xjr service manual

EAS00000

XJR1300(L) ’99SERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.1st Edition, August 1998

All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

EAS00002

NOTICEThis manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and theirqualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it isassumed that persons using this book to perform maintenance and repairs on Yamaha motorcycle hasa basic understanding of the mechanical concepts and procedures inherent in motorcycle repairtechnology. Without such knowledge, attempted repairs or service to this model may render it unfit touse and/or unsafe.

Yamaha Motor Cmpany, Ltd. is continually striving to improve all models manufactured by Yamaha.Modifications and significant changes in specifications or procedures will be forwarded to all Autho-rized yamaha dealers and will, where applicable, appear in future editions of this manual.

PARTICURARLY IMPORTANT INFORMATIONThis materials distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

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

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

12

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7

3

8

EAS00007

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter.Refer to “SYMBOLS”.2 Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) ap-pears.3 Sub-section titles appear in smaller print than the section title.4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.6 Symbols indicate parts to be lubricated or replaced.Refer to “SYMBOLS”.7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

21

1

3

5

7

9

2

4

8

6

23 24

2220

18 1917

1615

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELEC

CHAS

CHKADJ

TRBLSHTG

EAS00009

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 8 indicate the subject of eachchapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Carburetor(-s)

6 Chassis

7 Electrical system

8 Troubleshooting

Symbols 9 to 16 indicate the following.

9 Serviceable with engine mounted

10 Filling fluid

11 Lubricant

12 Special tool

13 Tightening torque

14 Wear limit, clearance

15 Engine speed

16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.17 Engine oil

18 Gear oil

19 Molybdenum disulfide oil

20 Wheel bearing grease

21 Lithium soap base grease

22 Molybdenum disulfide greaseSymbols 23 to 24 in the exploded diagrams indi-cate the following:23 Apply locking agent (LOCTITE )

24 Replace the part

GENINFO

SPEC

ENG

CARB

CHAS

ELEC

CHKADJ

TRBLSHTG

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION ANDADJUSTMENTS

ENGINE OVERHAUL

CARBURETORS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

1

2

3

4

5

6

7

8

EAS00013

INDEX

GENINFO

CHAPTER 1.GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 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 THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

GENINFO

1-1

GENINFOMOTORCYCLE IDENTIFICATION

EAS00014

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEAS00017

VEHICLE IDENTIFICATION NUMBER (For E)The vehicle identification number 1 is stampedinto the right side of the steering head.

EAS00018

MODEL CODEThe model code label 1 is affixed to the frame.This information will be needed to order spareparts.

1-2

GENINFOIMPORTANT INFORMATION

EAS00020

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. Before removal and disassembly, remove all

dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaningequipment.Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTSUse only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must becleaned.

2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

1-3

GENINFOIMPORTANT INFORMATION

CAUTION:

EAS00023

LOCK WASHERS/PLATES AND COTTERPINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut has beentightened to specification, bend the lock washertabs and the cotter pin ends along a flat of thebolt or nut.

EAS00024

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-ible. When installing oil seals, lubricate theoil seal lips with a light coat of lithium soapbase grease. Oil bearings liberally wheninstalling, if appropriate.

1 Oil seal

Do not spin the bearing with compressed airbecause this will damage the bearing sur-faces.

1 Bearing

EAS00025

CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use.When installing a circlip 1 , make sure that thesharp-edged corner 2 is positioned oppositethe thrust 3 that the circlip receives.

4 Shaft

1-4

GENINFOCHECKING THE CONNECTIONS

NOTE:

NOTE:

NOTE:

EAS00026

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: leadcouplerconnector

2. Check: leadcouplerconnectorMoisture Dry with an air blower.Rust/stains Connect and disconnect sev-eral times.

3. Check:all connectionsLoose connection Connect properly.

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: leadcouplerconnector

Make sure that all connections are tight.

5. Check:continuity(with a pocket tester)

Pocket tester90890-03112

If there is no continuity, clean the terminals.When checking the wire harness, performsteps (1) to (3).

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

1-5

GENINFOSPECIAL TOOLS

EB104000

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly.Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri-ate tools or improvised techniques.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Function Illustration

90890-0126890890-01403

Exhaust & steering nut wrenchRing nut wrenchThis tools are used to loosen and tightenthe steering ring nut.

90890-01304 Piston pin puller

This tool is used to remove the piston pins.

90890-01312 Fuel level gauge

This tool is used to measure the fuel level inthe float chamber.

90890-0136790890-01374

Fork seal driver weightFork seal driver attachment (ø43)These tools are used when installing thefork seal.

90890-0132690890-01327

T-handleDamper rod holderThese tools are used to hold the damperrod assembly when loosening or tighteningthe damper rod assembly bolt.

90890-0308190890-04082

Compression gaugeAdapter

These tools are used to measure enginecompression.

90890-03094 Vacuum gauge

This guide is used to synchronize the car-buretors.

90890-03112 Pocket tester

This tool is used to check the electrical sys-tem.

1-6



90890-03113 Engine tachometer

This tool is used to check engine speed.

90890-03141 Timing light

This tool is used to check the ignition tim-ing.

90890-03158 Carburetor angle driver

This tool is used to turn the pilot screwwhen adjusting the engine idling speed.

90890-04016 Valve guide reamer, remover and installer(5.5 mm)

These tools are used to rebore, remove andinstall the valve guide.

90890-04019 Valve spring compressor

This tool is used to remove or install thevalve assemblies.

90890-0315390890-03124

Oil pressure gaugeOil pressure adaptor B

These tools are used to measure the engineoil pressure.

90890-04086 Clutch holding tool

This tool is used to hold the clutch bosswhen removing or installing the clutch bossnut.

90890-04101 Valve lapper

This tool is used for removing and installingthe valve lifter and for lapping the valve.

90890-04110 Tappet adjusting tool

This tool is necessary to replace valve ad-justing pads.

1-7



90890-06754 Ignition checker

This tool is used to check the ignition sys-tem components.

90890-85505 Yamaha bond No. 1215

This bond is used to seal two mating sur-faces (e.g., crankcase mating surfaces).

GENINFO

SPEC

CHAPTER 2.SPECIFICATIONS

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

MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TIGHTENING TORQUES 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINT AND GRADE OF LUBRICANT 2-21. . . . . . . . . . . . . ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-1

SPECGENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model XJR1300(L)

Model code: 5EA2/5EA3/5EA4

Dimensions:Overall length

Overall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR)(SF) (AUS)2250 mm (N) (SF) (G) (A)775 mm1115 mm775 mm1500 mm120 mm2800 mm

Basic weight:With oil and full fuel tank 253 kg

Engine:Engine typeCylinder arrangementDisplacementBore strokeCompression ratioCompression pressure (STD)Starting systemLubrication system:

Air-cooled 4-stroke, DOHCForward-inclined parallel 4-cylinder1250 cm3

79.0 63.8 mm9.7: 11050 kPa (10.5 kg/cm2,10.5 bar) at 400 r/minElectric starterWet sump

Oil type or grade:Engine oil

SE or higher grade

Engine oilPeriodic oil changeWith oil filter replacementTotal amount

Oil cooler capacity (including all routes)

3.0 L3.35 L4.2 L0.2 L

Air filter: Dry type element

Fuel:TypeFuel tank capacityFuel reserve amount

Regular unleaded gasoline21 L4.5 L

2-2


Model XJR1300(L)

Carburetor:Type/quantityManufacturer

BS36/4MIKUNI

Spark plug:Type quantityManufacturerSpark plug gap

DPR8EA-9/X24EPR-U9 4NGK/DENSO0.8 0.9 mm

Clutch type: Wet, multiple-disc

Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio 1st

2nd3rd4th5th

Spur gear98/56 (1.750)Chain drive38/17 (2.235)Constant mesh 5-speedLeft foot operation40/14 (2.857)36/18 (2.000)33/21 (1.571)31/24 (1.292)29/26 (1.115)

Chassis:Frame typeCaster angleTrail

Double cradle25.5100 mm

Tire:TypeSize front

rearManufacturer front

rearType front

rear

Tubeless120/70ZR17 (58W)180/55ZR17 (73W)MICHELIN/DUNLOP/BRIDGESTONEMICHELIN/DUNLOP/BRIDGESTONEMACADAM 90X/D207F/BT57FMACADAM 90X/D207/BT57R

Tire pressure (cold tire):Maximum load-except motorcycleLoading condition A *

frontrear

Loading condition B *frontrear

High-speed ridingfrontrear

207 kg0 90 kg250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)90 207 kg250 kPa (2.5 kg/cm2, 2.5 bar)290 kPa (2.9 kg/cm2, 2.9 bar)

250 kPa (2.5 kg/cm2, 2.5 bar)290 kPa (2.9 kg/cm2, 2.9 bar)

*Load is the total weight of cargo, rider, passenger, and accessories.

2-3


Model XJR1300(L)

Brake:Front brake type

operationRear brake type

operation

Dual disc brakeRight hand operationSingle disc brakeRight foot operation

Suspension:Front suspensionRear suspension

Telescopic forkSwingarm

Shock absorber:Front shock absorberRear shock absorber

Coil spring/Oil DamperCoil spring/Gas-oil damper

Wheel travel:Front wheel travelRear wheel travel

130 mm110 mm

Electrical:Ignition systemGenerator systemBattery typeBattery capacity

T.C.I. (Digital)A.C. generatorGT14B-412 V 12AH

Headlight type: Halogen bulb

Bulb wattage quantity:HeadlightAuxiliary lightTail /brake lightFlasher lightMeter lightNeutral indicator lightHigh beam indicator lightOil level indicator lightTurn indicator light

12 V 60 W/55 W 112 V 4 W 112 V 5 W/21 W 212 V 21 W 412 V 1.7 W 412 V 1.7 W 112 V 3.4 W 112 V 1.7 W 112 V 1.7 W 2

2-4

SPECMAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONSENGINE

Model Standard Limit

Cylinder head:Warp limit 0.1 mm

Cylinder:Bore sizeTaper limitOut of round limitWear limit

79.00 79.01 mm

0.05 mm0.05 mm79.1 mm

Camshaft:Drive methodCam cap inside diameterCamshaft outside diameterShaft-to-cap clearanceCam dimensions

Chain drive (Center)25.000 25.021 mm24.967 24.980 mm0.020 0.054 mm

Intake “A”“B”“C”

Exhaust “A”“B”“C”

Camshaft runout limit

35.95 36.05 mm28.248 28.348 mm7.95 8.05 mm35.95 36.05 mm28.248 28.348 mm7.95 8.05 mm

35.85 mm28.15 mm

35.85 mm28.15 mm

0.03 mm

2-5


Head Dia. Face Width Seat Width Margin Thickness


Cam chain:Cam chain type/No. of linksCam chain adjustment method

79RH2015/156Automatic

Valve, valve seat, valve guide:Valve clearance (cold) IN

EXValve dimensions:

0.11 0.15 mm0.16 0.20 mm

“A” head diameter INEX

“B” face width INEX

“C” seat width INEX

“D” margin thickness INEX

Stem outside diameter INEX

Guide inside diameter INEX

Stem-to-guide clearance INEX

Stem runout limit

28.9 29.1 mm24.9 25.1 mm1.98 2.55 mm1.98 2.55 mm0.9 1.1 mm0.9 1.1 mm0.8 1.2 mm0.8 1.2 mm5.475 5.490 mm5.460 5.475 mm5.500 5.512 mm5.500 5.512 mm0.010 0.037 mm0.025 0.052 mm

5.445 mm5.43 mm5.552 mm5.552 mm0.08 mm0.1 mm0.01 mm

Valve seat width INEX

0.9 1.1 mm0.9 1.1 mm

1.6 mm1.6 mm

2-6



Valve spring:Inner springFree length IN

EXSet length (valve closed) IN

EXCompressed pressure (installed) IN

EXTilt limit IN

EX

39.65 mm39.65 mm32.8 mm32.8 mm61.7 72.5 N (6.29 7.39 kg)61.7 72.5 N (6.29 7.39 kg)

37.5 mm37.5 mm

2.5 /1.7 mm2.5 /1.7 mm

Direction of winding (top view) INEX

Outer springFree length IN

EXSet length (valve closed) IN

EXCompressed pressure (installed) IN

EXTilt limit IN

EXDirection of winding (top view) IN

EX

ClockwiseClockwise

41.1 mm41.1 mm34.8 mm34.8 mm130.4 154.0 N (13.3 15.7 kg)130.4 154.0 N (13.3 15.7 kg)

CounterclockwiseCounterclockwise

39 mm39 mm

2.5 /1.7 mm2.5 /1.7 mm

Piston:Piston to cylinder clearancePiston size “D”

0.015 0.040 mm78.970 78.985 mm

0.15 mm

Measuring point “H”Piston off-setPiston off-set directionPiston pin bore inside diameterPiston pin outside diameter

2 mm1 mmIN side18.004 18.015 mm17.991 18.000 mm

2-7



Piston rings:Top ring:

TypeDimensions (B T)End gap (installed)Side clearance (installed)

2nd ring:

Barrel1.00 3.05 mm0.20 0.35 mm0.045 0.080 mm

0.6 mm0.1 mm

TypeDimensions (B T)End gap (installed)Side clearance (installed)

Oil ring:

Taper1.2 3.0 mm0.35 0.50 mm0.03 0.07 mm

0.75 mm0.1 mm

Dimensions (B T)End gap (installed)Side clearance

2.5 2.9 mm0.2 0.5 mm0.050 0.155 mm

Connecting rod:Oil clearance 0.017 0.040 mm 0.08 mm

Crankshaft:

Crank width “A”Assembly width “B”Runout limit “C”Big end side clearance “D”Journal oil clearance

62.25 63.85 mm382.0 383.2 mm0.02 mm0.160 0.262 mm0.030 0.064 mm

0.5 mm0.09 mm

2-8



Clutch:Friction plate thicknessQuantity

Clutch plate thickness

QuantityClutch spring heightQuantity

Clutch housing thrust clearanceClutch housing radial clearanceClutch release methodPush rod bending limit

2.9 3.1 mm8 pcs1.9 2.1 mm

7 pcs6 mm1 pc0 0.2 mm0.004 0.048 mmHydraulic inner push

2.8 mm

0.1 mm<Warp limit>

0.1 mm

0.3 mm

Transmission:Main axle deflection limitDrive axle deflection limit

0.06 mm0.06 mm

Shifter:Shifter typeGuide bar bending limit

Guide bar

0.1 mm

Carburetor:I.D. markMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)Needle jet (N.J)Pilot jet (P.A.J.1)Pilot outlet (P.O)Pilot jet (P.J)Bypass 1 (B.P.1)Bypass 2 (B.P.2)Bypass 3 (B.P.3)Pilot screw (P.S)Valve seat size (V.S)Starter jet (G.S.1)Starter jet (G.S.2)Throttle valve size (Th.V)Float height (F.H)Fuel level (using special tool)Engine idle speedIntake vacuum

5EA1 10#95#455D96-2Y-2#127.50.85#400.91.00.81-1/22.3#32.50.6#12521.3 23.3 mm3.5 4.5 mm1000 1100 r/min31.3 kPa (235 mmHg)

2-9



Lubrication system:Oil filter typeOil pump typeTip clearanceHousing and rotor clearanceSide clearanceBypass valve setting pressure

Relief valve operating pressure

Oil pressure (hot)

Pressure check location

Paper typeTrochoid type0.12 0.17 mm0.03 0.08 mm0.03 0.08 mm180 220 kPa(1.8 2.2 kg/cm2, 1.8 2.2 bar)480 580 kPa(4.8 5.8 kg/cm2, 4.8 5.8 bar)80 kPa (0.8 kg/cm2, 0.8 bar)at 1000 r/minMAIN GALLERY

0.2 mm0.15 mm0.15 mm

2-10


Tightening torques

Part to be tightened Part name Threadsize

Q’tyTightening

torque Remarksgsize

yNm mkg

Camshaft capOil gallery boltSpark plugCylinder headCylinder head coverCylinderCylinderCylinderConnecting rodCam sprocketTiming chain tensionerTiming chain tensioner cap boltChain guide (upper)Chain guide (intake)Oil pumpOil pumpOil strainer housingOil filter caseOil panDrain bolt (engine oil)Oil gallery blind plugDrain filterOil delivery pipe (oil pan)Oil delivery pipe (oil cooler)Oil coolerOil cooler coverOil delivery pipe (clamp)Intake manifoldAir filter case capAir filter caseExhaust pipeMuffler and stayExhaust chamberExhaust pipe and exhaust chamberExhaust chamber and mufflerExhaust pipe blind plug (CO test)Bearing holder (main axle)Timing plate coverCrankcase cover (right)Clutch coverDrive sprocket coverClutch release cylinderCrankcase

BoltScrew

–Cap nut

BoltStud bolt

NutNutNutBoltBoltBoltBoltPlug

ScrewBoltBolt

Union boltBoltPlugPlug

ScrewBoltBoltBoltBoltBoltBoltBoltBoltNutBoltBolt

ScrewBoltBolt

ScrewBolt

ScrewBoltBoltBoltBolt

M6 1.0M6 1.0

M12 1.25M10 1.25

M6 1.0M8 1.25M8 1.25M6 1.0

M8 0.75M7 1.0M6 1.0M11 1.0M6 1.0

M10 1.25M6 1.0M6 1.0M6 1.0

M20 1.5M6 1.0

M14 1.5M16 1.5M5 0.8M6 1.0M6 1.0M6 1.0M6 1.0M6 1.0M6 1.0M5 0.8M6 1.0

M8 1.25M8 1.25

M10 1.25M8 1.25M8 1.25M6 1.0M6 1.0M6 1.0M5 0.8M6 1.0M6 1.0M6 1.0M6 1.0

1814

1281368421412321

17111442418438214243421133

16

127

1835108

201036201020101010101015104387

1010108

101057

2520252020101274

10101012

1.20.71.83.51.00.82.01.03.62.01.02.01.01.01.01.01.01.51.04.30.80.71.01.01.00.81.01.00.50.72.52.02.52.02.01.01.20.70.41.01.01.01.2

2-11


Part to be tightened Part nameThread

size Q’tyTightening

torque Remarksg size yNm mkg

CrankcaseCrankcaseMain galleryOil buffle plateStopper plateBearing housingHY-VO chain guideClutch bossClutch pressure platePush lever comp.Drive sprocketShift shaft stopperStopper plate(Starter clutch idle gear shaft)Stopper leverSide plateShift armShift lodA.C. generatorOil level sensorRotor

BoltBoltPlugBoltBolt

ScrewBoltNutBoltBoltNut

ScrewScrew

BoltScrewBoltNutBoltBoltBolt

M8 1.25M10 1.25M20 1.5M5 0.8M6 1.0M6 1.0M6 1.0

M20 1.5M6 1.0M6 1.0

M22 1.5M8 1.25M6 1.0

M6 1.0M5 0.8M6 1.0M6 1.0

M8 1.25M6 1.0

M10 1.25

17533132162112

1112221

2435124

101010708

1085227

104

108

251045

2.43.51.20.41.01.01.07.00.81.08.52.20.7

1.00.41.00.82.51.04.5

2-12


Tightening sequenceCylinder head

Crankcase

2-13


Lubrication chart:

Pressure feedSplashed

Generatorshaft

Clutch Transmission

Ex. camshaft Lifter

IN. camshaft Lifter

Timingchain area

Piston, Cylinder

Connecting rod bearing

Crankshaft bearings

Main gallery

Oil filter

Relief valve Oil pump

Oil cooler

Oil pan/Oil strainer

Model XJR1300(L)

2-14


CHASSIS


Steering system:Steering bearing type Angular bearing

Front suspension:Front fork travelFork spring free lengthFitting lengthCollar lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)Optional springOil capacityOil levelOil grade

130 mm407.3 mm363.3 mm150 mm4.9 N/mm (0.5 kg/mm)8.8 N/mm (0.9 kg/mm)0 83 mm83 130 mmNo538 cm3

137 mmFork oil 10W or equivalent

395 mm

Rear suspension:Shock absorber travelSpring free lengthFitting lengthSpring rate (K1)

(K2)Stroke (K1)

(K2)

88 mm210 mm190 mm20.6 N/mm (2.1 kg/mm)31.4 N/mm (3.2 kg/mm)0 50 mm50 88 mm

206 mm

Front wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Cast wheel17 MT3.50Aluminum

1 mm0.5 mm

Rear wheel:TypeRim sizeRim materialRim runout limit radial

lateral

Cast wheel17 MT5.50Aluminum

1 mm0.5 mm

Drive chain:Type/manufacturerNo. of linksChain free play

50ZVM/DAIDO11020 30 mm

2-15



Front disc brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness

Dual298 5 mm

5.5 mm

0.2 mm0.5 mm

Master cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

14 mm30.2 mm and 27 mmDOT #4

Rear disc brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness

Single267 5 mm

5.5 mm

0.15 mm0.5 mm

Master cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

12.7 mm42.85 mmDOT #4

Brake lever & brake pedal:Brake pedal position 45 mm

Throttle grip free play 3 5 mm

2-16


Tightening torques

Part to be tightened Part name Thread size Q’tyTightening

torque Remarksg yNm mkg

Handle crown and inner tubeHandle crown and steering stemHandle crown and handlebar holder(lower)Upper handlebar holderLower bracket and inner tubeSteering stem and ring nutFront master cylinder and holderFront brake hose union boltMeterHeadlight stay (lower)Grip endFront turn signal lightsFront fender and front forkHeadlight stay and upper coverEngine stay (front) and frameEngine mount (front)

(rear-upper)Engine stay (rear-upper) and frameEngine stay (rear-upper) and frameEngine stay (rear-lower)Frame and down tubePivot shaftRear shock absorber and frameRear shock absorber and swing armDrive chain guide and swing armChain case and swing armFuel tankFuel tank capFuel cockSeat lockFuel senderSide cover and frameTail lightRear fender and frameRear fender cover and coverRear fender cover and frameGrab barIgnitorRear turn signal light and rear fender

BoltNutNut

BoltBoltNutBoltBoltNutBolt

–NutBolt

Cap nutBoltNutNutBoltBoltNut

Nut and BoltNutBoltBoltBolt

ScrewBolt

ScrewScrew

NutBolt

ScrewNutBolt

ScrewScrewBolt

ScrewNut

M8 1.25M22 1.0

M10 1.25

M8 1.25M8 1.25M25 1.0M6 1.0

M10 1.25M6 1.0M6 1.0

M16 1.5M12 1.25

M6 1.0M6 1.0

M8 1.25M10 1.25M10 1.25M10 1.25M12 1.25M10 1.25M8 1.25M18 1.5M8 1.25

M10 1.25M6 1.0M6 1.0

M8 1.25M5 0.8M6 1.0M6 1.0M5 0.8M6 1.0M6 1.0M6 1.0M5 0.8M6 1.0

M8 1.25M6 1.0

M12 1.25

212

441212222444212224111121422423422422

3011040

23231810307

1026777

30645548886426

125233077

19677477747

3074

3.011.04.0

2.32.31.81.03.00.71.02.60.70.70.73.06.45.54.88.86.42.6

12.52.33.00.70.71.90.60.70.70.40.70.70.70.40.73.00.70.4

See “NOTE”

2-17


NOTE:

Part to be tightened Part name Thread size Q’tyTightening

torque Remarksg yNm mkg

HookHelmet holderTail light bracketSide standSide standSide stand switchFootrest bracketRear footrest bracketFootrest and footrest bracketRear brake reservoir tankRear master cylinder and bracketCenter standFront wheel axleFront wheel axle pinch boltFront brake caliper and front forkFront brake disk and hubFront brake caliper and bleed screwFront brake hoseTensionbar and swingarmDriven sprocket and hubChain pullerRear brake caliper and caliper bracketRear wheel axleRear brake hoseRear brake caliper and bleed screwRear brake disc and hub

ScrewBoltBoltBoltNut

ScrewBoltBoltBolt

ScrewBolt

Nut and Bolt–

BoltBoltBolt

–Union bolt

Nut and boltNutNutBoltNut

Union bolt–

Bolt

M6 1.0M6 1.0

M8 1.25M10 1.25M10 1.25

M5 0.8M8 1.25M8 1.25

M10 1.25M6 1.0

M8 1.25M10 1.25M16 1.5M8 1.0

M10 1.25M8 1.25M8 1.25

M10 1.25M8 1.25M8 1.25M8 1.25

M10 1.25M18 1.5

M10 1.25M8 1.25M8 1.25

224112442122114

122226221216

7133040404

2828555

2341731940206

3023601640

150306

20

0.71.33.04.04.00.42.82.85.50.52.34.17.31.94.02.00.63.02.36.01.64.0

15.03.00.62.0

1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, then loosenthe ring nut one turn.

2. Retighten the ring nut to specification.

2-18


ELECTRICAL


Voltage: 12 V

Ignition system:Ignition timing (B.T.D.C.)Advanced timing (B.T.D.C.)Advancer type

5 /1050 r/min50 /5000 r/minTPS & Electrical type

T.C.I.:Pickup coil resistance/colorT.C.I. unit model/manufacturer

248 372 Ω /W/R-W/G5EA20/YAMAHA

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

83R/YAMAHA6 mm1.9 2.9 Ω9.5 14.3 kΩ

Spark plug cap:TypeResistance

Resin type10 kΩ

Charging system:TypeModel/manufacturerNormal outputRotor coil resistanceStator coil resistanceBrush overall lengthSpring force

A.C. generatorB3G-B/DENSO13.5 V 28 A/3000 r/min2.8 3.0 Ω0.19 0.21 Ω13.7 mm5.10 5.69 N (0.52 0.58 kg)

4.7 mm

Voltage regulator:TypeModel/manufacturerNo load regulated voltage

Semi-conductor, field control typeB3G-B/DENSO14.2 14.8 V

Electric starter system:TypeStarter motor:Model/manufacturerOutputBrush overall lengthSpring forceCommutator diameter

Constant mesh type

SM-13/MITSUBA0.65 kW10 mm7.65 10.01 N (0.780 1.021 kg)28 mm

5 mm

27 mm

2-19



Mica undercutStarter relay:Model/manufacturerAmperage ratingCoil winding resistance

0.7 mm

MS5E-491/JIDECO100 A4.2 4.6 Ω

Horn:TypeQuantityModel/manufacturerMaximum amperage

Plane type2 pcsYF12/NIKKO3 A

Flasher relay:TypeModel/manufacturerSelf cancelling deviceFlasher frequency

Full transistor typeFE246BH/DENSONo75 95 cyl/min

Oil level switch:Model/manufacturer 5G2/DENSO

Fuel gauge:Model/manufacturerSender unit resistance full

empty

4 KG/NIPPON SEIKI4 10 Ω90 100 Ω

Starting circuit cut-off relay:Model/manufacturerCoil winding resistanceDiode

G8R-30Y-J/OMRON162 198 ΩYes

Oil level switch relay:Model/manufacturer G8D-117Y-2/OMRON

Circuit breaker:TypeAmperage for individual circuit Q’tyMAINHEAD LIGHTSIGNALIGNITIONReserve

Fuse

30 A 115 A 115 A 17.5 A 130 A 115 A 17.5 A 1

2-20

SPECCONVERSION TABLE/

GENERAL TORQUE SPECIFICATIONS

EAS00028

CONVERSION TABLEAll specification data in this manual are listed inSI and METRIC UNITS.Use this table to convert METRIC unit data toIMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMP

** mm x 0.03937 = ** in

2 mm x 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMP

Known Multiplier Result

Torque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kgg

2.2050.03527

lboz

Distance

km/hrkmmmcmmm

0.62140.62143.2811.0940.39370.03937

mphmiftydinin

Volume/Capacity

cc (cm3)cc (cm3)lt (liter)It (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)

Miscella-neous

kg/mmkg/cm2

Centigrade

55.99714.22349/5 (C) + 32

lb/ inpsi (lb / in2)Fahrenheit (F)

EAS00029

GENERAL TIGHTENING TORQUESThis chart specifies tightening torques for stan-dard fasteners with a standard ISO thread pitch.Tightening torque specifications for specialcomponents or assemblies are provided foreach chapter of this manual. To avoid warpage,tighten multi-fastener assemblies in a criss-cross pattern and progressive stages until thespecified tightening torque is reached. Unlessotherwise specified, tightening torque specifi-cations require clean, dry threads. Componentsshould be at room temperature.

A: Distance across flatsB: Outside thread diameter

A BGeneral specifications

A(Nut)

B(Bolt)

torques(Nut) (Bolt)

Nm mkg

10 mm 6 mm 6 0.6

12 mm 8 mm 15 1.5

14 mm 10 mm 30 3.0

17 mm 12 mm 55 5.5

19 mm 14 mm 85 8.5

22 mm 16 mm 130 13.0

2-21

SPECLUBRICATION POINT AND GRADE OF LUBRICANT

LUBRICATION POINT AND GRADE OF LUBRICANTENGINE

Lubrication Point Symbol

Oil seal lips

O-ring

Bearing

Piston surface

Piston pin

Crankshaft pin

Crankshaft journal/big end

Connecting rod bolt /nut

Camshaft cam lobe/journal

Valve stem (IN, EX)

Valve stem end (IN, EX)

Valve lifter

Oil pump rotor (inner/outer), housing

Oil strainer assembly

Starter idle gear inner surface

Starter wheel gear inner surface

Starter clutch (outer/roller)

Crankcase cover (push rod hole)

Primary drive gear/damper

Transmission gear (wheel/pinion)

Shift cam

Shift fork/guide bar

Shift shaft assembly

Crankcase mating surfaces Yamaha bond No. 1215

Blind plug and oil seal (crankcase main gallery) Yamaha bond No. 1215

2-22

SPECLUBRICATION POINT AND GRADE OF LUBRICANT

CHASSIS

Lubrication Point Symbol

Steering bearing (upper/ lower) and bearing cover lip

Front wheel oil seal (left /right)

Rear wheel oil seal (left /right)

Clutch hub fitting area

Rear brake pedal shaft

Shift pedal

Centerstand sliding surface

Sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever bolt, sliding surface

Clutch lever bolt, sliding surface

Rear footrest pivot

Swingarm pivot bearing

Swingarm pivot shaft outer surface

Swingarm thrust cover lip

2-23

1 Camshaft (intake)2 Camshaft (exhaust)3 Main gallery4 Oil strainer5 Oil pump6 Main axle7 Crankshaft

SPECLUBRICATION DIAGRAMS

LUBRICATION DIAGRAMS

2-24

1 Oil cooler2 Starter clutch3 Main axle4 Drive axle5 Oil pump6 Oil pan7 Relief valve8 Main gallery


2-25

1 Camshaft2 Crankshaft3 Oil pump4 Oil filter


2-26

A Fasten the wireharness to theseat rail with a plastic band. Makesure that the end of band downward.

B Align the white tape on the wire-harness with a plastic band andfasten them to the seat real.Make sure that the end of banddown ward.

C Fasten the wireharness with thesteel clamp on the frame.

9 Throttle position sensor10 Ignition coil lead (#2, 3)11 Throttle cable12 Engine ground lead13 Air ventilation hose14 Rear brake switch15 Starting circuit cutoff relay

1 Starter motor cable2 Battery negative (–) lead3 Battery negative (–) lead con-

nector4 AC generator connector5 Rear brake switch lead connec-

tor6 Neutral lead7 Pickup lead8 Sidestand switch lead

SPECCABLE ROUTING

CABLE ROUTING

2-27

I Fasten the high tension cablesand throttle cables with a plasticclamp.

J Route the air ventilation hoses,air filter case drain hose, fueltank drain hose and fuel tank bre-ather hose through the engineguide.

K Fasten the AC generator lead,pick-up coil lead, sidestand swi-tch lead and starter motor cablewith a plastic band.

F Fasten the wireharness to theframe with a plastic band. Makesure that the end of band down ward.

G Insert the plastic band throughthe hole of plastic panel and thenfasten the throttle cables with it.Make sure that the end of bandinside of motorcycle.

H Fasten the wireharness to theframe with a plastic band. Makesure that the end of band downward.

D Route the wireharness and start-er motor cable in front of the res-ervoir tank bracket and the bat-tery negative (–) lead behind thereservoir tank bracket. And fas-ten them with a plastic band.

E Fasten the wireharness, neutrallead, sidestand switch lead, pick-up coil lead, AC generator leadand rear brake switch lead to theframe with a plastic band. Makesure that the end of band forwardof motorcycle.

SPECCABLE ROUTING

2-28

L Route the wireharness and start-er motor cable behind the sidecover bracket and fasten themwith a plastic band at front of thebracket.

M Align the white paint marks of thefuel tank drain hose, fuel tankbreather hose and air filter casedrain hose.

N Touch the brake pipe to the brakecaliper stopper.

SPECCABLE ROUTING

2-29

E Fasten the high tension cables(#1, 2) with a plastic clamp. Posi-tion the clamp at 50 – 80 mmabove the high tension cablenumber.

F Fasten the horn lead to the framewith a plastic band. Make surethat the end of band down ward.

G Install the frame ground and ig-niter unit together with screw.

A Insert the plastic band through

the hole of plastic panel and thenfasten the clutch hose with it.Make sure that the end of bandinside of motorcycle.

B To headlight lower hole.C Route the wireharness and start-

er cable through the guide.D Connect the ignition lead with

white marking tape to the ignitioncoil (#1, 4).

1 Clutch hose2 Starter cable3 Air filter case drain hose4 Frame ground5 Flasher relay connector6 Oil light relay connector7 Igniter unit connectors8 Starter motor9 AC generator10 Sidestand switch11 Sidestand switch lead12 Ignition coil lead (#1, 4)

SPECCABLE ROUTING

2-30

N Route the speedometer cablethrough the guide.

O Touch the brake pipe to the bra-ke caliper stopper.

P Touch the brake pipe to the bra-ke hose joint.

K Fasten the sidestand switch leadwith steel clamp on the frameand then route it between thepickup cover, oil filter cover, ACgenerator and starter motor tothe right side of motorcycle.

L Fasten the clutch hose with steelclamp on the frame.

M Clamp the gromet on the clutchhose with wire holder on theframe.

SPECCABLE ROUTING

H Fasten the seat lock cable to theseat real with a plastic band.Make sure that the end of banddown ward.

I Route the air filter case drainhose over the starter motor toright side of motorcycle.

J Position the clutch pipe parallelwith the oil filter cover.

2-31

24 Taillight lead25 Starter cable

A Position the horn (high) to rightside.

B Fasten the throttle cable (frontside) to the frame with a plasticclamp.

C Fasten the throttle position sen-sor with steel clamp on the car-buretor (#4).

D To fuel sender.

12 Starter relay13 Seat lock cable14 Seat lock15 Battery positive (+) lead16 Fuse box17 Starter relay connector18 Flasher relay19 Oil light relay20 Igniter unit21 Fuel sender connector22 Starter cable23 Ignition coil (#1, 4)

SPECCABLE ROUTING

1 Throttle cables2 Ignition coil (#2, 3)3 Throttle position sensor4 Neutral switch connector5 Pickup coil connector6 Sidestand switch connector7 Battery8 Reservoir tank9 Battery negative (–) lead10 Starting circuit cutoff relay11 Battery positive (+) lead connec-

tor

2-32

J Position the seat lock cable in-side under the seat lock bracket.

K Fasten the wireharness to theframe with a plastic band. Makesure that the end of band downward.

L Route the starter cable betweenthe throttle cables.

M Fasten the wireharness, startercable to the frame with a plasticband. Make sure that end of ba-nd down ward.

G Fasten the battery positive (+)lead and battery positive (+) leadconnector on the groove of thebattery with the battery rubberband.

H Position the starter motor cableat 45 degree out side of the mo-torcycle.

I Position the wireharness, tail-light lead and rear turn signallight leads (left and right) be-tween the taillight bracket andrear fender rib.

E Connect the fuel sender connec-tor, neutral switch connector,pickup coil connector and side-stand switch connector abovethe air filter case.

F Route the battery negative (–)lead inside of the reservoir tankbracket and under the reservoirtank and then connect it.

SPECCABLE ROUTING

2-33

SPECCABLE ROUTING

N Fasten the wireharness, taillightlead and rear turn signal lightleads (left and right) with steelclamp on the frame make surethat the end of clamp forward.

O Route the rear turn signal lightleads (left and right) through theeach holes of the rear fender.

P Touch the starter cable to thestopper and position it vertical ofthe motorcyle.

2-34

D Route the handlebar switch lead(left) and front turn signal lightlead (left) into the left under holeof the headlight body.

E Route the front turn signal lightleads (left and right) in front ofthe headlight stay.

F Route the speedometer cablethrough the guide on the head-light stay.

G To front brake master cylinder.

A Route the throttle cables throughthe guide on the headlight stay.

B Route the meter leads, mainswitch lead into the upper hole ofthe headlight body.

C Route the handlebar switch lead(left) inside of the clutch hose.Fasten the handlebar switchlead (left), clutch hose and start-er cable with a plastic band.

1 Meter leads2 Main switch lead3 Starter cable4 Handlebar switch lead (left)5 Clutch hose6 Brake hose7 Handlebar switch lead (right)

SPECCABLE ROUTING

2-35

H Touch the brake pipe to the stop-per.

I Route the handlebar switch lead(right) and front turn signal lightlead (right) into the right underhole of the headlight stay.

J Fasten the handlebar switchlead (right) and front brake hosewith a plastic band.

SPECCABLE ROUTING

CHKADJ

CHAPTER 3.PERIODIC INSPECTION

AND ADJUSTMENT

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

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-2. . . . . . . . . . .

SEAT SIDE COVER AND FUEL TANK 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-4. . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETOR 3-9. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE IDLING SPEED 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-11. . . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-14. . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-16. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE ENGINE OIL 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-18. . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH LEVER 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH FLUID LEVEL 3-20. . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3-20. . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-22. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINTS AND INTAKE

MANIFOLDS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL AND VACUUM HOSES 3-23. . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-24. . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-24. . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-27. . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-28. . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-29. . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-32. . . . . . . . . . CHECKING THE FRONT FORK 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-35. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3-36. . . . CHECKING THE TIRES 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-40. . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-40. . . . . . . . . . . . . . . . . . .

CHKADJ

LUBRICATING THE SIDE STAND 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE CENTERSTAND 3-40. . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-40. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-41. . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULB 3-48. . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAM 3-49. . . . . . . . . . . . . . . . . . . . . . . . .

3-1

CHKADJ

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTIONThis 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 new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALSEVERY

ITEM REMARKSBREAK-IN1,000 km

6,000 kmor

6 months

12,000 kmor

12 months

Valves* Check valve clearance. Adjust if necessary. EVERY 24,000 km or 24 months

Spark plugs Check condition. Clean or replace of necessary.

Air filter Clean. Replace if necessary.

Carburetor*Check idle speed/synchronization/starter operation.Adjust if necessary.

Fuel line*Check fuel hose for cracks or damage.Replace if necessary.

Fuel filter* Check condition. Replace if necessary.

Engine oil Replace (Warm engine before draining).

Engine oil filter* Replace.

Brake*Check operation/ fluid leakage/See NOTE.Correct if necessary.

Clutch*Check operation/ fluid leakage/See NOTE.Correct if necessary.

Swingarm pivot*Check swingarm assembly for looseness.Correct if necessary. Moderately repack every24,000 km or 24 months.**

Rear suspension linkpivots*

Check operation. Apply grease lightly every24,000 km or 24 months.**

Wheels* Check balance/damage/runout. Replace if necessary.

Wheel bearings*Check bearing assembly for looseness/damage.Replace if damaged.

Steering bearings*Check bearing assembly for looseness.Correct if necessary. Moderately repack every24,000 km or 24 months.

Front forks* Check operation/oil leakage. Repair if necessary.

Rear shock absorber* Check operation/oil leakage. Repair if necessary.

Drive chainCheck chain free play/alignment. Adjust if necessary.Clean and lube.

EVERY 500 km

Fittings/Fasteners*Check all chassis fittings and fasteners.Correct if necessary.

Center andsidestand* Check operation. Repair if necessary.

Sidestand switch* Check operation. Clean or replace if necessary.

A.C. Generator* Replace generator brushes every 100,000 km.

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJ

NOTE:

*: It is recommended that these items be serviced by a Yamaha dealer.**: Molybdenum disulfide grease.***: Lithium soap base grease.

Brake fluid replacement:1. When disassembling the master cylinder, caliper cylinder or clutch release cylinder, replace the

brake fluid. Normally check the brake fluid level and add the fluid as required.2. On the inner parts of the master cylinder, caliper cylinder and clutch release cylinder, replace the oil

seals every two years.3. Replace the brake and clutch hoses every four years, or if cracked or damaged.

3-3

CHKADJSEAT, SIDE COVER AND FUEL TANK

19 Nm (1.9 mkg)

Order Job/Part Q’ty Remarks

1234

56789

Removing the seat, side cover andfuel tankSeatSide cover (left)Side cover (right)Fuel hose

Fuel tankFuel sender leadDrain hoseGrab barRear fender cover

111

1/1

11211

Remove the parts in the order listed.

Disconnect the fuel pipe, set the fuelcock lever “ON” or “RES” position.

For installation, reverse the removal procedure.

NOTE:

30 Nm (3.0 mkg)

SEAT, SIDE COVER AND FUEL TANK

3-4

CHKADJADJUSTING THE VALVE CLEARANCE

NOTE:

ENGINEADJUSTING THE VALVE CLEARANCEthe following procedure applies to all of thevalves.

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. Remove:seatside covers fuel tankRefer to “SEAT, SIDE COVER AND FUELTANK”.

2. Remove:oil cooler 1air ducts 2

3. Remove:spark plugs 1cylinder head cover 2 timing plate cover 3

4. Measure:valve clearanceOut of specification Adjust.

Valve clearance (cold):Intake valve 0.11 0.15 mmExhaust valve 0.16 0.20 mm

3-5


NOTE:

NOTE:

a. Turn the crankshaft counterclockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark a on thetiming plate with the mark b on the pickupcoil base plate.

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

c. Measure the valve clearance with a thick-ness gauge 1 .

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

Valve clearance measuring sequenceCylinder #1 #2 #4 #3

A Frontd. For each cylinder, starting with cylinder #1 at

TDC, turn the crankshaft counterclockwiseas specified in the following table.

B Degrees that the crank shaft is turned counterclockwise

C Cylinder

D Combustion cycle

Cylinder #2 180

Cylinder #4 360

Cylinder #3 540

3-6

ADJUSTING THE VALVE CLEARANCECHKADJ

EX IN

NOTE:

NOTE:

5. Adjust:Valve clearance

a. Align the intake and exhaust valve lifter slotswith each other.

b. Slowly turn the crankshaft until the cam liftedat maximum.

c. Install the tappet adjusting tool 1 as shown.

Tappet adjusting tool:P/N 90890-04110

Make sure that the tappet adjusting tool touchesonly the valve lifter 2 , not the valve pad 3 .

d. Slowly turn the crankshaft so that the valvepad can be removed.

e. Remove the valve pad from the valve lifterwith a small screwdriver and a pair of twee-zers. Make a note of the position of eachvalve pad and valve pad number so they canbe installed in the correct place.

f. Select the proper valve pad from the follow-ing table.

Valve padthickness range

Availablevalve pads

No. 200 No. 320

2.00 mm 3.20 mm

25 thicknesses in0.05 mmincre ments

The thickness of each valve pad is marked inhundredths of millimeters on the side thattouches the valve lifter (not the camshaft).

Since valve pads of various sizes are originallyinstalled, the valve pad number must berounded in order to reach the closest equiva-lent to the original.

g. Round off the original valve pad number ac-cording to the following table.

3-7

MEASURED

CLEARANCE

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

INSTALLED PAD NUMBER

VALVE CLEARANCE (cold):0.11 0.15 mm

Example: Installed is 250Measured clearance is 0.23 mm

Replace 250 pad with 260 padPad number: (example)Pad No. 250 = 2.50 mmPad No. 260 = 2.60 mm

Always install pad with number down.

VALVE CLEARANCE (cold):0.16 0.20 mm

Example: Instaled is 250Measured clearance is 0.32 mm

Replace 250 pad with 265 padPad number: (example)Pad No. 250 = 2.50 mmPad No. 265 = 2.65 mm

Always install pad with number down.

STANDARD CLEARANCE

STANDARD CLEARANCE

ADJUSTING THE VALVE CLEARANCECHKADJ

INTAKE

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.00 0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 3100.06 0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 3150.11 0.150.16 0.20 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.21 0.25 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.26 0.30 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.31 0.35 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.36 0.40 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.41 0.45 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.46 0.50 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.51 0.55 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.56 0.60 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.61 0.65 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.66 0.70 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.71 0.75 260 265 270 275 280 285 290 295 300 305 310 315 3200.76 0.80 265 270 275 280 285 290 295 300 305 310 315 3200.81 0.85 270 275 280 285 290 295 300 305 310 315 3200.86 0.90 275 280 285 290 295 300 305 310 315 3200.91 0.95 280 285 290 295 300 305 310 315 3200.96 1.00 285 290 295 300 305 310 315 3201.01 1.05 290 295 300 305 310 315 3201.06 1.10 295 300 305 310 315 3201.11 1.15 300 305 310 315 3201.16 1.20 305 310 315 3201.21 1.25 310 315 3201.26 1.30 315 3201.31 1.35 320

EXHAUST

200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.00 0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 3050.06 0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 3100.11 0.15 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 3150.16 0.200.21 0.25 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.26 0.30 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.31 0.35 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.36 0.40 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.41 0.45 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.46 0.50 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.51 0.55 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.56 0.60 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.61 0.65 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.66 0.70 250 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.71 0.75 255 260 265 270 275 280 285 290 295 300 305 310 315 3200.76 0.80 260 265 270 275 280 285 290 295 300 305 310 315 3200.81 0.85 265 270 275 280 285 290 295 300 305 310 315 3200.86 0.90 270 275 280 285 290 295 300 305 310 315 3200.91 0.95 275 280 285 290 295 300 305 310 315 3200.96 1.00 280 285 290 295 300 305 310 315 3201.01 1.05 285 290 295 300 305 310 315 3201.06 1.10 290 295 300 305 310 315 3201.11 1.15 295 300 305 310 315 3201.16 1.20 300 305 310 315 3201.21 1.25 305 310 315 3201.26 1.30 310 315 3201.31 1.35 315 3201.36 1.40 320

3-8


NOTE:

NOTE:

EXAMPLE:Original valve pad number = 248 (thickness =2.48 mm (0.098 in))Rounded value = 250h. Locate the rounded number of the original

valve pad and the measured valve clearancein the valve pad selection table.The point where the column and row inter-sect is the new valve pad number.

The new valve pad number is only an approxi-mation. The valve clearance must be measuredagain and the above steps should be repeated ifthe measurement is still incorrect.

i. Install the new valve pad with the numberedside facing down.

j. Remove the tappet adjusting tool.INTAKEEXHAUSTk. Measure the valve clearance again.i. If the valve clearance is still out of specifica-

tion, repeat al of the valve clearance adjust-ment steps until the specified clearance isobtained.

6. Install:all removed parts

For installation, reverse the removal procedure.Note the following points.

7. Install: fuel tankside coversseatRefer to “SEAT, SIDE COVER AND FUELTANK”.

3-9

CHKADJSYNCHRONIZING THE CARBURETORS

NOTE:

NOTE:

NOTE:

EAS00050

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:side coversseat fuel tankRefer to “SEAT, SIDE COVER AND FUELTANK”.

3. Install:vacuum gauge 1engine tachometer 2(to the spark plug lead of cyl. #1)

Vacuum gauge90890-03094

Engine tachometer90890-03113

4. Start the engine and let it warm up for severalminutes.

5. Check:engine idling speedOut of specification Adjust.Refer to “ADJUSTING THE ENGINE IDLINGSPEED”.

Engine idling speed:1,000 1,100 r/min

6. Adjust:carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read thesame.

After each step, rev the engine two or threetimes, each time for less than a second, andcheck the synchronization again.

3-10

CHKADJ

SYNCHRONIZING THE CARBURETORSADJUSTING THE ENGINE IDLING SPEED

NOTE:

NOTE:

b. Synchronize carburetor #4 to carburetor #3by turning the synchronizing screw 2 in ei-ther direction until both gauges read thesame.

c. Synchronize carburetor #2 to carburetor #3by turning the synchronizing screw 3 in ei-ther direction until both gauges read thesame.

Vacuum pressure at engine idling speed:

31.3 kPa (235 mm Hg)

The difference in vacuum pressure betweentwo carburetors should not exceed 1.33 kPa (10mm Hg, 0.4 in Hg).

7. Check:engine idling speedOut of specification Adjust.

8. Stop the engine and remove the measuringequipment.

9. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.

Throttle cable free play (at the throttle grip):

3 5 mm

10. Install: fuel tankseatside coversRefer to “SEAT, SIDE COVER AND FUELTANK”.

EAS00054

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjustedproperly, the air filter should be clean, and theengine should have adequate compression.

1. Start the engine and let it warm up for severalminutes.

2. Install:engine tachometer 1(to the spark plug lead of cyl. #1)

3-11

CHKADJ

ADJUSTING THE ENGINE IDLING SPEEDADJUSTING THE THROTTLE CABLE FREE PLAY

a

b

NOTE:


3. Measure:engine idling speedOut of specification Adjust.

Engine idling speed1,000 1,100 r/min

4. Adjust:engine idling speed

a. Turn the pilot screw 1 in or out until it is light-ly seated.

b. Turn the pilot screw out the specified numberof turns.

Carburetor angle driver 290890-03158

Pilot screw1–1/2 turns out

c. Turn the throttle stop screw 1 in direction aor b until the specified engine idling speed isobtained.

Direction Engine idling speed is in-creased.

Direction Engine idling speed is de-creased.

5. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.

Throttle cable free play (at the flange of the throttle grip)

3 5 mm

EAS00055

ADJUSTING THE THROTTLE CABLE FREEPLAY

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

1. Check: throttle cable free play aOut of specification Adjust.

Throttle cable free play (at the flange of the throttle grip)

3 5 mm

3-12

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

NOTE:

a

b

WARNING

2. Remove: seat fuel tank

Refer to “SEAT, SIDE COVER AND FUELTANK”.

3. Adjust: throttle cable free play

When the motorcycle is accelerating, the acceler-ator cable 1 is pulled.

Carburetor sidea. Loosen the locknut 2 3 on the decelerator

cable.b. Turn the adjusting nut 4 in direction a or b to

take up any slack on the decelerator cable.c. Loosen the locknut 5 on the accelerator

cable.d. Turn the adjusting nut 6 in direction a or b

until the specified throttle cable free play is ob-tained.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.

e. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable, usethe adjusting nut on the handlebar side.

Handlebar sidea. Loosen the locknut 7 .b. Turn the adjusting nut 8 in direction a or b

until the specified throttle cable free play is ob-tained.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.

c. Tighten the locknut.

After adjusting the throttle cable free play, turnthe handlebar to the right and to the left to en-sure that this does not cause the engine idlingspeed to change.

4. Install: fuel tank seat

Refer to “SEAT, SIDE COVER AND FUELTANK”.

3-13

CHECKING THE SPARK PLUGSCHECKING THE IGNITION TIMING

CHKADJ

CAUTION:

NOTE:

NOTE:

EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Disconnect:spark plug cap

2. Remove:spark plug

Before removing the spark plugs, blow awayany dirt accumulated in the spark plug wellswith compressed air to prevent it from fal-ling into the cylinders.

3. Check:spark plug typeIncorrect Change.

Spark plug type (manufacturer)DPR8EA-9 (NGK)X24EPR-U9 (DENSO)

4. Checkelectrode 1Damage/wear Replace the spark plug.

insulator 2Abnormal color Replace the spark plug.Normal color is a medium-to-light tan color.

5. Clean:spark plug(with a spark plug cleaner or wire brush)

6. Measure:spark plug gap a(with a wire gauge)Out of specification Regap.

Spark plug gap0.8 0.9 mm

7. Install:spark plug

Spark plug18 Nm (1.8 mkg)

Before installing the spark plug clean the sparkplug and gasket surface.

8. Connect:spark plug cap

EAS00063

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.

1. Remove: timing plate cover 1

3-14

CHKADJ

CHECKING THE IGNITION TIMINGMEASURING THE COMPRESSION PRESSURE

NOTE:

NOTE:

2. Install: timing light 1engine tachometer 2(to the spark plug lead of cyl. #1)

Timing light90890-03141


3. Check: ignition timing

a. Start the engine, warm it up for several min-utes, and then let it run at the specified en-gine idling speed.


b. Check that the pickup coil a is within the fir-ing range b on th timing plate.Incorrect firing range Check the ignitionsystem.

The ignition timing is not adjustable.

4. Remove:engine tachometer timing light

5. Install: timing plate cover

Timing plate cover bolt:7 Nm (0.7 mkg)LOCTITE

EAS00065

MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Check:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3-15

CHKADJMEASURING THE COMPRESSION PRESSURE

CAUTION:

3. Disconnect:spark plug cap

4. Remove:spark plug

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

5. Install:compression gauge 1adapter 2

Compression gauge90890-03081

Adapter90890-04082

6. Measure:compression pressureAbove the maximum pressure Inspect thecylinder head, valve surfaces, and pistoncrown for carbon deposits.Below the minimum pressure Squirt a fewdrops of oil into the affected cylinder andmeasure again.

Refer to the following table.

Compression pressure(With oil applied into cylinder)

Reading Diagnosis

Higher thanwithout oil

Piston wear or damage Repair.

Same aswithout oil

Piston ring(-s), valves, cyl-inder head gasketor piston possibly defec-tive Repair.Compression pressure (atsea level)

Compression pressure (at sea lev-el):Standard:

1,050 kPa (10.5 kg/cm 2, 10.5 bar)/400 r/min.

Minimum:900 kPa (9.0 kg/cm 2, 9.0 bar)/400 r/min.

Maximum:1,200 kPa (12.0 kg/cm 2, 12.0 bar)/400 r/min.

3-16

CHKADJ

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

WARNING

NOTE:

NOTE:

a. Turn the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar).

7. Install:spark plug

Spark plug18 Nm (1.8 mkg)

8. Connect:spark plug cap

EAS00069

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes, andthen stop it.

3. Check:engine oil levelThe engine oil level should be between theminimum level marks a and maximum levelmarks b .Below the minimum level mark Add therecommended engine oil to the proper level.

Recommended engine oilRefer to the chart for the en-gine oil grade which is best suited for certain atmospheric temperatures.API standard

SE or higher gradeACEA standard

G4 or G5

3-17

CHKADJ

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

CAUTION:

NOTE:

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD a or higher and donot use oils labeled “ENERGY CONSERV-ING II” b or higher.

Do not allow foreign materials to enter thecrankcase.


5. Check the engine oil level again.

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EAS00075

CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-

utes, and then turn it off.2. Place a container under the engine oil drain

bolt.3. Remove:engine oil filler capengine oil drain bolt 1

4. Drain:engine oil(completely from the crankcase)

5. If the oil filter element is also to be replaced,perform the following procedure.

a. Remove the oil filter element cover 1 and oilfilter element 2 .

b. Check the O-ring 3 and replace it of it iscracked or damage.

c. Install the new oil filter element and the oil fil-ter element cover.

Oil filter element cover bolt15 Nm (1.5 mkg)

6. Check:engine oil drain bolt gasketDamage Replace.

7. Install:engine oil drain bolt

Engine oil drain bolt43 Nm (4.3 mkg)

8. Fill:crankcase(with the specified amount of the recom-mended engine oil)

3-18

CHKADJ

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CAUTION:

WARNING

QuantityTotal amount

4.2 LWithout oil filter element re-placement

3 LWith oil filter element replace-ment

3.35 L

9. Install:engine oil filler cap


11. Check;engine(for engine oil leaks)

12. Check:engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.

EAS00077

MEASURING THE ENGINE OIL PRESSURE1. Check:engine oil levelBelow the minimum level mark Add therecommended engine oil to the proper level.


When the engine is cold, the engine oil willhave a higher viscosity, causing the engineoil pressure to increase. Therefore, be sureto measure the engine oil pressure afterwarming up the engine.

3. Remove:main gallery bolt

The engine, muffler and engine oil are ex-tremely hot.

4. Install:oil pressure gauge 1oil pressure adapter B 2

Oil pressure gauge90890-03153

Oil pressure adapter B90890-03124

5. Measure:engine oil pressure(at the following conditions)

3-19

MEASURING THE ENGINE OIL PRESSURE/ADJUSTING THE CLUTCH LEVER

CHKADJ

NOTE:

b a

ac

WARNING

Engine oil pressure80 kPa (0.8 kg/cm 2, 0.8 bar)

Engine speedApprox. 1000 r/min

Engine oil temperature70 80C (158 176F)

Out of specification Adjust.

Engine oil pressure Possible causes

Below specification

Faulty oil pumpClogged oil filterLeaking oil passageBroken or damagedoil seal

Above specificationLeaking oil passageFaulty oil filterOil viscosity too high

6. Install:main gallery bolt

Main gallery bolt12 Nm (1.2 mkg)

EAS00082

ADJUSTING THE CLUTCH LEVER1. Adjust:clutch lever position(distance a from the handlebar grip to theclutch lever)

a. While pushing the clutch lever forward, turnthe adjusting dial 1 until the clutch lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the clutch lever hold-er.

Position #1 Distance is the larg-est

Position #4 Distance is the small-est

After adjusting the clutch lever position,make sure that the pin on the clutch leverholder is firmly inserted in the hole in the ad-justing dial.

3-20

CHKADJ

CHECKING THE CLUTCH FLUID LEVEL/BLEEDING THE HYDRAULIC CLUTCH SYSTEM

NOTE:

WARNING

CAUTION:

NOTE:

WARNING

EAS00083

CHECKING THE CLUTCH FLUID LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Check:clutch fluid levelBelow the minimum level mark a Add therecommended clutch fluid to the proper lev-el.

Recommended clutch fluidBrake fluid DOT 4

Use only the designated clutch fluid. Otherclutch fluids may cause the rubber seals todeteriorate, causing leakage and poorclutch performance.

Refill with the same type of clutch fluid thatis already in the system. Mixing clutchfluids may result in a harmful chemicalreaction, leading to poor clutch perfor-mance.

When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the clutchfluid and could cause vapor lock.

Clutch fluid may damage painted surfacesor plastic parts. Therefore, always clean upany spilt clutch fluid immediately.

In order to ensure a correct reading of the clutchfluid level, make sure that the top of the reser-voir is horizontal.

EAS00084

BLEEDING THE HYDRAULIC CLUTCH SYS-TEM

Bleed the hydraulic clutch system whenev-er: the system was disassembled,a clutch hose was loosened or removed, the clutch fluid level is very low,clutch operation is faulty.

3-21

CHKADJBLEEDING THE HYDRAULIC CLUTCH SYSTEM

NOTE:

WARNING

Be careful not to spill any clutch fluid or allowthe clutch master cylinder reservoir to over-flow.

When bleeding the hydraulic clutch system,make sure that there is always enough clutchfluid before applying the clutch lever. Ignoringthis precaution could allow air to enter the hy-draulic clutch system, considerably lengthen-ing the bleeding procedure.

If bleeding is difficult, it may be necessary to letthe clutch fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

1. Bleed:hydraulic clutch system

a. Add the recommended clutch fluid to theproper level.

b. Install the clutch master cylinder reservoir di-aphragm.

c. Connect a clear plastic hose 1 tightly to thebleed screw 2 .

d. Place the other end of the hose into a con-tainer.

e. Slowly squeeze the clutch lever severaltimes.

f. Fully squeeze the clutch lever without re-leasing it.

g. Loosen the bleed screw.This will release the tension and cause theclutch lever to contact the handlebar grip.

h. Tighten the bleed screw and then release theclutch lever.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the clutchfluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mkg)

k. Add the recommended clutch fluid to theproper level.Refer to “CHECKING THE CLUTCH FLUIDLEVEL”.

After bleeding the hydraulic clutch system,check the clutch operation.

3-22

CHKADJCLEANING THE AIR FILTER ELEMENT

CAUTION:

NOTE:

EAS00087

CLEANING THE AIR FILTER ELEMENT1. Remove:side cover (right)Refer to “SEAT, SIDE COVER AND FUELTANK”.

air filter case cover 12. Remove:air filter element 2

3. Clean:air filter element 1Apply compressed air to the inner surface ofthe air filter element.

4. Check:air filter elementDamage Replace.

5. Install:air filter elementair filter case cover(along with the gasket)

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the air filter element will also affectthe carburetor tuning, leading to poor en-gine performance and possible overheat-ing.

Make sure that the air filter element is properlyinstalled in the air filter case.

6. Install:side cover (right)Refer to “SEAT, SIDE COVER AND FUELTANK”.

3-23

CHKADJCHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/

CHECKING THE FUEL AND VACUUM HOSESEAS00095

CHECKING THE CARBURETOR JOINTSAND INTAKE MANIFOLDSThe following procedure applies to all of the car-buretor joints and intake manifolds.1. Remove:seatside cover fuel tankRefer to “SEAT, SIDE COVER AND FUELTANK”.

2. Check:carburetor joint 1 intake manifold 2Cracks/damage Replace.Refer to “CARBURETOR” in chapter 6.

3. Install: fuel tankside coverseatRefer to “SEAT, SIDE COVER AND FUELTANK”.

EAS00096

CHECKING THE FUEL AND VACUUMHOSESThe following procedure applies to all of the fueland vacuum hoses.1. Remove:seat fuel tankRefer to “SEAT, SIDE COVER AND FUELTANK”.

2. Check:vacuum hose 1 fuel hose 2Cracks/damage Replace.Loose connection Connect properly.

3. Install: fuel tankseatRefer to “SEAT, SIDE COVER AND FUELTANK”.

3-24

CHKADJ

CHECKING THE CRANKCASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM

CAUTION:

EAS00098

CHECKING THE CRANKCASE BREATHERHOSEEAS00100

1. Check:crankcase breather hose 1Cracks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.

EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes, mufflers and gaskets.1. Check:exhaust pipe 1muffler 2Cracks/damage Replace.

gasket 3 , 4 , 5Exhaust gas leaks Replace.

2. Check: tightening torque

Exhaust pipe nut 625 Nm (2.5 mkg)

Exhaust pipe and exhaustchamber screw 720 Nm (2.0 mkg)

Muffler bracket bolt 820 Nm (2.0 mkg)

Exhaust chamber bolt 925 Nm (2.5 mkg)

Exhaust chamber and muffler bolt10

20 Nm (2.0 mkg)Muffler and stay bolt 11

20 Nm (2.0 mkg)

3-25

CHKADJ

ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE

NOTE:

b a

ac

WARNING

a

b

WARNING

EAS00107

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:brake lever position(distance a from the throttle grip to thebrake lever)

a. While pushing the brake lever forward, turnthe adjusting dial 1 until the brake lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the larg-est.

Position #4 Distance is the small-est.

After adjusting the brake lever position,make sure that the pin on the brake leverholder is firmly inserted in the hole in the ad-justing dial.

EAS00110

ADJUSTING THE REAR BRAKE1. Check:brake pedal position(distance a from the top of the rider footrestto the top of the brake pedal)Out of specification Adjust.

Brake pedal position (below the top of the rider footrest)

45 mm

2. Adjust:brake pedal position

a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified brake pedal position is ob-tained.

DirectionBrake pedal is lowered.

DirectionBrake pedal is raised.

After adjusting the brake pedal position,check that the end of the adjusting bolt 2 isvisible through the hole 3 .

3-26

CHKADJ

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

A B

WARNING

CAUTION:

NOTE:

WARNING

EAS00110

c. Tighten the locknut 1 to specification.

Locknut18 Nm (1.8 mkg)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, inspect and, if nec-essary, bleed the brake system.

After adjusting the brake pedal position,make sure that there is no brake drag.

3. Adjust: rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.

EAS00115

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.

2. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brakeB Rear brake

Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

3-27

CHKADJ

CHECKING THE BRAKE FLUID LEVEL/CHECKING THE BRAKE PADS/

ADJUSTING THE REAR BRAKE LIGHT SWITCH

A B

CAUTION:

NOTE:

NOTE:

a

b

When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure that the top of the reser-voir is horizontal.

EAS00118

CHECKING THE BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check: front brake pad rear brake padBrake pad almost worn to the wear indicatorline 1 Replace the brake pads as a set.Refer to “REPLACING THE FRONT BRAKEPADS” and “REPLACING THE REARBRAKE PADS” in chapter 6.

A Front brakeB Rear brake

EAS00128

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated by move-ment of the brake pedal.The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.

1. Check: rear brake light operation timingIncorrect Adjust.

2. Adjust: rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction Brake light comes onsooner.

Direction Brake light comes on later.

3-28

A

B

CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING

NOTE:

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS-TEM

Bleed the hydraulic brake system whenev-er: the system was disassembled,a brake hose was loosened or removed, the brake fluid level is very low,brake operation is faulty.

Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir or brakefluid reservoir to overflow.

When bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours.Repeat the bleeding procedure when the tinybubbles in the hose have disappeared.

1. Bleed:hydraulic brake system

a. Add the recommended brake fluid to theproper level.

b. Install the diaphragm (brake master cylinderreservoir or brake fluid reservoir).

c. Connect a clear plastic hose 1 tightly to thebleed screw 2 .

A FrontB Reard. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.g. Loosen the bleed screw.

This will release the tension and cause thebrake lever to contact the throttle grip or thebrake pedal to fully extend.

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

3-29

CHKADJ

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL/

ADJUSTING THE DRIVE CHAIN SLACK

WARNING

a

b

NOTE:

CAUTION:


k. Fill the reservoir to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

After bleeding the hydraulic brake system,check the brake operation.

EAS00136

ADJUSTING THE SHIFT PEDAL1. Check:shift pedal positionThe end 1 of the shift pedal is above the shiftrod. (The angle a should be approximately90.)Incorrect Adjust.

2. Adjust:shift pedal position

a. Loosen both locknuts 2 .b. Turn the shift rod 3 in direction a or b to

obtain the correct shift pedal position.

Direction Shift pedal is raised.

Direction Shift pedal is lowered.

Tighten both locknuts.

EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

The drive chain slack must be checked at thetightest point on the chain.

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swin-garm or cause an accident. Therefore, keepthe drive chain slack within the specifiedlimits.

3-30

CHKADJADJUSTING THE DRIVE CHAIN SLACK

WARNING

NOTE:

a

b

NOTE:

WARNING

1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.

2. Rotate the rear wheel several times andcheck the drive chain to locate its tightestpoint.

3. Check:drive chain slack aOut of specification Adjust.

Drive chain slack20 30 mm

4. Adjust:drive chain slack

a. Loosen the tensionbar bolt .b. Loosen the wheel axle nut 1 .c. Loosen both locknuts 2 .d. Turn both adjusting bolt 3 in direction a or

b until the specified drive chain slack is ob-tained.

Direction Drive chain is tightened.

Direction Drive chain is loosened.

To maintain the proper wheel alignment, adjustboth sides evenly.

f. Tighten both locknuts to specification.

Locknut16 Nm (1.6 mkg)

g. Tighten the wheel axle nut to specification.

Wheel axle nut150 Nm (15.0 mkg)

Always use a new cotter pin.

3-31

CHKADJ

ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN

CAUTION:

Do not loosen the wheel axle nut after tight-ening it to the specified torque. If the groovein the wheel axle nut is not aligned with thecotter pin hole in the wheel axle, tighten thenut further until they are aligned.

i. Tighten the tensionbar bolt to specification.

Tensionbar bolt23 Nm (2.3 mkg)

EAS00142

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained prop-erly, it will wear out rapidly.Therefore, the drive chain should be serviced,especially when the motorcycle is used in dustyareas. This motorcycle has a drive chain withsmall rubber O-rings 1 between each sideplate. Steam cleaning, high-pressure washing,certain solvents, and the use of a coarse brushcan damage these O-rings. therefore, use onlykerosine to clean the drive chain. Wipe the drivechain dry and thoroughly lubricate it with engineoil or chain lubricant that is suitable for O-ringchains. Do not use any other lubricants on thedrive chain since they may contain solvents thatcould damage the O-rings.

Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains

3-32

CHKADJCHECKING AND ADJUSTING THE STEERING HEAD

WARNING

NOTE:

EAS00146

CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding Adjust the steeringhead.

3. Remove:seat fuel tankRefer to “SEAT, SIDE COVER AND FUELTANK”.

4. Remove:headlight unit 1

5. Remove:headlight body 1

6. Disconnect:speed meter cable 1

7. Remove:meter assembly 2headlight stay 3

3-33

CHKADJCHECKING AND ADJUSTING THE STEERING HEAD

–0.2po

NOTE:

WARNING

8. Remove:upper handleber holder 1handleber 2

9. Remove:handle crown 1

10. Adjust:steering head

a. Remove the lock washer 1 , the upper ringnut 2 , and the rubber washer 3 .

b. Loosen the lower ring nut 4 and then tightenit to specification with a ring nut wrench 5 .

Set the torque wrench at a right angle to the ringnut wrench.

Ring nut wrench90890-01403

Lower ring nut (initial tightening torque)

52 Nm (5.2 mkg)

c. Loosen the lower ring nut 4 completely,then tighten it to specification.

Do not overtighten the lower ring nut.

Lower ring nut (final tightening torque)

18 Nm (1.8 mkg)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and inspect the upper andlower bearings.Refer to “STEERING HEAD AND HAN-DLEBAR” in chapter 7.

3-34

CHKADJ

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK

NOTE:

WARNING

e. Install the rubber washer 3 .f. Install the upper ring nut 2 .g. 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 upperring nut until their slots are aligned.

h. Install the lock washer 1 .

Make sure that the lock washer tabs a sit cor-rectly in the ring nut slots b .

11. Install:handle crown

Steering stem nut110 Nm (11.0 mkg)

Upper bracket pinch bolt30 Nm (3.0 mkg)

12. Install:handlebar

13. Install:upper handlebar holder

Handlebar holder bolt23 Nm (2.3 mkg)

EAS00149

CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.


2. Check: inner tubeDamage/scratches Replace.

oil sealOil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check:operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Unsmooth operation Repair.Refer to “FRONT FORK” in chapter 6.

3-35

CHKADJADJUSTING THE FRONT FORK LEGS

WARNING

CAUTION:

a

b

ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability.


Spring preload

Grooves are provided to indicate the ad-justment position.

Never go beyond the maximum or mini-mum adjustment positions.

1. Adjust:spring preload

a. Turn the adjusting bolt 1 in direction a orb .

DirectionSpring preload is in-creased (suspension isharder).

DirectionSpring preload is de-creased (suspension issofter).

EAS00155

Adjusting positionsStandard: 5Minimum: 7 (Soft)Maximum: 1 (Hard)

3-36

CHKADJADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES

WARNING

CAUTION:

NOTE:

a

b

EAS00161

ADJUSTING THE REAR SHOCK ABSORB-ER ASSEMBLIESThe following procedure applies to both of therear shock absorber assemblies.


Always adjust both rear shock absorberassemblies evenly. Uneven adjustmentcan result in poor handling and loss of sta-bility.

Spring preload

Never go beyond the maximum or minimumadjustment positions.

1. Adjust:spring preload

Adjust the spring preload with the specialwrench and extension bar in cluded in the own-er’s tool kit.

a. Turn the spring seat 1 in direction a or b .

Direction Spring preload is increased(suspension is harder).

Direction Spring preload is decreased(suspension is softer).

Adjusting positionsStandard: 1Minimum: 1Maximum: 3

3-37

CHKADJCHECKING THE TIRES

WARNING

EAS00162

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure: tire pressureOut of specification Regulate.

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.

Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

Basic weight(with oil and a fullfuel tank)

253 kg

Maxim m load 207 kgMaxim um load 207 kg

Cold tire pressure Front tire Rear tire

Up to 90 kgload*

250 kPa(2.5 kg/cm 2,

2.5 bar)

250 kPa(2.5 kg/cm 2,

2.5 bar)

90 kg Maximum load*

250 kPa(2.5 kg/cm 2,

2.5 bar)

290 kPa(2.9 kg/cm 2,

2.9 bar)

High speedriding

250 kPa(2.5 kg/cm 2,

2.5 bar)

290 kPa(2.9 kg/cm 2,

2.9 bar)

* Load is the total weight of cargo, rider, pas-senger and accessories

3-38

CHKADJCHECKING THE TIRES

A B

WARNING

WARNING

It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.

2. Check: tire surfacesDamage/wear Replace the tire.

Minimum tire tread depth1.6 mm

1 Tire tread depth2 Side wall3 Wear indicator

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from sudden defla-tion.

When using a tube tire, be sure to install thecorrect tube.

Always replace a new tube tire and a newtube as a set.

To avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe wheel groove.

Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement.

A Tire B Wheel

Tube wheel Tube tire only

Tubebeless wheel Tube or tubeless tire

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufactur-er and of the same design. No guaranteeconcerning handling characteristics canbe given if a tire combination other thanone approved by Yamaha is used on thismotorcycle.

3-39

CHKADJCHECKING THE TIRES/CHECKING THE WHEELS

WARNING

NOTE:

WARNING

NOTE:

Front tire

Manufacturer Size Type

MICHELIN 120/70ZR17 MACADAM 90X

DUNLOP 120/70ZR17 D207F

BRIDGESTONE 120/70ZR17 BT57F

Rear tire

Manufacturer Size Type

MICHELIN 180/55ZR17 MACADAM 90X

DUNLOP 180/55ZR17 D207

BRIDGESTONE 180/55ZR17 BT57R

New tires have a relatively low grip on theroad surface until they have been slightlyworn.Therefore, approximately 100 km should betraveled at normal speed before any high-speed riding is done.

For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in thedirection of wheel rotation.

Align the mark 2 with the valve installationpoint.

EAS00168

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:wheelDamage/out-of-round Replace.

Never attempt to make any repairs to thewheel.

After a tire or wheel has been changed or re-placed, always balance the wheel.

3-40

CHKADJ

CHECKING ANDLUBRICATING THE CABLES/LUBRICATING THELEVERS AND PEDALS LUBRICATING THE SIDE STAND/LUBRICATING

THE CENTERSTAND LUBRICATING THE REAR SUSPENSION

WARNING

NOTE:

EAS00170

CHECKING AND LUBRICATING THE CABLESThe following procedure applies to all of thecable sheaths and cables.

Damaged cable sheaths may cause thecable to corrode and interfere with its move-ment. Replace damaged cable sheaths andcables as soon as possible.

1. Check:cable sheathDamage Replace.

2. Check:cable operationUnsmooth operation Lubricate.

Recommended lubricantEngine oil or a suitable cable lubricant

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubing device.

EAS00171

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantEngine oil

EAS00172

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.


EAS00173

LUBRICATING THE CENTERSTANDLubricate the pivoting point and metal-to-metalmoving parts of the centerstand.


EAS00174

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.

Recommended lubricantMolydenum disulfide grease

3-41

CHKADJCHECKING AND CHARGING THE BATTERY

WARNING

CAUTION:

EAS00178

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.

Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

First aid in case of bodily contact:ExternalSKIN – Wash with water.EYES – Flush with water for 15 minutes andget immediate medical attention.

InternalDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medical atten-tion.

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and batteryperformance will deteriorate.

Charging time, charging amperage andcharging voltage for a MF battery are differ-ent from those of conventional batteries.The MF battery should be charged as ex-plained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when chargingthe battery.

3-42


NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove:seat

2. Disconnect:battery leads(from the battery terminals)

First, disconnect the negative lead 1 , thenthe positive lead 2 .

3. Remove:battery

4. Check:battery charge

a. Connect a pocket tester to the battery termi-nals.

Tester positive lead battery positiveterminalTester negative lead battery negativeterminal

The charge state of a MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive terminal isdisconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 30 %

5. Charge:battery(refer to the appropriate charging method il-lustration)

3-43


WARNING

CAUTION:

Do not quick charge a battery.

Make sure that the battery vent is free of ob-structions.

Never remove the MF battery sealing caps.Do not use a high-rate battery charger.They force a high-amperage current intothe battery quickly and can cause batteryoverheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

When charging a battery, be sure to removeit from the motorcycle. (If charging has tobe done with the battery mounted on themotorcycle, disconnect the negative leadfrom the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure that the battery charger leadclips are in full contact with the battery ter-minal and that they are not shorted. A cor-roded battery charger lead clip may gener-ate heat in the contact area and a weak clipspring may cause sparks.

If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!

As shown in the following illustration, theopen-circuit voltage of a MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30minutes after charging is completed beforemeasuring the open-circuit voltage.

3-44

Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Adjust the charging voltage to20 25 V.

Adjust the voltage to obtain thestandard charging amperage.

Monitor the amperage for 3 5 minutes. Is the standardcharging amperage exceed-ed?

Set the timer to the chargingtime determined by the open-circuit voltage.Refer to “CHECKING ANDCHARGING THE BATTERY”.

If the amperage does notexceed the standard charg-ing amperage after 5 min-utes, replace the battery.

If the required charging time exceeds 5 hours, it is advisable to checkthe charging amperage after 5 hours. If there is any change in the am-perage, readjust the voltage to obtain the standard charging amper-age.

Leave the battery unused for more than 30 minutes before measur-ing its open-circuit voltage.12.8 V Charging is complete.12.0 12.7 V Recharging is required.Under 12.0 V Replace the battery.

YES NO

YES

NO

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

NOTE:Set the charging voltage to 16 17 V.(If the charging voltage is lower charg-ing will be insufficient, if it is higher, thebattery will be over-charged.)

ChargerAmmeter


Charging method using a variable-voltage charger

3-45


Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Charge the battery until the chargingvoltage reaches 15 V.

This type of battery charger cannotcharge an MF battery. A variable-voltage charger is recommended.

Leave the battery unused for morethan 30 minutes before measuring itsopen-circuit voltage.12.8 V Charging is complete.12.0 12.7 V Recharging is re-quired.Under 12.0 V Replace the battery.

NOTE:Set the charging time to a maximum of20 hours.

YES NO

Voltmeter

Charger

Ammeter

CAUTION:Constant amperage chargers are notsuitable for charging MF battries.

Charging method using a constant-voltage charger

3-46

CHKADJ

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

CAUTION:

CAUTION:

NOTE:

6. Check:battery ventObstruction Clean.Damage Replace.

7. Install:battery

8. Connect:battery leads(to the battery terminals)

First, connect the positive lead 1 , then thenegative lead 2 .

9. Check:battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.

10. Lubricate:battery terminals

Recommended lubricantDielectric grease

11. Install:seat

EAS00181

CHECKING THE FUSESThe following procedure applies to all of thefuses.

To avoid a short circuit, always turn the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove:seat

2. Check: fuse

a. Connect the pocket tester to the fuse andcheck the continuity.

Set the pocket tester selector to “Ω x 1”.

3-47

CHKADJCHECKING THE FUSES

WARNING


b. If the pocket tester indicates “∞”, replace thefuse.

3. Replace:blown fuse

a. Turn off the ignition.b. Install a new fuse of the correct amperage

rating.c. Turn on the switches to verify if the electrical

circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

Fuses Amperage rating Quantity

Mainfuse

30 A 1

Headlightfuse

15 A 1

Signaling systemfuse

15 A 1

Ignitionfuse

7.5 A 1

Reserve 30 A 1

15 A 1

7.5 A 1

Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the wrong amperage ratingmay cause extensive damage to the electri-cal system, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.

4. Install:seat

3-48

CHKADJREPLACING THE HEADLIGHT BULB

WARNING

CAUTION:

EAS00182

REPLACING THE HEADLIGHT BULB1. Remove:headlight unit 1

2. Disconnect:headlight lead 1auxiliary light lead 2

3. Remove:cover 3

4. Remove:headlight bulb holder 1

5. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

6. Install:headlight bulb (New)Secure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

3-49

CHKADJ

REPLACING THE HEADLIGHT BULB/ADJUSTING THE HEADLIGHT BEAM

a

b

a

b

7. Install:headlight bulb holder

8. Install:cover

9. Connect:auxiliary light leadheadlight lead

10. Install:headlight unit

EAS00184

ADJUSTING THE HEADLIGHT BEAM1. Adjust:headlight beam (vertically)

a. Turn the adjusting screw 1 in direction a orb .

Direction Headlight beam is raised.

Direction Headlight beam is lowered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 2 in direction a orb .

Direction Headlight beam moves tothe right.

Direction Headlight beam moves tothe left.

CHKADJ

ENG

CHAPTER 4.ENGINE OVERHAUL

ENGINE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS, HOSES AND EXHAUST PIPES 4-1. . . . . . . . . . . . . . . . . . . . . . . LEADS AND DRIVE SPROCET 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFT SPROCKETS AND TIMING CHAINGUIDES 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 4-11. . . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEAD 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEAD 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 4-17. . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 4-20. . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDERS AND PISTONS 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDERS AND PISTONS 4-27. . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS 4-27. . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PISTONS AND CYLINDERS 4-30. . . . . . . . . . . . . . . . .

CLUTCH 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRING PLATE 4-36. . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 4-36. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRING 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRING PLATE 4-36. . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 4-37. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

CHECKING THE PRESSURE PLATE 4-37. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PUSH RODS 4-38. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH MASTER CYLINDER 4-43. . . . . . . . . . . . . . . ASSEMBLING THE CLUTCH MASTER CYLINDER 4-44. . . . . . . . . . . . . INSTALLING THE CLUTCH MASTER CYLINDER 4-44. . . . . . . . . . . . . . CLUTCH RELEASE CYLINDER 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CLUTCH RELEASE CYLINDER 4-49. . . . . . . . . CHECKING THE CLUTCH RELEASE CYLINDER 4-49. . . . . . . . . . . . . . . INSTALLING THE CLUTCH RELEASE CYLINDER 4-50. . . . . . . . . . . . . .

OIL PUMP 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING PLATE AND PICKUP COIL 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPES 4-61. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 4-65. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER CLUTCH 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 4-70. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE GENERATOR SHAFT 4-71. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH ROLLER 4-71. . . . . . . . . . . . . . . .

CRANKSHAFT 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING ROD 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 4-74. . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS 4-74. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS 4-74. . . . CHECKING THE TIMING CHAIN 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HY-VO CHAIN 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

CHECKING THE BEARINGS AND OIL SEALS 4-79. . . . . . . . . . . . . . . . . CHECKING THE CIRCLIPS AND WASHERS 4-79. . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING RODS 4-79. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT 4-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 4-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT CAM AND SHIFT FORK 4-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORK 4-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 4-86. . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 4-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 4-87INSTALLING THE TRANSMISSION 4-88. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

ENGENGINE


12345678

Removing the leads, hoses and ex-haust pipesSeat, side cover, fuel tank

CarburetorEngine oilExhaust bandExhaust pipeGasketMuffler left /rightExhaust chamberExhaust chamber bracketOil coolerAir duct left /right

644

1/1111

1/1


Refer to “SEAT, SIDE COVER ANDFUEL TANK” in Chapter 3.Refer to “CARBURETOR” in Chapter 5.Drain

12 Nm (1.2 mkg)

20 Nm (2.0 mkg)

20 Nm (2.0 mkg)

25 Nm (2.5 mkg)

25 Nm (2.5 mkg)

20 Nm (2.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

NewNew

EAS0018

ENGINE OVERHAULEENGINELEADS, HOSES AND EXHAUST PIPES

4-2

ENGENGINE


O-ringGround lead

Crankcase breather hose

21

1For installation, reverse the removal pro-cedure.

Disconnect ground lead.NOTE:

910

11

12 Nm (1.2 mkg)

20 Nm (2.0 mkg)

25 Nm (2.5 mkg)

25 Nm (2.5 mkg)

20 Nm (2.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

20 Nm (2.0 mkg)

NewNew

4-3


1

23456789

1011

Removing the leads and drivesprocketStarter motor lead

Starter motorPickup/neutral switch leadA.C. generator leadA.C. generatorClutch release cylinder comp.Shift armDrive sprocket coverDowel pinsGasketNut

1

1111111211


Refer to “INSTALLING THE ENGINE”

Disconnect starter motor lead.NOTE:

25 Nm (2.5 mkg)

10 Nm (1.0 mkg)

85 Nm (8.5 mkg)

10 Nm (1.0 mkg)

10.Nm (1.0 mkg)

New

New

ENGENGINE

EAS00190

LEADS AND DRIVE SPROCKET

4-4

ENGENGINE


121314

Lock washerDrive sprocketDrive chain

111

For installation, reverse the removalprocedure.

25 Nm (2.5 mkg)

10 Nm (1.0 mkg)

85 Nm (8.5 mkg)

10 Nm (1.0 mkg)

10.Nm (1.0 mkg)

New

New

4-5


12

34567

Removing the engineFootrestDown tube

Engine bracket (front)SpacerEngine bracket (rear upper) left, rightEngine bracket (rear lower)Engine

11

21211



Place a suitable stand under the frame and engine.

NOTE:

Refer to “INSTALLING THE ENGINE”.

88 Nm (8.8 mkg)

28 Nm (2.8 mkg)

26 Nm (2.6 mkg)

30 Nm (3.0 mkg)

64 Nm (6.4 mkg)

48 Nm (4.8 mkg)

55 Nm (5.5 mkg)

64 Nm (6.4 mkg)

ENGENGINE

ENGINE

4-6

ENGENGINE

NOTE:

EAS00192

INSTALLING THE ENGINE1. Tighten the bolts in the following order.

Bolt 1 :88 Nm (8.8 mkg)

Bolt 2 :48 Nm (4.8 mkg)

Bolt 3 :55 Nm (5.5 mkg)

Bolt 4 :30 Nm (3.0 mkg)

Bolt 5 :64 Nm (6.4 mkg)

Nut 6 :64 Nm (6.4 mkg)

2. Install:shift arm 1

Align the punch mark b in the shift shaft withthe punched mark a on the shift arm.

Align the bottom edge of the shift pedal withthe mark on the frame-to-swingarm bracket.

Shift arm bolt10 Nm (1.0 mkg)

4-7

ENGCAMSHAFT


12345

Removing the cylinder head coversSeat, fuel tank

BoltsAir duct (left /right)Plug capCylinder head coverGasket

21/1411

Remove the parts in the order listed.Refer to “SEAT, SIDE COVER ANDFUEL TANK”.


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

CAMSHAFTCYLINDER HEAD COVER

4-8


123456789

10

Removing the camshaftsSpark plugsTiming plate cover/GasketTiming chain guide (top side)Timing chain tensioner assemblyTiming chain guide (exhaust side)Camshaft capsDowel pinsCamshaft (intake)Camshaft (exhaust)Camshaft sprockets

41/11118

16112



Refer to “REMOVING/INSTALLINGTHE CAMSHAFTS”.

12 Nm (1.2 mkg)

18 Nm (1.8 mkg)

20 Nm (2.0 mkg)

20 Nm (2.0 mkg)

10 Nm (1.0 mkg)

New

ENGCAMSHAFTS

EAS00196

CAMSHAFTS

4-9

ENGCAMSHAFTS

NOTE:

NOTE:

NOTE:

CAUTION:

EAS00199

REMOVING THE CAMSHAFTS1. Align: “T” mark on the timing plate(with the stationary pointer on the pickup coilbase plate)

a. Turn the crankshaft counterclockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the “T” mark a with thepickup coil mark b .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

2. Remove: timing chain guide (top side) 1

3. Loosen:camshaft sprocket bolts

4. Loosen:cap bolt 2

5. Remove: timing chain tensioner

To prevent the timing chain from falling into thecrankcase, fasten it with a wire 5 .

6. Remove: timing chain guide (exhaust side)camshaft caps 3

For reference during installation, put identifica-tion marks on each camshaft cap.

To prevent damage to the cylinder head,camshafts or camshaft caps, loosen thecamshaft cap bolts in stages and in a criss-cross pattern, working from the outside in.

7. Remove: intake camshaft 6exhaust camshaft 7camshaft sprockets 4

4-10

ENGCAMSHAFTS

NOTE:

EAS000204

CHECKING THE CAMSHAFTS1. Check:camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.

2. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.

Camshaft lobe dimension limitIntake/exhaust

a Wear limit <28.15 mm>b Wear limit <35.85 mm>

3. Measure:camshaft runoutOut of specification Replace.

Camshaft runoutLess than 0.03 mm

4. Measure:camshaft-journal-to-camshaft-cap clear-anceOut of specification Measure the camshaftjournal diameter.

Camshaft-journal-to-camshaft-cap clearance

0.020 0.054 mm

a. Install the camshaft into the cylinder head(without the dowel pins and camshaft caps).

b. Position a strip of Plastigauge 1 onto thecamshaft journal as shown.

c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

Do not turn the camshaft when measuring thecamshaft journal-to-camshaft cap clearancewith the Plastigauge .

Camshaft cap bolt12 Nm (1.2 mkg)

d. Remove the camshaft caps and then mea-sure the width of the Plastigauge 2 .

4-11

ENGCAMSHAFTS

5. Measure:camshaft journal diameter aOut of specification Replace the cam-shaft.Within specification Replace the cylinderhead and the camshaft caps as a set.

Camshaft journal diameter24.967 24.980 mm

EAS00208

CHECKING THE CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDESThe following procedure applies to all of thecamshafts sprockets and timing chain guides.

1. Check:camshaft sprocketDamage/wear Replace the camshaftsprockets and the timing chain as a set.

2. Check: timing chain guide (exhaust side) timing chain guide (top side)Damage/wear Replace the defectivepart(-s).

EAS00210

CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain tensionerCracks/damage Replace.

2. Check:one-way cam operationRough movement Replace the timingchain tensioner housing.

3. Check:cap boltcopper washerspringone-way camgasket timing chain tensioner rodDamage/wear Replace the defectivepart(-s).

4-12

A B

ENGCAMSHAFTS

NOTE:

CAUTION:

NOTE:

NOTE:

INSTALLING THE CAMSHAFTS1. Install:camshaft sprockets

Be sure to set the sprockets in the specifiedposition as shown in the figure.

Temporarily tighten the bolts in this stage.

A Exhaust side

B Intake side

2. Install:camshaft (exhaust)camshaft (intake)

a. Turn the crankshaft counterclockwise untilthe TDC mark a is aligned with the pickupcoil mark b .

Do not turn the crankshaft during the cam-shafts installation. Damage or impropervalve timing will result.

b. Fit the timing chain onto both camshaftsprockets and install the camshafts.

Install the exhaust camshaft 1 first, then theintake camshaft 2 .

Install the camshafts with the punched markfacing upward.

Keep the timing chain as tense as possible onthe exhaust side.

c. Install the camshaft caps 3 with dowel pins.

Make sure that each camshaft cap is installedin its original place by reference to its em-bossed identification mark, as follows:Intake: IExhaust: E

Install the camshaft cap with the arrow markpointing towards the right side of the engine.

Temporarily tighten the bolts in this stage.

4-13

ENGCAMSHAFTS

CAUTION:

CAUTION:

NOTE:

CAMSHAFTS ENG

d. Check if the punched marks c on both cam-shafts are inside the holes of camshaft capsd . If they are not in the position, repeat theabove steps.

e. Tighten the bolts (camshaft cap) in a criss-cross pattern from the inside outwards.

The bolts (camshaft caps) must be tight-ened evenly or damage to the cylinder head,camshaft caps and camshaft will result.

Bolt (camshaft cap):12 Nm (1.2 mkg)

f. Remove the safety wire from the timingchain.

3. Install: timing chain tensioner

Installation steps:a. Remove the tensioner cap bolt 1 , washer

2 and springs 3 .b. Release the timing chain tensioner one-way

cam 4 and push the tensioner rod 5 all theway into the timing chain tensioner housing.

c. Install the timing chain tensioner with a gas-ket 6 onto the cylinder.

Always use a new gasket.

The timing chain tensioner teeth should facedown.

Timing chain tensioner bolt:10 Nm (1.0 mkg)

d. Install the springs 3 , washer 2 and cap bolt1 .

Cap bolt (timing chain tensioner):20 Nm (2.0 mkg)

4. Check:Valve timingOut of alignment Reinstall the camshaftsby referring the above steps.

4-14

ENGCAMSHAFTS

CAUTION:

a. Turn the crankshaft counterclockwise sever-al times until the TDC mark on the timingplate is aligned with the stationary pointer.

b. Check if both the camshaft timing punchmarks a are aligning with the camshaft caphole b .

5. Tighten:Bolts (cam sprockets)

Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine.

Bolts (cam sprockets):20 Nm (2.0 mkg)

4-15


12345

Removing the cylinder head

CamshaftsCylinder headGasketDowel pinsO-ringsIntake manifold

11224


Refer to “CAMSHAFTS”.


NOTE:

Refer to “REMOVING/INSTALLINGTHE CYLINDER HEAD”.

Remove the engine mount (front) and move the engine to front side.

35 Nm (3.5 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

New

New

ENGCYLINDER HEAD

EAS00221

CYLINDER HEAD

4-16

ENGCYLINDER HEAD

NOTE:

NOTE:

EAS00223

REMOVING THE CYLINDER HEAD1. Remove:cylinder head nuts 1 16

Loosen the nuts in the proper sequence asshown.

Loosen each nut 1/2 of a turn at a time. After allof the nuts are fully loosened, remove them.

EAS00228

CHECKING THE CYLINDER HEADThe following procedure applies to all of the cyl-inder heads.1. Eliminate:combustion chamber carbon deposits(with a rounded scraper)

Do not use a sharp instrument to avoid damag-ing or scratching:spark plug threadsvalve seats

2. Check:cylinder headDamage/scratches Replace.

3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.

Cylinder head warpageLess than 0.1 mm

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limited is exceeded, resurface the cylin-

der head as follows.d. Place a 400 600 grit wet sandpaper on the

surface plate and resurface the cylinderhead using a figure-eight sanding pattern.

4-17

NOTE:

ENGCYLINDER HEAD

NOTE:

To ensure an even surface, rotate the cylinderhead several times.

EAS00232

INSTALLING THE CYLINDER HEAD1. Install:gasket (New) 1dowel pins 2

2. Install:cylinder headwasherscopper washerscylinder head nuts

Apply engine oil onto the threads of the cylin-der head nuts.

Tighten the cylinder head nuts in the propertightening sequence as shown and torquethem in two stages.

Cylinder head Cap nut35 Nm (3.5 mkg)

Cylinder head nut10 Nm (1.0 mkg)

3. Install:exhaust camshaft intake camshaftRefer to “INSTALLING THE CAMSHAFTS”.

4-18

ENGVALVES AND VALVE SPRINGS


123456789

10

Removing the valves and valvespringsCamshaftCylinder headValve padsValve liftersValve cottersUpper springs seatsValve springs (outer)Valve springs (inner)Intake valvesExhaust valvesLower spring seatsOil seals

16163216161688

1616


Refer to “CAMSHAFTS”.Refer to “CYLINDER HEAD”.


Refer to “REMOVING/INSTALLINGTHE VALVES”.

EAS00236

VALVES AND VALVE SPRINGS

4-19


NOTE:

NOTE:

NOTE:

EAS00237

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure that the valves properly seal.

1. Remove:valve lifter 1valve pad 2

Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Check:valve sealingLeakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent 1 into the intake andexhaust ports.

b. Check that the valves properly seal.There should be no leakage at the valve seat2 .

3. Remove:valve cotters 1

Remove the valve cotters by compressing thevalve spring with the valve spring compressor2 .

Valve spring compressor90890-04019

4-20


NOTE:

NOTE:

4. Remove:upper spring seat 1valve springs 2oil seal 3 lower spring seat 4valve 5

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVE GUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:valve-stem to valve guide clearance

Valve-stem to valve-guide clearance =Valve guide inside diameter a –Valve stem diameter b

Out of specification Replace the valveguide.

Valve-stem to valve-guide clear-ance

Intake0.010 0.037 mm

Limit: 0.08 mmExhaust

0.025 0.052 mmLimit: 0.10 mm

2. Replace:valve guide

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C (212F) in an oven.

4-21

302-013


NOTE:

NOTE:

a. Remove the valve guide with a valve guideremover 1 .

b. Install the new valve guide with a valve guideinstaller 2 and valve guide remover 1 .

c. After installing the valve guide, bore thevalve guide with a valve guide reamer 3 toobtain the proper valve-stem to valve-guideclearance.

After replacing the valve guide, reface the valveseat.

Valve guide remover, reamer &installer

(5.5 mm): 90890-04016

3. Eliminate:carbon deposits(from the valve face and valve seat)

4. Check:valve facePitting/wear Grind the valve face.

valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.

5. Measure:valve margin thickness aOut of specification Replace the valve.

Valve margin thickness0.8 mm 1.2 mm

6. Measure:valve stem runoutOut of specification Replace the valve.

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

Valve stem runout0.01 mm

4-22


NOTE:

CAUTION:

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)

2. Check:valve seatPitting/wear Replace the cylinder head.

3. Measure:valve seat width aOut of specification Replace the cylinderhead.

Valve seat widthIntake: 0.9 1.1 mmExhaust: 0.9 1.1 mm

a. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

b. Install the valve into the cylinder head.c. 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 contacted oneanother, the blueing will have been removed.

4. Lap:valve facevalve seat

After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.

4-23


NOTE:

d. Turn the valve until the valve face and valveseat are evenly polished, then clean off all ofthe lapping compound.

For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

j. Measure the valve seat width c again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.

4-24


Valve spring free length (intake andexhaust)

Inner spring <Limit>39.65 mm <37.5 mm>

Outer spring <Limit>41.1 mm <39 mm>

2. Measure:compressed spring force aOut of specification Replace the valvespring.

b Installed length

Compressed spring forceIntake and exhaust inner spring

61.772.5 N (6.29 7.39 kg)at 32.8 mm

Intake and exhaust outer spring130.4154.0 N (13.3 15.7 kg)at 34.8 mm

3. Measure:valve spring tilt aOut of specification Replace the valvespring.

Spring tilt limitIntake and exhaust inner spring

2.5 /1.7 mmIntake and exhaust outer spring

2.5 /1.7 mm

EAS00242

CHECKING THE VALVE LIFTERSThe following procedure applies to all of thevalve lifters.1. Check:valve lifterDamage/scratches Replace the valve lift-ers and cylinder head.

EAS00245

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)

4-25


NOTE:

NOTE:

CAUTION:

NOTE:

Recommended lubricantMolybdenum disulfide oil

2. Install:valve 1 lower spring seat 2oil seal 3valve springs 4upper spring seat 5(into the cylinder head)

Install the valve spring with the larger pitch afacing up.

b Smaller pitch

3. Install:valve cotters 1

Install the valve cotters by compressing thevalve spring with the valve spring compressor2 .

Valve spring compressor90890-04019

4. To secure the valve cotters 1 onto the valvestem, lightly tap the valve tip with a soft-facehammer.

Hitting the valve tip with excessive forcecould damage the valve.

5. Install:valve pad 1valve lifter 2

Apply molybdenum disulfide oil onto the valvelifter and valve pad.

The valve lifter must move smoothly when ro-tated with a finger.

Each valve lifter and valve pad must be rein-stalled in its original position.

4-26

CYLINDERS AND PISTONS ENG


1234567

Removing the cylinders and pistonsCylinder headCylinder blockDowel pinsGasketPiston pin clipsPiston pinsPistonsOil ring sets

Remove the parts in the order listed.Refer to “CYLINDER HEAD”.

For installation, removal procedure.

Refer to “REMOVING/INSTALLING THECYLINDERS AND PISTONS”.

1218444

20 Nm (2.0 mkg)

New

New

New

EAS00252

CYLINDERS AND PISTONS

4-27

ENGCYLINDERS AND PISTONS

CAUTION:

NOTE:

NOTE:

EAS00254

REMOVING THE CYLINDERS AND PISTONSThe following procedure applies to all of the cyl-inders and pistons.1. Remove:piston pin clip 1piston pin 2piston 3

Do not use a hammer to drive the piston pinout.

Before removing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crank-case.

For reference during installation, put an identi-fication mark on each piston crown.

Before removing the piston pin, deburr the pis-ton pin clip’s groove and the piston’s pin borearea. If both areas are deburred and the pistonpin is still difficult to remove, remove it with thepiston pin puller 4 .

Piston pin puller90890-01304

2. Remove: top ring2nd ringoil ring

When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

EAS00260

CHECKING THE CYLINDERS AND PISTONSThe following procedure applies to all of the cyl-inders and pistons.1. Check:piston wallcylinder wallVertical scratches Replace the cylinder,and replace the piston and piston rings as aset.

2. Measure:piston to cylinder clearance

4-28


NOTE:

a. Measure cylinder bore “C” with the cylinderbore gauge.

1 20 mm from the top of the cylinder

Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cyl-inder. Then, find the average of the measure-ments.

Cylinder bore gauge

Standard 79.00 79.01 mm

Wear limit 79.1 mm

Cylinder bore “C” “C” = X + Y /2

b. If out of specification, replace the cylinder,and replace the piston and piston rings as aset.

c. Measure piston skirt diameter “P” with themicrometer.

a 2.0 mm from the bottom edge of the piston.

Piston size “P”

Standard 78.970 78.985mm

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston to cylinder clearancewith the following formula.

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

Piston-to-cylinder clearance0.015 0.040 mm

<Limit> : 0.15 mm

f. If out of specification, replace the cylinder,and replace the piston and piston rings as aset.

4-29


NOTE:

NOTE:

NOTE:

EAS00263

CHECKING THE PISTON RINGS1. Measure:piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

Piston ring side clearanceTop ring

0.045 0.080 mm<Limit>: 0.1 mm2nd ring

0.03 0.07 mm<Limit>: 0.1 mm

2. Install:piston ring(into the cylinder)

Level the piston ring in the cylinder with the pis-ton crown as shown.

a 30 mm3. Measure:piston ring end gapOut of specification Replace the pistonring.

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gapTop ring

0.20 0.35 mm<Limit>: 0.6 mm2nd ring

0.35 0.50 mm<Limit>: 0.75 mmOil ring

0.2 0.5 mm

4-30

1

2

4

5

3


NOTE:

NOTE:

EAS00270

INSTALLING THE PISTONS AND CYLIN-DERSThe following procedure applies to all of the pis-tons and cylinders.1. Install: top ring 12nd ring 2 lower oil ring rail 3upper oil ring rail 4oil ring expander 5

Be sure to install the piston rings so that themanufacturer’s marks or numbers a are lo-cated on the upper side of the rings.

The piston rings that have an “R” mark must beinstalled into the 2nd ring groove.

2. Install:piston 1piston pin 2piston pin clip (New) 3

Apply engine oil onto the piston pin.Make sure that the arrow mark a on the pistonpoints towards the exhaust side of the engine.

Before installing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crank-case.

Reinstall each piston into its original cylinder(numbering order starting from the left: #1 to#4).

4-31


NOTE:

3. Install:gasket (New) 1dowel pins 2

4. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)


5. Offset:piston ring end gaps

a Top ringb Lower oil ring railc Upper oil ring raild 2nd ringA forward

6. Install:cylinder block

Install pistons #2 and #3 before installing pis-tons #1 and #4.

Pass the timing chain and timing chain guide(intake side) through the timing chain cavity.

4-32


123

Removing the clutch cover.Engine oilClutch coverGasketDowel pins

112

Remove the parts in the order listed.Drain


10 Nm (1.0 mkg)

New

ENGCLUTCH

EAS00273

CLUTCHCLUTCH COVER

4-33


123456789

10111213

Removing the clutchPressure plateClutch springSpring housingPressure plateClutch push rod (short)BallClutch push rod (long)O-ringFriction platesClutch platesFriction platesClutch boss nutLock washer

1111111116611


Refer to “INSTALLING THE CLUTCH”.

Refer to “REMOVING/INSTALLINGTHE CLUTCH”.

70 Nm (7.0 mkg)

8 Nm (0.8 mkg)

New

New

ENGCLUTCH

EAS00274

CLUTCH

4-34

ENGCLUTCH


14151617181920212223

Clutch bossStopper ringClutch plateClutch spring plateClutch spring plate seatFriction plates (narrow)Thrust washerSpacerBearingClutch housing

1111111111


Refer to “REMOVING/INSTALLINGTHE CLUTCH”.

70 Nm (7.0 mkg)

8 Nm (0.8 mkg)

New

New

4-35

ENGCLUTCH

NOTE:

NOTE:

NOTE:

EAS00275

REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen:clutch boss nut 1

While holding the clutch boss 2 with the univer-sal clutch holder, loosen the clutch boss nut.

Universal clutch holder 390890-04086

3. Remove:clutch boss nut 1 lock washer 2clutch boss 3 thrust washer 4spacer 5bearing 6clutch housing 7

Insert two 6 mm bolts 8 into the spacer andthen remove the spacer by pulling on the bolts.

EAS00280

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check: friction plateDamage/wear Replace the friction platesas a set.

2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.

Measure the friction plate at four places.

Friction plate thickness2.9 3.1 mm<Limit>: 2.8 mm

4-36

ENGCLUTCH

EAS00281

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.

2. Measure:clutch plate warpage(with a surface plate and thickness gauge1 )Out of specification Replace the clutchplates as a set.

Clutch plate warpage limitLess than 0.1 mm

CHECKING THE CLUTCH SPRING1. Check:Clutch springDamage Replace as a set.

2. Measure:Clutch spring free heightOut of specification Replace spring as aset.

Free height limit (clutch spring):6.0 mm

EAS00283

CHECKING THE CLUTCH SPRING PLATE1. Check:clutch spring plateDamage Replace.

2. Check:clutch spring plate seatDamage Replace.

4-37

CLUTCH ENG

NOTE:

NOTE:

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:Clutch housing dogsDamage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

2. Check:bearingDamage/wear Replace the clutch hous-ing.

EAS00285

CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plateCracks/damage Replace.

4-38

ENGCLUTCH

NOTE:

NOTE:

EAS00288

CHECKING THE CLUTCH PUSH RODS1. Check:O-ring 1short clutch push rod 2 long clutch push rod 3ball 4bearing 5Cracks/damage/wear Replace the de-fective part(-s).

2. Measure: long clutch push rod bending limitOut of specification Replace the longclutch push rod.

Long clutch push rod bending limit0.3 mm

INSTALLING THE CLUTCH1. Install:clutch housing 1

Engage the notch of clutch housing and the pro-jection on the oil pump drive gear.

2. Install:bearing 1spacer 2 thrust washer 3

Install the spacer with the two screw holes fac-ing towards the clutch boss.

4-39

ENGCLUTCH

NOTE:

NOTE:

3. Tighten:clutch boss nut 1

While holding the clutch boss with the universalclutch holder 2 , tighten the clutch boss nut.

Universal clutch holder90890-04086

Clutch boss nut70 Nm (7.0 mkg)

4. Bend the lock washer tab along a flat side ofthe nut.

5. Lubricate: long clutch push rod 1ball 2short clutch push rod 3(with the recommended lubricant)

Recommended lubricantLithium soap base grease

6. Install:clutch spring plate seat 1clutch spring plate 2

Install the spring plate with the letters “OUTSIDE” facing outward.

4-40

ENGCLUTCH

NOTE:

NOTE:

7. Install:Friction plates (narrow type) 1Clutch plates 2Stopper ring 3Friction plates (wide type) 4

a. Install the friction plate of narrow contact face1 and one of the clutch plate to the clutchboss.

b. Install the stopper ring 3 .

Install the stopper ring onto the groove aroundthe clutch boss with both ends of the ring fitted inthe hole a on the boss.

c. Install the other 6 clutch plates and the 6 fric-tion plates of wide contact face alternately.

d. Install the another friction plate of narrowface.

8. Install:Pressure plate 1Spring housing 2Clutch spring 3Plate 4Bolts (clutch spring)

Tighten the bolts (clutch spring) in stages, usinga crisscross pattern.

Bolt (clutch spring):8 Nm (0.8 mkg)

4-41


123

4567

Removing the clutch mastercylinderClutch leverClutch switch leadClutch switch

Union boltCopper washers/Clutch hoseClutch lever holderClutch master cylinder

111

12/111


Before removing the clutch master cylin-der, drain the clutch fluid from the entireclutch system.


NOTE:

Refer to “INSTALLING THE CLUTCHMASTER CYLINDER”.

10 Nm (1.0 mkg)

30 Nm (3.0 mkg)

New

ENGCLUTCH

EAS00305

CLUTCH MASTER CYLINDER

4-42


Disassembling the clutch mastercylinderMaster cylinder bootCirclipMaster cylinder kitSpring

1111

Disassembly the parts in the order listed.

For assembly, reverse the disassemblyprocedure.

1234

New

ENGCLUTCH

4-43

ENGCLUTCH

CAUTION:

WARNING

EAS00307

Clutch components rarely require disas-sembly.Therefore, always follow these preventivemeasures:Never disassemble clutch components un-less absolutely necessary.

If any connection on the hydraulic clutchsystem is disconnected, the entire clutchsystem must be disassembled, drained,cleaned, properly filled, and bled afterreassembly.

Never use solvents on internal clutch com-ponents.

Use only clean or new clutch fluid forcleaning clutch components.

Clutch fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt fluid immediately.

Avoid clutch fluid coming into contact withthe eyes as it can cause serious injury.

First aid for clutch fluid entering the eyes:Flush with water for 15 minutes and get im-mediate medical attention.

EAS00308

CHECKING THE CLUTCH MASTER CYL-INDER

Recommended clutch componentreplacement schedule

Piston seals Every two years

Clutch hose Every two years

Clutch fluidEvery two years andwhenever the clutchis disassembled.

1. Check:clutch master cylinder body 1Cracks/damage Replace the clutch mas-ter cylinder.

clutch fluid delivery passage 2(clutch master cylinder body)Obstruction Blow out with compressed air.

Whenever a clutch master cylinder is disas-sembled, replace the piston seals.

4-44

ENGCLUTCH

WARNING

WARNING

WARNING

NOTE:

2. Check:clutch master cylinder 1clutch master cylinder kit 2Rust/scratches/wear Replace the clutchmaster cylinder and clutch master cylinderkit as a set.

clutch hose 3Cracks/damage/wear Replace.

EAS00309

ASSEMBLING THE CLUTCH MASTER CYL-INDER

Before installation, all internal clutch com-ponents must be cleaned and lubricatedwith clean or new clutch fluid.

Never use solvents on internal clutch com-ponents as they will cause the piston sealsto swell and distort.

Whenever a clutch master cylinder is dis-assembled, replace the piston seals.


EAS00310

INSTALLING THE CLUTCH MASTER CYL-INDER1. Install:clutch master cylinder 1

Install the clutch lever holder with the “UP”mark facing up.

Align the end of the clutch lever holder withthe punch mark a in the handlebar.

First, tighten the upper bolt, then the lowerbolt.

2. Install:copper washers (New)clutch hose 1union bolt 2

Proper clutch hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

While holding the clutch hose, tighten the unionbolt.

4-45

CLUTCH ENG

NOTE:

WARNING

CAUTION:

NOTE:

Union bolt30 Nm (3.0 mkg)

3. Install:clutch lever 1

Lubricate the clutch lever pivot bolt with lithiumsoap base grease.

4. Fill:clutch master cylinder reservoir(with the specified amount of the recom-mended clutch fluid)






In order to ensure a correct reading of the clutchfluid level, make sure that the top of the reser-voir is horizontal.

5. Bleed:clutch systemRefer to “BLEEDING THE HYDRAULICCLUTCH SYSTEM” in chapter 3.

4-46

ENGCLUTCH

6. Check:clutch fluid levelBelow the minimum level mark a Add therecommended clutch fluid to the proper lev-el.Refer to “CHECKING THE CLUTCH FLUIDLEVEL” in chapter 3.

7. Check:clutch lever operationSoft or spongy feeling Bleed the clutchsystem.Refer to “BLEEDING THE HYDRAULICCLUTCH SYSTEM” in chapter 3.

4-47


1

23456

Removing the clutch releasecylinder

Bolt

Union boltCopper washerSpacerClutch hoseClutch release cylinder

3

13111


Refer to “INSTALLING THE CLUTCHRELEASE CYLINDER”.

Before removing the clutch releace cylin-der, drain the clutch fluid from the entireclutch system.

NOTE:


Refer to “INSTALLING THE CLUTCHRELEASE CYLINDER”.

30 Nm (3.0 mkg)

10 Nm (1.0 mkg)

ENGCLUTCH

EAS00311

CLUTCH RELEASE CYLINDER

4-48

ENGCLUTCH


12345

Disassembling the clutch releasecylinderClutch release cylinderPiston sealClutch release cylinder pistonPiston sealSpring

11111


Refer to “DISASSEMBLING THECLUTCH RELEASE CYLINDER”.


4-49

ENGCLUTCH

WARNING

EAS00313

DISASSEMBLING THE CLUTCH RELEASECYLINDER1. Remove:piston seal 1clutch release cylinder piston 2spring 3piston seal 4

a. Blow compressed air into the clutch hosejoint opening a to force out the piston fromthe clutch release cylinder.

Cover the clutch release cylinder with arag. Be careful not to get injured when thepiston is expelled from the clutch releasecylinder.

Never try to pry out the clutch release cylin-der piston.

b. Remove the clutch release cylinder pistonseals.

EAS00314

CHECKING THE CLUTCH RELEASE CYL-INDER

Recommended clutch componentpreplacement schedule


Clutch hose Every two years

Clutch fluidEvery two years andwhenever the clutchis disassembled

1. Check:clutch release cylinder bodyCracks/damage Replace the clutch re-lease cylinder.

2. Check:clutch release cylinder 1clutch release cylinder piston 2Rust/scratches/wear Replace the clutchrelease cylinder and clutch release cylinderpiston as a set.

4-50

ENGCLUTCH

WARNING

WARNING

CAUTION:

EAS00315

INSTALLING THE CLUTCH RELEASE CYL-INDER1. Check:copper washers (New)clutch hose 1union bolt 2

Proper clutch hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.


2. Fill:clutch master cylinder reservoir(with the specified amount of the recom-mended clutch fluid)






4-51

ENGCLUTCH

NOTE:In order to ensure a correct reading of the clutchfluid level, make sure that the top of the reser-voir is horizontal.

3. Bleed:clutch systemRefer to “BLEEDING THE HYDRAULICCLUTCH SYSTEM” in chapter 3.

4. Check:clutch fluid levelBelow the minimum level mark a Add therecommended clutch fluid to the proper lev-el.Refer to “CHECKING THE CLUTCH FLUIDLEVEL” in chapter 3.

5. Check:clutch lever operationSoft or spongy feeling Bleed the clutchsystem.Refer to “BLEEDING THE HYDRAULICCLUTCH SYSTEM” in chapter 3.

4-52


123456789

1011

Removing the oil pump.ClutchOil pump drive gearCollarWasherOil buffer plateCirclipOil pump driven gearWasherOil pumpDowel pinCollarO-ring

11111111113

Remove the parts in the order listed.Refer to “INSTALLING THE CLUTCH”.

Refer to “INSTALLING THE OIL PUMP”.


New

4 Nm (0.4 mkg)

10 Nm (1.0 mkg)

ENGOIL PUMP

OIL PUMP

4-53

ENGOIL PUMP


Disassembling the oil pumpOil pump housingInner rotorOuter rotorPinDowel pinOil pump housingInner rotorOuter rotorPinOil pump shaftOil pump cover

11111111111


Refer to “ASSEMBLING THE OILPUMP”.


1

1011

23456789

4-54

ENGOIL PUMP

EAS00364

CHECKING THE OIL PUMP1. Check:oil pump drive gear 1oil pump driven gear 2oil pump housing 3oil pump housing cover 4Cracks/damage/wear Replace the de-fective part(-s).

2. Measure: inner-rotor to outer-rotor tip clearance Aouter-rotor to oil-pump-housing clearance Boil-pump-housing to inner-rotor and outer-rotor clearance COuter of specification Replace the oilpump.

1 Inner rotor2 Outer rotor3 Oil pump housing

Inner-rotor to outer-rotor tipclearance

0.12 0.17 mm <Limit 0.2 mm>Outer-rotor to oil-pump-housingclearance

0.03 0.08 mm <Limit 0.15 mm>Oil-pump-housing to inner-rotorand outer-rotor clearance

0.03 0.08 mm <Limit 0.15 mm>

3. Check:oil pump operationUnsmooth Repeat steps (1) and (2) or re-place the defective part(-s).

4-55

ENGOIL PUMP

NOTE:

CAUTION:

NOTE:

EAS00375

ASSEMBLING THE OIL PUMP1. Lubricate: inner rotorouter rotoroil pump shaft(with the recommended lubricant)


2. Install:oil pump shaft 1(to the oil pump cover 2 )

pin 3 inner rotor 4outer rotor 5pin 6oil pump housing 7screw

Oil pump housing screw10 Nm (1.0 mkg)

When installing the inner rotor, align the pin 3in the oil pump shaft with the groove on the innerrotor 4 .

3. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP1. Install:oil pump 1

Oil pump bolt10 Nm (1.0 mkg)

After tightening the bolts, make sure that theoil pump turns smoothly.

Align the arrow a on the oil pump with the arrowb on the crankcase.

4-56


12345678

Removing the shift shaft andstopper leverOil pumpDrive sprocket coverCirclipWasherShift shaftWasherShift lever springBoltStopper leverStopper lever spring

11111111


Refer to “OIL PUMP”.Refer to “ENGINE”.

Refer to “INSTALLING THE SHIFTSHAFT”.


10 Nm (1.0 mkg)

New

ENGSHIFT SHAFT

EAS00327

SHIFT SHAFT

4-57

ENGSHIFT SHAFT

NOTE:

EAS00328

CHECKING THE SHIFT SHAFT1. Check:shift shaft 1Bends/damage/wear Replace.

shift lever springDamage/wear Replace.

EAS00330

CHECKING THE STOPPER LEVER1. Check:stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

EAS00331

INSTALLING THE SHIFT SHAFT1. Install:stopper lever 1stopper lever spring 2shift shaft lever 3

Hook the ends of the stopper lever spring ontothe stopper lever and the crankcase boss.

Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install:washer 1shift shaft 2circlip 3

4-58

ENGSHIFT SHAFT

NOTE:Lubricate the oil seal lips with lithium soapbase grease.

Hook the end of the shift lever spring onto theshift lever spring stopper 4 .

4-59


1234567

Removing the timing plate andpickup coilSeat, side cover, fuel tankPickup coil readTiming plate coverGasketPickup coilTiming plateDowel pinPickup base

1111111



4 Nm (0.4 mkg)45 Nm (4.5 mkg)

7 Nm (0.7 mkg)

ENGTIMING PLATE AND PICKUP COIL

TIMING PLATE AND PICKUP COIL

4-60

10 Nm(1.0 mkg)

10 Nm(1.0 mkg)


123456789

Removing the oil panEngineOil level switch/O-ringOil panDowel pinGasketRelief valve/O-ringRelief valve/O-ringOil strainerOil strainer housingGasket

1/1121

1/11/1111

Remove the parts in the order listed.Refer to “ENGINE”.

Refer to “REMOVING/INSTALLINGTHE OIL PAN”.

Refer to “INSTALLING THE OILSTRAINER”.


New

New

New

New

New

ENGOIL PAN

OIL PAN

4-61

ENGOIL PAN

NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:oil level switch 1oil pan 2gasketdowel pins

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

EAS00365

CHECKING THE RELIEF VALVE1. Check: relief valve body 1 relief valve 2spring 3Cover 4Damage/wear Replace the defectivepart(-s).

circlip 5EAS00367

CHECKING THE OIL DELIVERY PIPESThe following procedure applies to all of the oildelivery pipes.1. Check:oil delivery pipe 1Damage Replace.Obstruction Wash and blow out with com-pressed air.

EAS00368

CHECKING THE OIL STRAINER1. Check:oil strainerDamage Replace.Contaminants Clean with engine oil.

4-62

ENGOIL PAN

NOTE:

NOTE:

WARNING

NOTE:

EAS00378

INSTALLING THE OIL STRAINER1. Install:oil strainer housing 1

Oil strainer housing bolt10 Nm (1.0 mkg)LOCTITE

The arrow a on the oil strainer housing mustpoint towards the front of the engine.

2. Install:oil strainer cover 1 relief valve 2

The arrow a on the oil strainer cover must pointtowards the front of the engine.

EAS00380

INSTALLING THE OIL PAN1. Install:dowel pinsgasket (New)oil pan 1oil level switch 2engine oil drain bolt

Always use new copper washers.

Tighten the oil pan bolts in stages and in acrisscross pattern.

Lubricate the oil level switch’s O-ring with en-gine oil.

Oil pan bolt10 Nm (1.0 mkg)

Oil level switch bolt10 Nm (1.0 mkg)

4-63

ENGCRANKCASE


123

Removing the oil panEngineCamshaftsCylinder headCylinder, pistonClutchOil pumpShift shaftTiming plate, pickup coil

Oil strainerSpring/rodChain guideCover

1/111

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CAMSHAFTS”.Refer to “CYLINDER HEAD”.Refer to “CYLINDERS AND PISTONS”.Refer to “CLUTCH”.Refer to “OIL PUMP”.Refer to “SHIFT SHAFT”.Refer to “TIMING PLATE AND PICKUPCOIL”.Refer to “OIL PAN”.

24 Nm (2.4 mkg)

35 Nm (3.5 mkg)

12Nm (1.2 mkg)

10 Nm (1.0 mkg)

35 Nm (3.5 mkg)

12Nm (1.2 mkg)

10Nm (1.0 mkg)

CRANKCASE

4-64

ENGCRANKCASE


45

6

Bearing coverCrankcase (lower)

Dowel pin

11

2

Refer to “DISASSEMBLING/ASSEM-BLING THE CRANKCASE”.

For installation, reverse the removal pro-cedure.

24 Nm (2.4 mkg)

35 Nm (3.5 mkg)

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

35 Nm (3.5 mkg)

12 Nm (1.2 mkg)

4-65

A

B

ENGCRANKCASE

NOTE:

CAUTION:

NOTE:

EAS00384

DISASSEMBLING THE CRANKCASE1. Remove:crankcase bolts

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-dicate the crankcase tightening sequence.

2. Place the engine upside down.3. Remove: lower crankcase

A Upper crankcase

: M10 bolts

: M8 bolts

∆ : M6 bolts

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure that the crankcase halvesseparate evenly.

4. Remove:dowel pinsO-ring

B Lower crankcase

: M10 bolts

: M8 bolts

∆ : M6 bolts5. Remove:crankshaft journal lower bearing(from the lower crankcase)

Identify the position of each crankshaft journallower bearing so that it can be reinstalled in itsoriginal place.

4-66

ENGCRANKCASE

NOTE:

NOTE:

EAS00399

CHECKING THE CRANKCASE1. Throughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:crankcaseCracks/damage Replace.

oil delivery passagesObstruction Blow out with compressed air.

EAS00412

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant(onto the crankcase mating surfaces)

Yamaha bond No. 121590890-85505

Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Install:crankshaft journal lower bearings(into the lower crankcase)

Align the projections a on the crankshaft jour-nal lower bearings with the notches b in thecrankcase.

Install each crankshaft journal lower bearing inits original place.

4-67

A

B

ENGCRANKCASE

CAUTION:

NOTE:

NOTE:

5. Set the shift drum assembly and transmis-sion gears in the neutral position.

6. Install: lower crankcase 1(onto the upper crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

Carefully position the shift forks so that theymesh smoothly with the transmission gears.

Mesh shift fork center with the 2nd pinion gear3 on the main axle.

7. Install: lower crankcase boltsupper crankcase bolts

Tighten the bolts in the tightening sequencecast on the crankcase.

A Upper crankcase

B Lower crankcase

M10 bolt ( 16 , 17 , 31 33 ):35 Nm (3.5 mkg)

M8 bolt ( 1 15 , 27 , 29 ):24 Nm (2.4 mkg)

∆ M6 bolt ( 18 26 , 28 , 30 , 34 36 ):12 Nm (1.2 mkg)

8. Install:clutch cover

Clutch cover bolt10 Nm (1.0 mkg)

4-68

ENGSTARTER CLUTCH


1234567

89

101112

Removing the starter clutchCrankcaseBearing housingO-ringOil sealNozzleGenerator shaftBearingStarter clutch drive gear

Starter clutch gearCollarCirclipStarter clutch rollerStopper plate

1111111

11111

Remove the parts in the order listed.Refer to “CRANKCASE”.

Refer to “INSTALLING THE STARTERCLUTCH”.

7 Nm (0.7 mkg)

10 Nm (1.0 mkg)

Refer to “INSTALLING THE STARTERCLUTCH”.

EAS00342

STARTER CLUTCH

4-69

ENGSTARTER CLUTCH


131415

Idle gear shaftStarter clutch idle gearBearing

111


7 Nm (0.7 mkg)

10 Nm (1.0 mkg)New

4-70

ENGSTARTER CLUTCH

EAS00350

CHECKINHG THE STARTER CLUTCH1. Check:starter clutch rollers 1Damage/wear Replace.

2. Check:starter clutch idle gear 2starter clutch drive gear 3starter clutch gear 4Burrs/chips/roughness/wear Replacethe defective part(-s).

3. Check:starter clutch gear’s contacting surfacesDamage/pitting/wear Replace the starterclutch gear.

4. Check:starter clutch operation

a. Install the starter clutch gear 4 onto thestarter clutch and hold the starter clutch.

b. When turning the starter clutch drive gearclockwise A , the starter clutch and the start-er clutch drive gear should engage.If the starter clutch drive gear and starterclutch do not engage, the starter clutch isfaulty and must be replaced.

c. When turning the starter clutch drive gearcounterclockwise B , it should turn freely.If the starter clutch drive gear does not turnfreely, the starter clutch is faulty and must bereplaced.

5. Check:starter clutch shaftBends/damage/wear Replace.

4-71

ENGSTARTER CLUTCH

CAUTION:

EAS00352

CHECKING THE GENERATOR SHAFT1. Check:generator shaft 1generator shaft splines 2Damage/wear Replace the generatorshaft.

oil passages 3Dirt /obstruction Wash the generator shaftand then blow out the oil passages with com-pressed air.

bearing 4Rough movement Replace.

INSTALLING THE STARTER CLUTCH ROLL-ER1. Install:circlip 1starter clutch roller 2starter clutch drive gear 3

Be sure to install the starter clutch roller tothe starter clutch drive gear so that the cir-clip is outside.

4-72


123456

7

Removing the crankshaft assemblyCrankcaseStarter clutchCrankshaftOil sealCoverTiming chainHY-VO chainCrankshaft journal bearings

HY-VO chain guide

11111

10

1

Remove the parts in the order listed.Refer to “CRANKCASE”.Refer to “STARTER CLUTCH”.

Refer to “REMOVING/INSTALLING THECRANKSHAFT ASSEMBLY”.


Refer to “INSTALLING THECRANKSHAFT ASSEMBLY”.

ENGCRANKSHAFT

EAS00381

CRANKSHAFTCRANKSHAFT

4-73

ENGCRANKSHAFT


12345

Removing the connecting rod.NutConnecting rod boltCoonecting rodConnecting rod capConnecting rod bearing

88448

Remove the parts in the order listed

For installation, reverse the removalprocedur.

Refer to ”REMOVING/INSTALLING THE CONNECTING RODS.”

Refer to ”INSTALLING THE CONNEECTING RODS.”

36 Nm (3.6 mkg)

CONNECTING ROD

4-74

ENGCRANKSHAFT

NOTE:

NOTE:

CAUTION:

EAS00387

REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:crankshaft assembly 1crankshaft journal upper bearings(from the upper crankcase)

Identify the position of each crankshaft journalupper bearing so that it can be reinstalled in itsoriginal place.

EAS00391

REMOVING THE CONNECTING RODS1. Remove:connecting rods 1big end bearings

Identify the position of each big end bearing sothat it can be reinstalled in its original place.

EAS00395

CHECKING THE CRANKSHAFT AND CON-NECTING RODS1. Measure:crankshaft runoutOut of specification Replace the crank-shaft.

Crankshaft runoutLess than 0.02 mm

2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.

3. Measure:crankshaft-journal-to-crankshaft-journal-bearing clearanceOut of specification Replace the crank-shaft journal bearings.

Crankshaft-journal to crankshaft-journal-bearing clearance

0.030 0.064 mm

Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clear-ance and prevent engine damage, the crank-shaft journal bearings must be installed intheir original positions.

4-75

ENGCRANKSHAFT

NOTE:

NOTE:

NOTE:

NOTE:

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

c. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.

Align the projections a of the crankshaft jour-nal upper bearings with the notches b in thecrankcase.

d. Put a piece of Plastigauge 2 on eachcrankshaft journal.

Do not put the Plastigauge over the oil hole inthe crankshaft journal.

e. Install the crankshaft journal lower bearingsinto the lower crankcase and assemble thecrankcase halves.

Align the projections a of the crankshaft jour-nal lower bearings with the notches b in thecrankcase.

Do not move the crankshaft until the clearancemeasurement has been completed.

f. Tighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Crankcase bolt M10 (No.16 , 17 , 31 33 ):35 Nm (3.5 mkg) M8 (No. 1 15 , 27 , 29 ):24 Nm (2.4 mkg)∆ M6 (No.1826 , 28 , 30 , ∆ M6 3436 ):12 Nm (1.2 mkg)

A Upper crankcase

B Lower crankcase

Lubricate the crankcase bolt threads (M8) withengine oil.

4-76

ENGCRANKSHAFT

g. Remove the lower crankcase and the crank-shaft journal lower bearings.

h. Measure the compressed Plastigauge

width 1 on each crankshaft journal.If the clearance is out of specification, selectreplacement crankshaft journal bearings.

4. Select:Crankshaft journal bearings (J1 J5)

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “6” and “2” respec-tively, then the bearing size for “J1” is:

Bearing size for J 1:J1 (crankcase) – J 1 (crankshaft web) =6 – 2 = 4 (green)

CRANKSHAFT JOURNAL BEARING(COLOR CODE)

1 Blue

2 Black

3 Brown

4 Green

5 Yellow

5. Measure:crankshaft-pin-to-big-end-bearing clear-anceOut of specification Replace the big endbearings.

Crankshaft-pin-to-big-end-bear-ing clearance

0.017 0.040 mm<Limit: 0.08 mm>

The following procedure applies to all of theconnecting rods.

4-77

CAUTION:

ENGCRANKSHAFT

NOTE:

NOTE:

CAUTION:

Do not interchange the big end bearings andconnecting rods. To obtain the correct crank-shaft-pin-to-big-end-bearing clearance andprevent engine damage, the big end bear-ings must be installed in their original posi-tions.

a. Clean the big end bearings, crankshaft pins,and bearing portions of the connecting rods.

b. Install the big end upper bearing into the con-necting rod and the big end lower bearinginto the connecting rod cap.

Align the projections a on the big end bearingswith the notches b in the connecting rod andconnecting rod cap.

c. Put a piece of Plastigauge 1 on the crank-shaft pin.

d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaftuntil the clearance measurement has beencompleted.

Apply molybdenum disulfide grease onto thebolts, threads, and nuts seats.

Make sure that the “Y” mark c on the connect-ing rod faces towards the left side of the crank-shaft.

Make sure that the characters d on both theconnecting rod and connecting rod cap arealigned.

e. Tighten the connecting rod nuts.

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

Without pausing, tighten the connectingrod nuts to the specified torque. Apply con-tinuous torque between 2.0 and 3.6 m kg.Once you reach 2.0 m kg, DO NOT STOPTIGHTENING until the specified torque isreached. If the tightening is interrupted be-tween 2.0 and 3.6 m kg, loosen the con-necting rod nut to less than 2.0 m kg andstart again.

4-78

ENGCRANKSHAFT

NOTE:

Refer to “INSTALLING THE CONNECTINGRODS”.

Connecting rod nut36 Nm (3.6 mkg)

f. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS”.

g. Measure the compressed Plastigauge

width 1 on the crankshaft pin.If the clearance is out of specification, selectreplacement big end bearings.

6. Select:big end bearings (P1 P4)

The numbers stamped into the crankshaft weband the numbers on the connecting rods areused to determine the replacement big endbearing sizes.

“P1” “P4” refer to the bearings shown in thecrankshaft illustration.

For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “4” and “1” re-spectively, then the bearing size for “P1” is:

Bearing size for “P 1”:“P 1” (connecting rod) – “P 1” (crak-kshaft) =4 – 1 = 3 (brown)

BIG END BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

4-79

ENGCRANKSHAFT

CHECKING THE TIMING CHAIN1. Check: timing chain 1Damage/stiffness Replace the timingchain and camshaft sprockets as a set.

2. Check timing chain guide (intake side)Damage/wear Replace.

EAS00400

CHECKING THE HY-VO CHAIN1. Check:HY-VO chain 1Damage/stiffness Replace the HY-VOchain and sprockets as a set.

2. Check:HY-VO chain guideDamage/wear Replace.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:bearingsClean and lubricate the bearings, then rotatethe inner race with your fingerRough movement Replace.

2. Check:oil sealsDamage/wear Replace.

EAS00402

CHECKING THE CIRCLIPS AND WASHERS1. Check:circlipsBends/damage/looseness Replace.

washersBends/damage Replace.

EAS00403

INSTALLING THE CONNECTING RODS1. Lubricate:bolt threadsnut seats(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide grease

2. Lubricate:crankshaft pinsbig end bearingsconnecting rod inner surface(with the recommended lubricant)

4-80

ENGCRANKSHAFT

NOTE:

CAUTION:


3. Install:big end bearings 1connecting rods 2connecting rod caps 3(onto the crankshaft pins)

Align the projections on the big end bearingswith the notches in the connecting rods andconnecting rod caps.

Be sure to reinstall each big end bearing in itsoriginal place.

Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.

Make sure that the characters b on both theconnecting rod and connecting rod cap arealigned.

4. Align:bolt heads 1(with the connecting rod caps)

5. Tighten:connecting rod nuts

Connecting rod nuts36 Nm (3.6 mkg)

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

Without pausing, tighten the connectingrod nuts to the specified torque. Apply con-tinuous torque between 2.0 and 3.6 m kg.Once you reach 2.0 m kg DO NOT STOPTIGHTENING unitl the specified torque isreached. If the tightening is interrupted be-tween 2.0 and 3.6 m kg, loosen the con-necting rod nut to less than 2.0 m kg andstart again.

4-81

ENGCRANKSHAFT

NOTE:

NOTE:

EAS00407

INSTALLING THE CRANKSHAFT1. Install:crankshaft journal upper bearings(into the upper crankcase)

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in thecrankcase.

Be sure to install each crankshaft journal up-per bearing in its original place.

2. Install:HY-VO chain 1 timing chain 2(onto the crankshaft sprocket)

crankshaft assembly 3

Pass the timing chain through the timing chaincavity.

To prevent the timing chain from falling into thecrankcase, fasten it with a wire.

4-82

ENGTRANSMISSION


123456789

Removing the transmission, shiftdrum assembly, and shift forks.CrankcaseMain axle assemblyOil sealBearingDrive axle assemblyCollarO-ringOil sealCirclipBearing

111111111


Refer to “CRANKCASE”.


Refer to “INSTALLING THE TRANSMIS-SION”.

EAS00419

TRANSMISSION

4-83

ENGTRANSMISSION


Disassembling the transmissionWasher1st wheel gear/CollarWasher4th wheel gearCirclipWasher3rd wheel gear/collarWasher5th wheel gearCirclipWasher2nd wheel gear/collarDrive axle

11/11111

1/11111

1/11

Disassembly the parts in the order listed.1234567891011

12

13

New

New

New

4-84

ENGTRANSMISSION


2nd pinion gear5th pinion gear/collarWasher3rd pinion gearCirclipWasher4th pinion gearMain axle (1st pinion gear)

11/1111111


1415

1617

18

192021

New

New

New

4-85

ENGTRANSMISSION


123456

Removing the shift cam and shiftfork.CrankcaseShif fork quide barShift fork (L)Shift fork (C)Shift fork (R)Stopper plateShift drum

111111

Remove the parts in the order listed.Refer to ”CRANKCASE”

For installation, reverse the removal produre.

Refer to ”INSTALLING THETRANSMISSION

SHIFT CAM AND SHIFT FORK

4-86

ENGTRANSMISSION

WARNING

EAS00421

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks and related components.1. Check:shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replacethe shift fork.

2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent shift forkguide bar.

3. Check:shift fork movement(on the shift fork guide bar)Rough movement Replace the shift forksand shift fork guide bar as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum groovesDamage/scratches/wear Replace theshift drum.

shift drum segment 1Damage/wear Replace.

shift drum bearing 2Damage/pitting Replace.

EAS00424

CHECKING THE TRANSMISSION1. Measure:main axle runout(with a centering device and dial gauge 1 )Out of specification Replace the mainaxle.

Main axle runout limit0.06 mm

4-87

ENGTRANSMISSION

NOTE:

NOTE:

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Drive axle runout limit0.06 mm

3. Check: transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(-s).

transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(-s).

4. Check: transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect Reassemble the transmissionaxle assemblies.

When reassembling the main axle, press the2nd pinion gear 1 onto it 2 as shown.

5. Check: transmission gear movementRough movement Replace the defectivepart(-s).

6. Check:circlipsDamage/bends/looseness Replace.

EAS00426

INSTALLING THE SHIFT FORKS AND SHIFTDRUM ASSEMBLY1. Install:shift drum aseembly 1shift fork guide bars 2shift fork “R” 3shift fork “C” 4shift fork “L” 5

The embossed marks on the shift forks shouldface towards the right side of the engine and bein the following sequence: “R”, “C”, “L”.

4-88

ENGTRANSMISSION

NOTE:

NOTE:

EAS00429

INSTALLING THE TRANSMISSION1. Install:main axle assembly 1drive axle assembly 2

Make sure that the drive axle bearing circlips3 are inserted into the grooves 4 in the uppercrankcase.

The drive axle bearing pin 5 must face to-wards the rear of the crankcase and the mainaxle bearing pin 6 must face towards the frontof the crankcase.

2. Check: transmissionRough movement Repair.

Oil each gear, shaft, and bearing thoroughly.

CARB

CHAPTER 5.CARBURETORS

CARBURETORS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS 5-5. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL 5-7. . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL COCK 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL COCK OPERATION 5-10. . . . . . . . . . . . . . . . . . .

5-1


123456789

1011

Removing the carburetorsSeat, fuel tank

Battery negative leadBattery positive leadBatteryCarburetor joint screwsAir filter joint screwsBoltsAir filter caseThrottle position sensor leadStarter cableThrottle cablesCarburetors

11144311121

Remove the parts in the order listed.Refer to “SEAT, SIDE COVER AND FUELTANK” in Chapter 3.

LoosenLoosenLoosenMove to rear wardDisconnect


CARBCARBURETORS

EAS00481

CARBURETORSCARBURETORS

5-2


12

345678910111213

Disassembling the carburetorStarter shaft /Starter leversUpper bracket

Lower bracketThrottle stop screw setCarburetorsThrottle cable bracketStarter plunger setVacuum chamber coverPiston valve springPiston valveJet needlePilot air jetPilot screw

1/41

11411111111


The following procedure applies to all of thecarburetors.

NOTE:

Refer to “ASSEMBLING THE CARBURE-TORS”.

New

CARBCARBURETORS

5-3


14

151617181920

Float chamberFloat chamber gasketFloat pinFloatNeedle valve ass’yPilot jetMain jetNeedle jet

1/1

111111


Refer to “ASSEMBLING THE CARBURE-TORS”.

New

CARBCARBURETORS

EAS00484

5-4

CARBCARBURETORS

EAS00486

CHECKING THE CARBURETORSThe following procedure applies to all of the car-buretors.1. Check:carburetor body float chamber jet housingCracks/damage Replace.

2. Check: fuel passagesObstruction Clean.

a. Wash the carburetor in a petroleum-basedsolvent. Do not use any caustic-carburetor-cleaning solution.

b. Blow out all of the passages and jets withcompressed air.

3. Check: float chamber bodyDirt Clean.

4. Check: float chamber rubber gasketCracks/damage/wear Replace.

5. Check: floatDamage Replace.

6. Check:needle valve 1needle valve seat 2Damage/obstruction/wear Replace theneedle valve, needle valve seat and O-ringas a set.

7. Check:O-ring 3Damage/wear Replace the needle valve,needle valve seat and O-ring as a set.

8. Check:piston valveDamage/scratches/wear Replace.

rubber diaphragmCracks/tears Replace.

9. Check:vacuum chamber coverpiston valve spring jet needle holderCracks/damage Replace.

5-5

CARBCARBURETORS

CAUTION:

NOTE:

10. Check: jet needle kit 1needle jet 2main jet 3pilot jet 4pilot screw 5Bends/damage/wear Replace.Obstruction Clean.Blow out the jets with compressed air.

11. Check:piston valve movementInsert the piston valve into the carburetorbody and move it up and down.Tightness Replace the piston valve.

12. Check: fuel feed pipeshose jointCracks/damage Replace.Obstruction Clean.Blow out the pipes with compressed air.

13. Check: fuel feed hoses fuel hosesCracks/damage/wear Replace.Obstruction Clean.Blow out the hoses with compressed air.

EAS00489

ASSEMBLING THE CARBURETORSThe following procedure applies to both of thecarburetors.

Before assembling the carburetors, washall of the parts in a petroleum-based sol-vent.

Always use a new gasket.

1. Install:needle jet 1pilot jetmain jet

Align the slot a on the needle jet with the pro-jection b on the carburetor body.

5-6

CARBCARBURETORS

NOTE:

NOTE:

EAS00489

2. Measure: float height aOut of specification Adjust.

Float height21.3 23.3 mm

a. Hold the carburetor upside down.b. Measure the distance from the mating sur-

face of the float chamber (with the gasket re-moved) to the top of the float.

The float arm should rest on the needle valvewithout depressing it.

c. If the float height is not within specification,inspect the needle valve seat and needlevalve.

d. If either the needle valve seat or needle valveis worn, replace them both.

e. If both the needle valve seat and needlevalve are fine, adjust the float height by bend-ing the float tang 1 .

f. Check the float height again.

3. Install:piston valvepiston valve springvacuum chamber cover

4. Install:connecting bracket

After installing the connecting bracket, checkthat the throttle cable lever and starter plungerlink operate smoothly.

5-7

CARBCARBURETORS

NOTE:

EAS00493

INSTALLING THE CARBURETORS1. Adjust:carburetor synchronizationRefer to “SYNCHRONIZING THE CARBU-RETORS” in chapter 3.

2. Adjust:engine idling speed


Refer to “ADJUSTING THE ENGINE IDLINGSPEED” in chapter 3.

3. Adjust: throttle cable free play

Throttle cable free play (at theflange of the throttle grip)

3 5 mm

Refer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

EAS00497

MEASURING AND ADJUSTING THE FUELLEVEL1. Measure: fuel level aOut of specification Adjust.

Fuel level (below the line on thefloat chamber)

3.5 4.5 mm

a. Stand the motorcycle on a level surface.b. Place the motorcycle on a suitable stand to

ensure that the motorcycle is standingstraight up.

c. Install the fuel level gauge 1 to the fuel drainpipe 2 .

Fuel level gauge90890-01312

d. Loosen the fuel drain screw 3 .e. Hold the fuel level gauge vertically next to the

line on the float chamberf. Measure the fuel level a .

Fuel level readings should be equal on bothsides of the carburetor assembly.

2. Adjust: fuel level

5-8

CARBCARBURETORS

NOTE:

1

2

12

a. Remove the carburetor assembly.b. Check the needle valve seat and needle

valve.c. If either is worn, replace them as a set.d. If both are fine, adjust the float level by slight-

ly bending the float tang 1 .e. Install the carburetor assembly.f. Measure the fuel level again.g. Repeat steps (a) to (f) until the fuel level is

within specification.

EAS00500

CHECKING AND ADJUSTING THE THROTTLEPOSITION SENSOR

Before adjusting the throttle position sensor,the engine idling speed should be properly ad-justed.

When installing the throttle position sensor,adjust its angle according to the r/min whichare displayed on the tachometer.Refer to the adjustment procedure below.

1. Check: throttle position sensor

a. Disconnect the throttle position sensor cou-pler.

b. Remove the throttle position sensor from thecarburetor.

c. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive lead Blue terminal Tester negative lead

Black/Blue terminal

d. Check the throttle position sensor maximumresistance.Out of specification Replace the throttleposition sensor.

Throttle position sensormaximum resistance

4.0 6.0 kΩ at 20C (68F)(Blue – Black/Blue)

e. Install the throttle position sensor onto thecarburetor.

f. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive lead Yellow Tester negative lead Black/Blue

g. While slowly opening the throttle, check thatthe throttle position sensor resistance iswithin the specified range.

5-9

CARBCARBURETORS

NOTE:

NOTE:

NOTE:

Out of specification Replace the throttleposition sensor.

Throttle position sensor resistance0 to 4 6 kΩ at 20C (68F)(Yellow – Black/Blue)

2. Adjust: throttle position sensor angle

a. Turn the main switch to “ON”.b. Disconnect the throttle position sensor cou-

pler.c. Reconnect the throttle position sensor cou-

pler.

After reconnecting the throttle position sensorcoupler, the tachometer switches to the throttleposition sensor adjustment mode.

d. Loosen the throttle position sensor screws1 .

e. Adjust the throttle position sensor angle ac-cording to the following table:

The angle of the throttle position sensor is indi-cated by the r/min which are displayed on thetachometer.

Tachometer readingThrottle position sensor angle

1,000 r/min 1Too small5,000 r/min 2Correct10,000 r/min 3Too large

f. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

To exit the throttle position sensor adjustmentmode, start the engine or turn the main switch to“OFF”.

5-10

CARBCARBURETORS

NOTE:

EAS00505

CHECKING THE FUEL COCK1. Check: fuel cockCracks/damage/wear Replace.

EAS00506

CHECKING THE FUEL COCK OPERATION

After installing the fuel cock, check its opera-tion.

1. Check that the fuel cock lever is positioned to“ON” or “R”.

2. Place a container under the end of the fuelhose.

3. Check: fuel cock operation

a. Suck on the end of the vacuum hose.

Fuel flows Fuel cock is OKFuel does not flows Replace the fuel

cock.

CHAS

CHAPTER 6.CHASSIS

FRONT WHEEL AND BRAKE DISCS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 6-7. . . . . . . . . .

REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET 6-9. . . . REAR WHEEL 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC AND REAR WHEEL SPROCKET 6-10. . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 6-12. . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET 6-12. INSTALLING THE REAR WHEEL 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 6-13. . . . . . . . . . . .

FRONT AND REAR BRAKES 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 6-16. . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 6-18. . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 6-20. . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6-24. . . . DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 6-24. . . . . CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDERS 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE

MASTER CYLINDERS 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 6-28. . . . . . . . FRONT BRAKE CALIPER 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 6-34. . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 6-35. . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 6-36. . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPERS 6-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 6-39. .

CHAS

FRONT FORK 6-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 6-44. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 6-44. . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 6-46. . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 6-47. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 6-50. . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR 6-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR 6-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR 6-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 6-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET 6-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET 6-59. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 6-59. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 6-60. . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 6-61. . . . . . HANDLING THE REAR SHOCK ABSORBER AND

GAS CYLINDER 6-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND

GAS CYLINDER 6-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 6-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND

GAS CYLINDER 6-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 6-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 6-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1


12345678

Removing the front wheel and brakediscs

Wheel axle pinch boltBrake hose holder (left /right)Caliper (left /right)Wheel axleFront wheelSpeedometer gear unitCollarBrake disc (left /right)

11/11/11111

1/1


Place the motorcycle on a suitable standso that the front wheel is elevated.

NOTE:

Refer to “REMOVING/INSTALLING THEFRONT WHEEL”.


73 Nm (7.3 mkg)

19 Nm (1.9 mkg)

20 Nm (2.0 mkg)

40 Nm (4.0 mkg)

CHASFRONT WHEEL AND BRAKE DISCS

EAS00514

CHASSISFRONT WHEEL AND BRAKE DISCS

6-2


Disassembling the front wheel.Oil sealBearingSpacerBearing

1111



1234


EAS00518

6-3


WARNING

NOTE:

NOTE:

NOTE:

WARNING

EAS00521

REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.



2. disconnect:speedometer cable 1

3. Remove:brake calipers 2 (left and right)

Do not squeeze the brake lever when removingthe brake calipers.

4. Loosen:pinch bolt (front wheel axle) 1 front wheel axle 2

5. Elevate: front wheel


EAS00525

CHECKING THE FRONT WHEEL1. Check:wheel axleRoll the wheel axle on a flat surface.Bends Replace.

Do not attempt to straighten a bent wheelaxle.

2. Check: tire front wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

3. Measure: front wheel radial runout 1 front wheel lateral runout 2Over the specified limits Replace.

6-4


NOTE:

CAUTION:

NOTE:

Front wheel radial runout limit1.0 mm

Front wheel lateral runout limit0.5 mm

4. Check:wheel bearingsFront wheel turns roughly or is loose Re-place the wheel bearings.

oil sealsDamage/wear Replace.

5. Replace:wheel bearings (New)oil seals (New)

a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag 2between the screwdriver and the wheel surface.

c. Remove the wheel bearings 3 with a gener-al bearing puller.

d. Install the new wheel bearings and oil sealsin the reverse order of disassembly.

Do not contact the wheel bearing centerrace 5 or balls 6 . Contact should be madeonly with the outer race 7 .

Use a socket 4 that matches the diameter ofthe wheel bearing outer race and oil seal.

EAS00531

CHECKING THE BRAKE DISCSThe following procedure applies to all of thebrake discs.1. Check:brake discDamage/galling Replace.

2. Measure:brake disc deflectionOut of specification Correct the brake discdeflection or replace the brake disc.

6-5


NOTE:

Brake disc deflection limit(maximum)

Front: 0.2 mmRear: 0.15 mm

a. Place the motorcycle on a suitable stand sothat the wheel is elevated.

b. Before measuring the front brake discdeflection, turn the handlebar to the left orright to ensure that the front wheel is station-ary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection 2 3 mm below the

edge of the brake disc.

3. Measure:brake disc thicknessMeasure the brake disc thickness at a fewdifferent locations.Out of specification Replace.

Brake disc thickness limit(minimum)

Front: 4.5 mmRear: 4.5 mm

4. Adjust:brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

Tighten the brake disc bolts in stages and in acrisscross pattern.

Brake disc bolt20 Nm (2.0 mkg)LOCTITE

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

6-6


NOTE:

NOTE:

NOTE:

CAUTION:

EAS00544

INSTALLING THE FRONT WHEELThe following procedure applies to both brakediscs.1. Lubricate:wheel axleoil seal lips


2. Install:brake disc 1

Apply LOCTITE 648 to the threads of thebrake disc bolts.

Tighten the brake disc bolts in stages and in acrisscross pattern.

3. Install:speedometer gear unit

Make sure that the speedometer gear unit andthe wheel hub are installed with the two projec-tions a meshed into the two slots b respec-tively.

4. Install: front wheel

Make sure that the slot a in the speedometergear unit fits over the stopper b on the outertube.

5. Tighten:wheel axle 1wheel axle pinch bolt 2

Wheel axle73 Nm (7.3 mkg)

Wheel axle pinch bolt19 Nm (1.9 mkg)

Before tightening the wheel axle nut, pushdown hard on the handlebar several timesand check if the front fork reboundssmoothly.

6-7


WARNING

NOTE:

NOTE:

6. Install:brake caliper

Brake caliper bolt40 Nm (4.0 mkg)

Make sure that the brake hose is routedproperly.

EAS00549

ADJUSTING THE FRONT WHEEL STATICBALANCE

After replacing the tire, wheel or both, the frontwheel static balance should be adjusted.

Adjust the front wheel static balance with thebrake discs installed.

1. Remove:balancing weight(-s)

Place the front wheel on a suitable balancingstand.

2. Find: front wheel’s heavy spot

a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.c. Turn the front wheel 90 so that the “X1” mark

is positioned as shown.d. Release the front wheel.e. When the wheel stops, put an “X2” mark at

the bottom of the wheel.f. Repeat steps (b) through (d) several times

until all the marks come to rest at the samespot.

g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

6-8


NOTE:

3. Adjust: front wheel static balance

a. Install a balancing weight 1 onto the rim ex-actly opposite the heavy spot “X”.

Start with the lightest weight.

b. Turn the front wheel 90 so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check: front wheel static balance

a. Turn the front wheel and make sure that itstays at each position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

6-9


1234567

Removing the rear wheel

Chain adjustersRear wheel axle nutPlate washerChain puller (left)Wheel axleChain Puller (right)Rear wheel

2111111


Place the motorcycle on a suitable standso that the rear wheel is elevated.

NOTE:

Refer to “REMOVING/INSTALLINGTHE REAR WHEEL”.


150 Nm (15.0 mkg)

CHASREAR WHEEL, BRAKE DISC AND

REAR WHEEL SPROCKET

EAS00550

REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKETREAR WHEEL

6-10


12345678

Removing the brake disc and rearwheel sprocketCollarBrake discClutch hubCollarRear wheel sprocketClutch dampersOil sealBearing

11111511


For installation, the removal procedure.

20 Nm (2.0 mkg)

60 Nm (6.0 mkg)


REAR WHEEL SPROCKET

BRAKE DISC AND REAR WHEEL SPROCKET

6-11


REAR WHEEL SPROCKET

WARNING

NOTE:

NOTE:

EAS00561

REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.



2. Loosen:adjusting bolt 1 locknut 2

3. Remove:wheel axle nut 3wheel axle 4 rear wheel right collar 5

Push the rear wheel forward and remove thedrive chain from the rear wheel sprocket.

EAS00565

CHECKING THE REAR WHEEL1. Check:wheel axle rear wheelwheel bearingsoil sealsRefer to “FRONT WHEEL”.

2. Check: tire rear wheelDamage/wear Replace.Refer to “INSPECTING THE TIRES” and“INSPECTING THE WHEELS” in chapter 3.

3. Measure: rear wheel radial runout rear wheel lateral runoutRefer to “FRONT WHEEL”.

6-12


REAR WHEEL SPROCKET

NOTE:

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB1. Check: rear wheel drive hubCracks/damage Replace.

rear wheel dive hub dampersDamage/wear Replace.

EAS00568

CHECKING AND REPLACING THE REARWHEEL SPROCKET1. Check: rear wheel sprocketMore than 1/4 tooth a wear Replace therear wheel sprocket.Bent teeth Replace the rear wheel sprock-et.

b Correct1 Drive chain roller2 Rear wheel sprocket2. Replace: rear wheel sprocket

a. Remove the self-locking nuts and the rearwheel sprocket.

b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.

c. Install the new rear wheel sprocket.

Rear wheel sprocketself-locking nut

60 Nm (6.0 mkg)

Tighten the self-locking nuts in stages and in acrisscross pattern.

6-13


REAR WHEEL SPROCKET

NOTE:

EAS00572

INSTALLING THE REAR WHEEL1. Lubricate:wheel axlewheel bearingsoil seal lips


2. Tighten:wheel axle nut

Wheel axle nut150 Nm (15.0 mkg)

EAS00575

ADJUSTING THE REAR WHEEL STATICBALANCE

After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.

1. Adjust: rear wheel static balanceRefer to “FRONT WHEEL”.

6-14


1234

Removing the front brake padsClipPad pinPad supportBrake pad

4224


Refer to “REPLACING THE FRONTBRAKE PADS”.


CHASFRONT AND REAR BRAKES

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

6-15


1234567

Removing the rear brake padsCaliperCoverClipPad pinPad springBrake padCaliper shim

1122122


Refer to “REPLACING THE REARBRAKE PADS”.


40 Nm (4.0 mkg)


EAS00578

REAR BRAKE PADS

6-16


CAUTION:

NOTE:

EAS00579

Disc brake components rarely require dis-assembly.Therefore, always follow these preventivemeasures:Never disassemble brake components un-less absolutely necessary.

If any connection on the hydraulic brakesystem is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled afterreassembly.

Never use solvents on internal brake com-ponents.

Use only clean or new brake fluid for clean-ing brake components.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt fluid immediately.

Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.

First aid for brake fluid entering the eyes:Flush with water for 15 minutes and get im-mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake hose holder 1speedometer cable guide 2brake caliper 3

2. Remove:brake pad clips 4brake pad pin 5brake pad spring 6

6-17


NOTE:

NOTE:

3. Remove:brake pads 7

4. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm

5. Install:brake padsbrake pad spring

Always install new brake pads, and a brake padspring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install new brake pads and a new brake padspring.

The arrow a on the brake pad spring must pointin the direction of disc rotation.

6-18


NOTE:

6. Install:brake pad pinsbrake pad clipsbrake caliper


7. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

8. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake caliper 1

2. Remove:brake pad cover 1brake pad clips 2brake pad pins 3brake pad spring 4

3. Remove:brake pads 5(along with the brake pad shims)

4. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm

6-19


NOTE:

NOTE:

5. Install:brake pad shims(onto the brake pads)

brake padsbrake pad spring

Always install new brake pads, brake padshims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install new brake pad shims onto the newbrake pads.

e. Install new brake pads and a new brake padspring.

The longer tangs a on the brake pad springmust point in the direction of disc rotation.

6. Install:brake pad pinsbrake pad clipsbrake pad coverbrake caliper




6-20


1234567

Removing the front brake mastercylinderBrake fluid

Brake leverBrake switch leadFront brake switchUnion boltCopper washers/Brake hoseMaster cylinder bracketMaster cylinder

1211

2 /111


Refer to “DISASSEMBLING/ASSEM-BLING AND INSTALLING THE REARBRAKE MASTER CYLINDER”.


10 Nm (1.0 mkg)

30 Nm (3.0 mkg)New


EAS00586

FRONT BRAKE MASTER CYLINDER

6-21



Disassembling the front brakemaster cylinderMaster cylinder bootCirclipMaster cylinder kitSpring

1111



1234

New

6-22


123456789

10

Removing the rear brake mastercylinderBrake fluidBoltsBrake pedalBrake switchUnion boltCopper washers/brake hoseClip/reservoir hoseCotter pin/copper washerPinMaster cylinder ass’yReservoir tank

2111

2/12/11/1111


Drain

Refer to “DISASSEMBLING/ASSEM-BLING THE REAR BRAKE MASTERCYLINDER”.

For installation, reverse removalprocedure.

30 Nm (3.0 mkg)

28 Nm (2.8 mkg)

23 Nm (2.3 mkg)


EAS00586

REAR BRAKE MASTER CYLINDER

6-23



Disassembling the rear brakemaster cylinderMaster cylinder bootCirclipMaster cylinder kitSpring

1111



1234

New

6-24


NOTE:

NOTE:

NOTE:

NOTE:

EAS00588

DISASSEMBLING THE FRONT BRAKE MAS-TER CYLINDER

Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system.

1. Remove: rear view mirror (right)brake lever 1

2. Disconnect:brake switch coupler 2(from the brake switch)

3. Remove:union bolt 3copper washers 4brake hose 5

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

EAS00589

DISASSEMBLING THE REAR BRAKE MAS-TER CYLINDER

Before disassembling the rear brake mastercylinder, drain the brake fluid from the entirebrake system.


To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

6-25


A B

C D

E F

EAS00592

CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to the both ofthe brake master cylinders.1. Check:brake master cylinder 1Damage/scratches/wear Replace.

brake fluid delivery passages 2(brake master cylinder body)Obstruction Blow out with compressed air.

A FrontB Rear

2. Check:brake master cylinder kit 1Damage/scratches/wear Replace.

C FrontD Rear

3. Check: front brake master cylinder reservoir 1Cracks/damage Replace.

front brake mater cylinder reservoir dia-phragm 2Damage/wear Replace.

rear brake fluid reservoir 1Cracks/damage Replace.

rear brake fluid reservoir diaphragm 2Cracks/damage Replace.

E FrontF Rear4. Check:brake hoses 1Cracks/damage/wear Replace.

6-26


WARNING

NOTE:

WARNING

CAUTION:

NOTE:

EAS00598

ASSEMBLING AND INSTALLING THEFRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents.


1. Install:brake master cylinder 1

Install the brake master cylinder holder withthe “UP” mark facing up.

Align the end of the brake master cylinderholder with the punch mark a on the handle-bar.

First, tighten the upper bolt, then the lower bolt.

Brake master cylinder bolt10 Nm (1.0 mkg)

2. Install:copper washers (New) 1brake hose 2union bolt 3


Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

When installing the brake hose onto thebrake master cylinder make sure that thebrake pipe touches the projection a asshown.

Turn the handlebar to the left and to the right tomake sure that the brake hose does not touchother parts (e.g., wire harness, cables, leads).Correct if necessary.

6-27


WARNING

CAUTION:

3. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)


Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.




4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.



6-28


WARNING

CAUTION:

WARNING

CAUTION:

EAS00610

ASSEMBLING THE REAR BRAKE MASTERCYLINDER1. Install:copper washers (New) 1brake hose 2

Union bolt 330 Nm (3.0 mkg)


When installing the brake hose onto thebrake master cylinder make sure that thebrake pipe touches the projection a asshown.

2. Fill:brake fluid reservoir






6-29




5. Adjust:brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.

Brake pedal position (below the top of the rider footrest) a

45 mm

6. Adjust: rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.

6-30


1234

Removing the front brake calipersBrake fluidUnion boltsCopper washersBrake hosesCaliper ass’y

2422



Refer to “DISASSEMBLING/ASSEMBLING AND INSTALLING THEFRONT BRAKE CALIPERS”.

7 Nm (0.7 mkg)

30 Nm (3.0 mkg)

40 Nm (4.0 mkg)


EAS00613

FRONT BRAKE CALIPER

6-31


6


12345678

Disassembling the front brake cali-pers.The following procedure applies to bothof the front brake calipers.ClipsPad pinPad springBrake pads/shimsCaliper pistonsBleed screwDust sealsPiston seals

211

2/24144



Refer to “DISASSEMBLING THE FRONTBRAKE CALIPERS”.

6 Nm (0.6 mkg)

6-32


1234

Removing the rear brake caliperBrake fluidUnion boltCopper washersBrake hoseCaliper ass’y

1211



Refer to “DISASSEMBLING/ASSEMBLING AND INSTALLING THEREAR BRAKE CALIPER”.

40 Nm (4.0 mkg)

30 Nm (3.0 mkg)

New


ESA00616

REAR BRAKE CALIPER

6-33


123456789

Disassembling the rear brake caliperCoverClipsPad pinsPad supportBrake pads/shimsCaliper pistonsDust sealsPiston sealsBleed screws

1221

2/22222



Refer to “DISASSEMBLING THE REARBRAKE CALIPER.”

6 Nm (0.6 mkg)

New

New

New

New


6-34


NOTE:

NOTE:

WARNING

EAS00625

DISASSEMBLING THE FRONT BRAKE CAL-IPERSThe following procedure applies to both of thebrake calipers.

Before disassembling either brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-tons from the brake caliper.

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side pistons from the brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts.

6-35


NOTE:

NOTE:

WARNING

EAS00629

DISASSEMBLING THE REAR BRAKE CAL-IPER

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.


Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-tons from the brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts.

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side pistons from the brake caliper.

6-36


A

B

WARNING

WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKECALIPERS

Recommended brake componentreplacement schedule

Brake pads If necessary


Brake hoses Every two years

Brake fluidEvery two years andwhenever the brakeis disassembled.

1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper.

brake caliper cylinders 2Scratches/wear Replace the brake cali-per.

brake calipers 3Cracks/damage Replace.

brake fluid delivery passages(brake caliper body)Obstruction Blow out with compressed air.

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.

A Front

B Rear

EAS00638

ASSEMBLING AND INSTALLING THEFRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.


6-37


WARNING

CAUTION:

Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake caliper 1(temporarily)

copper washers (New)brake hose 2union bolt 3



When installing the brake hose onto thebrake caliper 1 , make sure that the brakepipe a touches the projection b on thebrake caliper.

2. Remove:brake caliper

3. Install:brake padsbrake pad springsbrake caliper retaining boltbake caliperbrake hose holderRefer to “REPLACING THE BRAKE PADS”.


Brake hose holder bolt7 Nm (0.7 mkg)

4. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)

6-38


WARNING

CAUTION:









6-39


WARNING

New

30 Nm (3.0 mkg)

WARNING

CAUTION:

40 Nm (4.0 mkg)

7 Nm (7.0 mkg)

EAS00642

ASSEMBLING AND INSTALLING THE REARBRAKE CALIPER


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake caliper 1(temporarily)

copper washers brake hose 2union bolt 3


When installing the brake hose onto thebrake caliper 1 , make sure that the brakepipe a touches the projection b on thebrake caliper.

2. Remove:brake caliper

3. Install:brake padsbrake pad springsbrake caliperbrake hose holderRefer to “REPLACING THE REAR BRAKEPADS”.

6-40


WARNING

CAUTION:

4. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)




When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.




7. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

6-41


123456

Removing the front forkFront wheelBrake calipersBracketsFront fenderBolts (upper bracket)Cap boltsBolts (lower bracket)Front fork (left /right)

21224

1/1

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.


Refer to “REMOVING/INSTALLING THEFRONT FORK LEGS”.

23 Nm (2.3 mkg)

30 Nm (3.0 mkg)

23 Nm (2.3 mkg)

7 Nm (0.7 mkg)

CHASFRONT FORK

EAS00647

FRONT FORK

6-42

CHASFRONT FORK


12345678910111213

Disassembling the front forkCap boltsO-ringsPlatesSpacersSpring seatsFork springsDust sealsOil seal clipsOil sealsSeal spacersOuter tube bushingsBolts (damper rod)Gaskets

2222222222222


Refer to “DISASSEMBLING/ASSEMBLING THE FRONT FORK LEGS”.

23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

6-43

CHASFRONT FORK


141516171819

Inner tubesInner tube bushingsOil flow stoppersDamper rodsDamper rod springsOuter tubes

222222


Refer to “DISASSEMBLING/ASSEMBLING THE FRONT FORKLEGS”.

23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

6-44

CHASFRONT FORK

WARNING

NOTE:

WARNING

EAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.



2. Loosen:upper bracket pinch bolt 1cap bolt 2 lower bracket pinch bolt 3

Before loosening the upper and lowerbracket pinch bolts, support the front forkleg.

3. Remove: front fork leg

EAS00653

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Loosen the spring preload adjuster fully.2. Remove:cap bolt 1plate 2spacer 3spring seat 4spring

3. Drain fork oil

6-45

CHASFRONT FORK

CAUTION:

NOTE:

CAUTION:

4. Remove:dust seal 1oil seal clip 2(with a flat-head screwdriver)

Do not scratch the inner tube.

5. Remove:damper rod bolt 1

While holding the damper rod with the damperrod holder 2 and T-handle 3 , loosen thedamper rod bolt.

Damper rod holder (30 mm)90890-01327

T-Handle90890-01326

6. Remove: inner tube

a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket in a

vise with soft jaws.c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but care-fully.

Excessive force will damage the oil sealand bushing. A damaged oil seal or bush-ing must be replaced.

Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil flow stopper will be damaged.

6-46

CHASFRONT FORK

WARNING

CAUTION:

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure:spring free length aOver the specified limit Replace.

Spring free length limit395 mm

3. Check:damper rod 1Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.

oil flow stopper 2Damage Replace.

The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

4. Check:cap bolt O-ring 1Damage/wear Replace.

6-47

CHASFRONT FORK

WARNING

NOTE:

CAUTION:

NOTE:

EB703703

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Make sure that the oil levels in both frontfork legs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

When assembling the front fork leg, be sure toreplace the following parts:-inner tube bushing-outer tube bushing-oil seal-dust seal

Before assembling the front fork leg, makesure that all of the components are clean.

1. Install:damper rod 1

Allow the damper rod to slide slowly downthe inner tube 2 until it protrudes from thebottom of the inner tube. Be careful not todamage the inner tube.

2. Lubricate: inner tube’s outer surface

Recommended lubricantYamaha fork and shock oil 10Wor equivalent

3. Tighten:damper rod bolt 1

Damper rod bolt30 Nm (3.0 mkg)LOCTITE

While holding the damper rod with the damperrod holder 2 and T-handle 3 , tighten thedamper rod bolt.

Damper rod holder (30 mm)90890-01327

T-handle90890-01326

6-48

CHASFRONT FORK

CAUTION:

NOTE:

NOTE:

4. Install:outer tube bushing 1seal spacer 2oil seal 3(with the fork seal driver weight 4 andadapter 5 )

Fork seal driver weight90890-01367

Adapter90890-01374

Make sure that the numbered side of the oilseal faces up.

Before installing the oil seal, apply lithium soapbase grease onto its lips.

Apply fork oil onto the outer surface of the innertube.

5. Install:oil seal clip 1

Adjust the oil seal clip so that it fits into the outertube groove.

6. Install:dust seal 1(with the fork seal driver weight) 2

6-49

CHASFRONT FORK

CAUTION:

NOTE:

7. Fully compress the front fork leg.8. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)538 cm3

Recommended oilFork oil 10wor equivalent

Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

9. After filling up, slowly pump the fork up anddown to distribute the fork oil

10. Measure:Oil level aOut of specfication Adjust.

Oil level:137 mm

(from the top of the inner tube fully compressed and without the fork spring)

Hold the fork in an upright position.

11. Install: fork springspring seat 1spacer 2plate 3cap bolt 4

6-50

CHASFRONT FORK

NOTE:

NOTE:

WARNING

Install the fork spring with its smaller pitch up-ward.

Before installing the cap bolt, apply grease tothe O-ring.

Temporarily tighten the cap bolt.

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and lowerbracket pinch bolts.

Make sure that the inner fork tube is flush withthe top of the upper bracket.

2. Tighten: lower bracket pinch bolt 1cap bolt 2upper bracket pinch bolt 3

Lower bracket pinch bolt23 Nm (2.3 mkg)

Cap bolt23 Nm (2.3 mkg)

Upper bracket pinch bolt30 Nm (3.0 mkg)

Make sure that the brake hoses are routedproperly.

3. Adjust:spring preload adjusters (left and right)Refer to “ADJUSTING THE FRONT FORKLEGS” in chapter 3.

6-51


123456789

10111213

Removing the handlebarMaster cylinder bracketMaster cylinder (front brake)Throttle cable housingHandlebar switch (right)Throttle cable housingThrottle cablesGrip end (right)Throttle gripMaster cylinder bracketMaster cylinder (clutch)Handlebar switch (left)Starter lever/Starter cableGrip end (left)

11111211111

1/11


Refer to “INSTALLING THEHANDLEBAR”.

Refer to “INSTALLING THEHANDLEBAR”.

Refer to “REMOVING/INSTALLING THEHANDLEBAR”.

26 Nm (2.6 mkg)

10 Nm (1.0 mkg) 10 Nm (1.0 mkg)

26 Nm (2.6 mkg)

23 Nm (2.3 mkg)

CHASHANDLEBAR

EAS00664

HANDLEBAR

6-52


14151617

Handlebar gripCollarUpper handlebar holdersHandlebar

1121

Refer to “REMOVING THE HANDLEBAR”.

26 Nm (2.6 mkg)

10 Nm (1.0 mkg) 10 Nm (1.0 mkg)

26 Nm (2.6 mkg)

23 Nm (2.3 mkg)

Refer to “INSTALLING THE HANDLEBAR”.


CHASHANDLEBAR

6-53

CHASHANDLEBAR

WARNING

NOTE:

NOTE:

WARNING

WARNING

EAS00666

REMOVING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Remove: throttle cable housing 1

While removing the throttle cable housing, pullback the rubber cover 2 .

3. Remove:handlebar grip (left) 1

Blow compressed air between the handlebarand the handlebar grip, and gradually push thegrip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Check:handlebar 1Bends/cracks/damage Replace.

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

6-54

CHASHANDLEBAR

WARNING

WARNING

CAUTION:

NOTE:

3. Install:handlebar grip

a. Apply a light coat of rubber adhesive onto theleft end of the handlebar.

b. Slide the handlebar grip over the left end ofthe handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

Do not touch the handlebar grip until therubber adhesive has fully dried.

EAS00671

INSTALLING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Install:handlebar 1upper handlebar holders 2

Upper handlebar holder bolt23 Nm (2.3 mkg)

First, tighten the bolts on the front side ofthe handlebar holder, then on the rear side.

Turn the handlebar all the way to the leftand right. If there is any contact with thefuel tank, adjust the handlebar position.

The upper handlebar holders should beinstalled with the arrows a facing forward A .

Align the match marks b on the handlebarwith the upper surface of the lower handlebarholders.

6-55

CHASTHE HANDLEBAR

NOTE:

NOTE:

NOTE:

NOTE:

WARNING

WARNING

3. Install:handlebar grip 1 left grip end 2

There should be 1 3 mm of clearance a be-tween the handlebar grip and the left grip end.

4. Install: left handlebar switch 1

Align the pin on the left handlebar switch withthe hole a in the handlebar.

5. Install:master cylinder (clutch) 1master cylinder bracket 2

Align the mating surfaces of the master cylinderwith the punch mark a on the handlebar.

6. Install: throttle grip 1 throttle cable housing 2 throttle cables 3

Apply a thin coat of lithium soap base greaseonto the inside of the throttle grip and install itonto the handlebar.

Make sure that the pin a on the throttlecable housing is aligned with the hole b inthe handlebar.

7. Install: right grip end 1 right handlebar switch 2

Make sure that the throttle grip operatessmoothly.

6-56

CHASTHE HANDLEBAR

NOTE:Align the pin on the right handlebar switch withthe hole a in the handlebar.

There should be 1 3 mm of clearance b be-tween the throttle grip and the right grip end.

8. Install:master cylinder ass’y (front brake)

9. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

Throttle cable free play (at theflange of the throttle grip)

3 5 mm

6-57


123456789

10

Removing the lower bracketFront wheel

Front forkHandlebarSteering stem nut/WasherUpper bracketLock washerUpper ring nutRubber washerLower ring nutLower bracketRubber sealBearing coverBearing

1/1111111111

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.Refer to “FRONT FORK”.Refer to “HANDLEBAR”.

Refer to “REMOVING THE LOWERBRACKET/INSTALLING THESTEERING HEAD”.

Refer to “INSTALLING THE STEERINGHEAD”.

110 Nm (11.0 mkg)

40 Nm (4.0 mkg)

1st2nd

52 Nm (5.2 mkg)18 Nm (1.8 mkg)

CHASSTEERING HEAD

EAS00676

STEERING HEADLOWER BRACKET

6-58


111213

BearingDust sealLower handlebar holders

112


110 Nm (11.0 mkg)

40 Nm (4.0 mkg)

1st2nd

52 Nm (5.2 mkg)18 Nm (1.8 mkg)

CHASSTEERING HEAD

6-59

CHASSTEERING HEAD

WARNING

NOTE:

WARNING

EAS00679

REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.


2. Remove:upper ring nut 1 lower ring nut 2

Hold the lower ring nut with the exhaust andsteering nut wrench, then remove the upper ringnut with the ring nut wrench.

Exhaust and steering nut wrench90890-01268

Ring nut wrench90890-01403

Securely support the lower bracket so thatthere is no danger of it falling.

EAS00682

CHECKING THE STEERING HEAD1. Wash:bearing ballsbearing races

Recommended cleaning solventKerosine

2. Check:bearing balls 1Damage/pitting Replace.

3. Replace:bearing ballsbearing races

6-60

CHASSTEERING HEAD

CAUTION:

NOTE:

NOTE:

NOTE:

a. Remove the bearing races from the steeringhead pipe with a long rod 1 and hammer.

b. Remove the bearing race from the lowerbracket with a floor chisel 2 and hammer.

c. Install a new dust seal and new bearingraces.

If the bearing race is not installed properly,the steering head pipe could be damaged.

Always replace the bearing balls and bearingraces as a set.

Whenever the steering head is disassembled,replace the dust seal.

4. Check:upper bracket lower bracket(along with the steering stem)Bends/cracks/damage Replace.

EAS00683

INSTALLING THE STEERING HEAD1. Lubricate:upper bearing lower bearingbearing races


2. Install: lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “INSPECTING THE STEERINGHEAD” in chapter 3.

3. Install:upper bracketsteering stem nut

Temporarily tighten the steering stem nut.

4. Install: front fork legsRefer to “FRONT FORK”.

Temporarily tighten the upper and lower bracketpinch bolts.

6-61


123456789

10

Removing the rear shock absorber,swingarm and drive chain.Rear wheel

Drive sprocketRear shock absorber (left /right)Chain caseBrake hose holdersTension bar/Caliper bracketPivot shaftSwingarmDrive chain guideDust coversWashersBush

112

1/1111221


Refer to “REAR WHEEL, BRAKEDISCAND REAR WHEEL SPROCKET”.Refer to “ENGINE” in chapter 4.

Refer to “REMOVING THE SWINGARM”.

23 Nm (2.3 mkg)

125 Nm (12.5 mkg)

7 Nm (0.7 mkg)

23 Nm (2.3 mkg)

30 Nm (3.0 mkg)

7 Nm (0.7 mkg)

CHASREAR SHOCK ABSORBER,

SWINGARM AND DRIVE CHAIN

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN

6-62


1112

BearingsDrive chain

21


23 Nm (2.3 mkg)

125 Nm (12.5 mkg)

7 Nm (0.7 mkg)

23 Nm (2.3 mkg)

30 Nm (3.0 mkg)

7 Nm (0.7 mkg)



6-63


SWINGARMAND DRIVE CHAIN

WARNING

WARNING

EAS00687

HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER

This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following information. Themanufacturer cannot be held responsiblefor property damage or personal injury thatmay result from improper handling of therear shock absorber and gas cylinder.Do not tamper or attempt to open the rearshock absorber or gas cylinder.

Do not subject the rear shock absorber orgas cylinder to an open flame or any othersource of high heat. High heat can causean explosion due to excessive gas pres-sure.

Do not deform or damage the rear shockabsorber or gas cylinder in any way. If therear shock absorber, gas cylinder or bothare damaged, damping performance willsuffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORB-ER AND GAS CYLINDER

a. Gas pressure must be released before dis-posing of a rear shock absorber and gas cyl-inder. To release the gas pressure, drill a 2 3 mm hole through the gas cylinder at a point15 20 mm from its end as shown.

Wear eye protection to prevent eye damagefrom released gas or metal chips.

6-64


SWINGARMAND DRIVE CHAIN

WARNING

NOTE:

NOTE:

EAS00703

REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.



2. Remove: rear shock absorber assembly lower bolt 1

When removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

3. Check:swingarm side playswingarm vertical movement

a. Check the tightening torque of the pivot shaftnut.

Pivot shaft nut125 Nm (12.5 mkg)

b. Check the swingarm side play A by movingthe swingarm from side to side.

c. If the swingarm side play is out of specifica-tion, check the spacers, bearings, washers,and dust covers.

Swingarm side play (at the enof the swingarm)

0 mm

d. Check the swingarm vertical movement Bby moving the swingarm up and down.If swingarm vertical movement is not smoothof if there is binding, check the spacers, bear-ings, washers, and dust covers.

6-65



WARNING

EAS00696

CHECKING THE REAR SHOCK ABSORBERASSEMBLY AND GAS CYLINDER1. Check: rear shock absorber rod 1Bends/damage Replace the rear shockabsorber assembly.

rear shock absorberGas leaks/oil leaks Replace the rearshock absorber assembly.

spring 2Damage/wear Replace the rear shock ab-sorber assembly.

gas cylinder 3Damage/gas leaks Replace.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

EAS00707

CHECKING THE SWINGARM1. Check:swingarmBends/cracks/damage Replace.

2. Check:pivot shaftRoll the pivot shaft on a flat surface.Bends Replace.

Do not attempt to straighten a bent pivotshaft.

3. Wash:pivot shaftdust coversspacerwashersbearings

Recommended cleaning solventKerosine

6-66



NOTE:

CAUTION:

4. Check:dust covers 1washers 2Damage/Wear Replace.

bearings 3Damage/Pitting Replace.

bush 4Damage/Scratches Replace.

EAS00709

CHECKING THE DRIVE CHAIN1. Measure: ten-link section a of the drive chainOut of specification Replace the drivechain.

Ten-link drive chain section limit(maximum)

150 mm

While measuring the ten-link section, pushdown on the drive chain to increase its tension.

Measure the length between drive chain roller1 and 11 as shown.

Perform this measurement at two or three dif-ferent places.

2. Check:drive chainStiffness Clean and lubricate or replace.

3. Clean:drive chain

a. Wipe the drive chain with a clean cloth.b. Put the drive chain in kerosine and remove

any remaining dirt.c. Remove the drive chain from the kerosine

and completely dry it.

This motorcycle has a drive chain with smallrubber O-rings 1 between the drive chainside plates. Never use high-pressure wateror air, steam, gasoline, certain solvents(e.g., benzine), or a coarse brush to cleanthe drive chain. High-pressure methodscould force dirt or water into the drivechain’s internals, and solvents will deterio-rate the O-rings. A coarse brush can alsodamage the O-rings. Therefore, use onlykerosine to clean the drive chain.

6-67



4. Check:O-rings 1Damage Replace the drive chain.

drive chain rollers 2Damage/wear Replace the drive chain.

drive chain side plates 3Damage/wear Replace the drive chain.Cracks Replace the drive chain and makesure that the battery breather hose is proper-ly routed away from the drive chain and be-low the swingarm.

5. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

6. Check:drive sprocket rear wheel sprocketMore than 1/4 tooth a wear Replace thedrive chain sprockets as a set.Bent teeth Replace the drive chainsprockets as a set.

b Correct

1 Drive chain roller

2 Drive chain sprocket

ELEC

CHAPTER 7.ELECTRICAL

ELECTRICAL COMPONENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCHES 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCH CONTINUITY 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SWITCHES 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BULBS AND BULB SOCKETS 7-5. . . . . . . . . . . . . . . . . . TYPES OF BULBS 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 7-5. . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 7-7. . . . . . . .

IGNITION SYSTEM 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUTOFF SYSTEM OPERATION 7-14. . . . . . . . . . . TROUBLESHOOTING 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.C. GENERATOR 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 7-29. . . . . . . . . . . . . . . . . . . . . . . . .

SIGNALING SYSTEM 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 7-34. . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 7-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

ELECELECTRICAL COMPONENTS

Rear brake switchOil level switchHornsIgnition coils

Main switchFuel senderStarter relayStarting circuit cutoff relayBatteryOil level relayFlasher relayIgnitior unitNeutral switchSidestand switch

123456789

10

11121314

EAS00729

ELECTRICAL

ELECTRICAL COMPONENTS

7-2

ELECSWITCHES

B

B

CAUTION:

NOTE:

NOTE:

EAS0010

SWITCHESCHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.

Never insert the tester probes into the cou-pler terminal slots 1 . Always insert theprobes from the opposite end of the coupler,taking care not to loosen or damage theleads.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

When checking for continuity, switch back andforth between the switch positions a few times.

The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).

The example illustration on the left showsthat:There is continuity between blue/red and redwhen the switch is set to “ ”.There is continuity between blue/red and blue,between brown/blue and red, and betweenblue/yellow and black when the switch is set to“ON”.

7-3

ELECCHECKING THE SWITCHES

EAS00731

CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the termi-nals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear Repair or replace the switch.Improperly connected Properly connect.Incorrect continuity reading Replace the switch.

7-4

Start switchLights switch (for Europe)Rear brake switchFuseSide stand switchNeutral switchOil level switch

*1: for Europe*2: for AUS

Horn switchClutch switchDimmer switchPass switchTurn signal switchMain switchFront brake switchEngine stop switch

12345678

9101112131415

ELECCHECKING THE SWITCHES

7-5

ELECCHECKING THE BULBS AND BULB SOCKETS

EAS00732

CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear Repair or replace the bulb,bulb socket or both.Improperly connected Properly connect.Incorrect continuity reading Repair or replacethe bulb, bulb socket or both.

TYPES OF BULBSThe bulbs used on this motorcycle are shown inthe illustration on the left.Bulbs A and B are used for headlights andusually use a bulb holder which must be de-tached before removing the bulb. The majorityof these bulbs can be removed from their re-spective socket by turning them counterclock-wise.

Bulb C is used for turn signal and tail /brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.

Bulbs D and E are used for meter and indica-tor lights and can be removed from their re-spective socket by carefully pulling them out.

CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:bulb

7-6


WARNING

CAUTION:

NOTE:

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverse-ly affected. If the headlight bulb getssoiled, thoroughly clean it with a clothmoistened with alcohol or lacquer thinner.

2. Check:bult (for continuity)(with the pocket tester)No continuity Replace.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

a. Connect the tester positive probe to terminal1 and the tester negative probe to terminal2 , and check the continuity.

b. Connect the tester positive probe to terminal1 and the tester negative probe to terminal3 , and check the continuity.

c. If either of the readings indicate no continuity,replace the bulb.

7-7


NOTE:

CHECKING THE CONDITION OF THE BULB SOCKETSThe following procedure applies to all of thebulb sockets.1. Check:bulb socket (for continuity)(with the pocket tester)No continuity Replace.


Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.c. Check the bulb socket for continuity.

If any of the readings indicate no continuity,replace the bulb socket.

7-8

2 3 5 6 9 10 11 12 14 15 18

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Eng

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stop

sw

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ELECIGNITION SYSTEM

EAS00735

IGNITION SYSTEMCIRCUIT DIAGRAM

7-9

ELECIGNITION SYSTEM

NOTE:

YES NO

Replace the fuse(-s).

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?

2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.

Min. open-circuit voltage12.8 V or more at 20 C

Is the battery OK?

YES

Clean the batteryterminals.

Recharge or re-place the battery.

NO

3. Spark plugs

The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in chapter 3.

Standard spark plugDPR 8EA-9 (NGK)X24EPR-U9 (DENSO)

Spark plug gap0.8 0.9 mm

Is the spark plug in good condition, is it of thecorrect type, and its gap within specification?

YES

Re-gap or replace thespark plug.

NO

EAS00737

TROUBLESHOOTING

The ignition system fails to operate (nospark or intermittent spark).

Check:1. main and ignition fuses2. battery3. spark plugs4. ignition spark gap5. spark plug cap resistance6. ignition coil resistance7. pickup coil resistance8. main switch9. engine stop switch

10. neutral switch11. sidestand switch12. wiring

(of the entire ignition system)

Before troubleshooting, remove the followingpart(-s):

1) seat2) fuel tank3) headlight unit4) side cover (left)Troubleshoot with the following specialtool(-s).

Ignition checker90890-06754


EAS00738

EAS00739

EAS00741

7-10

4. Ignition spark gap

The following procedure applies to all of thespark plugs.Disconnect the spark plug cap from the sparkplug.

Connect the ignition checker as shown. Spark plug capSet the main switch to “ON”.Measure the ignition spark gap .Crank the engine by pushing the start switchand gradually increase the spark gap until amisfire occurs.

Min. ignition spark gap6 mm

Is there a spark and is the spark gap withinspecification?

NO

The ignition system isOK.

YES

EAS00745

5. Spark plug cap resistance

The following procedure applies to all of thespark plug caps.Disconnect the spark plug cap from the sparkplug.

Connect the pocket tester (Ω 1k) to thespark plug cap as shown.

Measure the spark plug cap resistance.

Spark plug cap resistance10 kΩ at 20C

Is the spark plug cap OK?

YES

Replace the sparkplug cap.

NO

EAS00747

6. Ignition coil resistance

The following procedure applies to all of theignition coils.Disconnect the ignition coil connectors fromthe ignition coil terminals.

Connect the pocket tester (Ω 1) to the igni-tion coil as shown.

Primary coil resistance1.9 2.9 Ω at 20C

Connect the pocket tester (Ω 1k) to theignition coil as shown.

Measure the secondary coil resistance.

Tester positive probe red/blackTester negative probe orange (gray)

Measure the primary coil resistance.

Tester positive probe

spark plug lead Tester negative probe

spark plug lead

1

1

2

a

2

ELECIGNITION SYSTEM

EAS00743

7-11

Secondary coil resistance9.5 14.3 kΩ at 20C

Is the ignition coil OK?

YES

Replace the ignitioncoil.

NO

EAS00748

7. Pickup coil resistance

Disconnect the pickup coil coupler from thewire harness.

Connect the pocket tester (Ω 100) to thepickup coil terminal.

Pickup coil resistance248 372 Ω at 20C(between white/red and white/green)

Is the pickup coil OK?

YES

Replace the pickupcoil.

NO

Tester positive probe white/red Tester negative probe white/green

12

Measure the pickup coil resistance.

EAS00749

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?

YES

Replace the mainswitch.

NO

8. Main switch

EAS00750

Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the engine stop switch OK?

YES

Replace the righthandlebar switch.

NO

9. Engine stop switch

EAS00751

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

YES

Replace the neutralswitch.

NO

10. Neutral switch

EAS00752

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES

Replace the side-stand switch.

NO

11. Sidestand switch

W/G

W/R

ELECIGNITION SYSTEM

7-12

EAS00754

Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-nected and without defects?

NO

Replace the ignitorunit.

YES

13. Wiring

Properly connect orrepair the ignitionsystem’s wiring.

ELECIGNITION SYSTEM

7-13

2 3 4 5 6 7 8 14 15 17 18

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Igni

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Sta

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Sta

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38

ELECELECTRIC STARTING SYSTEM

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

7-14


EAS00756

STARTING CIRCUIT CUTOFF SYSTEMOPERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met:

The transmission is in neutral (the neutralswitch is closed).

The clutch lever is pulled to the handlebar (theclutch switch is closed) and the sidestand is up(the sidestand switch is closed).

The starting circuit cutoff relay prevents thestarter motor from operating when neither ofthese conditions has been met. In this instance,the starting circuit cutoff relay is open so currentcannot reach the starter motor. When at leastone of the above conditions has been met thestarting circuit cutoff relay is closed and the en-gine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS INNEUTRAL

WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED TOTHE HANDLEBAR

1 Battery

2 Main fuse

3 Main switch

4 Ignition fuse

5 Engine stop switch

6 Starting circuit cutoff relay

7 Diode

8 Clutch switch

9 Sidestand switch

10 Neutral switch

11 Start switch

12 Starter relay

13 Starter motor

7-15


NOTE:

YES NO


1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?

2. Battery


Open-circuit voltage12.8 V or more at 20 C

Is the battery OK?

YES


Recharge or replace the battery.

NO

3. Starter motor

Connect the battery positive terminal andstarter motor lead with a jumper lead .

YES

Repair or replace thestarter motor.

NO

EAS00758

132

WARNINGA wire that is used as a jumper lead musthave at least the same capacity of thebattery lead, otherwise the jumper leadmay burn.

This check is likely to produce sparks,therefore make sure that no flammablegas or fluid is in the vicinity.

Does the starter motor turn?

EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:1. main and ignition fuses2. battery3. starter motor4. starting circuit cutoff relay5. diode6. starter relay7. main switch8. engine stop switch9. neutral switch

10. sidestand switch11. clutch switch12. start switch13. wiring

(of the entire starting system)

Before, troubleshooting, remove the followingpart(-s):

1) seat2) fuel tank3) headlight unitTroubleshoot with the following specialtool(-s).


EAS00738

EAS00739

7-16

4. Starting circuit cutoff relay

Disconnect the relay unit from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay unit terminals asshown.

YES

Replace the relayunit.

NO

Battery positive terminal red/blackBattery negative terminal

black/yellow

1

2

Tester positive probe blue/whiteTester negative probe black

34

Does the starting circuit cutoff relay havecontinuity between black and blue/white?

5. Diode

Disconnect the starting circuit cutoff relayfrom the coupler.

Connect the pocket tester (Ω 1) to thestarting circuit cutoff relay terminals asshown.

Measure the starting circuit cutoff relay forcontinuity as follows.

YES


NO


light greenTester negative probe

black/yellow

1

2

Continuity

NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in the abovechart will be reversed.

Are the tester readings correct?

EAS00760


black/yellowTester negative probe

light green

2

1

Nocontinuity


EAS00759

7-17

6. Starter relay

Disconnect the starter relay from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starter relay coupler asshown.

YES

Replace the starter relay.

NO

Battery positive terminal red/whiteBattery negative terminal

blue/white 2

EAS00750

Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the engine stop switch OK?

YES


NO

8. Engine stop switch

EAS00751



YES


NO

9. Neutral switch

EAS00752

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES

Replace the sidestand switch.

NO

10. Sidestand switch

EAS00763

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES

Replace the clutchswitch.

NO

11. Clutch switch

1

Tester positive probe red Tester negative probe black

34

Does the starter relay have continuity be-tween red and black?

EAS00749



YES


NO

7. Main switch


EAS00761

7-18

EAS00766

Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the starting system’s wiring properly con-nected and without defects?

NO

The starting systemcircuit is OK.

YES

13. Wiring

Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?

YES


NO

12. Start switch

Properly connect orrepair the startingsystem’s wiring.


EAS00764

7-19



12

1234567

Removing the starter motorStarter motor leadStarter motor assembly

Disassembling the starter motorStarter motor front coverWasher setStarter motor rear coverwasher setBrush holder/brushArmature assemblyStarter motor yoke

11

1111

1/111



Disassembly the pats in the order listed.

For assembly, reverse the disassemblyprocedure

10 Nm (1.0 mkg)

STARTER MOTOR

7-20


NOTE:

EAS00769

Checking The Starter Motor1. Check:commutatorDirt Clean with 600 grit sandpaper.

2. Measure:commutator diameter aOut of specification Replace the startermotor.

Min. commutator diameter27 mm

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladewhich has been grounded to fit the commuta-tor.

Mica undercut0.7 mm

The mica must be undercut to ensure properoperation of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.


Armature assemblyCommutator resistance 1

0.025 0.035 Ω at 20CInsulation resistance 2

Above 1 M Ω at 20C

b. If any resistance is out of specification, re-place the starter motor.

7-21

ELECTRIC STARTING SYSTEM ELEC

NOTE:

New

5 Nm (0.5 mkg)

NOTE:

5. Measure:brush length aOut of specification Replace the brushesas a set.

Min. brush length5 mm

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force7.65 10.01 N (0.780 1.021 kg)

7. Check:gear teethDamage/wear Replace the gear.

8. Check:oil sealDamage/wear Replace the defectivepart(-s).

EAS00772

Assembling The Starter Motor1. Install:brush holder 1

Align the tab a on the brush holder with the slotb in the starter motor rear cover.

2. Install:starter motor yoke 1O-rings 2 starter motor front cover 3starter motor rear cover 4bolts

Align the match marks a on the starter motoryoke with the match marks b on the front andrear covers.

7-22

CHARGING SYSTEM ELEC

1235

GeneratorMain fuseBatteryMain switch

EB804000

CHARGING SYSTEMCIRCUIT DIAGRAM

7-23


NOTE:

YES NO

Replace the fuse.

1. Main fuse

Check the main fuse for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Is the main fuse OK?

2. Battery



Is the battery OK?

YES



NO

EAS00775

3. Charging voltage

Connect the engine tachometer to the sparkplug lead of cylinder #1.

Connect the pocket tester (DC 20 V) to thebattery as shown.

Charging voltage14 V at 5,000 r/min


battery positive terminalTester negative probe

battery negative terminal

Start the engine and let it run at approximate-ly 5,000 r/min.

Measure the charging voltage.

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:1. main fuse2. battery3. charging voltage4. startor coil assembly resistance5. brush check6. field coil resistance7. main switch8. wiring

(of the entire charging system)





EAS00738

EAS00739

7-24

NO

The charging circuitis OK.

YES

NOTE:Make sure that the battery is fully charged.

Is the charging voltage within specification?

EAS00776

4. Stator coil assembly resistances

Remove the generator cover.Connect the pocket tester (Ω 1) to the sta-tor coil assembly coupler as shown.

Stator coil resistance0.19 0.21 Ω at 20C

Is the stator coil assembly OK?

YES

Replace the stator coil assembly.

NO

Tester positive probe white Tester negative probe black

12

Measure the stator coil assembly resis-tances.

Tester positive probe white Tester negative probe black

13

5. Brush check

Remove the brush holder .

Brush spring force5.10 5.69 N (0.52 0.58 kg)

Brush overall length <wear limit>13.7 mm <4.7 mm>

Are the brush spring and brush OK?

YES

Replace the brushesand brush spring as aset.

NO

Check the brush spring.Measure the overall length of brushes.

EAS00777

1


7-25

6. Field coil resistance

Connect the pocket tester (Ω 1) to the rotoras shown.

Field coil resistance2.8 3.0 Ω at 20C

Measure the field coil resistance.

Is the field coil OK?

YES

Replace the field coil.

NO

EAS00749

Check the mian switch for continuity.Refer to “CHECKING THE SWITCHES”.


YES


NO

7. Main switch

EAS00779

Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properly con-nected and without defects?

NO

Replace the rectifier.

YES

8. Wiring

Properly connect orrepair the chargingsystem’s wiring.


EAS00778

7-26


1234567891011

Disassembling the A.C. GeneratorCoverBrush holderRegulatorRectifier coverRectifierRear coverRotor assemblyBearing coverBearingBearingStator assembly

11111111111

Disassembly the parts in the order list.


7 Nm (0.7 mkg)

25 Nm (2.5 mkg)


A.C. GENERATOR

7-27

2 3 5 21 32 37 41 42 44 45 46

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Mai

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Ligh

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ligh

tH

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beam

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Aux

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ight

47

LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

7-28


NOTE:

YES NO


1. Main, and headlight fuses

Check the main, and headlight fuses for con-tinuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, and headlight fuses OK?

2. Battery



Is the battery OK?

YES



NO

EAS00749



YES


NO

3. Main switch

EAS00783

Check the lights switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the lights switch OK?

YES

The lights switch isfaulty. Replace theright handlebarswitch.

NO

4. Lights switch (for Europe)

EAS00781

TROUBLESHOOTING

Any of the following fail to light: head-light, high beam indicator light, taillight,auxiliary light (for Europe) or meter light.

Check:1. main, and headlight fuses2. battery3. main switch4. lights switch (for Europe)5. dimmer switch6. pass switch7. wiring

(of the entire charging system)




EAS00738

EAS00739

7-29

Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the dimmer switch OK?

YES

The dimmer switchis faulty. Replace theleft handlebarswitch.

NO

5. Dimmer switch

EAS00786

Check the pass switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the pass switch OK?

YES

The pass switch isfaulty. Replace theleft hadlebar switch.

NO

6. Pass switch

EAS00787

Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-nected and without defects?

YES

Properly connect orrepair the lightingsystem’s wiring.

NO

7. Wiring

Check the conditionof each of the light-ing system’s circuits.Refer to “CHECK-ING THE LIGHTINGSYSTEM”.

Check the headlight bulb and socket for con-tinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the headlight bulb and socket OK?

YES

Replace the head-light bulb, socket orboth.

NO

1. Headlight bulb and socket

2. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers as shown.

When the dimmer switch is set to “ ”When the dimmer switch is set to “ ”

AB

Headlight coupler (wire harness side)

Y

G


EAS00784 EAS00788

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.

7-30

HeadlightTester positive probe

yellow or green Tester negative probe black

High beam indicator lightTester positive probe yellow Tester negative probe black

Set the main switch to “ON”.Set the light switch to “ ”.Set the dimmer switch to “ ” or “ ”.Measure the voltage (12 V) of yellow (green)

on the headlight coupler (headlight side). Is the voltage within specification?

1 23

45

2

YES

Replace the meterlight bulb, socket orboth.

NO

EAS00789

2. A meter light fails to come on.

1. Meter light bulb and socket.

Check the meter light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the meter light bulb and socket OK?

The wiring circuitfrom the main switchto the headlight cou-pler is faulty and mustbe repaired.

NO

YES

2. Voltage

Connect the pocket tester (20 V) to the meterassembly coupler (wire harness side) asshown.

Tester positive probe blue Tester negative probe black

12

This circuit is OK.

Replace the tail /brake light bulb, sock-et or both.

NO

YES

The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.

NO

This circuit is OK.

EAS00790

3. A tail /brake light fails to come on.

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

YES

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue on themeter assembly coupler (wire harness side).

Is the voltage within specification?

1

ELECLIGHTING SYSTEM

7-31

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.

Tester positive probe blue/red Tester negative probe black

12

YES

The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.

NO

This circuit is OK.

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe tail /brake light coupler (wire harnessside).


1

Replace the auxiliarylight bulb, socket orboth.

NO

EB805413

4. The auxiliary light fails to come on. (for Eu-rope)

1. Auxiliary light bulb and socket

Check the auxiliary light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the auxiliary light bulb and socket OK?

YES

2. Voltage

Connect the pocket tester (DC 20 V) to theauxiliary light couplers (wire harness side) asshown.

Tester positive probe blue/red Tester negative probe black

12

YES

The wiring circuitfrom the main switchto the auxiliary lightconnectors is faultyand must be re-paired.

NO

This circuit is OK.

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe auxiliary light couplers (wire harnessside).


1

L/R


7-32

2 3 5 14 16 19 22 23 24 25 26

Mai

n fu

seB

atte

ry

Mai

n sw

itch

Neu

tral

sw

itch

Oil

leve

l rel

ayF

ront

bra

ke li

ght s

witc

hS

igna

ling

syst

em fu

seR

ear

brak

e lig

ht s

witc

hH

orn

Fla

sher

rel

ayO

il le

vel s

witc

hF

uel g

auge

30

Fue

l sen

der

31

Neu

tral

indi

cato

r lig

ht33

Turn

sig

nal i

ndic

ator

34

Turn

sig

nal i

ndic

ator

35

Oil

leve

l war

ning

ligh

t36

Turn

sig

nal s

witc

h39

Hor

n sw

itch

40

Tail/

brak

e lig

ht46

Fro

nt tu

rn s

igna

l lig

ht48

Rea

r tu

rn s

igna

l lig

ht49

light

(le

ft

light

(rig

ht)

SIGNALING SYSTEM ELEC

EAS00793

SIGNALING SYSTEMCIRCUIT DIAGRAM

7-33


YES


NO

YES


Recharge or re-place the battery.

NO


NO

EAS00749

3. Main switch



YES

1. Main and signaling system fuses

Check the main and signaling system fusesfor continuity.Refer to “CHECKING AND CHANGINGTHE FUSES” in chapter 3.

Are the main and signaling system fuses OK?

2. Battery

Check the condition of the battery.Refer to “CHECKING THE BATTERY” inchapter 3.

Is the battery OK?

NO

EAS00795

4. Wiring

Check the entire signaling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the signaling system’s wiring properly con-nected and without defects?

YES

Properly connect orrepair the signalingsystem’s wiring.

Check the conditionof each of the signal-ing system’s circuits.Refer to “CHECKINGTHE SIGNALINGSYSTEM”.


NOTE:

EB806010

TROUBLESHOOTING

Any of the following fail to light: turn sig-nal light, brake light or an indicator light.

The horn fails to sound.

Check:1. main and signaling system fuses2. battery3. main switch4. wiring

(of the entire signaling system)


1) seats2) fuel tank3) headlight unitTroubleshoot with the following specialtool(-s).


EAS00738

EAS00739

7-34

Replace the left han-dlebar switch.

NO

1. Horn switch

Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the horn switch OK?

YES

2. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the horn terminal asshown.

Tester positive probe brown Tester negative probe ground

1The horn is OK.

YES

3. Horn

Disconnect the black connector at the hornterminal.

Connect a jumper lead to the horn terminaland ground the jumper lead.

Set the main switch to “ON”.Does the horn sound?

NO

4. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the black terminal asshown.

Tester positive probe black Tester negative probe ground

1

Set the main switch to “ON”.Measure the voltage (12 V) of brown at thehorn terminal.


The wiring circuitfrom the main switchto the horn connectoris faulty and must berepaired.

NOYES

Set the main switch to “ON”.Measure the voltage (12 V) of black at thehorn terminal.


1

NOYES

Replace the horn.Repair or replace thehorn.

1

Br P

Br

Br P


EAS00796

CHECKING THE SIGNALING SYSTEM1. The horn fails to sound.

7-35

Replace the tail /brake light bulb, sock-et or both.

NO

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

YES

3. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.

Tester positive probe yellow Tester negative probe black

1

Replace the brakelight switch.

NO

2. Brake light switches

Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.

Is the brake light switch OK?

YES

2

YES

The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.

NO

This circuit is OK.

Set the main switch to “ON”.Pull in the brake lever or push down on thebrake pedal.

Measure the voltage (12 V) of yellow at thetail /brake light coupler (wire harness side).


Replace the turn sig-nal light bulb, socketor both.

NO

EAS00799

3. A turn signal light, turn signal indicator lightor both fail to blink.

1. Turn signal light bulb and socket

Check the turn signal light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the turn signal light bulb and socket OK?

YES


EAS00797

2. A tail /brake light fails to come on.

7-36

A B

Replace the left han-dlebar switch.

NO

2. Turn signal switch

Check the turn signal for continuity.Refer to “CHECKING THE SWITCHES”.

Is the turn signal switch OK?

YES

The wiring circuitfrom the main switchto the flasher relaycoupler (flasher relayside) is faulty andmust be repaired.

NO

3. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay coupler (wire harness side) asshown.

YES

Tester positive probe brown Tester negative probe ground

1

Set the main switch to “ON”.Measure the voltage (12 V) of brown at theflasher relay coupler (wire harness side).


1

4. Voltage

Connect the tester (DC 20 V) to the flasherrelay coupler (wire harness side) as shown.

The flasher relay isfaulty and must be re-placed.

NOYES

1

Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) or brown/white atthe flasher relay coupler (wire harness side).


Tester positive probe brown/white Tester negative probe ground

5. Voltage

Connect the pocket tester (DC 20 V) to theturn signal light connectors or the meter as-sembly coupler (wire harness side) asshown.

Turn signal lightTurn signal indicator light

AB

Left turn signal lightTester positive probe chocolate Tester negative probe ground

Right turn signal lightTester positive probe dark green Tester negative probe ground

1

2


7-37


Replace the neutralindicator light bulb,socket or both.

NO

YES

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must re-paired.

NO

This circuit is OK.

EAS00800

4. The neutral indicator light fails to come on.

1. Neutral indicator light bulb and socket

Check the neutral indicator light bulb andsocket for continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the neutral indicator light bulb and socketOK?

YES

Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) of chocolate or dark green at the turn signal light con-nector (wire harness side).


12


NO

2. Neutral switch



YES

3. Diode




YES


NO



sky blue

1

2

Continuity

NOTE:When you switch the “–” and “+” leads of thedigital pocket tester the readings in the abovechart will be reversed.


EAS00760


sky blue Tester negative probe

light green

2

1

Nocontinuity

7-38


4. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.

Tester positive probe brown Tester negative probe sky blue

12

Set the main switch to “ON”.Measure the voltage (12 V) of brown andsky blue at the meter assembly coupler.


12

YES

The wiring circuitfrom the main switchto the meter light bulbcoupler is faulty andmust be repaired.

NO

This circuit is OK.

Replace the oil levelwarning light bulb,socket or both.

NO

EAS00802

5. The oil level warning light fails to come on.

1. Oil level warning light bulb and socket

Check the oil level warnig light bulb and sock-et for continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”

Are the oil level warnig light bulb and socketOK?

YES

Replace the oil levelswitch.

NO

2. Oil level switch

Drain the engine oil and remove the oil levelswitch from the oil pan.

Check the oil level switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the oil level switch OK?

YES

Replace the oil levelrelay.

NO

3. Oil level relay

Disconnect the oil level relay from the cou-pler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the oil level relay terminals asshown.

YES

Battery positive terminal brown Battery negative terminal black/red

Does the oil level relay have continuity be-tween red/blue and black?

Tester positive probe red/blue Tester negative probe black

12

34

B / R

7-39



Disconnect the relay unit from the coupler.Connect the pocket tester (Ω 1) to the relayunit terminals as shown.

Relay unit resistance8.2 Ω at 20C

Tester positive probe red/blue Tester negative probe brack/red

Measure the relay unit resistance.

Is the relay unit OK?

Replace the startingcircuit cutoff relay.

NOYES

5. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.

Tester positive probe brown Tester negative probe black/red

12

Set the main switch to “ON”.Measure the voltage (12 V) of brown andblack/red at the meter assembly coupler.


YES


NO

This circuit is OK.

EAS00804

6. The fuel level gauge fails to operate.

1

Replace the fuelsender.

NO

1. Fuel sender

Disconnect the fuel sender coupler from thewire harness.

Drain the fuel from the fuel tank and removethe fuel sender from the fuel tank.

Connect the pocket tester to the fuel sendercoupler as shown.

YES

Tester positive probe green Tester negative probe black

1

Is the fuel sender OK?

2

Fuel sender resistance (up position) 4 10 Ω at 20C

Fuel sender resistance (down posi-tion)

90 100 Ω at 20C

Measure the fuel sender resistance.

12

7-40

Check that the fuel level gauge needle move to“F” to “E”.

Before reading the fuel level gauge, leave thefloat in one position (either up or down) for atleast three minutes.

Does the fuel level gauge needle move ap-propriately?

2. Voltage

Connect the pocket tester (DC 20 V) to the me-ter assembly coupler (wire harness side) asshown.

Tester positive probe brown Tester negative probe black

12

YES


NO

Set the main switch to “ON”.Measure the voltage (12 V). Is the voltage within specification?

YES

Replace the fuel levelgauge.

NO

NOTE:

3. Fuel level gauge

Set the main switch to “ON”.Move the float up or down .

This circuit is OK.

1 2


7-41

SELF-DIAGNOSIS ELEC

Revolution( 103 r /min)

Tachometer display

Time (seconds)

Engine speed

0 r /min ... 3 secondsCondition code ... 2.5 secondsEngine speed ... 3 seconds

123

0 r /min ... 3 secondsCondition code ... 2.5 seconds

12 Tachometer display

Time (seconds)

Revolution( 103 r /min)

EAS00834

SELF-DIAGNOSISThe XJR1300 (L) features a self-diagnosing system for the following circuit(-s): throttle position sensor ignition circuit

If any of these circuits are defective, their respective condition codes will be displayed on the tachome-ter when the main switch is set to “ON” (irrespective of whether the engine is running or not).The engine is not operated condition code at 2,000 r/min.

Circuit Defect(-s) System response Condition code

Throttle posi-tion sensor

DisconnectedShort-circuitLocked

The ignitor unit stays set to thewide-open throttle ignition timing.The motorcycle can be ridden.

The tachometer displays the condi-tion code.

3,000 r/min

Ignition circuit Incorrect input sig-nal for side standswitch and neutralswitch.

No ignitionThe tachometer displays the condi-tion code.

2,000 r/min

Tachometer display sequence1) Throttle position sensor

If the engine is stopped, the engine speed 3 is 0 r/min.2) Ignition circuit

7-42

SELF-DIAGNOSIS ELEC

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

NO

2. Throttle position sensor

Check the throttle position sensor for conti-nuity.Refer to “CHECKING AND ADJUSTINGTHE THROTTLE POSITION SENSOR” inchapter 6.

Is the throttle position sensor OK?

YES

Replace the throttleposition sensor.


NOTE:

13 Throttle position sensor9 Ignitor unit

EAS00835

TROUBLESHOOTING

The tachometer starts to display theself-diagnosis sequence.

Check:1. throttle position sensor2. ignition circuit


1) rider seat2) fuel tank3) air filter caseTroubleshoot with the following specialtool(-s).


EAS00836

1. Throttle position sensorCIRCUIT DIAGRAM

EB812401

7-43


NO

3. Main switch



YES

Repair or replace thewire harness.

NO

4. Wire harness

Check the ire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES







blue/yellow

1

2

Continuity


blue/yellowTester negative probe

light green

2

1

Nocontinuity

SELF-DIAGNOSIS ELEC

5 Main switch8 Starting circuit cutoff relay9 Ignitor unit

2. Ignition circuitCIRCUIT DIAGRAM

EAS00749

EB812400

EAS00760

7-44


NO

When you switch the “–” and “+” leads of thedigital pocket tester the readings in theabove chart will be reversed.


YES


NOTE:

SELF-DIAGNOSIS ELEC

TRBLSHTG

CHAPTER 8.TROUBLESHOOTING

STARTING PROBLEMS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INCORRECT ENGINE IDLING SPEED 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 8-2. . . . . . . . . . . . . ENGINE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY GEAR SHIFTING 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFTING IS DIFFICULT 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY CLUTCH 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPS 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGS 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR BRAKING PERFORMANCE 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY FRONT FORK LEGS 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKING OIL 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNSTABLE HANDLING 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY LIGHTING AND SIGNALING SYSTEM 8-5. . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT BULB BURNT OUT 8-5. . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT LIGHT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BUNKS SLOWLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

8-1

TRBLSHTGSTARTING PROBLEMS

NOTE:

EAS00844

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual forchecks, adjustments, and replacement of parts.

STARTING PROBLEMSENGINECylinders and cylinder head(-s)Loose spark plugLoose cylinder headDamaged cylinder head gasketWorn or damaged cylinder Incorrect valve clearance Incorrectly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timingFaulty valve springSeized valvePistons and piston rings Incorrectly installed piston ringDamaged, worn or fatigued piston ringSeized piston ringSeized or damaged pistonAir filter Incorrectly installed air filterClogged air filter elementCrankcase and crankshaft Incorrectly assembled crankcaseSeized crankshaft

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel tank breather hoseDeteriorated or contaminated fuelFuel cockClogged or damaged fuel hose/vacuum hoseCarburetorsDeteriorated or contaminated fuelClogged pilot jetClogged pilot air passageSucked-in airDamaged floatWorn needle valve Incorrectly installed needle valve seat Incorrect fuel level Incorrectly installed pilot jetClogged starter jetFaulty starter plunger Incorrectly adjusted starter cable

ELECTRICAL SYSTEMSBatteryFaulty batteryDischarged batteryFusesBlown, damaged or incorrect fuse Incorrectly installed fuseSpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug capIgnition coilsDamaged ignition coilBroken or shorted primary or secondary coilsFaulty spark plug lead

Ignition systemFaulty ignitor unitFaulty pickup coilSwitches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switch Incorrectly grounded circuitLoose connectionsStarting systemFaulty starter motorFaulty starter relayFaulty starting circuit cutoff relayFaulty starter clutch

8-2

INCORRECT ENGINE IDLING SPEED/POOR MEDIUM AND-HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING

TRBLSHTG

EAS00846

INCORRECT ENGINE IDLING SPEEDENGINECylinders and cylinder head Incorrect valve clearanceDamaged valve train componentsAir filterClogged air filter elementFUEL SYSTEMCarburetorsFaulty starter plungerLoose or clogged pilot jetLoose or clogged pilot air jetDamaged or loose carburetor joint Incorrectly synchronized carburetors Incorrectly adjusted engine idling speed(throttle stop screw)

Incorrect throttle cable free playFlooded carburetor

ELECTRICAL SYSTEMSBatteryFaulty batteryDischarged batterySpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug capIgnition coilsBroken or shorted primary or secondary coilsFaulty spark plug leadDamaged ignition coilIgnition systemFaulty ignition unitFaulty pickup coil

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING PROBLEMS”.ENGINEAir filterClogged air filter element

FUEL SYSTEMCarburetorsFaulty diaphragm Incorrect fuel levelLoose or clogged main jet

EAS00850

FAULTY GEAR SHIFTINGSHIFTING IS DIFFICULTRefer to “CLUTCH DRAGS”.SHIFT PEDAL DOES NOT MOVEShift shaft Incorrectly adjusted shift rodBent shift shaftShift drum and shift forksForeign object in a shift drum grooveSeized shift forkBent shift fork guide barTransmissionSeized transmission gearForeign object between transmission gears Incorrectly assembled transmission

JUMPS OUT OF GEARShift shaft Incorrect shift pedal position Incorrectly returned stopper leverShift forksWorn shift forkShift drum Incorrect axial playWorn shift drum grooveTransmissionWorn gear dog

8-3

FAULTY CLUTCH/OVERHEATINGTRBLSHTG

EAS00852

FAULTY CLUTCHCLUTCH SLIPSClutch Improperly assembled clutch Improperly assembled clutch master cylinder Improperly assembled clutch release cylinderLoose or fatigued clutch springLoose union boltWorn friction plateWorn clutch plateDamaged clutch release cylinderEngine oil Incorrect oil level Incorrect oil viscosity (low)Deteriorated oil

CLUTCH DRAGSClutchUnevenly tensioned clutch springsWarped pressure plateBent clutch plateSwollen friction plateBent clutch pull rodDamaged clutch bossBurnt primary driven gear bushingDamaged clutch release cylinderMatch marks not alignedEngine oil Incorrect oil level Incorrect oil viscosity (high)Deteriorated oil

EAS00854

OVERHEATINGENGINECylinder head(-s) and piston(-s)Heavy carbon buildupEngine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality

FUEL SYSTEMCarburetors Incorrect main jet setting Incorrect fuel levelDamaged or loose carburetor jointAir filterClogged air filter element

CHASSISBrakesDragging brake

ELECTRICAL SYSTEMSSpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeIgnition systemFaulty ignitor unit

8-4

POOR BRAKING PERFORMANCE/FAULTY FRONT FORKLEGS/UNSTABLE HANDLING

TRBLSHTG

EAS00857

POOR BRAKING PERFORMANCEWorn brake padWorn brake discAir in hydraulic brake systemLeaking brake fluidFaulty brake caliper piston seal

Loose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

EAS00860

FAULTY FRONT FORK LEGSLEAKING OILBent, damaged or rusty inner tubeDamaged outer tube Incorrectly installed oil sealDamaged oil seal lip Incorrect oil level (high)Loose damper rod assembly boltDamaged damper rod assembly bolt copperwasher

Damaged cap bolt O-ring

MALFUNCTIONBent or damaged inner tubeBent or damaged outer tubeDamaged fork springWorn or damaged outer tube busingBent or damaged damper rod Incorrect oil viscosity Incorrect oil level

EAS00862

UNSTABLE HANDLINGHandlebarBent or incorrectly installed right handlebarBent or incorrectly installed left handlebarSteering head components Incorrectly installed upper bracket Incorrectly installed lower bracket(incorrectly tightened ring nut)

Bent steering stemDamaged ball bearing or bearing raceFront fork legsUnevenoil levels (both front fork legs)Unevenly tensioned fork spring (both front forklegs)

Damaged fork springBent or damaged inner tubeBent or damaged outer tube

SwingarmWorn bearing or bushingBent or damaged swingarmRear shock absorber assemblyFaulty rear shock absorber springLeaking oil or gasTiresUneven tire pressures (front and rear) Incorrect tire pressureUneven tire wearWheels Incorrect wheel balanceDeformed cast wheelDamaged wheel bearingBent or loose wheel axleExcessive wheel runoutFrameBent frameDamaged steering head pipe Incorrectly installed bearing race

8-5

FAULTY LIGHTING AND SIGNALING SYSTEMSTRBLSHTG

EAS00866

FAULTY LIGHTING ANDSIGNALING SYSTEMSHEADLIGHT DOES NOT LIGHTWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection Incorrectly grounded circuitPoor contacts (main or light switch)Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/regulator Incorrectly grounded circuitFaulty main switchFaulty light switchHeadlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT LIGHTWrong tail /brake light bulbToo may electrical accessories Incorrect connectionBurnt-out tail /brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUTWrong tail /brake light bulbFaulty battery Incorrectly adjusted rear brake light switchTail /brake light bulb life expired

TURN SIGNAL DOES NOT LIGHTFaulty turn signal switchFaulty turn signal relayBurnt-out turn signal bulb Incorrect connectionDamaged or faulty wire harness Incorrectly grounded circuitFaulty batteryBlown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLYFaulty turn signal relayFaulty main switchFaulty turn signal switchWrong turn signal bulb

TURN SIGNAL REMAINS LITFaulty turn signal relayBurnt-out-turn signal bulb

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulbFaulty turn signal relayBurnt-out turn signal bulb

HORN DOES NOT SOUND Incorrectly adjusted hornDamaged or faulty hornFaulty main switchFaulty horn switchFaulty batteryBlown, damaged or incorrect fuseFaulty wire harness

TRBLSHTG

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . . L Blue. . . . . Lg Light green. . . .

O Orange. . . . Sb Sky blue. . . . P Pink. . . . . R Red. . . . . Y Yellow. . . . . B/L Black/Blue. . . B/R Black/Red. . . B/Y Black/Yellow. . .

Br/L Brown/Blue. . Br/W Brown/White. G/Y Green/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . . L/W Blue/White. . L/Y Blue/Yellow. . . R/B Red/Black. . .

R/L Red/Blue. . . R/W Red/White. . R/Y Red/Yellow. . . W/G White/Green. . W/R White/Red. . Y/B Yellow/Black. . .

1 AC generator2 Fuse (main)3 Battery4 Starter relay5 Main switch6 Fuse (ignition)7 Starter motor8 Starting circuit cut-off relay9 Ignitor unit10 Ignition coil11 Spark plug12 Pickup coil13 TPS (throttle position sensor)14 Neutral switch15 Sidestand switch16 Oil level relay17 Start switch18 Engine stop switch19 Front brake switch20 Handlebar switches (right)21 Lights switch22 Fuse (signal)23 Rear brake switch24 Horn25 Flasher relay26 Oil level switch27 Connector28 Meter assembly29 Tachometer30 Fuel gauge31 Fuel sender32 Meter lights33 Neutral indicator light34 Turn signal indicator light (left)35 Turn signal indicator light (right)36 Oil warning light37 High beam indicator light38 Clutch switch39 Turn signal switch40 Horn switch41 Pass switch42 Dimmer switch43 Handlebar switch (left)44 Fuse (headlight)45 Auxiliary light46 Tail /brake light47 Headlight48 Front turn signal lights49 Rear turn signal lights

XJR1300’99 WIRING DIAGRAM for EUR

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . . L Blue. . . . . Lg Light green. . . .

O Orange. . . . Sb Sky blue. . . . P Pink. . . . . R Red. . . . . Y Yellow. . . . . B/L Black/Blue. . . B/R Black/Red. . . B/Y Black/Yellow. . .

Br/L Brown/Blue. . Br/W Brown/White. G/Y Green/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . . L/W Blue/White. . L/Y Blue/Yellow. . . R/B Red/Black. . .

R/L Red/Blue. . . R/W Red/White. . R/Y Red/Yellow. . . W/G White/Green. . W/R White/Red. . Y/B Yellow/Black. . .

1 AC generator2 Fuse (main)3 Battery4 Starter relay5 Main switch6 Fuse (ignition)7 Starter motor8 Starting circuit cut-off relay9 Ignitor unit10 Ignition coil11 Spark plug12 Pickup coil13 TPS (throttle position sensor)14 Neutral switch15 Sidestand switch16 Oil level relay17 Start switch18 Engine stop switch19 Front brake switch20 Handlebar switches (right)22 Fuse (signal)23 Rear brake switch24 Horn25 Flasher relay26 Oil level switch28 Meter assembly29 Tachometer30 Fuel gauge31 Fuel sender32 Meter lights33 Neutral indicator light34 Turn signal indicator light (left)35 Turn signal indicator light (right)36 Oil warning light37 High beam indicator light38 Clutch switch39 Turn signal switch40 Horn switch41 Pass switch42 Dimmer switch43 Handlebar switch (left)44 Fuse (headlight)46 Tail /brake light47 Headlight48 Front turn signal lights49 Rear turn signal lights

XJR1300L WIRING DIAGRAM for AUS

xjr service manual

Documents

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rear shock absorber

spilt fluid immediately

tester positive probe

electric starting system

oil filter element

fouled spark plug

spark plug wells