Yamaha TDM850 1996, Service Manual

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Page 3: ...DM850 96 SERVICE MANUAL 1996 by Yamaha Motor Co Ltd First edition March 1996 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ... is continually striving to improve all models manufactured by Yamaha Modifi cations 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 PARTICULARY IMPORTANT INFORMATION This material is distinguished by the following notation The Safety Alert Symbol means ATTENTION BECOME ALE...

Page 5: ...elp identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an...

Page 6: ...entify the specifications appearing in the text 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Torque 15 Wear limit clearance 16 Engine speed 17 Ω V A Illustrated symbols 18 to 23 in the exploded dia grams indicate the types of lubricants and lubrica tion points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing g...

Page 7: ...MATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INSP ADJ INDEX ...

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Page 9: ...GEN INFO 1 ...

Page 10: ...AL NUMBER 1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL 1 2 ALL REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 HOW TO USE THE CONVERSION TABLE 1 5 SPECIAL TOOLS 1 6 ...

Page 11: ...GEN INFO ...

Page 12: ...ication number is used to identi fy the motorcycle and may be used to register the motorcycle with a licensing authority EB100030 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase The first three digits of the engine serial number indicate the model type the remaining digits are the unit production number MODEL LABEL The model label 1 is affixed to the frame This in for...

Page 13: ...clean all parts and place them in trays in the order of dis assembly This will speed up assembly time and help assure that all parts are correctly rein stalled 5 Keep away from fire ALL REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replace ments Use oil and or grease recommended by Yamaha for assembly and adjustment Oth er brands may be similar in function and ap pearance but inferior ...

Page 14: ...amped letters must be on the side exposed to view When instal ling oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bearings liberally when installing 1 Oil seal Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces 2 Bearing CIRCLIPS 1 All circlips should be inspected carefully before reassembly Always replace ...

Page 15: ... lead to check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect Connector The two connectors click together 7 Check for continuity with a tester If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wireharness For a field remedy use a contact revitalizer avail a...

Page 16: ...TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque mSkg mSkg cmSkg cmSkg 7 233 86 794 0 0723 0 8679 ftSlb inSlb ftSlb inSlb Weight kg 2 205 lb Weight g g 0 03527 oz Speed km hr 0 6214 mph Dis tance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cuSin qt IMP liq gal IMP liq Mi...

Page 17: ...ain axle assembly cover 90890 01304 Piston pin puller This tool is used to remove the piston pin 90890 01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber 90890 01325 90890 01352 Radiator cap tester Adapter This tester is needed for checking the cooling system 90890 01362 90890 01382 Flywheel puller Crankshaft protector These tools are used to remove the A C ma...

Page 18: ...m 90890 03113 Engine tachometer This tool is needed for detecting engine rpm 90890 03141 Timing light This tool is necessary for checking ignition timing 90890 04016 Valve guide remover installer and reamer 5 5 mm These tools are used to remove install and rebore the valve guide 90890 04019 90890 04108 Valve spring compressor Attachment These tools are needed to remove and install the valve assemb...

Page 19: ...1 8 SPECIAL TOOLS GEN INFO Tool No Tool name How to use Illustration 90890 85505 Yamaha bond No 1215 This sealant bond is used on crankcase mating surfaces etc ...

Page 20: ...SPEC 2 ...

Page 21: ...SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 11 ELECTRICAL 2 15 GENERAL TORQUE SPECIFICATIONS 2 17 LUBRICATION POINT AND GRADE OF LUBRICANT 2 18 ENGINE 2 18 CHASSIS 2 19 LUBRICATION DIAGRAMS 2 20 CABLE ROUTING 2 25 ...

Page 22: ...SPEC ...

Page 23: ...c weight With oil and full fuel tank 229 kg Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure STD Starting system Liquid cooled 4 stroke DOHC 5 valve Forward inclined parallel 2 cylinder 0 849 L 89 5 67 5 mm 10 5 1 1 200 kPa 12 kg cm2 12 bar at 300 r min Electric starter Lubrication system Dry sump Oil type or grade Engine oil API Standard API ...

Page 24: ...eduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Spur gear 67 39 1 718 Chain drive 42 17 2 471 Constant mesh 5 speed Left foot operation 37 13 2 846 37 20 1 850 30 21 1 429 27 23 1 174 28 27 1 037 Chassis Frame type Caster angle Trail Diamond 24 5 103 mm Tire Type Size front rear Manufacturer fro...

Page 25: ...ion Suspension Front suspension Rear suspension Telescopic fork Swingarm monocross Shock absorber Front shock absorber Rear shock absorber Coil spring Oil damper Coil spring Gas oil damper Wheel travel Front wheel travel Rear wheel travel 149 mm 144 mm Electrical Ignition system Generator system Battery type Battery capacity T C I digital A C magneto GT12B 4 12 V 10 AH Headlight type Quartz bulb h...

Page 26: ...de diameter Camshaft to cap clearance Cam dimensions Timing chain right 25 000 25 021 mm 24 967 24 980 mm 0 020 0 054 mm Intake A B C Exhaust A B C Camshaft runout limit 35 95 36 05 mm 27 95 28 05 mm 7 9 8 1 mm 35 95 36 05 mm 27 95 28 05 mm 7 9 8 1 mm 35 85mm 27 85mm 35 85 mm 27 85 mm 0 03 mm Cam chain Cam chain type No of links Cam chain adjustment method 82RH2015 138 Automatic Valve valve seat v...

Page 27: ...ce IN EX Stem runout limit 5 460 5 475 mm 5 500 5 512 mm 5 500 5 512 mm 0 010 0 037 mm 0 025 0 052 mm SSS 5 43 mm 5 55 mm 5 55 mm 0 08 mm 0 10 mm 0 01 mm Valve seat width IN EX 0 9 1 1 mm 0 9 1 1 mm 1 6 mm 1 6 mm Valve spring Free length IN EX Set length valve closed IN EX Compressed pressure installed IN EX Tilt li it IN 37 29 mm 37 29 mm 30 39 mm 30 39 mm 10 0 11 6 kg 10 0 11 6 k 35 2 mm 35 2 mm...

Page 28: ...m IN side 20 002 20 013 mm 19 991 20 000 mm 0 15 mm 20 043 mm 19 975 mm Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed 2nd ring Type Dimensions B T End gap installed Side clearance installed Oil ring Dimensions B T End gap installed Barrel 1 0 3 5 mm 0 30 0 45 mm 0 035 0 070 mm Taper 1 0 3 5 mm 0 30 0 45 mm 0 035 0 070 mm 2 00 2 85 mm 0 2 0 7 mm 0 7 mm 0 12 mm...

Page 29: ...tity Warp limit Clutch spring free length Quantity Clutch release method 2 9 3 1 mm 9 1 9 2 1 mm 8 55 mm 6 Outer pull rack pinion pull 2 8 mm 0 1 mm 53 mm Transmission Main axle deflection limit Drive axle deflection limit 0 08 mm 0 08 mm Shifter Shifter type Guide bar bending limit Guide bar 0 1 mm Carburetor I D mark Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot air jet 1 P...

Page 30: ...brication system Oil filter type Oil pump type Tip clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Paper type Trochoid type 0 0 12 mm 0 03 0 08 mm 39 78 kPa 0 4 0 8 kg cm2 0 4 0 8 bar 343 441 kPa 3 5 4 5 kg cm2 3 5 4 5 bar 0 17 mm 0 15 mm Cooling system Radiator core size Width height thickness Radiator cap opening pressure Reservoir tank capacity From low to...

Page 31: ...t arm Shift rod Shift pedal Stopper bolt Flange bolt Nut Bolt Bolt Bolt Nut Flange bolt Flange bolt Bolt Flange bolt Bolt Bolt Screw Flange bolt Bolt Screw Flange bolt Flange bolt Flange bolt Nut Bolt Flange bolt Screw Bolt Flange bolt Flange bolt Flange bolt Screw Flange bolt Flange bolt Flange bolt Flange bolt Flange bolt Flange bolt Bolt Screw Nut Screw Nut Bolt Bolt Flange bolt Flange bolt Nut...

Page 32: ...o be tightened Part name Thread size Q ty Tightening torque Remarks g size y Nm mSkg Stator coil Starter motor Thermo switch Thermo switch housing Screw Flange bolt M6 M6 M6 PT1 8 3 2 1 1 7 10 28 15 0 7 1 0 2 8 1 5 Crankcase tightening sequence ...

Page 33: ... suspension Shock absorber travel Spring free length K1 K2 Fitting length K1 K2 Spring rate K1 K2 Stroke K1 K2 Optional spring 47 mm 144 mm 69 mm 136 mm 65 mm 260 N mm 26 0 kg mm 182 N mm 18 2 kg mm 0 30 30 47 mm No Swingarm Free play limit end side 1 mm 0 3 mm Front wheel Type Rim size Rim material Rim runout limit radial lateral Cast wheel 18 MT3 00 Aluminum 1 mm 0 5 mm Rear wheel Type Rim size ...

Page 34: ... 15 8 mm 33 96 30 23 mm DOT 4 0 2 mm 0 5 mm 0 5 mm Rear disc brake Type Disc outside diameter thickness Disc deflection limit Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single 245 5 mm 5 5 mm 5 5 mm 14 mm 42 8 mm DOT 4 0 15 mm 0 5 mm 0 5 mm Controls Brake lever slack at lever pivot Brake pedal height Brake pedal slack C...

Page 35: ...cuum pump stay and vacuum pump Vacuum pump stay and frame Fuel cock and frame Tail cover and frame front Battery box and frame Coolant reservoir tank and frame Rear fender and frame Taillight bracket and frame Taillight Rectifier regulator and cowling stay Side cover and frame Rear fender stay and taillight bracket Sidestand Sidestand bolt and locknut Footrest bracket and frame Rear footrest brack...

Page 36: ... bolt Front wheel axle pinch bolt Brake hose joint and brake hose Chain puller and locknut Front fender and front fork Brake hose joint and front fork Rear brake caliper and brake hose joint M10 M8 M10 M8 M10 M8 M10 M8 M6 M6 M10 35 20 60 6 30 19 14 16 9 10 40 3 5 2 0 6 0 0 6 3 0 1 9 1 4 1 6 0 9 1 0 4 0 1 First tighten the ring nut approximately 48 Nm 4 8 mSkg by using the torque wrench then loosen...

Page 37: ...0 C Spark plug cap Type Resistance Resin type 10 kΩ Charging system Type Model manufacturer Normal output Stator coil resistance A C magneto LNZ29 NIPPONDENSO 14 V 25 A at 5 000 r min 0 23 0 35 Ω at 20 C W W Rectifier Model manufacturer Withstand voltage SH650A 12 SHINDENGEN 240 V Battery Specific gravity 1 320 Electric starter system Type Starter motor Model manufacturer Output Armature coil resi...

Page 38: ...cycle min 21 W 2 3 4 W Starting circuit cut off relay Model manufacturer Coil winding resistance Diode G8R 30Y F OMRON 180 X 270 Ω at 20 C Yes Thermostatic switch Model manufacurer 2EL NIHON THERMOSTAT Thermo unit Model manufacturer 11H NIPPON SEIKI Circuit breakers Type Amperage for individual circuits Main fuse Headlight fuse Signal system fuse Ignition fuse Radiator fan fuse Reserve fuse Reserv...

Page 39: ...k To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Components should be at room temperature A Distance across flats B Outside thread diameter A Nut B Bolt General torque specifications Nut Bolt Nm mSkg 10 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 m...

Page 40: ...pin Cylinder Piston ring oil ring Connecting rod bolt Crankshaft journal Balancer bearing shaft Camshaft camshaft cap Valve stem IN EX Valve stem end Water pump impeller shaft Oil pump assembly inner Oil strainer assembly Push rod Idle gear surface Starter clutch ball Primary driven gear Transmission gear wheel pinion Axle main drive Shift cam Shift fork guide bar Shift shaft assembly Shift boss i...

Page 41: ...ower Front wheel oil seal right left Rear wheel oil seal Clutch hub oil seal Clutch hub fitting area Rear brake pedal shaft Sidestand sliding surface Tube guide throttle grip inner surface Brake lever bolt sliding surface Clutch lever bolt sliding surface Rear shock absorber lower Swingarm pivot bearing Pivot shaft Thrust cover inner ...

Page 42: ...2 20 1 Oil pump for pumping oil to the oil tank 2 Oil pump for lubricating the engine parts 3 Oil strainer 4 Oil filter 5 Drain bolt 6 Oil tank LUBRICATION DIAGRAMS SPEC LUBRICATION DIAGRAMS ...

Page 43: ...2 21 LUBRICATION DIAGRAMS SPEC 1 Front balancer 2 Oil strainer 3 Oil pump 4 Relief valve 5 Oil pump for pumping oil to the oil tank 6 Oil pump for lubricating the engine parts ...

Page 44: ...2 22 LUBRICATION DIAGRAMS SPEC 1 Camshaft 2 Rear balancer 3 Main axle 4 Drive axle 5 Drain bolt 6 Front balancer ...

Page 45: ...2 23 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Rear balancer 3 Crankshaft 4 Drain bolt ...

Page 46: ...2 24 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Drive axle ...

Page 47: ...itch lead 7 Horn lead 8 Starter cable 9 Coolant reservoir hose 10 Headlight lead 11 Meter light lead 12 Thermo switch lead 13 Fan motor lead 14 Ignition coil left lead 15 Ignition coil right lead A Fasten the right handlebar switch lead with a plastic band B Fasten the left handlebar switch lead with a plastic band C 50 mm CABLE ROUTING ...

Page 48: ...ght lead and headlight lead with a plastic clamp I Fasten the wire harness with a plastic clamp J Fasten the wire harness right handlebar switch lead meter light lead and headlight lead with a plastic band K To the throttle position sensor L Fasten the wire harness and ignition coil left lead with a plastic clamp M Fasten the wire harness right handlebar switch lead main switch lead and fan motor ...

Page 49: ...lead 5 Spark plug lead 6 Carburetor breather hose 7 Fuel hose 8 Vacuum hose 2 9 Coolant reservoir hose 10 Sidestand switch lead 11 Neutral switch lead 12 A C magneto lead 13 Air filter case breather hose 14 Carburetor heater hose 15 Speedometer cable 16 Brake hose 17 Wire harness 18 Flasher relay lead 19 Fuel hose 5 ...

Page 50: ...idestand switch lead with a plastic clamp D Fasten the rear flasher light left lead with a plastic clamp E Fasten the sidestand switch lead neutral switch lead and A C magneto lead with a plastic clamp F Fasten the sidestand switch lead and air filter case breather hose with a metal band G Pass the air filter case breather hose over the carbu retor heater hose H Pass the speedometer cable through ...

Page 51: ...rburetor heater hose 11 Vacuum hose 1 12 Coolant reservoir breather hose 13 Carburetor breather hose 14 Rear brake switch lead 15 Battery positive lead 16 Battery negative lead A Pass the battery positive lead and battery negative lead through the guide B Fasten the wire harness coolant reservoir hose and flasher relay lead with a plastic clamp C Pass the carburetor breather hoses through the meta...

Page 52: ...he right handlebar switch lead with a plastic clamp I Fasten the throttle cables with a plastic clamp CABLE ROUTING SPEC J Pass the coolant reservoir hose over the throttle cables K Fasten the wire harness right handlebar switch lead meter light lead and headlight lead with a plastic band L Pass the clutch cable through the guide M Pass the carburetor air vent hose through the guide N Pass the coo...

Page 53: ...r hose through the guide Q Pass the rear brake switch lead through the guide R Fasten the wire harness and rear flasher light right lead with a plastic clamp S Fasten the wire harness with plastic clamps T To the engine U Fasten the coolant reservoir breather hose with a plastic clamp V To the starter relay W Pass the carburetor breather hoses through the guide ...

Page 54: ...1 Coolant reservoir breather hose CARBLE ROUTING SPEC 12 Coolant reservoir hose 13 Vacuum hose 2 14 Fuel hose 15 Carburetor breather hose 16 Cylinder head breather hose 17 Air filter case breather hose 18 Throttle cable A Fasten the meter light lead head light lead and wire harness with a plastic clamp B Fasten the wire harness and cool ant reservoir hose with a plastic clamp C Pass the starter re...

Page 55: ...J To the meter light K Fasten the headlight lead with a plastic clamp L To the auxiliary light M Fasten the meter light lead and headlight lead with plastic clamps N Fasten the meter light lead headlight lead and front flasher light lead connector with a plastic clamp O To the front flasher light right P Fasten the meter light lead headlight lead starting circuit cut off relay lead and front flash...

Page 56: ...SPEC ...

Page 57: ...INSP ADJ 3 ...

Page 58: ...OIL REPLACEMENT 3 23 CLUTCH ADJUSTMENT 3 25 AIR FILTER CLEANING 3 25 CARBURETOR JOINT INSPECTION 3 26 FUEL LINE INSPECTION 3 27 BREATHER HOSE INSPECTION 3 27 EXHAUST SYSTEM INSPECTION 3 28 COOLANT LEVEL INSPECTION 3 28 COOLANT REPLACEMENT 3 29 COOLING SYSTEM INSPECTION 3 32 CHASSIS 3 33 FRONT BRAKE ADJUSTMENT 3 33 REAR BRAKE ADJUSTMET 3 34 BRAKE FLUID LEVEL INSPECTION 3 35 BRAKE PAD INSPECTION 3 3...

Page 59: ...ND LUBRICATION 3 49 LEVER AND PEDAL LUBRICATION 3 50 SIDESTAND LUBRICATION 3 50 REAR SUSPENSION LUBRICATION 3 50 ELECTRICAL 3 51 BATTERY 3 51 REMOVAL 3 52 INSPECTION 3 53 INSTALLATION 3 58 FUSE INSPECTION 3 58 HEADLIGHT BEAM ADJUSTMENT 3 60 HEADLIGHT BULB REPLACEMENT 3 60 ...

Page 60: ...s or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter Replace Brake Check operation fluid leakage See NOTE Correct if necessary Clutch Check operation Adjust if necessary Swingarm pivot Check swingarm assembly for looseness Correct if necessary Moderately repack every 24 000 km or 24 months Wheels Check balance damage runout Replace if necessary Wheel be...

Page 61: ...ng the master cylinder or caliper 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 replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged ...

Page 62: ...r panel Damper Wind shield Inner panel Front flasher light lead Front flasher light left and right Auxiliary light lead coupler Headlight lead coupler Front cowling Headlight unit 2 1 1 1 1 4 2 1 1 1 1 Remove the parts in the order below Disconnect Disconnect Disconnect For installation reverse the removal procedure COWLINGS SEAT TAIL COVER AND FUEL TANK COWLINGS ...

Page 63: ...t Taillight lead coupler Tail cover Side cover Fuel hose RES Fuel hose ON Fuel tank breather hose Fuel tank 1 1 1 2 1 1 1 1 Remove the parts in the order below Refer to COWLINGS Disconnect Set the fuel cock fuel tank side to OFF before disconnecting the fuel hoses For installation reverse the removal procedure NOTE 16 Nm 1 6 m kg SEAT TAIL COVER AND FUEL TANK ...

Page 64: ...cowling seat side cover and fuel tank Cylinder head breather hose Air filter case breather hose Carburetor clamp Air filter case 1 1 2 1 Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Loosen For installation reverse the removal procedure AIR FILTER CASE AIR FILTER CASE ...

Page 65: ... Dead Center T D C on compression stroke to check or adjust the valve clearance 1 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Air filter case Refer to AIR FILTER CASE 2 Drain Coolant Refer to COOLANT REPLACEMENT 3 Disconnect Hose 2 1 Hose 3 2 Coolant reservoir hose from radiator side Fan motor lead coupler 4 Remove Radiator 1 ...

Page 66: ...ht plug 2 O ring 8 Check Valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 15 0 20 mm Exhaust valve 0 25 0 30 mm Checking steps Turn the crankshaft counterclockwise with a wrench Align the T D C mark a on the rotor with the align mark b on the crankcase cover when 1 piston is at T D C on compression stroke TDC on compression stroke can be found when the cam lobes are ...

Page 67: ...e opposite each other when the piston is at TDC on the com pression stroke 9 Adjust S Valve clearance Adjustment steps S Loosen the timing chain tensioner cap bolt S Remove the timing chain tensioner 1 timing chain guide upper 2 timing chain guide ex haust side 3 and camshaft caps Remove the camshaft cap bolts in a crisscross pattern from the outside working inwards S Remove the camshaft intake an...

Page 68: ...ct the proper pad using the pad selecting table Pad range Pad Availability 25 increments No 120 No 240 1 20 mm 2 40 mm Pads are available in 0 05 mm increments The thickness a of each pad is indicated in hun dreths of millimeters on the pad upper surface Round off the last digit of the installed pad num ber to the nearest increment Last digit of pad number Rounded value 0 or 2 0 5 NOT ROUNDED OFF ...

Page 69: ...pads with molyb denum disulfide oil Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place Install the new pads so that the side with the pad number faces up toward the valve lifter Install the camshafts exhaust and intake the timing chain and the camshaft caps Lubricate the cylinder head mating surfaces cam lobes and camsh...

Page 70: ... 1 00 200 205 210 215 220 225 230 235 240 1 01 1 05 205 210 215 220 225 230 235 240 1 06 1 10 210 215 220 225 230 235 240 1 11 1 15 215 220 225 230 235 240 1 16 1 20 220 225 230 235 240 1 21 1 25 225 230 235 240 1 26 1 30 230 235 240 1 31 1 35 235 240 1 36 1 40 240 EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 ...

Page 71: ...at all the clearance adjustment steps until the specified clearance is obtained 10 Install All removed parts Install all removed parts in reversed order of their removal Note the following points 11 Install Chain guide exhaust side Chain guide upper Timing chain tensioner Refer to CAMSHAFT in CHAPTER 4 12 Install Cylinder head cover Spark plugs ...

Page 72: ...e stand under the motorcycle 2 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 3 Remove Vacuum hose 1 1 carburetor 1 Vacuum hose 2 2 carburetor 2 4 Attach Adapters Vacuum gauge 1 Engine tachometer 2 to 1 spark plug lead Vacuum gauge 90890 03094 Engine tachometer 90890 03113 5 Start the engine and let it warm up for several minutes 6 Check Engine idling...

Page 73: ...ynchronization again Intake vacuum at idle speed 36 0 38 7 kPa 270 290 mm Hg The difference between both carburetors should be 0 67 kPa 5 mm Hg or less 8 Check Engine idling speed Out of specification Adjust 9 Stop the engine and detach the measuring equipment 10 Adjust Throttle cable free play Refer to THROTTLE CABLE FREE PLAY AD JUSTMENT Free play 3 5 mm At throttle grip flange 11 Install Fuel t...

Page 74: ...spark plug lead Engine tachometer 90890 03113 3 Check Engine idling speed Out of specification Adjust Engine idling speed 1 050 1 250 r min 4 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Air filter case Refer to AIR FILTER CASE 5 Adjust Engine idling speed Adjustment steps Turn the pilot screw 1 until it is lightly seated Turn out the pilot screw fo...

Page 75: ... THROTTLE CABLE FREE PLAY AD JUSTMENT Free play 3 5 mm At throttle grip flange THROTTLE CABLE ADJUSTMENT Engine idling speed and carburetor synchroniza tion should be adjusted properly before adjusting the throttle cable free play 1 Check Throttle cable free play a Out of specification Adjust Free play 3 5 mm At throttle grip flange 2 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS...

Page 76: ...an not be adjusted here adjust it at the throttle grip side of the cable Final step Loosen the locknut 3 Turn the adjuster 4 in or out until the specified free play is obtained Turnning in Free play is decreased Turnning out Free play is increased Tighten the locknut After adjusting turn the handlebar to the right and left making sure that the engine idling speed does not change 4 Install Air filt...

Page 77: ... 2 Inspect Spark plug type Incorrect Replace Standard spark plug DPR8EA 9 NGK X24EPR U9 NIPPONDENSO 3 Inspect Electrode 1 Wear Damage Replace Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 4 Clean Spark plug with spark plug cleaner or wire brush 5 Measure Spark plug gap a Use a wire gauge Out of specification Adjust Spark plug gap 0 8 0 9 mm 6 Install Spark plug Bef...

Page 78: ... Engine tachometer to the 1 spark plug lead Timing light 90890 03141 Engine tachometer 90890 03113 3 Check Ignition timing Checking steps Start the engine and let it warm up Let the en gine run at the specified speed Engine speed 1 050 1 250 r min Visually check the stationary pointer a is with in the firing range b on the A C magneto Incorrect firing range Check rotor and pick up assembly The ign...

Page 79: ...e engine 4 Remove Spark plug caps Spark plugs Before completely removing the spark plug use compressed air to clean the cylinder head cover areas to prevent dirt from falling into the engine 5 Attach Compression gauge 1 Adapter Compression gauge 90890 03081 6 Measure Compression pressure Above the maximum pressure Inspect the cylinder head valve surfaces and piston crown for carbon deposits Below ...

Page 80: ...dard 1 200 kPa 12 0 kg cm2 12 0 bar Minimum 1 000 kPa 10 0 kg cm2 10 0 bar Cylinder difference 100 kPa 1 0 kg cm2 1 0 bar Measurement steps Crank over the engine with the throttle wide open until the reading on the compression gauge stabilizes Before cranking the engine ground all spark plug leads to prevent sparking Repeat the previous steps for the other cylin ders The difference of compression ...

Page 81: ...and minimum b marks Oil level is below the minimum mark Add oil up to the proper level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommended engine oil classifica tion API STANDARD API SE or higher grade Do not put in any chemical additives or use oils with a grade of CD a or higher Be sure not to use oils labeled ENERGY CON...

Page 82: ...1 Oil filter drain bolt with gasket 2 Drain the crankcase and oil tank of its oil 5 If the oil filter is to be replaced during this oil change remove the following parts and rein stall them Replacement steps Remove the oil filter cover 1 and oil filter ele ment 2 Check the O rings 3 if cracked or damaged replace them with a new one Install the oil filter element and oil filter cover Oil filter cov...

Page 83: ... 8 Install Oil filler plug 9 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPECTION 10 Check Oil pressure Checking steps Slightly loosen the oil gallery bolt 1 Start the engine and keep it idling until oil starts to seep from the oil gallery bolt If no oil comes out after one minute turn the engine off so it will not seize Check oil passages oil filter and oil pump for damage ...

Page 84: ... s 2 in or out until the speci fied free play is obtained Turnning in Free play is increased Turnning out Free play is decreased Tighten the locknut s A Handlebar side B Engine side AIR FILTER CLEANING 1 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Air filter case cover 1 2 Remove Air filter element 2 The engine should never be run without the air f...

Page 85: ...re the element is properly seated in the fil ter case 6 Install All removed parts Install all removed parts in reversed order of their removal CARBURETOR JOINT INSPECTION 1 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Air filter case Refer to AIR FILTER CASE 2 Inspect Carburetor joints 1 Cracks Damage Replace Refer to CARBURETOR in CHAPTER 6 3 Insta...

Page 86: ...and flush the fuel tank if abrasive damage to any components is evident 3 Install All removed parts Install all removed parts in reversed order of their removal BREATHER HOSE INSPECTION 1 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Air filter case Refer to AIR FILTER CASE 2 Inspect Breather hose 1 Cracks Damage Replace Loosen connection Connect pro...

Page 87: ...t 1 Exhaust pipe bolt 2 Muffler bolt 3 Bolt exhaust pipe and muffler 4 COOLANT LEVEL INSPECTION Position the motorcycle straight up when inspect ing the coolant level 1 Place the motorcycle on a level surface Place the motorcycle on its centerstand if a cen terstand is equipped If not place a suitable stand under the motorcycle 2 Inspect Coolant level Coolant level should be between maximum a and ...

Page 88: ...the radiator cap by following this procedure Place a thick rag or a towel over the radiator cap Slowly rotate the cap counterclockwise to the detent This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it Position the motorcycle straight up when replac ing the coolant 2 Place the motorcycle on a level surface...

Page 89: ... 0 3 L From lower to upper level 0 2 L Put the sidestand down so the motorcycle leans to the side and fill with coolant To help dissipate the coolant throughout the cooling system hold the motorcycle in the upright position for a few se conds Then lean it back to the side and continue filling with coolant Handling notes for coolant Coolant is harmful and should be handled with special care If cool...

Page 90: ... Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminium engines 8 Install Radiator cap 9 Fill Coolant reservoir 1 to upper level mark 10 Install Coolant reservoir cap 11 Start the engine and let it warm up for several minutes 12 Stop the engine and inspect the level Refer to COOLANT LEVEL INSPECTION Wait a few minutes until the coolant settles before...

Page 91: ...3 32 COOLANT REPLACEMENT COOLING SYSTEM INSPECTION INSP ADJ COOLING SYSTEM INSPECTION 1 Inspect Radiator 1 Hose 2 2 Hose 3 3 Cracks Damage Replace Refer to RADIATOR in CHAPTER 5 ...

Page 92: ...ance is the smallest After adjusting the front brake lever position distance make sure align the mark on the ad juster with the mark on the brake lever Make sure that the brake does not drag after adjusting it A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem This air must be removed by bleeding the brake system before the motorcycle is oper ated Air...

Page 93: ...ke pedal height visually check the adjuster end through the hole a The adjuster end b must be visible within this hole Tighten the locknut 1 Make sure that the brake does not drag after adjusting it A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake sys tem This air must be removed by bleeding the brake system before the motorcycle is oper ated Air in the sys...

Page 94: ...nded fluid DOT 4 When inspecting the fluid level in the reservoir on the handlebar make sure the master cylinder top is horizontal Brake fluid may corrode painted surfaces or plastic parts Always clean up spilled fluid im mediately Use only the designated quality fluid Other wise the rubber seals may deteriorate caus ing leakage and poor brake performance Refill with the same type of fluid Mixing ...

Page 95: ...WITCH ADJUSTMENT The brake light switch is operated by movement of the brake pedal Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect 1 Check Brake light operation Incorrect Adjust 2 Adjust Brake light operating timing Adjustment steps Hold the main body 1 of the switch with your hand so that it does not rotate and turn the ad juster 2 in or out...

Page 96: ... Replace the hose Refer to FRONT AND REAR BRAKE in CHAPTER 7 AIR BLEEDING HYDRAULIC BRAKE SYSTEM Bleed the brake system if The system has been disassembled A brake hose has been loosened or removed The brake fluid has been very low The brake operation has been faulty A loss of braking performance may occur if the brake system is not properly bled 1 Bleed Brake system Air bleeding steps a Add prope...

Page 97: ...s been reached then release the le ver or pedal i Repeat steps e to h until all air bubbles have disappeared from the fluid j Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared k Add brake fluid to proper level Refer to BRAKE F...

Page 98: ...t cover DRIVE CHAIN SLACK ADJUSTMENT Before checking and or adjusting rotate the rear wheel several revolutions and check slack at sev eral points to find the tightest point Check and or adjust the chain slack with the rear wheel is in this tightest position Too little chain slack will overload the engine and other vital parts keep the slack within the specified limits Securely support the motorcy...

Page 99: ...ers 4 in or out until the speci fied slack is obtained Turnning in Slack is decreases Turnning out Slack is increases Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of the swin garm Use them to check for proper alignment Tighten the axle nut and caliper bracket bolt to specification while pushing the chain tight Axle nut 107 Nm 10 7 m k...

Page 100: ...s can damage these O rings Use only kero sene to clean the drive chain Wipe dry and thor oughly lubricate it with SAE30 50W motor oil Do not use any other lubricants on the drive chain They may contain solvents that could damage the O rings Recommended lubricant SAE30 50W motor oil or chain lubricant suitable for O ring chains STEERING HEAD INSPECTION Securely support the motorcycle so there is no...

Page 101: ...d Adjustment steps Remove the special washer 1 ring nut up per 2 and rubber washer 3 Loosen the ring nut lower 4 Tighten the ring nut lower using the ring nut wrench 5 Set the torque wrench to the ring nut wrench so that they form a right angle Ring nut wrench 90890 01403 Ring nut initial tightening 48 Nm 4 8 m kg Loosen the ring nut lower 4 completely then retighten it to specification Ring nut f...

Page 102: ...g nut upper 2 Finger tighten the ring nut upper 2 then align the slots of both ring nuts If necessary hold the ring nut lower and tighten the ring nut upper until their slots are aligned Install the special washer 1 Make sure the special washer tabs sit correctly in the slots 8 Install Upper bracket Handle crown nut Upper bracket pinch bolts Handlebar Handlebar holder upper bolts with plugs Cable ...

Page 103: ...RK ADJUSTMENT Always adjust each fork to the same setting Uneven adjustment can cause poor handling and loss of stability Securely support the motorcycle so there is no danger of it falling over Spring preload 1 Adjust Spring preload Turn the adjuster 1 in or out Turnning in Spring preload is increased Turnning out Spring preload is decreased Adjuster position Standard 3 Minimum 1 Maximum 5 2 Sett...

Page 104: ...andard 4 clicks out Minimum 5 clicks out Maximum 0 clicks out From the fully turned in position Always keep the adjustment level equal on both forks Never turn the adjuster beyond the maximum or minimum setting REAR SHOCK ABSORBER ADJUSTMENT Securely support the motorcycle so there is no danger of it falling over Spring preload 1 Adjust Spring preload Coarse adjustment top Turn the adjuster 1 S or...

Page 105: ...inimum 59 mm Maximum 63 mm Tighten the locknut Lock nut 70 Nm 7 0 m kg Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque Damping force 1 Adjust Damping force Turn the adjuster 1 in or out Turnning in Damping force is increased Turnning out Damping force is decreased Adjuster position Standard 20 clicks out Minimum 10 clicks out Maximum 0 cl...

Page 106: ...ated at high speed or not NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle could cause tire damage accident or injury Basic weight With oil and full fuel tank 229 kg Maximum load 180 kg Cold tire pressure Front Rear Up to 90 kg load 225 kPa 2 25 kg cm2 2 25 bar 275 kPa 2 75 kg cm2 2 75 bar 90 kg Maximum load 225 kPa 2 25 kg cm2 2 25 bar 275 kPa 2 75 kg cm2 2 75 bar High speed ri...

Page 107: ... install the correct tube when using tube type tires After extensive tests the tires mentioned be low have been approved by Yamaha Motor Co Ltd for this model No guarantee for handling characteristics can be given if a tire combina tions other than the approved is used on this motorcycle The front and rear tires should al ways be of the same manufacture and design FRONT TIRE Manufacture Size Type ...

Page 108: ... with possible injury to the rider or dam age to the motorcycle WHEEL INSPECTION 1 Inspect Wheels Damage Bends Replace Always balance the wheel when a tire or wheel has been changed or replaced Never attempt to make any repairs to the wheel CABLE INSPECTION AND LUBRICATION Damaged cable sheaths may cause corrosion and interfere with the cable movement Re place damaged cables as soon as possible 1 ...

Page 109: ...ATION Lubricate levers and pedals at their pivoting points Recommended lubricant Engine oil SIDESTAND LUBRICATION Lubricate the sidestand at pivoting points Recommended lubricant Engine oil REAR SUSPENSION LUBRICATION Lubricate the rear suspension at pivoting points Recommended lubricant Molybdenum disulfide grease ...

Page 110: ... terminal Battery assembly 1 1 1 1 1 1 Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK Refer to Battery removal Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK For installation reverse the removal procedure 7 Nm 0 7 m kg 23 Nm 2 3 m kg 7 Nm 0 7 m kg 8 Nm 0 8 m kg 30 Nm 3 0 m kg BATTERY INSP ADJ ELECTRICAL BATTERY ...

Page 111: ...Seat Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 2 Remove Negative terminal cover 1 Positive terminal cover 2 First disconnect the negative lead 1 then dis connect the positive lead 2 3 Remove Battery assembly Slide the battery assembly around the right side of the shock absorber and then pull it outward to re move 4 Remove Battery negative lead 1 Battery positive lead 2 Battery 3 Battery box ...

Page 112: ...rmance will deterio rate Charging time charging current and charg ing voltage for the MF battery are different from those of general type batteries The MF battery should be charged as explained in CHARGING METHOD If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery Batteries generate explosive hydrogen gas Always follow ...

Page 113: ...ery can be checked by measuring the open circuit voltage i e the voltage when the positive terminal is discon nected Open circuit voltage Charging time 12 8 V or higher No charging is necessary S Check the condition of the battery using the fol lowing charts Example S Open circuit voltage 12 0 V S Charging time 6 5 hours S Charge condition of the battery 20 30 S Charging method for MF batteries Ch...

Page 114: ...switch The open circuit voltage variation for the MF battery after charging is shown below As shown in the figure the open circuit voltage stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the opencircuit voltage Do not quick charge the battery ...

Page 115: ...olt age at 20 25 V Monitor the amperage for 3 5 minutes to check if the standard charging current is reached If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charg ing current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard ...

Page 116: ...r the machine is stopped Charge the battery until the battery s charging voltage is 15 V NOTE Set the charging time at 20 hours maxi mum YES NO Charging method using a constant current type charger This type of battery charger cannot charge the MF battery Volt meter Charger AMP meter Measure the battery open circuit volt age after leaving the battery unused for more than 30 minutes 12 8 V or more ...

Page 117: ...n a on the battery box aligns with the grommet on the frame Pass the battery leads through the cable guide 2 2 Install Positive terminal cover 1 Negative terminal cover 2 Connect the battery positive lead first and then the negative lead After connecting the leads securely cover the terminals with the covers FUSE INSPECTION Always turn off the main switch when check ing or replacing the fuse Other...

Page 118: ...r amperage Turn on the switches to verify operation of re lated electrical devices If the fuse immediately blows again check the electrical circuit Description Amperage Quantity Main 30A 1 Head 15A 1 Signal 15A 1 Ignition 7 5A 1 Fan 7 5A 1 Never use a fuse with a rating other than speci fied Never use other materials in place of a fuse An improper fuse may cause extensive damage to the electrical ...

Page 119: ...lly Turn the adjuster 2 in or out Right headlight Turnning in Headlight beam is to the right Turnning out Headlight beam is to the left Left headlight Turnning in Headlight beam is to the left Turnning out Headlight beam is to the right HEADLIGHT BULB REPLACEMENT 1 Remove Cover 1 2 Disconnect Headlight leads 1 3 Unhook Bulb holder 2 4 Remove Bulb Keep flammable products and your hands away from th...

Page 120: ...uching the glass part of the bulb Keep it free from oil otherwise the transpar ency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moist ened with alcohol or lacquer thinner 6 Hook Bulb holder 7 Connect Headlight leads 8 Install Cover ...

Page 121: ...INSP ADJ ...

Page 122: ...ENG 4 ...

Page 123: ...NSPECTION 4 9 INSTALLATION 4 11 CYLINDER HEAD 4 13 INSPECTION 4 14 INSTALLATION 4 14 VALVE AND VALVE SPRING 4 15 REMOVAL 4 16 INSPECTION 4 17 INSTALLATION 4 21 CYLINDER AND PISTON 4 23 REMOVAL 4 24 INSPECTION 4 24 INSTALLATION 4 27 CLUTCH 4 29 CRANKCASE COVER RIGHT 4 29 CLUTCH 4 30 REMOVAL 4 31 INSPECTION 4 31 INSTALLATION 4 32 CRANKCASE COVER LEFT 4 34 SHIFT SHAFT 4 35 INSPECTION 4 36 INSTALLATIO...

Page 124: ...VER AND OIL PUMP DRIVEN GEARS 4 41 OIL PUMP 4 42 INSPECTION 4 43 OIL TANK 4 44 OIL HOSE 4 44 OIL TANK 4 45 OIL PAN 4 46 OIL PAN 4 46 BALANCER 4 47 REMOVAL 4 49 INSTALLATION 4 50 CRANKSHAFT 4 52 CRANKSHAFT ASSEMBLY 4 52 CONNECTING ROD 4 53 REMOVAL 4 54 INSPECTION 4 55 INSTALLATION 4 60 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 63 REMOVAL 4 64 INSPECTION 4 65 INSTALLATION 4 66 ...

Page 125: ... 1 1 1 1 Disconnect the parts in the order below Refer to COWLINGS SEAT TAIL COV ER AND FUEL TANK in CHAPTER 3 Disconnect the negative lead first and then disconnect the positive lead Immediately after removing the battery leads securely cover the terminals with the covers to prevent the battery leads from being shorted 10 Nm 1 0 m kg Disconnect Disconnect For connecting reverse the disconnection ...

Page 126: ...ain Exhaust pipe Muffler Exhaust pipe gasket Clutch cable Spark plug caps 1 1 1 1 1 1 1 1 1 2 1 2 Remove the parts in the order below Refer to AIR FILTER CASE in CHAPTER 3 Refer to CARBURETOR in CHAPTER 6 Refer to RADIATOR in CHAPTER 5 Refer to THERMOSTATIC VALVE in CHAPTER 5 For installation reverse the removal procedure 20 Nm 2 0 m kg 20 Nm 2 0 m kg 24 Nm 2 4 m kg 5 Nm 0 5 m kg 70 Nm 7 0 m kg 24...

Page 127: ...olt Bolt Engine assembly 1 2 1 2 1 1 1 1 2 1 1 1 Remove the parts in the order below Place suitable stand under the frame and engine Refer to STARTER MOTOR in CHAP TER 8 45 mm 25 mm 60 mm 230 mm 115 mm Refer to INSTALLATION NOTE 60 Nm 6 0 m kg 10 Nm 1 0 m kg 30 Nm 3 0 m kg 30 Nm 3 0 m kg 60 Nm 6 0 m kg 89 Nm 8 9 m kg 64 Nm 6 4 m kg 30 Nm 3 0 m kg ENGINE ASSEMBLY ENG ENGINE ASSEMBLY ...

Page 128: ...e Part name Q ty Remarks 12 13 Engine stay left Engine bracket lower 1 1 For installation reverse the removal procedure 60 Nm 6 0 m kg 10 Nm 1 0 m kg 30 Nm 3 0 m kg 30 Nm 3 0 m kg 60 Nm 6 0 m kg 89 Nm 8 9 m kg 64 Nm 6 4 m kg 30 Nm 3 0 m kg ...

Page 129: ...hten the bolts in the order below 1 Bolt 30 Nm 3 0 m kg 2 Bolt 30 Nm 3 0 m kg 3 Bolt 64 Nm 6 4 m kg 4 Bolt 89 Nm 8 9 m kg 5 Bolt 60 Nm 6 0 m kg 6 Bolt 30 Nm 3 0 m kg 3 Install Shift arm 1 Align the punched mark a on the shift shaft with the slot on the shift arm The top of the shift pedal 1 should be aligned with the crankcase 2 ...

Page 130: ...d cover Cylinder head cover gasket 1 2 1 6 1 1 3 Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK in CHAPTER 3 Refer to AIR FILTER CASE in CHAPTER 3 Refer to COOLANT REPLACEMENT in CHAPTER 3 Refer to RADIATOR in CHAPTER 5 Refer to CARBURETOR in CHAPTER 6 Refer to THERMOSTATIC VALVE in CHAPTER 5 68 27 58 mm For installation reverse the removal procedure 10 Nm 1 0 ...

Page 131: ...ensioner Gasket Camshaft sprocket Timing chain guide exhaust Camshaft cap Dowel pin Intake camshaft Exhaust camshaft 2 2 2 1 1 1 2 1 4 8 1 1 Remove the parts in the order below For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 24 Nm 2 4 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 18 Nm 1 8 m kg 10 Nm 1 0 m kg 20 Nm 2 0 m kg CAMSHAFT ...

Page 132: ...pointer b when 1 piston is at TDC on compression stroke The 1 piston is in compression stroke TDC when the cam lobes are turned away from each other 3 Remove Timing chain guide upper 1 4 Loosen Camshaft sprocket bolts 2 5 Loosen Tensioner cap bolt 1 6 Remove Timing chain tensioner 2 7 Remove Camshaft sprockets 1 Attach a wire 2 to the timing chain to prevent it from falling into the crankcase ...

Page 133: ...must be removed evenly to prevent damage to the cylinder head camshafts or camshaft caps INSPECTION 1 Inspect Cam lobes Pitting Scratches Blue discoloration Re place 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 35 85 mm b 27 85 mm Exhaust a 35 85 mm b 27 85 mm 3 Measure Runout camshaft Out of specification Replace Runout camshaft Less than 0 03 mm...

Page 134: ...amshaft caps Tighten the bolts camshaft cap in a crisscross pattern from innermost to outer caps Do not turn the camshaft when measuring clear ance with the Plastigauge Remove the camshaft caps and measure the width of the Plastigauge 1 5 Measure Outside diameter camshaft a Out of specification Replace the camshaft Within specification Replace camshaft case and camshaft caps as a set Outside diame...

Page 135: ...amshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshaft will result 3 Install Camshaft sprockets Installation steps Turn the crankshaft counterclockwise until the T mark a on the A C magneto is aligned with the stationary pointer b on the crankcase cover left when 1 piston is at TDC Fit the timing chain onto both camshaft sprockets and install the cams...

Page 136: ...ioner cap bolt 1 washer 2 and springs 3 Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way in Install a gasket 6 Install the timing chain tensioner Timing chain tensioner 10 Nm 1 0 m kg Install the springs 3 and washer 2 Install the tensioner cap bolt 1 Cap bolt 20 Nm 2 0 m kg 6 Turn Crankshaft Counterclockwise several turns 7 Check A C magneto T mark Align w...

Page 137: ...Oil delivery pipe Clip Vacuum hose Cylinder head Cylinder head gasket Dowel pin 1 2 1 2 2 1 1 2 Remove the parts in the order below Refer to ENGINE ASSEMBLY Refer to CAMSHAFT For installation reverse the removal procedure Refer to INSTALLATION 40 Nm 4 0 m kg 10 Nm 1 0 m kg 60 Nm 6 0 m kg 21 Nm 2 1 m kg 10 Nm 1 0 m kg 60 Nm 6 0 m kg CYLINDER HEAD ...

Page 138: ...ead warp limit Less than 0 03 mm Warp limit measurement and resurfacement steps Hold a straight edge and a thickness gauge to the cylinder head Measure the warpage If the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the sur face plate and resurface the head using a figure eight sanding pattern Rotate the head several times to avoid removing too ...

Page 139: ...ifter Adjusting pad Valve cotter Valve retainer Valve spring Stem seal Valve spring seat Exhaust valve Intake valve center Intake valve left and right 5 5 10 5 5 5 5 2 1 2 Remove the parts in the order below Refer to CYLINDER HEAD COVER Refer to CYLINDER HEAD For installation reverse the removal pro cedure Refer to REMOVAL and INSTALLATION VALVE AND VALVE SPRING ...

Page 140: ...lve seat Inspect the valve face valve seat and the valve seat width Checking steps Pour a clean solvent a into the intake and ex haust ports Check the valve seating There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 Attach the valve spring compressor 2 and at tachment 3 between the valve spring retainer and cylinder head to remove the valve cotters Valve spring compressor 9089...

Page 141: ... Replacement steps Heat the cylinder head in an oven to 100_C to ease guide removal and installation and to main tain correct interference fit S Remove the valve guide using the valve guide remover 1 S Install the valve guide new using the valve guide installer 2 and valve guide remover 1 S After installing the valve guide bore the valve guide using the valve guide reamer 3 to obtain proper stem t...

Page 142: ... Replace Margin thickness 0 8 X 1 2 mm 6 Measure Runout valve stem Out of specification Replace Runout limit 0 01 mm Always replace the guide if the valve is replaced Always replace the oil seal if the valve is re moved 7 Eliminate Carbon deposit from valve face and valve seat 8 Inspect Valve seat Pitting Wear Reface valve seat 9 Measure Valve seat width a Out of specification Reface valve seat Va...

Page 143: ...the valve seat is too wide too narrow or the seat is not centered the valve seat must be re faced 10 Lap Valve face Valve seat After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped Lapping steps Apply a coarse lapping compound a to the valve face Be sure no compound enters the gap between the valve stem and guide Apply molybdenum disulf...

Page 144: ...e Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat 11 Measure Free length valve spring a Out of specification Replace Free length valve spring 37 29 mm Limi...

Page 145: ... 1 Install S Stem seal S Valve S Spring seat S Valve spring S Valve retainer into cylinder head S Make sure that each valve is installed in its origi nal place also referring to the embossed mark as follows Intake right left 3LD Intake middle 3LD Exhaust 3LD S Install the valve spring with the larger pitch a facing upwards b Smaller pitch ...

Page 146: ... 2 90890 04019 Attachment 3 90890 04108 3 Secure the valve cotters 1 onto the valve stem by tapping lightly with a piece of wood Do not hit so much as to damage the valve 4 Install Pads 1 Valve lifters 2 The valve lifters must move smoothly when ro tated with the finger Each valve lifter and pad must be reinstalled in their original position Refer to VALVE CLEARANCE ADJUSTMENT in CHAPTER 3 ...

Page 147: ...al Cylinder head Joint O ring O ring Dowel pin Cylinder Cylinder gasket O ring Circlip Piston pin Piston Piston ring set 1 1 1 4 1 1 2 4 2 2 2 Remove the parts in the order below Refer to CYLINDER HEAD For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 10 Nm 1 0 m kg CYLINDER AND PISTON ...

Page 148: ...he clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to re move use the piston pin puller 4 Piston pin puller 90890 01304 Do not use a hammer to drive the piston pin out INSPECTION 1 Inspect Cylinder and piston walls Vertical scratches Rebore or replace cylin der and piston 2 Measure Piston to cylinder clearance Measurement steps 1st step Measure ...

Page 149: ... skirt diameter P with a mi crometer a 5 5 mm from the piston bottom edge Piston size P Standard 89 420 X 89 435 mm Oversize 2 0 50 mm Oversize 4 1 00 mm If out of specification replace the piston and pis ton rings as a set 3rd step Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 0...

Page 150: ...5 X 0 070 mm 2nd ring 0 035 X 0 070 mm 4 Position Piston ring into cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 5 mm 5 Measure End gap Out of specification Replace You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings End gap Top ring 0 3...

Page 151: ...ston pin 19 991 X 20 000 mm Limit 19 975 mm Measure the piston inside diameter b Calculate the piston pin to piston clearance with following formula Piston pin to piston clearance Bore size piston pin b Outside diameter piston pin a If out of specification replace the piston Piston pin to piston clearance 0 002 X 0 022 mm Limit 0 07 mm INSTALLATION 1 Install Piston rings Be sure to install rings s...

Page 152: ...crankcase with a clean rag to prevent the piston from falling into the crankcase 3 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b Oil ring end lower c Oil ring end upper d 2nd ring end 4 Install Dowel pins O rings Cylinder gasket Cylinder Install the cylinder with one hand while compres sing the piston rings with the other hand Pass the timing chain a...

Page 153: ... Gasket Dowel pin Circlip Plain washer Pull lever Torsion spring Plain washer 1 1 1 2 1 1 1 1 1 Remove the parts in the order below Refer to ENGINE OIL REPLACEMENT in CHAPTER 3 For installation reverse the removal procedure Loosen the bolts in a crisscross pattern NOTE 1 2 3 4 5 6 7 8 9 10 Nm 1 0 m kg CLUTCH CRANKCASE COVER RIGHT ...

Page 154: ...r Bearing Pull rod Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer Bearing Clutch housing Thrust plate 2 Thrust plate 1 6 1 1 1 1 9 8 1 1 1 1 1 1 1 1 1 Remove the parts in the order below For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 70 Nm 7 0 m kg 8 Nm 0 8 m kg CLUTCH ...

Page 155: ... bolts 3 onto the spacer Then re move the spacer by pulling INSPECTION 1 Measure Friction plate thickness Out of specification Replace friction plates as a set Measure at four points Thickness 2 9 3 1 mm Limit 2 8 mm 2 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate and feeler gauge 1 Warp limit Less than 0 1 mm 3 Measure Free length clutch sprin...

Page 156: ...g Wear Damage Replace clutch boss Pitting on the clutch boss splines will cause erratic operation INSTALLATION 1 Install Clutch boss 1 Lock washer 2 Clutch boss nut 3 Tighten the clutch boss nut while holding the clutch boss with the universal clutch holder 4 Universal clutch holder 90890 04086 2 Bend the lock washer tab along a flat side of the nut 3 Install Friction plates Clutch plates Mount fr...

Page 157: ...Clutch spring bolts 2 Tighten the clutch spring bolts in stage using a crisscross pattern 6 Install Dowel pins Gasket Crankcase cover right Install the pull rod so that the splines a are toward the back then install the crankcase cover right 7 Install Plain washer 1 Torsion spring 2 Pull lever 3 Plain washer 4 Circlip 5 Align the punched mark a on the clutch pull lever shaft with the mark b on the...

Page 158: ...nkcase cover left Gasket Dowel pin Circlip Plain washer 1 1 1 1 1 2 1 1 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 For installation reverse the removal procedure Loosen the bolts in a crisscross pattern NOTE 12 Nm 1 2 m kg 10 Nm 1 0 m kg 5 Nm 0 5 m kg CRANKCASE COVER LEFT ENG CRANKCASE COVER LEFT ...

Page 159: ...t arm Shift shaft Circlip Plain washer Torsion spring Stopper level Bearing retainer Torsion spring 1 1 1 1 1 1 1 Remove the parts in the order below Refer to CLUTCH Refer to CRANKCASE COVER LEFT For installation reverse the removal procedure Refer to INSTALLATION 10 Nm 1 0 m kg 12 Nm 1 2 m kg SHIFT SHAFT ...

Page 160: ...lace Bends Damage Replace 2 Inspect Torsion spring shift shaft 1 Torsion spring stopper lever 2 Wear Damage Replace 3 Inspect Shift shaft 1 Shift pawls 2 Bends Wear Damage Replace INSTALLATION 1 Install Return spring 1 Bearing retainer 2 Stopper lever 3 Be sure the stopper lever roller fits into the shift cam segment ...

Page 161: ...ator coil lead Pickup coil lead Crankcase cover left Gasket Dowel pin Clamp Pickup coil Stator coil 1 1 1 1 2 1 1 1 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to CRANKCASE COVER LEFT For installation reverse the removal procedure 7 Nm 0 7 m kg 10 Nm 1 0 m kg A C MAGNETO AND STARTER WHEEL GEAR STATOR COIL ...

Page 162: ...aft Starter idle gear Starter clutch Plate washer Woodruff key Starter wheel gear 1 1 1 1 1 1 1 Remove the parts in the order below For installation reverse the removal procedure After reassembling the starter clutch stake the top of the bolts NOTE Refer to REMOVAL and INSTALLATION 130 Nm 13 0 m kg 10 Nm 1 0 m kg A C MAGNETO AND STARTER WHEEL GEAR ...

Page 163: ...l body is parallel with the magneto If nec essary one screw may be backed out slightly to level tool body Flywheel puller 90890 01362 Crankshaft protector 90890 01382 INSPECTION 1 Check Starter clutch operation Clutch operation checking steps Install the starter wheel gear to the starter clutch and hold the starter clutch When turning the starter wheel gear clockwise A the starter clutch and the w...

Page 164: ... key 2 2 Install Plate washer Rotor 1 Washer Clean the tapered portions of the crankshaft and rotor When installing the magneto make sure the woodruff key is properly seated in the key way of the crankshaft 3 Install Bolt rotor 1 Tighten the bolt rotor 1 while holding the mag neto with the sheave holder 2 Do not allow the sheave holder 2 to touch the projection on the rotor Sheave holder 90890 017...

Page 165: ...gine oil Oil pipe O ring Oil pump cover Gasket Dowel pin Collar Gasket Circlip Oil pump driven gear 1 1 1 1 2 1 1 2 2 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg OIL PUMP OIL PUMP COVER AND OIL PUMP DRIVEN GEARS ...

Page 166: ...pump removal Oil pump assembly 1 For pumping oil to the oil tank Gasket Dowel pin Oil pump assembly 2 For lubricating the engine parts Gasket 1 1 1 1 1 Remove the parts in the order below For installation reverse the removal procedure 6 Nm 0 6 m kg 6 Nm 0 6 m kg OIL PUMP ...

Page 167: ...de clearance b between the outer rotor 2 and the pump housing 3 between the inner rotor 1 outer rotor 2 and the pump housing 3 Side clearance c Out of specification Replace the oil pump as sembly Tip clearance a 0 0 12 mm Side clearance b 0 03 0 08 mm Side clearance c 0 03 0 08 mm 3 Check Oil pump operation Unsmooth Repeat steps 1 and 2 or replace defective parts ...

Page 168: ...olt Copper washer Oil delivery pipe Oil hose O ring Oil pipe O ring 2 4 1 1 2 1 2 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to ENGINE ASSEMBLY For installation reverse the removal procedure 21 Nm 2 1 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg OIL TANK OIL HOSE ...

Page 169: ...e oil Engine Oil tank case upper Gasket Dowel pin Oil tank case lower Gasket Dowel pin 1 1 2 1 2 2 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to ENGINE ASSEMBLY For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg OIL TANK ...

Page 170: ...owel pin O ring collar 1 2 1 1 1 1 2 2 2 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to ENGINE ASSEMBLY Refer to OIL TANK For installation reverse the removal procedure Install the oil filter with the projection towards the oil filter cover NOTE 10 Nm 1 0 m kg 10 Nm 1 0 m kg 30 Nm 3 0 m kg OIL PAN ENG OIL PAN OIL PAN ...

Page 171: ...cer holder Dowel pin Rear balancer shaft O ring 2 1 2 1 1 Remove the parts in the order below Refer to ENGINE OIL REPLACE MENT in CHAPTER 3 Refer to ENGINE ASSEMBLY Refer to CYLINDER AND PISTON Refer to SHIFT SHAFT Refer to A C MAGNETO AND STARTER WHEEL GEAR Refer to OIL PUMP Refer to OIL TANK Refer to OIL PAN Refer to INSTALLATION 10 Nm 1 0 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg BALANCER ...

Page 172: ...rks 4 5 6 7 Rear balancer weight Front balancer holder Dowel pin Front balancer shaft O ring Front balancer weight 1 1 2 1 1 1 For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 10 Nm 1 0 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg ...

Page 173: ...EMOVAL 1 Remove Plate 1 2 Remove Rear balancer holder 1 Dowel pins 3 Remove Rear balancer shaft 1 Rear balancer weight 2 4 Remove Front balancer holder 1 Dowel pins 5 Remove Front balancer shaft 1 Front blancer weight 2 ...

Page 174: ...he crankshaft until the keyway a is aligned with the embossed mark b on the crankcase While holding the crankshaft install the ba lancer weight and align the mark c on the front balancer gear with the embossed mark d on the crankcase Install the front balancer shaft 2 Install Dowel pins Front balancer holder 1 3 Install Rear balancer weight 1 Rear balancer shaft 2 O ring 3 Plate balancer shaft ...

Page 175: ...eyway a is aligned with embossed mark b on the crank case While holding the crankshaft install the balancer weight and align the mark c on the rear balanc er gear with the embossed mark d on the crank case Install the rear balancer shaft 4 Install Dowel pins Rear balancer holder 1 ...

Page 176: ... Dowel pin Nozzle Crankshaft assembly Main journal bearing Pin Timing chain guide intake 1 1 1 1 1 1 6 1 1 Remove the parts in the order below Refer to BALANCER Refer to WATER PUMP in CHAPTER 5 For installation reverse the removal proce dure Refer to REMOVAL and INSTALLATION 12 Nm 1 2 m kg 10 Nm 1 0 m kg 40 Nm 4 0 m kg 24 Nm 2 4 m kg CRANKSHAFT CRANKSHAFT ASSEMBLY ...

Page 177: ... 4 5 Connecting rod removal Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod bearing 4 4 2 2 4 Remove the parts in the order below For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 48 Nm 4 8 m kg CONNECTING ROD ...

Page 178: ...the bolts starting with the highest num bered one The embossed numbers in the crankcase desig nate the crankcase tightening sequence A Upper crankcase B Lower crankcase Use a soft hammer to tap on the case half Tap only on reinforced portions of the case Do not tap on the gasket mating surface Work slowly and carefully Make sure that the case halves separate evenly 3 Remove Crankshaft assembly 1 ...

Page 179: ...1 Timing chain guide intake 2 6 Remove Connecting rod cap 1 Connecting rod 2 Connecting rod bearing 3 Identify each bearing position very careful so that it can be reinstalled in its original place INSPECTION 1 Measure Runout crankshaft Out of specification Replace Runout Less than 0 035 mm 2 Inspect Main journal surfaces Crank pin surfaces Bearing surfaces Wear Scratches Replace ...

Page 180: ...f the crankcase Place the upper crankcase on a bench in an up side down position Install the upper half of the bearings 1 and the crankshaft into the upper crankcase Align the projection a of the bearing with the notch b in the crankcase Put a piece of Plastigauge c on each main journal Do not put the Plastigauge over the oil hole in the main journal of the crankshaft Install the lower half of the...

Page 181: ... oil Remove the lower crankcase and lower half of the bearing Measure the compressed Plastigauge width d on each main journal If oil clearance is out of specification select a re placement bearing 4 Measure Oil clearance crank pin Out of specification Replace bearing Oil clearance 0 020 0 038 mm Limit 0 1 mm Measurement steps Do not interchange the bearings and connect ing rod They must be install...

Page 182: ...se to the bolts threads and nut seats Make sure the Y marks on the connecting rods face the left side of the crankshaft Make sure that the letters on both components align to form a perfect character Tighten the nuts Nut connecting rod 48 Nm 4 8 m kg When you reach 35 Nm 3 5 m kg keep tight ening until the final torque is obtained Apply continuous torque until the specified torque is obtained Remo...

Page 183: ...then the bearing size for J1 is Bearing size of J1 Crankcase J1 Crankweb J1 6 2 4 Green BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red Example 2 Connecting rod bearing If P1 on the connecting rod is 4 and 1 on the crankweb then the bearing size for P1 is Bearing size of P1 Connecting rod P1 Crankweb P1 4 1 3 Brown BEARING COLOR CODE 1 Blue 2 Black 3 Brown 4 Green ...

Page 184: ... of bearing with the groove of the caps and connecting rod Make sure to reinstall each connecting rod bear ing in its original place The stamped Y mark a on the connecting rods should face towards the left of the crankshaft Be sure that the letter b on both components align to form a perfect character 3 Align Bolt head with connecting rod cap 4 Tighten Connecting rod nuts When you reach 3 5 Nm 3 5...

Page 185: ... in the crankcase Install each bearing in its original place 7 Apply Engine oil onto inner surfaces of main journal bearings Sealant onto crankcase mating surfaces Yamaha bond No 1215 90890 85505 DO NOT ALLOW any sealant to come in contact with the oil gallery or crankshaft bearings 8 Install Dowel pin 1 9 Install Crankshaft assembly 1 onto upper crankcase ...

Page 186: ...en Lower crankcase bolt follow the proper tightening sequence Upper crankcase bolt 1 6 M10 40 Nm 4 0 m kg 7 10 13 15 20 25 M8 24 Nm 2 4 m kg 11 12 13 15 19 26 27 M6 12 Nm 1 2 m kg A Upper crankcase B Lower crankcase Lubricate the threads of bolts No 1 6 with molybdenum disulfide motor oil Lubricate the threads of bolts No 7 27 with engine oil Install a copper washer on bolts No 18 21 23 25 Install...

Page 187: ...xle assembly Oil seal Circlip Shift fork guide bar 2 Shift fork R Shift fork L Shift fork guide bar 1 Shift fork C Shift cam Bearing housing Cover Main axle assembly 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to CRANKSHAFT For installation reverse the removal proce dure Refer to REMOVAL and INSTALLATION 12 Nm 1 2 m kg TRANSMISSION SHIFT CAM AND SHIFT FORK ...

Page 188: ...rs 1 Shift fork R 2 Shift fork L 3 Shift fork C 4 Shift cam 5 3 Remove Bearing housing 1 use the torx wrench 4 Remove Cover 1 Attach the slide hammer bolt 2 and weight 3 into the cover then remove the cover by pulling Slide hammer bolt 90890 01083 Weight 90890 01084 5 Remove Main axle assembly 1 Push out of clutch side ...

Page 189: ... Replace Do not attempt to straighten a bent guide bar 3 Check Shift fork movement on its guide bar Unsmooth operation Replace the fork and guide bar 4 Inspect Shift cam grooves Wear Damage Scratches Replace Shift cam segment 1 Damage Wear Replace Shift cam bearing 2 Pitting Damage Replace 5 Measure Axle runout main and drive Use a centering device and dial gauge 1 Out of specification Replace Run...

Page 190: ... movement Roughness Replace Main axle reassembling point Press the 2nd pinion gear 1 in the main axle as shown 8 Inspect Circlips Damage Looseness Bends Replace INSTALLATION 1 Install Main axle assembly 1 Use a pin 2 to align the bolt holes in the bearing housing with the holes in the lower crankcase and install the main axle assembly 2 Install Cover Bearing housing 1 After tightening the bearing ...

Page 191: ...ence R C L beginning from the right Install the shift fork guide bars with the tapered end a toward the clutch 4 Install Circlip 1 5 Install Drive axle assembly 1 The drive axle bearing pin must point to the front side of the crankcase Be sure that the drive axle bearing circlips are in serted into the upper crankcase positioning grooves a 6 Check Transmission Unsmooth rotation Repair Oil each gea...

Page 192: ...ENG ...

Page 193: ...COOL 5 ...

Page 194: ...5 COOLING SYSTEM RADIATOR 5 1 INSPECTION 5 2 INSTALLATION 5 3 THERMOSTATIC VALVE 5 4 THERMOSTATIC VALVE ASSEMBLY 5 4 THERMOSTATIC VALVE 5 5 INSPECTION 5 6 ASSEMBLY 5 6 WATER PUMP 5 7 WATER PUMP 5 7 INSTALLATION 5 8 ...

Page 195: ...COOL ...

Page 196: ...oolant hose 3 Coolant hose 2 Radiator assembly 1 1 1 1 1 Remove the parts in the order below Refer to COOLANT REPLACEMENT in CHAPTER 3 Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK in CHAPTER 3 Refer to AIR FILTER CASE in CHAPTER 3 Disconnect Disconnect For installation reverse the removal procedure Refer to INSTALLA TION 5 Nm 0 5 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg COOLING SYSTEM RADIATOR ...

Page 197: ...cks Damage Replace 4 Measure Radiator cap opening pressure Radiator cap opens at pressure below the spe cified pressure Replace Radiator cap opening pressure 75 105 kPa 0 75 1 05 kg cm2 0 75 1 05 bar Measurement steps Attach the radiator cap tester 1 and adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Adapter 90890 01352 Apply the specified pressure for 10 seconds and make sure the...

Page 198: ... REPLACEMENT in CHAPTER 3 3 Inspect Cooling system Decrease of pressure leaks Repair as re quired Inspection steps Attach the radiator cap tester 1 to the radiator Radiator cap tester 90890 01325 Adapter 90890 01352 Apply 100 kPa 1 0 kg cm2 1 0 bar pressure Do not apply pressure that is more than the specification mentioned above Measure the indicated pressure with the gauge ...

Page 199: ...coupler Thermo unit lead Coolant hose 1 Coolant hose 4 Thermostatic valve assembly 1 1 1 1 1 1 Remove the parts in the order below Refer to COOLANT REPLACEMENT in CHAPTER 3 Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK in CHAPTER 3 Refer to AIR FILTER CASE in CHAPTER 3 Refer to RADIATOR Disconnect Disconnect Disconnect For installation reverse the removal procedure 10 Nm 1 0 m kg THERMOSTATIC VA...

Page 200: ...Thermo switch Thermo unit Ground lead Thermostatic valve cover O ring Thermostatic valve Thermostatic valve housing 1 1 1 1 1 1 1 Remove the parts in the order below For installation reverse the removal procedure Refer to ASSEMBLY 1 2 3 4 5 6 7 28 Nm 2 8 m kg 15 Nm 1 5 m kg 10 Nm 1 0 m kg THERMOSTATIC VALVE ...

Page 201: ...tic valve 4 Vessel A CLOSE B OPEN Thermostatic valve is sealed and its setting is spe cialized work If its accuracy is in doubt replace it A faulty unit could cause serious overheating or over cooling ASSEMBLY 1 Install S Thermostatic valve housing 1 S Thermostatic valve 2 S O ring 3 S Thermostatic valve cover 4 Install the thermostatic valve with the breather hole a facing up 2 Install S Thermo s...

Page 202: ...Coolant hose 3 Water pump cover O ring Water pump housing Washer Circlip Impeller O ring 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to COOLANT REPLACEMENT in CHAPTER 3 For installation reverse the removal procedure Refer to INSTALLATION 10 Nm 1 0 m kg 10 Nm 1 0 m kg WATER PUMP WATER PUMP ...

Page 203: ...cessary to remove and inspect the wa ter pump if the coolant is not unusually low or if it has no engine oil mixed in it Always replace the entire water pump 1 Install Impeller 1 Circlip 2 After installation check that the impeller shaft ro tates smoothly 2 Install O ring 1 3 Install Water pump housing Water pump cover Coolant hose 3 ...

Page 204: ...CARB 6 ...

Page 205: ...CARB CHAPTER 6 CARBURETION CARBURETOR 6 1 CARBURETOR ASSEMBLY 6 1 CARBURETOR 6 2 ASSEMBLY 6 4 FUEL LEVEL ADJUSTMENT 6 5 TPS THROTTLE POSITION SENSOR ADJUSTMENT AND INSPECTION 6 5 ...

Page 206: ...CARB ...

Page 207: ... Throttle stop screw Fuel hose Starter cable Throttle cable pull Throttle cable push 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK in CHAPTER 3 Refer to AIR FILTER CASE in CHAPTER 3 Disconnect From frame For installation reverse the removal procedure After loosening the throttle cable locknut and removing the carburetor assembly remove the thro...

Page 208: ...arburetor disassembly Carburetor heater hose Float chamber Needle valve Float Starter jet Main jet Pilot jet Jet housing Jet needle Throttle valve 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order below Refer to INSTALLATION 1 2 3 4 5 6 7 8 9 10 CARBURETOR ...

Page 209: ...RBURETOR CARB Order Job name Part name Q ty Remarks Needle jet Pilot air jet 1 Main air jet 2 Diaphragm Starter plunger Pilot screw 1 1 1 1 1 1 For assembly reverse the disassembly procedure 11 12 13 14 15 16 ...

Page 210: ...troleum based solvent Always use a new gasket 1 Install Main jet 1 Starter jet 2 Pilot jet 3 2 Install Valve seat Make sure that projection a on the valve seat is aligned with the slot b on the carburetor body 3 Install O ring 1 Diaphragm 2 4 Install Pilot screw 1 Pilot screw turns out 2 0 ...

Page 211: ...t the carburetors are positioned vertically Connect the fuel level gauge 2 to the drain pipe Fuel level gauge 90890 01312 Loosen the drain screw Hold the gauge vertically next to the MIKUNI mark 3 Measure the fuel level a with the gauge THROTTLE POSITION SENSOR TPS AD JUSTMENT AND INSPECTION Idle speed should be adjusted properly before adjusting the TPS throttle position sensor When installing th...

Page 212: ... TPS throttle position sensor screws 1 Adjust the TPS throttle position sensor posi tion The angle of the TPS throttle position sensor is shown on the tachometer Adjust the angle of the TPS throttle position sen sor as appropriate as shown below When the angle is correct the tachometer reads 4 000 rpm When the angle is too wide the tachometer reads 8 000 rpm When the angle is too narrow the tachom...

Page 213: ...e TPS throttle position sensor resis tance TPS throttle position sensor resistance 3 5 X 6 5 kΩ at 20_C Blue Black Blue Out of specification Replace the TPS throttle position sensor S Connect the pocket tester Ω 1k to TPS throttle position sensor coupler Tester lead Yellow terminal 1 Tester lead Black Blue terminal 3 S Check the TPS throttle position sensor resis tance while turning throttle slowl...

Page 214: ...CARB ...

Page 215: ...CHAS 7 ...

Page 216: ...RAKE PAD 7 14 BRAKE PAD REPLACEMENT 7 15 FRONT BRAKE MASTER CYLINDER 7 18 REAR BRAKE MASTER CYLINDER 7 20 MASTER CYLINDER INSPECTION 7 22 MASTER CYLINDER ASSEMBLY 7 22 FRONT BRAKE CALIPER 7 26 REAR BRAKE CALIPER 7 28 CALIPER DISASSEMBLY 7 30 CALIPER INSPECTION AND REPAIR 7 31 CALIPER ASSEMBLY 7 31 CALIPER INSTALLATION 7 32 FRONT FORK 7 33 DISASSEMBLY 7 36 INSPECTION 7 37 ASSEMBLY 7 37 INSTALLATION...

Page 217: ...CHAS REAR SHOCK ABSORBER AND RELAY ARM 7 50 HANDLING NOTES 7 51 NOTES ON DISPOSAL 7 51 SWINGARM AND DRIVE CHAIN 7 52 INSPECTION 7 54 ...

Page 218: ...heel Speedometer gear unit Collar Brake disc left right 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Elevate the front wheel by placing a suitable stand under the engine Disconnect Loosen For installation reverse the removal procedure NOTE Refer to INSTALLATION 58 Nm 5 8 m kg 19 Nm 1 9 m kg 40 Nm 4 0 m kg 20 Nm 2 0 m kg FRONT WHEEL AND BRAKE DISCS CHAS CHASSIS FRONT WHEEL AND BRAKE DI...

Page 219: ...ame Part name Q ty Remarks Front wheel disassembly Oil seal Clutch retainer Meter clutch Oil seal Bearing Spacer Bearing 1 1 1 1 1 1 1 Disassemble the parts in order below Refer to ASSEMBLY For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 ...

Page 220: ... 1 mm Lateral b 0 5 mm 3 Inspect Wheel bearings Bearings allow free play in the wheel hub or wheel turns roughly Replace Oil seals Wear Damage Replace Wheel bearing and oil seal replacement steps Clean the outside of the wheel hub Remove the oil seals using a flat head screw driver Place a rag on the outer edge to prevent damage Remove the bearing 1 using a general bearing puller 2 Install the new...

Page 221: ... oil seal as set 5 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Remove the brake caliper before inspecting the brake disc deflection Maximum deflection 0 2 mm Brake disc thickness Out of specification Replace Minimum thickness 3 5 mm Measuring point 1 3 mm Replacement steps Remove the brake disc s Install the ...

Page 222: ...L procedure Note the following points 1 Lubricate Front wheel axle Drive Driven gear speedometer Recommended lubricant Lithium soap base grease 2 Install Speedometer gear unit 1 Be sure that two projections a inside the wheel hub mesh with the two slots b in the gear unit as sembly 3 Install Front wheel Front wheel axle Be sure that the projection torque stopper a of the gear unit housing is posit...

Page 223: ...rocedure a Spin the wheel and wait for it to rest b Put an X1 mark on the wheel bottom spot c Turn the wheel so that the X1 mark is 90_ up d Left the wheel fall and wait for it to rest Put an X2 mark on the wheel bottom spot e Repeat the above b c and d several times until these marks come to the same spot f This spot is the heavy spot X 4 Adjust S Wheel balance Adjusting steps S Install a balanci...

Page 224: ...0_ up S Check that the heavy spot is at rest there If not try another weight until the wheel is bal anced 5 Check S Wheel balance Checking steps S Turn the wheel so that is comes to each point as shown S Check that the wheel is at rest at each point If not readjust the wheel balance ...

Page 225: ...r wheel axle nut Plain washer Rear wheel axle Chain puller Rear wheel 1 1 1 2 1 2 1 Remove the parts in the order below Loosen For installation reverse the removal procedure Elevate the rear wheel by placing a suita ble stand under the engine NOTE 107 Nm 10 7 m kg 16 Nm 1 6 m kg 35 Nm 3 5 m kg 40 Nm 4 0 m kg REAR WHEEL BRAKE DISC AND DRIVEN SPROCKET REAR WHEEL ...

Page 226: ...6 7 8 Brake disc and driven sprocket removal Collar left right Brake disc Driven sprocket Clutch hub Rubber damper Collar Oil seal Bearing 1 1 1 1 1 6 1 1 1 Remove the parts in the order below For installation reverse the removal procedure 60 Nm 6 0 m kg 20 Nm 2 0 m kg BRAKE DISC AND DRIVEN SPROCKET ...

Page 227: ...ISC AND DRIVEN SPROCKET CHAS Order Job name Part name Q ty Remarks Rear wheel disassembly Oil seal Bearing Collar Bearing 1 1 1 1 Disassembly the parts in the order below For assembly reverse the disassembly procedure 1 2 3 4 ...

Page 228: ...o FRONT WHEEL AND BRAKE DISC 4 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Remove the brake caliper before inspecting the brake disc deflection Maximum deflection 0 15 mm Brake disc thickness Out of specification Replace Minimum thickness 4 5 mm Measuring point 1 3 mm 5 Inspect Clutch hub 1 Cracks Damage Repl...

Page 229: ... driven sprocket Clean the hub especially on the surfaces in con tact with the sprocket using a clean cloth Install the new driven sprocket Driven sprocket 60 Nm 6 0 m kg Tighten the self locknuts in stage using a criss cross pattern STATIC WHEEL BALANCE ADJUSTMENT After replacing the tire and or rim wheel balance should be adjusted Adjust the wheel balance with brake disc and hub installed 1 Adju...

Page 230: ...ad removal Cable guide Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw 1 1 2 2 1 2 2 1 Remove the parts in the order below For installation reverse the removal procedure Refer to BRAKE PAD REPLACE MENT 40 Nm 4 0 m kg 6 Nm 0 6 m kg FRONT AND REAR BRAKE FRONT BRAKE PAD ...

Page 231: ...1 2 3 4 5 6 7 Rear brake pad removal Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim left right Bleed screw 1 2 2 1 2 1 1 2 Remove the parts in the order below For installation reverse the removal procedure 40 Nm 4 0 m kg 6 Nm 0 6 m kg REAR BRAKE PAD ...

Page 232: ...erwise damage may oc cur Disconnect any hydraulic connection other wise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake cali per and brake hose to replace the brake pads Front brake 1 Remove Brake pads 1 Do not depress the brake lever when the wheel is off the motorcycle ot...

Page 233: ... the brake pads and pad spring The arrow mark a of the pad spring must point in the direction of the disc rotation After installing the retaining clip turn the retain ing pin so that the heads of the retaining clips face towards the center of the brake pad spring 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 4 Check Brake lever operation A soft or spongy feeling B...

Page 234: ...ew and push the pis tons into the caliper with the finger Tighten the caliper bleed screw 2 Bleed screw 6 Nm 0 6 m kg Install the pad shims 3 on the brake pad 4 The arrow mark a on the pad shim must point in the direction of the disc rotation Install the brake pads and pad spring 5 The longer tangs b of the pad spring must point in the direction of the disc rotation 3 Inspect Brake fluid level Ref...

Page 235: ... Front brake switch lead coupler Front brake switch Union bolt Copper washer Brake hose Master cylinder bracket Master cylinder assembly 1 1 1 1 2 1 1 1 Remove the parts in the order below Drain Disconnect Refer to MASTER CYLINDER ASSEMBLY For installation reverse the removal procedure 9 Nm 0 9 m kg 30 Nm 3 0 m kg FRONT BRAKE MASTER CYLINDER ...

Page 236: ... name Q ty Remarks Front brake master cylinder disas sembly Adjuster Spring Plate Boot Circlip Master cylinder kit Master cylinder body 1 1 1 1 1 1 1 Disassemble the parts in the order below For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 ...

Page 237: ...per washer Brake hose Brake reservoir hose Cotter pin Clevis pin Plain washer Master cylinder 1 2 1 1 1 1 1 1 Remove the parts in the order below Drain Refer to MASTER CYLINDER ASSEMBLY For installation reverse the removal procedure Remove from the master cylinder side NOTE 7 Nm 0 7 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg REAR BRAKE MASTER CYLINDER ...

Page 238: ...er Job name Part name Q ty Remarks Rear brake master cylinder discon nection Boot Circlip Master cylinder kit Master cylinder body 1 1 1 1 Disconnect the parts in the order below For assembly reverse the disconnection procedure 1 2 3 4 ...

Page 239: ...assage master cylinder body Blow out with compressed air A Front B Rear 2 Inspect Master cylinder kit 1 Scratches Wear Damage Replace as a set A Front B Rear MASTER CYLINDER ASSEMBLY All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Recommended brake fluid DOT 4 Replace the piston seals and dust seals whenever a caliper...

Page 240: ...mark a on the handlebar Tighten first the upper bolt then the lower bolt 2 Install Copper washers 1 Brake hose 2 Union bolt 3 Proper hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING Always use new copper washers 3 Fill Brake reservoir Recommended brake fluid DOT 4 Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid im mediately ...

Page 241: ...iling point of the fluid and may result in vapor lock 4 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 6 Check Brake level operation A soft or spongy feeling Bleed brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 Rear brake 1 Install Copper washer 1 Brake hose 2 U...

Page 242: ... Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 5 Check Brake pedal operation A soft or spongy feeling Bleed brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 6 Adjust Brake pedal height Refer to REAR BRAKE ADJUSTMENT in CHAPTER 3 7 Adjust Brake light switch Refer to BRAKE LIGHT SWITCH ADJUST MENT in CHAPTER 3 ...

Page 243: ...Copper washer Stay Brake hose and brake pipe Brake caliper assembly 1 1 2 1 1 Remove the parts in the order below Drain Refer to CALIPER INSTALLATION For installation reverse the removal procedure The brake pipe must not be disassembled Do not loosen the bolts indicated by WARNING 40 Nm 4 0 m kg 10 Nm 1 0 m kg 30 Nm 3 0 m kg FRONT BRAKE CALIPER ...

Page 244: ... Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw Brake caliper piston Piston seal 1 2 2 1 2 2 1 4 8 Disassemble the parts in the order below For assembly reverse the disassembly procedure Refer to CALIPER DISASSEMBLY and CALIPER ASSEMBLY 6 Nm 0 6 m kg 1 2 3 4 5 6 7 8 9 ...

Page 245: ...ke caliper removal Brake fluid Brake hose Brake hose joint Copper washer Brake caliper assembly 1 1 1 1 Remove the parts in the order below Drain For installation reverse the removal procedure Refer to CALIPER INSTALLATION 40 Nm 4 0 m kg 14 Nm 1 4 m kg 40 Nm 4 0 m kg REAR BRAKE CALIPER ...

Page 246: ...Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw Brake caliper piston Piston seal 1 2 2 1 2 2 2 2 4 Disassemble the parts in the order below For assembly reverse the disassembly procedure Refer to CALIPER DISASSEMBLY and CALIPER ASSEMBLY 1 2 4 5 6 7 8 9 3 6 Nm 0 6 m kg ...

Page 247: ...ir brake fluid 1 Remove Pistons Piston seals 1 Removal steps Using a wood piece 2 lock the right side piston Blow compressed air into the hose joint opening a to force out the left side piston from the caliper body Remove the piston seals and reinstall the piston Repeat previous step to force out the right side piston from the caliper body Never try to pry out the piston Do not loosen the bolts 3 ...

Page 248: ... will cause seals to swell and dis tort 1 Inspect Caliper piston 1 Scratches Rust Wear Replace caliper as sembly Caliper cylinder 2 Wear Scratches Replace caliper assembly Caliper body 3 Cracks Damage Replace Oil delivery passage caliper body Blow out with compressed air Replace the piston seals and dust seals when ever the caliper is disassembled CALIPER ASSEMBLY All internal parts should be clea...

Page 249: ...ontact with the front fender If it s not in contact loosen holding bolt B left and right and move the brake pipe so that the damper contacts the fender Then tighten the holding bolt Rear brake Brake caliper 1 temporarily Copper washer Brake hose joint 2 Brake hose 3 Proper hose routing is essential to insure safe motorcycle operation Rear to CABLE ROUTING Always use new copper washers 2 Install Pa...

Page 250: ...pper bracket Cap bolt Pinch bolt lower bracket Front fork left right 1 1 4 2 2 2 1 1 Remove the parts in the order below Refer to FRONT WHEEL AND BRAKE DISCS Loosen Loosen Loosen Loosen For installation reverse the removal procedure Refer to INSTAL LATION 24 Nm 2 4 m kg 23 Nm 2 3 m kg 10 Nm 1 0 m kg 9 Nm 0 9 m kg 30 Nm 3 0 m kg 10 Nm 1 0 m kg FRONT FORK ...

Page 251: ...assembly Cap bolt O ring Washer Fork spring Dust seal Retaining clip Damper rod bolt Gasket Oil seal Plain washer 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order below Drain the fork oil Refer to DISASSEMBLY and ASSEMBLY 30 Nm 3 0 m kg 24 Nm 2 4 m kg 1 2 3 4 5 6 7 8 9 ...

Page 252: ...e Q ty Remarks Inner tube Piston metal Oil lock piece Damper rod Damper rod spring Slide metal Outer tube 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLY and ASSEMBLY 24 Nm 2 4 m kg 30 Nm 3 0 m kg 10 11 12 13 14 ...

Page 253: ...ng the damper rod with the T handle 2 and holder 1 Damper rod holder 90890 01465 T handle 90890 01326 3 Remove Damper rod Damper rod spring 4 Remove Inner tube Removal steps Hold the fork leg holizontally Clamp the caliper mounting boss of the outer tube securely in a vise with soft jaws Pull out the inner tube from the outer tube by forcefully but carefully with drawing the inner tube Excessive f...

Page 254: ... inner fork tube as this may dangerously weaken the tube 2 Measure Fork spring free length a Over specified limit Replace Fork spring free length limit 500 mm 3 Inspect Cap bolt Bend Damage Replace ASSEMBLY 1 Install Damper rod Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom being careful not to damage the inner tube ...

Page 255: ...l lock piece 3 4 Tighten Damper bolt 1 Tighten the damper rod bolt while holding the damper rod with the T handle and holder T handle 90890 01326 Damper rod holder 90890 01465 5 Install Slide metal 1 Plain washer Use the fork seal driver weight 2 and adapter 3 6 Install Oil seal 1 Use the fork seal driver weight 2 and adapter 3 Fork seal driver weight 90890 01367 Adapter 90890 01374 ...

Page 256: ...eight Fork seal driver weight 90890 01367 8 Fill Fork oil Each fork 0 515 L For oil 10W or equivalent After filling slowly pump the fork up and down to distribute oil Oil level 130 mm from the top of inner tube fully compressed without spring Place the fork on upright position 9 Install O ring Cap bolt 1 Align the end of the cap bolt rod with the hole in the damper rod then install the cap bolt ro...

Page 257: ...NG INSTALLATION 1 Install Front fork s Temporarily tighten the pinch bolts Make sure that the inner tube end is flush with the top of the upper bracket 2 Tighten Pinch bolts lower bracket 1 Cap bolts 2 Pinch bolts upper bracket 3 Make sure that the brake hoses are routed properly ...

Page 258: ...ch switch lead coupler Clutch switch Left handlebar switch Clutch lever Grip end Front brake switch lead coupler Master cylinder bracket Master cylinder assembly Collar 2 1 1 1 1 1 2 1 1 1 1 Remove the parts in the order below Disconnect Disconnect Refer to INSTALLATION 23 Nm 2 3 m kg 9 Nm 0 9 m kg 26 Nm 2 6 m kg HANDLEBAR ...

Page 259: ...Throttle cable housing cover Throttle cable housing Throttle cable Throttle grip Plug Handlebar holder upper Handlebar grip left Clutch lever holder Handlebar 1 1 1 2 1 4 2 1 1 1 For installation reverse the removal procedure Refer to INSTALLATION Refer to INSTALLATION 23 Nm 2 3 m kg 9 Nm 0 9 m kg 26 Nm 2 6 m kg ...

Page 260: ...andlebar intact until the adhesive becomes dry enough to make the grip and handlebar stuck securely INSTALLATION 1 Install Handlebar Handlebar holders upper The handlebar holders upper should be installed with the arrow mark a forward A Install the handlebar so that the widths of the match marks b are equal Align the match mark c on the handlebar with the top of the handlebar holder lower First ti...

Page 261: ...dlebar 3 Install Right handlebar switch 1 Align the projection a on the handlebar switch with the hole b on the handlebar 4 Install Collar Master cylinder assembly 1 Master cylinder bracket 2 Align the slit in the master cylinder bracket with the punched mark a on the handlebar Tighten first the upper bolt then the lower bolt 5 Install Clutch lever holder 1 Align the slit in clutch lever holder wi...

Page 262: ...bar switch 1 Align the projection a on the handlebar switch with the hole b on the handlebar 7 Adjust Clutch cable free play Refer to CLUTCH ADJUSTMENT in CHAP TER 3 8 Adjust Throttle cable free play Refer to THROTTLE CABLE ADJUSTMENT in CHAPTER 3 ...

Page 263: ...n lead coupler Brake hose holder Steering stem nut Plate washer Upper bracket Special washer Ring nut upper 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to FRONT WHEEL AND BRAKE DISC Refer to FRONT FORK Refer to HANDLEBAR Disconnect Disconnect Refer to REMOVAL 7 Nm 0 7 m kg 108 Nm 10 8 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg 16 Nm 1 6 m kg 1st 7 Nm 0 7 m kg 2 nd STEERING HEAD LOWER B...

Page 264: ... seal Ring nut lower Plate washer Lower bracket Bearing upper Rubber seal Bearing lower Dust seal 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 7 Nm 0 7 m kg 108 Nm 10 8 m kg 10 Nm 1 0 m kg 48 Nm 4 8 m kg 16 Nm 1 6 m kg 1st 2nd 7 Nm 0 7 m kg ...

Page 265: ...ll down INSPECTION 1 Wash the bearing and bearing races with a sol vent 2 Inspect Bearings Bearing races Pitting Damage Replace Bearing race replacement steps Remove the bearing races on the head pipe us ing long rod 1 and the hammer as shown Install the new races Always replace bearings and races as a set If the bearing race is not fitted squarely the head pipe could be damaged ...

Page 266: ... times Loosen the ring nut completely and retighten it to specification Ring nut 16 Nm 1 6 m kg Do not overtighten Check the steering stem by turning lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the plate washer Install the ring nut upper Finger tighten the ring nut then align the slots of both ring nuts If not aligned hold the lo...

Page 267: ... removal Seat Self locknut Plain washer Bolt Collar Cap Self locknut Bolt Rear shock absorber 1 1 1 1 1 1 1 1 Remove the parts in the order below Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK in CHAP TER 3 For installation reverse the removal procedure 64 Nm 6 4 m kg 64 Nm 6 4 m kg REAR SHOCK ABSORBER ...

Page 268: ...e cylin der assembly 2 Do not subject shock absorber to an open flame or other high heat This may cause the unit to explode due to excessive gas pressure 3 Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance NOTES ON DISPOSAL Shock absorber disposal steps Gas pressure must be released before disposing of the shock absorber To do so drill a 2 3 mm...

Page 269: ... Drive sprocket Brake hose holder Collar Rear fender Drive chain case Caliper bracket Cap Pivot shaft 1 2 1 1 1 2 1 Remove the parts in the order below Refer to REAR WHEEL BRAKE DISC AND DRIVE SPROCKET Refer to REAR SHOCK ABSORBER Refer to ENGINE ASSEMBLY in CHAPTER 4 90 Nm 9 0 m kg 7 Nm 0 7 m kg 35 Nm 3 5 m kg 7 Nm 0 7 m kg 3SWINGARM AND DRIVE CHAIN ...

Page 270: ...r Job name Part name Q ty Remarks 8 9 10 11 12 13 14 Swingarm Drive chain Chain protector Collar Thrust cover Bush Bearing 1 1 1 3 2 1 2 For installation reverse the removal procedure 90 Nm 9 0 m kg 7 Nm 0 7 m kg 35 Nm 3 5 m kg 7 Nm 0 7 m kg ...

Page 271: ...ree different 10 link length should be measured 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain This motorcycle has a drive chain with small rubber O rings 1 between the chain plates Steam cleaning high pressure washes and certain solvent can damage these O rings Use only kerosene to clean the drive chain 3 I...

Page 272: ...garm free play Inspection steps Check the tightening torque of the pivot shaft swingarm 1 securing nut Check the swingarm side play A by moving it from side to side If side play is noticeable check the inner collar bearing washer and thrust cover Side play at end of swigarm 0 3 mm Check the swingarm vertical movement B by moving it up and down If vertical movement is tight binding or rough check t...

Page 273: ...CHAS ...

Page 274: ...ELEC 8 ...

Page 275: ...AGRAM 8 10 STARTING CIRCUIT OPERATION 8 11 TROUBLESHOOTING 8 12 STARTER MOTOR 8 16 CHARGING SYSTEM 8 20 CIRCUIT DIAGRAM 8 20 TROUBLESHOOTING 8 21 LIGHTING SYSTEM 8 24 CIRCUIT DIAGRAM 8 24 TROUBLESHOOTING 8 25 LIGHTING SYSTEM CHECK 8 27 SIGNAL SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 33 SIGNAL SYSTEM CHECK 8 34 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLESHOOTING 8 40 TPS THROTTLE POS...

Page 276: ...ELEC ...

Page 277: ...e switch Sidestand switch Neutral switch Ignition coil Horn Ignitor unit Starting circuit cut off relay Rectifier regulator Main switch Thermo switch Thermo unit Flasher relay Starter relay 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 278: ...few times when checking it INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the col umn and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart ...

Page 279: ...switch Dimmer switch Pass switch Turn switch Sidestand switch Gear position switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SWITCH INSPECTION ELEC SWITCH CONTINUITY INSPECTION Refer to SWITCH INSPECTION and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled ...

Page 280: ...tch Battery Main fuse Starting circuit cut off relay 1 3 4 5 8 9 10 12 13 14 45 Neutral switch Sidestand switch Ignitor unit Ignition coil Spark plug Engine stop switch Ignition fuse 47 IGNITION SYSTEM ELEC IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 281: ...D BECOME INOPERATIVE NO SPARK OR INTERMITTENT SPARK Procedure Check 1 Fuse main and ignition 2 Battery 3 Spark plug 4 Ignition spark gap 5 Spark plug cap resistance 6 Ignition coil resistance 7 Pickup coil resistance 8 Main switch 9 Engine stop switch 10 Neutral switch 11 Sidestand switch 12 Wiring connection entire ignition system S Remove the following parts before troubleshoot ing 1 Seat 2 Side...

Page 282: ...as shown Spark plug cap S Turn the main switch to ON 4 Ignition spark gap Repair or replace spark plug INCORRECT Standard spark plug DPR8EA 9 X24EPR U9 NGK NIPPONDENSO CORRECT 1 2 S Check the ignition spark gap S Crank the engine by pushing the starter switch and increase the spark gap until a mis fire occurs Minimum spark gap 6 0 mm a OUT OF SPECIFICATION OR NO SPARK S Remove the spark plug cap S...

Page 283: ...rom the wire harness S Connect the pocket tester Ω 1 to the igni tion coil 6 Ignition coil resistance Spark plug cap resistance 10 kΩ at 20_C Tester lead Spark plug lead Tester lead Red Black terminal S Check the primary coil for specified resistance Primary coil resistance 3 4 X 4 6 Ω at 20_C S Check the secondary coil for specified resis tance Secondary coil resistance 10 4 X 15 6 kΩ at 20_C OUT...

Page 284: ...sistance 192 X 288 Ω at 20_C Green White Blue Yellow OUT OF SPECIFICATION Replace pickup coil CORRECT Tester lead Green White terminal Tester lead Blue Yellow terminal 1 2 Refer to SWITCH INSPECTION 8 Main switch CORRECT Refer to SWITCH INSPECTION 9 Engine stop switch CORRECT INCORRECT Replace handlebar switch right Refer to SWITCH INSPECTION 10 Neutral switch CORRECT INCORRECT Replace neutral swi...

Page 285: ...8 9 IGNITION SYSTEM ELEC 12 Wiring connection S Check the entire ignition system for connec tions Refer to CIRCUIT DIAGRAM Replace ignitor unit POOR CONNECTION Correct CORRECT ...

Page 286: ... relay Starter motor Starting circuit cut off relay Neutral switch Sidestand switch Clutch switch Engine stop switch Start switch Ignition fuse 3 4 5 6 7 8 9 10 35 45 46 47 ELECTRIC STARTING SYSTEM ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 287: ...circuit cut off relay prevents the start er from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met however the starting circuit cut off relay is closed and the engine can be started by press ing the starter switch WHEN THE TRANSMISSION I...

Page 288: ...CT CORRECT TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE Procedure Check 1 Fuse main and ignition 2 Battery 3 Starter motor 4 Starting circuit cut off relay 5 Starter relay 6 Main switch 7 Engine stop switch 8 Neutral switch 9 Sidestand switch 10 Clutch switch 11 Start switch 12 Wiring connection entire starting system S Remove the following parts before troubleshoot ing 1 Seat 2 Side cowlings 3 ...

Page 289: ...S Disconnect the starting circuit cut off relay coupler from the wire harness S Connect the pocket tester Ω 1 and battery 12 V to the starting circuit cut off relay cou pler terminals 4 Starting circuit cut off relay Battery terminal Red Black terminal Battery terminal Black Yellow terminal 1 2 Tester terminal Blue White terminal Tester terminal Blue White terminal CONTINUITY WARNING This check is...

Page 290: ...ry terminal Red White terminal Battery terminal Blue White terminal 1 2 Refer to SWITCH INSPECTION 6 Main switch CORRECT Refer to SWITCH INSPECTION 7 Engine stop switch CORRECT INCORRECT Replace handlebar switch right Refer to SWITCH INSPECTION 8 Neutral switch CORRECT INCORRECT Replace gear position switch Refer to SWITCH INSPECTION 9 Sidestand switch INCORRECT Replace sidestand switch Tester lea...

Page 291: ...h Refer to SWITCH INSPECTION 10 Clutch switch CORRECT Refer to SWITCH INSPECTION 11 Start switch CORRECT INCORRECT Replace handlebar switch right S Check the entire starting system for connec tions Refer to CIRCUIT DIAGRAM 12 Wiring connection POOR CONNECTION Correct ...

Page 292: ...Front bracket Washer kit Rear bracket Washer kit Brush seat Brush 1 Armature coil 1 1 1 1 1 2 1 1 1 1 Remove the parts in the order below Refer to ENGINE ASSEMBLY in CHAP TER 4 Disassemble the parts in the order below For assembly reverse the disassembly pro cedure Be sure to remove the installation nut on brush 1 first NOTE Refer to ASSEMBLY 10 Nm 1 0 m kg 10 Nm 1 0 m kg 1 2 3 4 5 6 STARTER MOTOR...

Page 293: ... a hacksaw blade can be ground to fit Mica undercut 0 7 mm The mica insulation of the commutator must be undercut to ensure proper operation of commuta tor 4 Inspect Armature coil insulation continuity Defects Replace starter motor Inspecting steps Connect the pocket tester for continuity check 1 and insulation check 2 Measure the armature resistances Armature coil resistance Continuity check 1 0 ...

Page 294: ...Fatigue Out of specification Replace as a set Brush spring force 570 X 920 g 7 Inspect Bearing Roughness Replace Oil seal O rings Bushing Wear Damage Replace Assembly Reverse the Removal procedure Note the following points 1 Install Brush seat 1 Align the projection a on the brush seat with the slot on the housing 2 Install Shim 1 Armature coil 2 ...

Page 295: ...8 19 ELECTRIC STARTING SYSTEM ELEC New New New NOTE 3 Install Gasket 1 Yoke 2 Washer kit 3 Gasket 4 Front bracket 5 O ring 6 Align the match marks a on the yoke with the match marks b on the brackets ...

Page 296: ...8 20 A C magneto pickup coil Rectifier refulator Battery Main fuse 1 2 4 5 CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 297: ...ry terminals S Recharge or replace the battery INCORRECT CORRECT TROUBLESHOOTING THE BATTERY IS NOT CHARGED Procedure Check 1 Fuse main 2 Battery 3 Charging voltage 4 Stator coil resistance 5 Wiring connection entire charging system S Remove the following parts before troubleshoot ing 1 Seat 2 Side cowlings 3 Side covers 4 Fuel tank S Use the following special tool s in this trouble shooting Engin...

Page 298: ...ire harness Connect the pocket tester Ω 1 to the stator coils Measure the stator coil resistance 4 Stator coil resistance BOTH MEET SPECIFICATION Start the engine accelerate to about 5 000 r min then check the measured voltage Check battery voltage Charging voltage measured voltage terminal voltage Difference of 0 5 2 5 V NOTE Use a fully charged battery Stator coil resistance 0 23 0 35 Ω at 20 C ...

Page 299: ...8 23 CHARGING SYSTEM ELEC 5 Wiring connection S Check the entire starting system for connec tions Refer to CIRCUIT DIAGRAM Replace rectifier regulator POOR CONNECTION Correct CORRECT ...

Page 300: ...se Meter light 3 4 5 19 High beam indicator light 21 Headlight 25 Auxiliary light 26 Lights switch 30 Dimmer switch 31 Pass switch 32 Tail brake light 39 Headlight fuse 40 Diode 48 LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 301: ...WITCH INSPECTION 3 Main switch CORRECT Replace main switch INCORRECT TROUBLESHOOTING HEADLIGHT HIGH BEAM INDICATOR LIGHT TAILLIGHT AUXILIARY LIGHT AND OR METER LIGHT DO NOT COME ON Procedure Check 1 Fuse main and head 2 Battery 3 Main switch 4 Lights switch Dimmer switch 5 Pass switch 6 Wiring connection entire lighting system S Remove the following parts before troubleshoot ing 1 Seat 2 Side cowl...

Page 302: ...1 2 Tester lead Terminal Tester lead Terminal 1 2 Continuity No Continu ity When you switch the and leads of the dig ital pocket tester the readings in the above chart will be reversed NOTE CORRECT Refer to SWITCH INSPECTION 6 Pass switch Pass switch is faulty replace handlebar switch left INCORRECT CORRECT S Check the entire lighting system for connec tions Refer to WIRING DIAGRAM 7 Wiring connec...

Page 303: ...ck lead B 1 2 3 4 5 Turn the main switch to ON Turn the lights switch to ON position Turn the dimmer switch to LO or HI position Check for voltage 12 V on the Green and Yellow lead at bulb socket connectors Wiring circuit from main switch to bulb socket connector is faulty repair OUT OF SPECIFICATION MEETS SPECIFICATION Meter connector Headlight connector This circuit is good Dimmer switch Headlig...

Page 304: ...F SPECIFICATION This circuit is good MEETS SPECIFICATION 1 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Blue Red terminal Tester lead Black terminal 1 2 Turn the main switch to ON Turn the lights switch to ON or PO position Check for voltage 12 V on the Blue Red lead at the bulb socket connector MEETS SPECIFICATION Wiring circuit from main switch to bulb socke...

Page 305: ...urn the main switch to ON Turn the light switch to ON or PO position Check for voltage 12 V on the Blue Red lead at the bulb socket connector Wiring circuit from main switch to bulb socket connector is faulty repair OUT OF SPECIFICATION MEETS SPECIFICATION This circuit is good LIGHTING SYSTEM ELEC 4 Auxiliary light does not come on ...

Page 306: ...8 30 LIGHTING SYSTEM ELEC ...

Page 307: ...8 31 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 308: ...ar brake switch 42 Signal system fuse 44 Front brake switch SIGNAL SYSTEM ELEC 3 Main switch 4 Battery 5 Fuse main 8 Starting circuit cut off relay 9 Neutral switch 17 Tachometer 20 Neutral indicator light 22 Turn indicator light 23 Rear flasher light 24 Front flasher light 28 Horn switch ...

Page 309: ...als S Recharge or replace the battery INCORRECT CORRECT TROUBLESHOOTING S FLASHER LIGHTS BRAKE LIGHT AND OR INDICATOR LIGHTS DO NOT COME ON S HORN DOES NOT SOUND Procedure Check 1 Fuse main head and signal 2 Battery 3 Main switch 4 Wiring connection entire signal system S Remove the following parts before troubleshoot ing 1 Seat 2 Side cowlings 3 Side covers 4 Fuel tank 5 Air filter case S Use the...

Page 310: ...r to SWITCH INSPECTION 1 Horn switch CORRECT S Connect the pocket tester DC 20 V to the horn lead 2 Voltage OUT OF SPECIFICATION Wiring circuit from main switch to horn terminal is faulty repair Check condition of each circuit for signal sys tem Refer to SIGNAL SYSTEM CHECK Tester lead Black White lead Tester lead Frame ground S Turn the main switch to ON S Push the horn switch S Check for voltage...

Page 311: ...or voltage 0 V on the Black lead at the horn terminal Replace horn OUT OF SPECIFICATION Adjust or replace horn MEETS SPECIFICATION 1 Brake switch front rear Refer to SWITCH INSPECTION CORRECT Replace brake switch INCORRECT 2 Voltage S Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow lead Tester lead Black lead 1 2 SIGNAL SYSTEM ELEC 2 Brake light does not come on ...

Page 312: ...ndlebar switch left INCORRECT This circuit is good MEETS SPECIFICATION 1 Turn switch Refer to SWITCH INSPECTION MEETS SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty repair OUT OF SPECIFICATION S Turn the main switch to ON S Check for voltage 12 V on the Brown lead at the flasher relay terminal Wiring circuit from main switch to flasher relay connector is faulty re...

Page 313: ...CIFICATION This circuit is good 4 Voltage S Connect the pocket tester DC 20 V to the bulb socket connector MEETS SPECIFICATION S Turn the main switch to ON S Check for voltage 12 V on the Brown White lead at the flasher relay terminal Wiring circuit from turn switch to bulb socket connector is faulty repair OUT OF SPECIFICATION A B Flasher lights Turn indicator light At flasher light left Tester l...

Page 314: ...place neutral switch NO CONTINUITY This circuit is good 1 Neutral switch Refer to SWITCH INSPECTION MEETS SPECIFICATION Turn the main switch to ON Check for voltage 12 V Wiring circuit from main switch to bulb socket connector is faulty repair OUT OF SPECIFICATION CONTINUITY 2 SIGNAL SYSTEM ELEC 4 Neutral indicator light does not come on ...

Page 315: ...39 Main switch Battery Fuse main Thermo unit 3 4 5 15 Water temperature meter 18 Fan motor 36 Thermo switch 37 Radiator fan fuse 38 Signal system fuse 42 COOLING SYSTEM ELEC COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 316: ...r replace the battery INCORRECT TROUBLESHOOTING S FAN MOTOR DOES NOT MOVE S WATER TEMPERATURE METER DOES NOT MOVE WHEN ENGINE IS WARM Procedure Check 1 Fuse main signal and fan 2 Battery 3 Main switch 4 Fan motor 5 Thermo switch 6 Thermo unit 7 Water temperature 8 Wiring connection entire cooling system S Remove the following parts before troubleshoot ing 1 Seat 2 Side cowlings 3 Side covers 4 Fue...

Page 317: ...ry 12 V as shown Battery lead Blue lead Battery lead Black lead 1 Main switch is faulty replace it INCORRECT 3 Main switch Refer to SWITCH INSPECTION S Check the fan motors for operation Fan motor s is faulty replace it them DOES NOT MOVES CORRECT 2 MOVES COOLING SYSTEM ELEC ...

Page 318: ... the water S Check the thermo switch for continuity Note temperatures while heating the water with the temperature gauge Replace thermo switch BAD CONDITION GOOD CONDITION THERMO SWITCH ON THERMO SWITCH OFF A B 1 2 3 WARNING S Handle the thermo switch with special care S Never subject it to strong shock or allow it to be dropped Should it be dropped it must be re place ...

Page 319: ... 47 X 53 Ω 100_C 26 X 30 Ω Replace thermo unit BAD CONDITION 7 Wiring connection Check the entire cooling system for connec tions Refer to CIRCUIT DIAGRAM Correct POOR CONNECTION CORRECT GOOD CONDITION 1 2 WARNING S Handle the thermo unit with special care S Never subject it to strong shock or allow it to be dropped Should it be dropped it must be replaced Replace the temperature meter COOLING SYS...

Page 320: ...rcuit is broken shorted or the TPS throttle position sensor is locked In that case it would be best to inspect it 0 rpm 3 seconds 3 000 rpm 2 5 seconds present engine revolutions 3 seconds The above pattern is repeated The needle of the tachometer keeps pointing to 0 rpm for 6 seconds when the engine is not run ning If any trouble occurs in the TPS the ignition tim ing signal transmitted from the ...

Page 321: ...N SOR ADJUSTMENT AND INSPECTION in CHAPTER 6 GOOD CONDITION 2 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM CONTINUITY Replace the ignitor unit Repair or replace wire harness NO CONTINUITY Check the TPS throttle position sensor for continuity TROUBLESHOOTING IF THE TACHOMETER S TPS THROTTLE POSITION SENSOR SELF DIAGNOSIS OPERATES Procedure Check 1 TPS throttle positio...

Page 322: ...ELEC ...

Page 323: ...TRBL SHTG 9 ...

Page 324: ...NG 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMP OUT GEAR 9 3 CLUTCH SLIPPING DRAGGING 9 3 CLUTCH SLIPPING 9 3 CLUTCH DRAGGING 9 3 OVERHEATING 9 4 OVERHEATING 9 4 FAULTY BRAKE 9 4 POOR BRAKING EFFECT 9 4 FRONT FORK OIL LEAKAGE AND FORK MALFUNCTION 9 4 OIL LEAKAGE 9 4 MALFUNCTION 9 4 INSTABLE HANDLING 9 5 INSTABLE HANDLING 9 5 FAULTY LIGHTING AND SIGNAL SYSTEM 9 5 HEADLIGHT DARK 9 5 BULB BURNT OUT 9 5 FLA...

Page 325: ...TRBL SHTG ...

Page 326: ...d in air Deformed float Groove worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction Improperly adjusted starter cable Air cleaner Clogged air filter Fuel pump Faulty fuel pump ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark ...

Page 327: ...EED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot air jet Improperly synchronized carburetors Improperly adjusted idle speed throttle stop screw Improper throttle cable free play Flooded carburetor Electrical system Faulty battery Faulty spark plug Faulty ignitor unit Faulty pickup coil Faulty ignition coil Valve train Improper...

Page 328: ...Improperly returned stopper level Shift fork Worn shift fork Shift cam Improper thrust play Worn shift cam groove Transmission Worn gear dog CLUTCH SLIPPING DRAGGING CLUTCH SLIPPING Clutch Improperly adjusted clutch cable Loose clutch spring Fatigued clutch spring Worn friction plate clutch plate Incorrectly assembled clutch Engine oil Low oil level Improper quality low viscosity Deterioration CLU...

Page 329: ...h Clogged or damaged radiator Faulty radiator cap Seized impeller shaft Inoperative fan motor FAULTY BRAKE POOR BRAKING EFFECT Disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty cylinder cup kit Faulty caliper seal kit Loose union bolt Broken brake hose Oily or greasy disc brake pads Improper brake fluid level FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION OIL LE...

Page 330: ...ks Wheels Incorrect wheel balance Deformed wheel Damaged bearing Bent or loose wheel axle Excessive wheel run out Frame Twisted Damaged head pipe Improperly installed bearing race FAULTY LIGHTING AND SIGNAL SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken stator coil wire faulty rec tifier regulator Incorrect connection Improperly grounded Poor contacts main o...

Page 331: ...ER KEEPS ON Faulty flasher relay Bulb burnt out FLASHER WINKS QUICKER Improper bulb Faulty flasher relay Bulb burnt out HORN IS INOPERATIVE Faulty battery Faulty fuse Faulty main and or horn switch Improperly adjusted horn Faulty horn Broken wire harness ...

Page 332: ...Sidestand switch 11 T P S throttle position sensor 12 Ignitor unit 13 Ignition coil 14 Spark plug 15 Thermo unit 16 Meter assembly 17 Tachometer 18 Water temperature meter 19 Meter light 20 Neutral indicator light 21 High beam indicator light 22 Turn indicator light 23 Rear flasher light 24 Front flasher light 25 Headlight 26 Auxiliary light 27 Left handlebar switch 28 Horn switch 29 Horn 30 Light...