‘ever the middle gear is disassembly. (Middle rive shaft assembly Remove: Spring retainers © Damper cam @ NOTE: —__ ‘Attach tre dampor spring compressor ® on the sprng seat and compress the spring, then 1 spring retainer. “A mper spring compressor: "7N 90880-04080 2.Straighten: «+ Lock washer 3.Remave: «= Nut (mile drive shat) © Lock washer @ * Drivepinion gear @ + Bearing @moe cean service [ENG | yp Removal steps: ‘Attach the folded rag ©. feSecure the middle drive shaft end in the ‘@Fomove the nut (middle dive shaft), lock wather, drive pinion gear and bearing INSPECTION [Midele driven shaft assembly nsoect: ‘= Middle goar tooth PitingiGalling Wear -» Replace middle ‘98°98 8 set. 2ulnspect: ‘= Beering Piting/Damage ~> Replace bearing hous ing assembly Bulnspect + O-rng Sollser Damage -> Replace. 4.Check 5 ~» Replace Ujoint. [Midale drive shaft assembly “Unspect: «= Damper cam surface Wear/Scratches > Replace damper cam asaset 2insoect ‘= Damper spring Damage/Cracks -> Replace. REASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. ‘Midale driven shat assembly Tighten: «= Nut (middle driven shaft) ‘tach the universal joint holder onto the universal joint yoke, Universal joint holder: 90890-04062 ‘Nut (middle driven shaft ‘90 Non (8.0.m= ko)mippLe Gear service | ENG | Gp 2Position: Yoke Into the Ujoint Sunstalt: = Boarings ‘onto the yoke. ‘Check each bearing. The needles can easily fall out oftheir races. Slide the yoke back ‘and forth on the bearings; the yoke will not {90 all the way onto # beering if@ needle Is out of pace. ‘4Press each bearing into Ujoint using @ ‘suitable socket Sinstalt + Circlips @ into g:00ve of each bearing. (Middle drive shaft assembly 1Tighte: «= Nut (mie drive shar ‘Nut (middle drive shaft): ‘T10.Nm (11 m= kg)moe Gear service | ENG | yp instal ‘= Damper cam © + Spring ® += Spring seat 1 Spring rotainors @ NoTE: —————— Attach the damper spring compressor on the spring seat and compress the spring, then remove the spring retainer. INSTALLATION ‘nsall: «Middle drive shaft assembly {Middle driven shaft assembly Refer to “ENGINE ASSEMBLY AND ADJUSTMENT” wore: Before tighten the bolts 1.Adjust the gear lash ofthe middle gear. olor to “GEAR LASH ADJUSTMENT". 2.Check the middle driven gear operator Bolts, (midate driven gear assembly): ‘25 Nm (2.5m kg) GEAR LASH MEASUREMENT “.Measu = Gear Out of specification > Adjust. Gear lash: 01-02 mm.mioote Gear service | ENG| Sp] ‘Measurement steps: instal the middle gear backlash tool ©. ‘Middle gear backlash took. P/N 90890-04060 ‘@Align the dial gauge with the yoke. ‘@Masire the gear lash while rotating the vyoke gently back and forth. Nore; —____ ‘Measina the gear lash at each 80° rotation to obtan four measurements GEAR LASH ADJUSTMENT ‘Loosen: + Bolts driven gear bearing housing! 2Remeve: Shims 8.Tighter: {= Bolis (driven gear bearing housing) Nove: —__ Cleararce between the crankcase and driven gear bearing housing should be ‘about 2 mm. Measure gep with fecler gauge O. Do not overtighten bearing housing bolts ‘or you may obtain too litte gear lash and ‘cause damage to gears. If over tightened, loosen the 4 bolts so that orankcase/bear- Ing housing clearance is about 2 mm and peat al provious steps.MIDDLE GEAR SERVICE | ENG on] “eRott: + Ujoint Rotate it back and forth, while carefully tightaning the bolts in a crisscross pattern until the dial gauge reads 0.1 0.2mm, 5 Mossure: «+ Crankcaseybearing housing clearance Use a feeler gauge. Select: + Shims) © Selection stops: ‘elf the clearance between crankcase and ‘beating housing is 0.42 mm, (9The chart instructs you to round off 2 to 0 at the hundredth place. Thus, the shim Sa a ‘Shim sizes are supplied in the following thickness. ‘Thickness (mm)ae T.Loosen: += Bolts driven gear bearing housing) Binstal # Shims 9.Tighten: + Bolts driven gear bearing housing) Bolt (driven gear bearing housingh: 25Nm 5m kg) 10Measure: += Gear lash ‘Middle gear lash: (01-02 mm Ifthe gear lash is incorrect — Repeat. [MIDDLE DRIVE GEAR AND DRIVEN GEAR POSITIONING Note: —— Gear positioning Is necessary when any of the following parts are replaced. + Crankcase assembly + Middle dive shaft ‘+ Midale gear bearing housing Select: += Middle drive gear shim © Nove: Select ‘Re middle driven gear shim ® by calculating out the middle drive gear shim © and then actually measuring the gear lash, ‘Middle dive gear shim selection steps: ‘@Fosition middle drive gear by using shime © with their respective thickness cal: lated from information marked on erank- case, and drive gear end. © Shimibickness “A” (middle eve gear)race cea senvce [ES] So ‘eo find shim thickness “A” use following formula, ‘Middle drive, jar shim thickness: | “a"sO-0-@ Where: ‘numeral (usually @ decimal number) ‘on the drive pinion gear is elther added tw or subtracted from "43.00", @-bearing thickness (considered con- ‘sant ‘numeral (usually 8 decimal number) tn the crankcase (upper) half near the main bearing selection numbers ond ‘added to the nominal size “60”. Example 1) If he drive pinion gear is marked 9". D is 42.90 2) Bis 16.94 3) Ifthe crankcase (upper) is marked a3"... © 18 60.48 "A" =60.48— 42.90 - 16.94 = 0.64 44) Round off hundredths digit and select appropriate shies). In the example above, the calculated umber is 0.88. The chart instructs you to round off 4 to 6 at the hundredth place. Thus, the shim thickness is 0.65 mm. Hundredths | Rounded value O42 ° 3,4,5.6,7 5evan asset a ase ENGINE ASSEMBLY AND. ADJUSTMENT For engine reassembly, replace the follow: Ing parts with new ones: + Oring 2 Gasket Olt seat {= Copper washer 2 Locke washer ‘Lubricate: sinner rotor + Outer rotor = Pumpshatt Recommended lubricant: ‘SAE 20Wa0 motor olf 2instalk ump housing © + Reliefvaive Spring ® Pin ® Outerrotor @ Pump shaft © ‘nner rotor © + Pumpeover +Pin@ 1 Sprocket @ + Bolt @ S chain + Chaincover @ +l stsiner cover @ Fil strainer @ ‘Serew (pump housing): ‘12Nm (1.2m kg) Nore: When installing the inner rotor, align the pin @ in the pump shaft with the groove @ fn the inner rotor ©. 3.chook += Oil pup operation Foferto “INSPECTION AND REPAIR”ENGINE ASSEMBLY AND ADJUSTMENT | ENG [%o ‘CONNECTING ROD AND CRANKSHAFT 6 ‘CRANKSHAFT RUNOUT LIT: 803mm om 'p | CRANK Pin OW CLEARANCE: [SINT mT] 0.026 0.055 mm = a WAIN JOURNAL OiL CLEARANCE: 0.020 “0.082 mmENGINE ASSEMBLY AND apJUsTMENT | ENG | Gop ‘CONNECTING ROD Apply: + Molybdenum disulfide grease {onto threads of bolts and nut sats) + Engine oil {onto erank pins, erank pin bearings and inner surfaces of connecting rods) 2instalt ‘= Bearings crank pin) © {Connecting rods @ ‘Connecting rod caps @ (onto erank pins) NOTE: Align ihe projection of bearing with ‘ro0ve ofthe caps and connecting ro. ‘+ Make sure 10 reinstall each connecting rod bearing in its original place ‘+ The stamped "Y" mark @ on the connect- ing rods should face towards the left of ‘the crankshaft ‘= Bo sure that the letter © on both compo- nen align to form a perfect character 3.Align: = Bolthead © {with connecting rod cap) Tighten: += Nuts (connecting rods) ‘Nut (connecting rod): 37 Nn (3.7 m= kg) CAUTION: ‘+ Be sure to uso an Faype torque wrench ‘when tightening the nuts. ‘+ When you reach 3.0 m kg, keop tighton- Ing until the final torque is obtained. ‘Apply continuous torque until the speci fied torque Is obtained. 186ENGINE ASSEMBLY AND ADJUSTMENT | ENG = VALVE 2.Apply: «+ Molybdenum disulfide ol (onto valve stem @ and ol seal ®) ‘unstall: Valve O "Spring seat ® + Oil seal @ + Valve spring © Valve retainer @ (inte cylinder head) Nore: Instal the valve spring with the largor pitch @ facing upwards, ‘smote pitch instal + Valve cotters © nore: ie Instal the valve cottere while compressing ‘the valve spring withthe valve spring com. rossor. Valve spring compressor © ‘90890-04019 ‘Attachment O: 5.Secure the valve cotters ® onto the valve ‘tem by tapping lightly with a piece of Do not itso much as to damage thevalve:ENGINE ASSEMBLY AND ADJUSTMENT | ENG instal ‘CRANKSHAFT AND STARTER CLUTCH “Lnstal «Timing chain guide (intake side) © 1 Chain guide (H¥-VO chain) Bolt (timing chain guidel: 20.Nen [2.0.m = kg) Bole (HY-VO chain gui ‘TONm (1.0m kg) instal ‘Main journal bearings. (onto upper crankcase) Nove: —___ ‘+ Align ihe projection of the bearing with the noich in the case. + Be sure 10 install each bearing (crank- shaft) nits original place. ‘Apply engine oil to the bearing (main journal) surfoces.ENGINE ASSEMBLY AND ADJUSTMENT | ENG | “yp [BRIVE AXLE RUNOUT Limi: [0.08 mm fwaiN AXLE RUNOUT LIT 0.08 meENGINE ASSEMBLY AND ADJUSTMENT [ ENG |p) “sinetal s HY.VO chain © ‘= Timing chain @ Plus 2 Oil seal @ {Crankshaft assembly © instal 1 Starter clutch + Startercluteh shaft © 1 Bearing © + Oil nozle @ + Bearing holder @ Note: Align the projection of the oll nozzle with notch inthe crankcase. Bolt (bearing holder: 10 Nm (1.0 m= kg) + Idle gear © 1 Shaft tile gear ® flock washer @ PUN Alwaysuse @ now Took washer = Bon@ Bort ‘TON (1.0m -kg) ‘6.end the lock washer tab @ along a flat Bolt (bearing housing: ‘12.Nm (12 m= kg) install ‘= Main axlo assembly © Mid ‘drive shaft assembly holder @ ring ©ENGINE ASSEMBLY AND ADJusTMENT | ENG | Gp ‘SHIFT FORK AND SHIFT CAM, instal + Shiftcam assembly © {Boating holder @ Bolt bearing holder): 40 Nm (1.0 m+ kg) install: 1 Guide bars (shift fork) © { shitfork "R" @ S shittfork “c* @ ZT shift fork *L" @ Nore Install the shift Torts with the embossed ‘mark 0 the right and in sequence (R, C, L) beginning from the right ‘CRANKCASE ASSEMBLY 1Appy: + Engine ol {onto main journal bearings) «Sealant {onto crankcase mating surfaces) ‘Yamaha bond No, 1275: ‘90890-88505 Nore, DO NOT ALLOW any sealant to come im contact with the oil gallery or crankshaft fant to within 2 = install: += Main journal bearings (onto lower crankease) Nore, + Align tho projection @ of the bearing with the notch @ in the crankcase. + Install each bearing in its original place.ENGINE ASSEMBLY AND AnJusTmeNT [ENG] up] ‘CRANKCASE ‘© Crankesse upper @ Crankenss lower Bi crankcese sequence tigrtoning SC MBbok [aN aa Fa ‘A Mébor [Nm (12mko)ENGINE ASSEMBLY AND ADJUSTMENT | ENG | gp Se itt Sami lar oy “4Set shift cam and transmission gears in “NEUTRAL position. Sinstal + Lower crankcase (onto upper crankcase ®) Place the lower crankcase assembly onto the upper crankcase assembly. Nore, —__ ‘+ Carefully guide the shift forks so that they ‘mesh smoothly with the transmission gears. ‘+ Mesh the shift fork "C” withthe 2nd pin- jon gear @ on the main axle. ‘SCRUTION! Before tightening the crankcase bolts, chock the following points: ‘»Be sure the gears shift correctly when the shift cam is turned by han« Tighten: «+ Lower crankcase bolt {follow the proper tightening sequence) +» Upper crankcase bolt AMG bolt 2Nm (12 m-kg) Xs bolt 24 Nm (2.4 m + ko) 13 Upper erankcese Lower crankcase ore, —__ Tighten” the bots inthe tightening sequence cast on the crankcase,ENGINE ASSEMBLY AND ADJUSTMENT [ ENG |p “ie J Crnteee cover hd © ‘Screw (orankease cover): ‘SN (0.8 m*ko) MIDDLE GEAR SHAFT ‘Unstal + Shim + Middle drive shaft assembly © + Bearing holders @ ice ‘After tightening the bearing holder with the screws, make sure that you stake = shim idle driven shaft assombly © Bolt (driven shaft assembly): 25Nm (2.5 m+ kg) 4 Tighten: + Bolts lerankcase) © Bolt (erankease): 24 Nin (2.4m + kg) SHIFT SHAFT “Unstalt + Stopper lever D 2 Spring ® 1 Shift ver @ Nore: —__ Hook ine spring ends on the stopper lever an¢ crankcase boss. 1 Mash the stopper lever @ with the shift 4-64 _cam stopper.ENGINE ASSEMBLY AND ADJUSTMENT [ene] un] + Shif shaft lever cover ‘Screw (cover % ‘SNm (0.8 m= kg) Bolt (shift shaft lever cover): ‘12Nm (1.2m kg) (OIL PAN AND OIL PUMP. “Unstl + Oil pump assembly © {= Neutral switch @ 2.Comect: + Noutal switch lead @ hl Bolt (oll pump): 12 Nm (1.2m + kg) install: + Dowol pins + Gasket + il pan ® + Oil evel switch © ‘and gam «= Tighten the bolts (oll pan) in crisscross pattern. “+ ApEly engine oil to tho O-ring of the oil level site = Dren bolt Bolt (oll pani: 12 Nm(1.2m+kg) Bolt (ol level switch: ‘10Nm (1.0m + kg) Drain bolt: ‘43.Nm (6.3.m = kg)ENGINE ASSEMBLY AND ADJUSTMENT | ENG | yp) ‘cuuteH © Pressure plate @Spocor @Pulrod @ Bearing @Clteh pate @collar @Fricson pte @ cuten boss O Thrust pte @ clutch housing [SPRING FAEE LENGTH LIM: 50.0 mm [CLUTCH PLATE WARP Lim: 0.08 mm FRICTION PLATE WEAR LIT 28mm —OENGINE ASSEMBLY AND ADJUSTMENT | ENG | yp) ‘CLUTCH AND PICKUP COIL Vnstal «Washer ‘= Coller @ Oil ump drive sprocket @ J cluteh housing © + Boating © 2 Spacer ® = Thrust pate @ + Clutch boss © Lock washer @ + Nut clutch boss) wore —__ Install the spacer @ with the two screw hholas towards the clutch boss. ‘Always use a new Took washer 2. Tighten: ‘Nut clutch boss) © "Nat (clutch boss): "70.Nmn (7.0. = kg) Nove: —___ ten The nut (elutch boss) @ while ROW ing the clutch boss with the universal clutch holder. Universal clutch holder ‘90890-04086 2.Bend the lock washer tab along a flat: of the nut ‘Anstalt: + Fricion plates + Clutch plates Nore; —__ ‘Mount fiotion and clutch plate altematelyENGINE ASSEMBLY AND ADJUSTMENT ENG install = Washer® Nove: Apply ralvodenum disulfide grease onts bearing/gear teeth of pull rod. Binstal: + Prossu'e plate Nove: Align the punched mark @ on the clutch boss witr the punched mark) on the pres: “instal * Cluten springs © + Bolts (clutch spring) © Bolt (clutch spring! ‘BN (0.8 m= kg) Nove: —____ Tighten The bolls (clutch spring) in stage, sing a crisscross patter, Binetalk Pickup coil © sPin® FTiming plate © + Bolt timing plate) @ Bolt (timing plate): ‘45 Nn (45m » kg) instal: + Gasket + Dowol ins ryENGINE ASSEMBLY AND ADJUSTMENT | ENG PISTON AND CYLINDER Top ring @ caster Ott rng (ower @cretp Ot ving (upper) ®Piston pin @ Second ring DPicton {@ Dowel pin Boring Devling PISTON SIZE 68.48 ~ 68.60 mm PISTON-TO-CYLINDER CLEARANCE: 0.03 0.08 mm LINAS 0.1 mm PISTON RING END GAP: Top: 0.10 0.25 mm 2nd: 0.30 0.45 mm (i:020~ 0.70 ram PISTON RING SIDE CLEARANCE: Top: 0,025 - 0.90 mm 2nd: 0.02 0.08 mm ‘CYLINDER BORE SIZE 62.49 ~ 664 mmENGINE ASSEMBLY AND ADJUstwENT | ENG | Gp] Tolls + Clutch cover @ Bole (clutch cover: | 42 Nm (1.2 m+ ka) Nore: Tighton The bolts (clutch cover Ta stage, using a crisscross pattern. Tunstall: Plate washer ‘Return spring + Pulllever Washer 2 Cirelip Nor Align pull lever shaft with the slit © on the pull lever. PISTON AND CYLINDER “Lnstalt + Oitjetnozzies © (with O-ring) ‘NOTE: Apply exgine oll to the O-ring instal += Piston rings. Nove: {Be sure'o instal rings so that ihe manutac™ turer's marks or numbers are located on the ‘upper sde of the rings. Oil the pistons and sings literally.ENGINE ASSEMBLY AND ADJUSTMENT | ENG | Goqgp| ‘install «Piston pins © ton points to the exhaust side of the engine. + Before installing the piston pin clip, cover the erankcase with a clean rag to prevent the piston pin clip from falling into the crankcase, ‘+ Reinstall each piston into the cylinder it ‘came from {numbering order 1 to 4 from the left. OES ‘Always use new piston pin lp Tinsw ‘Gasket (yl + Dowel pine @ PUTO ‘Always use a new gasket leyinder 1 coating of engine ol Postion: + Topring {andring + il ing Offset the piston ring end gaps as shown, @ Top ring ena ‘®ottring end owen ©oilving end upper) @2ncring endENGINE ASSEMBLY AND ADJUSTMENT | ENG | “yp “instal = Cylindor ‘NoTE: + Instalthe #2 and #3 platone frat. ‘Pass the timing chain and timing chain ‘uide (intake side) through the timing hain cavity, Installation steps: ‘Sot the piston ring compressor @ to the #2 end #3 pistons. ‘install the #2 and #3 pistons to the eylin- jemove the piston ring compressors. ‘@Set the piston ring compressors @ and iston bases @ to the #1 and #4 pistons. ‘einstal the #1 and #4 pistons to the cylin der. ‘@femave the piston ring compressors and piston bases. Piston ring compressor: A] ‘90880-04008 Piston base: 90880-01067 Binstalt + Washer = Nut elinden) © ‘Nat (eylinder: \, '20.Nim (2.0 m+ kg) (CYLINDER HEAD AND CAMSHAFT “install += Gasker(cylindor head) © + Dowel pins @ = Orings @ PENN ‘Always use a new gasketENGINE ASSEMBLY AND ADJUSTMENT [ENG] ap ‘CYLINDER HEAD AND CYLINDER HEAD COVER. @ sparkplug OGestet A (NGK) X24EPR-U9 (NIPPON DENSO) TONM(IOm ka) > | SPARK PLUG GaP: 08-09 mm (CYLINDER HEAD WARPAGE LIT: | a ee ry NedENGINE ASSEMBLY AND ADJUSTMENT | ENG +n! CAMSHAFT, VALVE AND TIMING CHAIN Valve pad @ Cam sprocket @ Valve lite (Chain tensioner Valve coer ot Valve retainer {@ Chain guide cinta) @ Valve spring (nner) @ Chain guide cexhausy @ave spring (outen ‘CAMSHAFT RUNOUT LiF: 0.03 ra ‘CAMSHAFT-TO.CAP CLEARANCE (0.020 = 0.056 mr [VALVE CLEARANCE (COLD) Intake: 0.11 0.18 mm Exhaust 0.18 = 0.20 mnENGINE ASSEMBLY AND ADJUSTMENT | ENG install = Cylinder head washers Copper washers + Nuts ‘Nut (evlinder head: ‘32.Nn (32 m= kg) NOTE: + Aaply the engine oll onto the nut threads. 1 Tighten the nuts in a crisscross pattern. instal: = Washers: Nuts ‘Wat {cylinder head — front/rear side) ‘TON (1.0m + kg) instal «Exhaust camshaft © ‘Intake camshaft {with cam sprocket temporarily tighten) Nore; Install the camshaft with the punch mark {acing upwerd. 5insel: ‘Dowel pins {+ Camshaft caps (intake camshaft) ‘Camshaft caps (exhaust camshaft) Nore: —_____ Male “eure that each camshaft cap intaled init original place by reference to its embossed identification mark, a follows: Intake: | Exhaust E + Install the camshaft eap with the arrow ‘mark @ embossed facing right side of the engine instal: + Botts (camshaft caps) ‘Bolt (camshaft cap): ‘TON (1.0m + Kg)ENGINE ASSEMBLY AND ADyusTMenT | ENG | ogy Nore: ‘Tighten the bolts (camshaft cap) Ta r0ss pattern from the inside outwards. ‘The bots (camshaft caps) must be tight ened evenly or damage to the cylinder hhead, camshaft caps and camshaft will result, Tine = Cam sprockets © Installing stops: ‘eTurn the crankshaft counterclockwise Uunti the TOC mark @ is aligned with the ign mark ®. ‘#Fitthetiming chain onto both eam sprock- ‘ts and install the cam sprockets on the ccamahats, Nore: ———— When ihstaling the cam eproakets, start with the exhaust camshaft to keep the Jing chain as tense as possible on the ‘exhaust side, and set the hole of "EX" mark side ® on the cam sprocket to the cam- shat SINT: Intake side "EX": Exhaust si ‘SeauTiONS: — Do not turn the erankshaft during the am shafts installation, Damage or improper valve timing will result. ‘eTurn both camshafts opposite to each ‘other until the punch mark © on the cam: shaft & aligned with the hole @ on the ‘camshaft cap. Make sure that the “E" on the exhaust camshaft ® and the “I" on the intke camshaft © are visible from the top. ‘@While holding the camshafts, temporarily tighten the bots. instal: + Chain guide (exhaust) ©ENGINE ASSEMBLY AND ADJUSTMENT | ENG] %p| TIMING CHAIN TENSIONER “Unstal «+ Timing chain tensioner Installation steps: ‘@Remave the tensioner cap bolt ©, washer and springs ©. ‘@Release the timing chain tensioner one- ‘way car @ and push the tensioner rod @ the way in, ‘instal the tensioner with a new gasket © ‘onte the eylinder. ‘Bolt (timing chain tensioner ‘10Nm (1.0m = ka) ‘install the springs @, washer @ and cap bolt. ‘Gap bok (timing chain tensioner) '20.Nem 2.0.m = kg) Turn: = Crankshaft Gountercloc a.Chesks + TOC mark ® Aligy with the align mark ©. + Car'shaft timing punch mark @ ‘Alig with the camshaft cap hole @. ‘ut of alignment -> Adjust. Refer to "VALVE CLEARANCE ADJUST: MENT” in CHAPTER 3. ‘Alnetall: + Timag plate cover several tums ‘Screw (timing plate cover: ‘8m (0.8 m= ka) 5:Tigten: += Bolticam sprockot) Bolt (cam sprocket ‘24 Nem (2-4 m= kg)ENGINE ASSEMBLY AND ADJUSTMENT [ ENG | 49 ‘CYLINDER HEAD COVER: ‘Lnstal + Gastot cylinder head cover) = Cylindor head cover © i Bolt (cylinder head cover): ENGINE REMOUNTING When remounting the engine, reverse the ‘removal procedure. ‘Note the following points: “Ulnstall: + Engine assombly {from the right side of the motorcycle) install 1 Engine stay (rear) © {+ Mounting bolt (rearlower) @ { Mounting bol (rear-upper) = Down tube (right) © + Cross tube fron) © + Engine stay (front) © {= Mounting bot (ont) ® Bolt (engine stay): 30 Nm (8.0m + ka) ‘Mounting bolt (reer-upperilower 48.Nm (4.8 m+ kg) Bolt (down tube): 189 Nen (8.9 rm =k) ‘Mounting bolt front): 48 Nn (4.8 m+ kg) neta + Gaskets ‘Nat (exhaust pipe! ‘20 Nem (2.0m kg) Bolt: ‘25 Nm (25 m kg)ENGINE ASSEMBLY AND aDJusTmeNT | ENG] xp] “install: + Mutter © 5.Tighten: + Bot Bolt (ulor 25.Nm (25 m+ kg) Bolt exhaust pipe-muftier): ‘20Nm (2.0m kg) 6instalt: + AC. generator [SJ Bolt (AC. ganeraton 5 Bolt (AC. generaton @: Bolt (starter moton @: ‘2Nm (1.2m + kg) Bolt (starter motor @: 7Nm (07 m= kg) ‘YAMAHA Bond No.1215 8.Comect: + Stantr motor lead © Sinstall: «Shit pedat tink Bolt (shift pedal fink) O: ‘10Nm (1.0m «kad ore: —__ Align tha punched mark@ on the shaft with the slot ® on tho shift arm @. Bolt (cable stay ‘12Nm (1.2m kg)THinstal + Carburotor joint © Bot (carburetor joint: ‘121Nm (1.2m kg) + Carburetor Fofer to “CARBURETOR” in CHAPTER 5. 12.Connect: + Battery leads “SCAUTION: ———— Connect the postive lead © fst and then the negative lead ©. 13F + Crankease Rfer to “ENGINE OIL REPLACEMENT” in CHAPTER 3, Total amount VD) aac 1eAdjust: + Idle sp20d Refer io “IDLING SPEED ADJUSTMENT" in CHAPTER 3. C=) o80'° 80 ymin 15.Adjut: «+ Throttle cable free play Rofer to “THROTTLE CABLE ADJUST- in CHAPTER 3.CARBURETOR |CARB| eo CARBURETOR QAicfunnel @Main other Main jot (@Piot serow set CARBURETION @ Starter plunger set {© Vacuum chamber cover ® Spring ‘D Jetneodie holder @ dot nod set {Piston valve doin (tater lever) ors {throte position senson) ‘SPECICATIONS 1.0. Mark 'aKMO0 [APO MAIN JET "F100 MAIN AIR JET W258 PILOT JET 125 PLOTAIR JeT1 — | #120 JET NEEDLE /soT3-2 PiLoT SCREW 1-172 tuens out frHROTTLe vaLve | 4125 JENGINE IDLE SPEED | 950 ~ 1,050 min FUELLEVEL, J6~ 7 mm FUELLEVEL|carsureTor |CARB| fe! REMOVAL Remove: = Soat + Fuol ank Rofer to “SIDE COVER, FUEL TANK AND COW. ING" in CHAPTER 3. «= Airfiter case Refer to “VALVE CLEARANCE ADJUST: IMENT” in CHAPTER 2 2.isconneet «= Throttle cables © 2 Starter cable @ 3.Disconnect: ‘= Carbcretor heater coupler © ‘Remove: ‘+ Fuel hose @ S.Disconnect: +s Throtie sensor lead B.Loosen: 1 Sorews 7Remeve: «= Carburetor assembly DISASSEMBLY Nore; The folowing parts can be cleaned and Inspected without carburetor separation {All inner parts except starter plunger can be cleaned and inspected without carbure tor separation.) Throtle valve + Piston valveCARBURETOR = All ets 1 Fost I Needle valve ‘Valve seat Main nozzle tet needle «= Throttle sensor = Oring 2.Remove: + Seraws + Colars@ + Lover connecter @ = Throtte cable holder @ ster joint © rburetor hold bot © ar 10) hose © Soin pipe ® defective, do not reuse them. ove; — Be careful not to lose the return spring © under the synchronizing serew @ when dis- assembling the carburetor.CARBURETOR [cars| ee ‘3 Remove: + Starterplunger © Nove: —____ Unhook the hooks from the carburetor ‘body and then pull out the starter plunger. ‘TRemove: + Carburetor heator @ Washer + Terminal © 5.Remove: + Vacuum chamber cover © = Spring 1 Jet needle holder @ = Spring® = Jot needle © 1 Piston valve ® 6. Remove: + Float chamber © = Gasket + Screw Float ® + Float gin © + Sorew 2 Needle valve Valve soot Toring 7.Remove: Main jt © {Main jt holder @ Main jt nozzio Pseraw@ 1 Nese jet Pilot jot @ * Pilot screw © Remove: = Main ar jot ©carpureTor |CARB| Se gq INSPECTION “Linspect: « Carburetor body + Float chamber Svethousing Cracks/Damage > Replace. + Fusl passage Contamination -+ Clean as indicated. ‘+ Carburetor float chamber body Contamination -» Clean Cleaning steps: ‘@Wesh carburetor in petroleum based sol- vert. (Do not use any caustic carburetor loaning solution.) ‘@Blew out all passages and jets with com- pressed aie. inspect: Floats Damage - Replace. Binspect = Needle valve © 1S Vave seat @ + Oxing @ Damage/Wear/Contamination + Replace asaset inspect + Trrotte valve O ‘Scratches Wear/Damage -> Replace. ‘+ Rubber diaphragm @ “Tears -» Replace.caraureror [CARB] fg Binspect + Vacuurn chamber cover © = Spring @ * Jet neodle holder @ CracieyDamage -» Replace. Ginspect + Jet neodle © + Neode jet + Main jot @ BendyWoar/Damage > Replace. Contamination -» Blow out jets with com- pressed air 7.Check 1+ Free movernent Insert the throtle valve into the carbure- tor bedy, and check for ree movement. Stick > Replace. inspect: ‘Joint Iventilation hose) Joint ituel hose) + Joint fuel feed) Cracks/Damage ~> Replace.CARBURETOR [cars| oe "ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. 2ineal: ‘+ Throttle valve @ + Spiing @ ‘Vacuum chamber cover © Note: ‘slnsort the spring end onto tho spring ‘guide on the vacuum chamber cover. ‘+ Mach the tab on the diaphragm to the 0c258 in the carburetor body. ines ‘Starter plunger © STeminal @ S washer + Carburotor heater @ Carburetor heater ‘3Nm (03 m= ka) Nore, + Use “Heat Sinker” when installing the car= bburetor heater. + Align the corner of terminal @ with @ A Heat sinkercarsureTor [CARB ] Nove: “HEAT SINKER” fe the name of a product sold at most electrical appliance dealers ‘Anetall: Joint pipe © Joint Fase @ + Rod @ Scotter D + Carburetor hold bolt @ © 1 Tarottl cable holder + Lever connector ® Collars @ + Screws @ Nore: «+ Do noitighton the connecting bolts yet. {+ Insert the throttle arm @ (on the #, #2, #4 ‘carburstors) between the spring @ and synchronizing seraw @. ‘Nore: Hook the savior joint arm onto each starter plunger ‘NOTE: ‘+ Place the carburetor assombly on a sur ‘ace pate with the intake manifold side down and then tighten the connecting bolts while pushing down the respective ‘carburetor with an even force. “+ Aftor ightoning, check the throtte lever 3 stata joint for smooth action.CARBURETOR [cars| je INSTALLATION Revese the “REMOVAL” procedure. Note the following points. LAdust: + Carburetor synchronization Refer to "CARBURETOR SYNCHRONIZA ‘TION" in CHAPTER 3. 2.Adhist = lale speed ey] Saas ia seed: {950 ~ 1050 r/min Fofer to “IDLING SPEED ADJUSTMENT" in CHAPTER 3. Adu: «= Throttle cable free play Roler to “THROTTLE CABLE ADJUST- MENT” in CHAPTER 3. FUEL LEVEL ADJUSTMENT Measure: = Fuel level © Outof specication + Adjust. Fuel level: 6-7 mm Below the float chamber line Fuellevel measurement and adjustment steps: ‘@Plco the motorcycie on 8 level surface. ‘@Use a garage jack under the engine to ensure that the carburetor Is positioned vertically. ‘eConnect the fuel level gauge @ to the drain pipe . Z] Fuel evel gauge: ‘90890-01312 ‘Loosen the drain serew @. ‘eHcid the gauge vertically next to the float chamber line ©. feMeasure the fual level @ with the gauge.cansuneron [CARB] ‘TPS (THROTTLE POSITION SENSOR) ‘ADJUSTMENT AND INSPECTION Nore: —__ ‘Idle speed should be adjusted properiy before adjusting the throttle sensor posi- tion, + When installing the TPS, observe the dis- play on the tachometer and adjust the angle accordingly. Refer to the adjust: ‘ment procedure below. Adjust + Throttle position sensor position Adjustment steps: Turn the main switch to "ON", ‘eDisconnect the throttle sensor coupler. ‘eReconnect the throttle sensor coupler. ‘Note: |When the above procedure le commenced, ine switches to TPS adjustment Loosen the throttle sensor screws ©. ‘@Adjus: the throttle sensor position Nove: ‘The angle of the TPS ie shown on the tachometer. ‘@Adjusithe angle ofthe TPS as appropriate ‘a8 shown below. When the angle is correct, the tachome- tor reads 6,000 rpm. When the angle is too wide, the tachometer reads 10,000 rpm. When the angle is too narrow, the tachometer reads 0 rpm, ‘eAtter adjusting the ang! ‘throttle sensor screws. Nove: To retuin to normal mode, start the engine or resetthe main switch, tighten theCARBURETOR |CARB 2inspect 1 Throttle sensor Inspection steps: ‘eDisconnect the throttle sensor coupler. ‘@Remove the throttle sensor from carbure- tr. ‘eConnect the pocket tester (0 x 1H) to the ‘throtla sensor couples. sd > Blue torminal © Black/Blue terminal © ‘© Check the throttle sensor resistance. Throttie sensor resistance: 35 -65ko at 206 {Glue — Black/Blue) ‘Qutof specification > Replace the throttle ‘@Connect the pocket tester (2 1k) to throt feces GD Taser md Yoo ara . FE CE TAT @hDE-— ‘eCheck the throttle sensor resistance while x ing oy a: SJ] Tiree sor a S| | “ocstisaneewe tretow actus) ‘Out of specification > Replace the throttleALLS. (AIR INDI JUCTION SYSTEM) [cars| ie ALLS. (AIR INDUCTION SYSTEM) ‘AIR INJECTION ‘This system reburns unburned exhaust gas bby mixing fresh ar (secondary ai) in at the ‘exhaust pot to reduce hydrocarbon, When the pressure around the exhaust port Js reversed (negative), the reed valve is ‘openedand the secondary ar flows into the exhaust port. Required temperature for reburning of unburned exhaust gas. is approximately 600" to 700°C. @Air cleaner @aircavaive Reed valve @vvecurm signal © Carburtorjoint @ewhacst port ‘AIR CUT VALVE ‘The air cut valve Is operated by intake gas ‘prossure through the diaphragm. Normally, this val is opened in order to allow fresh air to flow into the exhaust port. When the throttles ciosed rapidly, negative pressure is generated and this valve is closed in ‘order ta prevent ater-burning. ‘Additionally, even if the engine is run at hhigh RPM and the pressure decreases, the valve automatically loses in order to guard against a loss of performance due to sel EGR. (Exhaust Gas Recirculation) (This “low-boost close” function is the same at the AIS. air cut valve function on the FZR500 (SHW), however, the XV750 ‘models work differently.) View 1. During normal operation, the valve s open. view? When decelerating suddenly (throtle valve suddeniy closes), the valve closes. views. When running at high PRM's, the valve is closed. Ii} From ir cleaner [To reed vaive CrTo carburetor joint,ALS. (AIR INDUCTION SYSTEM ‘ALS. (AIR INDUCTION SYSTEM) DIAGRAMS @ Reed valve To cylinders @Atrcleaner [BlTo alccutvaive @ Air cut valve [W)ToNo.t evinder No teyinderervretrjin) TONG Zone IE]ToNo,3evinder TE ToNo:AevingerLS. (AIR INDUCTION system) |CARB| |S. (IRINDUCTION SYSTEM) INSPECTION. Nore: tho. specified idling speed cannot be obtained, even after the adjustment proce: ‘dures described in the “Inspection and adjustmont” section have beon carried out, {ollow the procedures below. inspect ‘+ Hoseconnection Poor connection -» Correct, Loose connection ~> Correct properly. sHoses Cracts/Damage ~» Replace “Pipes Crachs/Damage ~» Replace inspect + Reed valves + Rood valve stopper Cracta/Damage -~» Replace. SMeasure: «= Red valve bending limit © Out f specification -> Replace. eed valve bending limit 4mm © Surhce paw Anspoct: «Airc valve Cracis/Damage -> Replace.ALLS (AIR INDI ucTION system) [CARB] "a [A.S. (AIR INDUCTION SYSTEM) ADJUSTMENT zation should be adjusted properly before ‘adjusting the ALS. Nore, —______ Place the motoravele on ls centerstand fra Centerstand is equipped. If not, place asuit- able stand under the motorcycle. ‘Remove: + Soa 1 Fuel tank. + Cowting Fofer to “SIDE COVER, FUEL TANK AND COWLING" in CHAPTER 3. 2Adjst: ALS. (Alrinduction System) Adjustment steps: ‘st sep: ‘@Remove the hose @ from the air cut valve . ‘eFit udbor plugs into the air cut valve @ and hose @ to cut off the air. ‘eStart the engine and let it warm up until it reaches the specified tomporature. ‘©Use a emperature probe tester connected to the drain bolt thread, Te re 6. 75C, ‘© djst engine idling speed. Nove: — Be careful not to get burned during th operation as the exhaust pipe generate considerable heat 980» 1,050 r/min Coy] Saas log spees: |ALS (AIR INDUCTION SYSTEM) [cara e ‘eRemove the exhaust bolt@ and install the exhaust attachment @, 4 or heed fe or moma te oe tae hast eanitan be Se hate vets conic hare ‘©Check the CO density by connecting a CO ‘meter to the exhaust attachment. Exhaust attachment: ‘90890-03136 (9Use a carburetor angle driver to adjust the pilot screw until the specified value is, ‘obtained z ‘eRiemove the exhaust attachment and install he exhaust bot Carburetor angle driver: ‘90890-05158 Be ca ing oF installing the exhaust bolt or ‘exhaust attachment, as the exhaust pipe valve Ss. ‘9Adjustengine idling speed once more. ey idling speed: | 050 r/e /@ and hose ©, and activate the A. Engine i 3Front wee [CHAS|AE%]Front wHeet |CHAS|GES| REMOVAL Snore suppor a noloTyaa a Ts inno dugora tang 1 Place the motoreycle ona level place. 2.isconnect: = Speedometer cable ® Remover += Speodomoter cable guide ® + Brake calipers (lft and righ) © = Bolt (rake hose holder) © Nore: —__ Do not depress the brake Tover when the wheel # off the motoreyele otherwise the ‘brake pads will bo forced shut. ‘4.Loosen: «Pinch bott front wheel axle) © {+ Frontwhoel axle @ ‘Elevate the front wheel by placing 2 sult ‘able stand under the exhaust pipe. Remove: + Frontwheel axlo 1 Frontwhee! ‘LRemove: Collar 2 Speeiometer gear unit @FRONT WHEEL |CHAS| io] INSPECTION “Lnspect: + Front wheel axle Folithe axle on a flat surface. Bands ~» Replace PUI Do not attempt to straighten abort ax inspect: oT Wear/Damage —» Replace. Rofer to “TIRE INSPECTION" in CHAPTER, 3 = Wi Refer to “WHEEL INSPECTION" in CHAP- TER. 3 Measure! ‘+ Wve! runout Over specified mit > Replace. Fm runout limits: Radial ©: 1.0mm Lateral Q: 0.5 mm Besrings allow play in the whee! hub or wheel turns roughly > Replace. = Oilseals ‘Wear/Damage -» Replace. ‘Wheel bearing and oll seal replacement steps: ‘Clean the outside ofthe whee! hub. feFemove the oil seals @ use a flathead screw driver, Nore: Place a 7ag @ on the outor edge to prevent damage.FRONT WHEEL ‘@Remove the bearing @ using @ generat bearing px ‘install the new bearing and oil seal by reversing the previous steps. Do not strike tha cantor race @ or balls © ff the bearing. Contact should be made only with the outer race © INSTALLATION Reverse the “REMOVAL” procedure. Note the following points ‘Lubricate: + Front wheel axle 1 Bearings + Oil seal (lips) + Driveriven gear (speedometer) Recommended lubricant thium soap base grease 2instal ‘= Speedometer gear unit Nove; Be sure that two projections inside the ‘wheel hub mesh with the two slots in the gar unit assembly. Install: 1 Front wh Nore: —__ Be sure hat the projection (torque stopper) ‘of the gear unit housing is positioned cor: rectly.Front weet [CHAS| S56] “Tighten: + Fromtwhool axle J Pines bolt front whoo! axle) 2 Bolttbrake caliper) Front wheel axe: '59.Nm (6.9 m « kg) Pinch bolt front wheel axtel: ‘19m (1.9 m= kg) ‘ole (brake caliper: '35.Nen (3.5 m= kg) Before tightening the pinch bolt, stroke the front fork several times to check for proper {ork operation. Make sure that the brake hose ts routed propery. STATIC WHEEL BALANCE ADJUSTMENT Nove, —___ After replacing the tire andlor im, wheel balancer should be adjustod, «+ Adjust the wheel balance with broke disk installed “URemove + Balancing weight 2.Setthe wheo! on suitable stand.enont wnesr [CHAS| AX] 3Fin: + Heavy spot Procedure: ‘Spin the wheel and wait for itt rest. bbPut an “X;" mark on the wheet bottom spot ceTur the wh 90" up. ile the whee! fall and walt fori to rest. ut an "X," mark on the wheel bottom spot, pest the above b,, ¢, and 4. several times until these marks come to the same spot {.This spots the heavy spat *X" so that the °X\" mark is 4Adjust = Whee balance ‘Adjusting stops: ‘instal @ balancing weight © on the rim ‘exactly opposite tothe heavy spot" NOTE: ‘Start with the smallest wolght ‘@Turn the wheel so that the heavy spot is 90" up. ‘@Check thatthe heavy spot is at rest there. I not, try another weight unt the wheel is balanced. 5.check 1+ Who bs Checking stops: (@Turn the wheel so that it comes to each point as shown. ‘eCheck that the wheel is at rest at each poiat.f not, readjust the whol balance.REAR WHEEL |CHAS|ean weet [CHAS| dt] REMOVAL Ce En Ts ROSE 3s os inne det tating oe ‘Place the motorcycie on a level place, 2Remove: += Brake caliper © Note: ———— Do not Japrass the brake padal while the calipar is removed, S.Loosen + Pinch bolt © ‘Remove: + Nut (rear whee! axle) @ + Washer + Rear wheel axle @ Pull tho wheel to the right, to separate it from the final gear case. 5 Remove «+ Rear wheelREAR WHEEL |CHAS| At] INSPECTION ‘Lnspect: «= Roar wh weet ‘= Whee! bearing 1 Oil soals Rofer to “FRONT WHEEL" 2.Messure: Whee! runout Rofor to “FRONT WHEEL”. INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Lutrioate: ‘+ Roar whee! axle 1 aearings + Botts (brake caliper) "Nut (roar whoo! ax “105 Nm (10.5 m + kg) inch bolt: 15 Nm (1.6 m+ kg) Bott (brake calipe ‘35 New (3.5 m= kg)REAR WHEEL |CHAS|ASSG| ‘STATIC WHEEL BALANCE ADJUSTMENT balance should be adjusted. + Adjust the whee! balance with brake disc nd hub installed. Adj: + Wheel balance Refer to “FRONT WHEELFRONT AND REAR BRAKE FRONT AND REAR BRAKE. @ Mater evindor ke (@Mastorevinder bracket @ Front brake switch Copper washer {@ Caliper assombly ‘® Union bor {© Caliper piston asaomby ‘BRAKE FLUID TYPE: bors ‘BRAKE PAB WEAR LIMIT 08 mm [BRAKE DISC WEAR LIMIT: 35mm [ionn rio mre SNWBSA IG!) 20Nim Ora ZONm Eom)FRONT AND REAR BRAKE |CHAS| a] REAR BRAKE, DReservirtankeap Brake pedal [the longer tangs (3) of tho pad spring @Kolder(deprragm) Brake caliper ‘must paint In the die reating rec: {@ Diaphragm Piston tion @ Reservorr tank {@ Piston soa! the arrow mark @ on the pad shim @ Reservoir nose ‘@ rote pad muse point In the dise rotating diroe- {© Union bot shim tor @ Copper washer Dad spring @ Brake nose BBrake ase @ Mester evinder {@ Caliper bracket { Mastoreyiner kit [BRAKE FLUID TYPE: DOT we [BRAKE PAD WEAR LIMIT: aa) SRS maT [BRAKE DISC WEAR LIMIT: [Nm z0m=167] E]PADSPAING | po F [PAD SHIN ut ‘ x he eyFRONT ICHAS| S| AND REAR BRAKE Dise brake components rarely require dis: assembly. DO NOT: ‘Disassemble components unless abso- lutely necessary ‘+ Use solvents on internal brake compo: nents. + Use contaminated brake fluid for clean- ing. Use only clean brake fluid + Allow brake fluid to come in contact with ‘the eyes, otherwise eye injury may occur. + Allow brake fluid to contact painted sur- {aces or plastic parts otherwise damage ‘may occur. + Disconnect any hydraulic connection oth- lerwise the entire system must be disas- sembled, drained, cleaned, and then property filed and bled after reassembly. ‘BRAKE PAD REPLACEMENT Note: ——— lis not necessary to diasseomble the brake calipor and brake hose to replace the brake pads. Front brake ‘Remove: « Boltibrake hose holden) = Calipar assembly @ 1 Retaining bolt 2Rerove: “Brake pads Nore «+ Repco the pad spring i the pad replace. ment is required, + Replace the pads as a set iether is found ‘to be worn tothe wear limit. a Wear fii ‘08 mmFRONT AND REAR BRAKE ICHAS| ‘instal = Brake pads = Pad springs Installation steps: ‘eConnect a suitable hose @ tightly to the ‘alipe: bleed screw. Then, place the other fend ofthis hase into an open container. ‘@Loosen the caliper bleed screw and push the pistons into the caliper withthe finger. feTighten the caliper bleed serow. Caliper bleed serew: 6 Nm (0.6m ka) (@Be careful to install the pad springs in ‘proper position ‘einstal the brake pods. Nore: Be sureto position the pad so that ts ide lis forward. sand ‘.Lubreate: Retaining bolt (caliper body) © 1 Caliper guide shatt @ ‘Recommended lubricant: Lithium soap bese grease er ‘+ Take care not fo allow the brake pads to be smeared by grease. + Wipe off any unnecessary grease that comes out of place. + Caliper assembly + Brake hose holderFRONT AND REAR BRAKE cuas|do| Retaining bott: '22.Nm (22 m+ ko) Bolt (caliper bracket): '35.Nm (3.5 m= kg) Bolt (brake hose holder): "7 Nem (0.7 m= kg) Ginspact: + Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC. TION" in CHAPTER 3. @ “LOWER level line 7.Cheeks «= Brale lever operation ‘Assoft spongy feeling -» Bleed brake sys- tem, Refer to “AIR BLEEDING (HYDRAUUC BRAKE SYSTEM)" in CHAPTER 3. Rear brake Remove + Brake caliper © + Padcover @) 2Remove: ‘Retaining clips © + Rewining pins @ + Padspring ©FRONT AND REAR BRAKE |CHAS|AT%)| ‘3 Remove: ‘= Brake pads © (with pad shims) Note: 1+ Won pad replacement is requ replaco the pad spring and shims. ‘= Replace the pads as a set iether is found to be worn tothe wear limit @. Wear limit O 05 mm Alnst “+ Pad shims (onto brake pads) «Brake pads Pad spring Installation steps: ‘eConneet @ suitable hose © tightly to th ‘caliper bleed screw @. Then, place the ‘other and of thie hose into an open con: tain ‘®Loosen the caliper bleed serow and push ‘the pistons into the caliper withthe finger. ‘eTighton the caliper bleed screw @. Caliper bleed serew: ‘6m (0.6 m = Kg) ‘instal the pad shim (new) @ on the pad (new! ©. Note: The arrow mark @ on point inthe direction oft