EB000000 FZS600 SERVICE MANUAL 1997 by Yamaha Motor Co., Ltd. First edition, December 1997 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter unfit for use.
YP002000 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal,disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS” on the following page. 2 Each chapter is divided into sections.
EB003000 1 SYMBOLS 2 The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 3 4 1 General information 5 6 7 8 9 10 11 12 Specifications Periodic inspection and adjustment Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting Symbols 10 to 17 indicate the following.
INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9
GEN INFO 1
GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEN INFO
MOTORCYCLE IDENTIFICATION GEN INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. 1 EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EB102000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EB102030 LOCK WASHERS/PLATES AND COTTER PINS 1. After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. OR EB102040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips.
CHECKING THE CONNECTIONS GEN INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. NOTE: If the pin 2 on the terminal is flattened, bend in up. 4.
SPECIAL TOOLS GEN INFO EB104000 SPECIAL TOOLS The 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 inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. 90890-01268 Tool name/Usage Illustration Ring nut wrench This tool is used to loosen and tighten the steering ringnut.
SPECIAL TOOLS Tool No. 90890-01399 Tool name/Usage Special thickness gauge This tool is used to measure the valve clearance. 90890-01401 Spark plug wrench This tool is used for removing or installing the spark plug. 90890-01403 Ring nut wrench This tool is used to tighten the steering ring nut. 90890-01469 Oil filter wrench This tool is used for removing or installing the oil filter. 90890-01701 Sheave holder This tool is used for holding the magneto rotor.
SPECIAL TOOLS Tool No. 90890-03141 Tool name/Usage Illustration Timing light This tool is necessary for checking ignition timing. 90890-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder. 90890-03158 Carburetor angle driver This tool is used to adjust the pilot screw. 90890-04086 Clutch holding tool This tool is used for holding the clutch boss.
SPECIAL TOOLS Tool No. 90890-85505 Tool name/Usage Yamaha bond No.1215 This sealant (bond) is used for crankcase mating surface, etc.
SPEC 2
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model FZS600 Model code: 5DM1 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,080 mm 710 mm 1,170 mm 790 mm 1,415 mm 130 mm 2,900 mm Basic weight: With oil and full fuel tank 210 kg Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Liquid cooled 4-stroke,
GENERAL SPECIFICATIONS Model SPEC FZS600 Carburetor: Type/quantity Manufacturer BSR 33/4 MIKUNI Spark plug: Type Manufacturer Spark plug gap CR9E, CR8E/U27ESR-NU24ESR-N NGK/DENSO 0.7 X 0.8 mm Clutch type: Wet, multiple-disc Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Spur gear 82/48 (1.708) Chain drive 48/15 (3.
GENERAL SPECIFICATIONS Model Brake: Front brake Rear brake type operation type operation FZS600 Dual disc brake Right hand operation Single disc brake Right foot operation Suspension: Front suspension Rear suspension Telescopic fork Swingarm (link suspension) Shock absorber: Front shock absorber Rear shock absorber Coil spring/Oil damper Coil spring/Gas-oil damper Wheel travel: Front wheel travel Rear wheel travel 120 mm 120 mm Electrical: Ignition system Generator system Battery type Battery capac
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.05 mm Cylinder: Bore size Taper limit Out of round limit 62.00 62.01 mm 62.1 mm 0.09 mm 0.07 mm Chain drive (center) 23.000 23.021 mm 23.967 22.980 mm 0.020 0.054 mm 0.08 mm 32.75 32.85 mm 25.0 25.1 mm 7.65 7.85 mm 32.45 32.55 mm 24.95 25.05 mm 7.4 7.6 mm 32.7 mm 24.95 mm 7.5 mm 32.4 mm 24.9 mm 7.25 mm 0.
MAINTENANCE SPECIFICATIONS Item Stem-to-guide clearance Stem runout limit Valve seat width Valve spring: Free length Set length (valve closed) Compressed pressure Tilt limit Direction of winding SPEC Standard Limit IN EX 0.010 0.037 mm 0.025 0.052 mm 0.9 1.1 mm 0.9 1.1 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm IN/EX IN/EX IN/EX IN/EX IN/EX 40.09 mm 34.5 mm 134 156 N (13.4 15.6 kg) Clockwise 37.5 mm 2.5 /1.8 mm 0.025 0.050 mm 61.960 61.975 mm 5 mm 0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Clutch: Friction plate thickness Quantity Wear limit Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit 2.94 3.06 mm 8 pcs 2.94 3.06 mm 1 pcs 1.9 2.1 mm 8 pcs 34.9 mm 6 pcs 0.05 0.13 mm 0.005 0.041 mm Inner push, screw push 2.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Lubrication system: Oil filter type Oil pump type Tip clearance “A” or “B” Side clearance Bypass valve setting pressure Relief valve operating pressure Pressure check location Paper type Trochoid type 0.03 0.09 mm 0.03 0.08 mm 80 120 kPa (0.8 1.2 kg/cm2) 450 550 kPa (4.5 5.5 kg/cm2) Main gallery 0.15 mm 0.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES ENGINE g Part to be tightened Camshaft cap Cylinder head Spark plug Cylinder head cover Cylinder head side cover Connecting rod cap Camshaft sprocket Timing chain tensioner case Timing chain guide (intake side) Timing chain tensioner cap Pipe 2 Pipe 3/Pipe 4 Thermostat cover Conduction assembly Radiator Joint Water pump Water pump housing Radiator cover Pipe 5/Pipe 6 Roter housing Oil pump assembly Strainer housing Strainer cover Oil cooler Oil drain bolt
MAINTENANCE SPECIFICATIONS Part to be tightened g Starter cover Oil gallery Clutch cover Clamp (A.C magneto cover) Starter clutch assembly Starter clutch outer Pressure plate Clutch boss Push lever Push rod adjuster Drive sprocket Shift drum retainer Shift arm Shift fork guide bar retainer Shift pedal adjuster Stopper lever Side plate 2 A.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Steering system: Steering bearing type Angular bearing Limit Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring Rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade 120 mm 323 mm 315.9 mm 200 mm 7.5 N/mm (0.75 kg/mm) 14 N/mm (1.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Dual 298 4 mm 5.5 mm 5.5 mm 14 mm 30.2 mm 27 mm DOT No.4 0.2 mm 0.5 mm 0.5 mm Rear disc brake: Type Disc outside dia. thickness Disc deflection limit Pad thickness inner Pad thickness outer Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Single 245 5 mm 5.5 mm 5.5 mm 12.7 mm 38.1 mm DOT No.4 0.15 mm 0.5 mm 0.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES CHASSIS g Part to be tightened Upper bracket and inner tube Upper bracket and steering stem Handlebar under holder Handlebar upper holder Under bracket and inner tube Ring nut (steering stem) Master cylinder bracket Master cylinder cap Brake hose union bolt Grip end Cowling stay Cowling bracket Front fender Engine bracket (front) Engine mount (front) Engine mount (rear upper) Engine mount (rear under) Engine bracket (rear) Pivot shaft Rear shock absorber
MAINTENANCE SPECIFICATIONS g Part to be tightened Side cover and frame Garb bar Front wheel axle Front wheel axle pinch bolt Front brake caliper Front brake disc Front brake caliper bleed screw Compression bar Rear wheel sprocket Drive chain puller nut Rear brake caliper and caliper bracket Rear wheel axle nut Rear brake hose union bolt Rear brake caliper bleed screw Rear brake disc Sidestand Bracket footrest and frame Rear master cylinder and bracket Footrest bracket and footrest Footrest bracket (rear) an
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advance type 10 /1,250 r/min 50 /4,500 r/min TPS and electrical type T.C.I.: Pickup coil resistance T.C.I. unit model/manufacturer 189 231 Ω Y-L J4T085/MITSUBISHI Ignition coil: Model/manufacturer Primary winding resistance Secondary winding resistance J0313/DENSO 1.87 2.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Starter motor: Model/manufacturer I.D. number Output Armature coil resistance Brush overall length Brush spring pressure Commutator dia. Mica undercut (depth) SM-13/MITSUBA SM-13 0.7 kW 0.0015 0.0025 Ω at 20 C 10 mm 7.8 10.2 N (780 1.020 gf) 28 mm 0.7 mm 4 mm 27 mm Starter relay: Model/manufacturer Amperage rating Coil winding resistance MS5F-631 /JIDECO 100 A 4.18 4.
MAINTENANCE SPECIFICATIONS Item Amperage for individual circuit: Main Headlight Signal Ignition Fan Back up Reserve SPEC Standard limit 30 A 20 A 20 A 20 A 10 A 5A 30 A 20 A 10 A 5A 2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EB201000 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
LUBRICATION POINT AND LUBRICATION TYPES SPEC LUBRICATION POINT AND LUBRICATION TYPES ENGINE Lubrication Point Oil seal lips Bearing Crankshaft journal Connecting rod big end and small end Piston, piston pin Connecting rod bolt Camshaft journal, profile Valve stem (IN, EX) Valve stem end (IN, EX) Cylinder head tightening nut mounting surface Valve lifter Camshaft cap Water pump seal Water pump shaft Radiator hose Oil pump Relief valve O-ring Oil cooler O-ring Oil filter Oil level gauge Starter moter O-ring
LUBRICATION POINT AND LUBRICATION TYPES SPEC CHASSIS Lubrication Point Steering bearing and bearing race (upper and lower) Pivot shaft Rear arm bearing Rear arm oil seal Rear arm cover oil seal lips Relay arm bearing Relay arm oil seal Rear shock absorber (upper/lower) Front wheel oil seal Speed sensor oil seal Rear wheel oil seal Clutch damper oil seal Clutch and rear wheel Throttle cable inner surface Starter cable inner surface and lever pivot Rear brake pedal shaft Shift pedal shaft Side stand sliding
COOLING SYSTEM DIAGRAMS SPEC EB203000 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 Engine outlet hose Engine outlet hose Carburetor inlet hose Carburetor outlet hose Water pump Coolant drain bolt Water pump outlet hose 8 Radiator outlet hose 9 Radiator 10 Radiator inlet hose 3 2 10 1 1 4 3 6 5 9 5 7 8 6 2-20
COOLING SYSTEM DIAGRAMS 1 2 3 4 5 Radiator Water pump outlet hose Oil cooler inlet hose Oil cooler outlet hose Carburetor outlet hose 2-21 SPEC
LUBRICATION DIAGRAMS SPEC EB204000 LUBRICATION DIAGRAMS 1 2 3 4 5 6 7 Oil nozzle (main nozzle) Oil nozzle (drive axle) Projection Oil filter Relief valve Oil strainer Oil pump 3 2 1 4 7 6 5 2-22 4
LUBRICATION DIAGRAMS 1 2 3 4 SPEC Main axle Drive axle Camshaft Oil delivery pipe 1 3 4 2-23 2
LUBRICATION DIAGRAMS SPEC 1 Camshaft 2 Crankshaft 1 2 2-24
CABLE ROUTING EB205000 CABLE ROUTING 1 2 3 4 5 6 7 8 Throttle cable Clutch cable Handlebar switch (right) Starter cable Main switch Brake hose Speed sensor lead Headlight lead 9 Handlebar switch (left) A Use a plastic clamp to fasten together the handlebar switch lead (left), clutch cable and starter cable. B Pass the brake hose out side of the speed sensor lead, then use a plastic clamp to fasten them.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Main switch lead Starter cable Handlebar switch lead (left) Clutch cable Rectifier/ regulator Horn lead Box Air guide plate Starter cable Flasher leray 11 12 13 14 15 16 17 18 19 20 Battery Starting circuit cut-off relay Battery positive (+) lead Seat lock cable AC magneto lead Starter motor lead Air filter drain hose Sidestand switch Neutral switch Oil level switch 2-26 21 22 23 24 25 26 27 28 29 30 31 SPEC Speed sensor lead Horn Starter relay Fuse box To front bra
CABLE ROUTING A Use a plastic clamp to fasten the handlebar switch lead (left), main switch lead, clutch cable and starter cable to the frame. B Use a plastic band to fasten together wireharness, starter motor lead, AC magneto lead, sidestand switch lead and oil level/ neutral switch lead, then hold the clamp to the frame bracket. Position the band end to out side of chassis.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 Battery negative (–) lead Rear brake switch lead Battery Reservoir tank hose Air filter Fuel tank breather hose Fuel tank drain hose T.P.S.
CABLE ROUTING C Pass the main switch lead under the throttle cables, headlight lead, handlebar switch lead (right) and speed sensor lead, then insert it right side of the box. D Pass the reservoir tank over flow hose, fuel tank breather hose and fuel tank drain hose through the cable holder. E Pass the battery negative (–) lead inside of the reservoir hose.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Throttle cable Handlebar switch lead (right) Headlight lead Speed sensor lead Carburetor heater hose Reservoir tank hose Fuel pump Fuel filter T.P.
CABLE ROUTING 31 32 33 34 35 36 37 A Starter cable Clutch cable Handlebar switch lead (left) Main switch lead To taillight Rear fender Clamp Pass the wireharness under the starter relay. B Pass the rectifier / regulator lead, fan motor lead, handlebar switch lead (left), main switch lead, headlight lead, handlebar switch lead (right) and speed sensor lead through front side of the box, then connecte each coupler in the box.
SPEC
CHK ADJ 3
CHK ADJ CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . . . . . . . . . . . . 3-1 FRONT COWLING/SEAT/SIDE COVER/FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHK ADJ
INTRODUCTION / PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
CHK ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS EVERY NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) √ √ 17 * Sidestand switch Check operation. Replace if necessary. 18 * Front fork Check operation and for oil leakage. Correct accordingly. √ √ 19 * Rear shock absorber assembly Check operation and shock absorber for oil leakage.
FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK CHK ADJ FRONT COWLING/SEAT/SIDE COVER/FUEL TANK FRONT COWLING 33 Nm (3.3 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Remarks Remove the parts in the order listed. Removing the front cowling View mirror (left/right) Inner panel (left/right) Cowling stay (left/right) Head light lead Front flasher light lead (left/right) Front cowling Head light assembly 1/1 1/1 1/1 2 2/2 1 1 NOTE: Disconnect the couplers.
FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK CHK ADJ SEAT, SIDE COVER AND FUEL TANK 19 Nm (1.9 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 4 Nm (0.4 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Removing the seat, side cover and fuel tank Seat Fuel tank Fuel sender lead Fuel tank breaser hose Fuel tank drain hose Fuel hose Side cover (left/right) Grab bar Tail cover Remarks Remove the parts in the order listed. 1 1 1 NOTE: 1 Disconnect the couplers.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: front cowling seat fuel tank (Refer to “FRONT COWLING SEAT, SIDE COVER AND FUEL TANK” in chapter 3) 2.
ADJUSTING THE VALVE CLEARANCE CHK ADJ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase. a NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. b c. Measure the valve clearance with a thickness gauge 1 . NOTE: S If the valve clearance is incorrect, record the measured reading.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 7. Remove: timing chain tensioner bolt 1 timing chain tensioner assembly 2 8. Remove: timing chain guide 1 timing chain guide (upper) 2 camshaft cap 3 9. Remove: camshaft 1 NOTE: Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chapter 4. When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase. 10. Adjust: valve clearance a.
ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. c. Round off the original valve pad number according to the following table. Last digit Rounded valve 0 or 2 0 5 5 8 10 EXAMPLE: Original valve pad number = 148 (thickness = 1.
CHK ADJ ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE Measured clearance # exa ! 0.00 0.02 0.03 0.07 0.08 0.10 0.11 0.20 0.21 0.22 0.23 0.27 0.28 0.32 0.33 0.37 0.38 0.42 0.43 0.47 0.48 0.52 0.53 0.57 0.58 0.62 0.63 0.67 0.68 0.72 0.73 0.77 0.78 0.82 0.83 0.87 0.88 0.92 0.93 0.97 0.98 1.02 1.03 1.07 1.08 1.12 1.13 1.17 1.18 1.22 1.23 1.27 1.28 1.32 1.33 1.
ADJUSTING THE VALVE CLEARANCE CHK ADJ e. Install the new valve pad 1 and the valve lifter 2 . NOTE: Apply molybdenum disulfide grease to the valve pad. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m kg) NOTE: Refer to “CAMSHAFT” in chapter 4.
ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS CHK ADJ 14. Install: cylinder head cover spark plugs Bolt (cylinder head cover): 10 Nm (1.0 m kg) Spark plug: 13 Nm (1.3 m kg) EB303010 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: cap 3.
SYNCHRONIZING THE CARBURETORS CHK ADJ 6. Adjust: carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EB303020 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: engine tachometer (to the spark plug lead of cyl. #1) Engine tachometer 90890-03113 3. Check: engine idling speed Out of specification ! Adjust.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EB303032 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly. 1. Check: throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3 5 mm 2. Remove: bracket ignition coil fuel pump 3.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS CHK ADJ After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. 4. Install: fuel pump ignition coil bracket EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: spark plug cap 2.
CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING CHK ADJ 8. Connect: spark plug cap EB303053 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: timing plug 1 2. Install: timing light 1 engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light 90890-03141 Engine tachometer 90890-03113 3. Check: ignition timing a.
CHK ADJ MEASURING THE COMPRESSION PRESSURE EB303060 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Check: valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: spark plug cap 4.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ Compression pressure (at sea level) Standard 1,500 kPa (15.0 kg/cm2) Minimum 1,200 kPa (12.0 kg/cm2) a. Turn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2, 1 bar). 7.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade ACEA standard G4 or G5 TEMP SAE 10W-30 SAE 10W-30 SAE 10W-30 CAUTION: Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.
CHANGING THE ENGINE OIL CHK ADJ a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01469 b. Apply a thin coat of engine oil onto the Oring 3 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. 3 c. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7m kg) 6. Check: engine oil drain bolt gasket Damage Replace. 7.
MEASURING THE ENGINE OIL PRESSURE CHK ADJ EB303090 MEASURING THE ENGINE OIL PRESSURE 1. Check: engine oil level Below the minimum level mark Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. CAUTION: When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3.
MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY 6. Install: oil gallery bolt CHK ADJ 8 Nm (0.8 m kg) EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: clutch cable free play a Out of specification Adjust. Clutch cable free play (at the end of the clutch lever) 10 15 mm Handlebar side 2. Adjust: clutch cable free play Engine side a Handlebar side a. Loosen the locknut 1 . b.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EB303130 CLEANING THE AIR FILTER ELEMENT 1. Remove: Seat Fuel tank Cover 1 2. Remove: air filter case cover 1 air filter element 2 3. Clean: air filter element Apply compressed air to the outer surface of the air filter element. 4. Check: air filter element Damage Replace. 5. Install: air filter element air filter case cover CAUTION: Never operate the engine without the air filter element installed.
CLEANING THE AIR FILTER ELEMENT/ CHK CHECKING THE CARBURETOR JOINTS AND IN TAKE MANIFOLDS/ ADJ CHECKING THE FUEL HOSES AND FUEL FILTER NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks. 6. Install: cover fuel tank seat EB303171 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the carburetor joints and intake manifolds. 1. Remove: seat fuel tank 2.
CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ EB303190 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: seat fuel tank carburetor 2. Check: crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly. 3. Install: carburetor fuel tank seat EB303200 3 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1.
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ EB303220 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Remove: side cover (right) 3. Check: coolant level The coolant level should be between the maximum level mark a and minimum level marks b . Below the minimum level mark Add the recommended coolant to the proper level.
CHANGING THE COOLANT CHK ADJ EB303240 CHANGING THE COOLANT 1. Remove: seat fuel tank 2. Disconnect: coolant reservoir hose 1 3. Drain: coolant (from the coolant reservoir) 4. Remove: radiator cap A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
CHANGING THE COOLANT CHK ADJ 9. Coonect: coolant reservoir hose 10. Fill: cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mix ratio 50% antifreeze/50 % water Quantity Total amount 1.95 L Coolant reservoir capacity 0.61 L From minimum to maximum level mark 0.22 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
CHANGING THE COOLANT CHK ADJ 12. Fill: coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install: coolant reservoir cap 14. Start the engine, warm it up for several minutes, and then turn if off. 15. Check: coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until it settles. 16.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 Position #1 Position #4 Distance a is the largest. Distance a is the smallest.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ After adjusting the brake pedal position, check that the end of the adjusting bolt 2 is visible through the hole c . c. Tighten the locknut 1 to specification. A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.
CHECKING THE BRAKE FLUID LEVEL / ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir.
CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: brake hose Cracks/damage/wear Replace. 2. Check: brake hose clamp Loose connection Tighten. 3. Hold the motorcycle upright and apply the brake. 4. Check: brake hose Activate the brake several times. Brake fluid leakage Replace damaged hose. Refer to “FRONT AND REAR BRAKES” in chapter 7.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL CHK ADJ 2. Bleed: hydraulic brake system Front a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. g.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ EB304090 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface.
ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ c. Tighten the wheel axle nut to specification. Wheel axle nut 117 Nm (11.7 m kg) Locknut 16 Nm (1.6 m kg) EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 4. Adjust: steering head 1 a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . 2 3 4 NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01403 Lower ring nut (initial tightening torque) 52 Nm (5.2 m kg) c. Loosen the lower ring nut completely, then tighten it to specification.
CHECKING ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ 5. Install: upper bracket handlebar Steering stem nut 110 Nm (11.0 m kg) Upper bracket pinch bolt 30 Nm (3.0 m kg) Handlebar upper holder bolt 23 Nm (2.3 m kg) EB304140 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Check: inner tube Damage/scratches Replace.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES a. Turn the adjusting ring 1 in direction a or b. b. Align the desired position on the adjusting ring with the stopper. adjusting position a CHK ADJ b Direction a Spring preload is increased (suspension is harder). Direction b Spring preload is decreased (suspension is softer). Minimum Standard Maximum Adjusting positions 1 4 9 EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1.
CHECKING THE TIRES CHK ADJ Basic weight (with oil and a full fuel tank) 210 kg Maximum load 187 kg Cold tire pressure Front tire Rear tire Up to 90 kg load* 225 kPa (2.25 kg / cm2) 250 kPa (2.50 kg / cm2) 90 kg maximum load* 225 kPa (2.25 kg / cm2) 280 kPa (2.80 kg / cm2) High speed riding 225 kPa (2.25 kg / cm2) 280 kPa (2.80 kg / cm2) *: total of cargo, rider, passenger and accessories It is dangerous to ride with a worn-out tire.
CHECKING THE TIRES/ CHECKING THE WHEELS CHK ADJ After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTER STAND/ LUBRICATING THE REAR SUSPENSION CHK ADJ EB304200 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: cable sheath Damage Replace. 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: seat 2. Disconnect: battery leads (from the battery terminals) CAUTION: First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: battery 4. Check: battery charge a.
CHECKING AND CHARGING THE BATTERY CHK ADJ Do not quick charge a battery. Make sure that the battery vent is free of obstructions. Never remove the MF battery sealing caps. Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.
CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Measure the open-circuit voltage prior to charging. Connect a charged and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the charging voltage at 16 17 V. (If the setting is lower, charging will be insufficient.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s charging voltage is 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. Install: battery 7. Connect: battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: battery terminals Recommended lubricant Dielectric grease 10. Install: seat EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses.
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BLUBS CHK ADJ 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.
REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS CHK ADJ 2. Remove: headlight bulb holder 1 3. Remove: headlight bulb 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: headlight bulb (New) Secure the new headlight bulb with the headlight bulb holder.
ADJUSTING THE HEADLIGHT BEAMS CHK ADJ 2. Adjust: headlight beam (horizontally) a. Turn the adjusting knob 2 4 in direction a or b . Left headlight 2 Direction a Headlight beam moves to the right. Direction b Headlight beam moves to the left. Right headlight 4 Direction a Headlight beam moves to the left. Direction b Headlight beam moves o the right.
CHK ADJ
ENG 4
ENG CHAPTER 4 OVERHAULING THE ENGINE REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 DRIVE SPROCKET AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE BRACKET AND ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 INSTALLING THE ENGINE .
ENG AC MAGNETO AND STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC MAGNETO ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH . . . . . . . . . . . . .
REMOVING THE ENGINE ENG OVERHAULING THE ENGINE REMOVING THE ENGINE DRIVE SPROCKET AND EXHAUST PIPE 25 Nm (2.5 m kg) 70 Nm (7.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 17 Nm (1.7 m kg) Order Job name/Part name Q’ty Removing the drive sprocket and exhaust pipe Drain the coolant Drain the engine oil Remove the parts in the order listed. Refer to “CHANGING THE ENGINE OIL” section in capter 3. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3.
ENG REMOVING THE ENGINE 25 Nm (2.5 m kg) 70 Nm (7.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 17 Nm (1.7 m kg) Order 4 5 6 7 8 9 Job name/Part name Q’ty Shift arm Drive sprocket cover Drive chain sprocket gasket Dowel pin Lock washer Drive sprocket/Drive chain 1 1 1 2 1 1/1 Remarks Refer to “INSTALLING THE ENGINE” section. For installation, reverse the removal procedure.
REMOVING THE ENGINE ENG LEADS AND HOSES Engine right side Engine left side 12 Nm (1.2 m kg) 12 Nm (1.2 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed.
REMOVING THE ENGINE ENG ENGINE BRACKET AND ENGINE 33 Nm (3.3 m kg) 55 Nm (5.5 m kg) 33 Nm (3.3 m kg) 55 Nm (5.5 m kg) 33 Nm (3.3 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Removing the engine bracket and engine Engine mounting bolt (front left) Engine mounting bolt (front right) Engine bracket (front) Engine mounting bolt (rear upper) Engine bracket (rear right) Engine mounting bolt (rear lower) Engine Remarks Remove the parts in the order listed.
REMOVING THE ENGINE ENG EB400700 INSTALLING THE ENGINE 1. Install: bolt 1 bolt 2 bolt 3 bolt 4 engine bracket 5 engine bracket 6 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. Bolt 1 55 Nm (5.5 m kg) Bolt 2 55 Nm (5.5 m kg) Bolt 3 55 Nm (5.5 m kg) Bolt 4 55 Nm (5.5 m kg) Engine bracket 5 33 Nm (3.3 m kg) Engine bracket 6 10 Nm (10 m kg) 3. Install: shift arm 1 NOTE: Align the punch mark a in the shift shaft with the slot in the shift arm.
CAMSHAFT ENG CAMSHAFT CYLINDER HEAD COVERS 10 Nm (1.0 m kg) 9 Nm (0.9 m kg) Order Job name/Part name Q’ty Removing the cylinder head cover Front cowling Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. Seat and fuel tank Drain the coolant Radiator Carburetor 1 2 3 Remarks Refer to “RADIATOR” section in chapter 5. Refer to “CARBURETOR” section in chapter 6. Refer to “REMOVING THE ENGINE” section.
CAMSHAFT ENG CAMSHAFT 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 20 Nm (2.0 m kg) 13 Nm (1.3 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Removing the camshafts Spark plug Magneto cover Timing chain guide (upper) Timing chain tensioner assembly Timing chain guide (exhaust side) Camshaft cap Dowel pin Camshaft (intake) Cmashaft (exhaust) Camshaft sprocket Remarks Remove the parts in the order listed. 4 1 1 1 1 4 12 1 1 2 Refer to “REMOVING/INSTALLING THE CAMSHAFT” section.
CAMSHAFT ENG EB401102 REMOVING THE CAMSHAFTS 1. Remove: magneto cover 2. Align: “T” mark on the magneto rotor (with the stationary pointer on the crankcase) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark a with the stationary pointer b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 3. Remove: timing chain guide (top side) 1 4. Loosen: camshaft sprocket bolts 2 2 5.
CAMSHAFT 2 ENG CAUTION: 3 To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in. 8. Remove: intake camshaft 1 exhaust camshaft 2 1 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3 . EB401401 CHECKING THE CAMSHAFTS 1. Check: camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 2.
CAMSHAFT ENG 4. Measure: camshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. Camshaft-journal-tocamshaft-cap clearance 0.08 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. 1 NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
CAMSHAFT ENG EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: timing chain tensioner Cracks/damage Replace. 2. Check: one-way cam operation Rough movement Replace the timing chain tensioner housing. 3. Check: cap bolt 1 copper washer 2 ball 3 spring 4 ball 5 one-way cam 6 gasket timing chain tensioner rod 7 Damage/wear Replace the defective part(-s). EB401702 INSTALLING THE CAMSHAFTS 1.
CAMSHAFT ENG CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Camshaft cap bolt 10 Nm (1.0 m kg) 4. Install: intake camshaft sprocket exhaust camshaft sprocket a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the magneto rotor with the stationary pointer b on the crankcase. c.
CAMSHAFT ENG Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 m kg) d. Install the springs 3 , washer 2 , and cap bolt 1 . Cap bolt 20 Nm (2.0 m kg) d 7. Turn: crankshaft (several full turns counterclockwise) 8. Check: “T” mark a Make sure that the “T” mark on the magneto rotor is aligned with the stationary pointer b on the crankcase. camshaft punch marks c Make sure that the punch marks on the camshafts are aligned with the embossed marks d on the camshaft cap.
CYLINDER HEAD ENG CYLINDER HEAD 35 Nm (3.5 m kg) 20 Nm (2.0 m kg) Order 1 2 3 4 5 6 Job name/Part name Q’ty Removing the cylinder head Camshaft Union bolt Copper washer Oil delivery pipe Cylinder head Cylinder head gasket Dowel pin Remarks Remove the parts in the order listed. Refer to “CAMSHAFT”section. 2 4 1 1 1 2 Refer to “REMOVING/INSTALLING THE CYLINDER HEAD” section. For installation, reverse the removal procedure.
CYLINDER HEAD ENG EB402101 REMOVING THE CYLINDER HEADS 1. Remove: cylinder head nuts NOTE: Loosen the nuts in the proper sequence as shown. Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EB402403 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 1.
CYLINDER HEAD ENG EB402702 INSTALLING THE CYLINDER HEAD 1. Install: gasket (New) 1 dowel pins 2 NOTE: The “UP” mark a on the gasket must face up. 2. Install: cylinder head NOTE: Apply engine oil onto the threads of the cylinder head nuts. Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. Cylinder head nut First 20 Nm (2.0 m kg) Second 35 Nm (3.5 m kg) 3. Install: exhaust camshaft intake camshaft Refer to “INSTALLING SHAFTS”.
VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Removing the valves and valve springs Camshaft Cylinder head Valve lifter Adjusting pad Valve cotters Upper spring seat Valve spring Valve (intake) Valve (exhaust) Oil seal Lower spring seat Remarks Remove the parts in the order listed. Refer to “CAMSHAFT” section. Refer to “CYLINDER HEAD” section. 4 4 8 4 4 2 2 4 4 Refer to “REMOVING/INSTALLING THE VALVES” section.
VALVES AND VALVE SPRINGS ENG EB403100 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: valve lifter 1 valve pad NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG EB403400 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: S valve-stem-to-valve-guide clearance a Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification Replace the valve guide. b Valve-stem-to-valve-guide clearance Intake Limit: 0.08 mm Exhaust Limit: 0.1 mm 2.
VALVES AND VALVE SPRINGS ENG 4. Check: valve face Pitting/wear Grind the valve face. valve stem end Mushroom shape of diameter larger than the body of the valve stem Replace the valve. 5. Measure: valve margin thickness a Out of specification Replace the valve. Valve margin thickness 0.5 mm 6. Measure: valve stem runout a Out of specification Replace the valve. When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal.
VALVES AND VALVE SPRINGS ENG a. Apply Mechanic’s blueing dye (Dykem) b onto 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 one another, the blueing will have been removed. 4.
VALVES AND VALVE SPRINGS ENG EB403420 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: valve spring free length a Out of specification Replace the valve spring. Valve spring free length (intake and exhaust) Spring 40.09 mm (Limit 37.5 mm) a 2. Measure: compressed spring force a Out of specification Replace the valve spring. b Installed length Compressed spring force Intake and exhaust spring 13,4 15,6 kg at 34.5 mm 3.
VALVES AND VALVE SPRINGS ENG EB403440 CHECKING THE CAMSHAFT CAP 1. Check: camshaft case camshaft caps 1 Cracks/damage Replace th camshaft case and camshaft caps as a set, and check the camshafts (Refer to “CHECKING THE CAMSHAFTS”.). camshaft bearing surfaces 2 Damage/pitting/scratches Replace the camshaft case and camshaft caps as a set, and check the camshafts (Refer to “CHECKING THE CAMSHAFTS”.). 2. Check: oil delivery pipes 1 Damage Replace the defective part(-s).
VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04019 Attachment 90890-04114 5. To secure the valve cotters 1 onto the a valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Install: valve pad 1 valve lifter 2 NOTE: Apply molybdenum disulfide oil onto the valve lifter and valve pad. The valve lifter must move smoothly when rotated with a finger.
CYLINDER AND PISTON ENG CYLINDER AND PISTON 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Removing the cylinder and pistons Cylinder head Water jacket joint O-ring Cylinder Cylinder gasket Dowel pin O-ring Piston pin circlip Piston pin Piston Piston ring set Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD” section. 1 2 1 1 2 4 8 4 4 4 Refer to “INSTALLING THE PISTON AND CYLINDER” section.
CYLINDER AND PISTON ENG EB404101 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: piston pin clip 1 piston pin 2 piston 3 1 CAUTION: 2 Do not use a hammer to drive the piston pin out. NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. For reference during installation, put an identification mark on each piston crown.
CYLINDER AND PISTON ENG Standard Cylinder 62.00 62.01 bore “C” X+Y “C” = 2 Wear limit 62.1 mm b. If out of specification, replace the cylinder, piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer. a 5 mm from the bottom edge of the piston. P Piston size P a Standard 61.960 61.975 d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula.
CYLINDER AND PISTON ENG 2. Install: piston ring 1 (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown as shown. a a 20 mm 3. Measure: piston ring end gap Out of specification Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 0.30 mm : 0.6 mm 2nd ring 0.25 0.40 mm : 0.7 mm Oil ring 0.1 0.
CYLINDER AND PISTON ENG 3. Calculate: piston-pin-to-piston clearance Out of specification Replace the piston pin. b Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.011 0.013 mm : 0.023 mm EB404701 2 INSTALLING THE PISTON AND CYLINDER The following procedure applies to all of the pistons and cylinders. 1.
CYLINDER AND PISTON d ENG 5. Offset: piston ring end gaps c a b c d e Top ring Lower oil ring rail Upper oil ring rail 2nd ringe Oil ring expander e b a 6. Install: cylinder 1 O-ring 2 1 NOTE: First, install pistons #2 and #3. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. 2 2 a. Install a piston ring compressor 1 to piston #2 and #3. b. Install pistons #2 and #3 onto the cylinder. c. Remove the piston ring compressor. d.
CLUTCH ENG CLUTCH CLUTCH COVER 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Removing the clutch cover Drain the engine oil 1 2 3 4 5 Remarks Remove the parts in the order listed. Refer to “CHANGING THE ENGINE OIL” section in chapter 3. Clutch cover Clutch cover gasket Dowel pin Drive sprocket cover Clutch cable 1 1 2 1 1 4-31 For installation, reverse the removal procedure.
CLUTCH ENG CLUTCH 70 Nm (7.0 m kg) 8 Nm (0.8 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Q’ty Removing the clutch Compression spring Pressure plate Short clutch push rod O-ring Ball Long clutch push rod Friction plate Clutch plate Fricition plate (large) Clutch spring plate Nut Remarks Remove the parts in the order listed. 6 1 1 1 1 1 8 8 1 1 1 4-32 Refer to “INSTALLING THE CLUTCH” section. Refer to “REMOVING/INSTALLING THE CLUTCH” section.
CLUTCH ENG 70 Nm (7.0 m kg) 8 Nm (0.8 m kg) Order Job name/Part name Q’ty Remarks Refer to “REMOVING/INSTALLING THE CLUTCH” section. Refer to “INSTALLING THE CLUTCH” section. Refer to “REMOVING/INSTALLING THE CLUTCH” section. 12 13 14 Lock washer Clutch boss Thrust washer 1 1 1 15 16 17 18 19 Spacer Bearing Clutch housing Thrust washer Spacer 1 1 1 1 1 Refer to “INSTALLING THE CLUTCH” seciton. For installation, reverse the removal procedure.
CLUTCH ENG EB405100 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: clutch boss nut 1 2 NOTE: While holding the clutch boss 2 with the universal clutch holder 3 , loosen the clutch boss nut. 3 Universal clutch holder 3 90890-04086 3. Remove: spacer 1 bearing 2 NOTE: Insert two M6-mm bolts 3 into the spacer and then remove the spacer by pulling on the bolts. EB405400 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1.
CLUTCH ENG EB405420 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: clutch spring Damage Replace the clutch springs as a set. 2. Measure: clutch spring free length a Out of specification Replace the clutch springs as a set. a Clutch spring free length 34.9 mm : 34.3 mm EB405430 CHECKING THE CLUTCH SPRING PLATE 1. Check: clutch spring plate Damage Replace. 2. Check: clutch spring plate seat Damage Replace.
CLUTCH ENG EB405450 CHECKING THE CLUTCH BOSS 1. Check: clutch boss splines 1 Damage/pitting/wear Replace clutch boss. the NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EB405450 CHECKING THE PRESSURE PLATE 1. Check: pressure plate 1 Cracks/damage Replace. bearing 2 Damage/wear Replace. EB405480 CHECKING THE CLUTCH PUSH RODS 1. Check: O-ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks/damage/wear Replace the defective part(-s).
CLUTCH 2. Tighten: clutch boss nut 1 ENG 70 Nm (7.0 m kg) NOTE: While holding the clutch boss with the universal clutch holder 2 , tighten the clutch boss nut. 1 3 Universal clutch holder 90890-04086 2 3. Bend the lock washer 3 tab along a flat side of the nut. 4. Lubricate: long clutch push rod 1 ball 2 short clutch push rod 3 O-ring 4 (with the recommended lubricant) Recommended lubricant Lithium soap base grease 5.
CLUTCH 9. Install: clutch cover 1 ENG 12 Nm (1.2 m kg) NOTE: Tighten the clutch cover bolts in stages and in a crisscross pattern.
SHIFT SHAFT ENG SHIFT SHAFT Order Job name/Part name Q’ty Removing the shift shaft Oil pump Drive sprocket cover 1 2 3 4 5 Remarks Remove the parts in the order listed. Refer to “OIL PUMP” section. Refer to “REMOVING THE ENGINE” section. Collar Shift shaft Shift lever spring Stopper lever SHift lever spring 1 1 1 1 1 Refer to “INSTALLING THE SHIFT SHAFT” section. For installation, reverse the removal procedure.
SHIFT SHAFT ENG EB408400 CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 shift lever 2 Bends/damage/wear Replace. shift lever spring 3 stopper lever spring 4 Damage/wear Replace. 1 2 3 4 EB408700 INSTALLING THE SHIFT SHAFT 1. Install: stopper lever 1 stopper lever spring 2 shift shaft lever 2 NOTE: Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss. Mesh the stopper lever with the shift drum segment assembly. 1 2.
AC MAGNETO AND STARTER CLUTCH ENG AC MAGNETO AND STARTER CLUTCH STATOR COIL 5 Nm (0.5 m kg) 10 Nm (1.0 m kg) 12 Nm (1.2 m kg) Order Job name/Part name Q’ty Removing the stator coil Seat Fuel tank 1 2 3 4 5 Stator/pickup coil lead Cover Generator cover Dowel pin Stator coil Remarks Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. 1/1 1 1 2 1 For installation, reverse the removal procedure.
AC MAGNETO AND STARTER CLUTCH ENG STARTER CLUTCH 12 Nm (1.2 m kg) 80 Nm (8.0 m kg) Order Job name/Part name Q’ty 1 2 3 4 Removing the starter clutch Generator cover Starter clutch cover Dowel pin Gasket Starter clutch assembly 1 2 1 1 5 6 7 8 9 10 11 Wood ruff key Starter wheel gear Shaft (Primary) Starter idle gear (primary) Shaft (Secondary) Starter idle gear (secondary) Shaft drive gear 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed.
AC MAGNETO AND STARTER CLUTCH ENG AC MAGNETO ROTOR 130 Nm (13.0 m kg) Order 1 2 3 Job name/Part name Removing the generator roter Bolt/washer Rotor Woodruff key Q’ty 1/1 1 1 Remarks Remove the parts in the order listed. Refer to “REMOVING/INSTALLING THE AC MAGNETO” section. For installation, reverse the removal procedure.
AC MAGNETO AND STARTER CLUTCH ENG EB410100 REMOVING THE STARTER CLUTCH 1. Remove: starter clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: starter clutch bolt 1 NOTE: While holding the magneto rotor 2 with the sheave holder 3 , remove the starter clutch bolt. Sheave holder 90890-01701 3.
AC MAGNETO AND STARTER CLUTCH ENG 2. Remove: AC magneto rotor 1 Woodruff key NOTE: Use a flywheel puller 2 to remove the AC magneto rotor 1 . Flywheel puller: 90890-01362 EB410401 CHECKING THE STARTER CLUTCH 1. Check: starter clutch idle gear 1 starter clutch drive gear 2 starter clutch gear 3 Burrs/chips/roughness/wear Replace the defective part(-s). 2 1 3 2. Check: starter clutch operation a.
AC MAGNETO AND STARTER CLUTCH ENG INSTALLING THE AC MAGNETO 1. Install: Woodruff key 1 AC magneto rotor 2 Bolt (AC magneto rotor) NOTE: Clean the tapered portion of the crankshaft and the AC magneto rotor. When installing the AC magneto rotor, make sure that the woodruff key is properly seated in the key way of the crankshaft. 2. Tighten: Bolt (magneto rotor) Bolt (AC magneto rotor): 130 Nm (13.
OIL PAN AND OIL STRAINER ENG OIL PAN AND OIL STRAINER OIL STRAINER 7 Nm (0.7 m kg) 43 Nm (4.3 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 63 Nm (6.3 m kg) Order Job name/Part name Q’ty Removing the oil strainer Engine 1 2 3 4 5 6 7 8 9 Oil level warning switch/O-ring Oil pan Dowel pin Oil pan gasket Relief valve/O-ring Oil strainer Oil strainer housing Oil bypass valve Oil cooler/O-ring Remarks Remove the parts in the order listed. Refer to “REMOVING THE ENGINE” section.
OIL PAN AND OIL STRAINER ENG OIL PUMP 10 Nm (1.0 m kg) Order 1 2 3 Job name/Part name Q’ty Remarks Remove the parts in the order listed. Refer to “CLUTCH” section. Removing the oil pump Clutch Oil pump assembly Oil pump gasket Dowel pin 1 1 1 Refer to “INSTALLING THE OIL PUMP” section. For installation, reverse the removal procedure.
OIL PAN AND OIL STRAINER ENG 7 Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Disassembling the oil pump Oil pump rotor housing Dowel pin Inner rotor/outer rotor Dowel pin Oil pump shaft assembly Oil pump cover Washer 1 2 1/1 1 1 1 1 Remarks Disassembly the parts in the order listed. Refer to “ASSEMBLING THE OIL PUMP” section. For assembly, reverse the disassembly procedure.
OIL PAN AND OIL STRAINER ENG EB411100 REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 gasket dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EB411401 CHECKING THE OIL PUMP 1. Check: oil pump drive gear 1 oil pump driven gear 2 oil pump housing 3 oil pump housing cover 4 Cracks/damage/wear Replace the defective part(-s). 2.
OIL PAN AND OIL STRAINER ENG EB411430 CHECKING THE OIL STRAINER 1. Check: oil strainer 1 Damage Replace. Contaminants Clean with engine oil. EB411470 CHECKING THE OIL NOZZLE 1. Check: oil nozzle 1 check ball 2 Damage/wear Replace the oil nozzle. O-ring 3 Damage/wear Replace. oil nozzle passage Obstruction Blow out with compressed air. EB411701 ASSEMBLING THE OIL PUMP 1.
OIL PAN AND OIL STRAINER ENG EB411710 INSTALLING THE OIL PUMP Install: 10 Nm (1.0 m kg) oil pump 1 CAUTION: After tightening the bolts, make sure that the oil pump turns smoothly. b NOTE: Align the projection a on the oil pump shaft with the slot b on the water pump shaft. NOTE: Align the arrow c on the oil pump with the arrow d on the crankcase. d c EB411720 INSTALLING THE OIL STRAINER 1.
OIL PAN AND OIL STRAINER ENG NOTE: Tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switch’s O-ring with engine oil. Oil pan bolt 12 Nm (1.2 m kg) Oil level switch bolt 7 Nm (0.
CRANKCASE ENG CRANKCASE 24 Nm (2.4 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 24 Nm (2.4 m kg) Order Job name/Part name Q’ty Disassembly the parts in the order listed. Refer to “REMOVING THE ENGINE” section. Refer to “CAMSHAFT” section. Refer to “CYLINDER HEAD” section. Refer to “CYLINDER AND PISTON” section. Refer to “CLUTCH” section in chapter 4. Refer to “OIL PUMP” section. Refer to “SHIFT SHAFT” section. Refer to “AC MAGNETO AND STARTER CLUTCH section. Refer to “OIL PAN AND OIL STRAINER” section.
CRANKCASE ENG 24 Nm (2.4 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 24 Nm (2.4 m kg) Order 4 5 6 7 8 9 Job name/Part name Q’ty O-ring Upper crankcase Dowel pin Oil seal Oil jet O-ring 1 1 1 1 1 1 Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE CRANKCASE” section. For assembly, reverse the disassembly procedure.
CRANKCASE ENG EB412100 DISASSEMBLING THE CRANKCASE 1. Remove: crankcase bolts 1 15 A Upper crankcase A NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence. 2. Place the engine upside down. 3.
CRANKCASE ENG EB412742 ASSEMBLING THE CRANKCASE 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 3 mm of the crankshaft journal bearings. 3. Install: dowel pin 4.
CRANKCASE ENG 7. Install: upper crankcase bolts lower crankcase bolts A NOTE: Lubricate the bolt threads with engine oil. Tighten the bolts in increasing numerical order. Install washers on bolts 1 12 . Install the cable holder on bolt #35. A Upper crankcase B Lower crankcase M8 bolt 24 Nm (2.4 m kg) M6 bolt 12 Nm (1.
CRANKSHAFT ENG CRANKSHAFT 10 Nm (1.0 m kg) Order 1 2 3 4 5 Job name/Part name Q’ty Removing the crankshaft Disassembly the crankcase Timing chain guide (intake side) Crankshaft assembly Oil seal Timing chain Crankshaft journal bearing Remarks Remove the parts in the order listed. Refer to “CRANKCASE” section. 1 1 1 1 12 Refer to “REMOVING/INSTALLING THE CRANKSHAFT ASSEMBLY” section. For installation, reverse the removal procedure.
CRANKSHAFT ENG CONNECTING ROD 15 Nm (1.5 mSkg) + 90_ Order 1 2 3 4 5 Job name/Part name Q’ty Removing the connecting rod Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod big end bearing 8 8 4 4 8 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE CONNECTING RODS” section. Refer to “REMOVING/INSTALLING THE CONNECTING RODS” section. For installation, reverse the removal procedure.
CRANKSHAFT ENG EB412110 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: crankshaft assembly 1 crankshaft journal upper bearing 2 (from the upper crankcase) timing chain guide (intake side) 1 NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. 2 EB412121 REMOVING THE CONNECTING RODS 1.
CRANKSHAFT ENG Crankshaft-journal-to-crankshaft-journal-bearing clearance 0.025 0.043 mm Limit 0.08 mm CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft journal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original position. a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c.
CRANKSHAFT ENG f. Tighten the bolts to specification in the tightening sequence cast on the crankcase. A Crankcase bolt M8: 24 Nm (2.4 m kg) M6: 12 Nm (1.2 m kg) A Upper crankcase B Lower crankcase NOTE: Lubricate the crankcase bolt threads (M8) and (M6) with engine oil. B g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge width C on each crankshaft journal.
ENG CRANKSHAFT For example, if the crankcase “J1” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is: Bearing size for J1: J1 (crankcase) – J1 (crankshaft web) + 1 = 6 – 2 + 1 = 5 (yellow) A CRANKSHAFT JOURNAL BEARING COLOR CODE 1 1 2 blue black 3 4 5 brown green yellow 6 pink 1 5. Measure: crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings. 1 Crankshaft-pin-to-big-endbearing clearance 0.043 0.
CRANKSHAFT ENG NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed. S Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. S Make sure that the “Y” mark c on the connecting rod faces towards the left side of the crankshaft. S Make sure that the characters d on both the connecting rod and connecting rod cap are aligned. c e. Tighten the connecting rod nuts. Nut (connecting rod): 15 Nm (1.
ENG CRANKSHAFT For example, if the connecting rod “P1” and the crankshaft web “P1” numbers are “4” and “1” respectively, then the bearing size for “P1” is: Bearing size for P1: P1 (connecting rod) – P1 (crankshaftweb) = 4 – 1 = 3 (brown) BIG END BEARING COLOR CODE 2 1 2 blue black 3 4 brown green 2 2 EB412700 INSTALLING THE CONNECTING RODS 1. Lubricate: bolt threads nut seats (with the recommended lubricant) 2 3 Recommended lubricant Molybdenum disulfide grease 2.
CRANKSHAFT ENG 4. Align: S bolt heads 1 (with the connecting rod caps) 5. Tighten: S Nuts (connecting rod) Nut (connecting rod): 15 Nm (1.5 mSkg) + (turn the nut another 90_) a. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d.
CRANKSHAFT ENG EB412720 INSTALLING THE CRANKSHAFT 1. Install: crankshaft journal upper bearings 1 (into the upper crankcase) a NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. Be sure to install each crankshaft journal upper bearing in its original place. b 2. Install: timing chain 1 (onto the crankshaft sprocket) crankshaft assembly 2 NOTE: Pass the timing chain through the timing chain cavity.
TRANSMISSION ENG TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Removing the transmission Disassembly the crankcase Main axle assembly Circlip Bearing Bearing Drive axle assembly Circlip Nozzle Bearing Plate washer Oil seal/collar Bearing Q’ty 1 1 1 1 1 1 1 1 1 1/1 1 Remarks Remove the parts in the order listed. Refer to “CRANKCASE” section. Refer to “INSTALLING THE TRANSMISSION” section. Refer to “INSTALLING THE TRANSMISSION” section.
TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Q’ty Disassembling the transmission 1st wheel gear 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear 2nd wheel gear Washer Circlip Drive axle 2nd pinion gear 6th pinion gear ENG Remarks Disassembly the parts in the order listed.
TRANSMISSION Order 14 15 16 17 18 Job name/Part name Q’ty 3rd/4th pinion gear Circlip Washer 5th Main axle ENG Remarks 1 1 1 1 1 For assembly, reverse the disassembly procedure.
TRANSMISSION ENG EB413422 CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1) Out of specification Replace the main axle. Main axle runout limit 0.02 mm 2. Measure: drive axle runout (with a centering device and dial gauge 1) Out of specification Replace the drive axle. Drive axle runout limit 0.02 mm 3. Check: transmission gears Blue discoloration/pitting/wear Replace the defective gear(-s).
TRANSMISSION ENG EB413710 INSTALLING THE TRANSMISSION 1. Install: oil baffle plate 1 crankcase breather hose 2 NOTE: Insert the metal clamp 3 on the crankcase breather hose into the slots 4 in the crankcase. 2. Install: main axle assembly 1 drive axle assembly 2 oil seals circlips lock washer NOTE: Make sure that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase.
SHIFT DRUM AND SHIFT FORKS ENG SHIFT DRUM AND SHIFT FORKS 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Remarks Remove the parts in the order listed. Removing the shift drum and shift forks Disassembly the crankcase Transmission Shift fork guide bar retainer Shift drum retainer Shift fork guide bar 1 Shift fork C Shift fork guide bar 2 Shift fork L Shift fork R Shift drum Refer to “CRANKCASE” section. Refer to “TRANSMISSION” section.
SHIFT DRUM AND SHIFT FORKS ENG EB413400 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: shift fork cam follower 1 shift fork pawl 2 Bends/damage/scoring/wear Replace the shift fork. 2 1 2. Check: shift fork guide bar Roll the shift fork guide bar on a flat surface. Bend Replace. Do not attempt to straighten a bent shift fork guide bar. 3.
SHIFT DRUM AND SHIFT FORKS 2 ENG 2. Install: S shift fork guide bars 1 S shift fork “L” 2 S shift fork “C” 3 S shift fork “R” 4 3 NOTE: S The embossed marks on the shift forks should face towards the left side of the engine and be in the following sequence: “L”, “C”, “R”. S The grooved side of the shift fork guide bar should face towards the right side of the engine. 1 1 3. Install: S shift drum retainer 1 LOCKTITER S shift fork guide bar retainer 2 10 Nm (1.0 mSkg) 10 Nm (1.
COOL 5
COOL CHAPTER 5 COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOL
RADIATOR COOL COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Removing the radiator Seat Fuel tank Drain the coolant 1 2 3 4 5 Fan motor leads Radiator outlet hose Radiator inlet hose Radiator Fan 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/SIDE COVER/FUEL TANK” section in chapter 3. Refer to “CHANGING THE COOLANT” section in chapter 3. NOTE: Disconnect the coupler. For installation, reverse the removal procedure.
RADIATOR COOL EB500010 CHECKING THE RADIATOR 1. Check: radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: radiator hoses radiator pipes Cracks/damage Replace. 3. Measure: radiator cap opening pressure Below the specified pressure Replace the radiator cap. Radiator cap opening pressure 95 125 kPa (0.95 1.25 kg/cm2) a.
RADIATOR COOL EB500020 INSTALLING THE RADIATOR 1. Fill: cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: cooling system Leaks Repair or replace any faulty part. a. Attach the radiator cap tester 1 to the radiator. Radiator cap tester: 90890-01325 b. Apply 100 kPa (1.0 kg/cm2) of pressure. c. Measure the indicated pressure with the gauge.
THERMOSTAT COOL THERMOSTAT 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Removing the thermostat Seat Fuel tank Drain the coolant 1 2 3 4 5 6 7 8 9 1 Thermo switch lead (engine temperature) Thermo switch lead (fan motor) Reservoir tank hose Carburetor inlet hose Engine outlet hose Engine outlet hose Radiator inlet hose Thermostat housing Ground read 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3.
THERMOSTAT COOL 23 Nm (2.3 m kg) 8 Nm (0.8 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 Job name/Part name Q’ty Disassembling the thermostat Thermo switch (fan motor) Thermo switch (engine temperature) Thermostat housing cover O-ring Thermostat Thermostat housing Remarks Disassembly the parts in the order listed. 1 1 1 1 1 1 Refer to “ASSEMBLING THE THERMOSTAT” section. For assembly, reverse the disassembly procedure.
THERMOSTAT COOL EB502021 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 80.5 83.5_C Replace. 1 a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermometer’s indicated temperature. Thermometer Water Thermostat Container A Closes B Opens 1 2 3 4 1 3 4 NOTE: If the accuracy of the thermostat is in doubt, replace it.
THERMOSTAT COOL EB502030 ASSEMBLING THE THERMOSTAT 1. Install: thermostat housing 1 thermostat 2 O-ring (New) 3 thermostat housing cover 4 NOTE: Install the thermostat with its breather hole a facing up. 2. Install: thermo switch (fan motor) 1 23 Nm (2.3 m kg) thermo switch (engine temperature) 2 8 Nm (0.8 m kg) CAUTION: Use extreme care when handling the thermo switch and temperature sender. Replace any part that was dropped or subjected to a strong impact.
WATER PUMP COOL WATER PUMP 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Removing the water pump Drain the coolant Remove the parts in the order listed. Refer to “CHANGING THE COOLANT” section in chapter 3. Refer to “REMOVING THE ENGINE” section in chapter 4.
WATER PUMP COOL EB503020 REMOVING THE WATER PUMP 1. Remove: water pump housing 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. EB503032 CHECKING THE WATER PUMP 1. Check: water pump housing cover water pump housing 1 impeller 2 1 2 2. Check: water pump seal 1 oil seal 2 Cracks/damage/wear Replace. 3. Check: bearing 1 Roughness Replace. 4. Check: water pump inlet pipe radiator outlet hose Cracks/damage/wear Replace.
WATER PUMP a COOL NOTE: Align the slot a on the impeller shaft with the projection b on the oil pump shaft. Before installing the water pump housing, apply a thin coat of lithium soap base grease onto the O-ring. b 2. Install: water pump housing cover 1 water pump outlet pipe 2 Always use a new gasket and O-rings. NOTE: Before installing the water pump outlet pipe, apply a thin coat of lithium soap base grease onto the O-rings. Water pump housing cover bolt 10 Nm (1.0 m kg) 3.
CARB 6
CARB CHAPTER 6 CARBURETORS CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARB
CARBURETORS CARB CARBURETORS CARBURETORS AIR FILTER CASE Order Job name/Part name Q’ty Removing the air filter case Seat, fueltank and sidecovers Remove the parts in the order listed. Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. Refer to “CHANGING THE COOLANT” section. Drain the coolant 1 2 3 4 5 Remarks Air filter case (left/right) Battery negative lead Battery positive lead Battery Stay 1/1 1 1 1 1 For installation, reverse the removal procedure.
CARBURETORS CARB CARBURETORS Order 1 2 3 4 5 6 Job name/Part name Q’ty Removing the carburetors Throttle position sensor lead Air filter joint screw Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable 4 4 1/1 1 1 2 Remarks Remove the parts in the order listed. NOTE: Disconnect the coupler. For installation, reverse the removal procedure.
CARBURETORS Order 1 2 3 4 5 6 7 8 9 10 11 12 Job name/Part name Q’ty Disassembling the carburetors Starter plunger link Carburetors assembly Vacuum chamber cover Piston valve spring Piston valve Needle kit Float chamber Float chamber gasket Float pin Float Needle valve assembly Main jet CARB Remarks Disassembly the parts in the order listed. 1 4 1 1 1 1 1 1 1 1 1 1 6-3 #1, #2, #3, #4 Refer to “ASSEMBLING THE CARBURETERS” section.
CARBURETORS Order Job name/Part name Q’ty 13 14 15 16 Main jet holder Needle jet Pilot jet Pilot screw set 1 1 1 1 17 Starter plunger kit 1 CARB Remarks Refer to “ASSEMBLING THE CARBURETORS” section. For assembly, reverse the disassembly procedure.
CARBURETORS CARB EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: carburetor body float chamber main jet holder Cracks/damage Replace. 2. Check: fuel passages Obstruction Clean. a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic-carburetor-cleaning solution. b. Blow out all of the passages and jets with compressed air. 3. Check: float chamber body 1 Dirt Clean. 4.
CARBURETORS CARB 8. Check: piston valve 1 Damage/scratches/wear Replace. rubber diaphragm 2 Cracks/tears Replace. 9. Check: vacuum chamber cover 1 piston valve spring 2 jet needle holder 3 Cracks/damage Replace. 10. Check: jet needle kit 1 needle jet 2 main jet 3 pilot jet 4 pilot screw 5 starter plunger 6 Bends/damage/wear Replace. Obstruction Clean. Blow out the jets with compressed air. 11.
CARBURETORS CARB EB600041 ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. CAUTION: Before assembling the carburetors, wash all of the parts in a petroleumbased solvent. Always use a new gasket. 1. Install: O-ring (New) washer pilot screw spring pilot screw 1 Pilot screw 2 turns out 2. Install: jet needle 1 washer 2 (0.5 mm) ring 3 clip 4 washer 5 (0.5 mm) Standard clip position: No. 3 Groove 3.
CARBURETORS CARB 4. Install: fuel feed joints 1 hose joints 2 spacer 3 connecting bolt 4 starter plunger link 5 throttle cable holder 6 spacer 7 connecting bolt 8 NOTE: Do not tighten the connecting bolts yet. Install the throttle arm 9 onto carburetors #1, #2, and #4 between the spring 10 and synchronizing screw 11 . Install the starter plunger link onto each starter plunger. Place the carburetor assembly on a surface plate with the intake manifold side down.
CARBURETORS CARB EB600062 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: fuel level a Out of specification Adjust Fuel level (above the float chamber mating surface) 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 standing straight up. c. Install the fuel level gauge 1 to the fuel drain pipe 2 . Fuel level gauge 90890-01312 3 2 d. Loosen the fuel drain screw 3 . e.
CARBURETORS CARB EB600070 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. S When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer. Refer to the adjustment procedure below. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor coupler. b. Connect the pocket tester (Ω 1k) to the throttle position sensor.
CARBURETORS CARB b. Disconnect the throttle position sensor coupler. c. Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode. d. Loosen the throttle position sensor screws 1 . e. Adjust the throttle position sensor angle according to the following table: NOTE: The angle of the throttle position sensor is indicated by the RPM which is displayed on the tachometer.
CARB 6-12
CHAS 7
CHAS CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE BRAKE DISCS . . . . . .
CHAS STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . .
FRONT WHEEL AND BRAKE DISC CHAS CHASSIS FRONT WHEEL AND BRAKE DISC 40 Nm(4.0 m kg) 67 Nm (6.7 m kg) 20 Nm (2.0 m kg) 23 Nm(2.3 m kg) Order Job name/Part name Q’ty 1 Removing the flont wheel and brake discs Wheel axle pinch bolt 2 3 4 5 6 7 8 Brake hose horder (left/right) Brake caliper (left/right) Wheel axle Front wheel assembly Speed sensor unit Collar Brake disc (left/right) Remarks Remove the parts in the order listed.
FRONT WHEEL AND BRAKE DISC CHAS FRONT WHEEL Order 1 2 3 4 Job name/Part name Q’ty Disassembling the front wheel Oil seal Bearing Spacer Bearing Remarks Disassembly the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly prodedure.
FRONT WHEEL AND BRAKE DISC CHAS EB700102 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: wheel axle pinch bolt brake hose holder (left/right) 3. Remove: left brake caliper right brake caliper NOTE: Do not squeeze the brake lever when removing the brake calipers. 4.
FRONT WHEEL AND BRAKE DISC CHAS 3. Measure: front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits Replace. 2 1 Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4. Check: wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. oil seals Damage/wear Replace. 5. Replace: wheel bearings (New) oil seals (New) a. Clean the outside of the front wheel hub. b.
FRONT WHEEL AND BRAKE DISC CHAS EB700414 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling Replace. 2. Measure: S brake disc deflection a Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.2 mm Rear: 0.15 mm a. Place the motorcycle on a suitable stand so that the wheel is elevated. b.
FRONT WHEEL AND BRAKE DISC CHAS EB700722 INSTALLING THE FRONT WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips Recommended lubricant Lithium soap base grease 2. Install: Speed sensor unit NOTE: Make sure that the speed sensor unit and the wheel hud are installed with the two projections a meshed into the two slots b respectively. 3. Install: front wheel NOTE: Make sure that the slot a in the speed sensor unit fits over the stopper on the outer tube b . 4.
FRONT WHEEL AND BRAKE DISC CHAS EB700901 A ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire. wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. X1 1. Remove: S balancing weight(-s) B NOTE: Place the front wheel on a suitable balancing stand. 2. Find: S 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.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 117 Nm (11.7 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Removing the rear wheel Brake caliper Nut Washer Wheel axle Washer Drive chain puller (left) Drive chain puller (right) Rear wheel assembly Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 Refer to “REMOVING/INSTALLING THE REAR WHEEL” section. For installation, reverse the removal procedure.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS BRAKE DISC AND REAR WHEEL SPROCKET 60 Nm (6.0 m kg) 23 Nm (2.3 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Removing the brake disk and rear wheel sprocket Collar (left/right) Brake disc Rear wheel sprocket Collar Drive hub damper Rear wheel drive hub Oil seal Bearing Remarks Remove the parts in the order listed. 1/1 1 1 1 6 1 1 1 For instalation, reverse the removal procedure.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS DIASSEMBLY THE REAR WHEEL Order 1 2 3 4 Job name/Part name Q’ty Disassembling the rear wheel Oil seal Bearing Collar Bearing Remarks Disassembly the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EB701100 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so. that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: brake caliper 1 NOTE: Do not depress the brake pedal when removing the brake caliper. 3. Loosen: locknut 1 adjusting nut 2 4.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS 3. Measure: rear wheel radial runout rear wheel lateral runout Refer to “FRONT WHEEL AND BRAKE DISC”. EB701440 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: rear wheel sprocket More than 1/4 tooth a wear Replace the rear wheel sprocket. Bent teeth Replace the rear wheel sprocket. correct b drive chain roller 1 rear wheel sprocket 2 2. Replace: rear wheel sprocket 1 a. Remove the self-locking nuts and the rear wheel sprocket.
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS EB701900 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: rear wheel static balance Refer to “FRONT WHEEL AND BRAKE DISC”.
FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m kg) Order 1 2 3 4 5 Job name/Part name Q’ty Removing the front brake pads Brake caliper Brake pads clip Brake pad pin Brake pad spring Brake pad Remarks Remove the parts in the order listed. 1 2 1 1 2 Refer to “REPLACING THE FRONT BRAKE PADS” section. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS REAR BRAKE PADS 10 Nm (1.0 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 Job name/Part name Removing the rear brake pads Caliper Brake pad pin Brake pad/shim Brake pad spring Q’ty Remarks Remove the parts in the order listed. 1 2 2/2 1 Refer to “REPLACING THE REAR BRAKE PADS” section. For instalation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702100 CAUTION: Disc brake componets rarely require disassembly. Tehrefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components.
CHAS FRONT AND REAR BRAKES 3. Remove: brake pads 1 (along with the brake pad shims) 4. Measure: brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: brake pad shims (onto the brake pads) brake pads brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b.
FRONT AND REAR BRAKES CHAS EB702113 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: brake caliper 1 2. Remove: brake pad pins 1 3. Remove: brake pads 2 (along with the brake pad shims) brake pad spring 4. Measure: brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5.
FRONT AND REAR BRAKES 6. Install: brake pad pins 1 brake caliper CHAS 10 Nm (1.0 m kg) 40 Nm (4.0 m kg) 7. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 8. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS FRONT BRAKE MASTER CYLINDER 10 Nm(1.0 m kg) 30 Nm(3.0 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Removing the front brake master cylinder Drain the brake fluid Brake lever Brake switch lead Brake switch Union bolt Copper washer/brake hose Master cylinder bracket Master cylinder Q’ty Remarks Remove the parts in the order listed. 1 2 1 1 2/1 1 1 Refer to “REMOVING/ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER” section.
FRONT AND REAR BRAKES Order 1 2 3 4 Job name/Part name Q’ty Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring CHAS Remarks Disassembly the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS REAR BRAKE MASTER CYLINDER 30 Nm(3.0 m kg) 4 Nm(0.4 m kg) 23 Nm(2.3 m kg) Order Job name/Part name Q’ty 1 2 3 Removing the rear brake master cylinder Side cover (right) Drain the brake fluid Master cylinder bolt Union bolt Copper washer/brake hose 2 1 2/1 4 5 6 7 8 Clip/hose Cotter pin Pin Washer Master cylinder 2/1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “REMOVING/ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER” section.
FRONT AND REAR BRAKES Order Job name/Part name Q’ty 1 2 3 4 Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring CHAS Remarks Disassembly the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702210 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Befor disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake switch coupler 1 (from the brake switch) 2. Remove: union bolt 2 copper washers 3 brake hoses 4 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. EB702220 REMOVING THE REAR BRAKE MASTER CYLINDER 1.
FRONT AND REAR BRAKES A B C D CHAS EB702242 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder Damage/scratches/wea Replace. brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. A Front B Rear 2. Check: brake master cylinder kit 1 Damage/scratches/wear Replace. C Front D Rear 3.
FRONT AND REAR BRAKES CHAS EB702270 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: copper washers (New) 1 brake hose 2 30 Nm (3.0 m kg) union bolt 3 a Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
FRONT AND REAR BRAKES CHAS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 5. Check: brake lever operation Soft or spongy feeling Bleed the brake system.
FRONT AND REAR BRAKES CHAS Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
FRONT AND REAR BRAKES CHAS FRONT BRAKE CALIPERS 40 Nm(4.0 m kg) Order 1 2 3 4 Job name/Part name 30 Nm(3.0 m kg) Q’ty Removing the front brake calipers Drain the brake fluid Union bolt Copper washer Brake hose Brake caliper assembly Remarks Remove the parts in the order listed. 1 2 1 1 Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS” section. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Disassembling the front brake calipers Clip Pad pin Brake pad spring Brake pad Bleed screw kit Brake caliper piston Dust seal Piston seal CHAS Remarks Disassembly the parts in the order listed. 2 1 1 2 1 4 4 4 Refer to “REPLACING THE FRONT BRAKE PADS” section. Refer to “DISASSEMBLING THE FRONT BRAKE CALIPER” section. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS REAR BRAKE CALIPER 30 Nm(3.0 m kg) 40 Nm(4.0 m kg) Order 1 2 3 4 Job name/Part name Q’ty Removing the rear brake caliper Drain the brake fluid Union bolt Copper washer Brake hose Rear brake caliper Remarks Remove the parts in the order listed. 1 2 1 1 Refer to “ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER” section. For installation, revers the removal procedure.
FRONT AND REAR BRAKES CHAS 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Disassembling the rear brake caliper Pad pin 2 Pad spring 1 Brake pad assembly/shim 2/2 Bleed screw kit 2 Brake caliper piston 2 Dust seal 2 Piston seal 2 Remarks Disassembly the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PAD” section. Refer to “DISASSEMBLING THE REAR BRAKE CARIPER” section. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702317 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: brake caliper pistons 1 brake caliper piston seals 2 a.
FRONT AND REAR BRAKES CHAS EB702322 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: brake caliper pistons 1 brake caliper piston seals 2 a. Secure the right side brake caliper piston with a piece of wood a b.
FRONT AND REAR BRAKES CHAS 1. Check: brake caliper pistons 1 Rust/scratches/wear Replace the brake caliper. brake caliper cylinders 2 Scratches/wear Replace the brake caliper. brake calipers 3 Cracks/damage Replace. brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air. A B Whenever a brake caliper is disassembled, replace the brake caliper piston seals. A Front B Rear 2. Check: brake caliper brackets 1 Cracks/damage Replace.
FRONT AND REAR BRAKES CHAS CAUTION: When installing the brake hose onto the brake caliper, make sure that the brake pipe a touches the projection a on the brake caliper. 2. Remove: brake caliper 3. Install: brake pads brake spring brake caliper pins brake caliper clips brake caliper brake hose holder Refer to “REPLACING THE BRAKE PADS”. Brake caliper bolt 40 Nm (40 m kg) 4.
FRONT AND REAR BRAKES CHAS 5. Bleed: brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: brake lever operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS 2. Remove: brake caliper 3. Install: brake pad spring brake pads brake pad pins brake caliper brake hose holder Refer to “REPLACING THE BRAKE PADS”. Brake caliper pad pin 10 Nm (1.0 m kg) Brake caliper bolt 40 Nm (4.0 m kg) 4. Fill: brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 Use only the designated brake fluid.
FRONT AND REAR BRAKES CHAS 6. Check: brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: brake pedal operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT FORK CHAS FRONT FORK 30 Nm (3.0 m kg) 30 Nm (3.0 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Removing the front fork Front wheel Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS” section. Refer to “FRONT AND REAR BRAKES” section.
CHAS FRONT FORK 23 Nm (2.3 m kg) 15 6 7 12 13 10 14 11 9 8 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Q’ty Disassembling the front fork Cap bolt O-ring Spacer Washer Front fork spring Dust seal Oil seal clip Bolt Gasket Damper rod/rebound spring Inner tube/Inner tube bushing Oil seal Washer 1 1 1 1 1 1 1 1 1 1/1 1 1 1 30 Nm (3.0 m kg) Remarks Disassembly the parts in the order listed. 7-41 Refer to “ASSEMBLING THE FRONT FORK LEGS” section.
CHAS FRONT FORK 23 Nm (2.3 m kg) 15 6 7 12 13 10 14 11 9 8 Order 14 15 Job name/Part name Outer tube bushing Oil flow stopper 30 Nm (3.0 m kg) Q’ty Remarks 1 1/1 Refer to “ASSEMBLING THE FRONT FORK LEGS” section. For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EB703100 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loosen: upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 3.
FRONT FORK CHAS 3. 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 carefully. CAUTION: Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.
FRONT FORK CHAS 4. Check: cap bolt O-ring Damage/wear Replace. EB703700 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Make sure that the oil levels in both front fork legs are equal. Uneven oil levels can result in poor handling and a loss of stability.
FRONT FORK CHAS 4. Install: outer tube bushing 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 5. Install: washer oil seal 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 CAUTION: Make sure that the numbered side of the oil seal, faces up. NOTE: Before installing the oil seal, apply lithium soap base grease onto its lips.
FRONT FORK CHAS NOTE: While filling the front fork leg, keep it upright. After filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install: spring 1 spring seat 2 spacer 3 cap bolt NOTE: Install the spring with the smaller pitch facing up. Before installing the cap bolt, apply grease onto the O-ring. Temporarily tighten the cap bolt. EB703710 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.
HANDLEBAR CHAS HANDLEBAR 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty 1 2 3 4 5 6 7 8 9 10 11 Removing the handle bar Master cylinder bracket Master cylinder assembly Throttle cable housing cover Handle bar switch (right) Throttle cable housing Throttle cable Grip end Grip assembly Clutch cable Clutch switch Handle bar switch (left) 1 1 1 1 1 1 1 1 1 1 1 12 13 Starter cable Grip end 1 1 Remarks Remove the parts in the order listed.
HANDLEBAR CHAS 10 Nm (1.0 m kg) 7 Nm (0.7 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) Order 14 15 16 17 Job name/Part name Q’ty Remarks 1 1 2 1 Refer to “REMOVING THE HANDLEBAR” section. Refer to “INSTALLING THE HANDLEBAR” section. For installation, reverse the removal procedure.
HANDLEBAR CHAS EB704100 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: throttle cable housing 1 throttle grip 2 NOTE: While removing the throttle cable housing, pull back the rubber cover 3 . 3. Remove: left handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. 1 EB704400 CHECKING THE HANDLEBAR 1.
HANDLEBAR CHAS EB704701 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Install: handlebar 1 upper handlebar holders 2 23 Nm (2.3 m kg) CAUTION: b First, tighten the bolts on the front side a of the handlebar holder, then on the rear side. turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
HANDLEBAR CHAS 6. Install: throttle grip 1 throttle cable housing 2 throttle cables 3 NOTE: Apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar. NOTE: Align the projection a on the throttle cable housing with the hole b in the handlebar. 7. Install: right grip end right handlebar switch 1 Make sure that the throttle grip operates smoothly.
STEERING HEAD CHAS STEERING HEAD LOWER BRACKET 110 Nm (11.0 m kg) Order 1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) Job name/Part name Removing the lower bracket Front cowling 1 2 3 4 5 6 7 8 Fuel tank Front wheel Front fork Handle bar Main switch lead coupler Brake hose joint/cover Steering stem nut Upper bracket Lock washer Ring nut (upper) Rubber washer 1 Ring nut (lower) Q’ty Remarks Remove the parts in the order listed.
STEERING HEAD CHAS 110 Nm (11.0 m kg) Order 9 10 11 12 13 1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) Job name/Part name Q’ty Lower bracket Ball race cover Ball bearing Rubber washer 1 Ball bearing 1 1 1 1 1 Remarks Refer to “INSTALLING THE STEERING HEAD” section. For installation, reverse the removal procedure.
STEERING HEAD CHAS EB705102 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: upper ring nut lower ring nut 1 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench 2 , then remove the upper ring nut with the ring nut wrench. Exhaust and steering nut wrench 90890-01268 Securely support the lower bracket so that there is no danger of it falling.
STEERING HEAD CHAS b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearing balls and bearing races 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.
REAR SHOCK ABSORBER AND RELAY ARM CHAS REAR SHOCK ABSORBER AND RELAY ARM 48 Nm (4.8 m kg) 40 Nm (4.0 m kg) 40 Nm (4.0 m kg) 48 Nm (4.8 m kg) Order Job name/Part name Q’ty Remove the parts in the order listed. Removing the rear shock absorber assembly and relay arm Side covers Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3 Refer to “REAR WHEEL, BRAKE DISK AND REAR WHEEL SPROCKET” section.
REAR SHOCK ABSORBER AND RELAY ARM CHAS 48 Nm (4.8 m kg) 40 Nm (4.0 m kg) 40 Nm (4.0 m kg) 48 Nm (4.8 m kg) Order 8 9 10 11 12 13 14 15 16 17 18 19 Job name/Part name Bolt Relay arm Self-locking nut/washer Bolt Connecting plate Spacer Spacer Spacer Oil seal Bearing Bearing Bearing Q’ty 1 1 1/1 1 2 1 2 1 2 2 1 1 Remarks = 80 mm = 120 mm For installation, reverse the removal procedure.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EB706101 HANDLING THE REAR SHOCK ABSORBER This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EB706204 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Disconnect: battery leads (from the battery terminals) CAUTION: First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: battery 4.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EB706401 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. rear shock absorber oil leaks Replace the rear shock absorber assembly. spring Damage/wear Replace the rear shock absorber assembly. bushings Damage/wear Replace. dust seals Damage/wear Replace. bolts Bends/damage/wear Replace. EB706701 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1.
SWINGARM AND DRIVE CHAIN CHAS SWINGARM AND DRIVE CHAIN 115 Nm (11.5 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Removing the swingarm and drive chain Rear wheel Removing the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET” section. Refer to “REAR SHOCK ABSORBER AND RELAY ARM” section.
SWINGARM AND DRIVE CHAIN CHAS 115 Nm (11.5 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) Order 10 11 12 Job name/Part name Q’ty Spacer Bearing Washer Remarks 1 2 2 For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN CHAS EB707100 NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a ten-link section of the drive chain. EB707111 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2.
SWINGARM AND DRIVE CHAIN CHAS EB707400 CHECKING THE SWINGARM 1. Check: swingarm Bends/cracks/damage Replace. 2. Check: pivot shaft Roll the pivot shaft on a flat surface. Bends Replace. Do not attempt to straighten a bent pivot shaft. 3. Wash: pivot shaft dust covers spacer washers bearings Recommended cleaning solvent Kerosine 4. Check: dust covers 1 spacer 2 washers 3 oil seals 4 Damage/wear Replace. bearings 5 Damage/pitting Replace. 5.
SWINGARM AND DRIVE CHAIN CHAS EB707410 CHECKING THE DRIVE CHAIN 1. Measure: ten-link section a of the drive chain Out of specification Replace the drive chain. Ten-link drive chain section limit (maximum) 150 mm NOTE: While measuring the ten-link section, push down on the drive chain to increase its tension. Measure the length between drive chain roller 1 and 11 as shown. Perform this measurement at two or three different places. 2.
SWINGARM AND DRIVE CHAIN CHAS 5. Lubricate: drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: drive sprocket rear wheel sprocket More than 1/4 tooth a wear Replace the drive chain sprockets as a set. Bent teeth Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket EB707700 INSTALLING THE SWINGARM 1.
SWINGARM AND DRIVE CHAIN CHAS 4. Adjust: drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 30 45 mm EB707710 INSTALLING THE DRIVE CHAIN 1. Lubricate: drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: drive chain 1 drive sprocket 2 washer 3 drive sprocket nut 4 70 Nm (7.0 m kg) NOTE: While applying the rear brake, tighten the drive sprocket nut.
– ELEC + 8
ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 CHECKING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CHECKING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC
ELECTRICAL COMPONENTS ELEC EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 Main switch Fuel sender Rear brake switch Battery Ignitor unit Starter relay 7 8 9 10 11 12 Starting circuit cut-off relay Flasher relay Sidestand switch Neutral switch Oil level gauge Ignition coil 8-1 13 14 15 16 17 Rectifier/ Regulator Thermo switch (warning light) Thermo switch (fan motor) Horn Diode
CIRCUIT DIAGRAM CIRCUIT DIAGRAM 8-2 ELEC
CIRCUIT DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 A.C.
CHECKING SWITCHES ELEC YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester, check switches for continuity between their terminals to determine whether they are correctly connected. Replace the switch component if any of the combinations does not produce the correct reading. Pocket tester: 90890-03112 NOTE: Turn the switch to the “ON”, “OFF” positions several times. Adjust the pocket tester to correct “0” position before checking switches. Set the pocket tester selector to “ 1” Ω.
CHECKING SWITCHES ELEC YP****** SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault Repair or replace. * indicates coupler positions.
12 13 14 3 Main switch 16 22 4 Battery 6 Fuse (main) 54 11 Ignitor unit 56 Ignition coil Spark plug Pickup coil Neutral switch Sidestand switch Engine stop switch Fuse (ignition) IGNITION SYSTEM 8-6 ELEC EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM
IGNITION SYSTEM ELEC EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main and ignition) 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Engine stop switch 9. Neutral switch 10. SIdestand switch 11. Diode (starting circuit cut-off relay) 12. Pickup coil resistance 13.
IGNITION SYSTEM ELEC : EB802013 3. Spark plugs Standard spark plug: CR9E, CR8E/U27ESR-N, U24ESR-N NGK/NIPPONDENSO S Check the spark plug condition. S Check the spark plug type. S Check the spark plug gap. Refer to “SPARK LUG INSPECTION” in CHAPTER 3. INCORRECT Spark plug gap: 0.7 X 0.8 mm CORRECT Repair or replace the spark plugs. EB802014 4. Ignition spark gap S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 as shown.
IGNITION SYSTEM ELEC : EB802015 5. Spark plug cap resistance S Remove the spark plug cap. S Connect the pocket tester (Ω spark plug cap. 1k) to the S Check if the spark plug cap has the specified resistance. OUT OF SPECIFICATION Spark plug cap resistance: 10 kΩ at 20_C Replace the spark plug cap. MEETS SPECIFICATION EB802016 Tester (+) lead Red/Black terminal Tester (–) lead Orange (Gray) terminal 6. Ignition coil resistance S Disconnect the ignition coil connector from the wire harness.
IGNITION SYSTEM ELEC : EB802017 7. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB802018 8. Engine stop switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Red/White 1 – Red/Black 2 NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB802019 9.
IGNITION SYSTEM ELEC NO CONTINUITY Replace the main switch. CONTINUITY EB80201A 10. Sidestand switch Disconnect the sidestand switch coupler from the wire harness. Check for continuity as follows: Black 1 – Black 2 NO CONTINUITY Replace the sidestand switch. CONTINUITY 11. Diode (starting circuit cut-off relay unit) Remove the relay unit from the wire harness.
IGNITION SYSTEM Tester lead!Blue/Yellow 1 Continuity Tester lead!Light green 2 Tester Tester ELEC INCORRECT lead!Blue/Yellow 1 No lead!Light green 2 Continuity Replace the relay unit. CORRECT EB80201C 12. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal. Tester (+) lead ! Yellow terminal 1 Tester (–) lead ! Blue terminal 2 S Check if the pickup coil has the specified resistance.
3 4 6 7 Main switch Battery Fuse (main) Starter relay 8 9 16 22 33 54 55 56 Starter motor Starting circuit cut-off relay Neutral switch Sidestand switch Clutch switch Engine stop switch Start switch Fuse (ignition) ELECTRIC STARTING SYSTEM 8-13 ELEC EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM ELEC EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can operate only if. The transmission is in neutral (the neutral switch is closed).
ELECTRIC STARTING SYSTEM ELEC EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Neutral switch 9. Sidestand switch 10. Clutch switch 11. Start switch 12. Diode (starting circuit cut-off relay) 13.
ELECTRIC STARTING SYSTEM ELEC : : EB803021 3. Starter motor S A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. S This check is likely to reduce sparks, so be sure that no flammable gas or fluid is in the vicinity. S Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 :. S Check the operation of the starter motor. DOES NOT MOVE Repair or replace the starter motor.
ELECTRIC STARTING SYSTEM : EB803024 5. Starter relay S Disconnect the relay unit coupler from the wire harness. S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit coupler terminals. Battery (+) terminal Red/White terminal 3 Battery (–) terminal Blue/White terminal 4 NO CONTINUITY Tester (+) lead Red terminal 3 Tester (–) lead Black terminal 4 S Check the starter relay for continuity. Replace the starter relay. CONTINUITY EB802017 6.
ELECTRIC STARTING SYSTEM ELEC : EB802018 7.Engine stop switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Red/White 1 – Red/White 2 NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB802019 8. Neutral switch S Disconnect the neutral switch/lead from the neutral switch. S Check for continuity as follows: Neutral switch terminal 1 – Ground NO CONTINUITY Replace the neutral switch.
ELECTRIC STARTING SYSTEM ELEC : EB80201A 9. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. S Check for continuity as follows: Black 1 – Black 2 NO CONTINUITY Replace the sidestand switch. CONTINUITY EB803025 10. Clutch switch S Disconnect the clutch switch coupler from the wire harness. S Check for continuity as follows: Black/Yellow 1 – Blue/Yellow 2 NO CONTINUITY Replace the clutch switch.
ELECTRIC STARTING SYSTEM ELEC : EB803027 11. Start switch S Disconnect the right handlebar switch coupler from the wire harness. S Check for continuity as follows: Blue/White 1 – Black 2 NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB803026 12. Diode (starting circuit cut-off relay) S Remove the relay unit from the wire harness. S Check for continuity as follows: Black/Yellow 1 – Light green 2 INCORRECT Replace the relay unit.
ELECTRIC STARTING SYSTEM ELEC : EB803028 13. Wiring connection POOR CONNECTION S Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system.
ELECTRIC STARTING SYSTEM ELEC EB803030 STARTER MOTOR Order 1 2 Job name/Part name Q’ty Starter motor removal Starter motor Starter motor lead Remarks Remove the parts in order. 1 1 Reverse the removal procedure for installation. 1 2 3 4 5 6 Starter motor disassembly Front bracket Washers Rear bracket Shims Brush holder/Brush Armature ass’y Disassembly the parts in order. 1 1 2 1 1/1 1 Reverse the disassembly procedure for assembly.
ELECTRIC STARTING SYSTEM ELEC CHECKING THE STARTER MOTOR 1. Measure: S Brush length a Out of specification Replace. Brush length wear limit: 4 mm 2. Measure: S Brush spring force Fatigue/out of specification Replace as a set. Brush spring force: 780 X 1,020 g 3. Inspect: S Commutator Dirty Clean it with #600 grit sandpaper. 4. Inspect: S Armature coil resistances (insulation/continuity) Defects Replace the starter motor.
ELECTRIC STARTING SYSTEM ELEC 5. Measure: Commutator diameter a Out of specification Replace the starter motor. Commutator wear limit: 27 mm 6. Measure: Mica undercut a Out of specification Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator. Mica undercut: 0.7 mm NOTE: The mica insulation of the commutator must be undercut to ensure proper operation of the commutator.
CHARGING SYSTEM ELEC EB804000 CHARGING SYSTEM 1 2 4 6 AC magneto Rectifier/regulator Battery Fuse (main) CIRCUIT DIAGRAM 8-25
CHARGING SYSTEM ELEC EB803020 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (the entire charging system) NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Side cover (left) S Use the following special tool(s) for troubleshooting. Engine tachometer: 90890-03113 Pocket tester: 90890-03112 EB802011 1. Fuses (main) NO CONTINUITY S Remove the fuses.
CHARGING SYSTEM ELEC : EB804011 3. Charging voltage S Connect the engine tachometer to the spark plug lead. S Connect the pocket tester (DC 20 V) to the battery. Tester (+) lead Battery (+) terminal Tester (–) lead Battery (–) terminal S Measure the battery terminal voltage. S Start the engine and accelerate to about 5,000 r/min. S Check the terminal voltage. Charging voltage = measured voltage-terminal voltage: 0.2 X 2.5 V up MEETS SPECIFICATION NOTE: Use a fully charged battery.
CHARGING SYSTEM ELEC : EB804015 5. Wiring connections POOR CONNECTION S Check the connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. Properly connect the charging system. CORRECT Replace the rectifier/regulator.
3 4 6 30 32 37 38 Main switch 43 Battery 44 Fuse (main) 45 High beam indicator light 49 Meter light 53 Pass switch Dimmer switch Headlight Tail/brake light Auxiliary light Fuse (head) Lights switch LIGHTING SYSTEM 8-29 ELEC EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM
LIGHTING SYSTEM ELEC EB803020 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAILLIGHT, AUXILIARY LIGHT AND/OR METER LIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main and head) 2. Battery 3. Main switch 4. Lights switch (for Europe) 5. Dimmer switch 6. Pass switch (for Europe and Australia) 7.
LIGHTING SYSTEM ELEC EB802017 3. Main switch Disconnect the main switch couplers from the wire harness. Check for continuity as follows: Red 1 – Brown/Blue 2 Blue/Red 1 – Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB805011 4. Lights switch Disconnect the right handlebar switch coupler from the wire harness. Turn the lights switch to “ON” or “PO”. Check for continuity as follows: Red/Yellow 1 – Blue 2 Turn the lights switch to “ON”.
LIGHTING SYSTEM ELEC 5. Dimmer switch Disconnect the left handlebar switch couplers from the wire harness. Turn the dimmer switch to “HI”. Check for continuity as follows: Blue/Black 1 – Yellow 2 NO CONTINUITY CONTINUITY The dimmer switch is faulty. Replace the left handlebar switch. EB805012 6. Pass switch Disconnect the left handlebar switch coupler from the wire harness. Turn the pass switch to “ON”.
LIGHTING SYSTEM ELEC EB805020 LIGHTING SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on: 1. Bulb and bulb socket. NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY Headlight: Tester (+) lead Black/Yellow lead 1 or Black/Blue lead 2 Tester (–) lead Black lead 3 High beam indicator light: Tester (+) lead Yellow lead 4 Tester (–) lead Black lead 5 2.
LIGHTING SYSTEM ELEC EB805021 2. If the meter light fails to come on: 1. Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage Connect the pocket tester (20 V) to the bulb socket coupler. 1 2 Tester (+) lead Blue terminal 1 Tester (–) lead Black terminal 2 Turn the main switch to “ON”. Turn the light switch to “ON” or “PO”. Check the voltage (12 V) of the “blue” lead on the bulb socket connector.
LIGHTING SYSTEM Turn the main switch to “ON”. Turn the lights switch to “ON” or “PO”. Check the voltage (12 V) of the “Blue” lead on the bulb socket connector. ELEC OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. MEETS SPECIFICATION This circuit is not faulty. EB805023 4. If the auxiliary light fails to come on: 1. Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity.
SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 8-36 ELEC
SIGNAL SYSTEM 3 4 6 16 18 20 25 26 28 29 31 34 35 36 39 40 41 42 44 50 51 52 55 Main switch Battery Fuse (main) Neutral switch Fuel sender Diode Fuel meter Fuel level warning light Neutral indicator light Oil level warning light Turn indicator light Oil level switch Flasher relay Horn Horn switch Turn switch Front turn signal light Rear turn signal light Tail/ brake light Rear brake switch Fuse (signal) Front brake switch Start switch 8-37 ELEC
SIGNAL SYSTEM ELEC B806010 TROUBLESHOOTING IF THE TURN SIGNAL LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON: IF THE HORN FAILS TO SOUND: Procedure Check: 1. Fuses (main and signal) 2. Battery 3. Main switch 4. Wiring connection (the entire signal system) NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side covers (left and right) 4) Front cowling assembly S Use the following special tool8s) for troubleshooting. Pocket tester: 90890-03112 EB802011 1.
SIGNAL SYSTEM ELEC EB802017 3. Main switch Disconnect the main switch coupler from the wire harness. Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB806011 POOR CONNECTION 4. Wiring connections Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM CHECK”.
SIGNAL SYSTEM ELEC EB806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound: 1. Horn switch Disconnect the left handlebar switch coupler from the wire harness. Disconnect the “Black/White” lead at the horn terminal. Check for continuity as follows: Pink 1 – Black 2 NO CONTINUITY Replace the left handlebar switch. CONTINUITY 2. Voltage Connect the pocket tester (DC 20 V) to the horn lead. Tester (+) lead Brown lead 1 Tester (–) lead Frame ground Turn the main switch to “ON”.
SIGNAL SYSTEM ELEC HORN SOUNDS The horn is not faulty. HORN DOES NOT SOUND 4. Voltage Connect the pocket tester (DC 20 V) to the horn at the “Pink” terminal. Tester (+) lead Brown lead 1 Tester (–) lead Pink Turn the main switch to “ON”. Check the voltage (12 V) of the “Pink” lead at the horn terminal. OUT OF SPECIFICATION MEETS SPECIFICATION Replace the horn. Adjust or replace the horn. EB806022 2. If the brake light fails to come on: 1.
SIGNAL SYSTEM ELEC 2. Brake switch Disconnect the front brake switch leads. Disconnect the rear brake switch coupler from the wire harness. Check for continuity as follows: Brown 1 – Green/Yellow 2 Black 3 – Black 4 A B NO CONTINUITY A Front brake switch B Rear brake switch CONTINUITY Replace the brake switch. 3. Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead Yellow terminal 1 Tester (–) lead Black terminal 2 Turn the main switch to “ON”.
SIGNAL SYSTEM ELEC EB806023 3. If the turn signal light and/or turn indicator light fails to blink: 1. Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2. Turn switch Disconnect the left handlebar switch couplers from the wire harness. Check for continuity as follows: Brown/White 1 – Chocolate 2 Brown/White 1 – Dark green 3 NO CONTINUITY Replace the left handlebar switch. CONTINUITY 3.
ELEC SIGNAL SYSTEM 4. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler. Tester (+) lead Brown/White terminal 1 Tester (–) lead Frame ground Turn the main switch to “ON”. Turn the turn switch to “L” or “R”. Check the voltage (12 V) on the “Brown/White” 1 lead at the flasher relay terminal. OUT OF SPECIFICATION The flasher relay is faulty, replace it. MEETS SPECIFICATION A 5. Voltage B Connect the pocket tester (DC 20 V) to the bulb socket connector.
SIGNAL SYSTEM ELEC EB806024 4. If the neutral indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2. Neutral switch Disconnect the neutral switch lead from the neutral switch. Check for continuity as follows: Neutral switch terminal 1 – Ground NO CONTINUITY Replace the neutral switch. CONTINUITY 3. Diode Remove the diode from the wire harness.
SIGNAL SYSTEM ELEC : 4. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket coupler. 1 Tester (+) lead Brown terminal 1 Tester (–) lead Frame ground OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V). MEETS SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. This circuit is not faulty. EB806025 5. If the oil level warning light fails to come on: 1.
SIGNAL SYSTEM ELEC 3. Oil level switch Drain the engine oil and remove the oil level switch from the oil pan. Connect the pocket tester (Ω 1) to the oil level switch. Tester (+) lead Black/Red terminal 1 Tester (–) lead Frame ground NO CONTINUITY Check the oil level switch for continuity. CONTINUITY Replace the oil level switch. 4. Diode (starting circuit cut-off relay) Remove the relay unit from the wire harness.
SIGNAL SYSTEM ELEC 5. Start switch Disconnect the right handlebar switch coupler from the wire harness. Check for continuity as follows: Blue/White 1 – Black 2 NO CONTINUITY Replace the right handlebar switch. CONTINUITY 6. Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. 1 Tester (+) lead Brown lead 1 Tester (–) lead Black/Red lead 2 2 OUT OF SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V).
SIGNAL SYSTEM ELEC 6. If the fuel level warning light fails to come on or the fuel meter fails to operate: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2. Fuel sender S Drain the fuel and remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel sender.
SIGNAL SYSTEM ELEC 3. Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. 1 Tester (+) lead Brown terminal 1 Tester (–) lead Green/Red terminal 2 2 OUT OF SPECIFICATION Drain the fuel. Turn the main switch to “ON”. Check the voltage (12 V). The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. MEETS SPECIFICATION This circuit is not faulty.
3 4 6 19 Main switch Battery Fuse (main) Thermo switch (warning light) 27 46 47 48 51 Engine temperature warning light Fan motor Thermo switch (fan) Fuse (fan) Fuse (signal) COOLING SYSTEM 8-51 ELEC EB807000 COOLING SYSTEM CIRCUIT DIAGRAM
COOLING SYSTEM ELEC EB807010 TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN: IF THE WATER TEMPERTATURE METER FAILS TO MOVE, WHEN THE ENGINE IS WARM: Procedure Check: 1. Fuses (main, signal and fan) 2. Battery 3. Main switch 4. Fan motor 5. Thermo switch 6. Engine temperature warning light 7. Voltage 8. Wiring connections (the entire cooling system) NOTE: S Remove the following part(s) before troubleshooting.
COOLING SYSTEM ELEC EB802017 3. Main switch Disconnect the main switch coupler from the wire harness. Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB807011 4. Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead Black terminal 1 Battery (–) led Black terminal 2 DOES NOT MOVE Check the operation of the fan motor. The fan motor is faulty, replace it.
COOLING SYSTEM ELEC : EB802017 5. Thermo switch (fan, engine temperature) Handle the thermo switch with special care. Never subjct it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. S Remove the thermo switch from the thermostatic valve housing. S Connect the pocket tester (Ω 1) to the thermo switch 1 . S Immerse the thermo switch in coolant 2 . S Check the thermo switch for continuity. While heating the coolant use a thermometer 3 to record the temperatures.
COOLING SYSTEM ELEC 6. Engine temperature warning light NO CONTINUITY Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 7. Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. 1 Tester (+) lead Brown lead 1 Tester (–) lead Green/White lead 2 2 OUT OF SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V).
3 4 6 10 11 21 54 56 Main switch Battery Fuse (main) Fuel pump relay Ignitor unit Fuel pump Engine stop switch Fuse (ignition) FUEL PUMP SYSTEM 8-56 ELEC EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM
FUEL PUMP SYSTEM EB808010 1 2 3 4 5 6 7 8 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay, fuel pump, engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fuel pump.
COOLING SYSTEM ELEC EB808020 TROUBLESHOOTING IF THE FUEL PUMP FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 2. Battery 3. Main switch 4. Engine stop switch 5. Fuel pump relay (starting circuit cut-off relay) 6. Fuel pump resistance 7. Wiring connections (the entire fuel system) NOTE: S Remove the following part(s) before troubleshooting: 1) Seat 2) Fuel tank 3) Side cover (left) S Use the following special tool(s) for troubleshooting. Pocket tester: 90890-03112 EB802011 1.
FUEL PUMP SYSTEM ELEC EB802017 3. Main switch Disconnect the main switch coupler from the wire harness. Check for continuity as follows: Red 1 – Brown/Blue 2 NO CONTINUITY Replace the main switch. CONTINUITY EB802018 4. Engine stop switch Disconnect the right handlebar switch coupler from the wire harness. Check for continuity as follows: Red/White 1 – Red/White 2 NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB803023 5.
FUEL PUMP SYSTEM Battery (+) terminal Red/Black terminal 1 Battery (–) terminal Blue/Red terminal 3 ELEC NO CONTINUITY Tester (+) lead Red/Black terminal 1 Tester (–) lead Blue/Black terminal 3 S Check the fuel pump relay for continuity. Replace the starting circuit cut-off relay. CONTINUITY EB808021 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler terminals.
FUEL PUMP SYSTEM ELEC EB808030 FUEL PUMP TEST Gasoline is extremely flammable and under certain circumstances there can be danger of an explosion or combustion. Be extremely careful and note the following points: Stop the engine before refuelling. Do not smoke and keep away from open flames, sparks, or any other source of fire. Take care not to spill gasoline. If you do accidentally spill some, wipe it up immediately with dry rags.
SELF-DIAGNOSIS ELEC SELF-DIAGNOSIS The YZF600R features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the tachometer (irrespective of whether the engine is running or not). Condition Item Display condition code Response Throttle position sensor (TPS) Disconnected Short-circuit Locked Enables the motorcycle to run so that the ignition timing is fixed when the throttle is fully opened.
SELF-DIAGNOSIS ELEC TROUBLESHOOTING The tachometer starts to display the self-diagnosis sequence. NOTE: Use the following special tool in this troubleshooting. Pocket tester: 90890-03112 1. Throttle position sensor (TPS) CIRCUIT DIAGRAM 11 Ignitor unit 15 Throttle position sensor (TPS) 1. Wire harness NO CONTINUITY Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Repair or replace the wire harness. CONTINUITY 2. TPS BAD CONDITION Check the TPS for continuity.
SELF-DIAGNOSIS ELEC 2. Speed sensor CIRCUIT DIAGRAM 11 Ignitor unit 17 Speed sensor 1. Wire harness NO CONTINUITY Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Repair or replace the wire harness. CONTINUITY Replace the speed sensor.
TRBL SHTG 9
TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRBL SHTG
STARTING FAILURE/HARD STARTING TRBL SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING/POOR ENGINE IDLE SPEED PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Faulty cylinder head gasket Worn, damaged or seized cylinder Improperly sealed valve Improper valve-to-valve seat contact Improper valve timing Faulty valve spring TRBL SHTG Piston and piston ring Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring
FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE TRBL SHTG EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”.
OVERHEATING/OVERCOOLING/ POOR BRAKING/FAULTY FRONT FORK LEGS TRBL SHTG EB905000 OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor main jet setting Improper fuel level Clogged air filter element Cooling system Faulty cooling fan Faulty thermo stat Faulty thermo switch Improper coolant level (low) Faulty radiator Faulty radiator cap Faulty water pump Compression system Heavy carbon
UNSTABLE HANDLING/ FAULTY LIGHTING AND SIGNAL SYSTEMS TRBL SHTG EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Improperly installed or bent Steering Improperly installed handlebar crown Bent steering stem Improperly installed steering shaft (improperly tightened ring nut) Damaged ball bearing or bearing race Swingarm Worn bearing or busing Bent or damaged Rear shock absorber Faulty spring Oil and gas leakage Tire Uneven tire pressures on both sides Incorrect tire pressure
TRBL SHTG
FZS600 ’98 WIRING DIAGRAM COLOR CODE B . . . . . Black Br . . . . Brown Ch . . . Chocolate Dg . . . Dark green G . . . . Green Gy . . . Gray L . . . . . Blue P ..... Lg . . . . O .... R..... Sb . . . . W .... Y ..... Pink Light green Orange Red Sky blue White Yellow B/L . . . B/R . . . B/W . . B/Y . . . Br/L . . Br/W . G/R . . Black/Blue Black/Red Black/ Black/Yellow Brown/Blue Brown/White Green/Red G/W . . G/Y . . L/B . . . L/R . . . L/W . . L/Y . . . R/B . . .
