YAMAHA 8 SERVICE MANUALFZ750 SERVICE MANUAL, ® 1985 by Yamaha Motor Co., Ltd. 1st Edition, January 1985 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in JapanNOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. !t is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorrepair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation NOTE A NOTE provides key information to make procedures easier or clearer. ue A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. Adel §— A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., *Bearings Pitting/Damage ~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols @ to ® are designed as thumb tabs to indicate the chapter's number and content. General information @® Periodic inspection and adjustment @éngine @ Cooling system ®Carduretion Chassis @Eleciical @ Appendices Illustrated symbols @ to @ are used to identify the specifications appearing OFilling fluid @Lubricant @Tightoning @Wear limit, clearance @Engine speed BQV.A lilustrated symbols @) to @ in the ex- ploded diagram indicate grade of lubricant and location of lubrication point. B Apply engine oil @Aoply gear oil ‘Apply molybdenum disulfide oil @Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @Apply locking agent (LOCTITE®)INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS E 0 ie Br 5 jae c ENGINE OVERHAUL Ea 3 | COOLING SYSTEM CHASSIS et — uN CARBURETION care fe ee cHas| i” ELECTRICAL mech AP ee PENDICES —CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 4 FRAME SERIAL NUMBER WW ENGINE SERIAL NUMBER WW IMPORTANT INFORMATION... a 12 ALL REPLACEMENT PARTS. ve one V2 GASKET, OIL SEALS, AND O-RINGS ...... soon V2 LOCK WASHER/PLATES AND COTTER PINS 7 12 BEARINGS AND OIL SEALS. scssnsssiessetsensesetieesoes VR CIRCLIPS. 13 SPECIAL TOOLS........ 7 18 FOR TUNE UP. 13 FOR ENGINE SERVICE 14 FOR CHASSIS SERVICE 17 FOR ELECTRICAL COMPONENTS. 18 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION 241 PERIODIC MAINTENANCE/LUBRICATION INTERVALS......... 24 ENGINE 0.0.0.0. 0c eeepe cece ee eres e ee eee eens i 23 VALVE CLEARANCE ADJUSTMENT . 228 CARBURETOR SYNCHRONIZATION .. 29 SPARK PLUG Pecepitiecbateet ect eee211 CRANKCASE VENTILATION SYSTEM 2411 FUEL LINE 2212 INTAKE MANIFOLD 212 EXHAUST SYSTEM Ee alte t te cert IDLE SPEED ..... wees R12 ENGINE OIL .......- seen BB IGNITION TIMING CHECK . . 2.15 COMPRESSION PRESSURE MEASUREMENT 2-16 COOLANT LEVEL .... 247CHASSIS ....... ioe ete 2218 FUEL COCK . . 2218 AIR FILTER 0002... ccs ecs ees 2.2419 FRONT AND REAR BRAKE . 2.19 DRIVE CHAIN ........ 221 CABLE INSPECTION AND LUBRICATION .... 22:24 BRAKE AND CHANGE PEDALS/BRAKE AND. CLUTCH LEVERS... «224 CENTERSTAND AND SIDESTAND - FRONT FORK OIL CHANGE . FRONT FORK AND REAR SHOCK ABSORBER ADJUSTMENT. : STEERING HEAD ........... WHEEL BEARINGS .. TUBE LESS TIRES AND ALUMINUM WHEELS 2-24 2-25 eit ehet att 2s: 229 2-30 2-30 CLUTCH FLUID .......- 7 2.33 ELECTRICAL ... 2:33 BATTERY él ‘ 2-33 HEADLIGHT . 2:35 FUSE... + 2:36 CHAPTER 3. ENGINE OVERHAUL ENGINE REMOVAL ........ PREPARATION FOR REMOVAL . a1 SEAT AND FUELTANK . 32 AIR CLEANER AND CARBURETOR 32 EXHAUST PIPE AND MUFFLER . Hoe eaieeedeetie bord RADIATOR HOSE AND SPARK PLUG LEAD... 0.0. ..0s2.s. 98 DRIVE CHAIN SPROCKET ..... LEADS. : ENGINE REMOVAL «0.2... ENGINE DISASSEMBLY Sie eae ae CAMSHAFT AND CYLINDERHEAD .....ccssscsssesssssses 38 CYLINDER AND PISTON ........6..000ceceeeceeseeeeeeeees 39 RIGHT CRANKCASE COVER cece teen e ee BIO CLUTCH OIL PUMP AND CHANGE LEVER ........... STARTER MOTOR AND AC GENERATOR ... viata WATER PUMP........ 313 OIL PAN AND OIL STRAINER 2.313 CRANKCASE DISASSEMBLY a4 UPPER CRANKCASE .........- fate od LOWER CRANKCASE .. 16INSPECTION AND REPAIR ...... ‘ ce 347 CYLINDER HEAD AND CAMSHAFT CASE BEE HeaeeeeE VALVE, VALVE GUIDE, VALVE SEATS AND VALVE SPRING. : : 3:20 CAMSHAFT, CAM CHAIN ‘AND CAM SPROCKET _ : 3:26 CYLINDER .......... i Hid eeatetheettaee 13:29 332 3-35 13:38 PISTON, PISTON RING AND PISTON PIN... CRANKSHAFT AND CONNECTING ROD. . OIL PUMP ...... 6s. cee eeeee PRIMARY DRIVE . STARTER DRIVES fe 337 CLUTCH . ceeteeeees 337 TRANSMISSION ..........05 nn SHIFTER .... 0... ss 00eeoeee : 3-40 RELIEF VALVE .... a OIL PIPES, 7 3-40 COOLANT PIPE ..... a CRANKCASE : oat BEARING AND OILSEALS . seve CIRCLIPS AND WASHERS om ENGINE ASSEMBLY AND ADJUSTMENT LOWER CRANKCASE .............. UPPER CRANKCASE ...,. CRANKCASE ASSEMBLY . OIL STRAINER AND OILPAN ... WATER PUMP ......... ‘AC GENERATOR AND STARTER MOTOR 7 CHANGE LEVER AND OIL PUMP... coveteeeeeee eres SBT CLUTCH ......... See c cele ete cate tao: RIGHT CRANKCASE COVER . PISTON AND CYLINDER . CYLINDER HEAD AND CAMSHAFT REMOUNTING ENGINE .. CHAPTER 4. COOLING SYSTEM COOLANT DRAINING .........2.-.4.. Seb al WATER PUMP ......... 4 -41 DISASSEMBLY aoe INSPECTION . E PEELE HEU tei ett BEARING AND SEAL REPLACEMENT |... ce vee ees #2 ASSEMBLY ......... 243 THERMOSTATIC VALVE 1.0.0.0... 000 cc cece eeetee cette ee 43 REMOVAL ...... : poet cence 43 INSPECTION... coves as 7 a4 ASSEMBLY wees LatRADIATOR REMOVAL, INSPECTION . feats ASSEMBLY .. : : COOLANT FILLING ..........5 Reise eet reese ele zy CHAPTER 5. CARBURETION CARBURETOR SECTION VIEW DISASSEMBLY INSPECTION ASSEMBLY FUEL LEVEL ADJUSTMENT . i D>! 2 AIR CLEANER AND CRANKCASE VENTILATIONS SYSTEM ....... 5:6 CHAPTER 6. CHASSIS

REAR WHEEL ...........02- 000 : REMOVAL INSPECTION .......- INSTALLATION . HAE 3) FRONT BRAKE ........ acta theet BRAKE PAD REPLACEMENT ... cafe feet Ree CALIPER DISASSEMBLY «02-00-0002 0 00 ee ree eee eee eee E10 MASTER CYLINDER DISASSEMBLY . INSPECTION AND REPAIR .... ASSEMBLY .. AIR BLEEDING . REAR BRAKE . BRAKE PAD REPLACEMENT .. CALIPER DISASSEMBLY ........ MASTER CYLINDER DISASSEMBLY . INSPECTION AND REPAIR ASSEMBLY ..... AIR BLEEDING ..HYDRAULIC CLUTCH ee ae CLUTCH RELEASE DISASSEMBLY . MASTER CYLINDER DISASSEMBLY INSPECTION AND REPAIR . ASSEMBLY AIR BLEEDING FRONT FORK Eee ee REMOVAL AND DISASSEMBLY . INSPECTION ASSEMBLY STEERING HEAD ADJUSTMENT REMOVAL, INSPECTION . ASSEMBLY REAR SHOCK ABSORBER/REAR ARMS HANDLING NOTES... . REMOVAL ...... INSPECTION INSTALLATION ..... SWING ARM AND DRIVE CHAIN ........ FREE PLAY INSPECTION . REMOVAL . INSPECTION a INSTALLATION ......... CABLES AND FITTINGS CABLES MAINTENANCE CHAPTER 7. ELECTRICAL FZ750 CIRCUIT DIAGRAM ....... ELECTRICAL COMPONENTS .... ELECTRIC STARTING SYSTEM TROUBLESHOOTING CHART . STARTING CIRCUIT OPERATION STARTER MOTOR STARTER RELAY a eee STARTER SAFETY UNIT (Relay Assembly) NEUTRAL SWITCH CLUTCH SWITCH STARTER SWITCH DIODE 617 +618 +619 619 +620 +621 +622 +623 +625 627 6-30 631 - 631 6-33 634 - 635 6:35 . 6-37 - 6:38 6-39 6-41 = 6-42 6-42 6-42 6-43 6-44 6-44CHARGING SYSTEM ....... - 715 TROUBLESHOOTING CHART 77 BATTERY . = 719 RECTIFIER 2724 IGNITION SYSTEM ....... eRe ee triers 7-23 TROUBLESHOOTING CHART........ 7-28 ENTIRE IGNITION SYSTEM CHECK - 727 IGNITION COIL SPARK GAP........ ‘ 7-28 LIGHTING SYSTEM . 7.29 TROUBLESHOOTING CHART. 7-31 SIGNAL SYSTEM ........000e00ee eee 735 TROUBLESHOOTING CHART....... 1:37 HORN eee aceasta let 7-42 OIL LEVEL SWITCH eatee 742 TEMPERATURE SENSOR .. 7-43 FUEL SENDER . . 7-44 REED SWITCH . fl TAB SWITCHES + 7-46 GOOLING SYSTEM. ...... ee eeeeeeeeee wee TAT TROUBLESHOOTING CHART...... 7-49 ELECTRICFAN........ +. 7-50 THERMOSTATIC SWITCH . 750 FUEL PUMP SYSTEM ......--- 0060s seer ree eeee . 7-53 FUEL PUMP CIRCUIT OPERATION . 7-55 TROUBLESHOOTING CHART.... +. 156 FUELPUMP CONTROLLER ... vanes 7-60 FUELPUMP ... - 7-61 FUEL RESERVE switch eee eene ne FET CHAPTER 8. APPENDICES SPECIFICATIONS: 81 GENERAL ‘SPECIFICATIONS . ot MAINTENANCE SPECIFICATIONS 83 ENGINE peesresicc eee 83 CHASSIS : peeee . . Fesnrresr 8-11 ELECTRICAL ...... ce ans GENERAL TORQUE SPECIFICATIONS eet Po 8-17 DEFINITION OF UNITS... : 817 LUBRICATION DIAGRAM . 8-18 CABLE ROUTING... a9 F2750 WIRING DIAGRAM ENGGENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number @® is stamped into the right side of the steering head pipe. ENGINE SERIAL NUMBER The engine serial number (1 is stamped into the right side of the engine, NOTE: ‘The first three digits of these ni model identifications; the remé the unit production number. Starting Serial Numbe FZ750 FZ750 (For Switzerland) . 1FN-000101 - 1FV-000101 NOTE: Designs and specifications are subject to change without notice,N IMPORTANT INFORMATION FN owe IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements, Use oil and/or grease recommended by Yamaha for as- senmbly and adjustment GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. Ali gasket surfaces, oil seal lips, and O- rings must be cleaned. 2. Properly oil all mating parts and bearings during teassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COT- TER PINS 1. All lock washers/plates ) and cotter pins must be replaced when thoy are removed Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened, BEARINGS AND OIL SEALS 1. Install the bearing(s) @ and oil seal(s) ® with their manufacture’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing, HeAUTIONS, Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1213 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ®, make sure that the sharp-edged corner @ is positioned opposite to the thrust @ it receives. See the sectional view. @Shatt SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. FOR TUNE UP 1, Inductive Tachometer P/N 90890-03113 This tool is needed for detecting engine rpm. 2. Inductive Timing Light P/N 90890-03109 This tool is necessary for checking ignition timing. 3. Compression Gauge P/N 90890-03081 This gauge is used to measure the engine com- pressionSPECIAL TOOLS fies ous 4, Fuol Level Gauge P/N 90890-01312 This gauge is used to measure the fuel level in the float chamber, 5 Vacuum Gauge P/N 90890-03094 This gauge is needed for carburetor synchroniza- tion. FOR ENGINE SERVICE 1. Universal Clutch Holder P/N 90890-04086 This tool is used to hold the clutch when re: moving or installing the clutch boss locknut. 2. Valve Spring Compressor D P/N 90890-04019 Attachment @ P/N 90890-04108 This tool is needed to remove and install the valve assemblies. 3. Valve Guide Remover (5.0 mm} P/N 90890-04097 This tool is used to remove the valve guides.4, Valve Guide Reamer (5,0 mm) P/N 90890-04099 This tool is used to rebore the new valve guide. 6. Valve Guide Installer P/N 90890-04098 This tool is needed to install the valve guides properly. 6. Valve Seat Cutter Set P/N YM-91043 This tool is needed to resurface the valve seat. 7. Piston Pin Puller P/N 90890-01304 This tool is used to remove the 8. #30 Torx Driver P/N 90890-05245 This tool is used to loosen or tighten the main axle bearing retainer bolt.SPECIAL TOOLS fie Swe 9, Plastigage® Set “Green” P/N YU-33210 This gauge is needed to measure the clearance for the connecting rod bearing. 10. Yamaha Bond No. 1215 P/N 90890-85505 This sealant (bond) is used for crankcase mating surfaces, etc. 11, Piston Ring Compressor P/N 90890-04008, This tool is used to compress piston rings when installing the cylinder. 12, Piston Base P/N 90890-01067 Use 4 of these to hold the piston during cylinder installation. 13, Radiator Cap Tester P/N 90890-01325 Adaptor P/N 90890-01352 This tester is needed for checking the cooling system, 16‘O} owe SPECIAL TOOLS Ww 14. Special Thickness Gauge P/N 90890-01399 This tool is used to adjust the valve clearance. 15. Hexagon Wrench (6 mm) P/N 90890-01395 This tool is used to loosen or tighten the cylin- der head securing nut, 16. Armature Shock Puller P/N 90890-01290 — @ Weight P/N 80890-01291 — @ These toals are used to remove the generator armature. 17. Cam Chain Cutter P/N 90890-01112 This tool is used when cu 1g the cam chain. FOR CHASSIS SERVICE 1. T-Handle P/N 90890-01326 — © Damper rod holder 25.5 mm P/N 90890-01397 — @ This tool is used to loosen and tighten the front fork damper rod holding bolt.SPECIAL TOOLS ey dws 2, Front Fork Seal Driver (weight) P/N 90890-01367 — (1) Adapter (39 mm) P/N 90890-01398 — @) These tools are used when installing the fork seat. 3. Ring Nut Wrench P/N 90890-01268 — D P/N YU-33975 — @ This tool is used to loosen and tighten the ste- ering ring nut. FOR ELECTRICAL COMPONENTS 1. Electro Tester P/N 90890-03021 This instrument is necessary for checking the ignition system components, 2, Pocket Tester P/N 90890-03112 This instrument is invaluable for checking the electrical system, 18INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. ‘These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE/LUBRICATION Unit: km (miles) TT T EVERY Correct if necessary. | Check operation fluid leakago/See NOTE, iG Breatein trem Remarks 6,000 J 12,000 1,000 1600) | (4,000) or | (8,000) or Gmonths 12 months _| Vatvois)™ Chock velve clearance. Adjust if necessary. | EVERY 42,000 (28000) Sa ekaut fk onion, Cea or reps i a 3S o_| Air filter Clean. Replace if necessary. ° ° faa Check idle speed/synchronization/startor . ee Operation. Adjust if necessary. 2 ic ° aime ‘Check fel hose and vacuum pipe for cracks Fuel Ii or damage. Replace if necessary. 7 ie aoe Check condition. Replace every 30,000 Fuel filter ere ° | Enaine oi Replace (Warm engine before draining) 3 o 6 Engine oil filter* Replace. oO fe) ae Check operation/flul leakage/See NOTE =. ° a Correct if necessary ‘Check rear arm assembly for looseness. Rear arm pivot* Gorrect if necessary. Moderately repack every 24,000 (16; we Rear suspension link | Check operation. Apply grease lightly every e pivots £24,000 (18,000) or 24 months."*" ane Check belance/damage/runout. Repair if a a necessary. weneenae Check bearings assembly for looseness? o a | damage. Replace if damaged Check bearings assembly for looseness Steering bearing” Correct if necessary. Moderately repack every | ° 24,000 (16,000) or 24 months.** payee nck open kos, Ra - Fer sheck aso” | Sk oa as, Ro = Check coolant leakage. Repair if necessary, EEEEE =H Coating syste Face colon every 22000 (16.0001 or © 24 months. Check chain slack/alignment, Adjust if necessary, Clean and lube, Drive chain EVERY 500 (300), 24PERIODIC MAINTENANCE/LUBRICATION Unit: kon (mites) —— EVERY Break-in 6,000 12,000 em Remar x es lerarks 1,000 (600) | (4,000) or | (6,000) or f ‘Smonths | 12 months Ffanenanse | Oheak al chasis fittings and festermers Fittings Fartone Et peeling ° ° Center and sidestand” Check operation. Repair if necessary. oo ° ‘Check specific gravity. Check breather pipa Battery’ tor proper operation. Cotrect if necessary. 7 ° are Check brutes for wear or damage. Replece a IF necessary. It is recommended that these items be serviced by a Yamaha dealer. 7) Medium woight wheel bearing grease. 7**) Molybdenum disulfide grease, NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder (clutch release cylinder), replace the brake fluid. Normally check the brake fluid level and add the fluid as required, 2. On the inner parts of the master cylinder and caliper cylinder (clutch release cylinder), replace ‘the oil seals every two years, 3, Replace the brake (clutch) hoses every four years, or if cracked or damaged. 22VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT Removal 1. Remove: Radiator cap cover Radiator cap @ ‘Right front pane! @ Starter knob @® ‘Left front panel ©) 2. Remove: ‘Lower cowlings @ 3. Drain: ‘*Coolant ® oylinderarain bot @® Warer pump drain bot 4, Remove: ‘Upper radiator bolts @ # Lower radiator bolts @ . Disconnect: ‘Upper radiator hose @ Lower radiator hose @)INSP VALVE CLEARANCE ADJUSTMENT | ADJ 6. Remove: ‘Air baffle plates D 7. Disconnect: fan motor coupler @ 9, Remove: ‘cylinder heed cover @ 10. Remove: ‘Left crankshaft end cover *Plug screw @ 14, Install: *Locknut @) Bolt (8mm) @ {into left crankshaft end) 12, Lock: eLocknut Valve Clearance Measurement 1, Measure: Valve clearance NOTE: ‘*Be sure piston is at Top Dead Center (TDC) on compression stroke when measuring clearance, Valve clearance must be measured when the engine is cool to the touch.VALVE CLEARANCE ADJUSTMENT Valve clearance measurement ste Turn the crankshaft counterclockwise Align the “T" mark @ on the crankshaft web with the stationary pointer @ when #1 piston is at TDC on compression stroke. ‘Measure the valve clearance using Special Thickness Gauge @ (90890-01399). ‘eRecord the measured amount if the clea- rance is incorrect, Intake Valve (cold): 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust Valve (cold): 0.21 ~ 0.30 mm (0.0083 ~ 0.0118 in) Measure valve clearance, in sequence, for #2, 4, and #3 cylinders, Out of specification -+ Adjust clearance. Firing Sequence: 1-2-4-3 @ From NOTE: Turn crankshaft each degrees counterclock- wise from #1 Cylinder TDC. O° 180° 360° 640° 720° #2 Cylinder 180 degrees #4 Cylinder 360 degrees #3 Cylinder 540 degrees [Al Crankshaft counterclockwise turning angle (8! Cvlinder @ Combustion ‘lf the clearance is correct, follow the As- sembly steps. *if the clearance is incorrect follow the Adjusting Pad Replacement steps. 25INSE VALVE CLEARANCE ADJUSTMENT | AD), Adjusting Pad Replacement 1, Remove: ‘Upper chain guide ‘Camshaft cap ‘Exhaust side chain guide Tensioner assembly Camshafts NOTE: Refer to camshaft of the ENGINE DISAS- SEMBLY 2. Remove: eVaive lifter © orad @ {of the incorrect valve clearance) Note the installed pud number 3. Select: ‘Proper pad Proper pad selection steps: ‘Select the proper pad from the chart below: Pad Availability: Pad range 25 increments 1.20 or | Pads stepped in No. 1201 (9.047 in) No. 240 0.05 mm (0,002 in) 2.40 mm | increments {0.094 in} NOTE: Thickness @ of each pad is marked on the pad sicle wall. ‘Round off the hundredths digit of the installed pad number to the nearest 0.05 mm increment. Hundredths digit. | _ Rounded valve or2 0 | 5~——«*Y NOT ROUNDED | OFF) 10 —— 26ADJ VALVE CLEARANCE ADJUSTMENT I TATINSTALLED PAD NUMBER 2 | i ee zo fe ie as 120] 125[190[198_ 140 145 s50[ 155 [160|165 [170[175 120 185] 190] 195) 200| 20 jo] 215] 2701225 126 12529] 135| 40 [145 [150] 155] 100 168 [170175] 190] ras [180] s96] 200] 205] 210 [2¥5] 220] 295) 270 20725 /190} 35} T4045 [150] 165 [160 185 170175 [180] v5 190] 195 230 [236 ‘RECOMMENDED CLEARANCE : 475 [a0 [185 [790 [¥95 [7007706 80 68 [190 [195 ]2001205 270 185 90 [15 |200]205]210 215 Fas |i60 |i55] 160] 65 170 175 190 195 [200 [205 210 215] 220 'i50 65 [160] 165170] 175 160 186 200 [20s [210 215220] 225 (0.43 ~0.47 | 50 88 [160 [765]170] 175 [160185 190 195/200 |20s [210 [215220225] 709 [c-48~0.02 | 155] 160 [165 [170] 175180 | 185 100195] 200)208 210 [215 220|225| 250235 '0583~0.57 [760/165 170 175 180] ies | 190 195 700|708]710|215|220]225|230| 235] 2<0 '.58-~0.62 [1651170175 180 185] 190 196 |200|205]210] 15 |220) 225230235 a0) '9.63~037 [170/175 [190 |ia5 [190] 195 200 [205] 10] 218] 220 [275 [250] 235] 240) ‘0.88 0.72 [175 180 | 86 190195 [00705 [710/215 [220] 225250 236 280 0.73~0.77 [180] 185 [190 206 210 fa j220 226] 200 [205 240 0.78082 [185] 190 [195 210218 [200236200] 205 [200 [195 !200 216 22026 230|295| 240, 200 05 1220 226 [290295240 "205 [210, 226 790298] 240 [210/215 230 235 a0] [215 [220 235 240 VALVE CLEARANCE (cold) “.08~ 1.12 [215220 225 Eu 0.11-~0.20 mm {0.0043~90,0079 in) RST. [320] 225 250 Example; Installed is 170 TBS 1.22 | 275 [290 [23 Measured clearance is 0.24 mn (0,009 in) Tatar ae Replace 170 ped with 180 pec THT [205] aU IS [aU [Fa] TT TOD] zor rag [140 [145] 160165760] 165 a0 [145 160/155] 160,168 170, EXHAUST eating [A] INSTALLED PAD NUMBER _ctenwante_ [729] [135 195] 140 [vas [960 [66 [180] 165 [170 [476] 100] 186 190] 195 [200] 205] 270275 [azo [as 230256 [220| [o0o~o.02 120/128 [130]138, 140] 148 [180] 155 160] 165 170175) 180] 185,100 195 [200] 205 [210 216 0.03=0.07, 1201125 [190 138 [:40[ 145 150 [166{160| 165| 70] 175/190 195{ 10/195 [200]206) 210| 215 220) 0,080.12, 10,125 10/195 [140/145 | 180/165 [160] 16511 70|178| 160] 185] 190] 195) 200205 [2t0l 215 220|225 9.13~0.17 [i20 125 20] 125 |140 (1481 160 [155| 180 [465] 170/175] 1a0| 185] 160] 195] 200| 205210 2ts| 720] 208 [220 10.18~0.20 | [72 |126 /190[ 196 [140145 160] 165 160] 165]170|175] 120| 105) 190] 195) 200) 208 210245 [220] 226] 2301296 10.21 ~0.30. RECOMMENDED CLEARANCE Sa ae ae Sea 7016 a0 [30202 2 zoe Aa] poig3-0187 [190] 1.36] 146][145 [160165 |160 165 |170/¥78/¥80]185] 190|195| 2004 208 /210| 215] 220| 2261230] 735| 240 (0.38~0.42 | 135/140 [145 (160 |165 [160 105 170 175 120188 190] 195) 200,205] 210[275|220] 226| 230) 235 240) [9430.47 | 140] 145160 |155 160|105|170|+75] 120 88 199| 195 |200| 208 210218 |270l 281250 | 238) 20 48 ~0352 145] 150 155 [60168170175 [1018 |100[195|200|205 210| 215220278 a0| ae 0530.57 | 180] 15 [60 |i65 [170175] 129185] 19 |185[ 200 [208] 210| 215 |200| 5 290] 6] 240 08-0162 135[ 100 165 [170175120390 195 [200 0s [ 210/21 220/208] 250|256 240 0.3037 [ To0| 185170 [75 1 | 185/190) 198 200|205|210| 16] 990 226{ aot 29620 8.80.77 105]170]175 [eo [ts 100 | 135 [200 [2s 210215 [220 298 |200|238] 0, 30.77 7o[175 6 [e510 195200 [ans |ao |ate| 220/205] 00 [206 |2a6| 8.18~0382| 175/180 |105 [90 [08|200|208 21016 220/225 | 230] 295 260 @3~0.87 | T80[ 185190 105 [0 905 ato l2T5,200|225/ 200/735 240] 190195 [00 os ava |2¥s [zo 795290235] 940 [i95| 210 215220 95|200| 236/290 "200/205 [210 v5 [00 zz [200 [70520 205 20 [ot p20 5 [390 [28 240 108~1.2 g08 210 [275220250 295200 SA9=117- 910|375 20 98 a0 35 200, VALVE CLEARANCE old) 220226 fo 5 oa0, 0.21~0,30 mm (0.0083~ 0.018 in) 4.28 1.27 | 2201226 [230 1735 [240 Example: installed is 175 1812 | 5] 20 228 fo, Measured clearance is 0.35 mm (0.014 in) Replace 178 pad with 185 pac 27VALVE CLEARANCE ADJUSTMENT Q EXAMPLE: Installed pad number = 148 (1.48 mm) Rounded off digit = 150 NOTE: ee Pads can only be selected in 0.05 mm (0.002 in) increments, Locate the “Rounded off Pad Number” on the chart, and then find the measured valve clearance. The point where these coordinates intersect is the new pad number, NOTE: Use the new pad number as a guide only as the number must be verified. 4, Install: New pad D Valve lifter @ NOTE: Apply molybdenum disulfide grease to the pad. 5. Install: ‘Camshafts ‘©Cam chain sprockets, ‘°Camshaft caps NOTE: Refer to CAMSHAFT step 3 to 27 of ENGINE ASSEMBLY AND ADJUSTMENT (CHAPTER 3). 6. Measure: Valve clearance Valve clearance verification steps: Follow the valve clearance measurement steps. elf the clearance is incorrect, repeat all Adjusting Pad Replacement steps until the proper clearance is obtained. 20INSP DJ CARBURETOR SYNCHRONIZATION 29 If the clearance is correct, follow the As mbly step Assembly, 1. Reverse removal steps, 2. Inspect: Head cover gasket ‘Crankshaft end cover O-ring @ Plug screw O-ring @ Damaye > Replace. 3, Tighten: )| Cylinder Head Cover: 10 Nm (1.0 m-kg, 7.2 ftlb) 4. Fill Coolant Coolant Amount: 2.3 L (2.0 Imp at, 2.4 US at) CARBURETOR SYNCHRONIZATION Carburetors must be adjusted to open and close simultaneously. NOTE: Valve clearance must be set properly before synchronizing the carburetors. 1, Remove: Seat #Side covers Front fuel tank mounting screws © ‘Rear fuel tank mounting bolt @ *Piare © Mounting rubber @ sHose ©INSP CARBURETOR SYNCHRONIZATION | ADJ 2, Remove: Vacuum plugs (0D) 3, Install: ‘Vacuum Gauge (90890-03094) Start the engine and let it warm up. Adjust: idle speed Turn throttle stop screw to adjust. 1,000 + 50 r/min ge 6. Adjust: ‘*Carburetors synchronization Carburetor synchronization adjustment steps: Lift up the front of fuel tank Synchronize carburetor No. 1 to carbure- tor No, 2 by turning synchronizing screw until both gauges read the same. ‘Racing the engine for less than a second, two or three times, and check the syn-| chronization again. Vacuum Pressure at Idle Speed: 26.66 + 0.6 kPa (200 = 5 mm Hg, 7.87 + 0.2 in Hg) Vacuum Synchronous Difference: 1.33 kPa (10 mm Hg, 0.4 in Hg) ‘Repeat the above steps to synchronize carburetor No. 4 to carburetor No, 3 by turning synchronizing screw @ until both gauges read the same, ‘Repeat the same steps to synchronize No. 2 carburetor to No. 3 carburetor by turn- ing synchronizing screw @ until both gauges read the same. 7. Adjust eldle speed 8. Install ‘¢Fuel tank mounting bolts ‘Side cover Seat *Vacuum plugs 240INSP. SPARK PLUG/ ADJ CRANKCASE VENTILATION SYSTEM SPARK PLUG 1, Remove: *Lower cowlings Spark plug 2. Inspect: Electrode Wear/Damage > Replace ‘Insulator color ® 3. Measure: Plug gap Out of specification Regap. Use a Wire Gauge of Fesler Gauge. YAS] spark Plug Gap: (a 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clean the plug with a spark plug cleaner if necessary. Standard Spark Plug: ORBES-L (NGK) X24ESR-U (ND) Before installing a spark plug, clean the gasket surface and plug surface, 4, Tighten: ‘Spark plugls) (6) ) Spark Plug: 17.5 Nm (1.75 mkg, 12.5 ft-lb) NOTE: Finger-tighten @ the spark plug(s) before torqu. ing @ to specification, CRANKCASE VENTILATION SYSTEM 1. Remove: Seat ‘Side cover Fuel tank 2. Inspect: *Crankcase ventilation hose @) Cracks/Damage + Replace.FUEL LINE/INTAKE MANIFOLD/ [INSP EXHAUST SYSTEM/IDLE SPEED FUEL LINE 1. Remove: Fuel tank 2, Inspect: Fuel hoses Cracks/Damage » Replace, INTAKE MANIFOLD 1, Tighten Carburetor clamps Carburetor joint bolts 2. Inspect: Carburetor joint Gaskets Cracks/Damage ~ Replace. EXHAUST SYSTEM 1. Inspect: ‘Exhaust pipe gasket(s) © Damage > Replace, Exhaust gas leakage + Repair. 2. Tighten: Exhaust Pipe Flange Nut @ : 10. Nm (1.0 m-kg, 7.2 ftlb) Muffler Stay Bolt @ 25 Nm (2.5 m-kg, 18 ft-lb) Muffler Clamp Bolt @ 20 Nm (2.0 m-kg, 14 ft.lb) Muffier/Rear Footrest Bolt © : 42 Nm (4.2 m-kg, 30 ft-lb) IDLE SPEED 1. Warm up engine for a few minutes. 2. Adjust: ‘Idle speed Turn the throttle stop screw @ clockwise to increase engine speed and counterclock- wise to decrease engine speed. ey Engine Idle Speed: 1,000 « 50 r/min 212INSP ENGINE OIL 243 60"F ‘SAE 201/40 SAE 1004/30 18°C ENGINE OIL At8°C (40°F) or Higher: SAE 20W40 Type SE Motor Oil At 15°C (60°F) or Lower: SAE 10W30 Type SE Motor Oit NOTE: Recommended engine oll classification; AP! Service "SE", "SF" type or equivalent (eg. “SF-SE", "SF-SE-CC”, “SF-SE-SD” ete,). Oil Level Measurement 1. Check: Oil level Oil level measurement steps: Place the motorcycle on the main stand, Warm up the engine for a few minutes, Stop the engine. ‘Observe the oil level through the level win- dow located at the lower part of left side crankcase cover. Oil level low > Add oil to proper level. NOTE: Position motorcycle straight up when check- ing oil level; a slight filt to the side can pro- duce false readings. ‘Wait 2 few minutes until level settles before checking. Oil level should be between maximum and minimum marks. Q Level window @ Maximum ® Minimum Oil Change (Without filter change) 1, Warm up engine for several minutes. 2. Place a receptacle under the engine. 3. Remove: *0il filler capINSP ENGINE Olt [ADJ 4, Remove: Drain plug © Drain the engine oil 5. Tighten: Drain plug © & ){ Oil Drain Plug: 43 Nm (4.3 m-kg, 31 ftlb) 6. Fill: *Crankease Recommended Engine Oil: 2.70 L (2.35 Imp qt, 2.85 US qt) Do not allow foreign material to enter the crankcase. 7, Install: Filler cap Oil Change (With filter change) Follow the “Oil Change (without filter change)’” steps 1-4, Then proceed as follows: 1. Remove: Bolt © °0il filter cover @ Spring ‘Washer Oil fitter Inspect: O-rings @ Gracks/Damage + Replace. 3. Install: eOil filter © Replace periodically Washer ® Spring © O-rings © Oil filter cover © *Bolt © Drain plug Drain Plug: 43 Nm (4.3 m-kg, 31 ft-lb) Oil Filter Bolt: 15. Nm (1.5 mkg, 11 ft.lb) NOTE: Mesh the oil filter cover projection @ with the crankcase slot.Q| IGNITION TIMING CHECK 4, Fill: *Crankease Recommended Engine Oil: 3.0 L (2.6 Imp gt, 3.1 US gt) 5. Warm up engine for a few minutes, then stop engine. 6. Observe: Oil level Check il pressure after replacing engine oil as follows: *Slightly loosen the cylinder head. ‘Start the engine. Keep it idling until oil begins to seep from the loosened oil gallery bolt. ‘Turn the engine off, and tighten the oil gallery bolt to specification, G | Oil gallery Bott: 10 Nm (1.0 m-kg, 7.2 ft-Ib) Turn off engine immediately if no oil seeps from oil gallery bolt after one minute to prevent engine seizure. Locate and resolve problem, then recheck oil pressure, il gallery bolt @ in the IGNITION TIMING CHECK 1. Remove: Plug screw 2. Connect: ‘#Timing Light (90890-03109) © (10 the No. 1 cylinder spark plug lead) 3. Warm up the engine and allow it to idle at ‘the specified speed. Use the tachometer, 74g] Engine ae Speeds 1,000 + 50 r/minCOMPRESSION PRESSURE MEASUREMENT K Q 4. Observe: Stationary pointer D The stationary pointer should be within the “TT” @ mark on the crankshaft web. Out of range/Unsteady + Check pick up assembly for tightness and/or damage. 5. Install Plug screw COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in performance loss and may indicate leaking valves or worn or damaged piston rings. 1. Measure: Valve clearance 2. Warm up engine for several minutes, then stop the engine. 3. Remove: Spark plugs 4. Connect: ‘Compression Gauge (90890-03081) 5. Measure: Compression NOTE: Tum over engine with the electric starter with choke and throttle valve wide-open until the pressure indicated on gauge can rise no further. Compression should be within the specified levels. Compression Pressure (at sea level): Standard... 1,079 kPa (11 kg/em?, 156 psi) Minimum ... 883 kPa (9 kg/em?, 128 psi) 1,17 kPa (12 kg/em?, 171 psi) Maximum NOTE:. ifference between the highest and lowest cylinder compression readings must not vary more than the specified value, 216INSP Q ADJ COOLANT LEVEL ifference Between Each Cylinder: Less than 98 kPa (1 kg/cm, 14 psi) WARNING When cranking engine, ground spark plug wires to prevent sparking. Compression test steps (betow minimum levels): ‘Squirt a few drops of oil into cylinder. ‘* Measure compression again. Reading Diagnosis Higher than without oil Worn cylinder, Same as without oil | eDefective piston, ring(s), valve(s) and cylinder head gasket ‘*Improper valve timing and valve clearance ‘Compression test steps (above maximum levels): ‘Check cylinder head, valve surfaces, or pis- ton crown for carbon deposits. COOLANT LEVEL 1, Check: Coolant level (of reservoir tank) Level low > Add tap water (Soft water), Coolant reservoir tank cap ULL" tevel OW" ievel 290FUEL COCK NST QI Do not remove the radiator cap when the engine is hot. ae Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can’t get soft water. Total Amount: (Including all routes) 2.59 L (2.28 Imp at, 2.74 US qt) Reservoir Tank Capacity: 0.29 L (0.26 Imp at, 0.31 US at) From LOW to FULL Level: 0.15 L (0.13 Imp at, 0.16 US at) CHASSIS FUEL COCK Removal and Inspection 1. Inspect: ¢Fuel cock operation Leakage/Contamination + Disassemble. 2. Remove: *Seat Side cover Fuel tank Position tank so that fuel when cock is removed. Fuel cock © not spill 3. Inspect: Filter screen @ Contamination -> Replace fuel cock. O-ring @ Damage + Replace Gasket surfaces ® Seratches/Corrosion -» Replace. NOTE:. Drain and flush fuel tank if abrasive damage to ‘any components is evident.INSP AIR FILTER/ ADJ FRONT AND REAR BRAKE 4, Assemble: Fuel cock stall Fuel cock (on to fuel tank} 5. AIR FILTER 1, Remove: Seat Fuel tank ‘Air filter case cover ® ‘Air filtor eloment SeAOTION:: The engine should never be run without the air/filter olement installed; excessive piston and/or cylinder wear may result, 2. Inspect: Element Clogging + Blow compressed air. Damage -> Replace NOTE: Below compressed air from outside the filter towards the inside so that dirt will be blown out of filter element. 3. Install: ¢Removed parts NOTE: _ qe eer eee Be sure that the air filter is properly seated against the filter case. FRONT AND REAR BRAKE Brake Fluid Inspection 1, Cheek: ‘Brake fluid lovel Fluid at lower level > Replenish. @D Front brake fluid lower levelINSP FRONT AND REAR BRAKE ADJ i CG Use only designated qualty brake fluid to avoid poor brake performance, Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance. Bo sure that water or other contaminants do not enter master cylinder when refilling. Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts. © Rear brake fluid flower level Brake Pad Inspection 1. Depress the brake lever. 2. Inspect: Wear indicator Indicator almost contacts disc > Replace pads. YAS] erake Pad Wear Limit O: FAQ] 05 mm (0.019 ® Brake pad woar indicator Front Brake Lever Free Play Adjustment 1, Loosen: ‘Adjuster locknut @ 2. Adjust: Free play Turn the adjuster @ until the free play @ is within the specified limits, [AA] Front Brake Lever Free Play: (z 2 ~ 5 mm (0.08 ~ 0.2 in) ECAUTION: SRE. Proper lever free play is essential to avoid excessive brake drag. 3. Tighten: Adjuster locknut 220J Q DRIVE CHAIN J 221 Rear Brake Pedal Height Adjustment 1, Check: ‘Brake pedal height Out of specification + Adjust. 2. Remove: eFootrest @ and brake pedal @ assembly. 3. Remove: Brake switch assembly @ 4, Loosen: ‘* Adjuster locknuts @ 5. Adjust: ‘*Brake podal height. Turn the adjuster @ until the brake pedal position is at the specified height. 35 mm (1.4 in) Below the Top of the Footrest 4 Brake Pedal Height: Gs After adjusting the brake pedal height, visually check the adjuster end @ through the hole of the joint holder @ . The adjuster end must appear within this hole. Rear Brake Light Switch Adjustment 1, Remove: Footrest and brake pedal assembly 2, Hold the switch body @ with your hand so it does not rotate and turn the adjusting nut @. DRIVE CHAIN Drive Chain Slack Cheok 1, Measurt ‘Drive chain deflection Motorcycle is on the centerstand Out of specification > Adjust.DRIVE CHAIN NS Drive chain slack measurement steps: ‘Turn the rear wheel several times. ‘Check the chain slack several times to find the point where the chain is the tightest, ‘Check the chain slack when the wheel is in this “tight chain” position. Drive Chain Deflection (1 15 ~ 20 mm (0.6 ~ 0. in) ‘If the chain deflection exceeds Specification, adjust the chain slack. Drive Chain Slack Adjustment Drive chain slack adjustment steps: ‘*Remove the cotter pin D ‘Loosen the axie nut @ ‘Loosen the locknuts ® ‘Adjust chain slack by turning the adjuster nut ®. Adjuster Nut Chain Slack Tum clockwise Tighten Turn counterclockwise Loosen Turn each nut exactly the same amount to maintain correct axle alignment. Excessive chain tension will overload the ‘engine and other vital parts; keep the tension within the specified limits, (There are marks on each side of the swing arm @ and on each chain puller alignment.) 2.22‘Tighten the axle nut and locknuts. Rear Axle Nut: 107 Nm (10.7 m-kg, 77.4 ft-lb) Locknut: 15 Nm (1.5 m-kg, 11 ft-lb} NOTE: Do not toosen the axle nut after torque tightening, If the axle nut groove is not aligned with the wheel shaft cotter pin hole, align groove to hole by tightening up on the axle nut. ‘install a new cotter pin @ into the axle nut and bend the end of cotter pin as shown, SONS Always use a new cotter pin on the axle nut. 223 Drive Chain Cleaning and Lubrication 1. Drive chain cleaner Drive Chain Cleaner: Kerosene “CAUTION: Do not use steam cleaning, high-pressure washes, and certain solvent of O-ring (@ damage may occur. 2. Drive chain lubricant SAE 30~ 50 Motor oil or chain lubricants for “CABLE INSPECTION AND LUBRICATION/ BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS/| INSP_ CENTERSTAND AND SIDESTAND| ADJ Do not use any other lubricants or O-rings damage may occur. CABLE INSPECTION AND LUBRICATION Cable inspection and lubrication steps: ‘Remove the two grip end that secure throt- tle to handlebar. Hold cable end high and apply several drops of lubricant to cable. Coat metal surface of disassembled throttle ‘twist arip with suitable all-purpose grease to minimize friction. ‘*Check for damage to cable insulation. Replace any corroded or obstructed cables. ‘Lubricate any cables that do not operate smoothly. SI Ss SAE 10W30 Motor Oil BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS Lubricate pivoting parts of each lever and pedal. >] NS SAE 10W30 Motor Oil CENTERSTAND AND SIDESTAND Lubricate conterstand and sidestand at their pivot points. mo Ss SAE 10W30 Motor Oil 224ADJ FRONT FORK OIL CHANGE 228 FRONT FORK OIL CHANGE CGS Securely support the motorcycle so there is no danger of it falling over. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove: Air valve cap NOTE: Keep the valve open by pressing it for several seconds so that the air can be let out of the inner tube. 3. Loosen: ‘¢Front fork upper pinch bolts D 4, Remove: Fork cap bolts @ Collar @ 5, Place receptacle under each drain hole. 6. Remove: Drain screws Drain the fork oil. (etn Do not allow any oil to contact the disc brake components. If oil is discovered, be sure to remove it, otherwise diminished braking capacity and damage to the rubber components of the brake assembly will occur. 7. After most of the oil has drained, slowly raise and lower outer tubes to pump out remaining oil, 8. Inspect: Cap bolt O-ring Drain screw gaskets Wear/Damage + Replace,FRONT FORK AND REAR SHOCK ABSORBER ADJUSTMENT ADJ Q 9. Install: ‘Drain screws 10. Fill: Front forks Front Fork Oil Capacity (each fork): 408 cm? (14.4 Imp 02, 13.8 US oz) Recommended Oil: Fork oil 10W or equivalent After filling pump the forks slowly up and down to distribute the oil 11. Install: Collar @ ‘Cap bolts @ ‘Pinch bolts @) Cap Bolt: 23 Nm (2.3 m-kg, 17 ftib) Front Fork Upper Pinch Bolt: 20 Nm (2.0 m:kg, 14 ft-lb) 12. Fill: Front forks (with specified amount of air.) Refer to “Front fork and rear shock absor- ber adjustment”, Maximum Air Pressure: 39 kPa (0.4 kg/cm? , 5.7 psi) Do not exceed this amount. FRONT FORK AND REAR SHOCK ABSORBER ADJUSTMENT Rear Shock Absorber Adjustment CS This shock absorber contains highly pressu- rized nitrogen gas Read and understand the following information before handling the shock absorber. The manufacture cannot be 228INSP ADJ FRONT FORK AND REAR SHOCK ABSORBER ADJUSTMENT held responsible for property damage or per- sonal injury that may result from improper handling. Do not tamper with or attempt to open the cylinder assembly. *Do not subject shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure, *Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. Rear Shock Absorber Adjustment 1. Adjust: Spring preload ‘*Damping ® The rear shock absorber of this model features a spring preload adjuster which is a combined spring preload and damping adjuster. Normal adjustment can be made by turning this spring preload adjuster, whereas damping adjustment can only be made by the damping adjuster. Tum spring preload adjuster and damping adjuster from 1 to 5, or 5 to 1 in progressive steps (1, 2, 3, 4, 5). Never turn adjuster diractly from 1 to 5, or 5 to 1. ‘Spring preload adjustment steps: 1. Elevate the wheel by placing the motor cycle on the centerstand. 2. Lift up the adjuster cover @ , and turn! the spring preload adjuster @) so that the| damping adjuster turns with it. Hard > Turn the adjuster clockwise, Soft > Turn the adjuster counterclockwise. 227FRONT FORK AND REAR SHOCK ABSORBER ADJUSTMENT | ADJ Damping adjustment steps: Soft + Turn the adjuster @ clockwi Hard > Turn the adjuster counterclockwise. Front Fork Air Adjustment 1. Elevate the front wheel by placing a suitable stand under the engine. NOTE: Be sure there is no weight on the front end of the motorcycle and the fork tube is at room temperature when sir pressure is checked and adjusted 2, Remove: ‘Air valve cap 3. Measure: Air pressure Use an air gauge and adjust as needed. NOTE: Increased air pressure causes stiffer suspension; decreased pressure causes softer suspension. Air pressure adjustment ‘To increase air | Use manual air pump or pressure pressurized air supply. To decrease air | Release air by pushing pressure valve pin. ‘Standard Air Pressure: 0 kPa (0 kg/em? , 0 psi) Maximum Air Pressure: 39 kPa (0.4kg/em? , 5.7 psi) Never exceed maximum pressure or oil seal damage may occur. 4, install: Air valve cap 228INSP Q ADJ STEERING HEAD Recommended combinations of the front fork and the rear shock absorber settings: Use this table as a guide for specific riding and motorcycle load conditions. Front fork Rear sock absorber Loading condition - With accessories [With accessories, ing prel i , Airpressure _[SPrina preload) Damping), ger] With and equipment, adjuster | adjuster Ipassonger| equipment _| and passenger 1.2 iz | o 0~ 39 kPa Seeeceae eee 3 3A (0~ 0.4 kglem?, 7 — - —_| 0~5,7 psi) 23 23 - 4,5 4,5 J STEERING HEAD Steering Head Inspection 1. Elevate the front wheel by placing a suitable stand under the engine, 2. Chee! Steering assembly bearings Grasp the bottom of the forks and gently rock the fork assembly back and forth. Looseness-> Adjust steering head. Steering Head Adjustment 1. Remove: Handlebar assembly 2. Loose ‘Upper front fork pinch balt @ 3. Remove: #Steering stem nut © Handle crown @ #Lock washer # Upper ring nut WasherWHEEL BEARINGS / [INSP TUBELESS TIRES AND ALUMINUM WHEELS | ADJ | 4, Tighten: ‘*Lower ring nut O Use the Ring Nut Wrench @ (90890-01268), Lower Ring Nut: 4st: 52 Nm (5.2 m-kg, 37 ft-lb) 2nd: Loosen it completely 3rd: 3 Nm (0.3 m>kg, 2.2 ft-lb) 5. Install: ‘*Washer ‘Upper ring nut (Finger tighten} * Lock washer Handle crown 6. Tighten Steering Stem Nut: 110 Nm (11 m-kg, 80 ft-1b] Upper Front Fork Pinch Bolt: 20 Nm (2.0 m-kg, 14 ftlb) WHEEL BEARINGS Front Wheel Bearings 1. Check’ Front wheel bearings Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fender while spining the wheel. Excessive vibration > Replace bearings. Rear Wheel Bearings, 1, Remove: ‘Rear wheel 2. Check: ‘Bearing movement Roughness + Replace bearings. TUBELESS TIRES AND ALUMINUM WHEELS WARNING Do not attempt to use tubeless tires on a wheel designed for tube type tires only. Tire failure and personal injury may result from sudden deflation. 2.90Ql TUBELESS TIRES AND ALUMINUM WHEELS Wheel Tire Tube type Tube type only Tubeless Tube type or tubeless 266 231 Be sure to install the correct tube when using tube type tires, A Tire bless tire Bl Wheet ©) Tube type tire Q Alrvawve ® Aluminum wheel (tubeless tye) © Ture @® Aluminum wheel (tube type) This motorcycle is fitted with “V"" range tires (for super high speed running). The following points must be observed in order for you to make fully effective use of these tires. Never fail to use “V" range tiras in tire ro- placement. “S" or “H’ tires may be in danger of bursting at super high-spoods. ‘eNew tires have a relatively poor adhesion on the road surface so do not allow them to be subjected to high speed load from maximum. speed until after a break-in run of approx, 100 km (60 mi). ‘*Before any high-speed runs, remember to allow a sufficient warm-up time for the tires. ‘*Always use the correct tire inflation pressure according to the operating conditions. Always perform the following steps to ensure safe operation, maximum tire performance, and sTire pressure Out of specification + Adjust,TUBELESS TIRES AND ALUMINUM WHEELS Basic weight With oil and full 232 kg (511 Ib) fuel tan Maximum load 213 ka (470 ib) Cold tire pressure | Front Rear T96kPa_| 225 kPa (rag) oa (2.0 kg/om? , |(2.3 kg/em?, 28 psi) ‘| "32 psi) 90 kg (188 6) ~ | 220 KPa | aaa KPa (223 kg/cm? ,|(2.9 kg/em*, 32 psi) 42 psi} 226 kPa | 245 kPa High speed riding |(2.3 ka/cm?, (2.5 ka/om?, 32 psi) 36 psi ¥ Load is the total weight of cargo, rider, passenger, and accessories, Maximum load* 2. Inspect: Tire surfaces Wear/Damage -> Replace. imum Tire Tread Depth: (Front and Rear) 1.0 mm (0.04 in) ® Tread depth ® Side wall ® Wear indicator 3. Inspect: Aluminum wheels Damage/Bends > Replace. Never attempt even small repairs to the wheel. NOTE: eee EEE EEE Ee Ee EEE Always balance the wheal when a tire or wheel has been changed or replaced, Ride conservatively after installing a tire to allow it to seat itself properly on the rim. 2.92CLUTCH FLUID/ BATTERY vier Leva, 1) 2.93 CLUTCH FLUID 1. Check: Clutch fluid level Fluid at lower level + Replenish. @D chuten tui Clutch Fluid: DOT #3 NOTE: Be sure that: ‘Water does not enter the master eylinder when refilling. Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding. ELECTRICAL BATTERY 1. Check: Fluid level Incorrect > Refill Fluid level should be between upper and lower level marks. ® Upper tev @® Lower evel Refill with distlles water only; tap water con- tains minerals harmful to a battery. 2. Connect: ‘Breather pipe © Be sure the hose is properly attached and routed, 3. Inspect: ‘Breather pipe Obstruction + Remove Damage + Replace. ® Pass through inside of battery case © Pass through inside of swingarm. @ Pass through the connecting rod holeBATTERY INSP. | Always charge a new battery before using it to ensure maximum performance. Charging Current: 1.4 amps/10 hrs Specific Gravity: 1,280 at 20°C (68°F) Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: *Avoid bodily contact with electrolyte as it can cause severe bruns or permanent eye injury. Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): ‘*SKIN-Flush with water. ‘SEYES-Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): Drink large quantities of water or milk follow with milk of magnesia beaten egg, or vegetable oil, Get immediate medical attention. Batteries also generate explosive hydrogen gas, therefore you should always follow these preventive measures: Charge batteries in a well-ven Keep batteries away from fire, sparks, or ‘open flames (e.g, welding equipment, lighted cigarettes, etc.) DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 2.04ADJ HEADLIGHT HEADLIGHT Headlight Bulb Replacement 1. Disconnect: Headlight coupler @ ‘*Rubber cover @ (Right side only) 2, Unhook: ‘Bulb holder spring (1) 3. Remove: “Bulb @ 4, Install: Bulb (New) WARNING Do not touch headlight bulb when it is on as bulb generates enormous heat; keep flammable abjects away. Avoid touching glass part (D of bulb, Alsokeep it free form oil otherwise, transparency of glass, bulb life and illuminous flux will be adversely affected. If oil gets on bulb, clean it with a cloth moistened thoroughly alcohol or lacquer 5. Hook ‘Bulb holder spring. 6. Connect: ‘Rubber cover Headlight coupler Headlight Adjustment Horizontal adjustment 1, Rotate: ‘* Horizontal adjusting screw @) Horizontal adjustment of head light beam Adjusting screw Beam directior Turn elockwise A Right Turn counterclockwise LeftINSP Fuse | ADJ | Vertical adjustment 1. Rotate: Vertical adjusting screw @ Vertical adjustment of headlight beam Adjusting screw Beam direction Tur clockwise + To raise Tur counterclockwise 4 To lower FUSE The fuse panel is located under the seat. 4. Inspect: oF uses Defective > Replace Blown fuse inew! > Inspect circuit. NOTE: Install new fuses of proper amperage. Description | Amperage | Quantilty @Main | 30a 1 @ Head 15a 1 @ Signal 108 1 @ Ignition rwa | 1 | [@Fan 7 70a 1 SOA ett OReserve 168A 1 1 108 Blown fuse remedy steps: Turn off ignition and the circuit. ‘Install a new fuse of proper amperage. Turn on switches to verify operation of electrical device. elf fuse blows immediately again, check in question. ES Do not use fuses of higher amperage rating than recommended. Extensive electrical system. damage and fire could result from substitution of a fuse of improper amperage.[ENG |] ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: It is not necessary to remove the engine in order to remove the following components: Piston Clute ‘Carburetor *AC Generator PREPARATION FOR REMOVAL 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2, Use proper tools and cleaning equipment. Refer to CHAPTER 1, “SPECIAL TOOL". NOTE:— ee When disassembling the engine, keep mated parts together. This includes gears, cylinders, pistons, and other parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 3. During the engine 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 reinstalled in the engine. 4, Drain engine oil completely. 8. Drain coolant completely.ENGINE REMOVAL ENG SEAT AND FUEL TANK 1, Remove! eseat @ ‘side covers (Left/Right) @ 2. Turn the fuel cock to the OFF” (0 position. 3. Disconnect: Fuel pipe @ #F uel sender lead coupler ® 4, Remove: Front fuel tank mounting screws ® ‘Rear fuel tank mounting bolt @ Plate @ ‘Mounting rubber ® Hose © Fuel tank AIR CLEANER AND CARBURETOR 1, Loosen Air cleaner joint clamp screw 2, Disconnect: ‘*Crankcase ventilation hose @) ‘Air vent hose @ 3. Remove: Air cleaner assembly @ 4. Loosen: #Carburetor joint clamp screw © 6. Disconnect: ‘Fuel hose @ 32=a o Zi 6. Disconnect: - sThrottie cable ® *Choke cable @) 7, Remove: *Carbure air vent hose @ Carburetor assembly EXHAUST PIPE AND MUFFLER, 1. Remove: ‘* Exhaust pipe flange bolts NOTE: *Remove the #2 and #3 exhaust pipe before #1 *Exhaust pipe number @ is mentioned at it’s tail, 2. Loosen: eMuffter clamp bots © 3, Remove: ‘eMuffler stay bolt @ eMuttler/Footrest bolt ® ‘Exhaust pipe Muffler RADIATOR HOSE AND SPARK PLUG LEAD 1, Remove: ‘*Lower cowling 2. Remove: ‘Air battle plates DENGINE REmovaL | ENG — 3, Remove: Spark plug leads @ Radiator lower bolts @ ‘Radiator hose @) 4. Loosen: Radiator upper bolts @ 5, Remove: *Radiator hose *Middle radiator pine @ 6. Remove: Lower radiator pipe *0-ring @ 7, Disconnect: ‘Upper radiator hose @ 8, Remove: Upper radiator pipe © DRIVE CHAIN SPROCKET 1. Remove: Cotter pin © 2. Loosen: Rear axle nut @ *Locknut @ Adjuster @ ‘*Drive chain 343, Remove: # Left crankcase cover Nut © Lock washer @ ‘Drive sprocket ® ‘Drive chain © LEADS 1. Disconnect: Battery ground lead @ Starter motor lead @ 2. Disconnect: #Pick up coil coupler 3. Disconnect: AC Generator coupler @ ‘*Neutral/Oil leve! switch coupler @ ENGINE REMOVAL 1. Place a suitable stand under the engine. 2. Remove: ‘*Front down tube bolts @. @Middle down tube bolts @ Rear down tube bolts @ ‘*Front upper mounting bolt @ ‘*Front lower mounting bolt ©)ENGINE pisassemaLy | ENG |p 3, Remove: ‘¢Rear upper mounting bolt © ‘*Rear lower mounting bolt @ ‘*Fear upper mounting collar @) ‘*Engine assombly {from right chassis) 4, Remove: ‘*Crankcase ventilation hose @) ‘Air vent hose @ ENGINE DISASSEMBLY CAMSHAFT AND CYLINDER HEAD 1, Remove: Cylinder head cover © Cylinder head gasket @ Spark plug @ 2. Remove: Loft crankshaft end cover @ #Plug scrow @ 3. Install: eLocknut @ Bolt (8mm) D {into left crankshaft end) 4. Turn Crankshaft (Counterclockwise) 5. Align: Crankshaft web “T” mark (With the stationary pointer @ when #1 piston is at TDC on compression stroke.) 36ENG " ENGINE DISASSEMBLY 37 6. Remove: * Tensioner assembly © 7. Remove: ‘*Upper chain guide @ ‘*Exhaust side chain guide @ NOTE: Piston and cylinder can be removed, when necessary, without removing the camshaft. The main steps are as follows, ‘Disconnect the cam chain using Cam Chain Cutter @ (90890-01112) ‘*Remove the cylinder head nuts in the comshaft case using Hexagon Wrench @ (90890-01395) *Remove the camshaft, camshaft case and cylinder head assembly. 8, Remove: ‘#No, 3 intake (1-3) camshaft cap ‘#No. 3 exhaust (E-3) camshaft cap @ENGINE DISASSEMBLY ENG 9, Remove: Sprocket bolts (all) Tur the crankshaft counterclockwise to remove opposite side sprocket bolt. [vc] {-asssasasasadasnansennsssnuasiannsssanainnan If difficult to loosen the cam sprocket securing bolts; hold the 8 mm bolt @ on the left crank: shaft end. 10, Remove Camshaft caps (all) elntake camshaft @ Exhaust camshaft @ Note: ____ Fasten safety wire @ to the cam chain to pre- vent it from falling into the crankcase. Do not rotate the camshaft or valve damage may occur. 11, Remove: #011 pipe union bolts @ Oil pipe 1 @ 38pon 12, Remove: ] ‘*Camshaft case and cylinder head assembly. ENG < ENGINE DISASSEMBLY NOTE: Loosen the nuts in thoir proper loosening sequence, NoTe:—______ Remove the cylinder head nuts in the camshaft case using Hexagon Wrench (1) (90890-01395) 13, Remove: ‘Cylinder head gasket ‘*Dowels @ CYLINDER AND PISTON 1, Remove: ‘*Water jacket joint @ ‘*Coolant feed pipe @ Cylinder @ 2, Remove: Cylinder gasket ‘*Dowels @) a9ENGINE DISASSEMBLY ENG 3, Mark: Pistons {with piston number @_ designations as shown) 4, Remove: Piston pin circlips © NOTE: Before removing piston pin circlip, cover crank case with a clean rag to prevent circlip from falling into crankcase cavity. 5, Remove: #Piston pins © *Pistons @ NOTE:. Remove the piston pin using ® (90890-01304) RIGHT CRANKCASE COVER 1. Remove: ‘®Right crankcase cover assembly. 2, Remove: eGasket © *Dowels @ 340ENG ~~ ENGINE DISASSEMBLY 3. Remove: Breather © # Gasket @ Washer © # Rubber ring *Cover CLUTCH 1, Remove: ‘Clutch spring holding screws © ‘Clutch springs @ Pressure plate @) Push rod #1 @ ‘*Friction plates ® ‘*Clutch plates @ ‘Push rod ball @ ‘Clutch boss securing nut @ *Lock washer © ‘*Clutch boss 0 Washer @ Spacer @ ‘Primary driven gear @ ‘Bearing @ Thrust washer @ Push rod #2 NOTE eee Eee Remove the clutch boss securing nut @ using Universal Clutch Holder @ (90890-04086) NoTe;____ Install the § mm screw (on the spacer @ then remove the spacer with pulling out screw.encine pisassematy | ENG | Quy OIL PUMP AND CHANGE LEVER 1. Remove: *0i! pump assembly @ Gasket @ ‘*Dowel © x Remove: eCirclip © Washer @ ‘Change lever assembly @ ° Remove: #Stopper lever D ‘Shift fork guide bar stopper @ *Spring © STARTER MOTOR AND AC GENERATOR 1, Remove: Starter motor © 2, Remove: enuts D *Generator cover @ sBolts © Generator ©