EB000000 TDM850 ’96 SERVICE MANUAL 1996 by Yamaha Motor Co., Ltd. First edition, March 1996 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
EB003000 1 GEN INFO 3 2 ILLUSTRATED SYMBOLS SPEC Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter. 4 INSP ADJ ENG 5 6 COOL CARB 7 1 2 3 4 5 6 7 8 9 General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting 8 CHAS ELEC 10 Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9
GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . .
GEN INFO
MOTORCYCLE IDENTIFICATION GEN INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. NOTE: The vehicle identification number is used to identify the motorcycle and may be used to register the motorcycle with a licensing authority. EB100030 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase.
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL 1. Remove all dirt, mud dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the motorcycle keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4.
IMPORTANT INFORMATION GEN INFO LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) and oil seal(s) with their manufacturer’s marks or numbers facing outward. (In other word, the stamped letters must be on the side exposed to view.
CHECKING OF CONNECTIONS GEN INFO CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
HOW TO USE THE CONVERSION TABLE CONVERSION TABLE HOW TO USE THE CONVERSION TABLE METRIC TO IMPERIAL All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC **mm 2 mm MULTIPLIER 0.03937 = 0.03937 = GEN INFO Metric unit Multiplier Imperial unit IMPERIAL **in 0.08 in 1-5 Torque mSkg mSkg cmSkg cmSkg 7.233 86.794 0.0723 0.8679 ftSlb inSlb ftSlb inSlb Weight kg g g 2.205 0.
SPECIAL TOOLS GEN INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. Tool No.
SPECIAL TOOLS Tool No. Tool name/How to use 90890-01701 Sheave holder 90890-03081 This tool is used to hold the rotor when loosening and tightening the rotor bolt. Compression gauge 90890-03094 This gauge is used to measure the engine compression. Vacuum gauge 90890-03112 This gauge is needed for carburetor synchronization. Pocket tester 90890-03113 This instrument is invaluable for checking the electrical system. Engine tachometer 90890-03141 This tool is needed for detecting engine rpm.
SPECIAL TOOLS Tool No. 90890-85505 Tool name/How to use Yamaha bond No. 1215 This sealant (bond) is used on crankcase mating surfaces, etc.
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . .
SPEC
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model: TDM850 Model code: 4TX1 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,165 mm, 2,200 mm (D, DK, SF, N, S) 790 mm 1,285 mm 805 mm 1,475 mm 165 mm 2,900 mm Basic weight (With oil and full fuel tank): 229 kg Engine: Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Compression pressure (STD) Starting system
GENERAL SPECIFICATIONS Item Standard Air filter: Dry type element Fuel: Type Fuel tank capacity Fuel reserve amount Regular unleaded gasoline 20 L 3.1 L Carburetor: Type/quantity Manufacturer BDST38/2 MIKUNI Spark plug: Type Manufacturer Spark plug gap DPR8EA-9/X24EPR-U9 NGK/NIPPONDENSO 0.8 X 0.
GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load-except motorcycle Loading condition A* front rear Loading condition B* front rear High speed riding front rear Brake: Front brake Rear brake type operation type operation 180 kg 0 90 kg 225 kPa (2.25 kg/cm2, 2.25 bar) 275 kPa (2.75 kg/cm2, 2.75 bar) 90 180 kg 225 kPa (2.25 kg/cm2, 2.25 bar) 275 kPa (2.75 kg/cm2, 2.75 bar) 225 kPa (2.25 kg/cm2, 2.25 bar) 275 kPa (2.75 kg/cm2, 2.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit Cylinder: Bore size Taper limit Out of round limit Intake Exhaust 0.03 mm 89.500 89.505 mm 89.6 mm 0.05 mm 0.03 mm Camshaft: Drive method Camshaft cap inside diameter Camshaft outside diameter Camshaft-to-cap clearance Cam dimensions “A” “B” “C” “A” “B” “C” Limit Timing chain (right) 25.000 25.021 mm 24.967 24.980 mm 0.020 0.054 mm 35.95 36.05 mm 27.95 28.
MAINTENANCE SPECIFICATIONS Item “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance Standard Valve spring: Free length Set length (valve closed) Compressed pressure (installed) it Tilt lilimit Direction of winding (top view) Limit IN EX IN EX IN EX IN EX IN EX IN EX 2.06 2.46 mm 2.06 2.46 mm 0.9 1.1 mm 0.9 1.1 mm 0.8 1.2 mm 0.8 1.2 mm 5.475 5.490 mm 5 460 5 475 mm 5.460 5.475 5.500 5.512 mm 5.500 5.512 mm 0.010 0.
MAINTENANCE SPECIFICATIONS Item Piston: Piston to cylinder clearance Piston size “D” SPEC Standard Limit 0.065 0.085 mm 89.420 89.435 mm 0.15 mm 4.5 mm 1 mm IN side 20.002 20.013 mm 19.991 20.000 mm 20.043 mm 19.975 mm Type Dimensions (B T) End gap (installed) Side clearance (installed) 2nd ring: Barrel 1.0 3.5 mm 0.30 0.45 mm 0.035 0.070 mm 0.7 mm 0.12 mm Type Dimensions (B T) End gap (installed) Side clearance (installed) Oil ring: Taper 1.0 3.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Crankshaft: 153.6 154.4 mm 64.75 65.25 mm 0.160 0.272 mm 0.8 1.0 mm 0.020 0.038 mm 0.035 mm 0.5 mm 0.1 mm Balancer: Balancer drive method Gear Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Clutch release method 2.9 3.1 mm 9 1.9 2.1 mm 8 55 mm 6 Outer pull, rack & pinion pull 2.8 mm 0.
MAINTENANCE SPECIFICATIONS Item Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level Engine idle speed Intake vacuum Standard (V.S) (G.S.1) (G.S.2) (Th. V) (F.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened g Camshaft cap Cylinder head Cylinder head cover Coolant drain bolt (cylinder body) Spark plug Connecting rod Rotor Camshaft sprocket Timing chain tensioner Radiator Delivery hose (crankcase-cylinder) Oil pump assembly Oil baffle plate Drain bolt (oil pan) Oil strainer Stay (relief valve) Oil filter cover Ring nut (exhaust pipe) Exhaust pipe (CO test) Exhaust pipe and frame Exhaust pipe and muffler Muffler Crankcase Balancer shaft B
SPEC MAINTENANCE SPECIFICATIONS Part to be tightened g Stator coil Starter motor Thermo switch Thermo switch housing Part name Screw Flange bolt — — Crankcase tightening sequence: 2-10 Thread size Q’ty y M6 M6 M6 PT1/8 3 2 1 1 Tightening torque Nm mSkg 7 10 28 15 0.7 1.0 2.8 1.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel Fork spring free length Spring rate Stroke Optional spring Oil capacity (per fork tube) Oil level Oil grade 149 mm 505 mm 6.4 N/mm (0.64 kg/mm) 0 149 mm No 0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Front disc brake: Type Disc outside diameter thickness Disc deflection limit Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Dual 298 4 mm 5.5 mm 5.5 mm 15.8 mm 33.96 + 30.23 mm DOT 4 0.2 mm 0.5 mm 0.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Thread size Part to be tightened g Upper bracket and inner tube Upper bracket and steering stem Steering stem and ring nut Inner tube and under bracket Horn bracket and brake hose holder Brake hose holder and under bracket Front brake hose union bolt Cowling stay and frame Meter and cowling stay Handlebar and grip end Front master cylinder Upper bracket and handlebar holder (upper) Upper bracket and cable holder Upper bracket and cable guide Engine moun
MAINTENANCE SPECIFICATIONS Thread size Part to be tightened g Caliper bracket and swingarm Brake disc and wheel hub (front and rear) Driven sprocket and rear hub Bleed screw and brake caliper Rear brake hose union bolt Front wheel axle pinch bolt Brake hose joint and brake hose Chain puller and locknut Front fender and front fork Brake hose joint and front fork Rear brake caliper and brake hose joint M10 M8 M10 M8 M10 M8 M10 M8 M6 M6 M10 SPEC Tightening torque Nm mSkg 35 20 60 6 30 19 14 16 9 10 40 3
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advancer type 10 at 1,150 r/min Electrical type 192 288 Ω at 20 C/Blue/Yellow – Green/White TNDF33/NIPPONDENSO Ignition coil: Model/manufacturer Minimum sspark ark gap ga Primary winding resistance Secondary winding resistance J0300/NIPPONDENSO 6 mm 3.4 4.6 Ω at 20 C 10.4 15.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Horn: Type Quantity Model/manufacturer Maximum amperage Plane type 1 YF-12/NIKKO 2.5 A Flasher relay: Type Model/manufacturer Self cancelling device Flasher frequency Wattage Semi transistor type FE246BH/NIPPONDENSO No 75 X 95 cycle/min 21 W 2 + 3.
GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication point Lubricant type Oil seal lips O-ring Bearing Crankshaft (big end) Piston surface Piston pin Cylinder Piston ring, oil ring Connecting rod bolt Crankshaft journal Balancer (bearing/shaft) Camshaft, camshaft cap Valve stem (IN/EX) Valve stem end Water pump impeller shaft Oil pump assembly (inner) Oil strainer assembly Push rod Idle gear surface Starter clutch ball Primary driven gear Transmissio
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC CHASSIS Lubrication point Lubricant type Steering bearing and bearing race (upper / lower) Front wheel oil seal (right / left) Rear wheel oil seal Clutch hub oil seal Clutch hub fitting area Rear brake pedal shaft Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever bolt, sliding surface Clutch lever bolt, sliding surface Rear shock absorber (lower) Swingarm pivot bearing Pivot shaft Thrust cover (inner) 2-19
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 2 3 4 5 6 Oil pump (for pumping oil to the oil tank) Oil pump (for lubricating the engine parts) Oil strainer Oil filter Drain bolt Oil tank 2-20 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 5 6 Front balancer Oil strainer Oil pump Relief valve Oil pump (for pumping oil to the oil tank) Oil pump (for lubricating the engine parts) 2-21 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 5 6 Camshaft Rear balancer Main axle Drive axle Drain bolt Front balancer 2-22 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Cylinder head Rear balancer Crankshaft Drain bolt 2-23 SPEC
LUBRICATION DIAGRAMS 1 Main axle 2 Drive axle 2-24 SPEC
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Throttle cable Right handlebar switch lead Brake hose Main switch lead Clutch cable Left handlebar switch lead Horn lead Starter cable Coolant reservoir hose Headlight lead 11 12 13 14 15 Meter light lead Thermo switch lead Fan motor lead Ignition coil (left) lead Ignition coil (right) lead A Fasten the right handlebar switch lead with a plastic band. B Fasten the left handlebar switch lead with a plastic band.
CABLE ROUTING D E F G Fasten the horn lead with a plastic band. 60 mm Fasten the brake hose with plastic bands. Fasten the coolant reservoir hose with a plastic clamp. H Fasten the right handlebar switch lead, meter light lead and headlight lead with a plastic clamp I Fasten the wire harness with a plastic clamp.. SPEC J Fasten the wire harness, right handlebar switch lead, meter light lead and headlight lead with a plastic band. K To the throttle position sensor.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Front flasher light (left) lead Main switch lead Starter cable Left handlebar switch lead Spark plug lead Carburetor breather hose Fuel hose Vacuum hose (#2) Coolant reservoir hose Sidestand switch lead 11 12 13 14 15 16 17 18 19 Neutral switch lead A.C.
CABLE ROUTING A Fasten the left handlebar switch lead and main switch lead with a plastic clamp. B To the air filter case. C Fasten the coolant reservoir hose, A.C. magneto lead, neutral switch lead and sidestand switch lead with a plastic clamp. D Fasten the rear flasher light (left) lead with a plastic clamp. SPEC E Fasten the sidestand switch lead, neutral switch lead and A.C. magneto lead with a plastic clamp. F Fasten the sidestand switch lead and air filter case breather hose with a metal band.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Starter motor lead Fuel tank breather hose Spark plug lead Right handlebar switch lead Clutch cable Brake hose Throttle cable Headlight lead Meter light lead Carburetor heater hose Vacuum hose (#1) 12 13 14 15 16 SPEC Coolant reservoir breather hose Carburetor breather hose Rear brake switch lead Battery positive lead Battery negative lead A Pass the battery positive lead and battery negative lead through the guide.
CABLE ROUTING D Pass the carburetor breather hoses and vacuum hose (#1) through the guide. E Pass the vacuum hose (#1) through the guide. F Fasten the coolant reservoir hose with a plastic clamp. G Fasten the wire harness, right handlebar switch lead, meter light lead and headlight lead with a plastic clamp. H Fasten the right handlebar switch lead with a plastic clamp. I Fasten the throttle cables with a plastic clamp. SPEC J Pass the coolant reservoir hose over the throttle cables.
CABLE ROUTING O Pass the fuel tank breather hose through the hole of the frame bracket. P Pass the coolant reservoir breather hose and fuel tank breather hose through the guide. Q Pass the rear brake switch lead through the guide. R Fasten the wire harness and rear flasher light (right) lead with a plastic clamp. SPEC S Fasten the wire harness with plastic clamps. T To the engine. U Fasten the coolant reservoir breather hose with a plastic clamp. V To the starter relay.
CARBLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Headlight lead Wire harness Meter light lead Throttle stop screw cable Vacuum hose (#1) Carburetor air vent hose Carburetor breather hose Starter motor lead Battery positive lead Battery negative lead Coolant reservoir breather hose 12 13 14 15 16 17 18 Coolant reservoir hose Vacuum hose (#2) Fuel hose Carburetor breather hose Cylinder head breather hose Air filter case breather hose Throttle cable A Fasten the meter light lead, headlight lead and wire harness with
CABLE ROUTING D Fasten the taillight lead with a plastic band to the taillight bracket. E 50 mm F Fasten the carburetor breather hoses with a plastic clamp. G Fasten the wire harness with a plastic clamp. H To the front flasher light (left). I To the headlight. J To the meter light. K Fasten the headlight lead with a plastic clamp. L To the auxiliary light. SPEC M Fasten the meter light lead and headlight lead with plastic clamps.
SPEC
INSP ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . . . . 3-1 COWLINGS, SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . 3-3 COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . .
INSP ADJ TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . LEVER AND PEDAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDESTAND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION LUBRICATION . . . . . . .
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ NOTE: Brake fluid replacement: 1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3. Replace the brake hoses every four years, or if cracked or damaged.
COWLINGS, SEAT, TAIL COVER AND FUEL TANK INSP ADJ COWLINGS, SEAT, TAIL COVER AND FUEL TANK COWLINGS Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Q’ty Cowlings removal Side cowling (left and right) Meter panel Damper Wind shield Inner panel Front flasher light lead Front flasher light (left and right) Auxiliary light lead coupler Headlight lead coupler Front cowling Headlight unit Remarks Remove the parts in the order below.
COWLINGS, SEAT, TAIL COVER AND FUEL TANK INSP ADJ SEAT, TAIL COVER AND FUEL TANK 16 Nm (1.6 m kg) Order Job name/Part name 1 2 3 4 5 6 Seat, tail cover and fuel tank removal Side cowling Seat Taillight lead coupler Tail cover Side cover Fuel hose (RES) Fuel hose (ON) 1 1 1 2 1 1 7 8 Fuel tank breather hose Fuel tank 1 1 Q’ty Remarks Remove the parts in the order below. Refer to “COWLINGS”. Disconnect NOTE: Set the fuel cock (fuel tank side) to “OFF” before disconnecting the fuel hoses.
AIR FILTER CASE INSP ADJ AIR FILTER CASE AIR FILTER CASE Order Job name/Part name 1 2 3 4 Air filter case removal Side cowling, seat, side cover and fuel tank Cylinder head breather hose Air filter case breather hose Carburetor clamp Air filter case Q’ty Remarks Remove the parts in the order below. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 1 1 2 1 Loosen For installation, reverse the removal procedure.
VALVE CLEARANCE ADJUSTMENT INSP ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: The valve clearance should be adjusted when the engine is cool to touch. The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance. 1. Remove: Side cowling Seat Side cover Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. Air filter case Refer to “AIR FILTER CASE”. 2. Drain: Coolant Refer to “COOLANT REPLACEMENT”. 3.
VALVE CLEARANCE ADJUSTMENT INSP ADJ 5. Disconnect: Thermo unit lead 1 Thermo switch lead 2 Ground lead 3 Thermostatic valve housing 4 6. Remove: Spark plug caps Spark plugs Cylinder head cover 7. Remove: Timing plug 1 Straight plug 2 O-ring 8. Check: Valve clearance Out of specification Adjust. Valve clearance (cold): Intake valve: 0.15 0.20 mm Exhaust valve: 0.25 0.30 mm Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the T.D.C.
VALVE CLEARANCE ADJUSTMENT INSP ADJ S Measure the valve clearance using a feeler gauge 2 . NOTE: S Record the measured reading if the clearance is incorrect. S Rotate the crankshaft 270_ counterclockwise and check the clearance of piston #2. NOTE: Make sure that the camshaft lobes are opposite each other when the piston is at TDC on the compression stroke. 9. Adjust: S Valve clearance Adjustment steps: S Loosen the timing chain tensioner cap bolt.
INSP ADJ VALVE CLEARANCE ADJUSTMENT Remove the valve lifters 1 and the pads 2 . NOTE: Place a rag in the timing chain space to prevent pads from falling into the crankcase. Identify each valve lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. Select the proper pad using the pad selecting table: Pad range Pad Availability: 25 increments No. 120 1.20 mm Pads are available in 0.05 mm increments No. 240 2.
VALVE CLEARANCE ADJUSTMENT INSP ADJ Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjustment. Install the new pads 1 and the valve lifters 2 . NOTE: Lubricate the valve lifters and pads with molybdenum disulfide oil. Valve lifter must turn smoothly when rotated with a finger.
VALVE CLEARANCE ADJUSTMENT INSP ADJ INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 0.00 0.04 0.05 0.09 0.10 0.14 0.15 0.20 0.21 0.25 0.26 0.30 0.31 0.35 0.36 0.40 0.41 0.45 0.46 0.50 0.51 0.55 0.56 0.60 0.61 0.65 0.66 0.70 0.71 0.75 0.76 0.80 0.81 0.85 0.86 0.90 0.91 0.95 0.96 1.00 1.01 1.05 1.06 1.10 1.11 1.15 1.16 1.20 1.21 1.25 1.26 1.30 1.31 1.35 1.36 1.
VALVE CLEARANCE ADJUSTMENT INSP ADJ Recheck the valve clearance. If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained. 10. Install: All removed parts NOTE: Install all removed parts in reversed order of their removal. Note the following points. 11. Install: Chain guide (exhaust side) Chain guide (upper) Timing chain tensioner Refer to “CAMSHAFT” in CHAPTER 4. 12.
CARBURETOR SYNCHRONIZATION INSP ADJ CARBURETOR SYNCHRONIZATION NOTE: Valve clearance and idling speed should be adjusted properly before synchronizing the carburetors. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand under the motorcycle. 2. Remove: Side cowling Seat Side cover Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 3.
CARBURETOR SYNCHRONIZATION INSP ADJ 7. Adjust: Carburetor synchronization Adjustment steps: Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw 1 until both gauges read the same. Race the engine for less than a second, two or three times and check the synchronization again. Intake vacuum at idle speed: 36.0 38.7 kPa (270 290 mm Hg) NOTE: The difference between both carburetors should be 0.67 kPa (5 mm Hg) or less. 8.
IDLING SPEED ADJUSTMENT INSP ADJ IDLING SPEED ADJUSTMENT NOTE: The carburetor synchronization should be adjusted properly before adjusting the idling speed. 1. Start the engine and let it warm up for several minutes. 2. Attach: Engine tachometer 1 (to the #1 spark plug lead). Engine tachometer: 90890-03113 3. Check: Engine idling speed Out of specification Adjust. Engine idling speed: 1,050 1,250 r/min 4.
IDLING SPEED ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ Turn the throttle stop screw 2 in or out until specified idling speed is obtained. Turnning in: Idling speed is increased. Turnning out: Idling speed is decreased. 6. Adjust: Throttle cable free play Refer to “THROTTLE CABLE FREE PLAY ADJUSTMENT”.
THROTTLE CABLE ADJUSTMENT INSP ADJ 3. Adjust: Throttle cable free play Adjustment steps: First step: Loosen the locknut 1 Turn the adjuster 2 in or out until the specified free play is obtained. Turnning in: Free play is increased. Turnning out: Free play is decreased. Tighten the locknuts. NOTE: If the free play can not be adjusted here, adjust it at the throttle grip side of the cable. Final step: Loosen the locknut 3 .
SPARK PLUG INSPECTION INSP ADJ SPARK PLUG INSPECTION 1. Remove: Spark plug caps Spark plugs CAUTION: Before completely removing the spark plug, use compressed air to clean the cylinder head cover areas to prevent dirt from falling into the engine. 2. Inspect: Spark plug type Incorrect Replace. Standard spark plug: DPR8EA-9 (NGK) X24EPR-U9 (NIPPONDENSO) 3. Inspect: Electrode 1 Wear/Damage Replace. Insulator 2 Abnormal color Replace. Normal color is a medium-to-light tan color. 4.
IGNITION TIMING CHECK INSP ADJ IGNITION TIMING CHECK NOTE: Carburetor synchronization, engine idle speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: Timing plug 1 2. Attach: Timing light Engine tachometer (to the #1 spark plug lead) Timing light: 90890-03141 Engine tachometer: 90890-03113 3. Check: Ignition timing Checking steps: Start the engine and let it warm up. Let the engine run at the specified speed.
COMPRESSION PRESSURE MEASUREMENT INSP ADJ COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1. Check: Valve clearance Out of specification Adjust. Refer to “VALVE CLEARANCE ADJUSTMENT”. 2. Start the engine and let it warm up for several minutes. 3. Stop the engine. 4.
COMPRESSION PRESSURE MEASUREMENT INSP ADJ Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher than without oil Worn or damaged pistons /piston rings Repair Same as without oil Defective ring(s), valves, cylinder head gasket or piston is possible Repair Compression pressure (at sea level): Standard: 1,200 kPa (12.0 kg/cm2, 12.0 bar) Minimum: 1,000 kPa (10.0 kg/cm2, 10.0 bar) Cylinder difference: 100 kPa (1.0 kg/cm2, 1.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspecting the oil level. 1. Place the motorcycle on a level surface. NOTE: After idling the engine for 15 minutes, be sure the motorcycle is vertical, then check that the oil level is between the maximum and minimum marks. Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand under the motorcycle. 2.
ENGINE OIL REPLACEMENT INSP ADJ ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: Oil filler plug 1 4. Remove: Drain bolt (with gasket) 1 Oil filter drain bolt (with gasket) 2 Drain the crankcase and oil tank of its oil. 5. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.
ENGINE OIL REPLACEMENT INSP ADJ 7. Fill: Crankcase CAUTION: The engine should be filled with oil in two steps. First fill the engine with 3.2 liters of oil. Then start the engine and race it five or six times. Stop the engine and fill it with oil to the specified level. Oil quantity: Total amount: 4.2 L Periodic oil change: 3.5 L With oil filter replacement: 3.6 L 8. Install: Oil filler plug 9. Inspect: Engine (for oil leaks) Oil level Refer to “ENGINE OIL LEVEL INSPECTION”. 10.
CLUTCH ADJUSTMENT/ AIR FILTER CLEANING INSP ADJ CLUTCH ADJUSTMENT 1. Check: Clutch cable free play a Out of specification Adjust. Free play: 10 15 mm At clutch lever end A 2. Adjust: Clutch cable free play B Adjustment steps: Loosen the locknut(s) 1 . Turn the adjuster(s) 2 in or out until the specified free play is obtained. Turnning in: Free play is increased. Turnning out: Free play is decreased. Tighten the locknut(s). A Handlebar side B Engine side AIR FILTER CLEANING 1.
AIR FILTER CLEANING/ CARBURETOR JOINT INSPECTION INSP ADJ 3. Inspect: Air filter element Damage Replace. 4. Clean: Air filter element Blow off dust from the outer surface of the element with compressed air. 5. Install: Air filter element Air filter case cover NOTE: Make sure the element is properly seated in the filter case. 6. Install: All removed parts NOTE: Install all removed parts in reversed order of their removal. CARBURETOR JOINT INSPECTION 1.
FUEL LINE INSPECTION/ BREATHER HOSE INSPECTION INSP ADJ FUEL LINE INSPECTION 1. Remove: Side cowling Seat Side cover Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Inspect: Vacuum hoses 1 Fuel hoses 2 Cracks /Damage Replace. Loose connection Connect properly. NOTE: Drain and flush the fuel tank if abrasive damage to any components is evident. 3. Install: All removed parts NOTE: Install all removed parts in reversed order of their removal. BREATHER HOSE INSPECTION 1.
EXHAUST SYSTEM INSPECTION/ COOLANT LEVEL INSPECTION INSP ADJ EXHAUST SYSTEM INSPECTION 1. Inspect: Exhaust pipes Mufflers Cracks /Damage Replace. Gaskets Exhaust gas leaks Replace. 2. Check: 20 Nm (2.0 m kg) Exhaust pipe nut 1 Exhaust pipe bolt 2 24 Nm (2.4 m kg) Muffler bolt 3 24 Nm (2.4 m kg) Bolt (exhaust pipe and muffler) 4 20 Nm (2.0 m kg) COOLANT LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspecting the coolant level. 1.
COOLANT LEVEL INSPECTION/ COOLANT REPLACEMENT INSP ADJ CAUTION: Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can’t get soft water. COOLANT REPLACEMENT 1. Remove: Side cowling (right) Seat Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
COOLANT REPLACEMENT INSP ADJ 5. Install: Gaskets New Drain bolt 1 10 Nm (1.0 m kg) Cylinder drain bolt 10 Nm (1.0 m kg) 6. Connect: Coolant reservoir hose 7. Fill: Cooling system (radiator and engine) (to specified level a ) Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminum engines Coolant and water mix ratio: 50% – 50% Radiator capacity (including all routes): 1.7 L Reservoir tank capacity: 0.3 L From lower to upper level: 0.
COOLANT REPLACEMENT INSP ADJ CAUTION: Hard water or salt water is harmful to the engine parts. Use boiled or distilled water if you can’t get soft water. Do not use water containing impurities or oil. Take care that no coolant splashes onto painted surfaces. If it does, wash it away with water immediately. Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminium engines. 8. Install: Radiator cap 9.
COOLANT REPLACEMENT/ COOLING SYSTEM INSPECTION INSP ADJ COOLING SYSTEM INSPECTION 1. Inspect: Radiator 1 Hose 2 2 Hose 3 3 Cracks /Damage Replace. Refer to “RADIATOR” in CHAPTER 5.
FRONT BRAKE ADJUSTMENT INSP ADJ CHASSIS FRONT BRAKE ADJUSTMENT 1. Adjust: Brake lever position (distance a from handle grip to front brake lever) Adjustment steps: Turn the adjuster 1 while pushing the front brake lever forward until the desired lever position is obtained. Direction b Direction c Distance a is the largest Distance a is the smallest WARNING After adjusting the front brake lever position (distance), make sure align the mark on the adjuster with the mark on the brake lever.
REAR BRAKE ADJUSTMENT INSP ADJ REAR BRAKE ADJUSTMENT 1. Check: Brake pedal height a Out of specification Adjust. Brake pedal height: 29 mm Below top of footrest. 2. Adjust: Brake pedal height Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out until the specified pedal height is obtained. Turnning in: Height is decreased. Turnning out: Height is increased. WARNING After adjusting brake pedal height, visually check the adjuster end through the hole a .
BRAKE FLUID LEVEL INSPECTION INSP ADJ BRAKE FLUID LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspecting the fluid level. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand under the motorcycle. 2. Inspect: Fluid level Fluid level is under “LOWER” level line a Fill to proper level.
BRAKE PAD INSPECTION/ BRAKE LIGHT SWITCH ADJUSTMENT INSP ADJ A BRAKE PAD INSPECTION 1. Activate the brake lever or brake pedal. 2. Inspect: Brake pad Wear indicator 1 almost contacting the brake disc Replace brake pad as a set. Refer to “FRONT AND REAR BRAKE” in CHAPTER 7. B A Front B Rear BRAKE LIGHT SWITCH ADJUSTMENT NOTE: The brake light switch is operated by movement of the brake pedal. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect. 1.
BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ BRAKE HOSE INSPECTION 1. Inspect: Brake hoses 1 Brake pipe 2 Cracks /Wear/Damage Replace. WARNING The brake pipe must not be disassembled. Do not loosen the bolts 3 . 2. Check: Brake hose clamp Loosen Tighten. 3. Hold the motorcycle on upright position. 4. Check: Brake hoses Activate the brake lever or pedal several times. Fluid leakage Replace the hose. Refer to “FRONT AND REAR BRAKE” in CHAPTER 7.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ SHIFT PEDAL ADJUSTMENT INSP ADJ d. Place the other end of the hose into a container. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h. Tighten the bleed screw when the lever or pedal limit has been reached, then release the lever or pedal. i.
SHIFT PEDAL ADJUSTMENT/ DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 2. Adjust: Change pedal position Adjustment steps: Remove the drive sprocket cover 1 . Loosen both locknuts 2 . Turn the shift pedal link 3 in or out to obtain the correct pedal position. Turnning in: Shift pedal is raised. Turnning out: Shift pedal is lowered. Tighten both locknuts. Install the drive sprocket cover.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 2. Check: Drive chain slack a Out of specification Adjust. Drive chain slack: 40 50 mm 3. Loosen: Caliper bracket bolt 1 Axle nut 2 4. Adjust: Drive chain slack Adjustment steps: Loosen both locknuts 3 . Turn the adjusters 4 in or out until the specified slack is obtained. Turnning in: Slack is decreases. Turnning out: Slack is increases. NOTE: Turn each adjuster exactly the same amount to maintain correct axle alignment.
DRIVE CHAIN LUBRICATION/ STEERING HEAD INSPECTION INSP ADJ DRIVE CHAIN LUBRICATION The chain consists of many parts that work with each other. If the chain is not maintained properly, it will wear out rapidly. Therefore, form the habit of periodically servicing the chain. This service is especially necessary when riding in dusty conditions. This motorcycle has a drive chain with small rubber O-rings between the chain plates.
STEERING HEAD INSPECTION INSP ADJ 4. Remove: Starter cable holder 1 Cable guide 2 Handlebar holder (upper) 3 (with plugs) Handlebar 4 5. Loosen: Upper bracket pinch bolts 1 6. Remove: Handle crown nut 2 Upper bracket 3 7. Adjust: Steering head Adjustment steps: Remove the special washer 1 , ring nut (upper) 2 and rubber washer 3 . Loosen the ring nut (lower) 4 . Tighten the ring nut (lower) using the ring nut wrench 5 .
STEERING HEAD INSPECTION/ FRONT FORK INSPECTION INSP ADJ Check the steering head by turning it lock to lock. If it binds, remove the steering stem assembly and inspect the steering bearings. Refer to “STEERING HEAD” in CHAPTER 7. Install the rubber washer 3 . Install the ring nut (upper) 2 . Finger tighten the ring nut (upper) 2 , then align the slots of both ring nuts. If necessary, hold the ring nut (lower) and tighten the ring nut (upper) until their slots are aligned.
FRONT FORK INSPECTION/ FRONT FORK ADJUSTMENT INSP ADJ 2. Check: Inner tube 1 Scratches /Bent/Damage Replace. Oil seal Excessive oil leakage Replace. 3. Hold the motorcycle in an upright position and apply the front brake. 4. Check: Operation Pump the front fork up and down for several times. Unsmooth operation Repair. Refer to “FRONT FORK” in CHAPTER 7. FRONT FORK ADJUSTMENT WARNING Always adjust each fork to the same setting.
FRONT FORK ADJUSTMENT/ REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ Damping force 1. Adjust: Damping force Turn the adjuster 1 in or out. Turnning in a : Damping force is increased. Turnning out b : Damping force is decreased. Adjuster position: Standard: 4 clicks out Minimum: 5 clicks out Maximum: 0 clicks out *: From the fully turned-in position. CAUTION: Always keep the adjustment level equal on both forks. Never turn the adjuster beyond the maximum or minimum setting.
REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ 2. Adjust: Spring preload Fine adjustment (bottom) Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out. Turnning in a : Spring preload is increased. Turnning out b : Spring preload is decreased. Measurement length c : Standard: 61 mm Minimum: 59 mm Maximum: 63 mm Tighten the locknut. Lock nut: 70 Nm (7.0 m kg) CAUTION: Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque.
TIRE INSPECTION INSP ADJ TIRE INSPECTION 1. Measure: Tire pressure Out of specification Adjust. WARNING Tire inflation pressure should only be checked and adjusted when the tire temperature equals the ambient air temperature. Tire inflation pressure and suspension must be adjusted according to the total weight of the cargo, rider, passenger and accessories (fairing, saddlebags, etc. if approved for this model), and according to whether the motorcycle will be operated at high speed or not.
TIRE INSPECTION A B INSP ADJ WARNING It is dangerous to ride with a worn-out tire. When a tire tread begins to show lines, replace the tire immediately. Do not use tubeless tires on a wheel designed for tube type tires only. Tire failure and personal injury may result from sudden deflation. A Tire B Wheel Tube type wheel Tube type tire only. Tubeless type wheel Tube type or tubeless tire. Be sure to install the correct tube when using tube type tires.
TIRE INSPECTION/WHEEL INSPECTION/ CABLE INSPECTION AND LUBRICATION INSP ADJ NOTE: For tires with a “DRIVE” mark 1 : Install the wheel with the “DRIVE” mark pointing in direction in which the wheel will rotate. WARNING After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle. WHEEL INSPECTION 1. Inspect: Wheels Damage/Bends Replace.
LEVER AND PEDAL LUBRICATION/SIDESTAND LUBRICATION/REAR SUSPENSION LUBRICATION INSP ADJ LEVER AND PEDAL LUBRICATION Lubricate levers and pedals at their pivoting points. Recommended lubricant: Engine oil SIDESTAND LUBRICATION Lubricate the sidestand at pivoting points. Recommended lubricant: Engine oil REAR SUSPENSION LUBRICATION Lubricate the rear suspension at pivoting points.
BATTERY INSP ADJ ELECTRICAL BATTERY 7 Nm (0.7 m kg) 23 Nm (2.3 m kg) 30 Nm (3.0 m kg) 7 Nm (0.7 m kg) 8 Nm (0.8 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. Battery removal Seat 1 2 3 4 5 6 Remarks 1 1 1 1 1 1 Brake hose guide Rear master cylinder Rear brake switch Battery negative lead terminal Battery positive lead terminal Battery assembly Refer to “Battery removal”.
REMOVAL INSP ADJ REMOVAL WARNING Immediately after removing the battery leads, securely cover the terminals with the covers 1 to prevent the battery leads from being shorted. 1. Remove: Seat Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Remove: Negative terminal cover 1 Positive terminal cover 2 WARNING First disconnect the negative lead 1 , then disconnect the positive lead 2 . 3.
INSPECTION INSP ADJ INSPECTION NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. CAUTION: This is a sealed type battery. Never remove the sealing caps. If the sealing caps have been removed, the balance will not be maintained and battery performance will deteriorate.
INSPECTION INSP ADJ 1. Check: S Battery condition Volt meter Battery condition checking steps: S Connect a digital voltmeter to the battery terminals. Open-circuit voltage Tester (+) lead battery (+) terminal Tester (–) lead battery (–) terminal (V) 13.0 NOTE: The charge state of an MF battery can be checked by measuring the open-circuit voltage (i.e. the voltage when the positive terminal is disconnected). Relationship between the open-circuit voltage and the charging time at 20_C 12.5 12.
INSPECTION INSP ADJ Before removing the clips from the battery terminals, be sure to turn off the charger’s power switch. The open-circuit voltage variation for the MF battery after charging is shown below. As shown in the figure, the open circuit voltage stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the opencircuit voltage. WARNING Do not quick charge the battery.
INSPECTION INSP ADJ Charging method using a variable-current (voltage) type charger Charger AMP meter Measure the open-circuit voltage prior to charging. 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. 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.
INSPECTION INSP 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. NO This type of battery charger cannot charge the MF battery.
INSPECTION/INSTALLATION/FUSE INSPECTION INSP ADJ 2. Inspect: Battery terminal Dirty Clean with a wire brush. Poor connection Correct. NOTE: After cleaning the terminals, grease them lightly. INSTALLATION 1. Install: Battery assembly 1 NOTE: During installation, be sure the projection a on the battery box aligns with the grommet on the frame. Pass the battery leads through the cable guide 2. 2.
FUEL INSPECTION INSP ADJ 2. Inspect: Fuses 1 Inspection steps: Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the tester selector to “Ω 1” Pocket tester: 90890-03112 If the tester indicates ∞, replace the fuse. 3. Replace: Blown fuse Replacement steps: Turn off the ignition. Install a new fuse of proper amperage. Turn on the switches to verify operation of related electrical devices. If the fuse immediately blows again, check the electrical circuit.
HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT INSP ADJ EB305021 HEADLIGHT BEAM ADJUSTMENT 1. Adjust: Headlight beam (vertically) Turn the adjuster 1 in or out. Turnning in: Headlight beam is lowered. Turnning out: Headlight beam is raised. 2. Adjust: Headlight beam (horizontally) Turn the adjuster 2 in or out. Right headlight: Turnning in: Headlight beam is to the right. Turnning out: Headlight beam is to the left. Left headlight: Turnning in: Headlight beam is to the left.
HEADLIGHT BULB REPLACEMENT INSP ADJ 5. Install: Bulb New Secure the new bulb with the bulb holder. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Hook: Bulb holder 7. Connect: Headlight leads 8.
INSP ADJ
ENG CHAPTER 4. ENGINE OVERHAUL ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER . . . . . . . . . . . . . . ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENG A.C. MAGNETO AND STARTER WHEEL GEAR . . . . . . . . . . . . . . . . . . . . . STATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND STARTER WHEEL GEAR . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . .
ENGINE ASSEMBLY ENG ENGINE OVERHAUL ENGINE ASSEMBLY LEADS 10 Nm (1.0 m kg) Order Job name/Part name 1 2 Leads disconnect Side cowling, seat, side cover and fuel tank. Battery negative lead Battery positive lead 3 4 5 6 Starter motor lead 1 Startor coil lead/pickup coil lead coupler 1/1 Neutral switch lead coupler 1 1 Clamp Q’ty Remarks Disconnect the parts in the order below. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3.
ENGINE ASSEMBLY ENG DRIVE SPROCKET AND EXHAUST PIPE/MUFFLER 12 Nm (1.2 m kg) 70 Nm (7.0 m kg) 24 Nm (2.4 m kg) 5 Nm (0.5 m kg) 24 Nm (2.4 m kg) 20 Nm (2.0 m kg) 20 Nm (2.0 m kg) Order Job name/Part name Q’ty Drive sprocket and exhaust pipe/muffler removal Air filter case Carburetor assembly Radiator assembly Thermostatic valve assembly 1 2 3 4 5 6 7 8 9 Remarks Remove the parts in the order below. Refer to “AIR FILTER CASE” in CHAPTER 3. Refer to “CARBURETOR” in CHAPTER 6.
ENGINE ASSEMBLY ENG ENGINE ASSEMBLY 10 Nm (1.0 m kg) 89 Nm (8.9 m kg) 60 Nm (6.0 m kg) 30 Nm (3.0 m kg) 30 Nm (3.0 m kg) 60 Nm (6.0 m kg) 30 Nm (3.0 m kg) 64 Nm (6.4 m kg) Order Job name/Part name Q’ty Engine removal 1 2 3 4 5 6 7 8 9 10 11 Remarks Remove the parts in the order below. NOTE: Place suitable stand under the frame and engine.
ENGINE ASSEMBLY ENG 10 Nm (1.0 m kg) 89 Nm (8.9 m kg) 60 Nm (6.0 m kg) 30 Nm (3.0 m kg) 30 Nm (3.0 m kg) 60 Nm (6.0 m kg) 30 Nm (3.0 m kg) 64 Nm (6.4 m kg) Order 12 13 Job name/Part name Q’ty Engine stay (left) Engine bracket (lower) Remarks 1 1 For installation, reverse the removal procedure.
ENGINE ASSEMBLY ENG INSTALLATION 1. Install: Bolt 1 X 6 NOTE: Do not fully tighten. 2. Tighten: Tighten the bolts in the order below. 1 2 3 4 5 6 Bolt Bolt Bolt Bolt Bolt Bolt 1 2 3 4 5 6 3. Install: Shift arm 1 30 Nm (3.0 m kg) 30 Nm (3.0 m kg) 64 Nm (6.4 m kg) 89 Nm (8.9 m kg) 60 Nm (6.0 m kg) 30 Nm (3.0 m kg) 12 Nm (1.2 m kg) NOTE: Align the punched mark a on the shift shaft with the slot on the shift arm. The top of the shift pedal 1 should be aligned with the crankcase 2 .
CAMSHAFT ENG CAMSHAFT CYLINDER HEAD COVER 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Cylinder head cover removal Side cowling, seat, side cover and fuel tank Air filter case Remove the parts in the order below. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3. Refer to “AIR FILTER CASE” in CHAPTER 3. Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Refer to “RADIATOR” in CHAPTER 5. Refer to “CARBURETOR” in CHAPTER 6. Refer to “THERMOSTATIC VALVE” in CHAPTER 5.
CAMSHAFT ENG CAMSHAFT 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 18 Nm (1.8 m kg) 10 Nm (1.0 m kg) 24 Nm (2.4 m kg) 20 Nm (2.0 m kg) Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Camshaft removal Spark plug Plug/O-ring Timing chain guide (upper) Timing chain tensioner/Gasket Camshaft sprocket Timing chain guide (exhaust) Camshaft cap Dowel pin Intake camshaft Exhaust camshaft 2 2/2 1 1/1 2 1 4 8 1 1 Remarks Remove the parts in the order below. Refer to “REMOVAL”, and “INSTALLATION”.
CAMSHAFT ENG REMOVAL 1. Remove: Timing plug 1 Straight plug 2 2. Align: “T” mark (with stationary pointer) NOTE: Turn the crankshaft counterclockwise and align the “T” mark a with the stationary pointer b when #1 piston is at TDC on compression stroke. The #1 piston is in compression stroke TDC when the cam lobes are turned away from each other. 3. Remove: Timing chain guide (upper) 1 4. Loosen: Camshaft sprocket bolts 2 5. Loosen: Tensioner cap bolt 1 6.
CAMSHAFT ENG 8. Remove: Timing chain guide (exhaust) Camshaft cap 1 NOTE: Remove the camshaft cap bolts in a crisscross pattern, working from the inside to the outside. CAUTION: The bolts (camshaft caps) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps. INSPECTION 1. Inspect: Cam lobes Pitting/Scratches /Blue discoloration Replace. 2. Measure: Cam lobes length a and b Out of specification Replace. Cam lobes length limit: Intake: a 35.85 mm b 27.
CAMSHAFT ENG 4. Measure: Camshaft-to-cap clearance Out of specification Measure bearing diameter (camshaft) Camshaft-to-cap clearance: 0.020 0.054 mm Measurement steps: Install the camshaft onto the cylinder head. Position a strip of Plastigauge 1 onto the camshaft. Install the dowel pins and camshaft caps. 10 Nm (1.0 m kg) NOTE: Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps. Do not turn the camshaft when measuring clearance with the Plastigauge.
CAMSHAFT ENG INSTALLATION 1. Install: Exhaust camshaft 1 Intake camshaft 2 (with camshaft sprocket temporarily tighten) Dowel pins 3 NOTE: Install the camshaft with the punch mark a facing upward. 2. Install: Camshaft caps 10 Nm (1.0 m kg) NOTE: Install the camshaft cap with the arrow mark a embossed facing timing chain of the engine. Tighten the camshaft cap bolts in a crisscross pattern from the inside to outwards. Do not install the bolts at b marked place in this stage.
CAMSHAFT ENG CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result. Make sure that marks d and e are aligned after the crankshaft is rotated twice and the piston is at TDC. 4. Install: Timing chain guide (exhaust) 5. Install: Timing chain tensioner Installation steps: Remove the tensioner cap bolt 1 , washer 2 and springs 3 . Release the timing chain tensioner one-way cam 4 and push the tensioner rod 5 all the way in.
CYLINDER HEAD ENG CYLINDER HEAD 40 Nm (4.0 m kg) 21 Nm (2.1 m kg) 10 Nm (1.0 m kg) 60 Nm (6.0 m kg) 10 Nm (1.0 m kg) 60 Nm (6,0 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Cylinder head removal Exhaust pipe Camshaft Union bolt Copper washer Oil delivery pipe Clip Vacuum hose Cylinder head Cylinder head gasket Dowel pin Remarks Remove the parts in the order below. Refer to “ENGINE ASSEMBLY”. Refer to “CAMSHAFT”. 1 2 1 2 2 1 1 2 Refer to “INSTALLATION”.
CYLINDER HEAD ENG INSPECTION 1. Eliminate: Carbon deposit (from combustion chamber) Use rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seat 2. Inspect: Cylinder head Scratches /Damage Replace. 3. Measure: Cylinder head warpage Out of specification Resurface. Cylinder head warp limit: Less than 0.03 mm Warp limit measurement and resurfacement steps: Hold a straight edge and a thickness gauge to the cylinder head.
VALVE AND VALVE SPRING ENG VALVE AND VALVE SPRING Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Valve and valve spring removal Cylinder head cover Cylinder head Valve lifter Adjusting pad Valve cotter Valve retainer Valve spring Stem seal Valve spring seat Exhaust valve Intake valve (center) Intake valve (left and right) Remarks Remove the parts in the order below. Refer to “CYLINDER HEAD COVER”. Refer to “CYLINDER HEAD”. 5 5 10 5 5 5 5 2 1 2 Refer to “REMOVAL”, and “INSTALLATION”.
VALVE AND VALE SPRING ENG REMOVAL 1. Remove: Valve lifters 1 Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: Valve sealing Leakage at valve seat Inspect the valve face, valve seat and the valve seat width. Checking steps: Pour a clean solvent a into the intake and exhaust ports. Check the valve seating. There should be no leakage at the valve seat 1 . 3.
VALVE AND VALVE SPRING ENG INSPECTION 1. Measure: S Stem-to-guide clearance Stem-to-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification Replace valve guide. Stem-to-guide clearance: Intake: 0.010 X 0.037 mm : 0.08 mm Exhaust: 0.025 X 0.052 mm : 0.10 mm 2. Replace: S Valve guide Replacement steps: NOTE: Heat the cylinder head in an oven to 100_C to ease guide removal and installation and to maintain correct interference fit.
VALVE AND VALVE SPRING ENG 3. Eliminate: Carbon deposit (from valve face) 4. Inspect: Valve face Pitting/Wear Reface the face. Valve stem end Mushroom shape or diameter larger than rest of stem Replace. 5. Measure: Margin thickness a Out of specification Replace. Margin thickness: 0.8 X 1.2 mm 6. Measure: Runout (valve stem) Out of specification Replace. Runout limit: 0.01 mm NOTE: Always replace the guide if the valve is replaced.
VALVE AND VALVE SPRING ENG Measurement steps: Apply the Mechanic’s blueing dye (Dykem) b to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. 10.
VALVE AND VALVE SPRING ENG NOTE: To obtain the best lapping result, lightly tap the valve seat while rotating the valve back and forth between your hand. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Be sure to clean off all compound from the valve face and valve seat after every lapping operation. Apply the Mechanic’s blueing dye (Dykem) b to the valve face. Install the valve into the cylinder head.
VALVE AND VALVE SPRING ENG 13. Measure: S Spring tilt a Out of specification Replace. Spring tilt limit: 2.5_/1.7 mm INSTALLATION 1. Install: S Stem seal New S Valve S Spring seat S Valve spring S Valve retainer (into cylinder head) NOTE: S Make sure that each valve is installed in its original place, also referring to the embossed mark as follows: Intake (right/left): “3LD:” Intake (middle): “3LD.” Exhaust “3LD” S Install the valve spring with the larger pitch a facing upwards.
VALVE AND VALVE SPRING ENG 2. Install: Valve cotters 1 NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor. Valve spring compressor 2 : 90890-04019 Attachment 3 : 90890-04108 3. Secure the valve cotters 1 onto the valve stem by tapping lightly with a piece of wood. NOTE: Do not hit so much as to damage the valve. 4. Install: Pads 1 Valve lifters 2 NOTE: The valve lifters must move smoothly when rotated with the 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 11 Job name/Part name Q’ty Cylinder and piston removal Cylinder head Joint O-ring O-ring Dowel pin Cylinder Cylinder gasket O-ring Circlip Piston pin Piston Piston ring set Remarks Remove the parts in the order below. Refer to “CYLINDER HEAD”. 1 1 1 4 1 1 2 4 2 2 2 Refer to “REMOVAL”, and “INSTALLATION”. For installation, reverse the removal procedure.
CYLINDER AND PISTON ENG REMOVAL 1. Remove: Piston circlips 1 Piston pins 2 Pistons 3 NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. Put identification marks on each piston head for reference during reinstallation. Before removing the piston pin, deburr the clip groove and pin hole area.
CYLINDER AND PISTON ENG Cylinder bore “C” 89.500 X 89.505 mm Taper limit “T” 0.05 mm Out of round “R” 0.03 mm “C” = Maximum D “T” = (Maximum D1, or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6) If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as set. 2nd step: Measure the piston skirt diameter “P” with a micrometer. a 5.5 mm from the piston bottom edge. Piston size P Standard 89.420 X 89.435 mm Oversize 2 0.
CYLINDER AND PISTON ENG 3. Measure: Side clearance Out of specification Replace piston and rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance: Top ring: 0.035 X 0.070 mm 2nd ring: 0.035 X 0.070 mm 4. Position: Piston ring (into cylinder) NOTE: Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. a 5 mm 5. Measure: End gap Out of specification Replace.
CYLINDER AND PISTON ENG 6. Inspect: Piston pin Blue discoloration/Grooves Replace, then inspect lubrication system. 7. Measure: Piston pin-to-piston clearance Measurement steps: Measure the piston pin outside diameter a . If out of specification, replace the piston pin. Outside diameter (piston pin): 19.991 X 20.000 mm : 19.975 mm Measure the piston inside diameter b .
CYLINDER AND PISTON ENG 2. Install: Piston pins 1 Pistons 2 Piston circlips 3 NOTE: Apply engine oil to the piston pins. Be sure that the arrow mark a on the piston points to the exhaust side of the engine. Before installing the piston, cover the crankcase with a clean rag to prevent the piston from falling into the crankcase. 3. Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. a Top ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 4.
CLUTCH ENG CLUTCH CRANKCASE COVER (RIGHT) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remarks Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Crankcase cover (right) removal Engine oil 1 2 Clutch cable Crankcase cover (right) 1 1 3 4 5 6 7 8 9 Gasket Dowel pin Circlip Plain washer Pull lever Torsion spring Plain washer 1 2 1 1 1 1 1 NOTE: Loosen the bolts in a crisscross pattern. 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 12 13 14 Job name/Part name Clutch removal Clutch spring Pressure plate Plain washer/Bearing Pull rod Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer/Bearing Clutch housing Thrust plate 2 Thrust plate 1 Q’ty Remarks Remove the parts in the order below. 6 1 1/1 1 9 8 1 1 1 1 1/1 1 1 1 Refer to “REMOVAL”, and “INSTALLATION”. For installation, reverse the removal procedure.
CLUTCH ENG REMOVAL 1. Straighten the lock washer tab. 2. Remove: Clutch boss nut 1 Lock washer 2 Clutch boss 3 NOTE: Loosen the clutch boss nut 1 while holding the clutch boss 3 with the universal clutch holder. Universal clutch holder: 90890-04086 3. Remove: Spacer 1 Bearing 2 NOTE: Install 6 mm bolts 3 onto the spacer. Then remove the spacer by pulling. INSPECTION 1. Measure: Friction plate thickness Out of specification Replace friction plates as a set. Measure at four points.
CLUTCH ENG 4. Inspect: Dogs (on the clutch housing) Pitting/Wear/Damage Deburr or replace. Clutch housing bearing Wear/Damage Replace clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic operation. Clutch boss splines Pitting/Wear/Damage boss. Replace clutch NOTE: Pitting on the clutch boss splines will cause erratic operation. INSTALLATION 1. Install: Clutch boss 1 Lock washer 2 New Clutch boss nut 3 70 Nm (7.
CLUTCH ENG 4. Install: Pressure plate NOTE: Align the punched mark a on the clutch boss with the punched mark b on the pressure plate. 5. Install: Clutch springs 1 Clutch spring bolts 2 8 Nm (0.8 m kg) NOTE: Tighten the clutch spring bolts in stage, using a crisscross pattern. 6. Install: Dowel pins Gasket New Crankcase cover (right) 10 Nm (1.0 m kg) NOTE: Install the pull rod so that the splines a are toward the back, then install the crankcase cover (right). 7.
CRANKCASE COVER (LEFT) ENG CRANKCASE COVER (LEFT) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 5 Nm (0.5 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Crankcase cover (left) removal Engine oil 1 2 3 Drive sprocket cover 1/2 Shift arm Crankcase cover (left) 4 5 6 7 Gasket Dowel pin Circlip Plain washer Remarks 1/1 1 1 NOTE: Loosen the bolts in a crisscross pattern. 1 2 1 1 For installation, reverse the removal procedure.
SHIFT SHAFT ENG SHIFT SHAFT 10 Nm (1.0 m kg) 12 Nm (1.2 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Remarks Remove the parts in the order below. Refer to “CLUTCH”. Refer to “CRANKCASE COVER (LEFT)”. Shift shaft removal Clutch Shift arm Shift shaft Circlip Plain washer Torsion spring Stopper level Bearing retainer Torsion spring 1 1 1 1 1 1 1 Refer to “INSTALLATION”. For installation, reverse the removal procedure.
SHIFT SHAFT ENG INSPECTION 1. Inspect: Stopper lever 1 Roller turns roughly Replace. Bends/Damage Replace. 2. Inspect: Torsion spring (shift shaft) 1 Torsion spring (stopper lever) 2 Wear/Damage Replace. 3. Inspect: Shift shaft 1 Shift pawls 2 Bends/Wear/Damage Replace. INSTALLATION 1. Install: Return spring 1 Bearing retainer 2 Stopper lever 3 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) NOTE: Be sure the stopper lever roller fits into the shift cam segment.
A.C. MAGNETO AND STARTER WHEEL GEAR ENG A.C. MAGNETO AND STARTER WHEEL GEAR STATOR COIL 7 Nm (0.7 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Refer to “CRANKCASE COVER (LEFT)”.
A.C. MAGNETO AND STARTER WHEEL GEAR ENG A.C. MAGNETO AND STARTER WHEEL GEAR 130 Nm (13.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remarks Remove the parts in the order below. 1 2 A.C. magneto and starter wheel gear removal Rotor Shaft 1 1 3 4 Starter idle gear Starter clutch 1 1 5 6 7 Plate washer Woodruff key Starter wheel gear 1 1 1 Refer to “REMOVAL” and “INSTALLATION”. NOTE: After reassembling the starter clutch stake the top of the bolts.
A.C. MAGNETO AND STARTER WHEEL GEAR ENG REMOVAL 1. Remove: Bolt (rotor) 1 Washer 2 NOTE: Loosen the bolt (rotor) 1 while holding the magneto with the sheave holder 3 . Do not allow the sheave holder 3 to touch the projection on the rotor. Sheave holder: 90890-01701 2. Remove: A.C. magneto 1 NOTE: Remove the rotor 1 using the rotor puller 2 and crankshaft protector 3 . Fully tighten the tool holding bolts, but make sure the tool body is parallel with the magneto.
A.C. MAGNETO AND STARTER WHEEL GEAR ENG 2. Inspect: Starter wheel gear 1 (contacting surfaces) Pitting/Wear/Damage Replace. INSTALLATION 1. Install: Starter wheel gear 1 Woodruff key 2 2. Install: Plate washer Rotor 1 Washer NOTE: Clean the tapered portions of the crankshaft and rotor. When installing the magneto, make sure the woodruff key is properly seated in the key way of the crankshaft. 3. Install: Bolt (rotor) 1 130 Nm (13.
OIL PUMP ENG OIL PUMP OIL PUMP COVER AND OIL PUMP DRIVEN GEARS 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Oil pump cover and oil pump driven gear removal Engine oil 1 Oil pipe O-ring Oil pump cover Gasket Dowel pin Collar Gasket Circlip Oil pump driven gear 1 1 1 2 1 1 2 2 Remarks Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. For installation, reverse the removal procedure.
OIL PUMP ENG OIL PUMP 6 Nm (0.6 m kg) 6 Nm (0.6 m kg) Order 1 2 3 4 5 Job name/Part name Q’ty Remarks Remove the parts in the order below. Oil pump removal Oil pump assembly 1 (For pumping oil to the oil tank) Gasket Dowel pin Oil pump assembly 2 (For lubricating the engine parts) Gasket 1 1 1 1 1 For installation, reverse the removal procedure.
OIL PUMP ENG INSPECTION 1. Inspect: Oil pump driven gears Wear/Cracks /Damage Replace. 2. Measure: Tip clearance a (between the inner rotor 1 and the outer rotor 2) Side clearance b (between the outer rotor 2 and the pump housing 3 ) (between the inner rotor 1 /outer rotor 2 and the pump housing 3 ) Side clearance c Out of specification Replace the oil pump assembly. Tip clearance a : 0 0.12 mm Side clearance b : 0.03 0.08 mm Side clearance c : 0.03 0.08 mm 3.
OIL TANK ENG OIL TANK OIL HOSE 21 Nm (2.1 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Refer to “ENGINE ASSEMBLY”. Oil hose removal Engine oil 1 2 3 4 5 6 7 Remarks Engine Union bolt Copper washer Oil delivery pipe Oil hose O-ring Oil pipe O-ring 2 4 1 1 2 1 2 For installation, reverse the removal procedure.
OIL TANK ENG OIL TANK 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Refer to “ENGINE ASSEMBLY”. Oil tank removal Engine oil 1 2 3 4 5 6 Remarks Engine Oil tank case (upper) Gasket Dowel pin Oil tank case (lower) Gasket Dowel pin 1 1 2 1 2 2 For installation, reverse the removal procedure.
OIL PAN ENG OIL PAN OIL PAN 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) 30 Nm (3.0 m kg) Order Job name/Part name Q’ty Remarks Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Refer to “ENGINE ASSEMBLY”. Refer to “OIL TANK”. Oil pan removal Engine oil 1 2 3 4 Engine Oil hose Oil filter cover O-ring Collar Oil filter 1 2 1 1 5 6 7 8 Oil pan Gasket Dowel pin O-ring /collar 1 1 2 2/2 NOTE: Install the oil filter with the projection towards the oil filter cover.
OIL PAN ENG BALANCER 10 Nm (1.0 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Refer to “ENGINE ASSEMBLY”. Refer to “CYLINDER AND PISTON”. Refer to “SHIFT SHAFT”. Refer to “A.C. MAGNETO AND STARTER WHEEL GEAR”. Refer to “OIL PUMP”. Refer to “OIL TANK”. Refer to “OIL PAN”. Balancer weight removal Engine oil Engine Piston Shift shaft A.C.
OIL PAN ENG 10 Nm (1.0 m kg) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) Order 4 5 6 7 Job name/Part name Rear balancer weight Front balancer holder/Dowel pin Front balancer shaft/O-ring Front balancer weight Q’ty Remarks 1 1/2 1/1 1 Refer to “REMOVAL” and “INSTALLATION”. For installation, reverse the removal procedure.
OIL PAN REMOVAL 1. Remove: Plate 1 2. Remove: Rear balancer holder 1 Dowel pins 3. Remove: Rear balancer shaft 1 Rear balancer weight 2 4. Remove: Front balancer holder 1 Dowel pins 5.
OIL PAN ENG INSTALLATION 1. Install: Front balancer weight 1 Front balancer shaft 2 O-ring 3 New Plate (balancer shaft) 12 Nm (1.2 m kg) Installation steps: Turn the crankshaft until the keyway a is aligned with the embossed mark b on the crankcase. While holding the crankshaft, install the balancer weight and align the mark c on the front balancer gear with the embossed mark d on the crankcase. Install the front balancer shaft. 2. Install: Dowel pins Front balancer holder 1 10 Nm (1.
OIL PAN ENG Installing steps: Turn the crankshaft until the keyway a is aligned with embossed mark b on the crankcase. While holding the crankshaft, install the balancer weight and align the mark c on the rear balancer gear with the embossed mark d on the crankcase. Install the rear balancer shaft. 4. Install: Dowel pins Rear balancer holder 1 10 Nm (1.
CRANKSHAFT ENG CRANKSHAFT CRANKSHAFT ASSEMBLY (M6) 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) 24 Nm (2.4 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Remove the parts in the order below. Refer to “BALANCER”. Refer to “WATER PUMP” in CHAPTER 5.
CRANKSHAFT ENG CONNECTING ROD 48 Nm (4.8 m kg) Order 1 2 3 4 5 Job name/Part name Q’ty Remarks Remove the parts in the order below. Connecting rod removal Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod bearing 4 4 2 2 4 Refer to “REMOVAL”, and “INSTALLATION”. For installation, reverse the removal procedure.
CRANKSHAFT ENG REMOVAL 1. Remove: Cover plate 1 2. Remove: Upper crankcase Lower crankcase Dowel pins A NOTE: Loosen the bolts 1/4 turn each and remove them after all are loosened. Remove the bolts starting with the highest numbered one. The embossed numbers in the crankcase designate the crankcase tightening sequence. B A Upper crankcase B Lower crankcase CAUTION: Use a soft hammer to tap on the case half. Tap only on reinforced portions of the case.
CRANKSHAFT ENG 4. Remove: Main journal bearings 1 NOTE: Identify each plain bearing position very carefully so that it can be reinstalled in its original place. 5. Remove: Pin 1 Timing chain guide (intake) 2 6. Remove: Connecting rod cap 1 Connecting rod 2 Connecting rod bearing 3 NOTE: Identify each bearing position very careful so that it can be reinstalled in its original place. INSPECTION 1. Measure: Runout (crankshaft) Out of specification Replace. Runout: Less than 0.035 mm 2.
CRANKSHAFT ENG 3. Measure: Oil clearance (main journal) Out of specification Replace bearing. Oil clearance: 0.020 0.038 mm : 0.1 mm Measurement steps: CAUTION: Do not interchange the bearings and connecting rod. They must be installed in their original positions, or the correct oil clearance may not be obtained causing engine damage. Clean the bearings, main journals and bearing portions of the crankcase. Place the upper crankcase on a bench in an upside down position.
CRANKSHAFT ENG Tighten the bolt to specification in the tightening sequence cast on the crankcase. A 1 6 (M10): 40 Nm (4.0 m kg) 7 10 , 13 , 15 , 20 25 (M8) 24 Nm (2.4 m kg) 11 , 12 , 14 , 16 19 , 26 , 27 (M6) 12 Nm (1.2 m kg) A Upper crankcase B Lower crankcase B NOTE: Lubricate the threads of bolts 1 6 with molybdenum disulfide motor oil. Lubricate the threads of bolts 7 27 with engine oil. Remove the lower crankcase and lower half of the bearing.
CRANKSHAFT ENG Install the upper half of the bearing into the connecting rod and lower half of the bearing into the connecting rod cap. Put a piece of Plastigauge a on the crank pin. Assemble the connecting rod halves. NOTE: Do not move the connecting rod or crankshaft until the oil clearance measurement has been completed. Apply molybdenum disulfide grease to the bolts, threads and nut seats. Make sure the “Y” marks on the connecting rods face the left side of the crankshaft.
CRANKSHAFT ENG 5.
CRANKSHAFT ENG INSTALLATION 1. Apply: Molybdenum disulfide grease (onto threads of bolts and nut seats) Engine oil (onto crank pins and inner surfaces of connecting rod bearings) 2. Install: Connecting rod bearings 1 Connecting rods 2 Connecting rod caps 3 (onto crank pins) NOTE: Align the projection of bearing with the groove of the caps and connecting rod. Make sure to reinstall each connecting rod bearing in its original place.
CRANKSHAFT ENG 5. Install: Timing chain guide (intake) Pin 6. Install: Main journal bearings NOTE: Align the projection a of the bearing with the notch b in the crankcase. Install each bearing in its original place. 7. Apply: Engine oil (onto inner surfaces of main journal bearings) Sealant (onto crankcase mating surfaces) Yamaha bond No. 1215: 90890-85505 NOTE: DO NOT ALLOW any sealant to come in contact with the oil gallery or crankshaft bearings. 8. Install: Dowel pin 1 9.
CRANKSHAFT ENG 10. Install: Lower crankcase 1 (onto upper crankcase 2 ) Place the lower crankcase assembly onto the upper crankcase assembly. A CAUTION: Before tightening the crankcase bolts, check the following point: Be sure the gears shift correctly when the shift cam is turned by hand. 11. Tighten: Lower crankcase bolt (follow the proper tightening sequence) Upper crankcase bolt B 1 6 (M10): 40 Nm (4.0 m kg) 7 10 , 13 , 15 , 20 25 (M8) 24 Nm (2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 12 Nm (1.2 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Transmission, shift cam and shift fork removal Lower crankcase Drive axle assembly/Oil seal Circlip Shift fork guide bar 2 Shift fork “R” Shift fork “L” Shift fork guide bar 1 Shift fork “C” Shift cam Bearing housing Cover Main axle assembly Q’ty Remarks Remove the parts in the order below. Refer to “CRANKSHAFT”.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG REMOVAL 1. Remove: Drive axle assembly 1 2. Remove: Shift fork guide bars 1 Shift fork “R” 2 Shift fork “L” 3 Shift fork “C” 4 Shift cam 5 3. Remove: Bearing housing 1 (use the torx wrench) 4. Remove: Cover 1 NOTE: Attach the slide hammer bolt 2 and weight 3 into the cover, then remove the cover by pulling. Slide hammer bolt: 90890-01083 Weight: 90890-01084 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG INSPECTION 1. Inspect: Shift fork cam follower 1 Shift fork pawl 2 Scoring/Bends/Wear/Damage Replace. 2. Inspect: Guide bar Roll the guide bar on a flat surface. Bends Replace. WARNING Do not attempt to straighten a bent guide bar. 3. Check: Shift fork movement (on its guide bar) Unsmooth operation Replace the fork and guide bar. 4. Inspect: Shift cam grooves Wear/Damage/Scratches Replace. Shift cam segment 1 Damage/Wear Replace.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 6. Inspect: Gear teeth Blue discoloration/Pitting/Wear Replace. Mated dogs Rounded edges/Cracks /Missing portions Replace. 7. Check: Proper gear engagement (each gear) (with its counterpart) Incorrect Reassemble. Gear movement Roughness Replace. 116.6 116.68 mm Main axle reassembling point: Press the 2nd pinion gear 1 in the main axle as shown. 8. Inspect: Circlips Damage/Looseness /Bends Replace. INSTALLATION 1.
TRANSMISSION,SHIFT CAM AND SHIFT FORK ENG 3. Install: Shift cam 1 Shift fork “C” 2 Shift fork “L” 3 Shift fork “R” 4 Shift for guide bars 5 NOTE: Install the shift forks with the embossed mark to the right and in sequence (R, C, L) beginning from the right. Install the shift fork guide bars with the tapered end a toward the clutch. 4. Install: Circlip 1 5. Install: Drive axle assembly 1 NOTE: The drive axle bearing pin must point to the front side of the crankcase.
ENG
COOL CHAPTER 5. COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 THERMOSTATIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTATIC VALVE ASSEMBLY . . . .
COOL
RADIATOR COOL COOLING SYSTEM RADIATOR 5 Nm (0.5 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Radiator removal Coolant Side cowling, seat, side cover and fuel tank Air filter case 1 2 3 4 5 1 1 1 1 1 Fan motor lead Coolant reservoir hose Coolant hose 3 Coolant hose 2 Radiator assembly Remarks Remove the parts in the order below. Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3.
RADIATOR COOL INSPECTION 1. Inspect: Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator. Flattened fin Repair/Replace. 2. Inspect: Fan 2 Cracks /Damage Replace. 3. Inspect: Radiator hoses Crancks /Damage Replace. 4. Measure: Radiator cap opening pressure Radiator cap opens at pressure below the specified pressure Replace. Radiator cap opening pressure: 75 105 kPa (0.75 1.05 kg/cm2, 0.75 1.
RADIATOR COOL INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Install: Radiator assembly 7 Nm (0.7 m kg) 2. Fill: Cooling system Refer to “COOLANT REPLACEMENT” in CHAPTER 3. 3. Inspect: Cooling system Decrease of pressure (leaks) Repair as required. Inspection steps: Attach the radiator cap tester 1 to the radiator. Radiator cap tester: 90890-01325 Adapter: 90890-01352 Apply 100 kPa (1.0 kg/cm2, 1.0 bar) pressure.
THERMOSTATIC VALVE COOL THERMOSTATIC VALVE THERMOSTATIC VALVE ASSEMBLY 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Thermostatic valve assembly removal Coolant 1 2 3 4 5 6 Remarks Side cowling, seat, side cover and fuel tank Air filter case Radiator assembly Ground lead Thermo switch lead coupler Thermo unit lead Coolant hose 1 Coolant hose 4 Thermostatic valve assembly 1 1 1 1 1 1 Refer to “COOLANT REPLACEMENT” in CHAPTER 3.
THERMOSTATIC VALVE COOL THERMOSTATIC VALVE 28 Nm (2.8 m kg) 15 Nm (1.5 m kg) 10 Nm (1.0 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Q’ty Remarks Remove the parts in the order below. Thermostatic valve housing disassembly Thermo switch Thermo unit Ground lead Thermostatic valve cover O-ring Thermostatic valve Thermostatic valve housing 1 1 1 1 1 1 1 Refer to “ASSEMBLY”. For installation, reverse the removal procedure.
THERMOSTATIC VALVE COOL INSPECTION 1. Inspect: S Thermostatic valve 1 Valve does not open at 80 84_C Replace. Inspection steps: S Suspend thermostatic valve in a vessel. S Place reliable thermometer in a water. S Observe thermometer, while stirring water continually. 1 Thermometer 2 Water 3 Thermostatic valve 4 Vessel A CLOSE B OPEN NOTE: Thermostatic valve is sealed and its setting is specialized work. If its accuracy is in doubt, replace it.
WATER PUMP COOL WATER PUMP WATER PUMP 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “COOLANT REPLACEMENT” in CHAPTER 3. Water pump removal Coolant 1 2 3 4 5 6 7 8 Remarks 1 1 1 1 1 1 1 1 Coolant hose 3 Water pump cover O-ring Water pump housing Washer Circlip Impeller O-ring Refer to “INSTALLATION”. For installation, reverse the removal procedure.
WATER PUMP COOL INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. NOTE: It is not necessary to remove and inspect the water pump if the coolant is not unusually low or if it has no engine oil mixed in it. Always replace the entire water pump. 1. Install: Impeller 1 Circlip 2 New NOTE: After installation, check that the impeller shaft rotates smoothly. 2. Install: O-ring 1 New 3. Install: Water pump housing Water pump cover Coolant hose 3 5-8 10 Nm (1.
CARB CHAPTER 6. CARBURETION CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .
CARB
CARBURETOR CARB CARBURETION CARBURETOR CARBURETOR ASSEMBLY Order Job name/Part name Q’ty Carburetor assembly removal Side cowling, seat, side cover and fuel tank Remove the parts in the order below. Refer to ”COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3. Refer to ”AIR FILTER CASE” in CHAPTER 3.
CARBURETOR CARB CARBURETOR Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Q’ty Remarks Disassemble the parts in the order below. Carburetor disassembly Carburetor heater hose Float chamber Needle valve Float Starter jet Main jet Pilot jet Jet housing Jet needle Throttle valve 1 1 1 1 1 1 1 1 1 1 6-2 Refer to ”INSTALLATION”.
CARBURETOR Order 11 12 13 14 15 16 Job name/Part name Q’ty CARB Remarks 1 1 1 1 1 1 Needle jet Pilot air jet 1 Main air jet 2 Diaphragm Starter plunger Pilot screw For assembly, reverse the disassembly procedure.
CARBURETOR CARB ASSEMBLY CAUTION: Before reassembling, wash all parts in clean petroleum based solvent. Always use a new gasket. 1. Install: Main jet 1 Starter jet 2 Pilot jet 3 2. Install: Valve seat NOTE: Make sure that projection a on the valve seat is aligned with the slot b on the carburetor body. 3. Install: O-ring 1 Diaphragm 2 4. Install: Pilot screw 1 Pilot screw (turns out): 2.
CARBURETOR CARB FUEL LEVEL ADJUSTMENT 1. Measure: Fuel level a Fuel level: 15.8 16.8 mm Below the MIKUNI mark Out of specification Adjust. NOTE: Adjust the float level by slightly bending the float tang 1 . Fuel level measurement and adjustment steps: Place the motorcycle on a level surface. Use a garage jack under the engine to ensure that the carburetors are positioned vertically. Connect the fuel level gauge 2 to the drain pipe. Fuel level gauge: 90890-01312 Loosen the drain screw.
CARBURETOR CARB 1. Adjust: TPS (throttle position sensor) position Adjustment steps: Turn the main switch to ”ON”. Disconnect the TPS (throttle position sensor) coupler. Reconnect the TPS (throttle position sensor) coupler. NOTE: When the above procedure is commenced, the machine switches to TPS (throttle position sensor) adjustment mode. Loosen the TPS (throttle position sensor) screws 1. Adjust the TPS (throttle position sensor) position.
CARBURETOR CARB 2. Inspect: S TPS (throttle position sensor) Inspection steps: S Disconnect the TPS (throttle position sensor) coupler. S Remove the TPS (throttle position sensor) from carburetor. S Connect the pocket tester (Ω 1k) to the TPS (throttle position sensor) couplers. Tester (+) lead Blue terminal 1 Tester (–) lead Black/Blue terminal 2 S Check the TPS (throttle position sensor) resistance. TPS (throttle position sensor) resistance: 3.5 X 6.
CARB
CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATIC WHEEL BALANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
CHAS REAR SHOCK ABSORBER AND RELAY ARM . . . . . . . . . . . . . . . . . . . . . . 7-50 HANDLING NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 NOTES ON DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL AND BRAKE DISCS CHAS CHASSIS FRONT WHEEL AND BRAKE DISCS 58 Nm (5.8 m kg) 19 Nm (1.9 m kg) 40 Nm (4.0 m kg) 20 Nm (2.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. NOTE: Elevate the front wheel by placing a suitable stand under the engine.
FRONT WHEEL AND BRAKE DISCS Order 1 2 3 4 5 6 7 Job name/Part name Q’ty CHAS Remarks Disassemble the parts in order below. Front wheel disassembly Oil seal Clutch retainer Meter clutch Oil seal Bearing Spacer Bearing 1 1 1 1 1 1 1 Refer to “ASSEMBLY”. For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISCS CHAS INSPECTION 1. Inspect: Front wheel axle. Roll it on a flat surface. Bends Replace. WARNING Do not attempt to straighten a bent axle. 2. Measure: Wheel runout Over the specified limit Replace. Rim runout limits: Radial a : 1 mm Lateral b : 0.5 mm 3. Inspect: Wheel bearings Bearings allow free play in the wheel hub or wheel turns roughly Replace. Oil seals Wear/Damage Replace.
FRONT WHEEL AND BRAKE DISCS CHAS NOTE: Use a socket 3 that matches the outside diameter of the race of the bearing and oil seal. CAUTION: Do not strike the center race 4 or balls 5 of the bearing. Contact should be made only with the outer race 6 . 4. Inspect: Collar Wear/Damage Replace collar and oil seal as set. 5. Measure: Brake disc deflection Out of specification Inspect wheel runout. If wheel runout is in good condition, replace the brake disc(s).
FRONT WHEEL AND BRAKE DISCS CHAS ASSEMBLY Reverse the “DISASSEMBLY” procedure. Note the following points. 1. Lubricate: Bearings Oil seals (lips) Recommended lubricant: Lithium soap base grease INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1. Lubricate: Front wheel axle Drive /Driven gear (speedometer) Recommended lubricant: Lithium soap base grease 2.
FRONT WHEEL AND BRAKE DISCS CHAS STATIC WHEEL BALANCE ADJUSTMENT NOTE: S After replacing the tire and/or rim, wheel balance should be adjusted. S Adjust the wheel balance with brake disk installed. 1. Remove: S Balancing weight 2. Set the wheel on a suitable stand. 3. Find: S Heavy spot Procedure: a. Spin the wheel and wait for it to rest. b. Put an “X1” mark on the wheel bottom spot. c. Turn the wheel so that the “X1” mark is 90_ up. d. Left the wheel fall and wait for it to rest.
FRONT WHEEL AND BRAKE DISCS CHAS S Turn the wheel so that the heavy spot is 90_ up. S Check that the heavy spot is at rest there. If not, try another weight until the wheel is balanced. 5. Check: S Wheel balance Checking steps: S Turn the wheel so that is comes to each point as shown. S Check that the wheel is at rest at each point. If not, readjust the wheel balance.
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET REAR WHEEL 107 Nm (10.7 m kg) 35 Nm (3.5 m kg) 40 Nm (4.0 m kg) 16 Nm (1.6 m kg) Order Job name/Part name Q’ty Remarks Remove the parts in the order below. NOTE: Rear wheel removal Elevate the rear wheel by placing a suitable stand under the engine.
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS BRAKE DISC AND DRIVEN SPROCKET 60 Nm (6.0 m kg) 20 Nm (2.0 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Remarks Remove the parts in the order below. Brake disc and driven sprocket removal Collar (left/right) Brake disc Driven sprocket Clutch hub Rubber damper Collar Oil seal Bearing 1/1 1 1 1 6 1 1 1 For installation, reverse the removal procedure.
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET Order 1 2 3 4 Job name/Part name Q’ty CHAS Remarks Disassembly the parts in the order below. Rear wheel disassembly Oil seal Bearing Collar Bearing 1 1 1 1 For assembly, reverse the disassembly procedure.
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS INSPECTION 1. Inspect: Rear wheel axle Refer to “FRONT WHEEL AND BRAKE DISC”. 2. Measure: Wheel runout Refer to “FRONT WHEEL AND BRAKE DISC”. 3. Install: Wheel bearings Oil seals Collars Refer to “FRONT WHEEL AND BRAKE DISC”. 4. Measure: Brake disc deflection Out of specification Inspect wheel runout. If wheel runout is in good condition, replace the brake disc(s). NOTE: Remove the brake caliper before inspecting the brake disc deflection.
REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS 6. Inspect: Driven sprocket More than 1/4 teeth a wear Replace sprocket. Bent teeth Replace sprocket. b Correct 1 Roller 2 Sprocket Driven sprocket replacement steps: Remove the self locknuts and driven sprocket. Clean the hub, especially on the surfaces in contact with the sprocket, using a clean cloth. Install the new driven sprocket. Driven sprocket: 60 Nm (6.0 m kg) NOTE: Tighten the self locknuts in stage, using a crisscross pattern.
FRONT AND REAR BRAKE CHAS FRONT AND REAR BRAKE FRONT BRAKE PAD 6 Nm (0.6 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Remarks Remove the parts in the order below. Front brake pad removal Cable guide Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw 1 1 2 2 1 2 2 1 Refer to “BRAKE PAD REPLACEMENT”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKE CHAS REAR BRAKE PAD 40 Nm (4.0 m kg) 6 Nm (0.6 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Rear brake pad removal Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim (left/right) Bleed screw Q’ty Remarks Remove the parts in the order below. 1 2 2 1 2 1/1 2 For installation, reverse the removal procedure.
FRONT AND REAR BRAKE CHAS CAUTION: Disc brake components rarely require disassembly. DO NOT: Disassemble components unless absolutely necessary. Use solvents on internal brake components. Use contaminated brake fluid for cleaning. Use only clean brake fluid. Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur. Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.
FRONT AND REAR BRAKE CHAS 2. Install: Pad shims New (onto brake pads) Brake pads New Pad spring New Installation steps: Connect a suitable hose 1 tightly to the caliper bleed screw 2 . Put the other end of this hose into an open container. Loosen the caliper bleed screw and push the pistons into the caliper with the finger. Tighten the caliper bleed screw 2 . Bleed screw: 6 Nm (0.6 m kg) Install the pad shims on the brake pad. Install the brake pads and pad spring.
FRONT AND REAR BRAKE CHAS Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 0.5 mm 2. Install: Pad shims New (onto brake pads) Brake pads New Pad spring New Installation steps: Connect a suitable hose 1 tightly to the caliper bleed screw 2 . Then, place the other end of this hose into an open container. Loosen the caliper bleed screw and push the pistons into the caliper with the finger. Tighten the caliper bleed screw 2 . Bleed screw: 6 Nm (0.
FRONT AND REAR BRAKE CHAS FRONT BRAKE MASTER CYLINDER 9 Nm (0.9 m kg) 30 Nm (3.0 m kg) Order 1 2 3 4 5 6 7 Job name/Part name Front brake master cylinder removal Brake fluid Brake lever Front brake switch lead coupler Front brake switch Union bolt Copper washer/Brake hose Master cylinder bracket Master cylinder assembly Q’ty Remarks Remove the parts in the order below. Drain 1 1 1 1 2/1 1 1 7-18 Disconnect Refer to “MASTER CYLINDER ASSEMBLY”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKE Order 1 2 3 4 5 6 7 Job name/Part name Q’ty CHAS Remarks Disassemble the parts in the order below. Front brake master cylinder disassembly Adjuster Spring Plate Boot Circlip Master cylinder kit Master cylinder body 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKE CHAS REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg) 30 Nm (3.0 m kg) 23 Nm (2.3 m kg) Order 1 2 3 Job name/Part name Rear brake master cylinder removal Brake fluid Union bolt Copper washer/Brake hose Brake reservoir hose Q’ty Remarks Remove the parts in the order below. Drain 1 2/1 1 NOTE: Remove from the master cylinder side. 4 5 6 7 1 1 1 1 Cotter pin Clevis pin Plain washer Master cylinder 7-20 Refer to “MASTER CYLINDER ASSEMBLY”.
FRONT AND REAR BRAKE Order 1 2 3 4 Job name/Part name Q’ty CHAS Remarks Disconnect the parts in the order below. Rear brake master cylinder disconnection Boot Circlip Master cylinder kit Master cylinder body 1 1 1 1 For assembly, reverse the disconnection procedure.
FRONT AND REAR BRAKE A CHAS MASTER CYLINDER INSPECTION 1. Inspect: Master cylinder 1 Wear/Scratches Replace the master cylinder assembly. Master cylinder body 2 Cracks /Damage Replace. Oil delivery passage (master cylinder body) Blow out with compressed air. B A Front B Rear A 2. Inspect: Master cylinder kit 1 Scratches /Wear/Damage Replace as a set. B A Front B Rear MASTER CYLINDER ASSEMBLY WARNING All internal parts should be cleaned in new brake fluid only.
FRONT AND REAR BRAKE CHAS Front brake 1. Install: Master cylinder 1 Master cylinder bracket 2 9 Nm (0.9 m kg) CAUTION: Align the end of the holder with the punch mark a on the handlebar. Tighten first the upper bolt, then the lower bolt. 2. Install: Copper washers 1 New Brake hose 2 Union bolt 3 30 Nm (3.0 m kg) WARNING Proper hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. Always use new copper washers. 3.
FRONT AND REAR BRAKE CHAS WARNING Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance. Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 4.
FRONT AND REAR BRAKE CHAS 2. Install: Clevis pin 1 Washer Cotter pin New 3. Fill: Brake reservoir Refer to “MASTER CYLINDER ASSEMBLY – Front brake”. 4. Inspect: Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3. 5. Check: Brake pedal operation A soft or spongy feeling Bleed brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in CHAPTER 3. 6. Adjust: Brake pedal height Refer to “REAR BRAKE ADJUSTMENT” in CHAPTER 3. 7.
FRONT AND REAR BRAKE CHAS FRONT BRAKE CALIPER 10 Nm (1.0 m kg) 30 Nm (3.0 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 Job name/Part name Q’ty Remarks Remove the parts in the order below. Drain Front brake caliper removal Brake fluid Cable guide Union bolt Copper washer Stay 1 1 2 Refer to “CALIPER INSTALLATION”. WARNING The brake pipe must not be disassembled. Do not loosen the bolts indicated by “ ”.
FRONT AND REAR BRAKE CHAS 6 Nm (0.6 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Disassemble the parts in the order below. Front brake caliper disassembly Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw Brake caliper piston Piston seal 1 2 2 1 2 2 1 4 8 Refer to “CALIPER DISASSEMBLY” and “CALIPER ASSEMBLY”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKE CHAS REAR BRAKE CALIPER 40 Nm (4.0 m kg) 14 Nm (1.4 m kg) 40 Nm (4.0 m kg) Order 1 2 3 4 Job name/Part name Q’ty Remarks Remove the parts in the order below. Drain Rear brake caliper removal Brake fluid Brake hose Brake hose joint Copper washer Brake caliper assembly 1 1 1 1 Refer to “CALIPER INSTALLATION”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKE CHAS 6 Nm (0.6 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Q’ty Remarks Disassemble the parts in the order below. Rear brake caliper disassembly Pad cover Retaining clip Retaining pin Pad spring Brake pad Pad shim Bleed screw Brake caliper piston Piston seal 1 2 2 1 2 2 2 2 4 Refer to “CALIPER DISASSEMBLY” and “CALIPER ASSEMBLY”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKE CHAS CALIPER DISASSEMBLY NOTE: Before disassembling the front brake caliper or rear brake caliper, drain the brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: Pistons Piston seals 1 Removal steps: Using a wood piece 2 , lock the right side piston. Blow compressed air into the hose joint opening a to force out the left side piston from the caliper body. Remove the piston seals and reinstall the piston.
FRONT AND REAR BRAKE CHAS CALIPER INSPECTION AND REPAIR Recommended brake component p replacement schedule: Brake pads As required Piston seal, dust seal Every two years Brake hoses Every two years Brake fluid Replace p only y when brakes are disassembled. WARNING All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Inspect: Caliper piston 1 Scratches /Rust/Wear Replace caliper assembly.
FRONT AND REAR BRAKE CHAS CALIPER INSTALLATION 1. Install: Front brake Brake caliper 1 (temporarily) Copper washers New Brake hose 2 Union bolt 3 30 Nm (3.0 m kg) CAUTION: When installing the brake hose on the caliper 1 , take care that the pipe touches the projection a on the brake caliper. NOTE: Make sure that the damper of the brake pipe is in contact with the front fender.
FRONT FORK CHAS FRONT FORK 23 Nm (2.3 m kg) 24 Nm (2.4 m kg) 30 Nm (3.0 m kg) 9 Nm (0.9 m kg) 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork removal Front wheel 1 2 3 4 5 6 7 Cable guide Front fender Plastic band Pinch bolt (upper bracket) Cap bolt Pinch bolt (lower bracket) Front fork (left/right) Remarks 1 1 4 2 2 2 1/1 Loosen Loosen Loosen Loosen Refer to “INSTALLATION”.
FRONT FORK CHAS 24 Nm (2.4 m kg) 30 Nm (3.0 m kg) Order 1 2 3 4 5 6 7 8 9 Job name/Part name Front fork disassembly Cap bolt O-ring Washer Fork spring Dust seal Retaining clip Damper rod bolt/Gasket Oil seal Plain washer Q’ty 1 1 1 1 1 1 1/1 1 1 7-34 Remarks Disassemble the parts in the order below. Drain the fork oil Refer to “DISASSEMBLY” and “ASSEMBLY”.
FRONT FORK CHAS 24 Nm (2.4 m kg) 30 Nm (3.0 m kg) Order 10 11 12 13 14 Job name/Part name Q’ty Inner tube/Piston metal Oil lock piece Damper rod/Damper rod spring Slide metal Outer tube 1/1 1 1/1 1 1 Remarks Refer to “DISASSEMBLY” and “ASSEMBLY”. For assembly, reverse the disassembly procedure.
FRONT FORK CHAS DISASSEMBLY NOTE: Do not reuse the front fork protector that was removed from the outer tube. When installing a new front fork protector, be sure it is not twisted and will not come off easily. 1. Remove: Dust seal 1 Retaining clip 2 Use a slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: Damper rod bolt NOTE: Loosen the damper rod bolt while holding the damper rod with the T-handle 2 and holder 1 .
FRONT FORK CHAS INSPECTION 1. Inspect: Inner fork tube 1 Outer fork tube 2 Scratches /Bends/Damage Replace. WARNING Do not attempt to straighten a bent inner fork tube as this may dangerously weaken the tube. 2. Measure: Fork spring free length a Over specified limit Replace. Fork spring free length (limit): 500 mm 3. Inspect: Cap bolt Bend/Damage Replace. ASSEMBLY 1.
FRONT FORK CHAS 2. Lubricate: Inner fork tube (outer surface) Recommended lubricant: Fork oil 10W or equivalent 3. Install: Piston metal 1 New Damper rod 2 Oil lock piece 3 4. Tighten: Damper bolt 1 30 Nm (3.0 m kg) NOTE: Tighten the damper rod bolt while holding the damper rod with the T-handle and holder. T-handle: 90890-01326 Damper rod holder: 90890-01465 5. Install: Slide metal 1 New Plain washer Use the fork seal driver weight 2 and adapter 3. 6.
FRONT FORK CHAS NOTE: Before installing the oil seal, apply the lithium soap base grease onto the oil seal lips. CAUTION: Be sure that the oil seal numbered side face upward. 7. Install: Dust seal 1 Use the fork seal driver weight. Fork seal driver weight: 90890-01367 8. Fill: Fork oil Each fork: 0.515 L For oil 10W or equivalent. After filling, slowly pump the fork up and down to distribute oil.
FRONT FORK CHAS INSTALLATION 1. Install: Front fork(s) Temporarily tighten the pinch bolts. CAUTION: Make sure that the inner tube end is flush with the top of the upper bracket. 2. Tighten: Pinch bolts (lower bracket) 1 30 Nm (3.0 m kg) 24 Nm (2.4 m kg) Cap bolts 2 Pinch bolts (upper bracket) 3 23 Nm (2.3 m kg) WARNING Make sure that the brake hoses are routed properly.
HANDLEBAR CHAS HANDLEBAR 23 Nm (2.3 m kg) 9 Nm (0.9 m kg) 26 Nm (2.6 m kg) Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Q’ty Remarks Remove the parts in the order below. Handlebar removal Band Clutch cable Clutch switch lead coupler Clutch switch Left handlebar switch Clutch lever Grip end Front brake switch lead coupler Master cylinder bracket Master cylinder assembly Collar 2 1 1 1 1 1 2 1 1 1 1 7-41 Disconnect Refer to “INSTALLATION”.
HANDLEBAR CHAS 23 Nm (2.3 m kg) 9 Nm (0.9 m kg) 26 Nm (2.6 m kg) Order 12 13 14 15 16 17 18 19 20 21 Job name/Part name Q’ty 1 1 1 2 1 4 2 1 1 1 Right handlebar switch Throttle cable housing cover Throttle cable housing Throttle cable Throttle grip Plug Handlebar holder (upper) Handlebar grip (left) Clutch lever holder Handlebar Remarks Refer to “INSTALLATION”. Refer to “INSTALLATION”. For installation, reverse the removal procedure.
HANDLEBAR CHAS INSPECTION 1. Inspect: Handlebar Bends/Crancks /Damage Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. Handlebar grip (left) replacement steps: Remove the handlebar grip. Apply a light coat of an adhesive for rubber on the handlebar end. Install the handlebar grip. NOTE: Wipe off excess adhesive with a clean rag.
HANDLEBAR CHAS 2. Install: Throttle grip 1 Throttle cable housing 2 Throttle cables 3 Throttle cable housing cover WARNING Align the projection a on the throttle cable housing with the hole b on the handlebar. 3. Install: Right handlebar switch 1 NOTE: Align the projection a on the handlebar switch with the hole b on the handlebar. 4. Install: Collar Master cylinder assembly 1 Master cylinder bracket 2 9 Nm (0.
HANDLEBAR CHAS 6. Install: Left handlebar switch 1 NOTE: Align the projection a on the handlebar switch with the hole b on the handlebar. 7. Adjust: Clutch cable free play Refer to “CLUTCH ADJUSTMENT” in CHAPTER 3. 8. Adjust: Throttle cable free play Refer to “THROTTLE CABLE ADJUSTMENT” in CHAPTER 3.
STEERING HEAD CHAS STEERING HEAD LOWER BRACKET 108 Nm (10.8 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) 1st 2 nd 48 Nm (4.8 m kg) 16 Nm (1.6 m kg) 10 Nm (1.
STEERING HEAD CHAS 108 Nm (10.8 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) 1st 2nd 48 Nm (4.8 m kg) 16 Nm (1.6 m kg) 10 Nm (1.0 m kg) Order 11 12 13 14 15 16 17 18 Job name/Part name Q’ty 1 1 1 1 1 1 1 1 Plate seal Ring nut (lower) Plate washer Lower bracket Bearing (upper) Rubber seal Bearing (lower) Dust seal Remarks Refer to “REMOVAL” and “INSTALLATION”. For installation, reverse the removal procedure.
STEERING HEAD CHAS REMOVAL 1. Remove: Ring nut (lower) 1 Use the ring nut wrench 2 . Ring nut wrench: 90890-01403 WARNING Support the lower bracket so that it may not fall down. INSPECTION 1. Wash the bearing and bearing races with a solvent. 2. Inspect: Bearings Bearing races Pitting/Damage Replace. Bearing race replacement steps: Remove the bearing races on the head pipe using long rod 1 and the hammer as shown. Install the new races. NOTE: Always replace bearings and races as a set.
STEERING HEAD CHAS INSTALLATION 1. Tighten: Ring nuts (lower and upper) Tightening steps: Tighten the ring nut (lower) 1 using the ring nut wrench 2 . Ring nut: 48 Nm (4.8 m kg) NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: 90890-01403 Turn the steering stem left and right for several times. Loosen the ring nut completely and retighten it to specification. Ring nut: 16 Nm (1.6 m kg) WARNING Do not overtighten.
REAR SHOCK ABSORBER CHAS REAR SHOCK ABSORBER 64 Nm (6.4 m kg) 64 Nm (6.4 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK” in CHAPTER 3. Rear shock absorber removal Seat 1 2 3 4 5 6 7 8 Remarks 1 1 1 1 1 1 1 1 Self locknut Plain washer Bolt Collar Cap Self locknut Bolt Rear shock absorber For installation, reverse the removal procedure.
REAR SHOCK ABSORBER CHAS HANDLING NOTES WARNING This shock absorber contains highly compressed nitrogen gas. Rear and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 1. Do not tamper or attempt to open the cylinder assembly. 2. Do not subject shock absorber to an open flame or other high heat. This may cause the unit to explode due to excessive gas pressure.
SWINGARM AND DRIVE CHAIN CHAS SWINGARM AND DRIVE CHAIN 3 7 Nm (0.7 m kg) 90 Nm (9.0 m kg) 35 Nm (3.5 m kg) 7 Nm (0.7 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “REAR WHEEL, BRAKE DISC AND DRIVE SPROCKET”. Refer to “REAR SHOCK ABSORBER”. Refer to “ENGINE ASSEMBLY” in CHAPTER 4.
SWINGARM AND DRIVE CHAIN CHAS 7 Nm (0.7 m kg) 90 Nm (9.0 m kg) 35 Nm (3.5 m kg) 7 Nm (0.7 m kg) Order 8 9 10 11 12 13 14 Job name/Part name Q’ty Remarks 1 1 1 3 2 1 2 Swingarm Drive chain Chain protector Collar Thrust cover Bush Bearing For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN CHAS INSPECTION 1. Measure: 10 link length (drive chain) a Out of specification Replace drive chain. 10 link length limit: 159 mm NOTE: For measurement make the chain tense by finger. 10 link length is a measurement between the insides of the 1 and 11 rollers as shown. Two or three different 10 link length should be measured. 2. Clean: Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.
SWINGARM AND DRIVE CHAIN CHAS 4. Lubricate: Drive chain Drive chain lubricant: SAE 30 50W motor oil or chain lubricants suitable for “O-ring” chains 5. Inspect: Drive chain stiffness Stiff Clean and lubricate or replace. 6. Check: Swingarm free play Inspection steps: Check the tightening torque of the pivot shaft (swingarm) 1 securing nut. 90 Nm (9.0 m kg) Check the swingarm side play A by moving it from side to side.
CHAS
ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTING A SWITCH SHOWN IN THE MANUAL . . . . . . . . . . . . . . . SWITCH CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Ignitor unit Starting circuit cut-off relay Rectifier / regulator Main switch Thermo switch Thermo unit Flasher relay Starter relay 9 10 11 12 13 14 15 Fuse box Battery Rear brake switch Sidestand switch Neutral switch Ignition coil Horn 8-1 ELEC
SWITCH INSPECTION ELEC SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch. Pocket tester: 90890-03112 NOTE: Set the pocket tester to “0” before starting the test. The pocket tester should be set to the “ 1” Ω range when testing the switch for continuity. Turn the switch on and off a few times when checking it.
SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled.
8-4 5 Main fuse 8 Starting circuit cut-off relay 9 Neutral switch 10 Sidestand switch 12 Ignitor unit 13 Ignition coil 14 Spark plug 45 Engine stop switch 47 Ignition fuse 4 Battery 1 A.C.
IGNITION SYSTEM ELEC TROUBLESHOOTING IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK) Procedure Check: 1. Fuse (main and ignition) 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Pickup coil resistance 8. 9. 10. 11. 12. NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank 5) Air filter case S Use the following special tool(s) in this troubleshooting.
IGNITION SYSTEM ELEC : 3. Spark plug Standard spark plug: DPR8EA-9/X24EPR-U9 NGK /NIPPONDENSO S Check the spark plug condition. S Check the spark plug type. S Check the spark plug gap. Refer to “SPARK PLUG INSPECTION” in CHAPTER 3. Spark plug gap: 0.8 X 0.9 mm INCORRECT CORRECT Repair or replace spark plug. 4. Ignition spark gap S Disconnect the spark plug cap from spark plug. S Connect the ignition checker 1 as shown. 2 Spark plug cap S Turn the main switch to “ON”.
IGNITION SYSTEM S Check the spark plug cap for specified resistance. ELEC OUT OF SPECIFICATION Spark plug cap resistance: 10 kΩ at 20_C Replace spark plug cap. MEETS SPECIFICATION Tester (+) lead Red/Black terminal 1 Tester (–) lead Orange (Gray) terminal 2 6. Ignition coil resistance S Disconnect the ignition coil connector from the wire harness. S Connect the pocket tester (Ω 1) to the ignition coil.
IGNITION SYSTEM ELEC : 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal. Tester (+) lead Green/White terminal 1 Tester (–) lead Blue/Yellow terminal 2 S Check the pickup coil for specified resistance. Pickup coil resistance: 192 X 288 Ω at 20_C (Green/White – Blue/Yellow) OUT OF SPECIFICATION MEET SPECIFICATION Replace pickup coil. 8. Main switch INCORRECT Refer to “SWITCH INSPECTION”.
IGNITION SYSTEM : 12. Wiring connection S Check the entire ignition system for connections. Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION CORRECT Correct. Replace ignitor unit.
3 4 5 6 7 8 9 10 35 45 46 47 Main switch Battery Main fuse Starter relay Starter motor Starting circuit cut-off relay Neutral switch Sidestand switch Clutch switch Engine stop switch Start switch Ignition fuse ELECTRIC STARTING SYSTEM 8-10 ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM ELEC 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 and the main switch are both closed, the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed). or if The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM ELEC TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. Procedure Check: 1. Fuse (main and ignition) 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. 9. 10. 11. 12. NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank 5) Air filter case S Use the following special tool(s) in this troubleshooting.
ELECTRIC STARTING SYSTEM : ELEC : WARNING This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. 3. Starter motor S Remove the starter motor from the engine. S Check the starter motor. Refer to “INSPECTION AND REPAIR”. DOES NOT MOVE MOVES S Repair or replace starter motor. Refer to “INSPECTION AND REPAIR”. 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness.
ELECTRIC STARTING SYSTEM ELEC : 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 1 Battery (–) terminal Blue/White terminal 2 NO CONTINUITY Tester (+) lead Red terminal 3 Tester (–) lead Black terminal 4 S Check the starter relay for continuity. Replace starter relay. CONTINUITY 6. Main switch INCORRECT Refer to “SWITCH INSPECTION”.
ELECTRIC STARTING SYSTEM ELEC : 10. Clutch switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace clutch switch. 11. Start switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace handlebar switch (right). 12. Wiring connection. S Check the entire starting system for connections. Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION Correct.
ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) Order Job name/Part name Q’ty Remove the parts in the order below. Refer to “ENGINE ASSEMBLY” in CHAPTER 4. Starter motor removal Exhaust pipe and muffler assembly 1 2 Starter motor/O-ring Starter motor lead 1/1 1 Disassemble the parts in the order below. Starter motor disassembly 1 2 3 4 5 Front bracket Washer kit Rear bracket Washer kit Brush seat/Brush 1 6 Armature coil Remarks 1 1 2 1 1/1 Refer to “ASSEMBLY”.
ELECTRIC STARTING SYSTEM ELEC Inspection and repair 1. Inspect: Commutator Dirty Clean it with #600 grit sandpaper. 2. Measure: Commutator diameter a Out of specification Replace starter motor. Commutator wear limit: 27 mm 3. Measure: Mica undercut b Out of specification Scrape the mica to proper value using a hacksaw blade can be ground to fit. Mica undercut: 0.7 mm NOTE: The mica insulation of the commutator must be undercut to ensure proper operation of commutator. 4.
ELECTRIC STARTING SYSTEM ELEC 5. Measure: Brush length a Out of specification Replace. Brush length limit: 5 mm 6. Measure: Brush spring force Fatigue/Out of specification Replace as a set. Brush spring force: 570 X 920 g 7. Inspect: Bearing Roughness Replace. Oil seal O-rings Bushing Wear/Damage Replace. Assembly Reverse the “Removal” procedure. Note the following points. 1. Install: Brush seat 1 NOTE: Align the projection a on the brush seat with the slot on the housing. 2.
ELECTRIC STARTING SYSTEM ELEC 3. Install: Gasket 1 New Yoke 2 Washer kit 3 Gasket 4 New Front bracket 5 O-ring 6 New NOTE: Align the match marks a on the yoke with the match marks b on the brackets.
1 2 4 5 A.C.
CHARGING SYSTEM ELEC TROUBLESHOOTING THE BATTERY IS NOT CHARGED. Procedure Check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connection (entire charging system) NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank S Use the following special tool(s) in this troubleshooting. Engine tachometer: 90890-03113 Pocket tester: 90890-03112 1. Fuse (main) NO CONTINUITY Refer to “SWITCH INSPECTION”.
CHARGING SYSTEM ELEC 3. Charging voltage Connect the engine tachometer to spark plug lead #1. Connect the pocket tester (DC 20 V) to the battery. Tester (+) lead Battery (+) lead Tester (–) lead Battery (–) lead Start the engine, accelerate to about, 5,000 r/min then check the measured voltage. Check battery voltage. Charging voltage = measured voltage – terminal voltage: Difference of 0.5 2.5 V MEETS SPECIFICATION NOTE: Use a fully charged battery. Replace battery.
CHARGING SYSTEM : 5. Wiring connection S Check the entire starting system for connections. Refer to “CIRCUIT DIAGRAM”. POOR CONNECTION CORRECT Correct. Replace rectifier/regulator.
3 4 5 19 21 25 26 30 31 32 39 40 48 Main switch Battery Main fuse Meter light High beam indicator light Headlight Auxiliary light Lights switch Dimmer switch Pass switch Tail/brake light Headlight fuse Diode LIGHTING SYSTEM 8-24 ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM
LIGHTING SYSTEM ELEC TROUBLESHOOTING HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT, AUXILIARY LIGHT AND/OR METER LIGHT DO NOT COME ON. Procedure Check: 1. Fuse (main and head) 2. Battery 3. Main switch 4. Lights switch/Dimmer switch 5. Pass switch 6. Wiring connection (entire lighting system) NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank 5) Air filter case S Use the following special tool(s) in this troubleshooting.
LIGHTING SYSTEM ELEC : 4. Lights switch/Dimmer switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Lights switch/Dimmer switch are faulty, replace handlebar switch (left). 5. Diode S Remove the diode from the wire harness.
LIGHTING SYSTEM ELEC LIGHTING SYSTEM CHECK 1. Headlight and high beam indicator light does not come on. 1. Voltage Headlight: Tester (+) lead Yellow 1 or Green 2 lead. Tester (–) lead Black 3 lead. High beam indicator light: Tester (+) lead Yellow 4 lead. Tester (–) lead Black 5 lead. B Meter connector Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers. A When dimmer switch is “LO” position. B When dimmer switch is “HI” position. Headlight connector.
LIGHTING SYSTEM ELEC 2. Meter light does not come on. 1. Voltage Connect the pocket tester (20 V) to the bulb socket coupler. Tester (+) lead Blue terminal 1 Tester (–) lead Black terminal 2 Turn the main switch to “ON”. Turn the lights switch to “ON” or “PO” position. Check for voltage (12 V) on the “Blue” lead at the bulb socket connector. OUT OF SPECIFICATION MEETS SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty, repair. This circuit is good. 3.
LIGHTING SYSTEM ELEC 4. Auxiliary light does not come on. 1. Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead Blue/Red lead Tester (–) lead Black lead 2 1 Turn the main switch to “ON”. Turn the light switch to “ON” or “PO” position. Check for voltage (12 V) on the “Blue/Red” lead at the bulb socket connector. OUT OF SPECIFICATION MEETS SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty, repair. This circuit is good.
LIGHTING SYSTEM 8-30 ELEC
SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 8-31 ELEC
SIGNAL SYSTEM 3 4 5 8 9 17 20 22 23 24 28 Main switch Battery Fuse (main) Starting circuit cut-off relay Neutral switch Tachometer Neutral indicator light Turn indicator light Rear flasher light Front flasher light Horn switch 29 33 34 39 40 41 42 44 Horn Turn switch Flasher relay Tail / brake light Headlight fuse Rear brake switch Signal system fuse Front brake switch 8-32 ELEC
SIGNAL SYSTEM ELEC TROUBLESHOOTING S FLASHER LIGHTS, BRAKE LIGHT AND/OR INDICATOR LIGHTS DO NOT COME ON. S HORN DOES NOT SOUND. Procedure Check: 1. Fuse (main, head and signal) 2. Battery 3. Main switch 4. Wiring connection (entire signal system) NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank 5) Air filter case S Use the following special tool in this troubleshooting. Pocket tester: 90890-03112 1.
SIGNAL SYSTEM ELEC : 3. Main switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace main switch. 4. Wiring connection S Check the entire signal system for connections. Refer to “WIRING DIAGRAM”. POOR CONNECTION CORRECT Correct. Check condition of each circuit for signal system. Refer to “SIGNAL SYSTEM CHECK”. SIGNAL SYSTEM CHECK 1. Horn does not sound. 1. Horn switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace handlebar switch (left). 2.
SIGNAL SYSTEM : 3. Voltage S Connect the pocket tester (DC 20 V) to the horn at the “Black” terminal. Tester (+) lead Black lead 1 Tester (–) lead Frame ground S Turn the main switch to “ON”. S Push the horn switch. S Check for voltage (0 V) on the “Black” lead at the horn terminal. OUT OF SPECIFICATION MEETS SPECIFICATION Replace horn. Adjust or replace horn. 2. Brake light does not come on. 1. Brake switch (front, rear) INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace brake switch. 2.
SIGNAL SYSTEM S Turn the main switch to “ON”. S Turn brake lever is pulled in or brake pedal is stepped down. S Check for voltage (12 V) on the “Yellow” lead at the bulb socket connector. ELEC OUT OF SPECIFICATION MEETS SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty, repair. This circuit is good. 3. Flasher light and/or turn indicator light does not blink. 1. Turn switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace handlebar switch (left). 2.
SIGNAL SYSTEM ELEC : 3. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay lead. Tester (+) lead Brown/White terminal 1 Tester (–) lead Frame ground S Turn the main switch to “ON”. S Check for voltage (12 V) on the “Brown/White” lead at the flasher relay terminal. OUT OF SPECIFICATION MEETS SPECIFICATION Replace flasher relay. 4. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector.
SIGNAL SYSTEM ELEC 4. Neutral indicator light does not come on. 1. Neutral switch NO CONTINUITY Refer to “SWITCH INSPECTION”. CONTINUITY Replace neutral switch. 2. Voltage Connect the pocket tester (DC 20 V) to the bulb socket coupler. Tester (+) lead Brown terminal 1 Tester (–) lead Sky blue terminal 2 Turn the main switch to “ON”. Check for voltage (12 V). OUT OF SPECIFICATION MEETS SPECIFICATION Wiring circuit from main switch to bulb socket connector is faulty, repair.
8-39 42 Signal system fuse 37 Thermo switch 38 Radiator fan fuse 15 Thermo unit 18 Water temperature meter 36 Fan motor 5 Fuse (main) 3 Main switch 4 Battery COOLING SYSTEM ELEC COOLING SYSTEM CIRCUIT DIAGRAM
COOLING SYSTEM ELEC TROUBLESHOOTING S FAN MOTOR DOES NOT MOVE. S WATER TEMPERATURE METER DOES NOT MOVE, WHEN ENGINE IS WARM. Procedure Check: 1. Fuse (main, signal and fan) 2. Battery 3. Main switch 4. Fan motor 5. Thermo switch 6. Thermo unit 7. Water temperature 8. Wiring connection (entire cooling system) NOTE: S Remove the following parts before troubleshooting. 1) Seat 2) Side cowlings 3) Side covers 4) Fuel tank 5) Air filter case S Use the following special tool in this troubleshooting.
COOLING SYSTEM ELEC : 3. Main switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Main switch is faulty, replace it. 4. Fan motors S Disconnect the fan motor couplers. S Connect the battery (12 V) as shown. Battery (+) lead Blue lead 1 Battery (–) lead Black lead 2 DOES NOT MOVES S Check the fan motors for operation. Fan motor(s) is faulty, replace it(them).
COOLING SYSTEM ELEC : WARNING 5. Thermo switch S Handle the thermo switch with special care. S Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replace. S Remove the thermo switch from the radiator. S Connect the pocket tester (Ω 1) to the thermo switch 1 . S Immerse the thermo switch in the water 2 . S Check the thermo switch for continuity. Note temperatures while heating the water with the temperature gauge 3 . BAD CONDITION Replace thermo switch.
COOLING SYSTEM : 6. Thermo unit S Remove the thermo unit from the radiator. S Connect the pocket tester (Ω 10) to the thermo unit 1 . S Immerse the thermo unit in the water 2 . S Measure the resistance. Thermo unit resistance: 80_C: 47 X 53 Ω 100_C: 26 X 30 Ω WARNING S Handle the thermo unit with special care. S Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced. BAD CONDITION GOOD CONDITION Replace thermo unit. 7.
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS ELEC TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS Revolution ( 103 r / min) Tachometer display Engine speed time (seconds) CIRCUIT DIAGRAM If the needle of the tachometer shows the following pattern while the engine is running, the throttle position sensor circuit is broken, shorted, or the TPS (throttle position sensor) is locked. In that case, it would be best to inspect it. 1 0 rpm – 3 seconds 2 3,000 rpm – 2.
TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS ELEC TROUBLESHOOTING IF THE TACHOMETER’S TPS (THROTTLE POSITION SENSOR) SELF-DIAGNOSIS OPERATES. Procedure Check: 1. TPS (throttle position sensor) 2. Wire harness NOTE: Use the following special tool(s) in this troubleshooting. Pocket tester: 90890-03112 1. TPS (throttle position sensor) Disconnect the throttle position sensor coupler from the wire harness. Connect the pocket tester (Ω 1) to the throttle position sensor.
ELEC
TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1 9-1 9-2 POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . .
TRBL SHTG
STARTING FAILURE/HARD STARTING TRBL SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. If 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 IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Worn, damaged or seized cylinder Improperly sealed valve Improperly contacted valve and valve seat Improper valve timing Broken valve spring TRBL SHTG Piston and piston rings Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring S
FAULTY GEAR SHIFTING/ CLUTCH SLIPPING/DRAGGING TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “Clutch dragging.
OVERHEATING/FAULTY BRAKE/ FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION TRBL SHTG OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor main jet (improper setting) Improperly adjusted fuel level Clogged air filler element Compression system Heavy carbon build-up Engine oil Incorrect oil level Improper oil viscosity Inferior oil quality.
INSTABLE HANDLING/ FAULTY LIGHTING AND SIGNAL SYSTEM TRBL SHTG INSTABLE HANDLING INSTABLE 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 bush Bent or damaged Rear shock absorber Fatigued spring Oil and gas leakage Tires Uneven tire pressures on both sides Incorrect tire pressure Unevenly w
FAULTY LIGHTING AND SIGNAL SYSTEM TRBL SHTG HORN IS INOPERATIVE Faulty battery Faulty fuse Faulty main and/or horn switch Improperly adjusted horn Faulty horn Broken wire harness FLASHER KEEPS ON Faulty flasher relay Bulb burnt out FLASHER WINKS QUICKER Improper bulb Faulty flasher relay Bulb burnt out 9-6
TDM850 ’96 WIRING 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 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 COLOR CODE B ...... Br . . . . . Ch . . . . Dg . . . . G ..... Gy . . . . Black Brown Chocolate Dark green Green Gray L ...... Lg . . . . . O ..... R...... Sb . . . . . W ..... Blue Light green Orange Red Sky blue White Y ...... B/L . . . . B/R. . . . B/W . . . B/Y . . . . Br / L . . .
