EB000000

XVS650
SERVICE MANUAL
1996 by Yamaha Motor Co.Ltd.
First edition, September 1996
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000

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

Yamaha Motor Company, Ltd.is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.

EXPLODED DIAGRAMS
To help 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 easy-to-read way by the use of symbol marks
6 . The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.

2 1 6

7
 EB003000

1 2 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on the
top right of each page and indicate the subject
of each chapter.
3 4
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Engine
5 6 5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
7 8

9 10 Illustrated symbols 10 to 17 are used to identify

the specifications appearing in the text.
10 Can be serviced with engine mounted
11 Filling fluid
11 12 12 Lubricant
13 Special tool
14 Torque
15 Wear limit, clearance
16 Engine speed
13 14
17 Ω, V, A

15 16 17
Illustrated symbols 18 to 23 in the exploded dia-
grams indicate the types of lubricants and lu-
brication points.
18 19 20 18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
21 22 23 23 Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded dia-
grams indicate where to apply locking agent 24
and when to install new parts 25 .
24 25 24 Apply locking agent (LOCTITE))
25 Replace
E004000

CHAPTER TITLES
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
ADJUSTMENTS INSP
ADJ 3
ENGINE OVERHAUL ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
 GEN
INFO
CHAPTER 1.
GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . 1-2
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

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

GEN
INFO
 GEN
MOTORCYCLE IDENTIFICATION INFO
EB100000

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped
into the right side of the steering head.

MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare parts.

1-1
 GEN
IMPORTANT INFORMATION INFO
EB101000

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1. Remove all dirt, mud, dust and foreign ma-
terial before removal and disassembly.

2. Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be reused
or replaced as an assembly.
4. During machine disassembly, clean all
parts and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5. Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

1-2
 GEN
IMPORTANT INFORMATION INFO
EB101030

LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates 1 and
cotter pins after removal. Bend lock tabs
along the bolt or nut flats after the bolt or nut
has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coating of lightweight lithium base grease
to the seal lips. Oil bearings liberally when
installing, if appropriate.
1 Oil seal

CAUTION:
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.

1 Bearing

EB101050

CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips af-
ter one use. Replace distorted circlips.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positioned op-
posite the thrust 3 it receives. See section-
al view.
4 Shaft

1-3
 GEN
CHECKING OF CONNECTIONS INFO
EB801000

CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
 Connector
2. Check:
 Connector
Moisture
Dry each terminal with an air
blower.
Stains/rust
Connect and disconnect
the terminals several times.
3. Check:
 Connector leads
Looseness
Bend up the pin 1 and con-
nect the terminals.

4. Connect:
 Connector terminals
NOTE:
The two terminals “click” together.

5. Check:
 Continuity (using a pocket tester)
NOTE:

If there is no continuity, clean the terminals.

When checking the wire harness be sure to
perform steps 1 to 3.

As a quick remedy, use a contact revitalizer
available at most part stores.

Check the connector with a pocket tester as
shown.

1-4
 GEN
SPECIAL TOOLS INFO
EB102001

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/How to use Illustration

Weight Slide hammer bolt/weight

90890-01084
Bolt These tools are used to remove the
90890-01085 rocker arm shaft.
Final gear backlash band

90890-01231
This tool is needed when measuring
final gear backlash.
Piston pin puller

90890-01304
This tool is used to remove the
piston pin.
Fuel level gauge

90890-01312
This gauge is used to measure the
fuel level in the float chamber.

T-handle T-handle/damper rod holder

90890-01326
Holder These tools are needed to loosen and
90890-01388 tighten the damper rod holding bolt.

Puller Flywheel puller/adapter

90890-01362
Adapter These tools are needed to remove
90890-04089 the rotor.

Weight Fork seal driver weight/adapter

90890-01367 These tools are needed when installing
Adapter the slide metal, oil seal and dust seal into
90890-01381 the fork.
Ring nut wrench

90890-01403
This tool is needed to loosen and tighten
the steering stem ring nut.

1-5
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name/How to use Illustration

Sheave holder

90890-01701 This tool is needed to hold the rotor

when removing or installing the rotor
bolt.
Compression gauge set

90890-03081
These tools are needed to measure
engine compression.
Vacuum gauge

90890-03094
This gauge is needed for carburetor
synchronization.
Pocket tester

90890-03112
This instrument is needed for checking
the electrical system.
Engine tachometer

90890-03113
This tool is needed for observing
engine rpm.
Timing light

90890-03141
This tool is necessary for checking
ignition timing.
Valve guide remover & installer

90890-04018
This tool is needed to remove and
install the valve guide.
Valve spring compressor

90890-04019
This tool is needed to remove and
install the valve assemblies.
Bearing retainer wrench

90890-04050
This tool is needed when removing or
installing the final drive shaft bearing.

1-6
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name/How to use Illustration

Bearing retainer wrench

90890-04057 This tool is needed when removing or

installing the middle driven shaft
bearing.
Driver
Middle driven shaft bearing driver
90890-04058
Plain bearing installer/remover
Installer/
These tools are needed when removing
remover
or installing the main journal bearing.
90890-04074
Universal joint holder

90890-04062
This tool is needed when removing or
installing the driven pinion gear nut.
Middle gear backlash tool

90890-04080
This tool is needed for the gear backlash
adjustment.
Clutch holding tool

90890-04086 This tool is needed to hold the clutch

when removing or installing the clutch
boss nut.
Damper spring compressor

90890-04090
This tool is needed when removing or
installing the damper spring.
Ignition checker

90890-06754
This instrument is necessary for checking
the ignition system components.
Yamaha bond No.1215

90890-85505
This sealant (bond) is used on crankcase
mating surfaces, etc.

1-7
GEN
INFO
 SPEC
CHAPTER 2.
SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

SPEC
 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS

Item Standard
Model code: XVS650: 4VR1, 4VR2
Dimensions:
Overall length 2,340 mm
Overall width 2,880 mm
Overall height 1,065 mm
Seat height 2,695 mm
Wheelbase 1,610 mm
Minimum ground clearance 2,140 mm
Minimum turning radius 3,100 mm
Basic weight:
With oil and a full fuel tank 227 kg
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement V-type 2-cylinder
Displacement 0.649 L
Bore stroke 81
63 mm
Compression ratio 9:1
Compression pressure (STD) 1,000 kPa (10 kg/cm2, 10 bar) at 300 r/min
Starting system Electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
Temp.
C

API standard: API SE or higher grade

Final gear oil: SAE80API “GL-4” Hypoid Gear Oil
Oil quantity:
Engine oil
Periodic oil change 2.6 L
With oil filter replacement 2.8 L
Total amount 3.2 L
Final gear case oil
Total amount 0.19 L
Air filter: Dry type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 16 L
Fuel reserve amount 3.0 L

2-1
 GENERAL SPECIFICATIONS SPEC

Item Standard
Carburetor:
Type/quantity BDS28/2
Manufacturer MIKUNI
Spark plug:
Type DPR7EA-9/X22EPR-U9
Manufacturer NGK/DENSO
Spark plug gap 0.8 X 0.9 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 68/38 (1.789)
Secondary reduction system Shaft drive
Secondary reduction ratio 19/18 32/11 (3.071)
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 38/14 (2.714)
2nd 38/20 (1.900)
3rd 35/24 (1.458)
4th 28/24 (1.167)
5th 29/30 (0.967)
Chassis:
Frame type Double cradle
Caster angle 35

Trail 153 mm
Tire:
Type With tube
Size front 100/90-19 57S
rear 170/80-15M/C 77S
Manufacturer front BRIDGESTONE/DUNLOP
rear BRIDGESTONE/DUNLOP
Type front L309/F24
rear G546/K555
Maximum load-except motorcycle: 180 kg
Tire pressure (cold tire):
0 X 90 kg load *
front 200 kPa (2.00 kg/cm2, 2.00 bar)
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
90 kg X Maximum load *
front 200 kPa (2.00 kg/cm2, 2.00 bar)
rear 250 kPa (2.50 kg/cm2, 2.50 bar)
* Load is the total weight of the cargo, rider,
passenger and accessories.
Brake:
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation

2-2
 GENERAL SPECIFICATIONS SPEC

Item Standard
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (Monocross)
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Gas-oil damper
Wheel travel:
Front wheel travel 140 mm
Rear wheel travel 86 mm
Electrical:
Ignition system T.C.I. (digital)
Generator system A.C. magneto
Battery type GT12B-4
Battery capacity 12 V 10 AH
Headlight type: Quartz bulb (halogen)
Bulb wattage
quantity:
Headlight 12 V 60 W/55 W
Tail/brake light 12 V 5 W/21 W
Turn signal 12 V 21 W
4
Auxiliary light 12 V 4 W
1
Licence light 12 V 5 W
1
Meter light 12 V 1.7 W
1
Neutral indicator light 12 V 3 W
1
High beam indicator light 12 V 1.7 W
1
Turn indicator light 12 V 3 W
1

2-3
 MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE

Item Standard Limit

Cylinder head:
Warp limit SSS 0.03 mm

Cylinder:
Bore size 80.945 X 80.995 mm 81.1 mm
Measuring point* 40 mm SSS

Camshaft:
Drive method Chain drive (left & right) SSS
Cam cap inside diameter 28.000 X 28.021 mm SSS
Camshaft outside diameter 27.96 X 27.98 mm SSS
Shaft-to-cap clearance 0.020 X 0.061 mm SSS
Cam dimensions

Intake “A” 39.733 mm 39.63 mm

“B” 32.217 mm 32.12 mm
“C” 7.733 mm SSS
Exhaust “A” 39.772 mm 39.67 mm
“B” 32.302 mm 32.20 mm
“C” 7.772 mm SSS
Camshaft runout limit SSS 0.03 mm

2-4
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Timing chain:
Timing chain type/No. of links SILENT CHAIN/118 SSS
Timing chain adjustment method Automatic SSS
Rocker arm/rocker arm shaft:
Bearing inside diameter 14.000 mm X 14.018 mm SSS
Shaft outside diameter 13.980 mm X 13.991 mm SSS
Arm-to-shaft clearance 0.009 mm X 0.038 mm SSS
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.07 X 0.12 mm SSS
EX 0.12 X 0.17 mm SSS
Valve dimensions:

Head Dia Face width Seat Width Margin Thickness

“A” head diameter IN 36.9 X 37.1 mm SSS

EX 31.9 X 32.1 mm SSS
“B” face width IN 2.3 mm SSS
EX 2.3 mm SSS
“C” seat width IN 1.0 X 1.2 mm 1.8 mm
EX 1.0 X 1.2 mm 1.8 mm
“D” margin thickness IN 1.0 X 1.4 mm 0.8 mm
EX 1.0 X 1.4 mm 0.8 mm
Stem outside diameter IN 6.975 X 6.990 mm 6.955 mm
EX 6.960 X 6.975 mm 6.935 mm
Guide inside diameter IN 7.000 X 7.012 mm 7.042 mm
EX 7.000 X 7.012 mm 7.042 mm
Stem-to-guide clearance IN 0.010 X 0.037 mm 0.08 mm
EX 0.025 X 0.052 mm 0.10 mm
Stem runout limit SSS 0.03 mm

Valve seat width IN 1.0 X 1.2 mm 1.8 mm

EX 1.0 X 1.2 mm 1.8 mm
Valve spring:
Free length IN 43.2 mm 42.0 mm
EX 43.2 mm 42.0 mm
Set length (valve closed) IN 37.1 mm SSS
EX 37.1 mm SSS

2-5
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Compressed pressure IN 21.8  25.6 kg



(installed)
EX 21.8  25.6 kg



Tilt limit * IN


2.5/1.9
mm
EX


2.5/1.9
mm

Direction of winding
(top view)IN Counter clockwise



EX Counter clockwise



Piston:
Piston to cylinder clearance 0.035  0.055 mm 0.15 mm
Piston size “D” 80.90  80.95 mm

Measuring point “H” 6 mm

Oversize 2nd 81.5 mm



Oversize 4th 82 mm



Piston off-set 0 mm



Piston pin bore inside diameter 20.004  20.015 mm



Piston pin outside diameter 19.995  20.000 mm



Piston rings:
Top ring:

Type Plain

Dimensions (B
T) 1.2
3.2 mm



End gap (installed) 0.15  0.30 mm 0.55 mm
Side clearance (installed) 0.03  0.07 mm 0.12 mm

2-6
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

2nd ring:

Type
Dimensions (B T) Taper SSS
End gap (installed) 1.5 3.6 mm SSS
Side clearance 0.30 X 0.45 mm 0.8 mm
Oil ring: 0.02 X 0.06 mm 0.12 mm

Dimensions (B T)
End gap (installed) 2.5 3.1 mm SSS
0.2 X 0.7 mm SSS
Connecting rod:
Oil clearance 0.026 X 0.050 mm SSS
Color code (corresponding size) 1 Blue 2 Black 3 Brown 4 Green SSS
Crankshaft:

Crank width “A” 93.95 X 94.00 mm SSS

Runout limit “C” SSS 0.02 mm
Big end side clearance “D” 0.270 X 0.424 mm SSS
Big end radial clearance “E” 0.026 X 0.050 mm SSS
Journal oil clearance 0.020 X 0.052 mm SSS
Clutch:
Friction plate thickness 2.9 X 3.1 mm 2.6 mm
Quantity 7 SSS
Clutch plate thickness 1.5 X 1.7 mm 0.2 mm
Quantity 6 SSS
Clutch spring free length 39.5 mm 38.5 mm
Quantity 5 SSS
Clutch housing thrust clearance 0.10 X 0.37 mm SSS
Clutch housing radial clearance 0.015 X 0.043 mm SSS
Clutch release method Inner push, cam push SSS
Push rod bending limit SSS 0.5 mm

2-7
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Transmission:
Main axle deflection limit


0.06 mm
Drive axle deflection limit


0.06 mm
Shifter:
Shifter type Guide bar



Carburetor:
I. D. mark 4VR 00



Main jet (M.J) #90



Main air jet (M.A.J) #50



Jet needle (J.N) 4CP10-3



Needle jet (N.J) O-6



Pilot air jet (P.A.J.1) #100



Pilot outlet (P.O) 0.85



Pilot jet (P.J) #20



Bypass 1 (B.P.1) 0.8



Bypass 2 (B.P.2) 0.8



Bypass 3 (B.P.3) 0.8



Pilot screw (P.S) 2



Valve seat size (V.S) 1.0



Starter jet (G.S.1) #17.5



Starter jet (G.S.2) 0.9



Throttle valve size (Th.V) #140



Fuel level (F.L) 7.5
8.5 mm



Engine idle speed 1,150
1,250 r/min



Intake vacuum 29.0 kPa (0.29 kg/cm2, 220 mmHg)



CO % 3
4%



Engine oil temperature 80
90 C



Fuel pump:
Type Electrical type



Model/manufacturer UC-Z6M/MITSUBISHI



Consumption amperage <max> 0.8 A



Output pressure 12 kPa (0.12 kg/cm2, 0.12 bar)



Lubrication system:
Oil filter type Paper type



Oil pump type Trochoid type



Tip clearance “A” or “B” 0.12 mm 0.2 mm
Side clearance 0.03
0.08 mm 0.15 mm
Relief valve operating pressure 440
540 kPa (4.5
5.5 kg/cm2,



4.5
5.5 bar)
Oil pressure (hot) 10 kPa (0.1 kg/cm2, 0.1 bar) at 1,200



r/min
Pressure check location H/C UNION BOLT



Shaft drive:
Middle gear backlash 0.05
0.10 mm



Final gear backlash 0.1
0.2 mm

2-8
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard
Lubrication chart:

Pressure feed

Splashed

Camshaft Rocker arm shaft

Piston

Middle gear housing Drive axle

Starter clutch Crankshaft

Main axle

Oil filter

Oil pump Relief valve

Oil strainer

2-9
 MAINTENANCE SPECIFICATIONS SPEC
Cylinder head tightening sequence:

Crankcase tightening sequence:

Left crankcase Right crankcase

2-10
 MAINTENANCE SPECIFICATIONS SPEC
Tightening torques
Tightening
Thread torque
g
Part to be tightened Part name Q’ty
y Remarks
size
Nm mSkg
Cylinder head Nut M10 8 35 3.5
Cylinder head Nut M8 2 20 2.0
Cylinder head Bolt M8 4 20 2.0
Cylinder head cover bracket Nut M10 8 35 3.5
Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5
Camshaft sprocket cover Bolt M6 4 10 1.0
Tappet cover Bolt M6 8 10 1.0
Rocker arm shaft (oil passage) Bolt M16 4 38 3.8
Bearing retainer (camshaft) Bolt M8 4 20 2.0 Use lock washer
Spark plug — M12 2 18 1.8
Cylinder Bolt M6 2 10 1.0
Lower cylinder head cover Bolt M6 6 10 1.0
Upper cylinder head cover Screw M6 8 5 0.5
Connecting rod Nut M8 4 36 3.6
Rotor Bolt M10 1 80 8.0
Valve adjusting locknut Nut M6 4 14 1.4
Camshaft sprocket Bolt M10 2 55 5.5
Timing chain tensioner Bolt M6 4 12 1.2
Timing chain guide Bolt M6 4 10 1.0
Oil pump Bolt M6 3 7 0.7
Oil strainer cover Bolt M6 3 10 1.0
Oil filter cover Bolt M6 5 10 1.0
Carburetor joint Bolt M6 4 12 1.2
Air filter case stay Bolt M6 2 12 1.2
Air filter case assembly Bolt M6 2 12 1.2
Exhaust pipe joint (rear) and
Nut M8 2 20 2.0
cylinder head
Exhaust pipe joint (rear) and
Bolt M8 2 20 2.0
muffler assembly (rear)
Exhaust pipe (front) Nut M8 2 25 2.5
Exhaust pipe and muffler Screw M8 2 20 2.0
Muffler Bolt M10 2 25 2.5
Crankcase (cylinder) Stud bolt M10 8 20 2.0
Crankcase (cylinder) Stud bolt M8 2 13 1.3
Crankcase Bolt M8 4 24 2.4
Crankcase Bolt M6 10 10 1.0
Bearing retainer (middle drive
Torx screw M8 4 25 2.5 Stake
pinion gear)
Crankcase cover (left) Bolt M6 13 10 1.0
Crankcase cover (right) Bolt M6 11 10 1.0
Clamp Bolt M6 1 10 1.0
One-way clutch Bolt M8 6 20 2.0
Primary drive gear Nut M10 1 70 7.0 Use lock washer

2-11
 MAINTENANCE SPECIFICATIONS SPEC

Tightening
Thread torque
Part to be tightened
g Part name Q’ty
y Remarks
size
Nm mSkg
Clutch spring Bolt M6 5 8 0.8
Clutch adjuster Nut M6 1 8 0.8
Clutch boss Nut M20 1 70 7.0 Use lock washer
Push lever axle Screw M8 1 12 1.2
Middle drive pinion gear Nut M20 1 120 12.0 Stake
Bearing retainer (middle driven
— M65 1 110 11.0
shaft)
Yoke (middle driven shaft) Nut M14 1 90 9.0
Bearing housing (middle drive
Bolt M8 4 25 2.5
shaft)
Shift lever stopper Bolt M8 1 22 2.2 Use lock washer
Shift pedal link Bolt M6 1 10 1.0
1 of 2 has LH
Shift pedal adjuster Nut M6 2 7 0.7 thread
Stator coil Screw M6 3 7 0.7
Pickup coil Screw M6 3 7 0.7

2-12
 MAINTENANCE SPECIFICATIONS SPEC
CHASSIS

Item Standard Limit

Steering system:
Steering bearing type Ball & taper roller bearing SSS
No./size of steel ball (upper) 19 pcs/0.25 in SSS
Front suspension:
Front fork travel 140 mm SSS
Fork spring free length 295 mm 289 mm
Fitting length 249.9 mm SSS
Spring rate (K1) 3.5 N/mm (0.35 kg/mm) SSS
Stroke (K1) 0 X 140 mm SSS
Optional spring No SSS
Oil capacity 0.454 L SSS
Oil level 114 mm SSS
Oil grade Fork oil 10W or equivalent SSS
Rear suspension:
Shock absorber travel 37 mm SSS
Spring free length 168.5 mm 165 mm
Fitting length 160.5 mm SSS
Spring rate (K1) 186 N/mm (18.6 kg/mm) SSS
Stroke (K1) 0 X 37 mm SSS
Optional spring No SSS
Swingarm:
Free play limit end SSS 1 mm
side SSS 1 mm
Front wheel:
Type Spoke wheel SSS
Rim size 19 MT2.50 SSS
Rim material Steel SSS
Rim runout limit radial 1.0 mm 2 mm
lateral 0.5 mm 2 mm
Rear wheel:
Type Spoke wheel SSS
Rim size 15M/C MT3.50 SSS
Rim material Steel SSS
Rim runout limit radial 1.0 mm 2 mm
lateral 0.5 mm 2 mm
Front brake:
Type Single disk SSS
Disc outside diameter thickness 298 5 mm SSS
Pad thickness inner 6.2 mm 0.8 mm
Pad thickness outer 6.2 mm 0.8 mm

2-13
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Master cylinder inside diameter 12.7 mm SSS

Caliper cylinder inside diameter 30.1 mm SSS
Caliper cylinder inside diameter 33.3 mm SSS
Brake fluid type DOT 4 SSS
Rear brake:
Type Leading, trailing SSS
Brake drum inside diameter 200 mm 201 mm
Lining thickness 4 mm 2 mm
Shoe spring free length 68 mm SSS
Brake lever & brake pedal:
Brake lever free play (at pivot) 1 X 2 mm SSS
Brake lever free play (at lever end) 10 X 15 mm SSS
Brake pedal position 85 m SSS
Brake pedal free play 20 X 30 mm SSS
Clutch lever free play (at pivot) 2 X 3 mm SSS
Clutch lever free play (at lever 10 X 15 mm SSS
end)

2-14
 MAINTENANCE SPECIFICATIONS SPEC
Tightening torques
Tightening
g
Part to be tightened Thread size torque Remarks
Nm mSkg
Upper bracket and inner tube M8 20 2.0
Lower bracket and inner tube M10 30 3.0
Upper bracket and steering shaft M22 110 11.0
Ring nut (steering shaft) — 18 1.8 See NOTE
Handlebar holder (lower) and upper bracket M12 20 2.0
Handlebar holder (lower) and handlebar
M8 23 2.3
holder (upper)
Master cylinder (front brake) M6 10 1.0
Union bolt (brake hose) M10 30 3.0
Brake hose holder and lower bracket M6 9 0.9
Front fender and outer tube M8 10 1.0
Headlight stay and lower bracket M6 7 0.7
Headlight stay and headlight M6 8 0.8
Front flasher light and lower bracket M6 7 0.7
Engine mounting:
Frame and stay (front - upper) M8 40 4.0
Frame and stay (front - lower) M8 30 3.0
Stay and engine (front - upper) M10 40 4.0
Stay and engine (front - lower) M10 40 4.0
Frame and engine (rear - upper) M10 40 4.0
Frame and engine (rear - lower) M12 74 7.4
Regulator stay and frame M6 13 1.3
Regulator and regulator stay M6 7 0.7
Muffler stay and frame M8 30 3.0
Rear shock absorber and swingarm M12 62 6.2
Rear shock absorber and frame M12 62 6.2
Pivot shaft (left) and frame M22 100 10.0
Pivot shaft (right) and frame M22 7 0.7
Pivot shaft (right) and locknut M22 100 10.0
Final gear case and swingarm M10 70 7.0
Fuel tank and fuel cock M6 7 0.7
Fuel tank bracket and frame M8 23 2.3
Rider’s seat M6 7 0.7
Passenger seat M6 7 0.7
Frame and rear fender stay M10 26 2.6
Rear fender and rear fender stay M8 26 2.6
Rear fender and tail/brake light M6 6 0.6
Rear fender stay and rear flasher light M12 23 2.3
Side cover (lower) M6 7 0.7
Battery cover M6 7 0.7
Side cover (right) M6 7 0.7
Starter relay and leads M6 7 0.7

2-15
 MAINTENANCE SPECIFICATIONS SPEC

Tightening
Part to be tightened
g Thread size torque Remarks
Nm mSkg
Passenger footrest and frame M8 26 2.6
Sidestand bracket and frame M10 64 6.4
Sidestand and sidestand bracket M10 56 5.6
Sidestand switch M5 4 0.4
Brake pedal/footrest and frame M6 64 6.4
Front wheel axle M16 59 5.9
Front wheel axle pinch bolt M8 20 2.0
Brake caliper M10 40 4.0
Brake disc and front wheel M8 23 2.3
Caliper bleed screw M7 6 0.6
Rear wheel axle nut M14 97 9.7
Tension bar and swingarm M8 20 2.0
Tension bar and brake shoe plate M8 20 2.0
Brake cam shaft lever M6 10 1.0
Clutch hub and damper M10 62 6.2
Final gear case (housing cover) M10 18 1.8
Bearing housing (final gear case) M8 23 2.3
Bearing housing (final gear case) M10 23 2.3
Bearing retainer (final drive pinion gear) M65 115 11.5 LH thread
Oil filter bolt (final gear) M14 23 2.3
Oil drain bolt (final gear) M14 23 2.3
Housing cover M10 42 4.2

NOTE:
1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then loosen
the ring nut completely.
2. Retighten the ring nut to specification.

2-16
 MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL

Item Standard Limit

Voltage: 12 V



Ignition system:
Ignition timing (B.T.D.C.) 12 at 1,200 r/min



Advancer type TPS and electrical type



T.C.I.:
Pickup coil resistance/color 182
222 Ω at 20C/Gray – Black



T.C.I. unit model/manufacturer J4T079/MITSUBISHI



Ignition coil:
Model/manufacturer F6T541 /MITSUBISHI



Minimum spark gap 6 mm



Primary winding resistance 3.8
4.6 Ω at 20C



Secondary winding resistance 10.1
15.1 kΩ at 20C



Spark plug cap:
Type Resin type



Resistance 10 kΩ



Charging system:
Type A.C. magneto



Model/manufacturer F4T459 /MITSUBISHI



Nominal output 14 V 20 A at 5,000 r/min



Stator coil resistance/color 0.50
0.62 Ω at 20C/White – White



Voltage regulator:
Type Semi-conductor, short-circuit type



Model/manufacturer SH650A-12/SHINDENGEN



No load regulated voltage 14.1
14.9 V



Rectifier:
Model/manufacturer SH650A-12/SHINDENGEN



Capacity 25 A



Withstand voltage 240 V



Battery:
Specific gravity 1.320



Electric starter system:
Type Constant mesh type



Starter motor:
Model/manufacturer SM-13/MITSUBA



I.D.number SM-13



Output 0.7 kW



Brush overall length 12.5 mm 4 mm
Commutator diameter 28 mm 27 mm
Mica undercut 0.7 mm



Starter relay:
Model/manufacturer MS-5F/JIDECO



Amperage rating 100 A

2-17
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Horn:
Type Plane type SSS
Quantity 1 SSS
Model/manufacturer YF-12/NIKKO SSS
Maximum amperage 1.5 A SSS
Flasher relay:
Type Full transistor type SSS
Model/manufacturer FE246BH/DENSO SSS
Self cancelling device No SSS
Flasher frequency 75 X 95 cycle/min SSS
Wattage 21 W 2 + 3W SSS
Fuel pump relay:
Model/manufacturer G8R-30Y/OMRON SSS
Circuit breaker:
Type Fuse SSS
Amperage for individual circuit
MAIN 30 A 1 SSS
HEAD LIGHT 15 A 1 SSS
SIGNALS 10 A 1 SSS
IGNITION 10 A 1 SSS
Reserve 30 A 1 SSS
Reserve 15 A 1 SSS
Reserve 10 A 1 SSS

2-18
 GENERAL TORQUE SPECIFICATIONS SPEC
EB202001
General torque
GENERAL TORQUE A B specifications
SPECIFICATIONS (nut) (Bolt)
This chart specifies torque for standard fasten- Nm mSkg
ers with standard I.S.O. pitch threads. Torque 10 mm 6 mm 6 0.6
specifications for special components or as- 12 mm 8 mm 15 1.5
semblies are provided for each chapter of this
14 mm 10 mm 30 3.0
manual. To avoid warpage, tighten multi-fasten-
er assemblies in a crisscross fashion, in pro- 17 mm 12 mm 55 5.5
gressive stages, until the specified torque is 19 mm 14 mm 85 8.5
reached. Unless otherwise specified, torque 22 mm 16 mm 130 13.0
specifications require clean, dry threads. Com-
ponents should be at room temperature.

A: Distance between flats

B: Outside thread diameter

2-19
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203000

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point Symbol

Oil seal lips

O-ring

Bearing

Connecting rod bolt/nut

Connecting rod small end and big end

Crankshaft pin

Crankshaft journal/big end

Piston surface

Piston pin

Camshaft cam lobe/journal

Rocker arm shaft

Valve stem (IN, EX)

Valve stem end (IN, EX)

Oil pump rotor (inner/outer), housing

Idle gear surface

Starter idle gear

Starter idle gear shaft

Middle drive gear

Primary driven gear

Push rod 1

Transmission gear (wheel/pinion)

Shift cam

Shift fork/guide bar

Shift shaft assembly

Valve spring (intake)

Push rod ball

Push lever assembly

2-20
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203010

CHASSIS

Lubrication point Symbol

Steering head pipe (upper/lower), bearing

Steering head pipe, bearing cover lip

Steering head pipe, oil seal lip

Front wheel oil seal lip (right/left)

Rear wheel oil seal lip

Clutch hub fitting area

Rear brake pedal shaft

Shift pedal shaft

Sidestand bolt, sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever pivot bolt, contact surface

Clutch lever pivot bolt, contact surface

Rear shock absorber (lower) oil seal lip

Swingarm pivot bearing inner surface

Swingarm pivot oil seal lip

2-21
 LUBRICATION DIAGRAMS SPEC
EB205000

LUBRICATION DIAGRAMS
1 Rocker arm (intake) 4 Drain bolt 7 Push rod 1
2 Rocker arm (exhaust) 5 Oil strainer 8 Oil pump
3 Camshaft 6 Push lever

2-22
 LUBRICATION DIAGRAMS SPEC
1 Rocker arm shaft (intake) 4 Drive axle 7 Oil filter
2 Rocker arm shaft (exhaust) 5 Relief valve 8 Crankshaft
3 Camshaft 6 Oil pump

2-23
 LUBRICATION DIAGRAMS SPEC
1 Crankshaft
2 Oil filter
3 Oil pump

2-24
 LUBRICATION DIAGRAMS SPEC
1 Camshaft 4 Drive axle
2 Rocker arm 5 Main axle
3 Starter idle gear

2-25
 CABLE ROUTING SPEC
EB206000

CABLE ROUTING
1 Clutch cable 10 Horn
2 Left handlebar switch lead 11 Headlight lead
3 Fuel tank breather hose 12 Right handlebar switch lead
4 Speedometer cable 13 Spark plug lead
5 Speedometer 14 Fuel hose
6 Speedometer light leads 15 Main switch lead
7 Rectifier/ regulator 16 Fuel pump lead
8 Rear brake switch lead 17 Main switch
9 Sidestand switch lead 18 Fuel pump

2-26
 CABLE ROUTING SPEC
A Pass the front flasher light leads (left and E Connect the rear brake switch coupler in front
right) and headlight lead through the of the roll over valve stay.
headlight cover hole. F To the speedometer light leads.
B Pass the left handlebar switch lead behind G Pass the right handlebar switch lead and head-
the upper bracket. light lead over the other harness and leads.
C Fasten the left handlebar switch lead with a H Pass the clutch cable through the cable guide.
plastic locking tie. I Fasten the sidestand switch lead and rectifier/
D Pass the speedometer cable, speedometer regulator lead with a plastic locking tie.
light leads and fuel tank breather hose J To the engine.
through the fuel tank hole. K The sidestand switch lead should not touch
the shift rod.

2-27
 CABLE ROUTING SPEC
L Fasten the sidestand switch lead with a metal Q Fasten the rear brake switch lead and rectifier/
clamp. regulator lead with a plastic locking tie.
M Fasten the rear brake switch lead, sidestand R Place the couplers behind the steering head.
switch lead and rectifier / regulator lead with S Pass the speedometer cable through the
a metal clamp. holder.
N Pass the speedometer cable through the T Pass the fuel tank breather hose through the
speedometer cable holder. holder.
O To the rectifier / regulator. U To the speedometer light leads.
P Pass the rear brake switch lead between the
frame and rectifier / regulator. Do not pinch
the rear brake switch lead.

2-28
 CABLE ROUTING SPEC
1 Frame bracket 12 Starter relay A Pass the tail/brake light lead
2 Wire harness 13 Carburetor heater relay between the frame bracket and
3 Fuse box 14 Neutral switch lead battery box.
4 Battery positive (+) lead 15 Pickup coil lead B Fasten the tail/brake light lead
5 Spark plug lead 16 A.C. magneto lead with a battery band. Do not
6 Starter cable 17 Battery negative (–) lead pinch the harness and tail/
7 Right handlebar switch lead 18 Starter motor lead brake light lead.
8 Brake hose 19 Starting circuit cut-off relay C To the ignition coil.
9 Throttle cables 20 Fuel tank breather hose D The end of the plastic locking
10 Thermo switch lead 21 Speedometer cable tie should face towards the
11 Flasher light relay 22 Ignitor unit under the handlebar.

2-29
 CABLE ROUTING SPEC
E Fasten the right handlebar switch lead with a K Fasten the fuse box lead with a plastic locking
plastic locking tie. tie.
F Pass the right handlebar switch lead behind L Fasten the battery positive (+) lead with a bat-
the upper bracket. tery box clamp.
G Fasten the brake hose with a brake hose M The carburetor heater relay should not touch
holder. the wire harness.
H Pass the left handlebar switch lead under the N Fasten the wire harness with a plastic locking
main switch. tie.
I Fasten the spark plug lead with a metal clamp. O From the engine.
J Pass the ignition coil lead inside of the starter P Pass the starter motor lead over the battery
cable. negative (–) lead.

2-30
 CABLE ROUTING SPEC
Q Fasten the pickup coil lead, A.C. magneto V Fasten the starter cable with a plastic locking
lead, neutral switch lead and starter motor tie.
lead with a plastic locking tie. W Inside the motorcycle.
R Fasten the battery negative (–) lead, starter X Pass the fuel tank breather hose through the
motor lead and wire harness with a plastic holder.
locking tie. Y Fasten the fuel tank breather hose with a
S Fasten the wire harness with a battery band. metal clamp.
T Pass the wire harness between the frame and Z Pass the speedometer cable through the
battery box. front side guide.
U Place the end of the plastic locking tie as a Fasten the wire harness and leads with a
shown. plastic locking tie.

2-31
 CABLE ROUTING SPEC
b Fasten the wire harness and leads with a h To the flasher light relay.
metal clamp. i To the rear fender.
c To the carburetor heater relay. j To the battery negative (–) lead.
d Fasten the wire harness and leads with a k Pass the ignitor unit leads through the
plastic locking tie. battery box hole.
e Pass the plastic band through the frame hole.
Fasten the wire harness with a plastic band at
the point where the tape is located.
f The wire harness and leads should not touch
the rear shock absorber.
g To the starter relay.

2-32
 CABLE ROUTING SPEC
1 Front flasher light (right) 12 Speedometer cable A Pass the throttle cables
2 Throttle cables 13 Neutral switch lead through the cable guide.
3 Brake hose 14 Pickup coil lead B Pass the brake hose in front
4 Right handlebar switch lead 15 A.C. magneto lead of the upper bracket.
5 Clutch cable 16 Thermo switch lead C Pass the left handlebar switch
6 Left handlebar switch lead 17 Fuel tank breather hose lead over the right handlebar
7 Front flasher light (left) 18 Frame switch lead.
8 Ignition coil 19 Wire harness D Pass the clutch cable through
9 Spark plug lead 20 Air filter case the cable guide.
10 Silencer E Fasten the handlebar switch
11 Starter cable leads with a plastic band.
F Fasten the wire harness with
a plastic locking tie.

2-33
 CABLE ROUTING SPEC
G To the ignition coil. N 20 mm
H Pass the starter cable between the ignition O Pass the thermo switch lead inside of the
coil and spark plug lead. silencer breather hose.
I To the throttle position sensor (TPS). P Place the end of the plastic locking tie as
J To the carburetor. shown.
K To the fuel tank. Q Inside the motorcycle.
L Pass the neutral switch lead, pickup coil lead R Fasten the wire harness with a plastic locking
and A.C. magneto lead under the ignition coil tie.
lead, thermo switch lead and throttle position S Pass the wire harness between the air filter
sensor (TPS) lead. case groove and frame.
M From the engine.

2-34
 INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 3-1

FUEL TANK AND SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
IDLING SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
IGNITION TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . 3-14
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CARBURETOR JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
EXHAUST SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
BRAKE SHOE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
BRAKE LIGHT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 3-25
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . . . . . . . . . . . . . . . 3-26
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FINAL GEAR OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3-28
FINAL GEAR OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
REAR SHOCK ABSORBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 3-32
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
SPOKE INSPECTION AND TIGHTENING . . . . . . . . . . . . . . . . . . . . . 3-35
CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . 3-35
LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
 INSP
ADJ
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
HEADLIGHT BEAM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
 INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
EB300000

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-
tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-
tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.
EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EVERY
BREAK-IN
BREAK IN
ITEM ROUTINE 1,000 km 6,000 km 12,000 km
or or
6 months 12 months

Check fuel hoses for cracks or damage.

* Fuel line
Replace if necessary. √ √

Check condition.
Spark plugs
Clean or replace if necessary. √ √ √

Check valve clearance.

* Valves
Adjust if necessary. √ √ √

Air filter
Clean or replace if necessary. √ √

Check loading condition.
* Battery
Recharge if necessary. √ √

Check operation.
Clutch
Adjust or replace cable. √ √

Check operation and for fluid leakage. (See NOTE.)

* Front brake
Replace pads if necessary. √ √

Check operation.
* Rear brake
Adjust or replace shoes if necessary. √ √

Check balance, runout, spoke tightness and for

* Wheels damage. √ √

Tighten spokes and rebalance / replace if necessary.

Check tread depth and for damage.
* Tires
Replace if necessary. √ √

Check bearing assembly for looseness or damage.

* Wheel bearings
Replace if damaged. √ √

Check swingarm assembly for looseness.

Swingarm pivoting
Repair if necessary.
*
Grease with molybdenum sulfide grease every √
point
24,000 km or 24 months.

Check steering for looseness and smooth operation.

Repair if necessary.
* Steering bearings
Grease with lithium soap base grease every √ √
24,000 km or 24 months.

Check all nuts, bolts and screws for tightness.
* Chassis fasteners
Tighten if necessary. √ √ √

Check operation.
Sidestand
Repair if necessary. √ √ √

Check operation.
* Sidestand switch
Replace if necessary. √ √ √

Check front fork operation and for oil leakage.

* Front suspension
Repair if necessary. √ √

Check operation and for shock absorber oil leakage.

* Rear suspension
Replace if necessary. √ √

Check idle speed, synchronization and starter

* Carburetors operation. √ √ √

Adjust if necessary.

3-1
 INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EVERY
BREAK-IN
BREAK IN
ITEM ROUTINE 1,000 km 6,000 km 12,000 km
or or
6 months 12 months

Engine oil
Replace. (Warm engine before draining.) √ √ √

Engine oil filter
Replace. √ √

Check oil level and for oil leakage.
Final gear oil
Change every 24,000 km or 24 months. Replace √ √

Items marked with an asterisk (*) require special tools, data and technical skills for servicing.
Take the motorcycle to a Yamaha dealer or refer to the Service Manual when servicing these items.
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
2. Replace the oil seals every two years on the inner parts of the master cylinder and caliper cylinder.
3. Replace the brake hoses every four years, or if cracked or damaged.

3-2
 INSP
FUEL TANK AND SEATS ADJ
FUEL TANK AND SEATS

30 Nm (3.0 m
kg)

7 Nm (0.7 m
kg)

7 Nm (0.7 m
kg)

Order Job name/Part name Q’ty Remarks

Fuel tank and seats removal Remove the parts in the order below.
1 Fuel hose 1 NOTE:
Set the fuel cock to “OFF” before
disconnecting the fuel hose.
2 Meter assembly 1
3 Meter lead couper 2
4 Speedometer cable 1 NOTE:
Disconnect the speedometer cable
from the front wheel side first.
5 Starter knob bracket 1
6 Fuel tank assembly 1
7 Passenger seat 1
8 Seat bracket 1
9 Rider’s seat 1
For installation, reverse the removal
procedure.

3-3
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
EB303003

ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:

Valve clearance adjustment should be made
with the engine cool, at room temperature.

When the valve clearance is to be measured
or adjusted, the piston must be at Top Dead
Center (T.D.C.) on the compression stroke.

1. Remove:
 Meter assembly
 Fuel tank
Refer to “FUELTANK AND SEATS”.
2. Remove:
 Carburetor assembly
Refer to “CARBURETOR” in CHAPTER 5.
3. Disconnect:
 Spark plug caps
4. Remove:
 Spark plugs
5. Remove:
 Ignition coil 1

6. Remove:
 Cylinder head covers
Refer to “ENGINE REMOVAL”.
 Cylinder head cover brackets
Refer to “CYLINDER HEADS”.

7. Remove:
 Tappet covers 1

3-4
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
8. Remove:
S Camshaft sprocket covers 1

9. Remove:
S Timing plug 1
S Straight plug 2

10. Measure:
S Valve clearance
Out of specification
Adjust.

Valve clearance (cold):

Intake valve:
0.07 X 0.12 mm
Exhaust valve:
0.12 X 0.17 mm
*****************************************************
Measuring steps:
D Turn the crankshaft clockwise with a wrench.
D Align the camshaft sprocket mark a with the
stationary pointer b on the cylinder head.
When the mark is aligned with the pointer, the
piston is at Top Dead Center (TDC).

A B D Check the front/rear cylinder timing mark c

on the rotor. If necessary, turn the crankshaft
to align the timing mark with the pointer d on
the AC magneto cover.
A For rear cylinder (“TI” mark)
B For front cylinder (“I” mark)

3-5
 INSP
VALVE CLEARANCE ADJUSTMENT ADJ
D Measure the valve clearance using a thick-
ness gauge 1 .
*****************************************************

11. Adjust:
S Valve clearance
*****************************************************
Adjustment steps:
D Loosen the locknut 1 .
D Insert a thickness gauge between the adjust-
er end and the valve end.
D Turn the adjuster 2 in or out until the speci-
fied clearance is obtained.

valve clearance is
Turning in:
decreased.
valve clearance is
Turning out:
increased.
D Hold the adjuster to prevent it from moving
and tighten the locknut.

Locknut:
14 Nm (1.4 mSkg)

D Measure the valve clearance again.

D If the clearance is still incorrect, repeat all the
clearance adjustment steps until the speci-
fied clearance is obtained.
*****************************************************

12. Install:
S All removed parts
NOTE:
Install all removed parts in the reverse order of
their disassembly. Note the following points.

3-6
VALVE CLEARANCE ADJUSTMENT/ INSP
CARBURETOR SYNCHRONIZATION ADJ
13. Install:

Camshaft sprocket covers
10 Nm (1.0 m
kg)

Tappet covers 10 Nm (1.0 m
kg)

Cylinder head cover 10 Nm (1.0 m
kg)

Spark plugs 18 Nm (1.8 m
kg)

EB303010

CARBURETOR SYNCHRONIZATION
NOTE:
Prior to synchronizing the carburetors, the valve
clearance should be properly adjusted and the
ignition timing should be checked.

1. Stand the motorcycle on a level surface.

NOTE:
Place the motorcycle on a suitable stand.

2. Remove:

Vacuum plugs 1

3. Attach:

Vacuum gauge 1

Engine tachometer 2
(to the #1 spark plug lead)

Vacuum gauge:
90890-03094
Engine tachometer:
90890-03113

4. Start the engine and let it warm up for sev-

eral minutes.
5. Check:

Engine idling speed
Out of specification
Adjust.
Refer to “IDLING SPEED ADJUST-
MENT”.

Engine idling speed:

1,150
1,250 r/min

3-7
 INSP
CARBURETOR SYNCHRONIZATION ADJ
6. Adjust:
S Carburetor synchronization
*****************************************************
Adjustment steps:
D Synchronize carburetor #1 to carburetor #2
by turning the synchronizing screw 1 until
both gauges read the same.
D Rev the engine two or three times, each time
for less than a second, and check the syn-
chronization again.

Vacuum pressure at idle speed:

29.0 kPa (0.29 kg/cm2, 220 mm Hg)
NOTE:
The difference between the two carburetors
should not exceed 1.33 kPa (10 mm Hg).

*****************************************************

7. Check:
S Engine idling speed
Out of specification
Adjust.
8. Stop the engine and detach the measuring
equipment.

9. Adjust:
S Throttle cable free play
Refer to “THROTTLE CABLE ADJUST-
MENT”.

Free play (throttle cable):

4
6 mm
At throttle grip flange

10. Install:
S Vacuum plugs

3-8
 INSP
IDLING SPEED ADJUSTMENT ADJ
EB303021

IDLING SPEED ADJUSTMENT

NOTE:
Prior to adjusting the idling speed, the carbure-
tor synchronization should be adjusted proper-
ly, the air filter should be clean and the engine
should have adequate compression.

1. Start the engine and let it warm up for sev-

eral minutes.
2. Attach:
S Engine tachometer
(to the #1 spark plug lead)

Engine tachometer:
90890-03113

3. Check:
S Engine idling speed
Out of specification
Adjust.

Engine idling speed:

1,150
1,250 r/min

4. Adjust:
S Engine idling speed
*****************************************************
Adjustment steps:
D Turn the throttle stop screw 1 in or out until
the specified idling speed is obtained.
Turning in: idling speed is increased.
Turning out: idling speed is decreased.
*****************************************************

3-9
 IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
5. Adjust:

Throttle cable free play
Refer to “THROTTLE CABLE ADJUST-
MENT”.

Free play (throttle cable):

4
6 mm
At throttle grip flange

EB303030

THROTTLE CABLE ADJUSTMENT

NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and carburetor synchro-
nization should be adjusted properly.

1. Check:

Throttle cable free play a
Out of specification
Adjust.

Free play (throttle cable):

4
6 mm
At throttle grip flange

2. Remove:

Rider’s seat

Fuel tank
Refer to “FUEL TANK AND SEATS”.

3. Adjust:

Throttle cable free play
*****************************************************
Adjustment steps:
NOTE:
When the motorcycle is accelerating, throttle
cable #1 1 is pulled and throttle cable #2 2 is
pushed.

3-10
THROTTLE CABLE ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
1st step:
D Loosen the locknut 3 on throttle cable #1.
D Turn the adjuster 4 in or out until the speci-
fied free play is obtained.

Turning in: free play is increased.

Turning out: free play is decreased.
D Tighten the locknuts.
NOTE:
If the specified free play cannot be obtained on
the carburetor end of the cable, use the adjuster
on the handlebar end.

Additional step:
D Loosen the locknut 5 .
D Turn the adjuster 6 in or out until the speci-
fied free play is obtained.

Turning in: free play is increased.

Turning out: free play is decreased.
D Tighten the locknut.

After adjusting, turn the handlebars to the

right and to the left to ensure that this does
not cause the engine idling speed to
change.

*****************************************************
4. Install:
S Fuel tank
S Rider’s seat
Refer to “FUEL TANK AND SEATS”.
EB303040

SPARK PLUG INSPECTION

1. Remove:
S Spark plug caps
S Spark plugs
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells, to prevent it
from falling into the cylinders.
3-11
 INSP
SPARK PLUG INSPECTION/IGNITION TIMING CHECK ADJ
2. Check:

Spark plug type
Incorrect
Replace.

Standard spark plug:

DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)

3. Inspect:

Electrode 1
Wear/damage
Replace.

Insulator 2
Abnormal color
Replace.
Normal color is a medium-to-light tan col-
or.

4. Clean:

Spark plug
(with spark plug cleaner or wire brush)
5. Measure:

Spark plug gap a
(with a wire gauge)
Out of specification
Adjust gap.

Spark plug gap:

0.8
0.9 mm

6. Install:

Spark plug 18 Nm (1.8 m
kg)

NOTE:
Before installing a spark plug, clean the gasket
surface and the plug surface.

EB303051

IGNITION TIMING CHECK

NOTE:
Prior to checking the ignition timing, check all
electrical connections related to the ignition
system. Make sure all connections are tight and
free of corrosion and that all ground connec-
tions are tight.

3-12
 INSP
IGNITION TIMING CHECK ADJ
1. Remove:
S Timing plug 1

2. Attach:
S Timing light 1
S Engine tachometer 2
(to the #1 spark plug lead)

Timing light:
90890-03141
Engine tachometer:
90890-03113

3. Check:
S Ignition timing
*****************************************************
Checking steps:
D Start the engine and let it warm up for several
minutes. Let the engine run at the specified
speed.

Engine idling speed:

1,150
1,250 r/min

D Check that the stationary pointer a is within

the firing range b on the rotor. Incorrect firing
range
Check the ignition system.
*****************************************************
NOTE:
Ignition timing is not adjustable.

4. Install:
S Timing plug 1

3-13
 INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
EB303060

COMPRESSION PRESSURE
MEASUREMENT
NOTE:
Insufficient compression pressure will result in a
loss of performance.

1. Check:

Valve clearance
Out of specification
Adjust.
Refer to “VALVE CLEARANCE ADJUST-
MENT”.
2. Start the engine and let it warm up for sev-
eral minutes.
3. Stop the engine.

4. Remove:

Spark plug caps

Spark plugs
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells, to prevent it
from falling into the cylinders.

5. Attach:

Compression gauge 1

Compression gauge set:

90890-03081

6. Measure:

Compression pressure
If it exceeds the maximum pressure al-
lowed
Inspect the cylinder head, valve
surfaces and piston crown for carbon de-
posits.
If it is below the minimum pressure

Squirt a few drops of oil into the affected
cylinder and measure again.

Refer to the table below.

3-14
 INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
Compression pressure
(with oil applied in the cylinder)
Reading Diagnosis
Higher than Worn or damaged pistons
without oil
Repair.
Possible defective ring(s),
Same as
valves, cylinder head gas-
without oil
ket or piston
Repair.

Compression pressure
(at sea level)
Standard:
1,100 kPa (11 kg/cm2, 11 bar)
Minimum:
1,000 kPa (10 kg/cm2, 10 bar)
Maximum:
1,200 kPa (12 kg/cm2, 12 bar)

*****************************************************
Measurement steps:
D Crank the engine with the throttle wide open
until the reading on the compression gauge
stabilizes.

To prevent sparking, ground all spark plug

leads before cranking the engine.

D Repeat the previous steps for the other cylin-

ders.
NOTE:
The difference in compression pressure be-
tween the highest and lowest cylinder compres-
sion readings should not exceed 100 kPa (1
kg/cm2, 1 bar).

*****************************************************

7. Install:
S Spark plugs 18 Nm (1.8 mSkg)

S Spark plug caps

3-15
 INSP
ENGINE OIL LEVEL INSPECTION ADJ
ENGINE OIL LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
NOTE:
D Make sure the motorcycle is upright when in-
specting the oil level.
D Place the motorcycle on a suitable stand.

2. Inspect:
S Oil level
Oil level should be between the maximum
a and minimum b marks.
Oil level is below the minimum mark

Add oil up to the proper level.

Recommended engine oil:

Refer to the chart for selection
of oils suited to the atmosperic
temperature.
Temp. API Standard:
API SE or higher grade

CAUTION:
D Do not put in any chemical additives or
use oils with a grade of CD a or higher.
D Be sure not to use oils labeled “ENERGY
CONSERVING ll” b or higher. Engine oil
also lubricates the clutch and additives
could cause clutch slippage.
D Be sure no foreign material enters the
crankcase.

3. Start the engine and let it warm up for sev-

eral minutes.
4. Stop the engine and inspect the oil level
once again.
NOTE:
Wait until the oil settles before inspecting the oil
level.

3-16
 INSP
ENGINE OIL REPLACEMENT ADJ
EB303080

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for sev-
eral minutes.
2. Turn off the engine and place a container
under the drain bolt.
3. Remove:
S Oil filler plug 1
S O-ring 2
S Drain bolt 3
S Gasket
Drain the crankcase of its oil.

4. If the oil filter is to be replaced during this

procedure, remove the following parts and
reinstall them afterwards.
*****************************************************
Replacement steps:
D Remove the oil filter element cover 1 and oil
filter element 2 .
D Check the O-ring 3 . If cracked or damaged,
replace them with new one.
D Install the oil filter element and oil filter ele-
ment cover.

Oil filter cover:

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

5. Install:
S Gasket
S Drain bolt 43 Nm (4.3 mSkg)

NOTE:
Inspect the drain bolt gasket. If it is damaged,
replace it.

3-17
 INSP
ENGINE OIL REPLACEMENT ADJ
6. Fill:
S Crankcase
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.

Oil quantity:
Total amount:
3.2 L (2.8 Imp qt)
Periodic oil change:
2.6 L (2.3 Imp qt)
With oil filter replacement:
2.8 L (2.6 Imp qt)

7. Install:
S Oil filler plug,
S Warm up the engine for a few minutes,
then turn it off.
8. Check:
S Engine (for oil leaks)
S Oil level

9. Check:
S Oil pressure
*****************************************************
Checking steps:
D Slightly loosen the oil gallery bolt 1 .
D 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 that it will not seize.
D Check the oil passages, oil filter and oil pump
for damage or leakage. Refer to “INSPEC-
TION AND REPAIR” in CHAPTER 4.
D Start the engine after solving the problem(s)
and check the oil pressure again.
D Tighten the oil gallery bolt to specification.

Oil gallery bolt:

8 Nm (0.8 mSkg)
*****************************************************

3-18
 INSP
CLUTCH ADJUSTMENT/AIR FILTER CLEANING ADJ
EB303090

CLUTCH ADJUSTMENT
1. Check:
S Clutch cable free play a
Out of specification
Adjust.

Free play (clutch cable):

10
15 mm
At clutch lever end

A B 2. Adjust:
S Clutch cable free play
*****************************************************
Adjustment steps:
D Loosen the locknuts 1 .
D Turn the adjusters 2 in or out until the speci-
fied free play is obtained.

Turning in: free play is increased.

Turning out: free play is decreased.
D Tighten the locknuts.
*****************************************************
A Handlebar end
B Engine end

EB303120

AIR FILTER CLEANING

1. Remove:
S Air filter case cover 1
2. Remove:
S Air filter element 2
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the filter element will also affect the
carburetor tuning, leading to poor engine
performance and possible overheating.

3-19
AIR FILTER CLEANING/CARBURETOR JOINT INSP
INSPECTION/FUEL LINE INSPECTION ADJ
3. Inspect:

Air filter element
Damage
Replace.

4. Clean:

Air filter element
Blow off the dust from the outside of the
element using compressed air.

5. Install:

Air filter element

Air filter case cover
NOTE:
When installing the element in its case, make
sure its sealing surface matches the sealing
surface of the filter case so that no air can leak
out.

EB303130

CARBURETOR JOINT INSPECTION

1. Inspect:

Carburetor joints 1
Cracks/damage
Replace.
Refer to “CARBURETOR” in CHAPTER 5.

EB303140

FUEL LINE INSPECTION

1. Inspect:

Fuel hose
Cracks/damage
Replace.

Fuel filter
Contamination/damage
Replace.

3-20
BREATHER HOSE INSPECTION/ INSP
EXHAUST SYSTEM INSPECTION ADJ
BREATHER HOSE INSPECTION
1. Remove:

Cylinder head cover (rear cylinder)
Refer to “ENGINE REMOVAL” in CHAP-
TER 4.
2. Inspection:

Breather hose 1
Cracks/damage
Replace.
Loose connection
Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.

EB303160

EXHAUST SYSTEM INSPECTION

1. Inspect:

Exhaust pipe (front) 1

Exhaust pipe joint (rear) 2

Muffler assembly (lower) 3

Muffler assembly (upper) 4
Cracks/damage
Replace.

Gaskets 5
Exhaust gas leaks
Replace.
2. Check:

Nut 6 20 Nm (2.0 m
kg)

Nut 7 25 Nm (2.5 m
kg)

Bolt 8 20 Nm (2.0 m
kg)

Bolts 9 25 Nm (2.5 m
kg)

Screws 10 20 Nm (2.0 m
kg)

3-21
 INSP
FRONT BRAKE ADJUSTMENT ADJ
EB304002

CHASSIS
FRONT BRAKE ADJUSTMENT
1. Check:
S Brake lever free play a
Out of specification
Adjust.

Free play (brake lever):

10
15 mm
(at brake lever end)

2. Adjust:
S Brake lever free play
*****************************************************
Adjustment steps:
D Loosen the locknut 1 .
D Turn the adjuster 2 in or out until the speci-
fied free play is obtained.

brake lever free play is

Turning in:
decreased.
brake lever free play is
Turning out:
increased.
D Tighten the locknut.
CAUTION:
After adjusting the front brake lever free
play, make sure that there is no brake drag.

A soft or spongy feeling in the brake lever

can indicate the presence of air in the brake
system. This air must be removed by bleed-
ing the brake system before the motorcycle
is operated. Air in the brake system will con-
siderably reduce braking performance and
could result in a loss of control and possibly
an accident. Inspect and if necessary, bleed
the brake system.

*****************************************************

3-22
 INSP
REAR BRAKE ADJUSTMENT ADJ
EB304012

REAR BRAKE ADJUSTMENT

1. Check:
S Brake pedal height a
Out of specification
Adjust.

Brake pedal height:

85 mm
(above the top of the footrest)

2. Adjust:
S Brake pedal height
*****************************************************
Adjustment steps:
D Loosen the locknut 1 .
D Turn the adjuster 2 in or out until the speci-
fied pedal height is obtained.

brake pedal height is

Turning in:
decreased.
brake pedal height is
Turning out:
increased.
D Tighten the locknut.

Locknut:
7 Nm (0.7 mSkg)
*****************************************************
3. Check:
S Brake pedal free play a
Out of specification
Adjust.

Free play (brake pedal):

20
30 mm

4. Adjust:
S Brake pedal free play
*****************************************************
Adjustment steps:
D Turn the adjuster 1 in or out until the speci-
fied free play is obtained.

brake pedal free play is

Turning in:
decreased.
brake pedal free play is
Turning out:
increased.

CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal height and the
free play.

*****************************************************
3-23
 REAR BRAKE ADJUSTMENT/ INSP
BRAKE FLUID LEVEL INSPECTION ADJ
5. Adjust:
S Brake light switch
Refer to “BRAKE LIGHT SWITCH AD-
JUSTMENT”.

EB304020

BRAKE FLUID LEVEL INSPECTION

1. Stand the motorcycle on a level surface.
NOTE:
D When inspecting the brake fluid level, make
sure the motorcycle is upright.
D Place the motorcycle on a suitable stand.

2. Inspect:
S Brake fluid level
Brake fluid level is below the “LOWER”
level line a
Fill to proper level.

Recommended brake fluid:

DOT 4

NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.

CAUTION:
Brake fluid may corrode painted surfaces or
plastic parts. Always clean up any spilt fluid
immediately.

D Use only the designated brake fluid. Other

fluids may deteriorate the rubber seals,
causing leakage and poor brake perfor-
mance.
D Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake perfor-
mance.
D When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the fluid and may cause vapor lock.
3-24
BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/ INSP
BRAKE LIGHT SWITCH ADJUSTMENT ADJ
EB304030

BRAKE PAD INSPECTION

1. Operate the brake lever.
2. Inspect:
S Brake pad
Wear indicators 1 almost touch the brake
disc
Replace the brake pads as a set.
Refer to “REAR WHEEL AND REAR
BRAKE” in CHAPTER 6.

EB304040

BRAKE SHOE INSPECTION

1. Operate the brake pedal.
2. Inspect:
S Brake shoes
Wear indicator 1 reaches the wear limit
line 2
Replace the brake shoes as a
set.
Refer to “REAR WHEEL AND REAR
BRAKE” in CHAPTER 6.
EB304050

BRAKE LIGHT SWITCH ADJUSTMENT

NOTE:
The brake light switch is operated by movement
of the brake pedal.
Adjustment is correct when the brake light
comes on just before the braking effect starts.

1. Check:
S Brake light operation timing
Incorrect
Adjust.
2. Adjust:
S Brake light operation timing
*****************************************************
Adjustment steps:
D Hold the main body 1 of the switch so that it
does not rotate, and turn the adjuster 2 in or
out until the proper operation timing is ob-
tained.

brake light comes on

Turning in:
later.
brake light comes on
Turning out:
sooner.
*****************************************************

3-25
 BRAKE HOSE INSPECTION INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
EB304060

BRAKE HOSE INSPECTION

1. Inspect:
S Brake hose(s)
Cracks/wear/damage
Replace.
2. Check:
S Brake hose clamp(s)
Loose
Tighten.
3. Hold the motorcycle upright and apply the
front or rear brake.
4. Check:
S Brake hose(s)
Activate the brake lever several times.
Brake fluid leakage
Replace the faulty
hose.
Refer to “FRONT BRAKE” in CHAPTER 6.

EB304070

AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM)

Bleed the brake system whenever:

D the system is disassembled
D a brake hose is loosened or removed
D the brake fluid level is very low
D brake operation is faulty
If the brake system is not properly bled, a
loss of braking performance may occur.

1. Bleed:
S Brake system
*****************************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2 .
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.

3-26
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP
SHIFT PEDAL ADJUSTMENT ADJ
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all the air
bubbles have disappeared from the brake
fluid.
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir, before applying the brake
lever. Ignoring this precaution could allow air to
enter the brake system, lengthening the bleed-
ing procedure, considerably.

j. Tighten the bleed screw.

Bleed screw:
6 Nm (0.6 m
kg)

NOTE:
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
brake system have disappeared.

k. Fill the brake fluid reservoir to the proper

level.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION”.

After bleeding the brake system check the

brake operation.

**************************************************

EB304080

SHIFT PEDAL ADJUSTMENT

1. Check:

Shift pedal position
Check the shift pedal rod length a .
If the position is incorrect
Adjust.

Shift pedal rod length:

188 mm

3-27
 SHIFT PEDAL ADJUSTMENT/ INSP
FINAL GEAR OIL LEVEL INSPECTION ADJ
2. Adjust:
S Shift pedal position
*****************************************************
Adjustment steps:
D Loosen both locknuts 1 .
D To obtain the correct pedal position turn the
shift pedal rod 2 in or out.

Turning in: shift pedal is lowered.

Turning out: shift pedal is raised.
D Tighten both locknuts.
*****************************************************

EB304110

FINAL GEAR OIL LEVEL INSPECTION

1. Stand the motorcycle on a level surface.
NOTE:
D When inspecting the final gear oil level, make
sure the motorcycle is upright.
D Place the motorcycle on a suitable stand.

2. Remove:
S Oil filler bolt 1
3. Inspect:
S Oil level
Oil level should be to the bottom brim 2 of
the hole.
Oil level is too low
Add oil to the proper
level.

Recommended oil:
SAE 80 API “GL-4” Hypoid
gear oil
If necessary an SAE 80W90
hypoid gear oil may be used
for all conditions.

NOTE:
“GL-4” is a quality and additive rating. “GL-5” or
“GL-6” rated hypoid gear oils may also be used.

4. Install:
S Oil filler bolt 23 Nm (2.3 mSkg)

3-28
FINAL GEAR OIL REPLACEMENT/ INSP
STEERING HEAD INSPECTION ADJ
EB304120

FINAL GEAR OIL REPLACEMENT

1. Place a container under the final gear case.
2. Remove:

Oil filler bolt 1

Drain plug 2
Drain the final gear case of its oil.
3. Install:

Drain plug 23 Nm (2.3 m
kg)

NOTE:
Check the drain plug gasket. If it is damaged, re-
place it.

4. Fill:

Final gear case

Oil quantity:
0.19 L

Refer to “FINAL GEAR OIL LEVEL IN-

SPECTION”.
5. Install:

Oil filler bolt 23 Nm (2.3 m
kg)

EB304130

STEERING HEAD INSPECTION

Securely support the motorcycle so that

there is no danger of it falling over.

1. Stand the motorcycle on a level surface.

NOTE:
Place the motorcycle on a suitable stand.

2. Elevate the front wheel by placing a suit-

able stand under the engine.
3. Check:

Steering assembly bearings
Grasp the bottom of the lower front fork
tubes and gently rock the fork assembly.
Looseness
Adjust the steering head.

3-29
 INSP
STEERING HEAD INSPECTION ADJ
4. Loosen
S Front fork pinch bolts (upper) 1
5. Remove
S Steering stem nut 2
S Upper bracket 3

6. Adjust:
S Steering head
*****************************************************
Adjustment steps:
D Remove the lock washer 1 , the upper ring
nut 2 and the rubber washer 3 .
D Loosen the lower ring nut 4 .
D Tighten the lower ring nut using the ring nut
wrench 5 .
NOTE:
Set the torque wrench at a right angle to the ring
nut wrench.

Ring nut wrench:

90890-01403

Lower ring nut:

(initial tightening):
52 Nm (5.2 mSkg)

D Loosen the lower ring nut 4 completely, then

tighten it to specification.

Do not overtighten the ring nut.

Lower ring nut:

(final tightening):
18 Nm (1.8 mSkg)

3-30
STEERING HEAD INSPECTION/ INSP
FRONT FORK INSPECTION ADJ
D Check the steering head for looseness or
binding by turning it all the way, in both direc-
tions. If it binds, remove the steering stem as-
sembly and inspect the steering bearings.
Refer to “STEERING HEAD AND HAN-
DLEBAR” in CHAPTER 6.
D Install the rubber washer 3 .
D Install the upper ring nut 2 .
D Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
D Install the lock washer 1 .
NOTE:
Make sure the lock washer tabs sit correctly in
the ring nut slots.

*****************************************************
7. Install:
S Upper bracket
S Steering stem nut 110 Nm (11.0 mSkg)

S Front fork pinch bolts (upper)

20 Nm (2.0 mSkg)

EB304140

FRONT FORK INSPECTION

Securely support the motorcycle so that

there is no danger of it falling over.

1. Stand the motorcycle on a level surface.

2. Check:
S Inner tube
Scratches/damage
Replace.
S Oil seal
Excessive oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
S Operation
Push down hard on the handlebars sever-
al times.
Unsmooth operation
Repair.
Refer to “FRONT FORK” in CHAPTER 6.
3-31
REAR SHOCK ABSORBER ADJUSTMENT/ INSP
TIRE INSPECTION ADJ
EB304160

REAR SHOCK ABSORBER ADJUSTMENT

Securely support the motorcycle so that

there is no danger of it falling over.

Spring preload
1. Adjust:
S Spring preload
NOTE:
Use the special wrench and extension bar in-
cluded in the owner’s tool kit to adjust the spring
preload.

*****************************************************
Adjustment steps:
D Turn the adjuster 1 in or out.

Selecting a
Spring preload is softer.
lower number:

Selecting a
Spring preload is harder.
higher number:

Adjustment numbers:
Standard number: 3
Minimum number: 1
Maximum number: 7

CAUTION:
Never turn the adjuster beyond the maxi-
mum or minimum adjustment number.

*****************************************************

EB304170

TIRE INSPECTION
1. Measure:
S Tire inflation pressure
Out of specification
Adjust.

3-32
 INSP
TIRE INSPECTION ADJ

D Tire inflation pressure should only be

checked and adjusted when the tire tem-
perature equals the ambient air tempera-
ture. Tire inflation pressure and suspen-
sion must be adjusted according to the
total weight of the cargo, rider, passenger
and accessories (fairing, saddlebags,
etc.if approved for this model), and ac-
cording to whether the motorcycle will be
operated at high speed or not.
NEVER OVERLOAD THE MOTORCYCLE.
D Operation of an overloaded motorcycle
could cause tire damage, an accident or
injury.

Basic weight:
With oil and 227 kg
full fuel tank
Maximum 180 kg (except for CH)
load*: 178 kg (for CH)
Cold tire
Front Rear
pressure:
200 kPa 225kPa
Up to 90 kg
(2.00 kgf / cm2, (2.25 kgf / cm2,
load*
2.00 bar) 2.25 bar)
90 kg
200 kPa 250 kPa
maximum (2.00 kgf / cm2, (2.50 kgf / cm2,
load* 2.00 bar) 2.50 bar)
200 kPa 250 kPa
High speed
(2.00 kgf / cm2, (2.50 kgf / cm2,
riding
2.00 bar) 2.50 bar)

* Load is the total weight of the cargo, rider,

passenger and accessories.

2. Inspect:
S Tire surfaces
Wear/damage
Replace.

Minimum tire tread depth:

(front and rear):
1.6 mm

1 Tread depth
2 Side wall
3 Wear indicator

3-33
 INSP
TIRE INSPECTION ADJ
A B

D It is dangerous to ride with a worn–out

tire. When the tire tread begins to show
signs of wear, replace the tire immediate-
ly.
D Do not use tubeless tires on a wheel de-
signed for tube type tires only. Tire failure
and personal injury may result from sud-
den deflation.
A Tire B Wheel

Tube type wheel: tube type tire only

Tubeless type tube type or
wheel: tubeless tire
D When using tube type tires be sure to
install the correct tube.
D After extensive tests, the tires listed be-
low have been approved by Yamaha Mo-
tor Co., Ltd. for this model. No guarantee
concerning handling characteristics can
be given if a tire combination, other than
one approved by Yamaha, is used on this
motorcycle. The front and rear tires
should always be by the same manufac-
turer and of the same design.

FRONT TIRE:

Manufacturer Size Type

BRIDGESTONE 100/90-19 57S L309
DUNLOP 100/90-19 57S F24
REAR TIRE:

Manufacturer Size Type

BRIDGESTONE 170/80-15M/C G546
77S
DUNLOP 170/80-15M/C K555
77S

After mounting a tire, ride conservatively for

a while to give the tire time to seat itself
properly in the rim. Failure to do so could
lead to an accident with possible injury to
the rider or damage to the motorcycle.

3-34
 WHEEL INSPECTION/SPOKE INSPECTION AND INSP
TIGHTENING/CABLE INSPECTION AND LUBRICATION ADJ
EB304180

WHEEL INSPECTION
1. Inspect:

Wheels
Bends/damage
Replace.
NOTE:
After a tire or wheel has been changed or re-
placed always balance the wheel.

Never attempt to make any repairs to the

wheels.

EB304190

SPOKE INSPECTION AND TIGHTENING

2. Inspect:

Spokes 1
Bending/damage
Replace.
Loose spoke
Retighten.
3. Tighten:

Spokes
2 Spoke wrench
NOTE:
Be sure to tighten the spokes before and after
break-in.

Nipple:
3 Nm (0.3 m
kg)

EB304200

CABLE INSPECTION AND LUBRICATION

Damaged cable sheaths may cause corro-

sion and interfere with cable movements.
Replace damaged cable sheaths and cables
as soon as possible.

3-35
CABLE INSPECTION AND LUBRICATION/LEVER AND INSP
PEDAL LUBRICATION/SIDESTAND LUBRICATION ADJ
1. Inspect:

Cable sheaths
Damage
Replace.
2. Check:

Cable operation
Unsmooth operation
Lubricate.

Recommended lubricant:
Engine oil

NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath.

EB304210

LEVER AND PEDAL LUBRICATION

Lubricate the pivoting points on the levers and
pedals.

Recommended lubricant:
Lithium soap base grease

EB304220

SIDESTAND LUBRICATION
Lubricate the pivoting point and the contact sur-
faces on the sidestand.

Recommended lubricant:
Lithium soap base grease

3-36
 INSP
BATTERY INSPECTION ADJ
EB305000

ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is a sealed type battery, it
is not possible to measure the specific gravity of
the electrolyte in order to check the charge state
of the battery. Therefore the charge of the bat-
tery has to be checked by measuring the volt-
age at the battery terminals.

CAUTION:
CHARGING METHOD
D This is a sealed type battery. Never re-
move the sealing caps. If the sealing caps
have been removed, the balance will not
be maintained and battery performance
will deteriorate.
D Charging time, charging current and
charging voltage for the MF battery are
different from those of general type bat-
teries. The MF battery should be charged
as explained in “CHARGING METHOD”. If
the battery is overcharged, the electrolyte
level will drop considerably. Therefore,
take special care when charging the bat-
tery.

Battery electrolyte is dangerous; it contains

sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
D Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
D Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
D SKIN – Wash with water.
D EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
D Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.

3-37
 INSP
BATTERY INSPECTION ADJ
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
D Charge batteries in a well-ventilated area.
D Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
D DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.

1. Remove:
S Rider’s seat
Refer to “FUEL TANK AND SEATS”.
S Battery cover 1

2. Disconnect:
S Battery leads
CAUTION:
First disconnect the negative lead 1 , then
disconnect the positive lead 2 .

3. Remove:
S Battery band
S Battery
4. Check:
Volt meter
S Battery condition
*****************************************************
Battery condition checking steps:
D Connect a digital voltmeter to the battery ter-
minals.
Tester (+) lead
battery (+) terminal
Tester (–) lead
battery (–) terminal

NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit voltage
(i.e. the voltage when the positive terminal is
disconnected).

Open-circuit
Charging time
voltage
No charging is
12.8V or higher
necessary.

3-38
 INSP
BATTERY INSPECTION ADJ
Relationship between open-circuit
D Check the condition of the battery using the
voltage and charging time at 20_C following charts.
Open-circuit voltage

Example:
D Open-circuit voltage = 12.0V
D Charging time = 6.5 hours
D Charge condition of the battery = 20 X 30%
D Charging method for MF batteries
Charging time (Hours)
D This varies depending on the temperature, the state of CAUTION:
charge in battery plates and the electro lyte level.

D If it is impossible to set the standard

charging current, be careful not to over-
Ambient
charge.
Open-circuit voltage (V)

temperature 20_C
D When charging the battery, be sure to re-
move it from the motorcycle. (If charging
has to be done with the battery mounted
on the motorcycle, be sure to disconnect
the wire at the negative terminal.)
D Never remove the sealing caps of an MF
Condition of charge in battery (%) battery.
D Make sure that the charging clips are in
Charging Ambient temperature
full contact with the terminal and that they
20_C are not shorted together. (A corroded clip
Open-circuit voltage (V)

18

17 on the charger may cause the battery to

16
generate heat in the contact area. A weak
15

14 clip spring may cause sparks.)

13
D Before removing the clips from the bat-
12

11
tery terminals, be sure to turn off the char-
10 0 10 20 30 40 50 60 Time (Minutes)
ger’s power switch.
D The open-circuit voltage variation for the
Check the Open-circuit voltage
MF battery, after charging, is shown be-
low. As shown in the figure, the open-cir-
cuit voltage stabilizes about 30 minutes
after charging has been completed.
Therefore, wait 30 minutes after charging
is completed before measuring the open-
circuit voltage.

*****************************************************

3-39
 INSP
BATTERY INSPECTION ADJ
Charging method using a variable-current (voltage) type charger

Charger
AMP meter
Measure the open-circuit NOTE:
voltage prior to charging. Voltage should be measured 30 min-
utes after the machine is stopped.

Connect a charger and NOTE:

AMP meter to the battery Set the charging voltage at 16 X 17 V. (If
the setting is lower, charging will be in-
and start charging. sufficient. If too high, the battery will be
over-charged.)

Make sure the current is

YES higher than the standard NO
charging current written on
the battery.

By turning the charging volt-

age adjust dial, set the charging
voltage at 20
25 V.

Adjust the voltage so that cur- Monitor the amperage for 3

YES
rent is at standard charging 5 minutes to check if the stan-
level. dard charging current is
reached.

NO

Set the timer according to the If the current does

charging time suitable for the not exceed stan-
open-circuit voltage. dard charging cur-
Refer to “Battery condition rent after 5 minutes,
checking steps.” replace the battery.

In case that charging requires more than 5 hours, it is advisable to

check the charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.

Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

3-40
 INSP
BATTERY INSPECTION ADJ
Charging method using a constant-voltage type charger

Measure the open-circuit NOTE:

voltage prior to charging. Voltage should be measured 30 min-
utes after the machine is stopped.

Connect a charger and

AMP meter to the battery
and start charging.

Make sure the current is

YES higher than the standard NO
charging current written on
the battery.

Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 V. charge the MF battery. A variable volt-
age charger is recommended.
NOTE:
Set the charging time at 20 hours (maxi-
mum).

Measure the battery open-circuit

voltage after having left the battery
Charger
unused for more than 30 minutes.
12.8 V or more --- Charging is com-
AMP meter
plete. Volt meter
12.7 V or less --- Recharging is re-
quired.
Under 12.0 V --- Replace the battery.

Charging method using a constant-current type charger

This type of battery charger cannot charge the MF battery.

3-41
BATTERY INSPECTION/ INSP
FUSE INSPECTION ADJ
5. Inspect:
S Battery terminals
Dirty
Clean with a wire brush.
Poor connection
Correct.
NOTE:
After cleaning the terminals, apply a light coat of
grease.

6. Install:
S Battery
S Battery band
7. Connect:
S Battery leads
CAUTION:
First, connect the positive lead 1 , then con-
nect the negative lead 2 .

8. Install:
S Rider’s seat
Refer to “FUEL TANK AND SEATS”.

EB305010

FUSE INSPECTION
CAUTION:
When checking or replacing the fuse always
turn off the main switch. Otherwise, a short
circuit may occur.

1. Remove:
S Battery cover
2. Inspect:
S Fuses
*****************************************************
Inspection steps:
D Connect the pocket tester and check the fuse
for continuity.

3-42
 INSP
FUSE INSPECTION ADJ
NOTE:
Set the tester selector to “Ω 1”.

Pocket tester:
90890-03112

D If the tester indicates ∞, replace the fuse.

*************************************

3. Replace:
S Blown fuse
*****************************************************
Replacement steps:
D Turn off the main switch.
D Install a new fuse with the proper current rat-
ing.
D Turn on switches to verify operation of related
electrical devices.
D If the fuse blows again, immediately check
the electrical circuit.
*****************************************************
Description Current rating Quantity
Main 30A 1
Headlight 15A 1
Carburetor
15A 1
heater
Signals 10A 1
Ignition 10A 1
Reserve 30A 1
Reserve 15A 1
Reserve 10A 1

Never use a fuse with a rating other than that

specified. Never use other materials in place
of a fuse. An improper fuse may cause ex-
tensive damage to the electrical system, a
malfunction of the lighting and ignition sys-
tems and could possibly cause a fire.

4. Install:
S Battery cover

3-43
HEADLIGHT BEAM ADJUSTMENT/ INSP
HEADLIGHT BULB REPLACEMENT ADJ
EB305020

HEADLIGHT BEAM ADJUSTMENT

1. Adjust:

Headlight beam (vertically)
Turn the adjuster 1 in or out.

Turning in: headlight beam is raised.

Turning out: headlight beam is lowered.

2. Adjust:

Headlight beam (horizontally)
Turn the adjuster 2 in or out.

Turning in: headlight beam to the left.

Turning out: headlight beam to the right.

EB305030

HEADLIGHT BULB REPLACEMENT

1. Remove:

Headlight lens unit
2. Disconnect:

Leads (in headlight body) 1
3. Remove:

Bulb cover 2

4. Unhook:

Bulb holder 1
5. Remove:

Bulb 2

Since the bulb may be hot, keep flammable

products and your hands away from it. Do
not touch the bulb until it has cooled down.

6. Install:

Bulb (new)
Secure the new bulb with the bulb holder.

3-44
 INSP
HEADLIGHT BULB REPLACEMENT ADJ
CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil, otherwise the transpar-
ency of the glass, life of the bulb and the lu-
minous flux will be adversely affected. If oil
gets on the bulb, thoroughly clean it with a
cloth moistened with alcohol or lacquer
thinner.

7. Hook up:

Bulb holder
8. Install:

Bulb cover
9. Connect:

Leads (in headlight body)
10. Install:

Headlight lens unit

3-45
INSP
ADJ
 ENG
CHAPTER 4.
ENGINE

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MUFFLERS, BRAKE PEDAL AND SIDE COVER . . . . . . . . . . . . . . . 4-1
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
SIDESTAND AND CRANKCASE COVER (LEFT) . . . . . . . . . . . . . . . 4-5
ENGINE MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SHIFT PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BRAKE PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

ROCKER ARM AND CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . 4-18
ROCKER ARM AND CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . 4-18
ROCKER ARM AND CAMSHAFT INSTALLATION . . . . . . . . . . . . . . 4-19

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

VALVE AND VALVE SPRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 4-22
VALVE AND VALVE SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . 4-22
VALVE AND VALVE SPRING INSTALLATION . . . . . . . . . . . . . . . . . . 4-26

CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
CYLINDER AND PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 4-29
PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
PISTON PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
CYLINDER AND PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . 4-33

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
CRANKCASE COVER (RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
PRIMARY DRIVE GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
PRIMARY DRIVE GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 4-40
CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

SHIFT SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
SHIFT SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
 ENG
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

AC MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

STATOR COIL AND PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
AC MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . 4-49
AC MAGNETO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
STARTER CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
AC MAGNETO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . 4-53

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . 4-55
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
SHIFT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
SHIFT CAM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

MIDDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

MIDDLE DRIVEN PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
MIDDLE DRIVE PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
MIDDLE DRIVEN PINION GEAR REMOVAL . . . . . . . . . . . . . . . . . . . 4-72
MIDDLE DRIVE PINION GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . 4-73
MIDDLE GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
MIDDLE DRIVE PINION GEAR INSTALLATION . . . . . . . . . . . . . . . . 4-74
MIDDLE DRIVEN PINION GEAR INSTALLATION . . . . . . . . . . . . . . . 4-75
MIDDLE DRIVE GEAR SHIM SELECTION . . . . . . . . . . . . . . . . . . . . . 4-78
GEAR BACKLASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
 ENGINE REMOVAL ENG

ENGINE
ENGINE REMOVAL
MUFFLERS, BRAKE PEDAL AND SIDE COVER

64 Nm (6.4 m
kg)

25 Nm (2.5 m
kg)

20 Nm (2.0 m
kg)

10 Nm (1.0 m
kg) 20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

Muffler, brake pedal and side cover Remove the parts in the order below.
removal Stand the motorcycle on a level sur-
face.

Securely support the motorcycle so

there is no danger of it falling over.

1 Muffler assembly (upper) 1

2 Muffler assembly (lower) 1
3 Exhaust pipe gasket 1
4 Brake pedal link 1 Refer to “BRAKE PEDAL INSTALLA-
TION”.
5 Rear brake switch 1
6 Brake pedal/footrest (right) 1/1
7 Exhaust pipe 1
8 Exhaust pipe gasket 1

4-1
 ENGINE REMOVAL ENG

64 Nm (6.4 m
kg)

25 Nm (2.5 m
kg)

20 Nm (2.0 m
kg)

10 Nm (1.0 m
kg) 20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

9 Battery cover 1
10 Side cover (right) 1
For installation, reverse the removal
procedure.

4-2
 ENGINE REMOVAL ENG

CYLINDER HEAD COVERS

5 Nm (0.5 m
kg)

5 Nm (0.5 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)
10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

Cylinder head covers removal Remove the parts in the order below.
Fuel tank Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
Carburetor assembly Refer to “CARBURETOR” in CHAPTER
5.
1 Battery leads 2 Disconnect
NOTE:
First, disconnect the negative lead,
then disconnect the positive lead.

2 Starter motor assembly 1

3 Spark plug cap 1
4 Ignition coil (cylinder #1 side) 1
5 Baffle cover 1
6 Upper cylinder head cover (rear) 1
7 Lower cylinder head cover (rear) 1
8 Upper cylinder head cover (front) 1

4-3
 ENGINE REMOVAL ENG

5 Nm (0.5 m
kg)

5 Nm (0.5 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)
10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

9 Lower cylinder head cover (front) 1
For installation, reverse the removal
procedure.

4-4
 ENGINE REMOVAL ENG

SIDESTAND AND CRANKCASE COVER (LEFT)

64 Nm (6.4 m
kg)

30 Nm (3.0 m
kg)
10 Nm (1.0 m
kg)
10 Nm (1.0 m
kg)
13 Nm (1.3 m
kg)

Order Job name/Part name Q’ty Remarks

Side stand and crankcase cover Remove the parts in the order below.
(left) removal
Engine oil Drain
Refer to “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
1 Side cover (left) 1 Do not remove the “*” bolts.
2 Middle gear case cover 1
3 Sidestand assembly 1
4 Shift pedal/footrest (left) 1/1 Refer to “SHIFT PEDAL INSTALLA-
TION”.
5 Clutch cable 1
6 Neutral switch lead 1
7 Crankcase cover (left)/gasket 1/1
8 Dowel pins 2
9 Rectifier/regulator 1
For installation, reverse the removal pro-
cedure.

4-5
 ENGINE REMOVAL ENG

ENGINE MOUNTING BOLTS

74 Nm (7.4 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)
40 Nm (4.0 m
kg)
30 Nm (3.0 m
kg)

40 Nm (4.0 m
kg)

30 Nm (3.0 m
kg)

Order Job name/Part name Q’ty Remarks

Engine mounting bolt removal Remove the parts in the order below.
Place a suitable stand under the frame
and engine.

Securely support the motorcycle so

there is no danger of it falling over.

1 Engine stay (front-upper/left) 1

2 Engine stay (front-upper/right) 1
3 Cable holder 1
4 Engine stay (front-lower/left) 1
5 Engine stay (front-lower/right) 1
6 Engine mounting bolt (rear-upper/ 1 L=75 mm
left)
7 Engine mounting bolt (rear-upper/ 1 L=60 mm
right)

4-6
 ENGINE REMOVAL ENG

74 Nm (7.4 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)
40 Nm (4.0 m
kg)
30 Nm (3.0 m
kg)

40 Nm (4.0 m
kg)

30 Nm (3.0 m
kg)

Order Job name/Part name Q’ty Remarks

8 Engine mounting bolt (rear-lower) 1 L=150mm
9 Rubber boot 1
10 Engine assembly 1 NOTE:
Remove the engine assembly from the
right side of the motorcycle.

For installation, reverse the removal

procedure.

4-7
 ENGINE REMOVAL ENG
SHIFT PEDAL INSTALLATION
1. Connect

Shift pedal link 1 10 Nm (1.0 m
kg)

NOTE:
Align the punch mark a on the shift rod with the
slot b on the shift pedal link

BRAKE PEDAL INSTALLATION

1. Connect

Brake pedal link 1 10 Nm (1.0 m
kg)

NOTE:
Align the punch mark a on the brake rod with
the slot b on the brake pedal link

4-8
 CYLINDER HEADS ENG

CYLINDER HEADS

35 Nm (3.5 m
kg)
35 Nm (3.5 m
kg)

10 Nm (1.0 m
kg)
20 Nm (2.0 m
kg)

10 Nm (1.0 m
kg)

20 Nm (2.0 m
kg)

12 Nm (1.2 m
kg)

55 Nm (5.5 m
kg)

20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

Cylinder head removal Remove the parts in the order below.
Engine assembly Refer to “ENGINE REMOVAL”.
1 Cylinder head cover brackets 2
2 Tappet cover (exhaust)/O-ring 1/1
3 Tappet cover (intake)/O-ring 1/1
4 Camshaft sprocket cover/O-ring 1/1
5 Baffle plate/O-ring (only rear cylin- 1/1
der head)
6 Timing chain tensioner/gasket 1/1
7 Camshaft sprocket plate (only rear 1 Refer to “CYLINDER HEAD
cylinder head) REMOVAL/INSTALLATION”.
8 Camshaft sprocket 1
9 Exhaust pipe joint (rear)/gasket 1/1
10 Carburetor joint/O-ring 1/1
11 Cylinder head 1

4-9
 CYLINDER HEADS ENG

35 Nm (3.5 m
kg)
35 Nm (3.5 m
kg)

10 Nm (1.0 m
kg)
20 Nm (2.0 m
kg)

10 Nm (1.0 m
kg)

20 Nm (2.0 m
kg)

12 Nm (1.2 m
kg)

55 Nm (5.5 m
kg)

20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

12 Dowel pins 2
13 Cylinder head gasket 1
For installation, reverse the removal pro-
cedure.

4-10
 CYLINDER HEADS ENG
CYLINDER HEAD REMOVAL
Rear cylinder head
1. Align:
S “T” mark
(with the stationary pointer)
*****************************************************
Removal steps:
D Temporarily install the AC magneto cover
without the pickup coil and stator coil.
D Turn the crankshaft clockwise.
D Align the “T” mark a with the stationary
pointer b on the crankcase cover (left) when
the rear piston is at TDC on the compression
stroke.
D When the “T” mark is aligned with the station-
ary pointer the punch mark c on the cam-
shaft sprocket should be aligned with the sta-
tionary pointer d on the cylinder head.
D The rear piston is at TDC on the compression
stroke when there is clearance at both of the
rocker arms. If there is no clearance then turn
the crankshaft clockwise one full turn.
D Check that the rear piston is at TDC in the
compression stroke.
*****************************************************
2. Loosen:
S Bolt (camshaft sprocket) 1
NOTE:
Use the sheave holder 2 to hold the rotor.

Sheave holder:
90890-01701

3. Loosen:
S Cap bolt (timing chain tensioner)
4. Remove:
S Timing chain tensioner
S Gasket
5. Remove:
S Bolt (camshaft sprocket) 1
S Camshaft sprocket plate 2
(only rear)
S Camshaft sprocket 3
NOTE:
To prevent the timing chain from falling into the
crankcase fasten a wire to it.

4-11
 CYLINDER HEADS ENG
6. Remove:
S Cylinder head
NOTE:
D Loosen the bolts and nuts in the proper se-
quence.
D Follow the numerical order shown in the il-
lustration. Loosen each bolt 1/4 of a turn at a
time until all of the bolts are loose.

Front cylinder head

NOTE:
When removing the front cylinder head cam-
shafts, repeat the rear cylinder head camshafts
removal procedures. However, note the follow-
ing points.

1. Align:
S “I” mark
(with the stationary pointer)
*****************************************************
Removal steps:
D Turn the crankshaft clockwise 290_.
D Align the “I” mark a with the stationary point-
er b on the crankcase cover (left) when the
front piston is at TDC on the compression
stroke.
D When the “I” mark is aligned with the station-
ary pointer the punch mark c on the cam-
shaft sprocket should be aligned with the sta-
tionary pointer d on the cylinder head.
D The front piston is at TDC on the compres-
sion stroke when there is clearance at both of
the rocker arms. If there is no clearance then
turn the crankshaft clockwise one full turn.
D Check that the front piston is at TDC in the
compression stroke.
*****************************************************
CYLINDER HEAD INSPECTION
1. Eliminate:
S Carbon deposits (from the combustion
chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
D Spark plug threads
D Valve seats

2. Inspect:
S Cylinder heads
Scratches/damage
Replace.

4-12
 CYLINDER HEADS ENG
3. Measure:
S Cylinder head warpage
Out of specification
Resurface.

Cylinder head warpage:

Less than 0.03 mm
*****************************************************
Warpage measurement and resurfacement
steps:
D Place a straightedge 1 and a feeler gauge
2 across the cylinder head.
D Use a feeler gauge to measure the warpage.
D If the warpage is out of specification, resur-
face the cylinder head.
D Place a 400
600 grit wet sandpaper on the
surface plate, and resurface the head using a
figure-eight sanding pattern.
NOTE:
To ensure an even surface rotate the cylinder
head several times.

*****************************************************

4. Inspect:
S Camshaft sprockets
Wear/damage
Replace the camshaft
sprockets and the timing chain as a set.
a 1 / 4 tooth
b Correct
1 Roller
2 Sprocket
5. Check:
S One-way cam operation (tensioner)
Unsmooth operation
Replace.

4-13
 CYLINDER HEADS ENG
CYLINDER HEAD INSTALLATION
Rear cylinder head
1. Install:
S Nuts (cylinder head) (M10: 1
4)
35 Nm (3.5 mSkg)

S Bolts (cylinder head) (M8: 5
7)

20 Nm (2.0 mSkg)

NOTE:
D Tighten the bolts and nuts in the proper se-
quence.
D Follow the numerical order shown in the il-
lustration. Tighten the bolts and nuts in two
stages.

2. Install:
S Camshaft sprocket
*****************************************************
Installation steps:
D Turn the crankshaft clockwise.
D Align the “T” mark a with the stationary
pointer b on the crankcase cover (left).
D Install the camshaft sprocket with the timing
mark c facing out.
D Turn the camshaft just enough to remove any
slack from the exhaust side of the timing
chain.
D Insert your finger into the hole and timing
chain tensioner hole and push the timing
chain guide inward.
D While pushing the timing chain guide, be sure
that the timing mark c and the stationary
pointer d are properly aligned at TDC.
*****************************************************

4-14
 CYLINDER HEADS ENG
3. Install:
S Timing chain tensioner
*****************************************************
Installation steps:
D Remove the tensioner cap bolt 1 , washer 2
and spring 3 .
D Release the timing chain tensioner one-way
cam 4 and push the tensioner rod 5 all the
way in.
D Install the tensioner 6 with a new gasket into
the cylinder.

Bolts (timing chain tensioner):

12 Nm (1.2 mSkg)

Always use a new gasket.

D Install the spring, washer and cap bolt.

Cap bolt (timing chain tensioner):

20 Nm (2.0 mSkg)

*****************************************************
4. Install:
S Camshaft sprocket plate 1
S Bolt (camshaft sprocket) 2
55 Nm (5.5 mSkg)

NOTE:
D Be sure the projection on the camshaft
sprocket plate is aligned with the hole in the
sprocket.
D Use the sheave holder 3 to hold the rotor.

Sheave holder:
90890-01701

5. Check:
S Alignment marks
If the marks do not aligh
Adjust.
6. Measure:
S Valve clearance
Out of specification
Adjust.
Refer to “VALVE CLEARANCE AD-
JUSTMENT” in CHAPTER 3.

4-15
 CYLINDER HEADS ENG
Front cylinder head
NOTE:
When installing the front cylinder head cam-
shafts, repeat the rear cylinder head camshafts
installation procedure. However, note the fol-
lowing points.

1. Install:
S Camshaft sprocket
*****************************************************
Installation steps:
D Turn the crankshaft clockwise 290_.
D Align the “I” mark a with the stationary point-
er b on the crankcase cover (left).
D Install the camshaft sprocket with the timing
mark c facing out.
D Turn the camshaft just enough to remove any
slack from the intake side of the timing chain.
D Insert your finger into the hole and timing
chain tensioner hole and push the timing
chain guide inward.
D While pushing the timing chain guide, be sure
that the timing mark c and the stationary
pointer d are properly aligned at TDC.
*****************************************************

4-16
 ROCKER ARMS AND CAMSHAFT ENG

ROCKER ARMS AND CAMSHAFT

14 Nm (1.4 m
kg)
38 Nm (3.8 m
kg)

20 Nm (2.0 m
kg)

14 Nm (1.4 m
kg)

Order Job name/Part name Q’ty Remarks

Rocker arm and camshaft removal Remove the parts in the order below.
Cylinder heads Refer to “CYLINDER HEAD”.
1 Lock washer 1
2 Stopper plate 1
3 Union bolt/gasket 2/2
4 Rocker arm shafts 2
5 Rocker arms 2 Refer to “ROCKER ARM AND CAM-
6 Camshaft bushing 1 SHAFT REMOVAL/INSTALLATION”.
7 Camshaft/dowel pin 1/1
8 Locknuts 2
9 Valve adjusters 2
For installation, reverse the removal
procedure.

4-17
ROCKER ARMS AND CAMSHAFT ENG
ROCKER ARM AND CAMSHAFT REMOVAL
1. Remove:

Rocker arm shafts (intake and exhaust) 1

Rocker arms 2
NOTE:
Use a slide hammer 3 to remove the rocker
arm shafts.

Slide hammer bolt (M8):

90890-01085
Weight:
90890-01084

2. Remove:

Camshaft bushing 1

Camshaft 2
NOTE:
Screw a 10 mm bolt 3 into the threaded end of
the camshaft and pull out the camshaft.

ROCKER ARM AND CAMSHAFT

INSPECTION
1. Inspect:

Camshaft bushings
Damage/wear
Replace.
2. Inspect:

Camshaft lobes 1

Valve adjusters 2
Blue discoloration/pitting/scratches

Replace.
3. Measure:

Camshaft lobe length a and width b
Out of specification
Replace.

Camshaft lobe limit:

Intake
a 39.63 mm
b 32.12 mm
Exhaust
a 39.67 mm
b 32.20 mm

4-18
ROCKER ARMS AND CAMSHAFT ENG
4. Inspect:
S Rocker arms
S Rocker arm shafts
Damage/wear
Replace.
*****************************************************
Inspection steps:
D Inspect the two contact areas on the rocker
arms for signs of abnormal wear.
1) Rocker arm shaft hole.
2) Camshaft lobe contact surface.
Excessive wear
Replace.
D Inspect the surface of the rocker arm shafts.
Blue discoloration/pitting/scratches
Re-
place/check lubrication.
D Measure the inside diameter a of the rocker
arm holes.
Out of specification
Replace.

Rocker arm inside diameter:

14.000
14.018 mm

D Measure the outside diameter b of the rock-

er arm shafts.
Out of specification
Replace.

Rocker arm outside diameter:

13.980
13.991 mm

D Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the
rocker arm inside diameter.
Clearance greater than 0.08 mm
Replace
the defective part(s).

Rocker arm to shaft standard

clearance:
0.009
0.038 mm

*****************************************************

ROCKER ARM AND CAMSHAFT

INSTALLATION
1. Apply:
S Molybdenum disulfide oil
(onto the camshaft journals)
2. Install:
S Camshaft 1
S Camshaft bushing 2
S Stopper plate 3
S Lock washer 4
S Bolts (stopper plate) 5
20 Nm (2.0 mSkg)

4-19
ROCKER ARMS AND CAMSHAFT ENG
NOTE:
D The dowel pin a on the end of the camshaft
must align with the timing mark b on the cyl-
inder head.
D Make sure that the No.1 camshaft 6 is
installed in the rear cylinder head and the
No.2 camshaft 7 is installed in the front cyl-
inder head.

3. Apply:
S Engine oil
(onto the rocker arm shafts)
4. Install:
S Rocker arms 1
S Rocker arm shafts (intake and exhaust) 2
NOTE:
D The thread hole a of the rocker arm shafts
must face to the outside.
D After installation, make sure that the thread
hole a of the rocker arm shaft is positioned
correctly, as shown in the illustration.

4-20
 VALVES AND VALVE SPRINGS ENG

VALVES AND VALVE SPRINGS

Order Job name/Part name Q’ty Remarks

Valve and valve spring removal Remove the parts in the order below.
Cylinder heads Refer to “CYLINDER HEADS”.
Rocker arms and camshafts Refer to “ROCKER ARMS AND CAM-
SHAFT”.
1 Valve cotters 4 Refer to “VALVE AND VALVE SPRING
REMOVAL/INSTALLATION”.
2 Valve spring retainers 2
3 Valve springs 2
4 Valve (intake) 1 Refer to “VALVE AND VALVE
5 Valve (exhaust) 1 SPRING INSTALLATION”.
6 Valve stem seals 2
7 Valve spring seats 2
For installation, reverse the removal
procedure.

4-21
VALVES AND VALVE SPRINGS ENG
VALVE AND VALVE SPRING REMOVAL
1. Check:
S Valve sealing
Leakage at the valve seat
Inspect the
valve face, valve seat and valve seat
width.
Refer to “INSPECTION”.
*****************************************************
Checking steps:
D Pour a clean solvent 1 into the intake and
exhaust ports.
D Check that the valve seals properly.
There should be no leakage at the valve seat
2.
*****************************************************

2. Remove:
S Valve cotters
NOTE:
Attach a valve spring compressor 1 between
the valve spring retainer and the cylinder head
to remove the valve cotters.

Valve spring compressor:

90890-04019

VALVE AND VALVE SPRING INSPECTION

1. Measure:
S Stem-to-guide clearance

Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification
Replace the valve
guide.

Clearance (stem to guide):

Intake:
0.010
0.037 mm
<Limit>: 0.08 mm
Exhaust:
0.025
0.052 mm
<Limit>: 0.10 mm

4-22
VALVES AND VALVE SPRINGS ENG
2. Replace:
S Valve guide
*****************************************************
Replacement steps:
NOTE:
To ease guide removal, installation and to main-
tain correct fit heat the cylinder head in an oven
to 100_C.

D Remove the valve guide using a valve guide

remover 1 .
D Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
D After installing the valve guide, bore the valve
guide using a valve guide reamer 3 to obtain
proper stem-to-guide clearance.

Valve guide remover & installer

(7.0 mm):
90890-04018

NOTE:
After replacing the valve guide reface the valve
seat.

*****************************************************

3. Inspect:
S Valve face
Pitting/wear
Grind the face.
S Valve stem end
Mushroom shape or diameter larger than
the body of the stem
Replace.

4. Measure:
S Margin thickness a
Out of specification
Replace.

Margin thickness:
Intake:
1.0
1.4 mm
<Limit>: 0.8 mm
Exhaust:
1.0
1.4 mm
<Limit>: 0.8 mm
4-23
 VALVES AND VALVE SPRINGS ENG
5. Measure:
S Runout (valve stem)
Out of specification
Replace.

Runout limit:
0.03 mm

NOTE:
D When installing a new valve always replace
the guide.
D If the valve is removed or replaced always re-
place the oil seal.

6. Eliminate:
S Carbon deposits
(from the valve face and valve seat)
7. Inspect:
S Valve seats
Pitting/wear
Reface the valve seat.

8. Measure:
S Valve seat width a
Out of specification
Reface the valve
seat.

Valve seat width:

Intake:
1.0
1.2 mm
<Limit>: 1.8 mm
Exhaust:
1.0
1.2 mm
<Limit>: 1.8 mm

*****************************************************
Measurement steps:
D Apply Mechanic’s blueing dye (Dykem) b to
the valve face.
b D Install the valve into the cylinder head.
D Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
D Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
D If the valve seat is too wide, too narrow, or the
seat is not centered, the valve seat must be
refaced.
*****************************************************

4-24
VALVES AND VALVE SPRINGS ENG
9. Lap:
S Valve face
S Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.

*****************************************************
Lapping steps:
D Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap be-
tween the valve stem and the guide.

D Apply molybdenum disulfide oil to the valve

stem.
D Install the valve into the cylinder head.
D Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.

D Apply a fine lapping compound to the valve

face and repeat the above steps.
NOTE:
After every lapping operation be sure to clean
off all of the compound from the valve face and
valve seat.

D Apply Mechanic’s blueing dye (Dykem) to the

valve face.
D Install the valve into the cylinder head.
D Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
D Measure the valve seat width again. If the
valve seat width is out of specification, reface
and relap the valve seat.
*****************************************************

4-25
VALVES AND VALVE SPRINGS ENG
10. Measure:
S Valve spring free length a
Out of specification
Replace.

Free length (valve spring):

43.2 mm
<Limit>: 42.0 mm

11. Measure:
S Compressed spring force a
Out of specification
Replace.
b Installed length

Compressed spring force:

21.8
25.6 kg at 37.1 mm

12. Measure:
S Spring tilt a
Out of specification
Replace.

Spring tilt limit:

2.5_/1.9 mm

VALVE AND VALVE SPRING INSTALLATION

1. Apply:
S Molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2. Install:
S Valve spring seats
S Valve stem seals
S Valves
S Valve springs
S Valve spring retainers
NOTE:
Install the valve springs with the larger pitch a
facing upwards.

b Smaller pitch

4-26
VALVES AND VALVE SPRINGS ENG
3. Install:

Valve cotters
NOTE:
While compressing the valve spring with a valve
spring compressor 1 install the valve cotters.

Valve spring compressor:

90890-04019

4. To secure the valve cotters onto the valve

stem lightly tap the valve tip with a piece of
wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

4-27
 CYLINDERS AND PISTONS ENG

CYLINDERS AND PISTONS

10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

Cylinder and piston removal Remove the parts in the order below.
Cylinder heads Refer to “CYLINDER HEADS”.
1 Timing chain guide 1 The “up” mark should face towards
the cylinder head.
2 Cylinder/O-ring 1/1 Refer to “CYLINDER AND PISTON
INSTALLATION”.
3 O-ring/collar 1/1
4 Dowel pins 2
5 Cylinder gasket 1
6 Piston pin clips 2
Refer to “PISTON REMOVAL/
7 Piston pin 1
CYLINDER AND PISTON
8 Piston 1
INSTALLATION”.
9 Piston ring set 1
For installation, reverse the removal
procedure.

4-28
CYLINDERS AND PISTONS ENG
PISTON REMOVAL
1. Remove:
S Piston pin clips 1
S Piston pin 2
S Piston 3
NOTE:
D Put identification marks on each piston head
for reference during reinstallation.
D Before removing each piston pin, deburr the
clip groove and pin hole area. If the piston pin
groove is deburred and the piston pin is still
difficult to remove, use the piston pin puller
4.

Piston pin puller:

90890-01304

CAUTION:
Do not use a hammer to drive the piston pin
out.

2. Remove:
S Piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the pis-
ton crown, as shown in the illustration.

CYLINDER AND PISTON INSPECTION

1. Inspect:
S Cylinder and piston walls
Vertical scratches
Rebore or replace
the cylinder and the piston.

2. Measure:
S Piston-to-cylinder clearance
*****************************************************
Measurement steps:
1st step:
D Measure the cylinder bore “C” with a cylinder
bore gauge.
a 40 mm from the top of the cylinder

4-29
CYLINDERS AND PISTONS ENG
NOTE:
Measure the cylinder bore “C” horizontally and
laterally.

Wear
Standard
limit
Cylinder
80.965
81.015 mm 81.1 mm
bore C:
X+Y
C=
X2Y
D Find the average of the measurements.
D If out of specification, rebore or replace the
cylinder and replace the piston and piston
rings as a set.
2nd step:
D Measure the piston skirt diameter “P” with a
micrometer.
b 6 mm from the piston bottom edge.

Piston size P
Standard 80.92
80.97 mm
D If out of specification, replace the piston and
the piston rings as a set.
3rd step:
D Use the following formula to calculate the pis-
ton-to-cylinder clearance:

Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”

Clearance (piston to cylinder):

0.035
0.055 mm
<Limit>: 0.15 mm

D If out of specification, rebore or replace the

cylinder and replace the piston and the piston
rings as a set.
*****************************************************

4-30
CYLINDERS AND PISTONS ENG
PISTON RING INSPECTION
1. Measure:

Side clearance (piston to piston rings)
Out of specification
Replace the piston
and the piston rings as a set.
NOTE:
Before measuring the side clearance remove
the carbon deposits from the piston ring
grooves and rings.

Side clearance (piston ring):

Top ring:
0.03
0.07 mm
<Limit>: 0.12 mm
2nd ring:
0.02
0.06 mm
<Limit>: 0.12 mm

2. Position:

Piston ring
(into the cylinder)
NOTE:
Using the piston crown push the ring into the
cylinder so that the ring will be at a right angle to
the cylinder bore.

a 40 mm

3. Measure:

End gap
Out of specification
Replace.
NOTE:
You cannot measure the end gap on the expan-
der spacer of the oil ring. If the oil ring rails show
excessive gap, replace all three rings.

End gap:
Top ring:
0.15
0.30 mm
<Limit>: 0.55 mm
2nd ring:
0.30
0.45 mm
<Limit>: 0.80 mm
Oil ring:
0.2
0.7 mm

4-31
CYLINDERS AND PISTONS ENG
PISTON PIN INSPECTION
1. Inspect:
S Piston pin
Blue discoloration/grooves
Replace,
then inspect the lubrication system.
2. Measure:
S Piston pin-to-piston clearance
*****************************************************
Measurement steps:
D Measure the piston pin outside diameter a .
If out of specification, replace the piston pin.

Outside diameter (piston pin):

19.995
20.000 mm

D Measure the piston inside diameter b .

D Calculate the piston pin-to-piston clearance
using the following formula:

Piston pin-to-piston clearance =

Bore size (piston pins) b –
Outside diameter (piston pins) a

D If out of specification, replace the piston.

Clearance (piston pin to piston):

0.004
0.020 mm
*****************************************************

4-32
CYLINDER AND PISTONS ENG
CYLINDER AND PISTON INSTALLATION
1. Install:
S Piston ring (top ring) 1
S Piston ring (second ring) 2
NOTE:
D Be sure to install the piston rings so that the
manufacturer’s marks or numbers are lo-
cated on the upper side of the rings.
D Lubricate the piston and piston rings liberally
with engine oil.

2. Position:
S Top ring 1
S 2nd ring 2
S Oil ring 3
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
3. Install:
S Piston 1
S Piston pin 2
S Piston pin clips 3
NOTE:
D Apply engine oil onto the piston pin, piston
ring and piston.
D Be sure that the piston is positioned correctly,
as shown in the illustration.

a “EX” mark
4. Lubricate:
S Piston
S Piston rings
S Cylinder
NOTE:
Apply a liberal coating of engine oil.

5. Install:
S Cylinder
NOTE:
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.

4-33
 CLUTCH ENG

CLUTCH
CRANKCASE COVER (RIGHT)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

Crankcase cover (right) removal Remove the parts in the order below.
Stand the motorcycle on a level surface.

Securely support the motorcycle so

there is no danger of it falling over.

Engine oil Refer to “ENGINE OIL REPLACE-

MENT” in CHAPTER 3.
Muffler assembly 1,2
Brake pedal link Refer to “ENGINE REMOVAL”.
1 Oil filter cover plate 1
2 Oil filter cover 1 L=70 mm 1, 65 mm 1, 25 mm 3
3 O-ring 1
4 Oil filter 1
5 Crankcase cover (right) 1 L=65 mm 1, 55 mm 1, 45 mm 4,
30 mm 4

4-34
 CLUTCH ENG

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

6 Dowel pins 2
7 Crankcase cover gasket 1
For installation, reverse the removal
procedure.

4-35
 CLUTCH ENG

CLUTCH ASSEMBLY

70 Nm (7.0 m
kg)

70 Nm (7.0 m
kg)

8 Nm (0.8 m
kg) 8 Nm (0.8 m
kg)

Order Job name/Part name Q’ty Remarks

Clutch assembly removal Remove the parts in the order below.
Oil pump driven gear Refer to “OIL PUMP”.
1 Clutch springs 5
2 Pressure plate 1
3 Push plate/push rod #1 1/1
Refer to “CLUTCH INSTALLATION”.
4 Ball 1
5 Friction plates 6
6 Clutch plates 5
7 Nut/locknut 1/1 Refer to “CLUTCH REMOVAL/INSTAL-
LATION”.
8 Clutch boss 1
9 Thrust washer 1
10 Nut (primary drive gear) 1 Refer to “PRIMARY DRIVE GEAR
REMOVAL/INSTALLATION”.
11 Clutch housing 1
12 Push rod #2 1 Refer to “INSTALLATION”.

4-36
 CLUTCH ENG

70 Nm (7.0 m
kg)

70 Nm (7.0 m
kg)

8 Nm (0.8 m
kg) 8 Nm (0.8 m
kg)

Order Job name/Part name Q’ty Remarks

13 Lock washer 1
14 Claw washer 1
15 Drive gear (oil pump) 1
16 Primary drive gear 1
17 Straight key 1
For installation, reverse the removal
procedure.

4-37
 CLUTCH ENG
CLUTCH REMOVAL
1. Straighten:

Lock washer tab
2. Loosen:

Nut (clutch boss) 1
NOTE:
Loosen the nut (clutch boss) 1 while holding
the clutch boss 2 with the clutch holding tool
3.

Clutch holding tool:

90890-04086

PRIMARY DRIVE GEAR REMOVAL

1. Straighten:

Lock washer tab
2. Loosen:

Nut (primary drive gear) 1
NOTE:
Place a copper plate 2 between the teeth of the
primary drive gear 3 and primary driven gear to
lock them.

CLUTCH INSPECTION
1. Inspect:

Friction plates
Wear/damage
Replace the friction
plates as a set.
2. Measure:

Friction plate thickness
Out of specification
Replace the friction
plates as a set.
Measure at four places.

Thickness (friction plate):

2.9
3.1 mm
<Wear limit>: 2.6 mm

3. Inspect:

Clutch plate
Damage
Replace the clutch plates as a
set.
4. Measure:

Clutch plate warpage
Out of specification
Replace the clutch
plates as a set.
Use a surface plate and a feeler gauge 1 .

Warp limit (clutch plate):

Less than 0.2 mm

4-38
 CLUTCH ENG
5. Inspect:

Primary drive gear teeth
Wear/damage
Replace the clutch
housing.
6. Check:

Circumferential play
Free play
Replace the clutch housing.
7. Inspect:

Clutch spring
Damage
Replace the clutch spring.
8. Measure:

Clutch spring free length
Out of specification
Replace the clutch
springs as a set.

Free length (clutch spring):

39.5 mm
<Wear limit>: 38.5 mm

9. Inspect:

Dogs (on the clutch housing)
Pitting/wear/damage
Deburr or re-
place.

Clutch housing bearing
Wear/damage
Replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic operation.

10. Inspect:

Clutch boss splines
Pitting/wear/damage
Replace the
clutch boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic operation.

11. Inspect:

Pressure plate
Cracks/damage
Replace.

4-39
 CLUTCH ENG
PUSH ROD INSPECTION
1. Inspect:
 Push rod #1 1
 O-ring
 Ball 2
 Push rod #2 3
Cracks/wear/damage
Replace.

PRIMARY DRIVE GEAR INSTALLATION

1. Install:
 Drive gear (oil pump) 1
 Claw washer
 Lock washer
 Nut (primary drive gear)
70 Nm (7.0 mkg)

NOTE:

Place a copper plate 2 between the teeth of
the primary drive gear 3 and primary driven
gear to lock them.
2. Bend:

Lock washer tab (along a flat side of the nut)

CLUTCH INSTALLATION
1. Install:
 Lock washer 1
 Nut (clutch boss) 2 70 Nm (7.0 mkg)

NOTE:
Tighten the nut (clutch boss) 2 while holding
the clutch boss with a clutch holding tool 3 .

Clutch holding tool:

90890-04086

2. Bend:
 Lock washer tab (along a flat side of the
nut)
3. Install:
 Friction plates 1
 Clutch plates 2
*****************************************************
Installation steps:

Install one friction plate and one clutch plate
alternately.

4-40
 CLUTCH ENG
NOTE:
D Apply engine oil onto the friction plates.
D Align the two slots a on the friction plates
with the two punch marks b on the clutch
housing.

*****************************************************

4. Install:
S Push rod #2
S Ball
S Push rod #1 1
S O-ring 2
S Push plate 3
S Washer 4
S Nut 5
NOTE:
Apply lithium soap base grease onto the push
rod and the ball.

5. Install:
S Pressure plate 1
S Clutch springs 2
S Bolts 3 8 Nm (0.8 mSkg)

NOTE:
Tighten the pressure plate bolts in stages, using
a crisscross pattern.

6. Check:
S Push lever position
S Push the push lever assembly in the direc-
tion of the arrow and make sure that the
match marks are aligned.
Match marks not aligned.
Adjust.
a Match mark on the push lever assembly
b Match mark on the crankcase
7. Adjust:
S Push lever position
*****************************************************
Adjustment steps:
D Loosen the nut 1 .
D Turn the push rod #1 2 clockwise or counter-
clockwise so that the match marks are
aligned.
D Tighten the nut 1 .

Nut (clutch adjuster):

8 Nm (0.8 mSkg)
4-41 *****************************************************
 SHIFT SHAFT ENG

SHIFT SHAFT

Order Job name/Part name Q’ty Remarks

Shift shaft removal Remove the parts in the order below.
Engine oil Refer to “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
Clutch assembly Refer to “CLUTCH”.
Crankcase cover (left) Refer to “ENGINE REMOVAL”.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Stopper lever 1
Refer to “SHIFT SHAFT INSTALLA-
6 Torsion spring (stopper lever) 1
TION”.
7 Washer 1
8 Circlip 1
9 Torsion spring (shift shaft) 1
For installation, reverse the removal
procedure.

4-42
 SHIFT SHAFT ENG
SHIFT SHAFT INSPECTION
1. Inspect:
 Shift shaft 1
 Shift pawls 2
 Return spring (shift arm) 3
Bends/wear/damage
Replace.

2. Inspect:
 Stopper lever
Roller turns roughly
Replace.
Bends/damage
Replace.

3. Inspect:
 Torsion spring (shift shaft) 1
 Torsion spring (stopper lever) 2
Wear/damage
Replace.

SHIFT SHAFT INSTALLATION

1. Install:
 Shift shaft 1
 Torsion spring (shift shaft) 2
 Washer 3
 Stopper lever 4
 Torsion spring (stopper lever) 5
 Washer 6
NOTE:

Hook the spring end on the stopper lever and
the crankcase boss.

Mesh the stopper lever 7 with the shift cam
stopper 8 .

4-43
 SHIFT SHAFT ENG
2. Install:

Shift lever
NOTE:
Insert the shift arm 1 between the pins on the
shift cam segment.

4-44
 OIL PUMP ENG

OIL PUMP

7 Nm (0.7 m
kg)

Order Job name/Part name Q’ty Remarks

Oil pump removal Remove the parts in the order below.
Crankcase cover (right) Refer to “CLUTCH”.
1 Circlip 1
2 Driven gear (oil pump) 1
3 Oil pump assembly 1
4 O-rings/collar 2/1
For installation, reverse the removal
procedure.

4-45
 OIL PUMP ENG

Order Job name/Part name Q’ty Remarks

Oil pump disassembly Disassembly the parts in the order
below.
1 Spring retainer 1
2 Spring 1
3 Relief valve 1
4 Oil pump cover 1
5 Pin 1
6 Shaft 1
7 Inner rotor 1
8 Outer rotor 1
9 Dowel pins 2
10 Oil pump housing 1
For assembly, reverse the disassembly
procedure.

4-46
 OIL PUMP ENG
OIL PUMP INSPECTION
1. Inspect:

Drive gear (oil pump) 1

Driven gear (oil pump) 2
Cracks/wear/damage
Replace.
2. Measure:

Tip clearance a
(between the inner rotor 1 and the outer
rotor 2 )

Side clearance b
(between the outer rotor 2 and the pump
housing 3 )
Out of specification
Replace the oil
pump assembly.

Tip clearance:
0.12 mm
<Limit>: 0.2 mm
Side clearance:
0.03
0.08 mm
<Limit>: 0.15 mm

3. Check:

Oil pump operation
Unsmooth operation
Replace.

4-47
 AC MAGNETO AND STARTER CLUTCH ENG

AC MAGNETO AND STARTER CLUTCH

STATOR COIL AND PICKUP COIL

7 Nm (0.7 m
kg)

7 Nm (0.7 m
kg)

Order Job name/Part name Q’ty Remarks

Stator removal Remove the parts in the order below.
Engine oil Refer to “ENGINE OIL REPLACE-
MENT” in CHAPTER 3.
Crankcase cover (left) Refer to “CLUTCH”.
Rider’s seat Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
1 Stator coil 1
2 Pickup coil 1
For installation, reverse the removal
procedure.

4-48
 AC MAGNETO AND STARTER CLUTCH ENG

AC MAGNETO AND STARTER CLUTCH

20 Nm (2.0 m
kg)

80 Nm (8,0 m
kg)

Order Job name/Part name Q’ty Remarks

AC magneto and starter clutch Remove the parts in the order below.
removal
1 Shaft 1
2 Starter idler gear 1
3 Bolts 3
Refer to “AC MAGNETO
4 Rotor 1
REMOVAL/INSTALLATION”.
5 Woodruff key 1
6 Starter wheel gear 1 Refer to “AC MAGNETO
7 Washer 1 INSTALLATION”.
8 Starter clutch assembly 1
For installation, reverse the removal
procedure.

4-49
AC MAGNETO AND STARTER CLUTCH ENG
AC MAGNETO REMOVAL
1. Remove:
 Rotor
 Woodruff key
*****************************************************
Removal steps:

Remove the starter clutch bolts 1 .

Remove the rotor bolt 2 and washer 3 .
NOTE:
Loosen the starter clutch bolts 1 and rotor bolt
2 while holding the rotor with a sheave holder
4.

Sheave holder:
90890-01701
Flywheel puller:
90890-01362
Adapter:
90890-04089

Remove the rotor and the woodruff key.

NOTE:

When installing the flywheel puller remove
three of the starter clutch bolts.

Remove the rotor by pushing back the rotor,
the flywheel puller 5 and the adapter 6 .

Install the flywheel puller bolts and tighten the
center bolt, making sure that the tool body
stays parallel to the rotor. If necessary, one
holding bolt may be backed out slightly for re-
alignment of the tool.

*****************************************************

STARTER CLUTCH INSPECTION

1. Inspect:
 Gear teeth (idler) 1
 Gear teeth (starter wheel) 2
Burrs/chips/roughness/wear
Re-
place.
 Shaft 3
Bends/damage
Replace.

4-50
AC MAGNETO AND STARTER CLUTCH ENG
2. Inspect:
 Oil passage (rotor bolt)
Clogged
Blow out with compressed air.
3. Inspect:
 Stator coil
Damage
Replace.

4. Check:
 Starter clutch assembly operation
*****************************************************
Clutch operation checking steps:
D Install the starter wheel gear to the starter
clutch, and hold the starter clutch.

When turning the starter wheel gear clock-
wise a , the starter clutch and the starter
wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.

When turning the starter wheel gear counter-
clockwise b , the starter wheel gear should
turn freely.
If not, the starter clutch is faulty. Replace it.
*****************************************************

AC MAGNETO INSTALLATION
1. Install:
 Washer 1
 Starter wheel gear 2
 Woodruff key 3
 Rotor 4
NOTE:

Clean the tapered portion of the crankshaft
and the rotor hub.

When installing the magneto rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.

4-51
AC MAGNETO AND STARTER CLUTCH ENG
2. Tighten:

Bolt (rotor) 1 80 Nm (8.0 m
kg)

Bolts (starter clutch) 2

20 Nm (2.0 m
kg)

NOTE:
Tighten the rotor bolt 1 and starter clutch bolts
2 while holding the magneto rotor with a
sheave holder 3 .

Sheave holder:
90890-01701

4-52
 CRANKSHAFT AND CONNECTING RODS ENG

CRANKSHAFT AND CONNECTING RODS

CRANKCASE

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)

24 Nm (2.4 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)
10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

Crankcase separation Remove the parts in the order below.
Engine assembly Refer to “ENGINE REMOVAL”.
Cylinder head Refer to “CYLINDER HEADS”.
Cylinder and piston Refer to “CYLINDERS AND PISTONS”.
Clutch assembly Refer to “CLUTCH”.
Shift shaft Refer to “SHIFT SHAFT”.
Oil pump assembly Refer to “OIL PUMP”.
AC magneto and starter clutch Refer to “AC MAGNETO AND
STARTER CLUTCH”.
Middle drive pinion gear Refer to “MIDDLE GEAR”.
1 Timing chain guide (rear-intake) 1
2 Timing chain guide (front-exhaust) 1
3 Timing chains 2
4 Oil strainer cover 1
5 Oil seal 1

4-53
 CRANKSHAFT AND CONNECTING RODS ENG

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)

24 Nm (2.4 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)
10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

6 O-rings 2
7 Oil strainer 1
8 Crankcase (right) 1 Refer to “CRANKCASE
SEPARATION/ASSEMBLY”.
9 Dowel pins 3
10 O-ring 1
For assembly, reverse the separation
procedure.

4-54
 CRANKSHAFT AND CONNECTING RODS ENG

CRANKSHAFT AND CONNECTING RODS

36 Nm (3.6 m
kg)

Order Job name/Part name Q’ty Remarks

Crankshaft and connecting rod Remove the parts in the order below.
removal
1 Crankshaft assembly 1
2 Main journal bearings 2
3 Nuts (connecting rod caps) 4
Refer to “CRANKSHAFT
4 Connecting rod bolts 4
REMOVAL/INSTALLATION”.
5 Connecting rods 2
6 Connecting rod caps 2
7 Plain bearings 4
For installation, reverse the removal
procedure.

4-55
 CRANKSHAFT AND CONNECTING RODS ENG
A CRANKCASE SEPARATION
1. Separate:
 Left crankcase
 Right crankcase
*****************************************************
Separation steps:

Remove the crankcase bolts.
NOTE:

Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove them.
B
Loosen the bolts in numerical order (see
numbers on the illustration).

Turn the shift cam 15 to the position shown in
the figure so that it does not contact the
crankcase when separating the crankcase.

A Right crankcase
B Left crankcase

Remove the right crankcase 16 .
NOTE:
For this removal, slits a in the crankcase can
be use as shown.

CAUTION:
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crank-
case mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.

Remove the dowel pins and O-ring.

*****************************************************

4-56
CRANKSHAFT AND CONNECTING RODS ENG
CRANKSHAFT REMOVAL
1. Remove:

Main journal bearings 1
NOTE:
Remove the main journal bearings by the plane
bearing installer/remover 2 middle driven
shaft bearing driver 3 .

Plane bearing installer/remover:

90890-04074
Middle driven shaft bearing driver:
90890-04058

2. Remove:

Connecting rod caps 1

Connecting rod 2

Plain bearings
NOTE:
Identify the position of each bearing very care-
fully so that it can be reinstalled in its original
place.

CRANKSHAFT INSPECTION
1. Thoroughly wash the crankcase halves in
mild solvent.
2. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
3. Inspect:

Crankcase
Cracks/damage
Replace.

Oil delivery passages
Blockage
Blow out the passages with
compressed air.
4. Measure:

Runout (crankshaft)
Out of specification
Replace.

Runout limit:
0.02 mm

4-57
CRANKSHAFT AND CONNECTING RODS ENG
5. Inspect:
 Crank pin surfaces
 Bearing surfaces
Wear/scratches
Replace.
6. Inspect:
 Timing chain sprockets 1
Damage/wear
Replace the crankshaft.

7. Measure:
 Oil clearance (crank pin)
Out of specification
Replace the bear-
ing.

Oil clearance (crank pin):

0.026
0.050 mm
*****************************************************
Measurement steps:
CAUTION:
Do not interchange the bearings and con-
necting rods. To obtain the correct oil clear-
ance and to prevent engine damage they
must be installed in their original positions.

Clean the bearings, crank pins and bearing

portions of the connecting rods.

Install the upper half of the bearing into the
connecting rod and the lower half of the bear-
ing into the connecting rod cap.
NOTE:
Align the projection a of the bearing with the
notch b of the connecting rod and its cap.

Put a piece of Plastigauge 1 on the crank

pin.

Assemble the connecting rod halves.
NOTE:

Do not move the connecting rod or crank-
shaft until the oil clearance measurement
has been completed.

Apply molybdenum disulfide grease to the
bolts, threads and nut seats.

4-58
CRANKSHAFT AND CONNECTING RODS ENG

The stamped “Y” mark 2 on the connect-
ing rods should face towards the left side
of the crankcase.

Be sure that the characters 3 on the side of
the cap and connecting rod are aligned.

Tighten the nuts.

Nuts (connecting rod caps):

36 Nm (3.6 mkg)

CAUTION:

When tightening the nuts be sure to use
an F-type torque wrench.

Without pausing tighten to full torque
specifications. Apply continuous torque
between 3.0 and 3.6 mkg. Once you reach
3.0 mkg DO NOT STOP TIGHTENING un-
til final torque is reached. If the tightening
is interrupted between 3.0 and 3.6 mkg,
loosen the nut to less than 3.0 mkg and
start again.

Remove the connecting rods and bearings.

On each crank pin measure the width of the
compressed Plastigauge 1 .
If the oil clearance is out of specification, se-
lect a replacement bearing.
*****************************************************
8. Select:
 Crank pin bearing (P1)
NOTE:

The numbers 1 indicate crankshaft jour-
nal sizes are stamped on the crankweb, as
shown in the illustration.

The numbers 2 are stamped in ink on the
connecting rod and connecting rod cap, as
shown in the illustration.

*****************************************************
Selection of crank pin bearings:

If “P1” on the connecting rod is “4” and “P1” on
the crankweb is “2”, then the bearing size for
“P1” is:

Bearing size of P1:

Connecting rod P1 – Crankweb P1 =
4 – 2 = 2 (black)

4-59
CRANKSHAFT AND CONNECTING RODS ENG

BEARING COLOR CODE

1 blue
2 black
3 brown
4 green

*****************************************************

9. Measure:
 Oil clearance (main journal)
Out of specification
Replace the bear-
ing.

Oil clearance (main journal):

0.020
0.052 mm
*****************************************************
Measurement steps:
CAUTION:
On the journal, the larger value is used as a
basis for calculation of the oil clearance,
and on the journal bearing, the smaller value
is used.

Clean the surface of main journal and journal

bearings.

Check the bearing surface. If the bearing sur-
face is worn or scratched, the bearings
should be replace.
NOTE:
If either of the right or left journal bearing is worn
or scratched, both bearings should be replaced
as a set.

Measure the outside diameter a of each

main journal at two places. If it is out of speci-
fication, replace the crankshaft.

Outside diameter limit (main

journal):
44.95 mm

Measure the inside diameter b of each jour-

nal bearing at two places.

4-60
CRANKSHAFT AND CONNECTING RODS ENG

If journal bearing inside diameter is “45.03”
and crankshaft journal outside diameter is
“44.98”, then the main journal oil clearance
is:

Main journal oil clearance:

Journal bearing inside diameter –
Main journal outside diameter =
45.03 – 44.98 = 0.05 mm
If the oil clearance is out of specification, se-
lect a replacement bearings.
*****************************************************

10. Select:
 Main journal bearing
*****************************************************
Selection of main journal bearings:

Remove the main journal bearings out of
crankcase.

Clean the bearing seat in the crankcase
where the bearing is fitted.

Measure the diameter a of the bearing seat
at two places.
NOTE:
If the diameter of the bearing seat in the crank-
case exceeds 49.02 mm, the crankcase should
be replaced with a new one. The new crankcase
includes new journal bearings. The each inside
diameter of bearing is normally 45.000

45.012 mm.

CAUTION:
The average of the two values is used to
choose the bearing.

Select the proper oversized main journal

bearing with the following table.

DIAMETER OF
COLOR CODE
THE BEARING SEAT
49.000
49.010 mm blue
49.011
49.020 mm green
4-61 *****************************************************
CRANKSHAFT AND CONNECTING RODS ENG
CRANKSHAFT INSTALLATION
1. Attach:
 Main journal bearings 1
NOTE:

Attach the main journal bearing to the plane
bearing installer/remover 2 middle driven
shaft bearing driver 3 .

Align the projection a on the bearing with the
projection b and slot c on the special tools.

Plane bearing installer/remover:

90890-04074
Middle driven shaft bearing driver:
90890-04058

2. Install:
 Main journal bearings 1
NOTE:
Align the projection a on the bearing with the
slit b on the crankcase.

3. Install:
 Connecting rod bearings 1
NOTE:

Align the projection a of the bearings with
the notches b in the connecting rod cap.

Install each bearing in its original place.

4. Install:
 Connecting rods 1
NOTE:

The stamped “Y” mark a on the connecting
rods should face towards the left side of the
crankcase.

Install each connecting rod in its original
place.

4-62
CRANKSHAFT AND CONNECTING RODS ENG
5. Install:
 Connecting rod cap 1
NOTE:
Be sure that the characters a on the side of the
cap and connecting rod are aligned.

6. Tighten:
 Nuts (connecting rod cap)
36 Nm (3.6 mkg)

NOTE:
Apply molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.

CAUTION:

When tightening the nuts be sure to use
an F-type torque wrench.

Without pausing tighten to full torque
specification. Apply continuous torque
between 3.0 and 3.6 mkg. Once you reach
3.0 mkg DO NOT STOP TIGHTENING un-
til final torque is reached. If the tightening
is interrupted between 3.0 and 3.6 mkg,
loosen the nut to less than 3.0 mkg and
start again.

7. Install:
 Crankshaft 1
NOTE:
Align the left connecting rod with the rear cylin-
der sleeve hole.

CRANKCASE ASSEMBLY
1. Apply:
 Engine oil
(onto the main journal bearings)
 Sealant
(onto the crankcase mating surfaces)

Yamaha Bond No.1215:

90890-85505

4-63
CRANKSHAFT AND CONNECTING RODS ENG
2. Install:
 Right crankcase
(onto the left crankcase)
NOTE:
Turn the shift cam to the position shown in the
figure so that it does not contact the crankcase
when installing the crankcase.

3. Tighten:
 Crankcase bolts
(follow the proper tightening sequence)
NOTE:
The numbers embossed on the crankcase indi-
cate the crankcase tightening sequence.

4 X 7 (M8) 24 Nm (2.4 mkg)

1 X 3 , 8 X14 (M6) 10 Nm (1.0 mkg)

NOTE:

Lubricate the bolt threads with engine oil.

Tighten the bolts in increasing numerical or-
der.

M6 45 mm 1 , 3 , 9 X 14
M6 55 mm 2
M6 95 mm 8
M8 60 mm 4, 6
M8 80 mm 7
M8 100 mm 5

4-64
 TRANSMISSION ENG

TRANSMISSION

25 Nm (2.5 m
kg)

Order Job name/Part name Q’ty Remarks

Transmission removal Remove the parts in the order below.
Crankcase separation Refer to “CRANKSHAFT”.
1 Guide bar 1 1
2 Guide bar 2 1
3 Shift fork 2 “C” 1
4 Shift fork 3 “R” 1 Refer to “TRANSMISSION
5 Shift fork 1 “L” 1 INSTALLATION”.
6 Shift cam 1
7 Main axle assembly 1
8 Drive axle assembly 1
9 Bearing retainer 2
10 Bearings 4
11 Shim 1
For installation, reverse the removal
procedure.

4-65
 TRANSMISSION ENG
SHIFT FORK INSPECTION
1. Inspect:

Shift fork cam follower 1

Shift fork pawl 2
Scoring/bends/wear/damage
Re-
place.

2. Inspect:

Guide bar
Roll the guide bar on a flat surface.
Bends
Replace.

Do not attempt to straighten a bent guide

bar.

3. Check:

Shift fork movement
(on the guide bar)
Unsmooth operation
Replace the shift
fork and the guide bar.

SHIFT CAM INSPECTION

1. Inspect:

Shift cam grooves
Scratches/wear/damage
Replace.

Shift cam segment 1
Wear/damage
Replace.

Shift cam bearing 2
Pitting/damage
Replace.

TRANSMISSION INSPECTION
1. Measure:

Axle runout
Use a centering device and a dial gauge.
Out of specification
Replace the bent
axle.

Runout limit (main and drive

axle):
0.06 mm

4-66
 TRANSMISSION ENG
2. Inspect:

Gear teeth
Blue discoloration/pitting/wear

Replace.

Mated dogs
Rounded edges/cracks/missing portions

Replace.

3. Check:

Proper pinion gear engagement (each
gear to its counter part)
Incorrect
Reassemble.

Gear movement
Roughness
Replace.
*************************************
Transmission gear reassembling point:
Press the 2nd pinion gear 1 into the 1st pinion
gear (main axle) 2 .
*************************************
4. Inspect:

Circlip
Bends/looseness/damage
Replace.

5. Inspect:

Bearings
Unsmooth
Replace.

4-67
 TRANSMISSION ENG
TRANSMISSION INSTALLATION
1. Tighten:
 Torx screws (bearing retainer) 1
25 Nm (2.5 mkg)

Use #40 torx screw wrench.

2. Lock the torx screw head with drift punch.

3. Install:
 Shift cam 1
 Shift fork 2 “C” 2
 Shift fork 3 “R” 3
 Shift fork 1 “L” 4
 Guide bar 1 5
 Guide bar 2 6
NOTE:
The number stamped into the shift fork must al-
ways face towards the right side of the crank-
case. Be sure that the shift fork guide pin is
properly seated in the shift drum groove.

4. Check:
 Shift operation
Unsmooth operation
Repair.
NOTE:

Oil each gear and bearing thoroughly.

Before assembling the crankcase, be sure
that the transmission is in neutral and that the
gears turn freely.

4-68
 MIDDLE GEAR ENG

MIDDLE GEAR
MIDDLE DRIVEN PINION GEAR

25 Nm (2.5 m
kg)

90 Nm (9.0 m
kg)

Order Job name/Part name Q’ty Remarks

Middle driven pinion gear removal Remove the parts in the order below.
Engine assembly Refer to “ENGINE REMOVAL”.
1 Bolts 4
2 Shim 1
3 Circlips 4
4 Bearings 4
5 Yoke 1
6 Nut 1
Refer to “MIDDLE DRIVEN PINION
7 Yoke 1
GEAR REMOVAL/INSTALLATION”.
8 Collar 1
9 Bearing housing/O-ring 1/1
10 Spring retainers 2
11 Spring seat 1
12 Damper spring 1
13 Damper cam 1

4-69
 MIDDLE GEAR ENG

25 Nm (2.5 m
kg)

90 Nm (9.0 m
kg)

Order Job name/Part name Q’ty Remarks

14 Middle driven pinion gear 1 Refer to “MIDDLE DRIVEN PINION
15 Middle driven shaft 1 GEAR REMOVAL/INSTALLATION”.
For installation, reverse the removal
procedure.

4-70
 MIDDLE GEAR ENG

MIDDLE DRIVE PINION GEAR

12 Nm (1.2 m
kg)
120 Nm (12.0 m
kg)

Order Job name/Part name Q’ty Remarks

Middle drive pinion gear removal Remove the parts in the order below.
1 Middle gear cover/O-ring 1/1
2 Nut 1 Refer to “MIDDLE DRIVE PINION
3 Middle drive pinion gear 1 GEAR REMOVAL/INSTALLATION”.
4 Screw/gasket 1/1
5 Push lever axle 1
6 Torsion spring 1
7 Washer 1
8 Oil seal 1
For installation, reverse the removal
procedure.

4-71
 MIDDLE GEAR ENG
MIDDLE DRIVEN PINION GEAR REMOVAL
1. Remove:
 Universal joint
*****************************************************
Disassembly steps:

Remove the circlips 1 .

Place the universal joint in a press.

Using a suitable diameter pipe beneath the
yoke, press the bearing into the pipe as
shown.
NOTE:
It may be necessary to lightly tap the yoke with a
punch.

Repeat the steps for the opposite bearing.

Remove the yoke.
*****************************************************
2. Loosen:
 Nut (middle driven shaft) 1
NOTE:
Use the universal joint holder 2 to hold the
yoke 3 .

Universal joint holder:

90890-04062

3. Remove:
 Bearing housing assembly 1
*****************************************************
Removal steps:

Clean the outside of the middle driven shaft.

Place the middle driven shaft assembly onto
a hydraulic press.
CAUTION:

Never directly press the shaft end with a
hydraulic press, this will result in damage
to the shaft thread.

Install the suitable socket 2 on the shaft
end to protect the thread from damage.

NOTE:
When the middle driven shaft is removed from
the bearing housing assembly, always replace
the bearing.

Press the shaft end, and remove the bearing

housing.
*****************************************************
4-72
 MIDDLE GEAR ENG
4. Remove:
 Spring retainers
NOTE:
Attach the damper spring compressor 1 on the
spring seat 2 and compress the damper
spring, then remove the spring retainers.

Damper spring compressor:

90890-04090

5. Remove:
 Bearing retainer 1
 Bearing
*****************************************************
Removal steps:

Attach the folded rag 2 .

Secure the bearing housing edge in the vise.

Attach the bearing retainer wrench 3 .

Bearing retainer wrench:

90890-04057

CAUTION:
The middle driven shaft bearing retainer has
left-handed threads. To loosen the retainer
turn it clockwise.

Remove the bearing retainer and bearing.

*****************************************************
MIDDLE DRIVE PINION GEAR REMOVAL
1. Loosen:
 Nut (middle drive pinion gear) 1
NOTE:

Flatten the punched position of the middle
drive pinion gear nut using the drift punch.

Put the engine in 1st, and carry out the opera-
tion.

Loosen the nut (middle drive pinion gear) 1
while holding the rotor with the sheave holder
2.

Sheave holder:
90890-01701

4-73
 MIDDLE GEAR ENG
MIDDLE GEAR INSPECTION
1. Inspect:
 Damper cam surface
Wear/scratches
Replace the damper
cam as a set.
2. Inspect:
 Damper spring
Damage/cracks
Replace.

3. Inspect:
 Middle driven pinion gear teeth 1
 Middle drive pinion gear teeth 2
Pitting/galling/wear
Replace the
middle gear as a set.

4. Inspect:
 Bearing
Pitting/damage
Replace the bearing
housing assembly.
 O-rings
Damage
Replace.
5. Check:
 Universal joint movement
Roughness
Replace the universal joint.

MIDDLE DRIVE PINION GEAR

INSTALLATION
1. Install:
 Middle drive pinion gear 1
 Nut 2 120 Nm (12.0 mkg)

NOTE:

Tighten the nut (middle drive pinion gear) 2
while holding the rotor with the sheave holder
3.

To lock the threads stake them with a center
punch.

Sheave holder:
90890-01701

4-74
 MIDDLE GEAR ENG
MIDDLE DRIVEN PINION GEAR
INSTALLATION
1. Install:
 Spring retainers
NOTE:
Attach the damper spring compressor 1 on the
spring seat 2 and compress the damper
spring, then install the spring retainers.

Damper spring compressor:

90890-04090

2. Install:
 Bearing
*****************************************************
Installation steps:

Install the new bearing by reversing the re-
moval steps.
NOTE:
Use a socket 1 that matches the diameter of
the outer bearing race and the oil seal.

CAUTION:
Do not contact the bearing center race 2 or
balls 3 . Contact should be made only with
the outer race 4 .

*****************************************************
3. Install:
 Bearing retainer 1
*****************************************************
Install steps:

Attach the folded rag 2 .

Secure the bearing housing edge in the vise.

Attach the bearing retainer wrench 3 .

Bearing retainer wrench:

90890-04057

Tighten the bearing retainer.

CAUTION:
The middle driven shaft bearing retainer has
left-handed threads. To tighten the retainer
turn it counterclockwise.

Bearing retainer:
110 Nm (11.0 mkg)
*****************************************************
4-75
 MIDDLE GEAR ENG
4. Install:
 Middle driven shaft assembly
*****************************************************
Install steps:

Clean the outside of the middle driven shaft
and the inside of the bearing.

Fit the middle driven shaft assembly onto the
bearing housing.

Place the middle driven shaft assembly onto
a hydraulic press.
CAUTION:

Never directly press the shaft end with a
hydraulic press, this will result in damage
to the shaft thread.

Install the hand-made tool 1 to protect
the bearing and bearing housing from
damage.

Install the wood piece 2 on the shaft end
to protect the thread from damage.

Press the wood piece and secure the middle

driven shaft assembly.
*****************************************************

5. Tighten:
 Nut (middle driven pinion gear) 1
90 Nm (9.0 mkg)

NOTE:
Use the universal joint holder 2 to hold the
yoke 3 .

Universal joint holder:

90890-04062
6. Install:
 Yoke (cross joint) 1
(into the hole on yoke)

4-76
 MIDDLE GEAR ENG
7. Install:

Bearings 1
(onto the cross joint)
CAUTION:
The needles can easily fall out of their races,
so check each bearing. Slide the universal
joint yoke back and forth on the bearings. If
a needle is out of place the yoke will not go
all the way onto the bearing.

8. Using a suitable socket press each bearing

into the hole on yoke.
NOTE:
The bearings must be inserted far enough into
the cross joint so that the circlips can be
installed.

9. Install:

Circlips 3
(into the groove of each bearing)

10. Install:

Middle driven pinion gear assembly
NOTE:
Just finger tighten the bolts at this stage.

11. Install:

Shims 1

Bolts 25 Nm (2.5 m
kg)

NOTE:
When installing the shims, make sure that the
tabs a are positioned correctly.

4-77
 MIDDLE GEAR ENG

NOTE:
Before tightening the bolts:
1. Adjust the gear lash of the middle gear.
Refer to “GEAR BACKLASH ADJUST-
MENT”.
2. Check the operation of the middle driven
gear.

MIDDLE DRIVE GEAR SHIM SELECTION

NOTE:
Gear positioning is necessary when any of the
following parts are replaced.

Crankcase assembly

Middle gear assembly

1. Select:
 Middle drive gear shim 1
*****************************************************
Middle drive gear shim selection steps:

Position middle drive gear by using shims 1
with their respective thickness calculated
from information marked on crankcase, bear-
ing housing and drive gear end.
1 Shim thickness “A”

To find shim thickness “A” use following for-
mula:

Middle drive pinion gear shim thickness:

“A” = a – b
Where:
a = a numeral (usually a decimal num-
ber) on the middle drive pinion gear is
either added to or subtracted from
“44”.
b = a numeral (usually a decimal num-
ber) on the left crankcase specifies a
thickness of “43.5”.
Example:
1) If the middle drive pinion gear is marked
“+03”
. . . a is 44.03
2) If the crankcase (left) is marked “43.45”
. . . b is 43.45
3) Therefore, the shim thickness is 0.58 mm

4-78
 MIDDLE GEAR ENG
A = 44.03 – 43.45
= 0.58

6) Round off hundredths digit and select

appropriate shim(s).
In the example above, the calculated
shim thickness is 0.58 mm. The chart
instructs you, however, to round off 8 to
10.

Hundredths Round value

0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10
Shims are supplied in the following thickness.

Middle drive pinion gear shim

0.20 0.40
Thickness (mm)
0.30

*****************************************************

GEAR BACKLASH ADJUSTMENT

1. Install:
 Middle gear backlash tool 1
NOTE:
This tool will prevent the drive axle from turning.

Middle gear backlash tool:

90890-04080

2. Install:
 Bolts (driven gear bearing housing)
NOTE:

Just finger tighten the bolts at this stage.

Clearance between the crankcase and the
driven bearing housing should be about 2
mm.

Measure the gap with a feeler gauge 2 .

4-79
 MIDDLE GEAR ENG
3. Position:
S Dial gauge
(onto the outside edge of the universal
joint)
NOTE:
Be sure that the gauge is positioned over the
centerline of the yoke bearing hole.

4. Rotate:
S Universal joint 1
NOTE:
Move the universal joint gently back and forth.

5. Measure:
S Gear backlash
Over specification
Follow the next
steps
Under or same specification
Incorrect
Check for faulty parts and/or reassemble
the bearing housing.

Backlash (gear):
0.05
0.10 mm

CAUTION:
Do not hammer the universal joint or the col-
lapsible collar of the driven pinion gear may
be distorted. This will result in a change in
the standard spinning torque, requiring re-
placement of the collapsible collar and reas-
sembly of the driven gear assembly.

NOTE:
Check the gear backlash at four positions. Ro-
tate the universal joint 90_ each time and repeat
the gear backlash check.

4-80
 MIDDLE GEAR ENG
6. Tighten:
 Bolts (driven gear bearing housing) 1
25 Nm (2.5 mkg)

NOTE:
Tighten the bolts carefully, one thread turn at a
time, only. Push in the bearing housing and
tighten the bearing housing bolts.

CAUTION:
Do not overtighten the bearing housing
bolts or you may obtain too little gear back-
lash and cause damage to the gears. If over
tightened, loosen the three bolts so that the
crankcase/bearing housing clearance is
about 2 mm and repeat all previous steps.

7. Repeat steps #4 and #5 until the correct

gear backlash is achieved.

Backlash (gear):
0.05
0.10 mm

8. Measure:
 Crankcase/bearing housing clearance
Use a feeler gauge

9. Select:
 Shim(s)
*****************************************************
Selection steps:

For example, the clearance between the
crankcase and the bearing housing is 0.46
mm.

The shim can only be selected in 0.05 mm in-
crements, round off the hundredths digit and
select the appropriate shim(s).

Hundredths Rounded value

0, 1, 2 0
3, 4, 5, 6, 5
7, 8, 9 10

4-81
 MIDDLE GEAR ENG

Shims are supplied in the following thick-
nesses.

Middle drive pinion gear shim:

Thickness (mm) 0.10, 0.15, 0.20

*****************************************************

10. Tighten:
 Bolts (driven gear bearing housing) 1
25 Nm (2.5 mkg)

11. Measure:
 Gear backlash

4-82
 CARB
CHAPTER 5.
CARBURETION

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
THROTTLE POSITION SENSOR (TPS) INSPECTION
AAND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CARB
 CARBURETOR CARB

CARBURETION
CARBURETOR

Order Job name/Part name Q’ty Remarks

Carburetor removal Remove the parts in the order below.
Fuel tank Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
1 Air filter case assembly 1
2 Air duct 1
3 Cylinder head breather hose 1 Disconnect
4 Throttle position sensor lead 1
5 Thermo switch lead 1
6 Fuel hose 1
7 Carburetor assembly 1
8 Starter cable 1 NOTE:
9 Throttle cables 2 After removing the carburetor
assembly, remove the starter cable
and throttle cables.

10 Cover 1
For installation, reverse the removal pro-
cedure.

5-1
 CARBURETOR CARB

Order Job name/Part name Q’ty Remarks

Carburetor disassembly Disassemble the parts in the order
below.
1 Carburetor heater lead 1
2 Carburetor heaters 1 2 12V 15W
3 Carburetor heaters 2 2 12V 30W
4 Float chamber 1
5 Float 1
6 Needle valve set 1
7 Main jet 1
8 Jet holder 1
9 Pilot jet 1
Refer to “CARBURETOR
10 Jet needle set 1
ASSEMBLY”.
11 Needle jet 1
12 Starter plunger set 1

5-2
 CARBURETOR CARB

Order Job name/Part name Q’ty Remarks

13 Diaphragm set 1 Refer to “CARBURETOR ASSEMBLY”.
14 Throttle position sensor 1 Refer to “THROTTLE POSITION
SENSOR (TPS) INSPECTION AND
ADJUSTMENT”.
15 Pilot screw 1 Refer to “CARBURETOR ASSEMBLY”.
16 Main air jet 1
For assembly, reverse the disassembly
procedure.

5-3
 CARBURETOR CARB
EB600030

CARBURETOR INSPECTION
1. Inspect:
 Carburetor body
 Float chamber
 Jet housing
Cracks/damage
Replace.
 Fuel passage
Blockage
Clean as indicated.
 Carburetor float chamber body
Contamination
Clean.
*****************************************************
Cleaning steps:

Wash the carburetor in a petroleum based
solvent. (Do not use any caustic carburetor
cleaning solution.)

Blow out all of the passages and jets with
compressed air.
*****************************************************

2. Inspect:
 Float
Damage
Replace.

3. Inspect:
 Needle valve 1
 Valve seat 2
 O-ring 3
Contamination/wear/damage
Re-
place as a set.

4. Inspect:
 Piston valve 1
Scratches/wear/damage
Replace.
 Rubber diaphragm 2
Tears
Replace.

5-4
 CARBURETOR CARB
5. Inspect:

Vacuum chamber cover 1

Springs 2

Plastic bushing 3

Plastic screw cap 4
Cracks/damage
Replace.

6. Inspect:

Jet needle 1

Main jet 2

Main jet holder 3

Pilot jet 4

Needle jet 5

Pilot air jet 6

Pilot screw 7

Starter plunger
Bends/wear/damage
Replace.
Blockage
Blow out the jets with com-
pressed air.
7. Check:

Free movement
Insert the throttle valve into the carburetor
body and check for free movement.
Sticks/tight
Replace.

8. Inspect:

Joints (fuel) 1

Joints (air vent hose-vacuum chamber) 2

Joints (carburetor breather hose) 3
Cracks/damage
Replace.

CARBURETOR ASSEMBLY
CAUTION:
Before reassembling, wash all of the parts in
a clean petroleum based solvent.

5-5
 CARBURETOR CARB
1. Install:
 Needle jet 1
NOTE:

Align the groove on the needle jet with the
projection on the carburetor body.

Install the needle jet from the piston valve
side.

2. Install:
 Pilot screw 1

Pilot screw (turns out):

2

3. Install:
 Jet needle
NOTE:
Align the projection a on the plastic stopper
with the hole b in the piston valve.

4. Install:
 Diaphragm 1
NOTE:
Match the tab on the diaphragm to the recess in
the carburetor body.

5. Install:
 Diaphragm 1
 Compression spring 2
 Cover 3
NOTE:
Match the tab on the diaphragm to the recess in
the carburetor body.

5-6
 CARBURETOR CARB
FUEL LEVEL ADJUSTMENT
1. Measure:
 Fuel level a
Out of specification
Adjust

Fuel level:
7.5
8.5 mm
(below the float chamber line)

*****************************************************
Measurement and adjustment steps:

Place the motorcycle on a level surface.

Put the motorcycle on a suitable stand to en-
sure that the carburetor assembly is posi-
tioned vertically.

Connect the fuel level gauge 1 to the drain
pipe.

Fuel level gauge:

90890-01312

Loosen the drain screw 2 .

Hold the gauge vertically next to the float
chamber line b .

Measure the fuel level with the gauge.

If the fuel level is incorrect, adjust it.

Remove the carburetor assembly.

Inspect the valve seat and needle valve.

If either is worn, replace them both.

If both are fine, adjust the float level by slightly
bending the float tang 3 .

Install the carburetor assembly.

Check the fuel level again.
*****************************************************

5-7
 CARBURETOR CARB
THROTTLE POSITION SENSOR (TPS) IN-
SPECTION AND ADJUSTMENT
NOTE:
Before adjusting the TPS, the idling speed
should be properly adjusted.

1. Inspect:
S TPS resistance
*****************************************************
Inspect steps:
D Disconnect the TPS coupler.
D Remove the TPS from the carburetor.
D Connect the pocket tester (Ω 1 k) to the
TPS connector.

Tester (+) lead
Black terminal 1

Tester (–) lead
Blue terminal 2

D Check the TPS resistance.

TPS resistance “R1”:

4.0 X 6.0 kΩ at 20_C
(Black — Blue)

Out of specification
Replace the TPS.

D Connect the pocket tester (Ω 1 k) to the
TPS connector.

Tester (+) lead
Yellow terminal 3

Tester (–) lead
Black terminal 1

D While slowly turning the throttle check the

TPS resistance.

TPS resistance “R2”:

0 X 5 ± 1.0 kΩ at 20_C
(Yellow — Black)

Out of specification
Replace the TPS.

*****************************************************

5-8
 CARBURETOR CARB
2. Adjust:
 TPS position
*****************************************************
Adjustment steps:

Loosen the TPS mounting screws 1 .

Adjust the TPS resistance by turning the sen-
sor body to the right or left. Stop turning the
sensor body when the specified resistance is
indicated on the tester.

Resistance when the throttle is closed =

Resistance “R1” (0.13 X 0.15)

Example:

If “R1” = 5 kΩ:
5 (0.13 X 0.15) = 0.65 X 0.75
The specified resistance when the throttle is
closed is 650 X 750 Ω.

Tighten the TPS mounting screws.

Detach the pocket tester leads and connect
the TPS connector.
*****************************************************

5-9
CARB
 CHAS
CHAPTER 6.
CHASSIS

FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

FRONT WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
FRONT WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
BRAKE DISK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
FRONT WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
FRONT WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
FRONT WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . 6-6

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
MASTER CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

MUFFLER AND REAR BRAKE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
REAR WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
REAR WHEEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
REAR WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
REAR BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
REAR BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
REAR WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
REAR WHEEL STATIC BALANCE ADJUSTMENT . . . . . . . . . . . . . . 6-29

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

FRONT FORK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
FRONT FORK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
FRONT FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
FRONT FORK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
HANDLEBAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
 CHAS
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
STEERING HEAD REMOAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
STEERING HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
STEERING HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-46

HANDLING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
NOTES ON DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
REAR SHOCK ABSORBER INSPECTION . . . . . . . . . . . . . . . . . . . . . 6-48
SWINGARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
SWINGARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
REAR SHOCK ABSORBER INSTALLATION . . . . . . . . . . . . . . . . . . . 6-50

SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
FINAL GEAR BACKLASH MEASUREMENT . . . . . . . . . . . . . . . . . . . . 6-55
FINAL GEAR BACKLASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 6-56
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
FINAL GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
FINAL DRIVE GEAR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
FINAL DRIVE ROLLER BEARING REMOVAL
AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
FINAL DRIVE/RING GEAR POSITIONING . . . . . . . . . . . . . . . . . . . . . 6-61
DEIVE SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
FINAL GEAR CASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
 FRONT WHEEL AND BRAKE DISC CHAS

CHASSIS
FRONT WHEEL AND BRAKE DISC

59 Nm (5.9 m
kg)

20 Nm (2.0 m
kg)

23 Nm (2.3 m
kg)

Order Job name/Part name Q’ty Remarks

Front wheel and brake disc removal Remove the parts in the order below.
Stand the motorcycle on a level
surface.

Securely support the motorcycle so

there is no danger of it falling over.

1 Speedometer cable 1 Disconnect

2 Front wheel axle pinch bolt 1 Loosen
3 Front wheel axle 1
4 Front wheel assembly 1 Refer to “FRONT WHEEL
5 Collar 1 INSTALLATION”.
6 Speedometer gear unit 1
7 Brake disc 1
For installation, reverse the removal
procedure.

6-1
 FRONT WHEEL AND BRAKE DISC CHAS

Order Job name/Part name Q’ty Remarks

Front wheel disassembly Disassemble the parts in the order
below.
1 Oil seals 1
2 Clutch retainer 1
3 Speedometer clutch 1
4 Oil seal 1
5 Bearing 1 Refer to “FRONT WHEEL
6 Collar 1 DISASSEMBLY/ASSEMBLY”.
7 Bearing 1
For assembly, reverse the disassembly
procedure.

6-2
FRONT WHEEL AND BRAKE DISC CHAS
FRONT WHEEL DISASSEMBLY
1. Remove:
S Oil seals
S Bearings 1
S Collar
*****************************************************
Removal steps:
D Clean the outside of the front wheel hub.
D Use a flat-head screwdriver to remove the oil
seals.
NOTE:
To prevent damage place a rag between the
screwdriver and the wheel surface.

D Remove the bearings using a standard bear-

ing puller 2 .
*****************************************************

FRONT WHEEL INSPECTION

1. Inspect:
S Front wheel axle
(by rolling it on a flat surface)
Bent
Replace.

Do not attempt to straighten a bent axle.

2. Inspect:
S Front tire
Refer to “TIRE INSPECTION” in CHAP-
TER 3.
S Front wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.

3. Check:
S Spokes
Bends/damage
Replace.
Loose spokes
Retighten.
Turn the wheel and tap the spokes with a
screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.

6-3
FRONT WHEEL AND BRAKE DISC CHAS
4. Tighten:

Loose spokes 3 Nm (0.3 m
kg)

NOTE:
After tightening the spokes check the front
wheel runout.

5. Measure:

Front wheel runout
Over the specified limits
Replace.

Front wheel runout limits:

Radial 1 : 2.0 mm
Lateral 2 : 2.0 mm

6. Inspect:

Front wheel bearings
Bearings allow free play in the wheel hub
or the wheel does not turn smoothly
Re-
place.

Oil seals
Wear/damage
Replace.

BRAKE DISK INSPECTION

1. Inspect:

Brake disc
Galling/damage
Replace.
2. Measure:

Brake disc deflection a
Out of specification
Inspect the wheel
runout.
If wheel runout is within the limits, replace
the brake disc.

Brake disc maximum deflection:

0.15 mm

Measuring point 2 mm

Brake disc thickness b
Out of specification
Replace.

Brake disc minimum thickness:

4.5 mm

6-4
FRONT WHEEL AND BRAKE DISC CHAS
FRONT WHEEL ASSEMBLY
1. Install:
S Collar
S Bearings
S Oil seals
*****************************************************
Installation steps:
D Install the new bearings and oil seals by re-
versing the removal steps.
NOTE:
Use a socket 1 that matches the diameter of
the outer bearing race and the oil seal.

CAUTION:
Do not contact the bearing center race 2 or
balls 3 . Contact should be made only with
the outer race 4 .

*****************************************************
FRONT WHEEL INSTALLATION
1. Install:
S Brake disc 1 23 Nm (2.3 mSkg)

NOTE:
D Apply LOCTITE to the threads of the brake
disc bolts.
D Tighten the brake disc bolts in stages using a
crisscross pattern.

2. Install:
S Speedometer gear unit 1
NOTE:
Be sure that two projections a inside the wheel
hub mesh with the two slots b in the gear unit
assembly.

3. Tighten:
S Front wheel
S Front wheel axle 59 Nm (5.9 mSkg)

NOTE:
Be sure that the projection (torque stopper) a
of the gear unit housing is positioned correctly.

S Axle pinch bolt 20 Nm (2.0 mSkg)

6-5
FRONT WHEEL AND BRAKE DISC CHAS
EB700040

FRONT WHEEL STATIC BALANCE

ADJUSTMENT
NOTE:
D After replacing the tire and/or rim, the wheel
static balance should be adjusted.
D Adjust the front wheel static balance with the
brake discs installed.

1. Remove:
S Balancing weight
2. Set:
S Front wheel (on a suitable stand)
3. Find:
S Heavy spot
*****************************************************
Procedure:
a. Spin the wheel and wait for it to rest.
b. Put an “X1” mark on the wheel’s bottom
spot.
c. Turn the wheel so that the “X1” mark is 90_
up.
d. Release the wheel and wait for it to rest. Put
an “X2” mark on the wheel’s bottom spot.
e. Repeat steps (b), (c) and (d) several times
until all the marks come to the same spot.
f. This spot is the wheel’s heavy spot “X”.
*****************************************************
4. Adjust:
S Front wheel static balance
*****************************************************
Adjusting steps:
D Install a balancing weight 1 onto the rim ex-
actly opposite to the heavy spot “X”.
NOTE:
Start with the smallest weight.

D Turn the wheel so that the heavy spot is 90_

up.
D Check that the heavy spot is at rest there. If
not, try another weight until the wheel is bal-
anced.
*****************************************************

6-6
FRONT WHEEL AND BRAKE DISC CHAS
5. Check:
S Front wheel static balance
*****************************************************
Checking steps:
D Turn the wheel so that it comes to each point
as shown.
D Check that the wheel is at rest at each point. If
not, readjust the front wheel static balance.
*****************************************************

6-7
 FRONT BRAKE CHAS

FRONT BRAKE
FRONT BRAKE PADS

40 Nm (4.0 m
kg)

23 Nm (2.3 m
kg)

Order Job name/Part name Q’ty Remarks

Front brake pad removal Remove the parts in the order below.
1 Retaining bolt 1
2 Brake caliper 1 Refer to “BRAKE PAD
3 Brake pads 2 REPLACEMENT”.
4 Pad spring 1
For installation, reverse the removal
procedure.

6-8
 FRONT BRAKE CHAS

CAUTION:
Disc brake components rarely require dis-
assembly. DO NOT:
D disassemble components unless abso-
lutely necessary;
D use solvents on internal brake compo-
nents;
D use spent brake fluid for cleaning; (use
only clean brake fluid)
D allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
D splash brake fluid onto painted surfaces
or plastic parts, as this may cause dam-
age;
D disconnect any hydraulic connection, as
this would require the entire brake system
to be disassembled, drained, cleaned,
properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake cal-
iper and brake hose to replace the brake pads.

1. Remove:
S Bolt (caliper support bolt) 1
Move the direction brake caliper to the ar-
row mark.
2. Remove:
S Brake pads 1
NOTE:
D Install new brake pad springs when the brake
pads have to be replaced.
D Replace the brake pads as a set if either is
found to be worn to the wear limit.

3. Install:
S Brake pads
S Brake pads spring
*****************************************************
Installation steps:
D Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2 . Put the other
end of this hose into an open container.

6-9
 FRONT BRAKE CHAS
D Loosen the brake caliper bleed screw and us-
ing a finger push the caliper pistons into the
brake caliper.
D Tighten the brake caliper bleed screw 2 .

Brake caliper bleed screw:

6 Nm (0.6 mSkg)

D Install new brake pads and a new brake pad

spring.
D Install the brake caliper 3 and retaining bolt
4.

Bolt (brake caliper):

40 Nm (4.0 mSkg)
Retaining bolt:
23 Nm (2.3 mSkg)

*****************************************************

4. Inspect:
S Brake fluid level
Refer to “BRAKE FLUID INSPECTION” in
CHAPTER 3.
a “LOWER” level line

5. Check:
S Brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.

6-10
 FRONT BRAKE CHAS

MASTER CYLINDER

10 Nm (1.0 m
kg)

30 Nm (3.0 m
kg)

Order Job name/Part name Q’ty Remarks

Master cylinder removal Remove the parts in the order below.
Brake fluid Drain
1 Rear view mirror (right) 1
2 Brake lever/compression spring 1/1
3 Front brake switch 1
4 Union bolt 1
5 Copper washers 2
Refer to “MASTER CYLINDER
6 Brake hose 1
INSTALLATION”.
7 Master cylinder bracket 1
8 Master cylinder 1
For installation, reverse the removal
procedure.

6-11
 FRONT BRAKE CHAS

Order Job name/Part name Q’ty Remarks

Master cylinder disassembly Disassemble the parts in the order
below.
1 Dust boot 1
2 Circlip 1 Refer to “MASTER CYLINDER
3 Master cylinder cup kit 1 ASSEMBLY”.
4 Spring 1
For assembly, reverse the disassembly
procedure.

6-12
 FRONT BRAKE CHAS
MASTER CYLINDER INSPECTION
1. Inspect:
S Master cylinder
Wear/scratches
Replace the master
cylinder assembly.
S Master cylinder body
Cracks/damage
Replace.
S Oil delivery passage
(master cylinder body)
Blockage
Blow out with compressed
air.
2. Inspect:
S Master cylinder cup kit 1
Scratches/wear/damage
Replace as a
set.

3. Inspect:
S Diaphragm
Wear/damage
Replace.
4. Inspect:
S Brake hose
Cracks/wear/damage
Replace.

EB702060

MASTER CYLINDER ASSEMBLY

D All internal brake components should be

cleaned and lubricated with new brake
fluid only before installation.

Recommended brake fluid:

DOT 4

D Whenever a master cylinder is disas-

sembled replace the piston seals and
dust seals.

1. Install:
S Spring 1
S Master cylinder cup kit 2

6-13
 FRONT BRAKE CHAS
2. Install:
S Circlip 1
S Dust boot 2

MASTER CYLINDER INSTALLATION

1. Install:
S Master cylinder 1
S Master cylinder bracket 2
10 Nm (1.0 mSkg)

CAUTION:
D Install the master cylinder holder with the
“UP” mark facing upward.
D Align the end of the holder with the punch
mark a on the handlebar.
D First, tighten the upper bolt, then tighten
the lower bolt.

2. Install:
S Copper washers 1
S Brake hose 2
S Union bolt 3 30 Nm (3.0 mSkg)

NOTE:
D Tighten the union bolt while holding the brake
hose as shown.
D Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.

D Proper brake hose routing is essential to

insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
D Always use new copper washers.

6-14
 FRONT BRAKE CHAS
3. Fill:
S Reservoir tank

Recommended brake fluid:

DOT 4

CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.

D Use only the designated quality brake

fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
D Refill with the same type of brake
fluid: mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
D Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.

4. Air bleed:
S Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.

5. Inspect:
S Brake fluid level
Brake fluid level is under the “LOWER”
level line
Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” in CHAPTER 3.
a “LOWER” level line

6-15
 FRONT BRAKE CHAS

FRONT BRAKE CALIPER

7 Nm (0.7 m
kg)

30 Nm (3.0 m
kg)

6 Nm (0.6 m
kg)

40 Nm (4.0 m
kg)

23 Nm (2.3 m
kg)

Order Job name/Part name Q’ty Remarks

Front brake caliper removal Remove the parts in the order below.
Brake fluid Drain
1 Brake hose holder 1
2 Union bolts 1
3 Copper washers 2
4 Brake hose 1 Refer to “CALIPER INSTALLATION”.
5 Retaining bolt 1
6 Brake caliper assembly 1
For installation, reverse the removal
procedure.

6-16
 FRONT BRAKE CHAS

Order Job name/Part name Q’ty Remarks

Front brake caliper disassembly Disassemble the parts in the order
below.
Brake pads Refer to “FRONT BRAKE PADS”.
1 Pad spring 1
2 Brake caliper pistons 2
Refer to “CALIPER DISASSEMBLY/
3 Dust seals 2
ASSEMBLY”.
4 Caliper piston seals 2
5 Bleed screw 1
For assembly, reverse the disassembly
procedure.

6-17
 FRONT BRAKE CHAS
CALIPER DISASSEMBLY
1. Remove:
S Brake caliper pistons
S Dust seals 1
S Caliper piston seals 2
*****************************************************
Removal steps:
D Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.

D Never try to pry out the caliper pistons.

D Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.

D Remove the caliper piston seals.

*****************************************************
EB702040

CALIPER INSPECTION
Recommended brake component
replacement schedule:
Brake pads As required
Piston seals, dust
Every two years
seals
Brake hoses Every two years
Replace when
Brake fluid brakes are
disassembled.

All internal brake components should be

cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.

1. Inspect:
S Brake caliper piston 1
Scratches/rust/wear
Replace the
brake caliper assembly.
S Brake caliper cylinder 2
Wear/scratches
Replace the brake cal-
iper assembly.
S Brake caliper body 3
Cracks/damage
Replace.

6-18
 FRONT BRAKE CHAS
S Oil delivery passage (brake caliper body)
Blockage
Blow out with compressed
air.

Replace the caliper piston seal and dust

seal whenever the brake caliper is disas-
sembled.

CALIPER ASSEMBLY

D All internal brake components should be

cleaned and lubricated with new brake
fluid only before installation.

Recommended brake fluid:

DOT 4

D Replace the caliper piston seals whenev-

er a brake caliper is disassembled.

1. Install:
S Caliper piston seals 1
S Dust seals 2

2. Install:
S Brake caliper pistons 1

CALIPER INSTALLATION
1. Install:
S Brake caliper 1
S Retaining bolt 2 23 Nm (2.3 mSkg)

S Brake hose 3
S Copper washers 4
S Union bolt 5 30 Nm (3.0 mSkg)

6-19
 FRONT BRAKE CHAS

CAUTION:
When installing the brake hose on the brake
caliper, make sure that the brake pipe
touches the projection a on the brake cali-
per.

Proper brake hose routing is essential to in-

sure safe motorcycle operation. Refer to
“CABLE ROUTING”.

2. Fill:
S Brake reservoir

Recommended brake fluid:

DOT 4

CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.

D Use only the designated quality brake

fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
D Refill with the same type of brake
fluid: mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
D Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.

3. Air bleed
S Brake system
Refer to “AIR BLEEDING” in CHAPTER 3.
4. Inspect:
S Brake fluid level
Brake fluid level is under the “LOWER”
level line
Fill up.
Refer to “BRAKE FLUID INSPECTION” in
CHAPTER 3.
a “LOWER” level line

6-20
 REAR WHEEL AND REAR BRAKE CHAS

REAR WHEEL AND REAR BRAKE

MUFFLER AND REAR BRAKE ROD

20 Nm (2.0 m
kg)

25 Nm (2.5 m
kg)
20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

Muffler and rear brake rod removal Remove the parts in the order below.
1 Muffler 1
2 Adjuster 1
3 Pin 1
4 Compression spring 1
5 Cotter pin 1
6 Nut/plate washer 1/1
7 Bolt 1
8 Tension bar 1
For installation, reverse the removal
procedure.

6-21
 REAR WHEEL AND REAR BRAKE CHAS

REAR WHEEL

70 Nm (7.0 m
kg)
92 Nm (9.2 m
kg)

Order Job name/Part name Q’ty Remarks

Rear wheel removal Remove the parts in the order below.
Stand the motorcycle on a level
surface.

Securely support the motorcycle so

there is no danger of it falling over.

Final gear oil Drain

Refer to “FINAL GEAR OIL
REPLACEMENT” in CHAPTER 3.
1 Bolts 4
Refer to “REAR WHEEL REMOVAL/
2 Rear axle nut/washer 1/1
INSTALLATION”.
3 Rear wheel assembly 1
For installation, reverse the removal
procedure.

6-22
 REAR WHEEL AND REAR BRAKE CHAS

62 Nm (6.2 m
kg)

Order Job name/Part name Q’ty Remarks

Rear wheel disassembly Disassemble the parts in the order
below.
1 Lock washers 2
2 Clutch hub 1
3 Dampers 6
4 O-rings 2
5 Bearing 1
Refer to “REAR WHEEL
6 Spacer/collar 1/1
DISASSEMBLY/ASSEMBLY”.
7 Bearing 1
For assembly, reverse the disassembly
procedure.

6-23
 REAR WHEEL AND REAR BRAKE CHAS

10 Nm (1.0 m
kg)

Order Job name/Part name Q’ty Remarks

Rear brake disassembly Disassemble the parts in the order
below.
1 Brake shoes 2
2 Tension springs 2
3 Bolt 1
4 Camshaft lever 1
Refer to “REAR BRAKE
5 Wear indicator 1
ASSEMBLY”.
6 Camshaft 1
7 Washer 1
For assembly, reverse the disassembly
procedure.

6-24
REAR WHEEL AND REAR BRAKE CHAS
REAR WHEEL REMOVAL
1. Stand the motorcycle on a level surface.

Securely support the motorcycle so there is

no danger of it falling over.

2. Remove:

Bolts (final gear case)

3. Loosen:

Rear axle nut 1

4. Remove:

Rear wheel assembly
NOTE:
Remove the rear wheel assembly, rear wheel
axle and drive shaft by pulling back on the rear
wheel assembly.

REAR WHEEL DISASSEMBLY

1. Remove:

Bearings 1
Remove the bearings using a standard
bearing puller 2 .

REAR WHEEL INSPECTION

1. Inspect:

Rear wheel axle
Refer to “FRONT WHEEL”.

Rear tire
Refer to “TIRE INSPECTION” in CHAP-
TER 3.

Rear wheel
Refer to “WHEEL INSPECTION” in
CHAPTER 3.

6-25
REAR WHEEL AND REAR BRAKE CHAS
2. Check:

Spokes
Refer to “FRONT WHEEL”.
3. Tighten:

Loose spokes
Refer to “FRONT WHEEL”.
4. Measure:

Rear wheel runout
Refer to “FRONT WHEEL”.
5. Inspect:

Rear wheel bearings
Refer to “FRONT WHEEL”.

REAR BRAKE INSPECTION

1. Inspect:
Brake lining surface

Glazed areas
Polish.
Use coarse sandpaper.
NOTE:
Wipe the polished areas with a cloth.

2. Measure:

Brake lining thickness a
Out of specification
Replace.
1 Measuring points
NOTE:
Replace the brake shoes as a set if either is
found to be worn to the wear limit.

Brake lining thickness:

4.0 mm
Wear limit:
2.0 mm

6-26
REAR WHEEL AND REAR BRAKE CHAS
3. Measure:
S Brake drum inside diameter a
Out of specification
Replace the wheel.

Brake drum inside diameter:

200 mm
Wear limit:
201 mm

4. Inspect:
S Brake drum inner surface
Oil/scratches
Repair.

Use a rag soaked in lacquer

Oil
thinner or solvent.
Use an emery cloth (polish
Scratches
lightly and evenly)
5. Inspect:
S Camshaft face
Wear
Replace.

REAR WHEEL ASSEMBLY

1. Install:
S Spacer
S Collar
S Bearings
*****************************************************
Installation steps:
D Install the new bearings by reversing the re-
moval steps.
NOTE:
Use a socket 1 that matches the diameter of
the outer bearing race and the oil seal.

CAUTION:
Do not contact the bearing center race 2 or
balls 3 . Contact should be made only with
the outer race 4 .

*****************************************************
6-27
REAR WHEEL AND REAR BRAKE CHAS
REAR BRAKE ASSEMBLY
1. Install:

Brake shoe plate 1

Camshaft 2

Wear indicator 3

Camshaft lever 4 10 Nm (1.0 m
kg)

NOTE:
Apply lithium soap base grease onto the cam-
shaft and pin.

After installing the spring and brake shoes,

take care not to damage the spring.

REAR WHEEL INSTALLATION

1. Install

Rear wheel assembly
NOTE:
Make sure that the splines of the clutch hub fit
correctly into the final gear case.

2. Install:

Rear wheel axle

Washer

Rear wheel axle nut 92 Nm (9.2 m
kg)

Bolt 90 Nm (9.0 m
kg)

3. Adjust:

Brake pedal free play
Refer to “REAR BRAKE ADJUSTMENT”
in CHAPTER 3.

6-28
REAR WHEEL AND REAR BRAKE CHAS
EB701040

REAR WHEEL STATIC BALANCE

ADJUSTMENT
NOTE:
D After replacing the tire and/or wheel, the stat-
ic wheel balance should be adjusted.
D Adjust the static wheel balance with the rear
brake disc and hub installed.

1. Adjust:
S Rear wheel static balance
Refer to “FRONT WHEEL”.

6-29
 FRONT FORK CHAS

FRONT FORK

20 Nm (2.0 m
kg)

23 Nm (2.3 m
kg)
7 Nm (0.7 m
kg)

30 Nm (3.0 m
kg)

10 Nm (1.0 m
kg)
40 Nm (4.0 m
kg)

Order Job name/Part name Q’ty Remarks

Front fork removal Remove the parts in the order below.
Front wheel Refer to “FRONT WHEEL”.
1 Brake hose holder 1
2 Brake caliper assembly 1
3 Front fender 1
4 Front flasher light holder nuts 2
5 Upper bracket bolts 2
Loosen
6 Cap bolts 2
Refer to “FRONT FORK
7 Lower bracket bolts 2
INSTALLATION”.
8 Front forks 2
For installation, reverse the removal
procedure.

6-30
 FRONT FORK CHAS

23 Nm (2.3 m
kg)

30 Nm (3.0 m
kg)

Order Job name/Part name Q’ty Remarks

Front fork disassembly Disassemble the parts in the order
below.
1 Cap bolt 1
2 O-ring 1
3 Spacer collar 1 Refer to “FRONT FORK ASSEMBLY”.
4 Spring seat 1
5 Fork spring 1
6 Dust seal 1
7 Retaining clip 1
8 Damper rod bolt 1 Refer to “FRONT FORK
9 Gasket 1 DISASSEMBLY/ASSEMBLY”.
10 Damper rod/rebound spring 1/1
11 Oil seal 1

6-31
 FRONT FORK CHAS

23 Nm (2.3 m
kg)

30 Nm (3.0 m
kg)

Order Job name/Part name Q’ty Remarks

12 Seal spacer 1
13 Slide metal 1
14 Inner tube/piston metal 1/1 Refer to “FRONT FORK ASSEMBLY”.
15 Oil lock piece 1
16 Outer tube 1
For assembly, reverse the disassembly
procedure.

6-32
 FRONT FORK CHAS
FRONT FORK DISASSEMBLY
1. Remove:
S Dust seal 1
S Retaining clip 2
(use a slotted-head screwdriver)
CAUTION:
Take care not to scratch the inner tube.

2. Remove:
S Damper rod bolt 1
NOTE:
Loosen the damper rod bolt while holding the
damper rod with the T-handle 2 and the damp-
er rod holder 3 .

T-Handle:
90890-01326
Damper rod holder:
90890-01388

3. Remove:
S Damper rod
S Rebound spring

4. Remove
S Inner tube
*****************************************************
Removal steps:
D Hold the fork leg horizontally.
D Securely clamp the caliper mounting boss of
the outer tube in a vise with soft jaws.
D Separate the inner tube from the outer tube
by pulling forcefully but carefully on the inner
tube.
CAUTION:
D Excessive force will damage the oil seal
and/or the slide metal. A damaged oil
seal and metal must be replaced.
D Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil lock piece will be damaged.

*****************************************************

6-33
 FRONT FORK CHAS
EB703030

FRONT FORK INSPECTION

1. Inspect:
S Inner tube 1
S Outer tube 2
Scratches/bends/damage
Replace.

Do not attempt to straighten a bent inner

tube as this may dangerously weaken the
tube.

2. Measure:
S Fork spring length a
Over the specified limit
Replace.

Fork spring free length (limit):

289 mm

3. Inspect:
S Damper rod 1
Wear/damage
Replace.
Contamination
Blow out all of the oil
passages with compressed air.
S Oil lock piece 2
Damage
Replace.

4. Inspect:
S O-ring (cap bolt)
Wear/damage
Replace.

FRONT FORK ASSEMBLY

NOTE:
D When reassembling the front fork, replace
the following parts.
*Piston metal
*Slide metal
*Oil seal
*Dust seal
D Before reassembly make sure that all the
components are clean.

6-34
 FRONT FORK CHAS
1. Install:

Damper rod 1

Rebound spring

Oil lock piece 2

Inner tube 3
CAUTION:
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom, being careful not to damage the inner
tube.

2. Lubricate:

Inner tube (outer surface)

Recommended lubricant:
Yamaha fork oil 10WT or
equivalent

3. Install:

Inner tube 1
(to outer tube 2 )
4. Install:

Gasket 1

Damper rod bolt 2

5. Tighten:

Damper rod bolt 1 30 Nm (3.0 m
kg)

NOTE:
Apply LOCTITE to the threads of the damper
rod holder. Tighten the damper rod bolt while
holding the damper rod with a T-handle 2 and a
damper rod holder 3 .

T-handle:
90890-01326
Damper rod holder:
90890-01388

6-35
 FRONT FORK CHAS
6. Install:

Slide metal 1

Seal spacer
Use the fork seal driver weight 2 and the
adapter 3 .

7. Install:

Oil seal 1
Use the fork seal driver weight 2 and the
adapter 3 .

Fork seal driver weight:

90890-01367
Adapter:
90890-01381

NOTE:
Before installing the oil seal, apply lithium soap
base grease onto the oil seal lips.

CAUTION:
Make sure that the numbered side of the oil
seal faces up.

8. Install:

Retaining clip 1
NOTE:
Adjust the retaining clip so that it fits into the out-
er tube groove.

9. Install:

Dust seal 1
Use the fork seal driver weight.

Fork seal driver weight:

90890-01367

6-36
 FRONT FORK CHAS
10. Fill:
S Fork oil

Each fork:
0.454L (454 cm3)
Yamaha fork oil 10WT or equiv-
alent. After filling up, slowly
pump the fork up and down to
distribute the fork oil.
Oil level a :
114 mm
(from the top of the inner tube
fully compressed and without
the fork spring)

NOTE:
Hold the fork in an upright position.

11. Install:
S Fork spring 1
S Spring seat 2
S Spacer collar 3
S O-ring
S Cap bolt
NOTE:
D Before installing the cap bolt, apply grease to
the O-ring.
D Temporarily tighten the cap bolt.

FRONT FORK INSTALLATION

1. Install:
S Front forks 1
NOTE:
Make sure that the inner tube end is flush with
the top of the upper bracket.

2. Tighten:
S Lower bracket bolts 1
30 Nm (3.0 mSkg)

S Cap bolts 2 23 Nm (2.3 mSkg)

S Upper bracket bolts 3

20 Nm (2.0 mSkg)

6-37
 HANDLEBAR CHAS

HANDLEBAR

23 Nm (2.3 m
kg)

10 Nm (1.0 m
kg)

20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

Handlebar removal Remove the parts in the order below.
Stand the motorcycle on a level surface.

Securely support the motorcycle so

that there is no danger of it falling over.

1 Plastic locking ties 4

2 Clutch cable 1
3 Clutch switch lead 1
4 Handlebar switch (left) 1 Refer to “HANDLEBAR INSTALLA-
TION”.
5 Grip (left) 1
6 Clutch lever assembly 1
7 Master cylinder bracket 1
8 Master cylinder assembly 1 Refer to “HANDLEBAR INSTALLA-
9 Handlebar switch (right) 1 TION”.
10 Throttle cables 2

6-38
 HANDLEBAR CHAS

23 Nm (2.3 m
kg)

10 Nm (1.0 m
kg)

20 Nm (2.0 m
kg)

Order Job name/Part name Q’ty Remarks

11 Throttle grip assembly 1
12 Cable guide 1
Refer to “HANDLEBAR INSTALLA-
13 Handlebar holder (upper) 2
TION”.
14 Handlebar 1
15 Handlebar holder (lower) 2
For installation, reverse the removal
procedure.

6-39
 HANDLEBAR CHAS
HANDLEBAR INSPECTION
1. Inspect:
S Handlebar
Bends/cracks/damage
Replace.
CAUTION:
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

*****************************************************
Left handlebar grip replacement steps:
D Remove the handlebar grip.
D Apply a light coat of rubber adhesive on the
end of the handlebar.
D Install the handlebar grip.
NOTE:
Wipe off excess adhesive with a clean rag.

Do not touch the grip until the adhesive has

set.

*****************************************************

HANDLEBAR INSTALLATION
1. Install:
S Washers
S Handlebar holder (lower) 1
S Cable guide 2
NOTE:
Temporarily tighten the nuts 3 .

2. Install:
S Handlebar
S Handlebar holder (upper)
23 Nm (2.3 mSkg)

NOTE:
D The upper handlebar holder should be
installed with the punch mark a forward A .

6-40
 HANDLEBAR CHAS
D Align the match marks b on the handlebar
with the lower handlebar holder bolt hole.
D Apply a light coat of lithium soap base grease
onto the right end of the handlebar.

CAUTION:
D First tighten the bolts on the front side of
the handlebar holder, and then tighten the
bolts on the rear side.
D Check the handlebar by turning it all the
way to the left and then to the right. If there
is any contact with the fuel tank, adjust
the handlebar position.

3. Tighten:
S Nut (lower handlebar holder)
20 Nm (2.0 mSkg)

4. Install:
S Throttle cables 1
S Throttle grip assembly 2
NOTE:
Align the projection on the handlebar switch
(right) 3 with the hole a in the handlebar 4 .

5. Install:
S Master cylinder (front brake)
Refer to “MASTER CYLINDER (FRONT
BRAKE)”.

6. Install:
S Clutch lever holder 1
NOTE:
Align the slit of clutch lever holder with the
punch mark a on the handlebar.

6-41
 HANDLEBAR CHAS
7. Install:

Handlebar switch (left) 1
NOTE:
Align the matching surface of the handlebar
switch (left) with the punch mark a on the han-
dlebar.

8. Adjust:

Throttle cable free play
Refer to “THROTTLE CABLE ADJUST-
MENT” in CHAPTER 3.

6-42
 STEERING HEAD CHAS

STEERING HEAD

52 Nm (5.2 m
kg)
18 Nm (1.8 m
kg)

110 Nm (11.0 m
kg)

32 Nm (3.2 m
kg)

Order Job name/Part name Q’ty Remarks

Steering head removal Remove the parts in the order below.
Stand the motorcycle on a level surface.

Securely support the motorcycle so

that there is no danger of it falling over.

Front forks Refer to “FRONT FORK”.

Handlebar Refer to “HANDLEBAR”.
1 Headlight lens unit 1
2 Leads (in the headlight body) – Disconnect
3 Front flasher light (left/right) 1/1
4 Headlight body 1
5 Upper bracket 1
6 Lock washer 1
7 Upper ring nut 1

6-43
 STEERING HEAD CHAS

52 Nm (5.2 m
kg)
18 Nm (1.8 m
kg)

110 Nm (11.0 m
kg)

32 Nm (3.2 m
kg)

Order Job name/Part name Q’ty Remarks

8 Rubber washer 1
9 Lower ring nut 1 Refer to “STEERING HEAD
REMOVAL/INSTALLATION”.
10 Bearing cover 1
11 Lower bracket 1
12 Bearing (upper) 1
13 Rubber seal 1
14 Bearing (lower) 1
For installation, reverse the removal
procedure.

6-44
 STEERING HEAD CHAS
STEERING HEAD REMOAL
1. Remove:
S Lower ring nut 1
Use the ring nut wrench 2 .

Ring nut wrench:

90890-01403

Support the lower bracket so that it does not

fall down.

EB704020

STEERING HEAD INSPECTION

1. Wash the bearings and the bearing races
with a solvent.
2. Inspect:
S Bearings
Pitting/damage
Replace.
*****************************************************
Bearing and bearing race replacement
steps:
D Remove the bearing races from the steering
head pipe using a long rod 1 and a hammer,
as shown.
D Remove the bearing race on the lower brack-
et using a floor chisel 2 and a hammer, as
shown.
D Install the new rubber seal and races.
*****************************************************
NOTE:
D Always replace the bearings and bearing
races as a set.
D Whenever the steering head is disassembled
replace the rubber seal.

CAUTION:
If the bearing race is not fitted squarely, the
steering head pipe could be damaged.

3. Inspect:
S Upper bracket
S Lower bracket
(with the steering stem)
Cracks/bends/damage
Replace.
EB704030

STEERING HEAD INSTALLATION

1. Tighten:
S Ring nuts (lower and upper)
Refer to “STEERING HEAD INSPEC-
TION” in CHAPTER 3.
6-45
 REAR SHOCK ABSORBER AND SWINGARM CHAS

REAR SHOCK ABSORBER AND SWINGARM

100 Nm (10.0 m
kg)

7 Nm (0.7 m
kg)

62 Nm (6.2 m
kg)

62 Nm (6.2 m
kg)

100 Nm (10.0 m
kg)

Order Job name/Part name Q’ty Remarks

Rear shock absorber and swingarm Remove the parts in the order below.
removal
Stand the motorcycle on a level surface.

Securely support the motorcycle so

there is no danger of it falling over.
Seats Refer to “FUEL TANK AND SEATS” in
CHAPTER 3.
Rear wheel
Final gear case Refer to “REAR WHEEL”.
Muffler assembly
Refer to “ENGINE REMOVAL” in
Battery cover
CHAPTER 4.
Side cover (right)
1 Side cover (left) 1 Do not remove the “*”bolts.
2 Tool box cover 1

6-46
 REAR SHOCK ABSORBER AND SWINGARM CHAS

100 Nm (10.0 m
kg)

7 Nm (0.7 m
kg)

62 Nm (6.2 m
kg)

62 Nm (6.2 m
kg)

100 Nm (10.0 m
kg)

Order Job name/Part name Q’ty Remarks

3 Tool box 1
4 Bolt/nut (rear shock absorber - 1/1
upper)
5 Pivot shaft nut 1 Loosen
6 Pivot shaft (right) 1 Refer to “SWINGARM INSTALLA-
7 Pivot shaft (left) 1 TION”.
8 Swingarm 1
9 Rear shock absorber 1 Refer to “REAR SHOCK ABSORBER
INSTALLATION”.
10 Collars 2
11 Rubber boot 1
12 Bushing 1
13 Collars 2
14 Oil seals 2
15 Bearings 2
For installation, reverse the removal
procedure.

6-47
REAR SHOCK ABSORBER AND SWINGARM CHAS
HANDLING NOTES

This shock absorber contains highly com-

pressed nitrogen gas. Read and understand
the following information before handling
the shock absorber. The manufacturer can-
not be held responsible for property dam-
age of personal injury that may result from
improper handling.
1. Do not tamper or attempt to open the
cylinder 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 re-
sult in poor damping performance.

NOTES ON DISPOSAL
*****************************************************
Shock absorber disposal steps:
D Gas pressure must be released before dis-
posing of the shock absorber. To do so, drill a
2
3 mm hole through the cylinder wall as
shown.

Wear eye protection to prevent eye damage

from escaping gas and/or metal chips.

*****************************************************
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
S Rear shock absorber rod
Bends/damage
Replace the rear
shock absorber assembly.
S Rear shock absorber
Oil leaks/gas leaks
Replace the rear
shock absorber assembly.
S Spring
Wear/damage
Replace the rear shock
absorber assembly.
S Bushings
S Collars
Damage/scratches
Replace.
S Dust seals
Wear/damage
Replace.
S Bolts
Wear/bends/damage
Replace.
6-48
REAR SHOCK ABSORBER AND SWINGARM CHAS
SWINGARM INSPECTION
1. Check:
S Swingarm free play
*****************************************************
Inspection steps:
D Check the tightening torque of the swingarm
pivot shaft securing nuts.

Securing nut (swingarm pivot

shaft):
Left:
100 Nm (10 mSkg)
Right:
7 Nm (0.7 mSkg)
Right - nut:
100 Nm (10 mSkg)

D Check the swingarm side play A by moving

the swingarm from side to side.
If side play is noticeable, check the inner col-
lar, bearing, washer and thrust cover.

Side play (at swingarm end):

Zero mm

D Check the swingarm vertical movement B

by moving it up and down.
If vertical movement is not smooth or if there
is binding, check the inner collar, bearing,
washer and thrust cover.
*****************************************************
2. Inspect:
S Swingarm
Cracks/bends/damage
Replace.

3. Inspect:
S Pivot shafts
Damage/wear
Replace.
NOTE:
Wash the swingarm pivoting parts in a solvent.

6-49
REAR SHOCK ABSORBER AND SWINGARM CHAS
4. Inspect:
S Collars 1
S Oil seals 2
S Bearings 3
S Rubber boot 4
Wear/damage
Replace.

SWINGARM INSTALLATION
1. Install:
S Swingarm
S Pivot shaft (left) 1
S Pivot shaft (right) 2
S Pivot shaft nut 3
*****************************************************
Tightening steps:
D Tighten the pivot shaft (left) 1 to specifica-
tion.

Pivot shaft (left):

100 Nm (10 mSkg)
LOCTITE

D Tighten the pivot shaft (right) 2 until it con-

tacts the collar.

Pivot shaft (right):

7 Nm (0.7 mSkg)

D Tighten the pivot shaft nut 3 to specification.

Pivot shaft nut:

100 Nm (10 mSkg)

*****************************************************

REAR SHOCK ABSORBER INSTALLATION

1. Install:
S Rear shock absorber 1
62 Nm (6.2 mSkg)

NOTE:
Install the rear shock absorber with the warning
label 2 facing up.

6-50
 SHAFT DRIVE CHAS

SHAFT DRIVE
EB707010

TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:

A Symptoms B Possible causes

1. A pronounced hesitation or jerky movement A. Bearing damage
during acceleration, deceleration, or sus-
B. Improper gear lash
tained speeds (This must not be confused
with engine surging or transmission- related C. Damaged gear teeth
movements.) D. Broken drive shaft
2. A rolling “rumble” noticeable at low speeds, a
high-pitched whine, or a “clunk” from a shaft E. Broken gear teeth
drive component or area F. Seizure due to lack of lubrication
3. A locked-up condition of the shaft drive mech-
G.Small foreign objects lodged between moving
anism or no power transmitted from the en-
gine to the rear wheel parts

NOTE:
Causes A, B and C may be extremely difficult to diagnose. The symptoms are quite subtle and difficult
to distinguish from normal operating noises. If there is reason to believe these components are dam-
aged, remove them for individual inspection.

6-51
 SHAFT DRIVE CHAS
Inspection notes
1. Investigate any unusual noises.
*****************************************************
The following noises may indicate a me-
chanical defect:
a. A rolling “rumble” during coasting, accel-
eration, or deceleration. The noise in-
creases with rear wheel speed, but does
not increase with higher engine or trans-
mission speeds.
Diagnosis: Possible wheel bearing dam-
age
b. A whining noise that varies with accelera-
tion and deceleration.
Diagnosis: Possible incorrect reassemb-
ly, too little gear lash
CAUTION:
Insufficient gear lash is extremely destruc-
tive to the gear teeth. If a test ride following
reassembly indicates this condition, stop
riding immediately to minimize gear dam-
age.

c. A slight “clunk” evident at low speed opera-

tion. This noise must be distinguished from
normal motorcycle operation.
Diagnosis: Possible broken gear teeth

Stop riding immediately if broken gear teeth

are suspected. This condition could result
in a locking of the shaft drive assembly,
causing loss of control of the motorcycle
and possible injury to the rider.

*****************************************************
2. Inspect:

Drained oil
Drained oil contains a large amount of
metal particles
Check the bearing for
seizure.
NOTE:
A small amount of metal particles in the oil is
normal.

6-52
 SHAFT DRIVE CHAS
3. Inspect:
S Oil leakage
*****************************************************
Inspection steps:
D Clean the entire motorcycle thoroughly, then
dry it.
D Apply a leak-locating compound or dry pow-
der spray to the shaft drive.
D Road test the motorcycle for the distance
necessary to locate the leak.
Leakage
Inspect the component housing,
gasket and/or seal for damage.
Damage
Replace the component.
1 Oil seal
2 O-ring
3 Forward
A Middle gear
B Final gear
NOTE:
D An apparent oil leak on a new or nearly new
motorcycle may result from the application of
a rust preventive coating or excessive seal
lubrication.
D Always clean the motorcycle and recheck the
suspected location of an apparent leak.

*****************************************************

6-53
 SHAFT DRIVE CHAS

Troubleshooting chart
When causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist,
check the following points:

YES
Elevate and spin the front wheel. Feel for Replace the wheel bearing.
wheel bearing damage. Refer to “FRONT WHEEL”.

NO

NO Rear wheel bearings and shaft drive bear-

Check the rear wheel. Feel for bearing dam-
age. ings are probably not damaged. Repeat the
test or remove the individual components.

YES

YES
Remove the rear wheel. Check for wheel Replace the rear wheel bearing.
bearing damage. Refer to “REAR WHEEL”.

NO

Remove the drive shaft components.

6-54
 SHAFT DRIVE CHAS
EB707030

FINAL GEAR BACKLASH MEASUREMENT

1. Secure the final drive gear case in a vise or
a similar supporting device.
2. Remove:
S Drain plug
Drain the oil.
3. Install:
S Specified bolt 1
(into the drain plug hole)
4. Finger tighten the bolt until it holds the ring
gear.
NOTE:
Do not overtighten the bolt; just finger-tighten it.

5. Attach:
S Final gear backlash band 1
S Dial gauge 2

Final gear backlash band:

90890-01231

S Position mark a

6. Measure:
S Final gear backlash
Gently rotate the final drive gear coupling
from engagement to engagement.
Over the specified limit
Adjust.

Final gear backlash:

0.1
0.2 mm

NOTE:
Measure the final gear backlash at four posi-
tions. Rotate the final drive shaft 90_ each time.

6-55
 SHAFT DRIVE CHAS
EB707031

FINAL GEAR BACKLASH ADJUSTMENT

1. Remove:
S Bolts (bearing housing)
NOTE:
Working in a crisscross pattern, loosen each nut
1 /4 of a turn. After all the nuts are loosened, re-
move them.

2. Remove:
S Bearing housing 1
S Ring gear 2
S Thrust washer 3
S Shim(s) 4
3. Adjust:
S Final gear backlash
*****************************************************
Adjustment steps:
D Use the following chart to select the suitable
shims and thrust washer.
Reducing the shim gear backlash is
thickness: increased.
Increasing the gear backlash is
shim thickness: decreased.
D If it is necessary to increase the final gear
backlash by more than 0.1 mm:
Reduce the thrust washer thickness by 0.1
mm for every 0.1 mm increase of ring gear
shim thickness.
D If it is necessary to reduce the final gear back-
lash by more than 0.1 mm:
Increase the thrust washer thickness by 0.1
mm for every 0.1 mm decrease of ring gear
shim thickness.

Ring gear shim

Thickness (mm) 0.25, 0.30, 0.40

Thrust washer

Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

*****************************************************

6-56
 SHAFT DRIVE CHAS

DRIVE SHAFT

23 Nm (2.3 m
kg)

115 Nm (11.5 m
kg)

23 Nm (2.3 m
kg)

42 Nm (4.2 m
kg)

Order Job name/Part name Q’ty Remarks

Drive shaft removal Remove the parts in the order below.
Stand the motorcycle on a level surface.

Securely support the motorcycle so

there is no danger of it falling over.

Rear wheel assembly Refer to “REAR WHEEL”.

1 Collar 1
2 Drive shaft assembly 1
3 Final drive pinion gear assembly 1 Refer to “FINAL DRIVE GEAR DISAS-
SEMBLY”.
4 Final gear assembly 1
For installation, reverse the removal
procedure.

6-57
 SHAFT DRIVE CHAS

FINAL GEAR

23 Nm (2.3 m
kg)

Order Job name/Part name Q’ty Remarks

Final gear disassembly Disassemble the parts in the order
below.
1 Bolts (bearing housing) 2 NOTE:
2 Bolt (bearing housing) 6 Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the bolts
are loosened, remove them.
3 Bearing housing/O-ring 1/1
4 Ring gear 1
5 Thrust washer 1
6 Shim(s) 1
For assembly, reverse the disassembly
procedure.

6-58
 SHAFT DRIVE CHAS
FINAL DRIVE GEAR DISASSEMBLY
1. Remove:

Bearing retainer (final drive shaft)
Use a bearing retainer wrench 1 .

Bearing retainer wrench:

90890-04050

CAUTION:
The final drive shaft bearing retainer has
left-handed threads. To loosen the retainer
turn it clockwise.

2. Remove:

Final drive shaft assembly
With a soft hammer lightly tap on the final
drive shaft end.
CAUTION:
Removal of the final drive shaft should only
be performed if gear replacement is neces-
sary.

Always use new bearings and races.

EB707033

FINAL DRIVE ROLLER BEARING REMOVAL

AND REASSEMBLY
1. Remove:

Guide collar 1

Oil seal 2

Roller bearing 3
Use a suitable press tool 4 and an ap-
propriate support for the final gear case.
2. Inspect:

Final drive roller bearing
NOTE:
The roller bearing can be reused, but Yamaha
recommends installation of a new bearing. Do
not reuse the oil seal.

6-59
 SHAFT DRIVE CHAS
3. Remove:
S Final drive roller bearing 1
*****************************************************
Removal steps:
D Heat the final gear case to 150_C.
D Using an appropriately shaped punch 2 re-
move the roller bearing outer races.
D Remove the inner race from the final drive
shaft.
NOTE:
The removal of the final drive shaft roller bear-
ing is a difficult procedure and is rarely neces-
sary.

*****************************************************

4. Install:
S Final drive roller bearing (new)
*****************************************************
Installation steps:
D Heat the final gear case to 150_C.
D Install the roller bearing outer races using the
proper adapter.
D Install the inner race onto the drive shaft.
*****************************************************
5. Install:
S Guide collar 1
S Oil seal 2
S Roller bearing (outer race) 3
To install the above components into the
final gear case use a suitable press tool 4
and a press.

6-60
 SHAFT DRIVE CHAS
EB707034

FINAL DRIVE/RING GEAR POSITIONING

NOTE:
Ring gear positioning is necessary when any of
the following parts are replaced:
D Final gear case
D Ring gear bearing housing
D Bearing(s)

1. Select:
S Final drive gear shim 1
S Ring gear shim 2
*****************************************************
Selection steps:
D Position the final drive gear and the ring gear
by using shims 1 and 2 with their respec-
tive thicknesses calculated from information
marked on the final gear case and the drive
gear end.
1 Final drive gear shim thickness “A”
2 Ring gear shim thickness “B”
3 Thrust washer “C”
D To find the final drive gear shim thickness “A”,
use the following formula

Final drive gear shim thickness:

A= a – b
Where:
a = a numeral (usually a decimal number) on
the final drive pinion gear is either added to or
subtracted from “80”.
b = a numeral on the final drive gear case
(i.e.79.50)
Example:
a is 80.01
If the final gear case is marked “50” . . . b
is 79.50.
“A” = 80.01 – 79.50
= 0.51
Therefore, final drive gear shim thickness is
0.51 mm. Shim sizes are supplied in the fol-
lowing thickness.

Final drive gear shim

Thickness (mm) 0.40, 0.50

6-61
 SHAFT DRIVE CHAS
Since final drive gear shims can only be se-
lected in 0.10 mm increments, round off the
hundredths digit and select the appropriate
shim(s).

Hundredths Rounded value

0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10
In the example above, the calculated final drive
gear shim thickness is 0.51 mm. The chart
instructs you to round off the 1 to 0. Thus you
should use a 0.50 mm final drive gear shim.
D To find the ring gear shim thickness “B”, use
the following formula.

Ring gear shim thickness:

B= c + d –( e + f )
Where:
c = a numeral on the final gear case (i.e.45.55)
d = a numeral on the bearing housing (i.e.1.35)
e = a numeral (usually a decimalnumber) on
the inside of the ring gear either added to or sub-
tracted from “35.40”.
f = the ring gear bearing thickness (consid-
ered constant).

Ring gear bearing thickness f :

11 mm

Example:
If the final gear case is marked
“55” . . . . . c is 45.55
d is 1.35
If the ring gear is marked “–05” . . . . . . . e
is 35.35
f is 11.00
“B” = 45.55 + 1.35 – (35.35 + 11.00)
= 46.9 – (46.35)
= 0.55

6-62
 SHAFT DRIVE CHAS
Therefore, the ring gear shim thickness is
0.55 mm. Shim sizes are supplied in the fol-
lowing thickness.

Ring gear shim

Thickness (mm) 0.25, 0.30, 0.40

Since ring gear shims can only be selected in

0.10 mm increments, round off the hundredths
digit and select the appropriate shim(s).

Hundredths Rounded value

0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10
*****************************************************

2. Install:

Shims (proper size as calculated)

Final drive shaft assembly

Bearing retainer (final drive shaft)
115 Nm (11.5 m
kg)

Use a bearing retainer wrench.

CAUTION:
The final drive shaft bearing retainer has
left-hand threads. Turn the retainer counter-
clockwise to tighten it.

Bearing retainer wrench:

90890-04050

3. Adjust:

Gear backlash
Refer to “FINAL GEAR BACKLASH MEA-
SUREMENT” and “FINAL GEAR BACK-
LASH ADJUSTMENT”.
4. Measure/select:

Ring gear thrust washer clearance

6-63
 SHAFT DRIVE CHAS
*****************************************************
Ring gear thrust washer clearance mea-
surement steps:
D Remove the ring gear assembly.
D Place four pieces of Plastigauge between
the originally installed ring gear thrust washer
and the ring gear.
D Install the ring gear assembly and tighten the
bolts to specification.

Bolt (bearing housing):

23 Nm (2.3 mSkg)

NOTE:
When using Plastigauge to measure the ring
gear thrust washer clearance do not turn the
shaft drive and ring gear.

D Remove the ring gear assembly.

D Measure the ring gear thrust washer clear-
ance and the width of the flattened Plasti-
gauge 1 .

Ring gear thrust washer

clearance:
0.1
0.2 mm

D If the clearance is correct, install the ring gear

assembly.
D If out of specification, select the correct thrust
washer.
Ring gear thrust washer selection steps:
D Using the following chart select the suitable
thrust washer.

Thrust washer

Thickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0

D Repeat the measurement steps until the ring

gear thrust washer clearance is within the
specified limits.

Ring gear thrust washer

clearance:
0.1
0.2 mm
*****************************************************

6-64
 SHAFT DRIVE CHAS
EB707040

DEIVE SHAFT INSPECTION

1. Inspect:

Drive shaft splines
Wear/damage
Replace.

FINAL GEAR CASE INSTALLATION

1. Apply:

Sealant
(onto the mating surface of both final gear
case halves)

Yamaha Bond No. 1215:

90890-85505

6-65
CHAS
 ELEC
CHAPTER 7.
ELECTRICAL

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
INSPECTING A SWITCH SHOWN IN THE MANUAL . . . . . . . . . . . . 7-2
SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
STARTER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
STARTER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
LIGHTING SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

CARBURETOR HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
 ELEC
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
 ELECTRICAL COMPONENTS ELEC
EB800000

ELECTRICAL
ELECTRICAL COMPONENTS
1 Thermo switch 9 Starter relay
2 Main switch 10Igniter unit IGNITION COIL:
3 Ignition coil 11Flasher relay PRIMARY WINDING RESISTANCE:
4 Fuse 12Neutral switch 3.8
4.6 Ω at 20
C
5 Carburetor heater relay 13Rear brake switch SECONDARY WINDING RESISTANCE:
6 Relay unit 14Side stand switch 10.1
15.1 kΩ at 20
C
7 Battery 15Rectifier/regulator
8 Headlight relay 16Horn

7-1
SWITCH INSPECTION ELEC

SWITCH INSPECTION
SWITCH INSPECTION
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty as any point,
replace the switch.

Pocket tester:
90890-03112

NOTE:
D Set the pocket tester to “0” before starting the
test.
D The pocket tester should be set to the ” 1” Ω
range when testing the switch for continuity.
D Turn the switch on and off a 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 shows that:
1 There is continuity between the “Black and
Black/White” leads when the switch is set
to “OFF”.
2 There is continuity between the “Red and
Brown” leads when the switch is set to
“ON”.

7-2
 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.

7-3
 SWITCH INSPECTION ELEC
1 Clutch switch 8 Engine stop switch
2 Horn switch 9 Lights switch
3 Dimmer switch 10 Start switch
4 Pass switch 11 Fuse
5 Turn switch 12 Rear brake switch
6 Main switch 13 Sidestand switch
7 Front brake switch 14 Neutral switch

7-4
 EB802000

CIRCUIT DIAGRAM
IGNITION SYSTEM

7-5
3 Main switch
4 Battery
5 Main fuse
IGNITION SYSTEM

8 Relay unit
10 Sidestand switch
12 Ignitor unit
13 Ignition coil
14 Spark plug
ELEC

15 Pickup coil
16 Neutral switch
43 Ignition fuse
46 Engine stop switch
E
 IGNITION SYSTEM ELEC
EB802010

TROUBLESHOOTING

IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):

Procedure
Check: 8. Main switch
1. Fuses (main and ignition) 9. Engine stop switch
2. Battery 10. Neutral switch
3. Spark plugs 11. Sidestand switch
4. Ignition spark gap 12. Relay unit (diode)
5. Spark plug cap resistance 13. Wiring connection (the entire ignition
6. Ignition coil resistance system)
7. Pickup coil resistance

NOTE:
D Remove the following part(s) before trouble- Ignition checker:
shooting: 90890-06754
1) Battery cover Pocket tester:
2) Rider’s seat 90890-03112
3) Fuel tank
4) Steering head side covers
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and ignition) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuses.

EB802012

2. Battery
S Check the battery condition. INCORRECT
Refer to “BATTERY INSPECTION” in
CHAPTER3.
Open-circuit voltage: S Clean the battery terminals.
12.8 V or more at 20_C S Recharge or replace the battery.

CORRECT
:

7-6
 IGNITION SYSTEM ELEC
:

EB802013

3. Spark plugs Standard spark plug:

DPR7EA-9/NGK
S Check the spark plug condition.
X22EPR-U9/DENSO
S Check the spark plug type.
S Check the spark plug gap.
Refer to “SPARK PLUG INSPECTION” in
CHAPTER3.

INCORRECT
Spark plug gap:
0.8 X 0.9 mm

CORRECT Repair or replace the spark plugs.

EB802014

4. Ignition spark gap

S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 as shown.
2 Spark plug cap
S Turn the main switch to “ON”.

S Check the ignition spark gap a.

S Crank the engine by pushing the starter MEETS SPECIFICATION
switch, and increase the spark gap until a
misfire occurs.
Minimum spark gap: The ignition system is not faulty.
6.0 mm
OUT OF
SPECIFICATION
OR NO SPARK
EB802015

5. Spark plug cap resistance

S Remove the spark plug cap.
S Connect the pocket tester (Ω 1k) to the
spark plug cap.

7-7
 IGNITION SYSTEM ELEC
OUT OF SPECIFICATION
S Check if the spark plug cap has the specified
resistance.
Spark plug cap resistance:
10 kΩ at 20_C Replace the spark plug cap.

MEETS
SPECIFICATION
EB802016

6. Ignition coil resistance Tester (+) lead
Red/Black terminal

Tester (–) lead
Orange (Gray) terminal
S Disconnect the ignition coil connector from
the wire harness.
S Connect the pocket tester (Ω 1) to the
ignition coil.

S Check if the primary coil has the specified re- Tester (+) lead
spark plug lead 1
sistance. Tester (–) lead
Red/Black terminal 2
Primary coil resistance:
3.8 X 4.6 Ω at 20_C
S Connect the pocket tester (Ω 1 k) to the
ignition coil.

S Check if the secondary coil has the specified

resistance. OUT OF SPECIFICATION

Secondary coil resistance:

10.1 X 15.1 kΩ at 20_C
Replace the ignition coil.
BOTH MEET
SPECIFICATION

7-8
 IGNITION SYSTEM ELEC
:

EB80201C

7. Pickup coil resistance

S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester (Ω 100) to the
pickup coil terminal.
Tester (+) lead
Gray terminal 1
Tester (–) lead
Black terminal 2

S Check if the pickup coil has the specified re-

OUT OF SPECIFICATION
sistance.
Pickup coil resistance:
182 X 222 Ω at 20_C
(Gray — Black) Replace the pickup coil.

MEETS
SPECIFICATION

8. Main switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace main switch.

9. Engine stop switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace handlebar switch (right).

10. Neutral switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace neutral switch.

11. Sidestand switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace sidestand switch.

7-9
 IGNITION SYSTEM ELEC
:

12. Relay unit (diode)

S Remove the relay unit from the wire har-
ness.
S Check for continuity as follows:
Sky blue – Blue/Yellow 2
Tester (+) lead
Sky blue 1 Conti-
Tester (–) lead
Blue/Yellow 2 nuity
Tester (+) lead
Blue/Yellow 2 No Con-
Tester (–) lead
Sky blue 1 tinuity
NOTE: INCORRECT
When you switch the “–” and “+” leads of the
digital pocket tester the readings in the
above chart will be reversed.
Replace the relay unit.

CORRECT
EB80201D

13. Wiring connection POOR CONNECTION

S Check the connections of the entire ignition

system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system.

CORRECT

Replace the ignitor unit.

7-10
 EB803000

CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM

7-11
3 Main switch
4 Battery
ELECTRIC STARTING SYSTEM

5 Main fuse
6 Starter relay
7 Starter motor
8 Relay unit
10 Sidestand switch
16 Neutral switch
ELEC

30 Clutch switch
43 Ignition fuse
46 Engine stop switch
48 Start switch
E
ELECTRIC STARTING SYSTEM ELEC
EB803010

STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the
starter motor, starter relay, and the starting cir-
cuit cut-off relay. If the engine stop switch is on
“RUN” and the main switch is on “ON” (both
switches are closed), the starter motor can op-
erate only if:

The transmission is in neutral (the neutral

switch is closed).
or if
The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the side-
stand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter from operating when neither of these
conditions have 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 have

been met however, the starting circuit cut-off
relay is closed, and the engine can be started by
pressing the starter switch.

WHEN THE TRANSMISSION IS IN

NEUTRAL

WHEN THE SIDESTAND IS UP AND

THE CLUTCH LEVER IS PULLED IN
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor

7-12
 ELECTRIC STARTING SYSTEM ELEC
EB803020

TROUBLESHOOTING

IF THE STARTER MOTOR FAILS TO OPERATE:

Procedure
Check:
1. Fuses (main and ignition) 8. Engine stop switch
2. Battery 9. Neutral switch
3. Starter motor 10. Sidestand switch
4. Relay unit (starting circuit cut-off relay) 11. Clutch switch
5. Relay unit (diode) 12. Start switch
6. Starter relay 13. Wiring connection (the entire starting
7. Main switch system)

NOTE:
D Remove the following part(s) before trouble- Pocket tester:
shooting: 90890-03112
1) Battery cover
2) Rider’s seat
3) Fuel tank
4) Steering head side covers
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and ignition) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuses.

EB802012

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

CORRECT
:

7-13
 ELECTRIC STARTING SYSTEM ELEC
:

EB803021
:
3. Starter motor
S Connect the battery positive terminal 1 and D A wire that is used as a jumper lead must
starter motor cable 2 using a jumper lead 3 have the equivalent capacity or more as
:. that of the battery lead, otherwise the
S Check the operation of the starter motor. jumper lead may burn.
D This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.

DOES NOT MOVE

Repair or replace the starter motor.

MOVES
EB803023

4. Relay unit (starting circuit cut-off relay)

S Remove the relay unit from the wire har-
ness.
S Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the relay unit terminals.
Battery (+) terminal

Red/Black terminal 1
Battery (–) terminal

Black/Yellow terminal 2
Tester (+) lead
Blue terminal 3
Tester (–) lead
Blue/White terminal 4

S Check the starting circuit cut-off relay for NO CONTINUITY

continuity.

CONTINUITY
Replace the relay unit.
:

7-14
 ELECTRIC STARTING SYSTEM ELEC
:

5. Relay unit (diode)

S Remove the relay unit from the wire har-
ness.
S Check for continuity as follows:
Sky blue 1 – Black/Yellow 2
Sky blue 1 – Blue/Yellow 3
Tester (+) lead
Sky blue 1 Conti-
Tester (–) lead
Black/Yellow 2 nuity
Tester (+) lead
Black/Yellow 2 No Con-
Tester (–) lead
Sky blue 1 tinuity
Tester (+) lead
Sky blue 1 Conti-
Tester (–) lead
Blue/Yellow 3 nuity
Tester (+) lead
Blue/Yellow 3 No Con-
Tester (–) lead
Sky blue 1 tinuity
NOTE: INCORRECT
When you switch the “–” and “+” leads of the
digital pocket tester the readings in the
above chart will be reversed.
Replace the relay unit.

CORRECT
EB803024

6. Starter relay
S Remove the starter relay from the wire har-
ness.
S Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the starter relay terminals.

Battery (+) terminal

Red/White terminal 1
Battery (–) terminal
Blue terminal 2 NO CONTINUITY
Tester (+) lead
Red terminal 3
Tester (–) lead
Black terminal 4
S Check the starter relay for continuity. Replace the starter relay.

CONTINUITY
:

7-15
 ELECTRIC STARTING SYSTEM ELEC
:

INCORRECT
7. Main switch
Refer to “SWITCH INSPECTION”.
Replace main switch.
CORRECT
INCORRECT
8. Engine stop switch
Refer to “SWITCH INSPECTION”.
Replace handlebar switch (right).
CORRECT
INCORRECT
9. Neutral switch
Refer to “SWITCH INSPECTION”.
Replace neutral switch.
CORRECT
INCORRECT
10. Sidestand switch
Refer to “SWITCH INSPECTION”.
Replace sidestand switch.
CORRECT
INCORRECT
11. Clutch switch
Refer to “SWITCH INSPECTION”.
Replace clutch switch.
CORRECT
INCORRECT
12. Start switch
Refer to “SWITCH INSPECTION”.
Replace handlebar switch (right).
CORRECT
EB803028 POOR CONNECTION
13. Wiring connection
S Check the connections of the entire starting
system. Properly connect the starting system.
Refer to “CIRCUIT DIAGRAM”.

7-16
 ELECTRIC STARTING SYSTEM ELEC
STARTER MOTOR

Order Job name/Part name Q’ty Remarks

Starter motor removal Remove the parts in the order below.
Exhaust pipe assembly Refer to “ENGINE ASSEMBLY” in
CHAPTER 4.
1 Starter motor/O-ring 1/1
2 Starter motor lead 1
Starter motor disassembly Disassemble the parts in the order
below.
1 Front bracket 1
2 Washer kit 1 Refer to “STARTER MOTOR
3 Rear bracket 2 ASSEMBLY”.
4 Shims 1
5 Brush seat/Brush 1 1/1 NOTE:
Be sure to remove the installation nut on
brush #1 first.
6 Armature coil 1
For assembly, reverse the disassembly
procedure.

7-17
 E

ELECTRIC STARTING SYSTEM ELEC

EB803034

STARTER MOTOR INSPECTION

1. Inspect:
 Commutator
Dirty
Clean it with #600 grit sandpaper.
2. Measure:
 Commutator diameter a
Out of specification
Replace the starter
motor.

Commutator wear limit:

27 mm

3. Measure:
 Mica undercut b
Out of specification
Scrape the mica to
the proper measurement using a hacksaw
blade which has been grounded to fit the
commutator.

Mica undercut:
0.7 mm

NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of the com-
mutator.

4. Inspect:
 Armature coil resistances (insula-
tion/continuity)
Defects
Replace the starter motor.
*****************************************************
Inspection steps:

Connect the pocket tester for the continuity
1 and insulation 2 checks.
D Measure the armature coil resistances.

Armature coil continuity

resistance 1 :
0 Ω at 20C
Armature coil insulation
resistance 2 :
More than 1 MΩ at 20C

D If the resistance is incorrect, replace the

starter motor.
*****************************************************

7-18
ELECTRIC STARTING SYSTEM ELEC
5. Measure:
S Brush length a
Out of specification
Replace.

Brush length wear limit:

4 mm

6. Measure:
S Brush spring force
Fatigue/out of specification
Replace as
a set.

Brush spring force:

520
920 g

7. Inspect:
S Bearing
Roughness
Replace.
S Oil seal
S Bushing
Wear/damage
Replace.

EB803036

STARTER MOTOR ASSEMBLY

Reverse the “Removal” procedure.
Note the following points.
1. Install:
S Brush seat 1
NOTE:
Align the projection a on the brush seat with
the slot on the housing.

2. Install:
S Shims 1
S Armature coil 2

7-19
ELECTRIC STARTING SYSTEM ELEC
3. Install:
S Gasket 1
S Yoke 2
S Washer kit 3
S Brackets 4
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.

7-20
 E

CHARGING SYSTEM ELEC

EB804000

CHARGING SYSTEM
CIRCUIT DIAGRAM

1 AC magneto (stator coil)

2 Rectifier/ regulator
4 Battery
5 Main fuse

7-21
 CHARGING SYSTEM ELEC
EB804010

TROUBLESHOOTING

IF THE BATTERY IS NOT CHARGED:

Procedure
Check:
1. Fuse (main) 4. Stator coil resistance
2. Battery 5. Wiring connections (the entire charging
3. Charging voltage system)

NOTE:
D Remove the following part(s) before trouble- Engine tachometer:
shooting: 90890-03113
1) Battery cover Pocket tester:
2) Rider’s seat 90890-03112
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuses.

EB802012

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

CORRECT
EB804011

3. Charging voltage
S Connect the engine tachometer to the spark
plug lead #1.
S Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead
Battery (+) terminal
Tester (–) lead
Battery (–) terminal

7-22
 CHARGING SYSTEM ELEC

S Start the engine and accelerate to about

5,000 r/min.
Charging voltage: MEETS SPECIFICATION
14 V at 5,000 r/min
NOTE:
Use a fully charged battery. The charging circuit is not faulty.

OUT OF
EB804012
SPECIFICATION

4. Stator coil resistance

S Disconnect the AC magneto coupler from
the wire harness.
S Connect the pocket tester (Ω 1) to the sta-
tor coils.
Tester (+) lead
White terminal 1
Tester (–) lead
White terminal 2
Tester (+) lead
White terminal 1
Tester (–) lead
White terminal 3 OUT OF SPECIFICATION
S Measure the stator coil resistance.
Stator coil resistance:
0.50 X 0.62 Ω at 20_C Replace the stator coil assembly.
BOTH MEET
SPECIFICATION
EB804015

5. Wiring connections POOR CONNECTION

S Check the connections of the entire charg-
ing system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the charging system.
CORRECT

Replace the rectifier/regulator.

7-23
 3 Main switch
EB805000
4 Battery
5 Main fuse
18 Meter light
22 High beam indicator light
25 Headlight
27 Pass switch
CIRCUIT DIAGRAM

28 Dimmer switch
35 Tail / brake light
36 Auxiliary light
LIGHTING SYSTEM

42 Headlight fuse
47 Lights switch

7-24
LIGHTING SYSTEM
ELEC
E
 LIGHTING SYSTEM ELEC
EB805010

TROUBLESHOOTING

IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAIL/BRAKE LIGHT, AUXILIARY

LIGHT AND/OR METER LIGHT FAIL TO COME ON:

Procedure
Check:
1. Fuses (main and head light) 5. Dimmer switch
2. Battery 6. Pass switch
3. Main switch 7. Wiring connections
4. Lights switch (the entire lighting system)

NOTE:
D Remove the following part(s) before trouble- Pocket tester:
shooting: 90890-03112
1) Battery cover
2) Rider’s seat
3) Fuel tank
4) Steering head side covers
5) Headlight lens unit
6) Tail/brake light unit
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and head light) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuses.

EB802012

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

CORRECT
:

7-25
 LIGHTING SYSTEM ELEC
:

3. Main switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace main switch.

4. Lights switch
Refer to “SWITCH INSPECTION”.

CORRECT Lights switch is faulty, replace handlebar

switch (right).

5. Dimmer switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Dimmer switch is faulty, replace handlebar

switch (left).

6. Pass switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Pass switch is faulty, replace handlebar

switch (left).
EB805013

7. Wiring connection
POOR CONNECTION
S Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”.
Properly connect the lighting system.
CORRECT

Check the condition of each of the lighting

system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”.

7-26
 LIGHTING SYSTEM ELEC
EB805020

LIGHTING SYSTEM CHECK

1. If the headlight and the high beam indicator
light fail to come on:
1. Bulb and bulb socket NO CONTINUITY

S Check the bulb and bulb socket for continu-

ity.
Replace the bulb and/or bulb socket.
CONTINUITY

2. Voltage Headlight:
Tester (+) lead

S Connect the pocket tester (DC 20 V) to the Yellow terminal 1 or Green terminal 2
headlight and high beam indicator light cou- Tester (–) lead
Black terminal 3
plers. High beam indicator light:
A When the dimmer switch is on “LO”. Tester (+) lead
Yellow terminal 4
B When the dimmer switch is on “HI”. Tester (–) lead
Black terminal 5
B
Headlight connector Meter connector

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Turn the dimmer switch to “LO” or “HI”.
S Check the voltage (12 V) of the “Green” and
“Yellow” leads on the bulb socket connec- The wiring circuit from the main switch to the
tor. bulb socket connector is faulty, repair it.
MEETS
SPECIFICATION

This circuit is not faulty.

7-27
 LIGHTING SYSTEM ELEC
EB805021

2. If the meter light fails to come on:

1. Bulb and bulb socket NO CONTINUITY

S Check the bulb and bulb socket for continu-

ity.
Replace the bulb and/or bulb socket.
CONTINUITY

2. Voltage
S Connect the pocket tester (20 V) to the bulb
socket coupler.
Tester (+) lead
Blue terminal 1
Tester (–) lead
Black terminal 2

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V) of the “blue” lead
on the bulb socket connector.

MEETS The wiring circuit from the main switch to the

SPECIFICATION bulb socket connector is faulty, repair it.

This circuit is not faulty.

EB805022

3. If the taillight fails to come on:

NO CONTINUITY
1. Bulb and bulb socket
S Check the bulb and bulb socket for continu-
ity. Replace the bulb and/or bulb socket.

CONTINUITY

2. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead
Blue terminal 1
Tester (–) lead
Black terminal 2

7-28
 LIGHTING SYSTEM ELEC

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V) of the “blue” lead
on the bulb socket connector.

MEETS The wiring circuit from the main switch to the

SPECIFICATION bulb socket connector is faulty, repair it.

This circuit is not faulty.

EB805023

4. If the auxiliary light fails to come on:

1. Bulb and bulb socket NO CONTINUITY

S Check the bulb and bulb socket for continu-

ity.
Replace the bulb and/or bulb socket.
CONTINUITY

2. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead
Blue/Red lead 1
Tester (–) lead
Black lead 2

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V) of the “Blue/Red”
lead on the bulb socket connector.

MEETS The wiring circuit from the main switch to the

SPECIFICATION bulb socket connector is faulty, repair it.

This circuit is not faulty.

7-29
 E

SIGNAL SYSTEM ELEC

EB806000

SIGNAL SYSTEM
CIRCUIT DIAGRAM

7-30
 SIGNAL SYSTEM ELEC
3 Main switch
4 Battery
5 Main fuse
12 Ignitor unit
16 Neutral switch
19 Engine indicator light
20 Turn indicator light
21 Neutral indicator light
23 Front turn signal
24 Rear turn signal
29 Horn switch
31 Turn switch
32 Flasher relay
33 Horn
34 Rear brake switch
35 Tail/ brake light
41 Signal system fuse
45 Front brake switch

7-31
 SIGNAL SYSTEM ELEC
EB806010

TROUBLESHOOTING

IF THE TURN SIGNAL, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON:
IF THE HORN FAILS TO SOUND:

Procedure
Check:
1. Fuses (main and signals)
2. Battery
3. Main switch
4. Wiring connections (the entire signal
system)

NOTE:
D Remove the following part(s) before trouble- Pocket tester:
shooting: 90890-03112
1) Battery cover
2) Rider’s seat
3) Fuel tank
4) Steering head side covers
5) Headlight lens unit
6) Tail/brake light unit
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and signals) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuse(s).

EB802012

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

CORRECT
:

7-32
 SIGNAL SYSTEM ELEC
:

3. Main switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT Replace main switch.

EB806011

4. Wiring connections
POOR CONNECTION
S Check the connections of the entire signal
system.
Refer to “CIRCUIT DIAGRAM”.
Properly connect the signal system.
CORRECT

Check the condition of each of the signal sys-

tem’s circuits.
Refer to “SIGNAL SYSTEM CHECK”.

7-33
 SIGNAL SYSTEM ELEC
EB806020

SIGNAL SYSTEM CHECK

1. If the horn fails to sound:

NO CONTINUITY
1. Horn switch
Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the handlebar switch (left).

2. Voltage
S Connect the pocket tester (DC 20 V) to the
horn lead.
Tester (+) lead
Black/White lead 1
Tester (–) lead
Frame ground

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V) of the “Black/
White” lead at the horn terminal.

MEETS The wiring circuit from the main switch to the

SPECIFICATION horn terminal is faulty, repair it.

3. Voltage
S Connect the pocket tester (DC 20 V) to the
horn at the “Pink” terminal.
Tester (+) lead
Pink lead 1
Tester (–) lead
Frame ground

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V) of the “Pink” lead
at the horn terminal.

MEETS Replace the horn.

SPECIFICATION

Adjust or replace the horn.

7-34
 SIGNAL SYSTEM ELEC
EB806022

2. If the brake light fails to come on:

INCORRECT
1. Brake switch (front, rear)
Refer to “SWITCH INSPECTION”.

CORRECT Replace brake switch.

2. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead
Yellow terminal 1
Tester (–) lead
Black terminal 2

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S The brake lever is pulled in or the brake
pedal is pressed down.
S Check the voltage (12 V) of the “Yellow” The wiring circuit from the main switch to the
lead on the bulb socket connector. bulb socket connector is faulty, repair it.
MEETS
SPECIFICATION

This circuit is not faulty.

EB806023

3. If the turn signal and/or turn indicator light

fails to blink:
INCORRECT
1. Turn switch
Refer to “SWITCH INSPECTION”.

CORRECT Replace handlebar switch (left).

2. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
Tester (+) lead
Brown terminal 1
Tester (–) lead
Frame ground

7-35
 E

SIGNAL SYSTEM ELEC

Turn the main switch to “ON”. OUT OF SPECIFICATION

Check the voltage (12 V) of the “Brown” 1
lead at the flasher relay terminal.

MEETS The wiring circuit from the main switch to the

SPECIFICATION flasher relay connector is faulty, repair it.

3. Voltage

Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
Tester (+) lead

Brown/White terminal 1
Tester (–) lead
Frame ground

Turn the main switch to “ON”. OUT OF SPECIFICATION

Check the voltage (12 V) on the “Brown/
White” 1 lead at the flasher relay terminal.

MEETS The flasher relay is faulty, replace it.

SPECIFICATION

A B
4. Voltage

Connect the pocket tester (DC 20 V) to the
bulb socket connector.

A Flasher light
B Turn indicator light

At the flasher light (left):

Tester (+) lead
Chocolate lead 1
Tester (–) lead
Frame ground
At the flasher light (right):
Tester (+) lead
Dark green lead 2
Tester (–) lead
Frame ground
At turn indicator light:
Tester (+) lead

Brown/White terminal 3
Tester (–) lead
Frame ground

7-36
 SIGNAL SYSTEM ELEC

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Turn the turn switch to “L” or “R”.
S Check the voltage (12 V) of the “Chocolate”
lead or “Dark green” lead on the bulb socket
connector.

MEETS The wiring circuit from the turn switch to the

SPECIFICATION bulb socket connector is faulty, repair it.

This circuit is not faulty.

EB806024

4. If the neutral indicator light fails to come on:

1. Neutral switch NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the neutral switch.

2. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket coupler.
Tester (+) lead
Brown terminal 1
Tester (–) lead
Sky/blue ground 2

S Turn the main switch to “ON”. OUT OF SPECIFICATION

S Check the voltage (12 V).

MEETS
SPECIFICATION The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.
This circuit is not faulty.

7-37
 EB808000

CIRCUIT DIAGRAM
FUEL PUMP SYSTEM

7-38
FUEL PUMP SYSTEM

3 Main switch
4 Battery
5 Main fuse
8 Relay unit (fuel pump relay)
ELEC

9 Fuel Pump
12 Ignitor unit
43 Ignition fuse
46 Engine stop switch
E
 FUEL PUMP SYSTEM ELEC
EB808010

FUEL PUMP CIRCUIT OPERATION

The fuel pump circuit consists of the fuel pump 1 Battery
2 Main fuse
relay, fuel pump, engine stop switch and ignitor
3 Main switch
unit. 4 Ignition fuse
The ignitor unit includes the control unit for the 5 Engine stop switch
fuel pump. 6 Ignitor unit
7 Fuel pump relay
8 Fuel pump

7-39
 FUEL PUMP SYSTEM ELEC
EB808020

TROUBLESHOOTING

IF THE FUEL PUMP FAILS TO OPERATE:

Procedure
Check:
1. Fuses (main and ignition) 5. Relay unit (fuel pump relay)
2. Battery 6. Fuel pump
3. Main switch 7. Wiring connections (the entire fuel system)
4. Engine stop switch

NOTE:
D Remove the following part(s) before trouble- Pocket tester:
shooting: 90890-03112
1) Battery cover
2) Rider’s seat
3) Fuel tank
4) Steering head side covers
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and ignition) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuse(s).

EB802012

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

CORRECT
:

7-40
 FUEL PUMP SYSTEM ELEC
:

INCORRECT
3. Main switch
Refer to “SWITCH INSPECTION”.
Replace main switch.

4. Engine stop switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT
Replace handlebar switch (right).
EB803023

5. Relay unit (fuel pump relay)

S Remove the relay unit from the wire har-
ness.
S Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the relay unit terminals.

Battery (+) terminal

Red/Black terminal 1
Battery (–) terminal

Blue/Red terminal 2 NO CONTINUITY
Tester (+) lead
Red/Black terminal 1
Tester (–) lead
Blue/Black terminal 3
S Check the fuel pump relay for continuity. Replace the relay unit.

CONTINUITY
EB808021

6. Fuel pump resistance

S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler terminals.
Tester (+) lead
Blue/Black terminal 1
Tester (–) lead
Black terminal 2

7-41
 FUEL PUMP SYSTEM ELEC
OUT OF SPECIFICATION
S Check if the fuel pump has the specified re-
sistance.
Fuel pump resistance:
1.6
2.2 Ω at 20_C Replace the fuel pump.

MEET
SPECIFICATION
EB808022

POOR CONNECTION
7. Wiring connections
S Check the connections of the entire fuel
pump system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the fuel pump system.

CORRECT

Replace the ignitor unit.

7-42
FUEL PUMP SYSTEM ELEC
EB808030

FUEL PUMP TEST

Gasoline is extremely flammable and under

certain circumstances there can be a dan-
ger of an explosion or combustion. Be ex-
tremely careful and note the following
points:
D Stop the engine before refuelling.
D Do not smoke and keep away from open
flames, sparks, or any other source of fire.
D Take care not to spill gasoline. If you do
accidentally spill some, wipe it up im-
mediately with dry rags.
D If gasoline touches the engine when the
engine is still hot, there is a danger of
combustion. Make sure that the engine is
completely cool before performing the
following test.

1. Check:
S Fuel pump operation
*****************************************************
Checking steps:
D Fill up the fuel tank.
D Put the end of the fuel hose into an open con-
tainer.
D Connect the battery (12 V) to the fuel pump
coupler terminals.

Battery (+) lead
Blue/Black terminal 1

Battery (–) lead
Black terminal 2
D If fuel flows out from the fuel hose, the fuel
pump is good. If not, replace the fuel pump
assembly.
*****************************************************

7-43
 3 Main switch
4 Battery
5 Main fuse
16 Neutral switch
37 Carburetor heater
38 Carburetor heater relay
39 Thermo switch
CIRCUIT DIAGRAM

40 Carburetor heater fuse

CARBURETOR HEATER SYSTEM

7-44
CARBURETOR HEATER SYSTEM
ELEC
E
 CARBURETOR HEATER SYSTEM ELEC
TROUBLESHOOTING

IF THE CARBURETER HEATER FAILS TO OPERATE:

Procedure
Check:
1. Fuses (main and carburetor heater) 5. Carburetor heater relay
2. Battery 6. Thermo switch
3. Main switch 7. Carburetor heater
4. Neutral switch 8. Wiring connections
(the entire carburetor heater system)

NOTE:
D Remove the following part(s) before trouble- Pocket tester:
shooting: 90890-03112
1) Battery cover
2) Rider’s seat
3) Fuel tank
4) Steering head side covers
D Use the following special tool(s) for trouble-
shooting.

EB802011

1. Fuses (main and carburetor heater) NO CONTINUITY

Refer to “SWITCH INSPECTION”.

CONTINUITY Replace the fuses.

EB802012

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

CORRECT
:

7-45
 CARBURETOR HEATER SYSTEM ELEC
:

INCORRECT
3. Main switch
Refer to “SWITCH INSPECTION”.
Replace main switch.
CORRECT

4. Neutral switch INCORRECT

Refer to “SWITCH INSPECTION”.

CORRECT
Replace neutral switch.

5. Caburetor heater relay.

S Remove the carburetor heater relay from
the wire harness.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the carburetor heater relay termi-
nals.

Battery (+) terminal

Brown/Yellow terminal 1
Battery (–) terminal

Sky blue terminal 2 CONTINUITY
Tester (+) lead

Brown/Black terminal 3
Tester (–) lead
Replace carburetor heater relay.
Black/Yellow terminal 4
S Check the carburetor heater relay for no
continuity.

NO CONTINUITY
:

7-46
 E

CARBURETOR HEATER SYSTEM ELEC

6. Thermo switch
 Remove the thermo switch from the thermo
switch plate.
 Connect the pocket tester to the thermo
switch lead.
Tester (+) lead

Brown/Yellow terminal 1
Tester (–) lead

Black/Yellow terminal 2
 Immerse the thermo switch in the water 3 .
 Check the thermo switch for continuity. Note
the temperatures while heating the water
with the temperature gauge 4 .

Good
Test step Water temperature
condition
OFF
1 Less than 23 ± 3C 

2 More than 23 ± 3C

ON
3 More than 12 ± 4C
Thermoswitch Thermoswitch
12 ± 4C 23 ± 3C
4 Less than 12 ± 4C 

Test 1 & 2: Heat-up test

Test 3 & 4: Cool-down test INCORRECT
: Continuity : No continuity

 If condition is not good, replace the thermo

switch. Replace thermo switch.

CORRECT

7. Carburetor heater
 Remove the carburetor heater from the car-
buretor body.
 Connect the pocket tester to the carburetor
heater.
Tester (+) lead
Heater terminal 1
Tester (–) lead
Heater body 2

7-47
 CARBURETOR HEATER SYSTEM ELEC
INCORRECT
S Measure the heater resistance.
Carburetor heater resistance:
12V15W: 6
12 Ω at 20_C
12V30W: 6
10 Ω at 20_C Replace carburetor heater.

CORRECT

POOR CONNECTION
1. Wiring connection
S Check the connections of the carburetor
heater system.
Properly connect the carburetor heater
Refer to “CIRCUIT DIAGRAM”.
system.

7-48
 SELF-DIAGNOSIS ELEC

SELF-DIAGNOSIS
The XVS650 features self-diagnosis.
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine indicator light (irrespective of whether the engine is running or not). 1
NOTE:
The XVS650 features a self-diagnosing system.
In the XVS650, when the main switch is turned on the “Engine indicator light” in the speedometer
comes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes on for 1.4 seconds,
goes off and then begins flashing. (However, it is on while the engine is running.)

Display condition
code
Item Condition Response When When
engine is engine is
stationary running
Throttle position Disconnected S Enables the motorcycle to Blinks in Light on
sensor (TPS) Short-circuit run so that the ignition tim-
Locked ing is fixed when the throttle
is fully opened.
S Displays the condition code
on the engine indicator light.

Display order on the engine indicator light

1 Light on (seconds) . . . . . 0.5 seconds

2 Light off (seconds) . . . . . 0.5 seconds
3 Number of blinks . . . . . . Fault code
4 Light off (seconds) . . . . . 3 seconds

Light on

LIght off

1 2 Repetition

3 4

7-49
 E

SELF-DIAGNOSIS ELEC
TROUBLESHOOTING

The engine indicator light starts to display the self-diagnosis sequence.

NOTE:
Use the following special tool in this trouble- Pocket tester:
shooting. 90890-03112

1. Throttle position sensor (TPS)

CIRCUIT DIAGRAM

11 Throttle position sensor (TPS)

12 Ignitor unit

1. Wire harness NO CONTINUITY

Check the wire harness for continuity.

Refer to “CIRCUIT DIAGRAM”.
Repair or replace the wire harness.
CONTINUITY

2. TPS

Check the TPS for continuity. BAD CONDITION

Refer to “THROTTLE POSITION SENSOR
(TPS) INSPECTION AND ADJUSTMENT”
in CHAPTER 5.
Replace the TPS.

GOOD
CONDITION

Replace the ignitor unit.

7-50
 TRBL
SHTG
CHAPTER 8.
TROUBLESHOOTING

STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE . . . . . . . . . . 8-2

FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
JUMPS-OUT-OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION . 8-4

MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

FAULTY LIGHTING AND SIGNAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8-5

HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FLASHER DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FLASHER BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FLASHER REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
FLASHER BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
TRBL
SHTG
 TRBL
STARTING FAILURE/HARD STARTING SHTG
EB900000

TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of problems. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for in-
spection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM
Fuel tank Carburetor

Empty
Deteriorated or contaminated fuel

Clogged fuel filter
Clogged pilot jet

Clogged fuel strainer
Clogged pilot air passage

Clogged fuel tank drain hose
Sucked-in air

Clogged roll-over valve
Deformed float

Clogged roll-over valve breather hose
Worn needle valve

Deteriorated or contaminated fuel
Improperly sealed valve seat
Fuel cock
Improperly adjusted fuel level

Clogged fuel hose
Improperly set pilot jet

Clogged starter jet

Faulty starter plunger

Improperly adjusted starter cable
Air filter

Clogged air filter element
Fuel pump

Faulty fuel pump

Faulty relay unit (fuel pump relay)

ELECTRICAL SYSTEM
Spark plug Switch and wiring

Improper plug gap
Faulty main switch

Worn electrodes
Faulty engine stop switch

Wire between terminals severed
Broken or shorted wiring

Improper heat range
Faulty neutral switch

Faulty spark plug cap
Faulty start switch
Ignition coil
Faulty sidestand switch

Broken or shorted primary/secondary
Faulty clutch switch

Faulty spark plug lead Starter motor

Broken body
Faulty starter motor
Full-transistor system
Faulty starter relay

Faulty ignitor unit
Faulty relay unit (starter circuit cut-off relay)

Faulty pickup coil
Faulty starter clutch

8-1
 STARTING FAILURE/HARD STARTING/POOR IDLE SPEED TRBL
PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE SHTG
COMPRESSION SYSTEM
Cylinder and cylinder head Piston and piston ring

Loose spark plug
Improperly installed piston ring

Loose cylinder head or cylinder
Worn, fatigued or broken piston ring

Faulty cylinder head gasket
Seized piston ring

Worn, damaged or seized cylinder
Seized or damaged piston

Improperly sealed valve Crankcase and crankshaft

Improper valve-to-valve seat contact
Improperly seated crankcase

Improper valve timing
Seized crankshaft

Faulty valve spring

EB901000

POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Electrical system

Improperly returned starter plunger
Faulty battery

Loose pilot jet
Faulty spark plug

Clogged pilot air jet
Faulty ignitor unit

Improperly synchronized carburetors
Faulty pickup coil

Improperly adjusted idle speed
Faulty ignition coil
(throttle stop screw) Valve train

Improper throttle cable free play
Improperly adjusted valve clearance

Flooded carburetor Air filter

Clogged air filter element

EB902000

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING”. (Fuel system, electrical system, compression
system and valve train)

Carburetor Air filter

Faulty diaphragm
Clogged air filter element

Improperly adjusted fuel level Fuel pump

Clogged or loose main jet
Faulty fuel pump

8-2
 FAULTY GEAR SHIFTING/ TRBL
CLUTCH SLIPPING/DRAGGING SHTG
EB903000

FAULTY GEAR SHIFTING

HARD SHIFTING
Refer to “CLUTCH DRAGGING”.

SHIFT PEDAL DOES NOT MOVE

Shift shaft Transmission

Improperly adjusted shift pedal link
Seized transmission gear

Bent shift shaft
Jammed impurities
Shift cam, shift fork
Incorrectly assembled transmission

Groove jammed with impurities

Seized shift fork

Bent shift fork guide bar

JUMPS-OUT-OF GEAR
Shift shaft Shift cam

Improperly adjusted shift lever position
Improper thrust play

Improperly returned stopper lever
Worn shift cam groove
Shift fork Transmission

Worn shift fork
Worn gear dog

EB904000

CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
Clutch Engine oil

Improperly adjusted clutch cable
Improper oil level

Loose clutch spring
Improper viscosity (low)

Fatigued clutch spring
Deterioration

Worn friction plate/clutch plate

Incorrectly assembled clutch

CLUTCH DRAGGING
Clutch Engine oil

Warped pressure plate
Improper oil level

Unevenly tensioned clutch springs
Improper viscosity (high)

Bent push rod
Deterioration

Broken clutch boss

Burnt primary driven gear bushing

Bent clutch plate

Swollen friction plate

Match marks not aligned

8-3
 OVERHEATING/FAULTY BRAKE/FRONT FORK OIL TRBL
LEAKAGE AND FRONT FORK MALFUNCTION SHTG
EB905000

OVERHEATING
OVERHEATING
Ignition system Compression system

Improper spark plug gap
Heavy carbon build-up

Improper spark plug heat range Engine oil

Faulty ignitor unit
Improper oil level
Fuel system
Improper oil viscosity

Improper carburetor main jet setting
Inferior oil quality

Improper fuel level Brake

Clogged air filter element
Brake drag

EB906001

FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake Drum brake

Worn brake pad
Worn brake shoe

Worn disc
Worn or rusty brake drum

Air in brake fluid
Improper brake free play adjustment

Leaking brake fluid
Improper brake cam lever position

Faulty cylinder kit cup
Improper brake shoe position

Faulty caliper kit seal
Fatigue/faulty return spring

Loose union bolt
Oily or greasy brake shoe/brake drum

Broken brake hose
Broken brake rod

Oily or greasy disc/brake pad

Improper brake fluid level

EB907000

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

MALFUNCTION OIL LEAKAGE

Bent, deformed or damaged inner tube
Bent, damaged or rusty inner tube

Bent or deformed outer tube
Damaged or cracked outer tube

Damaged fork spring
Damaged oil seal lip

Worn or damaged slide metal
Improperly installed oil seal

Bent or damaged damper rod
Improper oil level (too high)

Improper oil viscosity
Loose damper rod holding bolt

Improper oil level
Broken cap bolt O-ring

Loose drain bolt

Damaged drain bolt gasket

8-4
 UNSTABLE HANDLING/ TRBL
FAULTY LIGHTING AND SIGNAL SYSTEMS SHTG
EB908000

UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar Front fork

Improperly installed or bent
Uneven oil levels on both sides
Steering
Uneven spring tension

Improperly installed handlebar crown (uneven damping force adjuster position)

Bent steering stem
Broken spring

Improperly installed steering shaft
Twisted front fork
(improperly tightened ring nut)

Damaged ball bearing or bearing race

Swingarm Wheel

Worn bearing or bushing
Incorrect wheel balance

Bent or damaged
Deformed cast wheel
Rear shock absorber
Damaged bearing

Faulty spring
Bent or loose wheel axle

Oil and gas leakage
Excessive wheel runout
Tire
Loosed spoke

Uneven tire pressures on both sides Frame

Incorrect tire pressure
Bent

Uneven tire wear
Damaged steering head tube

Improperly installed bearing race

EB909000

FAULTY LIGHTING AND SIGNAL SYSTEMS

HEADLIGHT DOES NOT LIGHT BULB BURNT OUT

Improper bulb
Improper bulb

Too many electric accessories
Faulty battery

Hard charging (broken stator coil wire, faulty
Faulty rectifier/regulator
rectifier/regulator)
Improperly grounded

Incorrect connection
Faulty main and/or lights switch

Improperly grounded
Bulb life expired

Poor contacts (main or lights switch)

Bulb life expired

FLASHER DOES NOT LIGHT FLASHER REMAINS LIT

Improperly grounded
Faulty flasher relay

Discharged battery
Burnt-out bulb

Faulty turn switch FLASHER BLINKS QUICKLY

Faulty flasher relay
Improper bulb

Faulty wire harness
Faulty flasher relay

Loosely connected coupler
Burnt-out bulb

Burnt-out bulb HORN DOES NOT SOUND

Faulty fuse
Faulty battery
FLASHER BLINKS SLOWLY
Faulty fuse

Faulty flasher relay
Faulty main and/or horn switch

Faulty main and/or turn switch
Improperly adjusted horn

Improper bulb
Faulty horn

Broken wire harness

8-5
TRBL
SHTG
XVS650 ’97 WIRING DIAGRAM
1 A.C. magneto
2 Rectifier/ regulator
3 Main switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
8 Relay unit
9 Fuel pump
10 Sidestand switch
11 Throttle position sensor (TPS)
12 Ignitor unit
13 Ignition coil
14 Spark plug
15 Pickup coil
16 Neutral switch
17 Meter assembly
18 Meter light
19 Engine warning light
20 Turn indicator light
21 Neutral indicator light
22 High beam indicator light
23 Front turn signal
24 Rear turn signal
25 Headlight
26 Left handlebar switch
27 Pass switch
28 Dimmer switch
29 Horn switch
30 Clutch switch
31 Turn switch
32 Flasher relay
33 Horn
34 Rear brake switch
35 Tail/ brake light
36 Auxiliary light
37 Carburetor heater
38 Carburetor heater relay
39 Thermo switch
40 Carburetor heater fuse
41 Signal system fuse
42 Headlight fuse
43 Ignition fuse
44 Right handlebar switch
45 Front brake switch
46 Engine stop switch
47 Lights switch
48 Start switch

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