VMXl2N, NC~K, KC
LIT-11616-10-12
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the VMX12H/VMX12HC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. I VMX12N SERVICE MANUAL: 2WE-28197-10 VMXl2F SUPPLEMENTARY SERVICE MANUAL: 2WE-28197-11 I 1 I VMX 12H/VMX12HC SUPPLEMENTARY SERVICE MANUAL 01995 by Yamaha Motor Co. Ltd. 1st Edition, July 1995 All rights resewed.
NOTICE This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbo Is" 1st title This is a chapter with its symbol on the upper right of each page. 2nd title This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.) 3rd title This is a final title.
EB003000 ILLUSTRATED SYMBOLS Illustrated symbols to are printed on top right of each page and indicate the subject of each chapter. General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text.
. .- CONTENTS GENERAL INFORMATION .............................................................................. MOTORCYCLE IDENTIFICATION............................................................ VEHICLE IDENTIFICATION NUMBER ................................................ FRAME SERIAL NUMBER .................................................................. ENGINE SERIAL NUMBER ................................................................. SPECIAL TOOLS ............................................
MOTORCYCLE IDENTIFICATION GEN GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFlCATlON NUMBER The vehicle identification number is stamped into the right side of the steering pipe. Starting serial number: JYA2WEE0 TA050101 (USA) JYA2WFC0 TA012101 (California) The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state.
SPECIAL TOOLS SPECIAL TOOLS GEN Refer to the list provided to avoid errors when placing an order. 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. YM- Except for P/N.
GENERAL SPECIFICATIONS/ MAINTENANCE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS VMX12 Model 3JPM (USA) 3JPN (California) 3LRA (EUR) 2WE-050101 (USA) 2WF-012101 (California) 2EN-042101 (EUR) JYA2WEE0*TA050101 (USA) JYA2WFC0 * TA012 10 1 ( California) 2EN-042101 (EUR) Model code: Engine starting number: Vehicle identification number: Frame starting number: Basic weight: With oil and full fuel tank 283 kg (624 Ib) (USA) 284 kg (626 Ib) (California) 281 kg (620 Ib) (EUR) MAINTENANCE SPECIFICATION
MAINTENANCE SPECIFICATIONS ELECTRICAL Model Rectifier: Model / manufacturer Capacity Withstand Voltage Electric starter system: TYPe Starter motor: Model / manufacturer output Brush overall length Commutator diameter Mica undercut Starter switch: Model / manufacturer Amperage rating Coil winding resistance Thermostatic switch : Model / manufacturer VMX12 SH662-12 / SHINDENGEN 25 A 200 v Constant mesh type SM-13 / MITSUBA 0.65 kW 12.5 mm (0.49 in) <5.0 mm (0.20 in) 28 mm (1.
ENGINE OIL REPLACEMENT PERIODIC INSPECTION AND ADJUSTMENT ENGINE ENGINE OIL REPLACEMENT 1.Start the engine and let it warm up for severa I min 2.Stop the engine and place an oil pan under the drain bolt. 3.Remove: Oil filler cap 4. Remove: Drain bolt (with gasket) Drain the crankcase of its oil. the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.
ENGINE OIL REPLACEMENT Drain bolt: 43Nm(4.3m-kg,31ft• Ib) NOTE: Always use a new gasket. I 30 0 40 5 50 10 7.Fill: Crankcase 60" F Recommended oil: At 5°C (40°F)or higher SAE 20W40 type SE motor oil At 15°C (60°F)or lower SAE 10W30 type SE motor oil Oil quantity: Total amount: 4.7 L (4.1 Imp qt, 5.0 US qt) Periodic oil change: 3.5 L (3.1 Imp qt, 3.7 US qt) With oil filter replacement: 3.8 L (3.3 Imp qt, 4.
INSPECTION AND REPAIR ENGINE OVERHAUL INSPECTION AND REPAIR CRANKSHAFT AND CONNECTING ROD 1.Measure: Runout (crankshaft) Out of specification Replace. Runout: Less than 0.03 mm (0.0012 in) 2.1 nspect: Main journal surfaces Crank pin surfaces Bearing surfaces Wear/Scratches Replace. 3. Measure: Oil clearance (main journal) Replace bearing. Out of specification 0.020 ~ 0.038 mm (0.0008 ~ 0.0015 in) Measurement steps: Do not interchange the bearings and connecting rod.
IN SPEC TIO N A N D R EPA IR a piece of Plastigauge® journal. on each m ain N O TE: D o not put the Plastigauge® over the oil hole in the m ain journal of the crankshaft, installthe low er half of the bearings into the crankcase (low er) and assem ble the crankcase halves. N O TE: Align the projection of the bearing w ith the notch in the crankcase. D o not m ove the crankshaft until the oil clearance has been com pleted.
INSPECTION AND REPAIR the bearings, crank pins and bearing portions of the connecting rods. the upper half of the bearing into the connecting rod and lower half of the bearing into the connecting rod cap. NOTE: Align the projection of the bearing with the notch of the cap and connecting rod. /--- a piece of Plastigauge® on the crank pin. the connecting rod halves. NOTE: Do not move the connecting rod or crankshaft until the oil clearance measurement has been completed.
IN SPEC TIO N A N D R EPA IR M ain journal bearing C rank pin bearing P 2 J,) P,) Selection of bearings: Exam ple 1: M ain journal bearing “J,” on the crankcase is “6” and “1” on the crankw eb, then the bearing size for is: Exam ple 2: C rank pin bearing on the connecting rod is “4” and “2” on the crankw eb, then the bearing size for is:
INSPECTION AND REPAIR BALANCER SHAFT 1.Measure: Oil clearance (balancer shaft bearing) Out of specification Replace bearing. Oil clearance: 0.020 0.048 mm (0.0008 0.002 in) Measurement steps: the bearings, balancer shaft and bearing portions of the crankcase. the crankcase (upper) o n a bench in an upside down position. the upper half of the bearings and the balancer shaft into the crankcase (upper). a piece of Plastigauge® on each balancer shaft journal.
INSPECTION AND REPAIR 2.Select: Balancer shaft bearing I J5 J6 I Selection of bearings: Example: o n the crankcase is "6" and "2" o n the balancer shaft, then the bearing size for "J," is: Bearing size of Crankcase - Balancer shaft No.
MIDDLE GEAR SERVICE Universaljoint Dust seal Housing O-ring Bearing Collapsible collar Bearing Middle drive shaft Middle driven pinion gear Spring seat Damper spring Damper cam Middle drive pinion gear @Thrust washer Retainer - 13-
SHAFT DRIVE CHASSIS SHAFT DRIVE Dust cover Bearing housing Ring gear stopper shim Ring gear stopper O-ring Oil seal Ring gear shim Bearing Ring gear Thrust washer Bearing Oil seal Collar Bearing Bearing Drive pinion gear Final drive gear shim Bearing Bearing retainer O-ring Oil seal @Coupling gear Spring Circlip Drive shaft Oil seal 27Washer Circlip Bearing Circlip Universal joint 23 Nm (2.
VAMAHA MOTOR CO.,LTD. PRINTED IN U.S.A.
E LIT-11616-08-77
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the VMX12E/VMX12EC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. VMX12N/VMX12NC SERVICE MANUAL: LIT-11616-04-67 VMX12S/VMX12SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-04-98 VMX12U/VMX12UC SUPPLEMENTARY SERVICE MANUAL: LIT-I1616-06-08 VMXl2E/VMXl2EC SUPPLEMENTARY SERVICE MANUAL © 1992 by Yamaha Motor Co., Ltd.
NOTICE /- This manual was written by Yamaha Motor Company Ltd. primarilyfor use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so persons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe.
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1 st title : This is a chapter with its symbol on the upper right of each page. 2nd title : This title appearsonthe upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspectionand adjustment" the 3rd title appears.) 3rd title : This is a final title.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols to are designed as thumb tabs to indicate the chapter's number and content. General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text.
CONTENTS GENERAL INFORMATION .............................................................................. MOTORCYCLE IDENTIFICATION .............................................................. VEHICLE IDENTIFICATION NUMBER .................................................. ENGINE SERIAL NUMBER ................................................................... SPECIAL TOOL ........................................................................................... FOR CHASSIS SERVICE ....................
MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number stamped into the steering head pipe. Starting serial number: ........... ......... is PA035101 PA008101 NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. ENGINE SERIAL NUMBER The engine serial number the left side of the engine.
SPECIAL TOOLS Referto the list providedto avoid errorswhen placing an order. SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and 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.
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number: Engine starting number: Vehicle identification number: Minimum turning radius: Carburetor: Ty pe/Manufacturer Tire: Type Size (F) Size (R) Wear Iim it Tire pressure (cold tire): Basic weight: With oil and full fuel tank Maximum load* Cold tire pressure: Up to 90 kg (198lb) load* /--- 2WE-035101 2WF-008101 I BDS 35 x 4/MlKUNl Tubeless 110/90V 18 B RIDGESTONE G525AW/DUNLOP F20 150/90V 15 BRIDGESTONE G526BW/DUNLOP K525
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE VMX12E Carburetor: I.D. Mark Main jet Main air jet Jet needle Needle jet Pilot jet Pilot air jet Pilot screw Pilot outlet Bypass (M.J.) (M.A.J.) (J.N.) (N.J.) (P.J.) (P.A.J.1) (P.S.) (P.O.) (B.P.l) (B.P.2) (B.P.3) (V.S.) (G.S.1) (G.S.2) Valve seat size Starter jet Fuel level Engine idling speed Vacuum pressure at idling speed VMX12EC 1FK01 #152.5 02.0 5EZ43 Y-0 #37.5 #9 0 Preset 0.9 0.8 0.8 0.9 1.5 #45 #0.8 15~17 mm (0.59~0.
MAINTENANCE SPECIFICATIONS LECTRICAL VMX12E/EC Model T.C.I.: Pickup coil resistance (color) T.C.I. Unit-modeI/Manufacturer A.C. magneto: M o d e l / Ma nufacturer Normal output 81 at 20°C (68°F) (Black- Orange) TID14-93/HITACHI HI FL 13 14V, 25A at 5,000 r/min 1 3 2 Engine speed /-- 0.
FRONT A N D REAR BRAKE CHASSIS FRONT AND REAR BRAKE Air bleed screw Retaining pin Dust seal Piston seat Piston Brake pad Pad spring Caliper assembly Brake disc The arrow mark on the pad spring must point in the disc rotating direction.
FRONT FORK CHAS FRONT FORK Front fork assembly Inner fork tube Piston metal Dust cover Retaining clip Oil seal Seal spacer Slide metal Outer fork tube Oil lock piece Damper rod Fork spring Spring seat Collar Cap bolt Fork cap CAPACITY: 619 (21.8 Imp oz, 20.9 US E Yamaha Fork Oil 1Owt or equivalent STD. AIR PRESSURE: 39.2 (0.4 5.7 psi) MIN. TO MAX. AIR PRESSURE: 39.2 98.1 (0.4 1.0 5.7 14.2 psi) 23 N m (2.
FRONT FORK REMOVAL Securely support t h e motorcycle so there is no danger of it falling over. 1. Place the motorcycle on a level place. 2.Elevate the front wheel by placing suitable stand under the engine. 3. Remove: Caliper assembly Brake hose holder 4. Disconnect: Speedometer cable NOTE: Do not depress the brake lever w h e n the wheel is off the motorcycle otherwise the brake pads will be forced shut. 5. Loosen: Pinch bolt (wheel axle) 6. Remove: Wheel axle Front wheel assembly 7.
FRONT FORK 9. Loosen: Pinch bolt Cap bolt Pinch bolts I (handle crown) (under bracket) Support the fork before loosening the pinch bolts. DISASSEMBLY 1. Remove: Cap bolt Spacer Spring seat Spring 2. Drain: Fork oil 3. Remove: Dust seal Retaining clip Use a thin slotted head screw driver. Take care not to scratch the inner tube. 4. Remove: Bolt (damper rod) Copper washer NOTE: Loosen the bolt (damper rod) while holding the damper rod with the T-handle and holder.
FRONT FORK Removal steps: Hold the fork leg horizontally. • Clamp the caliper mounting boss of the outer tube securely in a vise with soft jaws. Pull out the inner fork tube from the outer tube by forcefully, but carefully, with drawing the inner tube. • Excessive force will damage the oil seal and/or the bushes. Damage oil seal and bushing m u s t b e replaced. Avoid bottoming t h e innert u b e i nthe outer tube during t h e above procedure, as the oil lock piece will b e damaged. 6.
FRONTFORK 3. Inspect: Damper rod Replace. Wear/Damage Contamination Blow out all oil passages with compressed air. 4. Inspect: Oil lock piece O-ring (cap bolt) Wear/Damage Replace. ASSEMBLY Reverse the "DISASSEMBLY" procedure. Note the following points. NOTE: In front fork reassembly, be sure to use following new parts. * Piston metal * Slide metal Oil seal Dust seal Make sure that all components are clean before reassembly. 1.
FRONTFORK 2. Lubricate: Inner fork tube (outer surface) Recommended lubricant: Fork oil or equivalent 3. Install: Piston metal Oil lock piece 4. Tighten: Bolt (damper rod) Bolt (damper rod): 62 Nm (6.2 m kg, 45 ft lb) LOCTITE® NOTE: Tighten the bolt (damper rod) while holding the damper rod with theT-handle and holder. ‘ I 5.
FRONT FORK I I 6.Install: Retaining clip NOTE: Fit the retaining clip correctly in the groove in the outer tube. 8.Fill: Fork oil (21.8 Imp oz,20.9 US oz) Fork oil 10w or equivalent after filling, slowly pump the fork up and down to distribute oil. I Oil level: 123 mm (4.8 in) from the top of inner fork tube fully compressed without spring. NOTE: Place the front fork on upright position. 9.
FRONT FORK INSTALL ON Reverse the “REMOVAL” procedure. Note the following points. Front Temporary tighten the pinch bolts. NOTE: Be sure the inner fork tube end is flush with the top of the handle crown. 2. Tighten Pinch bolts (under bracket) Cap bolt (front fork) • Pinch holt ,handle crown) Pinch bolt (lower bracket): 23 Nm (2.3 m kg, 17 ft Cap bolt (front fork): 23 Nm (2.3m kg, 17 ft Pinch bolt (handle crown): 23 Nm (2.3 m kg, 17 ft . 3.
FRONT FORK 6. Install: Caliper assembly Brake hose holder Speedometer cable Bolt (caliper bracket): 35 Nm (3.5 m kg, 25 ft Ib) I - Make sure that the brake hose are routed properly.
CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM I I -1
CIRCUIT DIAGRAM Reed switch "TURN" switch "TURN" indicator light Front/Rear brake switch TaiI/Brake light Horn "HORN" switch Temperature meter Thermo unit "FUEL" indicator light Fuel sender unit Tachometer Fuse (FAN) Thermo switch Fan motor Fuse (HEAD) Control unit Servo motor "LIGHTS" (Dimmer) switch Head light "HIGH BEAM" indicator light Meter light Auxiliary light Battery A.C.
IGNITION SYSTEM IGNITION SYSTEM DIGITAL IGNITION CONTROL SYSTEM DESCRIPTION The electronic ignition that sparksthe engine is computer controlled and operated by the digital CPU (microprocessor). It has a preprogramed ignition advance curve. This programed advance curve closely matches the spark timing to the engine's ignition requirements. Only one pickup coil is needed to meet the requirements of the digital ignitor unit. The digital ignitor also includes the control unit for the electric fuel pump.
7 VMX12E/EC WIRING DIAGRAM Clutch switch 'LIGHTS' (Dimmer) switch 'HORN' switch 'TURN' switch Temp.
VAMAHA MOTOR CO.,LTD. PRINTED IN U.S.A.
I LIT-I1616-06-08
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the VMX12U/UC. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual: VMX12N/NC Service Manual: LIT-11616-04-67 VMX12S/SC Supplementary Service Manual: LIT-11616-04-98 VMX12U/UC SUPPLEMENTARY SERVICE MANUAL © 1987 by Yamaha Motor Corporation U.S.A. 1st Edition, August 1987 All rights reserved.
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.
ILLUSTRATED SYMBOLS (Refer to the illustration) lo Illustrated symbols to are designed as thumb tabs t o indicate the chapter‘s number and content. General information Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Appendices Illustrated symbols to are used t o identify the specifications appearing.
MOTORCYCLE IDENTIFICATION GENERAL INFORMAT ION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number i s stamped into the steering head pipe. NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. Starting Serial Number: ........ JYA2WEE0 .......JYA2WFC0 VMX12U VMX12UC ENGINE SERIAL NUMBER The engine serial number is stamped into the left side of the engine.
SPECIF ION APPENDICES FICATIONS GENERAL Model Model Code Number Engine Starting Number Vehicle Identification Number 2WE 2WE-000101 JYA2W E EO Basic Weight: Weight Oil and Full Fuel Tank 283 (624 283 216 (624 (476 Tire Pressure (Cold Tire): Basic Weight: With Oil and Full Fuel Tank Maximum Load* Cold Tire Pressure: Up t o 90 90 (198 (198 J 01 284 (626 2WF 2WF-000101 284 215 235 Load* (626 (474 255 Maximum Load* High Speed Riding Brake: Front Operation Rear Operation Brake Fluid (2
SPECIFICATION Model Exhaust "A" < Limit > Exhaust < Limit > Camshaft 36.25 36.35 mm (1.427 1.431 in) 28.02 28.12 mm (1.103 1.107 in) 27.97- 28.07 mm (1.101 27.87 mm (1.097 in) > 0.03 mm (0.0012 in) 1.105 in) < 36.15 mm (1.423 in) > < 27.92 mm (1.099 in) > Limit Carburetor: I.D.
TO IWATA, JAPAN PRINTED IN U.S.A.
LIT-1
.- FOREWORD Service Manual: LIT-11616-04-67 VMX 1 SUPPLEMENTARY SERVICE MANUAL 1985 by Yamaha Motor Corporation U.S.A. 1 Edition, September 1985 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in U.S.A.
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.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols to are designed as t h u m b tabs to indicate the chapter's number and content. General information Periodic inspection and adjustment Engine system Carburetion @Electrical Illustrated symbols to are used identify t h e specifications appearing.
MOTORCYCLE I GENERAL INFORMATION RCYCLE I DENT I F ION VEHICLE IDENTIFICATION NUMBER T h e vehicle identification number is stamped into t h e steering head pipe. NOTE: T h e vehicle identification number is used t o i d e n t i f y your motorcycle and m ay be used to register your motorcycle with t he licensing a u t h o r i t y in your state. VMX VMX Serial Number: UTOO GAOOOl01 GAOOOl01 ....... ......
SPECIFICATIONS APPENDICES SPECIFICATIONS GENERAL FICATIONS VMX Model Model Code Number Engine Starting Number Vehicle Identification 1UT 1UT-000101 Dimensions: Overall Length Overall Width Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: Weight Oil and Full Fuel Tank Minimum Turning Radius: Engine: Engine Type Cylinder Arrangement Displacement Bore x Stroke Compression Ratio Compression Pressure Starting System Lubrication System: Oil Type or Grade: Engine Oil 30 40 50 282 (622 I
VMX Model BDS 34 x Spark Plug: anufacturer Ty - DP R GK , 0.8 0.9 mm (0.031 Wet, multiple-disc Type: Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type 0peration Gear Ratio: 1 2nd 3rd 4th 5th Chassis: Frame Type Caster Angle Traii Tire: Spar gear 87/49 1.775) Shaft drive (2.851) 21/27 x Constant mesh, 5-speed Left foot operation 43/17 (2.529) 39/22 31/23 (1.347) 28/26 1.076) 26/28 Double cradle 29" 119 mm (4.
I W A T A . JAPAN PRINTED IN U.S.A.
I Serr-ice L 1616-04-67 --
VMX 12 NC SERVICE MANUAL Edition December 1984 2nd Printing September 1985 JEM B 171 ALL RIGHTS RESERVED BY MOTOR CORPORATION, U. S. A.
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible t o 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.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated designed as thumb tabs to indicate the chapter's number and content. General information Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Appendices Illustrated are used to identify the specifications appearing in the text. A Filling fluid Lubricant Tightening Wear limit, clearance Engine speed Illustrated symbols in the exploded diagram indicate grade of lubricant and location of lubrication point.
-\ Being a Yamaha owner, you obviously prefer a quality product. 2. Authentic, not artificial 3. Yamaha. PARTS ACCESSORIES Don’t compromise the quality and performance of your Yamaha with off-brand alternatives. You’ll be getting exactly what you’re paying for.
I /--- EX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL APPENDICES
. CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER ......................... ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A L L REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS. O I L SEALS. AND O-RINGS ...........
MOTORCYCLE IDENTIFICATION GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER is stamped The vehicle identification number into the steering head pipe. NOTE: The vehicle identification number is used to identify your motorcycle and may be used t o register your motorcycle with the licensing authority in your state. Starting Serial Number: ....... ...... Starting Serial Number: FK-000101 JH-000101 ................ ...............
IMPORTANT INFORMATION IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. \ LOCK COTTER PINS 1.
1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a make sure that the sharp-edged corner is positioned opposite to the thrust it receives. See the sectional view. Shaft 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.
I 4. Fuel Level Gauge P/N YM-01312-A This gauge is used to measure the fuel level in the float chamber. 5. Vacuum Gauge P/N YU-08030 This gauge is needed for carburetor nization. 6. Radiator Cap Tester P/N YU-24460 This tester is needed for checking the cooling system. FOR ENGINE SERVICE 1. Clutch Holder P/N YM-91042 This tool is used to hold the clutch when removing or installing the clutch boss locknut. 2. Tappet Adjusting Tool P/N YM-33961 This tool is necessary to replace valve adjusting pads.
SPECIAL TOOLS 3. Valve Spring Compressor P/N YM-04019 This tool is needed t o remove and install the valve assemblies. 4. Valve Guide Remover (5.5 mm) P/N YM-01122 This tool is used t o remove the valve guides. 5. Valve Guide Reamer (5.5 mm) P/N YM-01196 This tool i s used t o new valve guide. 6. Valve Guide Installer P/N YM-01129 This tool is needed t o install the valve guides properly. 7. Valve Seat Cutter Set P/N YM-91043 This tool is needed t o resurface the valve seat.
SPECIAL TOOLS 8. Flywheel Puller P/N YU-33270 Adapter P/N YM-33282 These tools are used to remove the flywheel. 9.8 mm Wrench Adapter P/N YM-28897 This tool is used to loosen or tighten thecylinder head securing nut. 10. Piston Ring Compressor P/N YM-8037 This tool is used when installing the piston into the cylinder. 11. Water Pump Seal Installer Handle P/N YM-04085 - 1 Adapter P/N YM-33221 This tool is needed for proper installation of the water pump seal, 12.
SPECIAL TOOLS 13. #40 Torx Driver P/N YU-29843-7 This tool is used to loosen or tighten the middle gear bearing retainer bolt. 14. #30 Torx Driver P/N YU-29843-6 This tool i s used to loosen or tighten the drive axle bearing retainer bolt. 15. #25 Torx Driver P/N Y U-29843-4 This tool is used to loosen or tighten the shift cam segment securing bolt. 16. Set "Green" P/N YU-33210 This gauge i s needed to measure the clearance for the connecting rod bearing. 17.
SPECIAL TOOLS 18. Sealant (Quick Gasket@) P/N This sealant (bond) is used for crankcase mating surfaces, etc. FOR CHASSIS SERVICE 1. T-Handle P/N YU-01326 Damper Rod Holder (24 mm) P/N YM-01328 This tool is used to loosen and tighten the front fork cylinder holding bolt. 2. Front Fork Cap Socket mm) P/N YM-01104 This tool i s neededwhen looseningand tightening the front fork cap bolt. 3.
SPECIAL TOOLS FOR MIDDLE GEAR SERVICE 1. Universal Joint Holder P/N YM-04062 This tool i s used when adjusting the gear lash in the middle gear. 2. Middle Drive Gear Holder P/N YM-33222 This tool is needed when measuring the middle gear lash. 3. Damper Spring Plate P/N YM-33286 This tool is used with a middle drive gear holder t o disassemble and reassemble the middle gear damper. 4. Dial Gauge P/N YU-03097 This tool is used to measure the gear lash for the middle gear and final gear. 5.
SPECIAL TOOLS Final Drive Shaft Holder P/N YM-01229 This tool is used when for the final gear. the gear lash /-- 7. Final Drive Shaft Bearing Retainer Wrench P/N YM-04050 This tool i s used to remove and install the bearing retainer, 8. Gear Lash Measurement Tool P/N YM-01230 This tool is used to measure gear lash. FOR ELECTRICAL COMPONENTS 1. Electro Tester P/N YU-33260 This instrument is necessary for checking the ignition system components. 2.
. CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ............................................. 2-1 2-1 MAINTENANCE INTERVALS CHARTS ........................... PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM . . . . . . . . 2-1 G ENE RA L MA INTENANC LUBR ICAT I0N .................... ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE ADJUSTMENT .......................... CRANKCASE SYSTEM INSPECTION . . . . . . . . .
. . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 BATTERY INSPECTION . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . .2-37 BRAKE SPAR PLUG INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37 HEADLIGHT BULB REPLACEMENT.. . . . . . . . . . . . . . . . . . .
INTERVALS CHARTS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary t o 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. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale.
MAINTENANCE INTERVALS CHARTS GENERAL Odometer reading Initial 000 km Remarks /-- Engine oil Narm-up engine draining. or month mi) NOTE. Oil filter Air filter Cooling system Replace coolant Brake system Final gear oil Control and meter cable Adjust free play Replace pads if necessary. Check oil level and leakage. Replace every 24,000 km or 24 months.
MAINTENANCE INTERVALS CHARTS Odometer reading Initial Remarks or (600 mi) Check bearings assembly for looseness. Moderately repack every 24,000 km (15,200 mi). Check bearings for smooth rotation. Check specific gravity and breather pipe for proper operation.
VALVE CLEARANCE ADJUSTMENT ENGINE ,-- VALVE CLEARANCE ADJUSTMENT Removal 1. Remove: cover ( l e f t and right) m 2. Remove: .Electrical components board 3. Disconnect: electrical component leads 4. Remove: covers (radiator) (radiator) NOTE: It is not necessary t o remove the radiator completely from the motorcycle. 5. Disconnect: plug caps 6. Remove: baffle plate (rear) 7. Remove: head covers NOTE: Be sure you do not lose the oil plugs camshaft caps.
VALVE CLEARANCE ADJUSTMENT 8. Remove: *Crankcase cover plate *Special washer plug NOTE: Check for clog of oil passage If any, clean the oil passage. in the bolt. Inspection and Adjustment 1. Measure: *Valve clearance NOTE: Be sure piston is at Top Dead Center when measuring clearance. By the following measurement steps. Valve clearance measurement steps: *Turn the crankshaft counterclockwise with a 32 mm (1.26 in) socket wrench .
VALVE CLEARANCE ADJUSTMENT 360' TDC 540' 720' 180' 110 Crankshaft degree Cylinder *Measure the valve clearance, in sequence, for and No. 2 cylinders. Nor. Out of specification Adjust clearance. Front Firing Sequence: 1- 3- 4- 2 2. Adjust: *Valve clearance By the following adjustment steps. Valve clearance adjustment steps: the valve lifter slots (intake and exhaust side) opposite each other.
VALVE CLEARANCE ADJUSTMENT Remove the pads from the lifters. Use a small screwdriver and a magnetic rod for removal. pad numbers. the proper valve adjusting pad from the chart below: Pad range Pad Availability : 25 increments mm (0.
VALVE CLEARANCE ADJUSTMENT INTAKE INSTALLED PAD NUMBER MEASURED 205 0.00-0.05 0121 220122512301235 250125512601265 1270127512801 0.11 0.21- 0.25 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 295 300 305 310 315 320 I - VALVE CLEARANCE (cold): 0.1 1 0.15 mm (0.004 0.
CRANKCASE VENTILATION SYSTEM INSPECTION/ FUEL LINE INSPECTION Assembly When installing the top cover, reverse the removal procedure. Note the following points. 1. Install: head covers NOTE: sure all cam caps are coverd with oil plug on the cover should face *Arrow mark toward the exhaust side. *Inspect the head cover gasket and replace it if damaged. 2. Tighten: *Bolts (cylinder head cover) Bolts (Cylinder Head Cover): 10 Nm (1.0 7.2 I 3. Tighten: Bolts (radiator) Bolts (Radiator): 7 Nm (0.7 5.
FUEL FILTER REPLACEMENT/ INTAKE MANIFOLD INSPECTION/ EXHAUST SYSTEM INSPECTION FUEL FILTER REPLACEMENT Remove: Bracket filter 2. Inspect: filter Replace. 3. Install: .Components in above list (step "1") INTAKE MANIFOLD INSPECTION Tighten : Carburetor clamps joint bolts Carburetor joint nuts 2. Inspect: joint Gaskets Replace EXHAUST SYSTEM INSPECTION 1. Inpsect: pipe clamp Damage Replace. 2. Tighten: pipe bolts bolts 7 Nm (0.7 5.1 Exhaust Pipe Flange: 20 N m (2.0 14 Muffler Clamp: 20 Nm (2.
CANISTER I R ETOR SYNCHRONIZATION CANISTER INSPECTION (FOR CALIFORNIA ONLY) 1. Inspect: Hose connection Poor condition Correct. Hoses Canister Replace. Clogs Clean.
CARBURETOR SYNCHRONIZATION NOTE: Valve clearance must be set properly before synchronizing the carburetors. 1. Remove: Carburetor joint covers (left and right) plugs (left and right) hose 2. Attach: Gauge (YU-08030) To the vacuum plugs. 3. Start the engine and let it warm up. 4. Adjust: speed Out of specification Turn the throttle stop screw . . to adjust. Carburetor synchronization adjustment steps: .Synchronize carburetor No. 1 to carburetor No.
ID LIN G SPEED A D JU STM EN T/ TH R O TTLE C A B LE A D JU STM EN T V acuum S ynchronous D ifference: 2.66 kPa (30 m m H g, 0.79 in H g) *R epeat the above steps to synchronize carburetor N o. 3 to carburetor N o. 4 by turning synchronizing screw “B ” until both gauges read the sam e. • R epeat the sam e steps to synchronize N o. 4 carburetor to N o. 2 carburetor, then turn synchronizing screw “C ” until both gauges read the sam e. ID LE SPEED A D JU STM EN T 1.
EN G IN E O IL LEVEL IN SPEC TIO N / EN G IN E O IL R EPLA C EM EN T EN G IN E O IL LEVEL IN SPEC TIO N 1. Inspect : • O il level O il level low A dd sufficient oil. B y the follow ing inspection steps. Engine oil level visual inspection steps: the m otorcycle on its centerstand and w arm up the engine for several m inutes. NO TE: Position m otorcycle straight up w hen checking oil level, a slight tilt to the side can produce false readings.
EN G IN E O IL R EPLA C EM EN T D o not allow foreign m aterial to enter the crankcase. 6. Install: cap 7. Inspect: leaks *O il level Engine O ilR eplacem ent (W ith O ilFilter) 1. W arm up the engine and place a receptacle under the engine. 2. Rem ove: filler cap plug D rain the engine oil. 3. Rem ove: filter cover 4. Install: • D rain plug filter (new ) • O -ring (new ) filter cover NO TE: Be sure the O -ring is positioned properly. 5. Tighten: *Bolt (oil filter) 6.
COOLANT LEVEL SYSTEM INSPECTION 7. Install: f i l t e r cap 8. Inspect: leaks level COOLANT LEVEL INSPECTION 1. Remove: Top cover 2. Inspect: *Coolant level (reservoir t a n k ) Level low Add t a p water (soft water). Change t h e Coolant every two years. Refer to Chapter 4 "COOLING SYSTEM" for m o r e detail. "FULL" level "LOW" Do not remove the radiator cap when the engine is hot. Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can't get soft water.
COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. 1. Measure: clearance Out of specification Adjust. 2. Warm up the engine. 3. Remove: plugs 4. Measure: pression pressure By the following measurement steps. Compression pressure measurement steps: the Compression 33223)using an adapter.
FINAL GEAR OIL LEVEL INSPECTION OIL REPLACEMENT Same as without oil Defective valves, cylinder head gasket or piston is possible. Inspect cylinder head, valve surfaces, or Above maximum level piston crown for carbon deposits. NOTE: The difference between the highest and lowest cylinder compression readings must not vary more than the specified value. Difference Between Each Cylinder: (1 14 psi) Less than 98 CHASSIS FINAL GEAR OIL LEVEL INSPECTION 1.
AIR FILTER CLEANING 3. Install: plug Drain Plug (Final Gear): 23 (2.3 17 4. Fill: gear case Oil Capacity: 0.2 L (0.18 Imp qt, 0.21 US qt) Final Gear Oil: SAE 80 API "GL-4" Hypoid Gear Oil I f desired, an SAE Hypoid gear oil may be used for all conditions. I Do not allow the gear oil to contact the tire or wheel. 5. Install: filler cap Oil Filler Cap (Final Gear): 23 Nm (2.3 17 AIR FILTER CLEANING 1. Remove: cover 2.
BRAKE FLUID LEVEL INSPECTION 3. Eliminate: *Dust Use the compressed air. Blow out dust in the element from the outer surface. 4. Inspect: /-- Damage Replace. 5. Install: filter case cover cover BRAKE FLUID LEVEL INSPECTION Brake Inspection 1. Inspect: fluid level (brake master cylinder) Level low Replenish fluid. Lower NOTE: Be sure that: fluid is cleaned up immediately to prevent painted surfaces or plastic parts from e rodina.
FRONT AND REAR BRAKE PAD INSPECTION Clutch Inspection This motorcycle has a hydraulic clutch. There are no adjustments t o perform, but the clutch system must be inspected periodically for fluid level and leakage. 1. Inspect: fluid level (clutch master cylinder) Level low Replenish fluid. Lower NOTE: Be sure that: only the designated quality brake fluid. does not enter the master cylinder when ref iII ing. .Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding.
FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENT FRONT BRAKE ADJUSTMENT 1. Loosen: Lockunt 2. Adjust: *Free play Turn the adjuster until the free is within the specified limits. Proper lever free play is essential to avoid excessive brake drag. A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated.
CABLE INSPECTION AND LUBRICATION/BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS LUBRICATION/CENTERSTAND AND SIDESTAND LUBRICATION/SWINGARM LUBRICATION CABLE INSPECTION AND LUBRICATION Cable inspection and lubrication steps: *Remove the screws that secure throttle housing to handlebar. cable end high and apply several drops of lubricant to cable. metal surface of disassembled throttle twist grip with suitable all-purpose grease to minimize friction. for damage to cable insulation.
FRONT FORK ADJUSTMENT FRONT FORK OIL CHANGE /- • Fork oil leakage can cause loss of stability and safe handling. Have any problem corrected before operating the motorcycle. support the motorcycle so there is no danger of it falling over. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove: valve cap (left) caps NOTE: Keep the valve open by pressing it for several seconds so that the air can be let out of the inner tube. 3. Loosen: bolts (steering crown) 4.
FRONT FORK ADJUSTMENT 8. Install: Drain screws 9. Fill: forks Each Fork: 451 cm³ (15.9 Imp oz. 15.3 US oz) Yarnaha Fork Oil 10wt or Equivalent After filling, pump the forks slowly up and down to distribute the oil. 10. Tighten: bolts Use the Front Fork Cap Socket (YM01 104). bolts (steeringcrown) Cap Bolt: 17 23 Nrn (2.3 Pinch Bolts (Steering Crown): 20 Nrn (2.0 14 I 11. Adjust: Front fork air pressure Refer to ”FRONT FORK ADJUSTMENT” section. FRONT FORK ADJUSTMENT 1.
REAR SHOCK ABSORBER ADJUSTMENT By the following adjustment steps. Air pressure adjustment steps: Remove the valve cap. the air check gauge adjust the air pressure. Stiffer Softer , check and Increase the air pressure. (Use an air pump or pressurized air supply.) Decrease the air pressure. (Release the air by pushing the valve.) Standard Air Pressure: 39.2 kPa (0.4 kg/cm², 5.7 psi) Maximum Air Pressure: 98.1 kPa (1.0 kg/cm², 14.2 psi) Never exceed the maximum pressure, or oil seal damage may occur.
REAR SHOCK ABSORBER ADJUSTMENT By the following adjustment steps. Spring preload adjustment steps: *Using the screwdriver, adjust the spring preload. Stiffer Softer A Increase the spring preload. clock(Turn the spring seat wise.) Decrease the spring preload. (Turn the spring seat counterclockwise.) Position: 5 (Maximum) 4 3 2 1 (Minimum/Standard) Standard Position (Minimum Position): 1 Maximum Position: 5 Never attempt to turn the spring seat beyond the maximum or minimum setting.
RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER SETTINGS/ STEERING HEAD INSPECTION/STEE R I NG HEAD ADJUSTMENT RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER S ETTlNGS Use this table as guidance to meet specific riding conditions and motorcycle load. I Loading condition I B Air pressure Spring seat 39.2 58.8 (0.4 0.6 5.7 8.5 psi) 1 or 39.2 98.1 (0.4 1.0 5.7 14.2 psi) 3 - 39.2 (0.4 5.
ING HEAD ADJUSTMENT 2. Remove: lens unit 3. Disconnect: leads (in the headlight body) 4. Remove: Bolt (headlight body bracket) Emblem 5. Remove: *Flasher light bracket assembly 6. Remove: holder assembly 7. Loosen: *Pinch bolts (steeringcrown) 8.
STEERING H E A D ADJUSTMENT 9. Remove: washer (ring nut) nut (upper) nut (lower) Support the under bracket so that it may not fall down. 10. Tighten: nuts (lower and upper) By the following tightening steps. Ring nuts tightening steps: the ring nut (lower) . The tapered side of ring nut must face downward. the ring nut Wrench (YU-33975). using the Ring Nut Ring Nut 6 (Initial Tightening): 50 Nm (5.0 36 the ring nut completely and retighten it to specification. Do not over-tightening.
WHEEL BEARINGS CHECK/TIRES CHECK the lock washer . NOTE: Make sure the lock washer tab i s placed in the slots. the steering crown and tighten the steering stem nut to specification. Nut (Steering Stem) : 110 Nm (11.0 m-kg, 80 ft-lb) 11. Install: in above l i s t (steps "6 Handlebar Lower Holder: 40 Nm (4.0 m-kg, 29 ft-lb) 2") I WHEEL BEARINGS CHECK Front Wheel 1. Check: Front wheel bearings Raise the front end of the motorcycle, and spin the wheel by hand.
TIRES CHECK Be sure to install the correct tube when using tube type tires. Tire Tubeless tire Wheel Tube type tire Air valve Aluminum wheel (tubeless type) Tube Aluminum wheel (tube type) This motorcycle is fitted with "V" range tires (for super high speed running). The following points must be observed in order for you to make fully effective use of these tires. fail to use "V" range tires in tire replacement; "S" or "H" tires may be in danger of bursting a t super high-speeds.
TIRES CHECK inflation pressure should b e checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed. loading of your motorcycle is important for the handling, braking, and other performance and safety characteristics of your motorcyle. Do not carry loosely packed items that can shift.
WHEELS CHECK/IGNITION TIMING CHECK WHEELS CHECK 1. Inspect: A num wheels Damage/Bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. Never attempt even small repairs to the wheel. 2. Tighten: stem locknut Valve Stem Locknut: 1.5 Nm (0.15 rn-kg, 1.1 ft-lb) I Ride conservatively after installing a tire to allow it to seat itself properly on the rim. ELECTRICAL IGNITION TIMING CHECK 1. Check: Ignition timing By the following steps.
BATTERY INSPECTION BATTERY INSPECTION 1. Inspect: fluid level Battery fluid level low Fill. Fluid level should be between upper and lower level marks. U p p e r level L o w e r level Refill with distilled water only; tap water contains minerals harmful to a battery. Acid Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
BATTERY INSPECTION 2. Remove: 3. Inspect: Battery fluid specific gravity Out of specification Charge. Always charge a new battery before using it to ensure maximum performance. 1.4 amps/10 hrs Specific Gravity: 4. Install: Battery 5. Connect: Breather hose Be sure the hose is properly attached and routed. When inspecting the battery, be sure the breather hose is routed correctly.
BRAKE LIGHT SWITCH ADJUSTMENT/ SPARK PLUG INSPECTION BRAKE LIGHT SWITCH ADJUSTMENT 1. Adjust: light operating timing of the switch with Hold the main body your hand so it does not rotate, and turn the adjuster until the operating timing is correct. SPARK PLUG INSPECTION 1. Inspect: Replace. .Insulator color Normal condition is a medium to light tan color. Check the Distinctly different color engine condition. Spark plug gap 2. Clean: plug Clean the spark plug with a spark plug cleaner or wire brush. 3.
HEADLIGHT BULD REPLACEMENT NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turns part finger tight. Have the spark plug torqued to the correct value as soon as possible with a torque wrench. /-- HEADLIGHT BULB REPLACEMENT 1. Remove: Headlight lens unit 2. Disconnect: lens unit leads 3. Remove: Turn the bulb holder to release bulb.
HEADLIGHT BEAM ADJUSTMENT/FUSE INSPECTION HEADLIGHT BEAM ADJUSTMENT 1. Adjust: Headlight beam (horizontally) I Horizontal Adjustment Turn adjusting screw clockwise Turn adjusting screw counter- Right Left clockwise 2. Adjust: beam (vertically) I Vertical Adjustment Turn the adjusting screw Lower I Turn the adjusting screw clockwise. I clockcounter- I I FUSE INSPECTION The fuse panel is located under the top cover and seat. 1. Inspect: fuse Defective Replace. Blown fuse (new) Inspect circuit.
.. . . CHAPTER 3 ENGINE OVERHAUL ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-BOOST CONTROL CABLE AND AIR BAFFLE PLATE . . . . . . . . . . .
ENGINE ASSEMBLY AND ADJUSTMENT ........................ LOWER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPPER CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE ASSEMBLY ................................... OIL PUMP AND OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: It i s not necessary t o remove the engine in order t o remove the following components: .Clutch Carburetor pump magneto PREPARATION FOR REMOVAL Remove all dirt, mud, dust, and foreign material before removal and disassembly. Use proper tools and cleaning equipment. Refer t o "CHAPTER 1. SPECIAL TOOL" section. NOTE: When disassembling the engine, keep mated parts together.
ENGINE REMOVAL CARBURETOR 1. Remove: (left and right) 2. Remove: (carburetor overflow hose) 3. Loosen: (air cleaner joint) 4. Remove: hose (crankcase) cleaner assembly 5. Disconnect: hose 6. Disconnect: hose (ignition advance) 7. Loosen: (carburetor joint) 8.
ENGINE REMOVAL Electrical components board cable cylinder 10. Disconnect: leads and cables 11. Remove: assembly NOTE: Cover the carburetor with a clean rag t o prevent dirt or foreign matter into the carburetor. RADIATOR 1. Remove: *Radiator covers 2. Remove: *Bolts (radiator) 3. Disconnect: *Upper hose Lower hoses 4. Disconnect: *Fan motor coupler 5.
ENGINE REMOVAL 6. Disconnect: hoses and leads (conduit) 7. Remove: *Screws (conduit) V-BOOST CONTROL CABLE BAFFLE PLATE 1. Disconnect: *Control cable (V-boost) AND AIR 2. Disconnect: *Spark plug caps 3. Straighten: *Tabs (front baffle plate) 4. Remove: baffle plate (front) baffle plate (rear) FOOTREST (RIGHT) AND BRAKE PEDAL 1.
lead 3. Remove: Rear brake switch FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER 1. Remove: Footrest (left) pedal assembly gear case cover 2. Remove: Seat cover (left) 3. Disconnect: leads (engine) 4. Remove: 5. Remove: release cylinder 6. Remove: 7.
ENGINE REMOVAL EXHAUST PIPE AND MUFFLER 1. Remove: Flange bolts (front exhaust pipe) 2. Loosen: *Bolts (front exhaust pipe) 3. Remove: Front exhaust pipes 4. Remove: *Bolt (muffler chamber) 5. Loosen: *Bolts (muffler) 6. Remove: *Bolts (muffler bracket) 7. Remove: *Screws (rear exhaust protector) (rear exhaust) 8.
ENGINE REMOVAL SERVO MOTOR 1. Remove: *Screws (servo motor bracket) *Servomotor 2. Disconnect: *Servo motor coupler ENGINE REMOVAL 1. Place a suitable stand under the engine. 2. Remove: *Bolt (engine) *Bolts (down tube) *Down tube frame (right) 3. Remove: *Engine assembly from right side. NOTE: Remove the rear cylinder head cover if difficulties are encountered with any of the previous steps. V-BOOST 1. Remove: assembly NOTE: Working in a crisscross pattern, loosen the bolts 1/4 turn each.
ENGINE DISASSEMBLY ENG INE DISASSEMBLY CYLINDER HEAD AND CAMSHAFT Rear Cylinder Head 1. Remove: Cylinder head covers (rear and front) Gaskets plugs Front Front cylinder Rear cylinder 2. Remove: cover plate washer plug NOTE: Check for clog of oil passage I f any, clean the oil passage. in the bolt. 3. Align: pointer "T-1" mark with stationary on crankcase cover 4. Remove: chain tensioner (rear) 5.
ENGINE DISASSEMBLY 6. Remove: (cam chain sprocket) Use 22 mm wrench t o hold camshaft. 7. Remove: *Camshaft caps , NOTE: When loosing camshaft cap bolts, be sure camshaft cam lobes do not touching valve lifters. 8. Remove: Camshafts Sprockets Slip the sprockets from mounting boss on camshaft. NOTE: Fasten a safety wire t o the cam chain. 9. Remove: pin *Water jacket joint 10. Remove: (cylinder head) Use 8 mm Wrench Adapter (YM-28897). NOTE: Follow numerical order shown in photo.
ti I NE DISASSEMBLY I I I 11. Remove: delivery pipe NOTE: When removing the pipe, be sure not to lose the washers that may fall out. head 12. R emove : chain guide (rear) Gasket pins Front Cylinder Head When removing the front cylinder head, repeat the rear cylinder head removal procedure. However, note the following points. 1. Rotate: Counterclockwise 360" plus an added (430" total) from the mark. . . 2. Align: Flywheel "T-2" mark with stationary pointer on crankcase cover 3.
1. Remove: *Crankcase cover (left) Dowel pins 2. Remove: *Starter idle gears 3. Remove: Bolt (flywheel) Plain washer NOTE: Check for clog of oil passage If any, clean the oil passage. in the bolt. 4. Remove: Flywheel Use the Flywheel Puller (YU-33270) with the Puller Adapter (YM-33282) . NOTE: When removing the flywheel, do not allow the oil baffle plate t o touch the projections on the flywheel.
ENGINE DISASSEMBLY 5. Remove: Woodruff key Starter clutch gear 6. Remove: Oil baffle plate CLUTCH AND OIL PUMP DRIVE GEAR 1. Remove: Crankcase cover (right) NOTE: Working in a crisscross pattern, loosen the bolts 1/4 turn each. Remove them after all are loosened. pins 2.
3. Straighten the lock washer tabs. 4. Loosen: (clutch boss) Use the Clutch Holder (YM-91042) hold the clutch boss. to 5. Remove: (clutch boss) washer boss washer housing 6. Remove: pump drive gear WATER PUMP AND THERMOSTATIC VALVE 1. Remove: pump cover / Water pump cable Gasket pins 2.
ENGINE DISASSEMBLY STARTER MOTOR AND BREATHER COVER 1. Remove: motor 2. Remove: Breather cover Breather cover spacer pipe OIL PAN AND OIL PUMP 1. Remove: filter cover 2. Remove: pan Gasket pins 3.
ENGINE DISASSEMBLY 4. Straighten the bracket tabs 5. Remove: pipe oil gallery pipe , 6. Remove: (oil pump pipe) pump pipe CRANKCASE DISASSEMBLY 1. Remove: (main axle bearing) (middle gear bearing) Use the # 4 0 Torx Driver (YU-29843-7).
ENGINE DISASSEMBLY 3. Remove: (crankcase) NOTE: Remove the bolts starting with the highest numbered one. embossed numbers in the crankcase designate the crankcase tightening sequence. W i t h washer UPPER CASE LOWER CASE 3. Remove: (upper) Use a soft hammer. NOTE: Pull out the crankcase (upper) while pulling up the cam chain. pins UPPER CRANKCASE 1. Remove: rod caps rod/Piston assembly Do not hammer out the connecting bolts to remove the connecting rod assembly.
ENGINE DISASSEMBLY 2. Remove: Plane bearings (crankshaft/connecting rods/ balancer shaft) NOTE: Identify each plane bearing position very carefully so that it can be reinstalled in i t s original p Iace. 3. Remove: pin clip pin *Piston TRANSM I ON 1. Remove: shaft *Main axle assembly *Drive axle assembly driven gear assembly Plane bearings shaft) NOTE: Identify each plane bearing position very carefully so that it can be reinstalled in i t s original place. LOWER CRANKCASE 1.
Unhook: spring 3. Remove: cam stopper lever 4. Remove: /-- retainer (shift cam) bars forks cam NOTE: Note the position of each part. Pay particular attention to the location and direction of shift forks. 5.
INSPECTION A N D REPAIR INSPECTION A N D REPAIR I 2 3 4 I 2 3 4 CYLINDER HEAD 1. Remove: Valve pads Lifters 0 Spark plugs NOTE: Identify each lifter and pad position very carefully so that it can be reinstalled in its original place. 2. Attach: 0 n Valve Spring Compressor 3. Remove: 0 0 retainers spring seat springs seal spring seat NOTE: Deburr any deformed valve stem end. Use an oil stone t o smooth the stem end. Deburr Valve stem 4. Eliminate: deposit Use rounded scraper.
INSPECTION AND REPAIR 5. Measure: head Under specification Over specification Resurface. Replace. Cylinder Head Warp Limit: Less than 0.03 mm (0.0012 in) VALVE, VALVE GUIDE, AND VALVE SEAT Intake and Exhaust Valve 1. Inspect: *Valve face *Stem end of specification Replace. Minimum Thickness (Service limit) 0.7 mm (0.028 in) Beveled : 0.5 mm (0.020 in) limit) 4.0 mm (0.16 in) I : : I 2. Measure: Valve stem clearance Replace either valve Out of specification and/or guide.
INSPECTION A N D REPAIR 3. Inspect: stem end diameter than rest Mushroom of stem Replace valve, valve guide, and oil seal. 4. Measure: Valve stem O u t of specification Replace. Maximum 0.01 mm (0.0004 i n ) Valve Guide NOTE: replace valve guide if valve is replaced. replace oil seal if valve is removed. 1. Inspect: guide into cylinder Replace.
INSPECTIO N AND REPAIR NO TE: After installing valve guide: *U se the 5.5 m m Valve G uide R eam er (YM 01196) to obtain proper valve guide/ valve stem clearance, the valve seat. C irclip Valve guide Valve Seat 1. Inspect *V alve seat W ear/Pitting/Valve replacem ent Resurface seat at 45° angle. C lean valve seat if pitted or w orn using a 45° Valve Seat C utter (YM -91043) , W hen tw isting cutter, keep an even dow nw ard pressure to prevent chatter m arks.
INSPECTIO N AND REPAIR 6. M easure: seat w idth O ut of specification/R em aining pitting/ Cut valve Variation of valve seat w idth further. R em ove just enough m aterial to achieve satisfactory seat. 1.0 0.1 m m 0.039 0.004 in Valve seat recutting steps are necessary if: *Valve seat is uniform around perim eter of valve face but too w ide or not centered on valve face.
INSPECTION AND REPAIR seat is too narrow and is located down near the bottom edge of the valve face (see diagram "d"). Valve Seat Cutter Set /-- 45° cutter Desired Result to increase its width Valve/Valve Seat Assembly Lapping 1. Apply: Coarse lapping compound (small amount) To valve face. disulfide oil To valve stem. 2. Position: I n cylinder head. 3. Rotate: Turn until valve and valve seat are evenly polished, then clean off all compound. 4. Apply: lapping compound (small amount) To valve face. 5.
INSPECTION AND REPAIR 10. Apply: .Solvent Into each intake and exhaust port. Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of all head parts. 11. Check: .valve seals Leakage past valve seat (See procedure below) Replace valve. Valve guide Relapping steps: head parts. Repeat lapping steps using f i n e lapping compound. all parts thoroughly. and check for leakage again using solvent. steps as o f t e n as necessary to effect a satisfactory seal.
INSPECTION AND REPAIR 2. Measure: force (installed length) Out of specification Replace. - Valve Compressed Force: 34.6 Outer: 13.3 15.7 at 33.8 mm (1.331 in) (13.9 16.3 Inner: 6.29 -7.39 at 31.8 mm (1.75 in) Valve Lifter 1. Inspect: lifter wall Scratches/Damage and cylinder head. Replace both lifter Valve Installation 1. Lubricate: Valve stem seal High-Quality Molybdenum Disulfide Motor Oil or Molybdenum Disulfide Grease -0 2.
INSPECTIO N AND REPAIR C A M S H A FT, C A M C H A IN , A N D C A M SPR O C K ET C am shaft 1. Inspect: lobes Pitting/Scratches/Blue Replace. 2. M easure: • Cam lobes U se the M icrom eter. O ut of specification discoloration R eplace. C am shaft/C ap C learance M easurem ent 1. Install: *C am shaft 2. Attach: (VU-33210) O nto cam shaft. For Exhaust For Intake 3. Attach: *C am shaft cap (“l-3” or “E-3”) 4. Install: *C am shaft caps (others) 5. Tighten: *C am shaft cap bolts First Tighten the N os.
INSPECTION A N D REPAIR 6. Remove: caps 7. Measure: W i d t h of Out of specification F o l l o w step 8. - Camshaft-to-cap Clearance: Standard: 0.020 0.054 mm (0.0008 0.0021 i n ) (0.006 in) M a x i m u m : 0.160 8. Measure: Camshaft outside diameter Use a micrometer. Replace camshaft. O u t of specification Replace cylinder W i t h i n specification head. -- Camshaft Outside Diameter: Standard: 24.967 24.980 mm (0.9830 0.9835 in) C a m Cap Inside Diameter: Standard: 25.000 25.021 mm 0.
INSPECTIO N AND REPAIR C am C hain Tensioner 1. Check: cam operation Unsm ooth operation Replace. 2. Inspect: *All parts Dam age/W ear Replace. Tensioner body End Plug W asher O ne w ay cam Tensioner rod Spring C YLIN D ER 1. Inspect: *Cylinder wall W ear/Scratches Rebore or replace. 2. Measure: bore “C” Use the Cylinder Bore Gauge Out of specification Rebore. C T mm M axim um D M axim um M inim um or or PISTO N , PISTO N R IN G , A N D PISTO N PIN P iston 1.
INSPECTION A N D REPAIR NOTE: Measurement should be made a t a point 6.2 mm (0.244 in) above the bottom edge of the piston. Size Standard 75.905 75.955 mm (2.9884 2.9903 in) Oversize 1 Oversize 2 76.25 mm (3.002 in) 76.50 mm (3.012 in) I 3. Measure: clearance Out of specification or replace piston. cylinder - Piston Clearance = C P: 0.055 0.075 mm (0.0022 -0.0030 C: Cylinder bore P: Piston outside Piston Ring 1. Measure: clearance Use the Feeler Gauge Out of specification and/or rings. .
INSPECTIO N AND REPAIR 2. P osition: Piston ring Into cylinder. Push the ring w ith the piston crow n, 3. M easure: End gap U se the Feeler G auge . O ut of specification Replace rings as set. 2nd Ring 0.35 ~ 0.50 m m (0.0138 ~ 0.0197 in) O il Ring 0. 2~0. 8m m (O.OO8O.~ 0.032 in) 0.75 m m (0.0295 in) Oversize Piston Rings • The oversize top and m iddle ring sizes are stam ped on top of the ring. Oversize 1 0.25 m m (0.0098 in) Oversize 2 0.50 mm (0.
INSPECTION AND REPAIR 3. Check: Free play Inspect connecting rod for Free play wear. Wear Inspect connecting rod and piston pin. 4. Position: pin Into piston. 5. Check: play When pin i s in place in piston. Replace piston pin and/or Free play piston. , STARTER DRIVES Electric Starter Clutch Check: operation cap operation operation Replace one-way Unsmooth operation clutch. 2. Check: housing Rubber dampers Replace. 3. Install: damper housing clutch 4. Tighten: (one-way clutch) 24 Nm (2.
INSPECTION A N D REPAIR Starter Gears 1. Inspect: gear surfaces Pi tting/Wear/Damage I R ep lace. I PRIMARY GEARS The drive gear is mounted on the crankshaft; the driven gear is mounted on the transmission and is intergrated with the clutch assembly. 1. Inspect: gear Scratches/Wear/Damage shaft. gear Scratches/Wear/Damage housing assembly. Replace crank- Replace clutch CLUTCH Clutch Housing 1. Inspect: on the housing Cracks/Wear/Damage Deburr or replace. housing bearing Replace.
INSPECTION AND REPAIR 1. Inspect: Clutch boss splines Scoring/Wear/Damage boss assembly. Replace clutch NOTE: Scoring on the clutch plate splines will cause erratic operation. Friction Plates Inspect: Friction plate Damage/Wear Replace friction plate as a set. 2. Measure: 0 Friction plate thickness Measure a t all four points. Replace friction Out of specification plate as a set. Wear Limit: 2.8 mm (0.11 in) Clutch Plates 1.
INSPECTION A N D REPAIR Clutch Bearing 1. Inspect: Pitting/Damage Replace. Clutch Spring 1. Inspect: .Clutch spring Wear/Bends/Cracks Replace. 2. Measure: spring free height O u t of specification Replace. Clutch Spring Minimum Height: 6.5 mm (0.26 in) 3. Measure: spring warpage Use a surface plate and the Feeler Gauge O u t of specification Replace. Warp Limit: 0.1 mm (0.004 in) Clutch Spring Seat 1. Inspect: spring seat Wear/Bends/Damage Replace, OIL PUMP 1.
INSPECTION AND REPAIR 2. Measure: rotor /Inner rotor Use t h e Feeler Gauge. O u t of specification assemb Iy . clearance Replace oil pump Tip Clearance Limit: 0.17 rnm (0.0067 in) O I L GALLERY PIPE 1. Inspect: Wear/Cracks/Damage Replace. pipe Replace. Cracks/Damage U CRANKSHAFT Crankshaft 1. Measure: Runout Use t h e V-Blocks and Dial Gauge (YU-03097). Out of specification Replace. Runout Limit: 0.03 mrn (0.0012 in) 2. Inspect: Crankshaft bearing surfaces Replace.
INSPECTION A N D REPAIR 4. Attach: (YU-33210) O n t o t h e crankshaft journal surface. NOTE: Do not turn t h e crankshaft until clearance measurement has been completed. 5. Install: Bearings lower crankcase. 6. Tighten: Tighten to full torque in torque sequence as shown. 10 mm Bolts (Crankcase): 40 Nm (4.0 m-kg, 29 ft-lb) * W i t h a washer 7. Remove: Reverse assembly order. Crankcase (lower) Use care in removing. 8.
INSPECTION AND REPAIR Connecting Rod Bearing Clearance Measurement 1. Clean all parts. 2. Install: *Connecting rod bearings Into connecting rod and cap. 3. Attach: (YU-33210) Onto the crank pin. 4. Install: Connecting rod *Connecting rod cap -- NOTE: Be sure the letter on both components align t o form perfect character. 5. Lubricate: *Bolt threads (connecting rod) Molybdenum Disulfide Grease 6.
INSPECTION A N D REPAIR 7. Remove: rod cap Use care in removing. 8. Measure: Width of Plastigage® Replace bearings Out of specification and/or replace crankshaft if necessary. Connecting Rod Bearing Clearance: 0.021 -0.045 mm (0.0008 0.0018 in) J2 Pl J3 J4 Crankshaft Main and Connecting Rod Bearing Selection used to indicate crankshaft journal sizes are stamped on the crankweb. The first are main bearingjournal numbers, two starting with the l e f t journal.
INSPECTIO N AND REPAIR Exam ple 1: Selection of the crankshaft m ain bearings; the crankcase J1 and crankshaft J1 sizes are No. 4 and No. 1, respectively, the bearing size N o. is: B earing Size N o. = C rankcase N o.-C rankshaft N o. = 4 - 1 = 3 (B row n) BEAR IN G C O LO R C O D E N o. 1 I B lue N o. 2 I Black N o. 3 Brown G reen N o. 4 N o. 5 Yellow N o. 6 Pink Exam ple 2: Selection of the connecting rod bearing; the connecting rod P1 and crankshaft P1 sizes are N o. 4 and N o.
INSPECTION A N D REPAIR 3. Install: Bearings Into the upper crankcase. 4. Install : Balancer shaft Into the upper crankcase. 5. Attach: Onto the balancer shaft journal surface. NOTE: Do not move balancer shaft until clearance measurement has been completed. 6. Install: Bearings Into lower crankcase. 7. Tighten: Bolts (crankcase) Tighten to full torque in torque sequence cast on the crankcase. 8 mm Bolt (Crankcase): 24 Nm (2.4 kg, 9.6 I 8. Remove: Bolts Reverse assembly order.
INSPECTIO N AND REPAIR B alancer S haft B earing S election • Num bers used to indicate balancer shaft journal sizes are stam ped on the R H balancer w eb corner, starting w ith the left journal. Left balancer shaft journal size num ber Right balancer shaft journal size num ber low er crankcase half is num bered J5, and J6 as shown. Exam ple: ngs; Selection of the balancer shaft bear- If the crankcase J5 and left balancer shaft sizes are N o. 4 and N o.
INSPECTION AND REPAIR Shift Cam 1. Inspect: cam grooves Replace. Wear/Damage/Scratches Shift cam segment Damage/Wear Replace. *Shift cam bearing Replace. Pitting/Damage Main and Drive Axles 1. Measure: runout Use the centering device and Dial Gauge (YU-03097) O u t of specification Replace. Runout Limit: 0.08 mm (0.0031 in) Gears 1. Inspect: Gears Damage/Wear Replace. 2. Check: Gear movement Unsmooth operation Replace. 3. Inspect: Mating dogs Replace. Cracks/Wear/Damage BEARINGS 1.
MIDDLE GEAR SERVICE MIDDLE GEAR SERVICE joint Dust seal @Middle drive pinion gear washer Retainer @Collapsible collar @Middle drive shaft @Middle driven pinion gear Spring seat Damper spring Damper cam 3-44
MIDDLE GEAR SERVICE Drive axle Drive pinion gear shim Bearing Middle drive pinion gear Collapsible collar (Always use a new one) Spacer Middle driven pinion gear O-ring Universal joint seal Bearing retainer Bearing housing Driven pinion gear shim Nut (drive pinion gear) Nut (driven pinion gear) @Bearing stopper 0.28 0.
MIDDLE GEAR SERVICE . I DRIVE AXLE POSITIONING When the crankcase assembly and/or the drive axle are replaced, you must position the drive axle in place. Refer to "Drive Pinion Gear Shim Selection and Middle Gear Lash Adjustment" section. Drive pinion gear Driven pinion gear A Drive pinion gear shim Driven pinion gear shim Drive Pinion Gear Shim Selection = 54.5 plus or minus the number stamped on the drive pinion gear. = 53 plus the number stamped on the left- side rear of the upper crankcase.
M IDDLE G EAR SERVICE Exam ple: Selection of the drive pinion gear shim ; Shim Thickness = Distance “A ” -D istance “B ” Ifthe drive pinion gearis stam ped “03”(plus (+ 03) is im plied here since only the m inus (-) designations are stam ped alongside the num bers), then: “A” = 53 -- 0.03 = 54.53 NO TE: All stam ped num bers are in hundredths of a mm. If the left-side-rear of the upper crankcase is stam ped then: = 53 + 0.95 = 53.95 Therefore: T = A -B 54.53 53.95 = 0.
MIDDLE GEAR SERVICE Middle Gear Lash Adjustment 1. Attach: Middle Drive Gear Holder (YM-33222) This tool will prevent the drive axle from turning. 2. Install: Bolts (three) On driven bearing housing. Finger-tighten the bolts. NOTE: Clearance between the crankcase and driven bearing housing should be about 2 mm. Measure gap with Feeler Gauge 3. Position: Dial Gauge (YU-03097) On the outside edge of U-joint. NOTE: Be sure the gauge is positioned over the centerline of the yoke bearing hole. 4.
MIDDLE GEAR SERVICE 6. Tighten: Bolt (Three) Tighten carefully one-threadturn only. Push in bearing housing and hold in position while tightening bearing housing bolts. Do not overtighten bearing housing bolts or you may obtain too little gear lash and cause damage to gears. If over tightened, loosen the 3 bolts so that crankcase/bearing housing clearance is about 2 mm (0.08 in) and repeat all previous steps. 7. Repeat steps 4 and 5 until correct gear lash is achieved. Middle Gear Lash: 0.05 0.12 mm (0.
MIDDLE GEAR SERVICE Tighten: Bolts (bearing housing) Bolts (Bearing Housing): 30 Nm (3.0 22 NOTE: Before tightening the bolts, make sure that the arrow on the bearing housing points to the upper crankcase. 11. Measure: Gear lash REMOVAL 1. Remove: Drive axle assembly 2. Attach: Damper Spring Plate Middle Drive Gear Holder (YM-33222) Onto drive pinion. 3. Position: Drive axle shaft assembly Onto a Hydraulic Press. 4. Compress the damper spring on the drive axle shaft assembly. 5.
MIDDLE GEAR SERVICE 6. Remove: Nut (drive gear) Use the Offset Wrench Bearing (YM-04054). INSPECT ION 1. Inspect: Damper cam surfaces Replace damper and drive pinion gear as a set. 2. Inspect: Damper spring Replace. ASSEMBLY 1. Install: Shim Bearing Nut (drive gear) Use the Offset Wrench 110 Nm (11 LOCT I (YM-04054). kg, 80 2. Lock the threads with center punch shown. 3.
MIDDLE GEAR SERVICE 4. Attach: Damper Spring Plate (YM-33286) Drive Gear Holder (YM-33222) 5. Position: Drive axle shaft assembly Onto a Hydraulic Press. 6. Compress the damper spring on the drive axle assembly. 7. Install: Retainers drive axle shaft groove. Drive axle shaft assembly Onto the crankcase. MIDDLE DRIVEN GEAR BEARINGS The following procedures should be performed only i f the middle driven gear or middle drive must be replaced. shaft Universal Joint Removal 1.
MIDDLE GEAR SERVICE 3. Remove: Nut (driven pinion gear) Washer *Yoke Bearing Bearing housing *Collapsible collar Spacer Inspection 1. Inspect: Gear teeth Replace middle gear as a set. Bearings Replace. 2. Check: U-joint movement Roughness Replace U-joint. Assembly 1. Install: Bearing outer race the bearing housing. Do not press the bearing outer race. Always press the inner race with care when installing. 2. Install: Inner bearing *Spacer .
M I DDL E GEAR SERVICE 5. Measure: *Starting torque (driven pinion gear) Under specification Repeat steps from 4. Starting Torque (Driven Pinion Gear): 0.4 0.5 Nm (0.04 0.05 kg, 0.29 0.36 Ib) Never exceed the standard starting torque. *Be sure to tighten the driven pinion gear nut slowly, carefully checking measurements each time. Exceeding the standard starting torque may depress t h e collapsible collar, requiring reassembly.
ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT LOWER CRANKCASE 1. Install: pump idle gear 2. Install : cam Shift forks (No. 1, Guide bars NOTE: All numbers should face the left side and be in begining from the left. sequence (1, 2, 3. Install: Bearing retainer (shift cam) 4.Tighten: (bearing retainer) Screws (Bearing Retainer): LOCTI 7 Nm (0.7 5.1 5. Rotate the shift cam to neutral position. 6. Install: cam stopper lever spring Washer Bolt (shift cam stopper lever) 7.
ENGINE ASSEMBLY AND ADJUSTMENT NG Piston ring “Y” mark Matching mark Connecting rod bearing size Projection Washer Journal bearing size Crank pin size Balancer matching mark U 3-56
TRANSMISSION Bearing 1st wheel gear 4th wheel gear Washer 3rd wheel gear Drive axle Plug 3-57 2nd wheel gear 5th wheel gear Bearing 3rd pinion gear 5th pinion gear @Washer Bearing axle pinion gear
ENGINE ASSEMBLY AND ADJUSTMENT 8. Install: shaft assembly lever 1 Shift lever 2 TRANSMISSION 1. Install: Plane bearings shaft) Identify each plane bearing position very carfuly so that it can be reinstalled in i t s original palce. 2. Install: *Main axle assembly Drive axle assembly NOTE: the bearing circlips completely into lower crankcase positioning grooves. Position the bearing pin as shown. 3.
ENGINE ASSEMBLY AND ADJUSTMENT 5. Check: *Transmission and shifter operation Unsmooth operation Repair. NOTE: Oil each gear and bearingthoroughly. 6. Install: *Crankshaft with cam chains Balancer shaft NOTE: Align the mark on the balancer shaft gear with the mark on the crankshaft gear. UPPER CRANKCASE 1. Install: Plane bearings gear) NOTE: Identify each plane bearing positionvery carefuly so that it can be reinstalled in i t s original place. 2.
ENGINE ASSEMBLY AND ADJUSTMENT 5. Install: *Piston Piston pin pin clip /-- NOTE: sure the piston i s positioned correctly as shown. *Always install new piston pin clips. Plane bearings (connecting rods) Onto the connecting rod and cap. Mark "EX" Exhaust side "IN" Intake side Projection 6. Install : rod assembly (#1 Into the upper crankcase. By the following steps. rod assembly installation steps: the Piston Ring Compressor 8037) to the piston. Install the piston t o the cylinder.
CRANKCASE ASSEMBLY 1. Apply: Sealant (Quick Gasket@) To the mating surfaces of both case halves. NOTE: DO NOT ALLOW any sealant to come in contact with the oil gallery O-ring, or crankshaft bearings. Do not apply sealant to within 2 3 mm (0.08 0.12 in) of the bearings. - 2. Set shift cam and transmission gears in NEUTRAL position. 3. Install: Upper crankcase pins To the lower crankcase. NOTE: Attach a length of wire to each cam chain and place cam chains on timing gear sprockets.
ENGINE ASSEMBLY AND ADJUSTMENT I I 6. Tighten: Nuts (connectingrod cap) Nut (Connecting Rod): 36 Nm (3.6 kg, 25 NOTE: Molybdenum disulfide grease to the rod cap bolt threads and nut surfaces. projection on the connecting rod cap should faces the crankshaft web. A 1 When tightening the rod cap, apply continuous Once you torque between 3.0 and 3.8 reach 3.0 of torque, DO NOT STOP TIGHTENING until final torque i s reached. If tightening is interrupted between 3.0 and 3.8 loosen the nut to less than 3.
Crankshaft on Unsmooth operation Repair. Bolts (middle driven gear housing) The arrow mark on the bearing housing points to the upper crankcase. 10. Install: Retainer (main axle bearing) NOTE: Be sure that the groove in the shaft mesh with the slot in the retainer. Retainer (Main Axle Bearing): 7 Nm (0.7 5.1 I I 11. Install: Retainers (middle gear bearing) Use the #40 Torx Drive (YU-29843-7). Stake screw head with center punch to lock. Retainers (Middle Gear Bearing): 25 Nm (2.
ENGINE ASSEMBLY AND ADJUSTMENT 2. Install: 0 Main oil gallery pipe pipe NOTE: Make sure the correct O-rings gallery pipe. are installed on 3. Tighten: (main oil gallery pipe) 6 mm Flange Bolt 12 Nm (1.2 8 mm Union Bolt 18 Nm (1.8 I 4. Bend the bracket tabs , : 8.7 : 14 I . 5. Install: pins pump assembly NOTE: sure the correct O-ring is installed on oil pump pipe. arrow mark on the oil should face toward the rear. Oil Pump: Nm (1.0 7.2 6. Install: Gasket Dowel pins pan Nm (1.0 7.2 7.
ENGINE ASSEMBLY AND ADJUSTMENT 8. Install: filter cover NOTE: Be sure that the projections on the filter on the crankcase. cover mesh with the slots Oil Filter Cover: 32 Nrn (3.2 kg, 23 BREATHER COVER AND STARTER MOTOR 1. Install: pipe Breather cover spacer Breather cover Bolt (Breather Cover): Nrn (1.0 7.2 O-ring 2. Install: *Starter motor Bolts (Starter Motor) : 10 (1.0 rn-kg, 7.2 WATER PUMP AND THERMOSTATIC VALVE 1. Install: Thermostat assembly Thermostatic Valve Housing: 10 (1.0 7.
ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH AND OIL PUMP DRIVE GEAR 1. Install: pump drive gear 2. Install: Clutch housing Thrust washer Clutch boss 0 Lock washer (new) (clutch boss) 3. Tighten: (clutch boss) Use the Clutch Holder hold the clutch boss. Nut (Clutch Boss): 70 Nm (7.0 to 50 4. Bend the lock washer tabs along the nut flat.
ENGINE ASSEMBLY A N D ADJUSTMENT CLUTCH AND OIL PUMP D R I V E GEAR @Clutch spring @Spring seat @Pressure plate pcs) @Friction plate plate (7 pcs) @Friction plate (6 pcs) @Bearing rod (No. 1) Ball @Push rod (No. 2) washer boss @Thrust washer tch housing pin pump pump driven gear pump drive gear axle 6.5 mm (0.
ENGINE ASSEMBLY AND ADJUSTMENT Friction plates and clutch plates installation steps: Install the six friction plates (with the double semi-circular slots) and the six clutch plates. NOTE: Be sure the double semi-circular slots on the friction plate is aligned with the clutch housing embossed match marks . Install the clutch plate and the friction plate (with the wide square slot).
ENGINE ASSEMBLY AND ADJUSTMENT 6. Install: 0 Pressure plate NOTE: Be sure t h e m atch mark on t h e c lut c h boss i s aligned with t h e m a t c h m a r k on t h e pressure plate. 7. Install: 0 Spring seat 0 Clutch spring Plate washer Bolts ( c lut c h spring) Bolt (Clutch Spring): 8 (0.8 kg, 5.8 8. Install: pins 0 Gasket Crankcase cover (right) NOTE: Tighten t h e bolts in a crisscross pattern. Crankcase Cover (Right): 7.2 10 Nm (1.0 FLYWHEEL AND STARTER IDLE GEAR 1.
ENGINE ASSEMBLY AND ADJUSTMENT 2. Install: clutch gear Woodruff key /- Be sure t o remove any oil and or grease from the tapered portion of the crankshaft and rotor with a thinner. 3. Install: Flywheel NOTE: When installing the flywheel, do not allow the oil baffle plate t o touch the projections on the flywheel. 4. Install: Plain washer Bolt (flywheel) NOTE: Check for clot of oil passage If any, clean the oil passage. Bolt (Flywheel) : 130 Nm (13.0 in the bolt. 94 5. Install: idle gears 6.
ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD AND CAMSHAFT Rear Cylinder Head 1. Install: Dowel pins Gasket Rear cam chain guide NOTE: gasket "HEAD" mark should the upward. lower end of chain guide must rest in the cam chain guide slot in the crankcase. Cylinder head Pass cam chain through cam chain cavity. 2. Nuts (cylinder head) Use 8 mm Wrench Adapter (YM-28897). NOTE: sequence as shown and torque nuts in two stages. Never lubricate the bolt threads with engine oil. Nuts (Cylinder Head): 43 Nm (4.
ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD AND CAMSHAFT Washer Rubber washer Pad Valve lifter Valve retainer Spring seat spring Outer spring Spring seat seal Valve Gasket plug @Joint O-ring plug Valve guide I CYLINDER HEAD WARP LIMIT: 0.03 mm (0.0012 in) I 15 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENT 4. Install: Camshafts By the following installation steps. t installation steps : the mark on the flywheel with the stationary pointer on the crankcase cover use 32 mm wrench. Never turn the flywheel installing bolt. Rotating the bolt may loosen it, causing the rotor to fall out. not turn the crankshaft during the camshafts installation. the cam chain sprockets onto the camshafts.
ENGINE ASSEMBLY AND ADJUSTMENT Tighten the cap bolts. NOTE: First tighten the No. 3, 1 and 4 cap bolts in that order, then the No. 2 cap bolts, Camshaft Cap: 10 Nm (1.0 7.2 5. Install: Cam chain sprockets By the following installation steps. :am chain sprockets installationsteps: the mark on the flywheel with the stationary pointer on the crankcase cover use 32 mm wrench. turn the flywheel installing bolt. Rotating the bolt may loosen it, causing the rotor to fall out.
ENGINE ASSEMBLY AND ADJUSTMENT Force the intake camshaft counterclockwise to remove the cam chain slack. the cam chain onto the exhaust sprocket. Install the sprocket with the punched mark " REAR" facing outward and finger-tighten the sprocket bolt. NOTE: Align the "EX" mark hole on the sprocket with the thread hole on the camshaft. the exhaust camshaft to align the timing mark small hole) on the camshaft with the embossed match mark on the camshaft cap (E-4).
NE ASSEMBLY AND ADJUSTMENT 7. Turn the crankshaft and tighten the cam sprocket bolts. Camshaft Sprocket: kg, 17 24 Nm (2.4 Be sure to attain the specified torque value to avoid the possibility of these bolts coming loose and causing damage to the engine. 8. Install: caps , and Camshaft Cap: 10 Nm (1.0 7.2 chain guides 9. Apply: Engine oil To the cam chain, sprockets, camshaft and va Ives.
ENGI NE ASSEMBLY AND ADJUSTMENT 2. Install: Cam chain sprocket the "T-2" mark on the flywheel with the stationary pointer on the crankcase cover use 32 mm wrench. 2) Install the sprocket with the punched mark "FRONT" facing outward and finger-tighten the sprocket bolts. 3) Rotate the intake and exhaust camshafts to align the timing mark (0: big hole) on the camshaft with the embossed match the camshaft caps (1-4 and E-4). 3. Measure: Valve clearance Out of specification Adjust. Refer to "CHAPTER 2.
NOTE: sure all cam caps are covered with oil plugs mark on the cover should face toward the exhaust side. the head cover gasket and replace it if damaged. 3. Tighten: Bolts (cylinder head cover) *Spark plugs Cylinder Head Cover: 10 Nm (1.0 7.2 Spark Plug: 17.5 Nm (1.75 12.5 I I 4. Install: plug *Special washer Crankcase cover plate NOTE: Check for clog of oil passage any, clean the oil passage. in the bolt.
ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE When remounting the engine, reverse the removal procedure. Note the following points. 1. Install: Down tube frame (right) Bolts (down tube) Bolts (engine) , NOTE: Tighten the bolts (#1 #9) in that order. Engine Mounting: Bolts (Down Tube)@, 45 Nm (4.5 kg, 32 Bolts (Engine) : 70 Nm (7.0 50 Bolts (Engine)@, : 40 Nm (4.0 29 Bolts (Down Tube) , : 15 Nm (1.5 11 2.
ENGINE ASSEMBLY AND ADJUSTMENT 3. Tighten: nuts or bolts By the following specification torque. Clutch Release Cylinder: 12 Nm (1.2 8.7 Middle Gear Case Cover: 10 Nm (1.0 7.2 Change Pedal: 10 Nm (1.0 7.2 Footrest (Left) : 40 Nm (4.0 29 Footrest (Right): 23 Nm (2.3 17 Rear Brake Master Cylinder: 23 Nm (2.3 17 4. Adjust: 0 Rear brake switch Refer t o "CHAPTER 2. REAR BRAKE SWITCH ADJ USTMENT" section, 5. Bend the tabs on the air baffle plate (front) as shown. 6.
ENGINE ASSEMBLY AND ADJUSTMENT 8. Connect: hoses and lead (conduit) Refer t o "CHAPTER 4. COOLING SYSTEM, RADIATOR AND CONDUIT" section. 9. Adjust: cable free play Refer t o "CHAPTER 5. CARBURETION, THROTTLE CABLE CYLINDER" section. Add: Engine oil Refer to "CHAPTER 2. ENGINE OIL REPLACEMENT" section. 11. Add: Coo lant Refer t o "CHAPTER 4. COOLING SYSTEM, COOLANT" section.
ENGINE ASSEMBLY AND ADJUSTMENT - MEMO - ............................................................................................................................................................................. ............................................................................................................................................................................. .........................................................................................................................
CHAPTER 4 . COOLING SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT F LOW .......................................... COOLANT REPLACEMENT .................................. /-- I ' WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D LY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . .
COOLANT COOLING SYSTEM COOLANT COOLANT FLOW Radiator Coolant drain valve Bypass pipe to the coolant drain valve Bypass pipe to the thermostatic valve Thermostatic valve Water pump To the reservoir tank Thermostat housing Conduit 4- 1
COOLANT COOLANT REPLACEMENT 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. When the engine has cooled, open the radiator cap by the fo Ilowing procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
CO O LANT 5. Rem ove: covers (cylinder) 6. Rem ove: plugs D rain the coolant. NO TE: To facilitate rem oval of the rubber plug’s, screw a spark plug into the threaded hole and hand-pull the spark plug firm ly. 7. D rain: *C oolant (com pletely) NO TE: Thoroughly flush the cooling system w ith clean tap w ater, 8. Inspect: *R ubber plugs D am age R eplace, 9. Tighten: bolt D rain B olt: 43 N m (4.3 m .kg, 31 ft.lb) 10. Fill: • C ooling system By the follow ing steps.
Reservoir Tank Capacity: 0.30 L (0.26Imp qt, 0.32 US qt) *Hard water or salt water is harmful to the engine. Y o u may use distilled water if you can't get soft water. not mix more than one t y pe of ethlen glycol antifreeze containing corrosion for aluminum engine inhabitors. Coolant filling steps: the coolant into the conduit until the conduit i s full. *Start the engine (coolant level decreases.) Always check level, and check for coolant leakage before starting engine.
WATER PUMP W A T E R PUMP DISASSEMBLY NOTE: sure to dr ain t h e c oolant before disassembly of t h e c ooling system components. *Refer to Engine Disassembly for water pump disassembly . 1. Remove: *Drive gear *Gear stopper pin *Impeller shaft 2. Eliminate: From t h e impeller and water pump housing. I NSPECT ION 1. Inspect: *Bearing Replace. seal Replace. Impeller Replace. *Water pump seal set Replace. BEARING AND SEAL REPLACEMENT 1. Remove: *Bearing Tap off both components from water pump seal side.
WATER PUMP 3. Install: pump Use Water Pump Seal Installer Apply Sealant (Quick to crankcase cover @ before installing seal. PRESS APPLY SEALANT (QUICK I 4. Remove: No. 2 From impeller. Pry out with a small screwdriver. NOTE: Be careful not to scratch or bend the impeller shaft. Damper rubber 5. Apply: or coolant To outer surface of damper rubber impeller hub. and Never apply oil or grease to water pump seal surfaces. 6. Assemble: No. rubber To impeller hub.
WATER PUMP ASSE MB LY Mechanical seal seat Bearing Gear stopper pin Drivengear Drive gear Water pump cover O-ring Crankcase cover FRONT F R O M RADIATOR Impeller shaft Gear stopper pin gear sure not to scratch the water pump seal while installing. any scratched seal.
THERMOSTATIC VALVE THERMOSTATIC VALVE A REMOVAL 1. Remove: Thermostat cover Thermostatic valve Thermostat housing 80 (176 INSPECTION AND ASSEMBLY 1. Inspect: .Thermostatic valve 84°C (176 Valve does not open a t 80 Replace. By the following inspection steps. - Thermostatic valve inspection steps: thermostatic valve in a vessel or water. reliable thermometer in water. water slowly.
COOLANT DRAIN VALVE 2. Inspect: Replace. 3. Install: .Thermostatic valve NOTE: Line up t h e valve breather hole housing projection . with t h e cover housing COOLANT DRAIN VALVE DISASSEMBLY 1. Remove: .Retaining screw assembly INSPECTION 1. Inspect: O-ring Replace. Damage Replace. .Stopper ball Replace. ASSEMBLY 1. Install: assembly Be sure stopper ball falls into body cavity. 2. Secure valve assembly with retaining screw.
CYLINDER HEAD WATER JACKET RADIATOR AND CONDUIT CYLINDER HEAD WATER JACKET JOINT sure to drain the coolant before you disassemble the water jacket joints otherwise the coolant will flow into the crankcase. not remove the water jacket joints unless absolutely essential; when overhauling the engine. REMOVAL 1. Remove: .Stopper pins jacket joints INSPECTION 1. Inspect: jacket joint Clogging Clean. Replace. Stopper pin Replace. ASSEMBLY 1. Install: jacket joints pins RADIATOR AND CONDUIT DI SASSEMBL Y 1.
RADIATOR AND CONDUIT 2. Remove: (radiator) 3. Disconnect: hose hoses 4. Disconnect: motor coupler 5. Remove: Radiator assembly 6. Disconnect: hoses and leads (conduit) 7. Remove: (conduit) 8. Remove: motor assembly INSPECTION 1. Inspect: Obstruction Blow out with compressed air through rear of radiator. Flattened fins Repair. hoses Replace.
RADIATOR AND CONDUIT 2. Inspect: *Vacuum valve spring Fatigue Replace. *Vacuum valve seating condition Poor condition Replace. 3. Measure: *Valve opening pressure By the following measurement steps. Valve opening pressure measurement steps: the radiator cap pressure using the (YU-24460). Radiator Cap Tester Valve opens a t pressure below specified valve or defective Replace. - Valve Opening Pressure: 73.6 103.0 (0.75 10.7 14.9 - 1.
AND CONDUIT 5. Inspect *Cooling system By the following inspection steps. I Cooling system inspection steps: Connect Radiator Cap Tester *Apply 1.0 (14 pressure. *Measure pressure with gauge. Decrease of pressure (leaks) Repair at requ ired.
. CHAPTER 5 CARBURETION ............................................... ............................................ REMOVAL ............................................... DISASSEMBLY ............................................. INSPECTION .............................................. ASSEMBLY ............................................... INSTALLATION ........................................... . ADJUSTMENT ............................................
CARBURETOR CARBURETION CARBURETOR Throttle cable (Close side) Throttle cable (Open side) Fuel overflow hose Fuel feed hose rod Float needle valve Needle j e t screw Float Main j e t Main bleed pipe Rubber plug Fuel drain hose jet Jet shaft Fuel overflow hose Fuel feed hose air j e t Coasting enrichment valve assembly Pilot air jet No.
CARBURETOR SECTION VIEW ,,- Pilot air jet No. 1 Main air jet Jet needle Pilot air jet No. 2 Piston valve Diaphragm Purge jet No. 2 Purge jet No.
REMOVAL 1. Remove: Carburetor Refer to engine removal section. NOTE: The following parts can be cleaned and inspected bIy . without d valve plunger enrichment valve DISASSEMBLY The plastic piston valve is fragile and highly susceptible to damage. Be sure to handle with extreme care. Do not drop the valve or subject it to undue abuse as this can cause cracks that could severely weaken the piston valve. 1. Remove: lines 2. Number each carburetor before removing it from carburetor bracket. 3.
CARBURETOR 5. Remove: brackets 6. Remove: lever shafts 7. Remove: *Synchronization screws *Synchronization rod NOTE: When separating the carburetors be sure not to lose the small spring that may fall out. This spring connects the throttle levers. 8. Remove: plunger plunger body Nut Spring , 9. Remove: *Vacuum chamber cover Use the Special Torx Driver U-25359-2).
CARBURETO R 10. Rem ove: • Spring • Vacuum piston • O -ring • Pilot air jet N o. 2 11. Rem ove: • C oasting enrichm ent cover • D iaphragm 12. Rem ove: • Float cham ber cover • Needle valve 13. Rem ove: • M ain jet block 14. Rem ove: • G asket • N eedle jet N O TE: M ove the needle jet tow ard the vacuum piston.
CARBURETOR 15. Remove: Rubber caps jet bleed pipe 16. Remove: air jet No. 1 INSPECTION 1. Inspect: Carburetor body Contamination Clean. NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 2. Inspect: Float Damage Replace. valve Wea nt amination R ep Iace. 3. Inspect: piston Cracks Replace. NOTE: If you suspect the piston valve has been damaged, check the component for cracks by pouring gasoline into the valve.
CARBURETOR 4. Inspect: needle Replace. 5. Inspect: Tears Replace. 6. Inspect: plunger Replace. 7. Inspect Damage Replace. ASSEMBLY To assemble t h e carburetors, reverse the disassembly procedures. N o t e t h e following points. reassembling, wash all parts in clean gasoline. use a new gasket. 1. Install: jet NOTE: Make sure t h e projections on the carburetor body are meshed with t h e holes on t h e gasket.
CARBURETOR 2. Install: block NOTE: Make sure the projection on the j e t block is meshed with the groove on the needle jet. 3. Install: enricher piston NOTE: There is a tab on the rubber diaphragm and a matching recess in the carburetor body to accept the diaphragm tab. 4. Install: lever shafts Apply to the starter plunger lever securing screws. 5. Install: brackets: Apply screws. to the bracket securing NOTE: When reassembling, the surface plate should be used for proper carburetor alignment.
CARBURETOR ADJUSTMENT 1. Measure: level Out of specification Adjust. By the following measurement steps. Fuel Level: 16 1.0 mm (0.63 0.04 in) Below the Carburetor Piston Valve Center Fuel level measurement steps: t h e motorcycle on a level surface. a garage jack under the engine to ensure t h a t t h e carburetor is positioned vertically. t h e Fuel Level Gauge (YM-01312) to t h e drain pipe using a level gauge adapter t h e drain screw and w a r m up t h e engine for several minutes.
THROTTLE CABLE CYLINDER THROTTLE CABLE CYLINDER Cable cylinder Slider Cable adjustment mark (Open side) Standard adjuster distance Cable adjuster (Carburetor side) Locknut (Carburetor side) Throttle stop screw tape Cable adjustment mark (Close side) Cable adjuster (Throttle grip side) .Turning direction Free play (Throttle grip) ADJUSTMENT 1. Loosen: .Throttle stop screw To set the throttle valve to full closed. 2. Adjust: Between the threaded end of the tubular control cable guide and the adjuster.
THROTTLE CABLE CYLINDER 3. Measure: Free play (throttel grip) Out of specification Adjust. Throttle Grip Free Play : 4 7 (0.16 0.28 in) 4. Check: 2 carburetor throttle valve operation By the following checking steps. No. 2 carburetor throttle valve operation checking steps: Loosen the locknut (carburetor side) throttle grip back and forth. No. 2 carburetor to see if the throttle valve operates a t full open and full closed.
THROTTLE CABLE CYLINDER Second step: a. Loosen the locknut (carburetor side). b. Turn the adjuster (carburetor side) counterclockwise a little. c. Turn adjuster (throttle grip side) clockwise so that the free play (throttle grip) is within 4 7 mm (0.16 0.28 in). d. Check to see if throttle valve operates a t full open. If not, repeat steps a d. e. Tighten locknut (carburetor side). f. Check to see if throttle valve operates a t full open or full closed.
V-BOOST 6. Install: cleaner 7. Set engine idle speed. V-BOOST REMOVAL 1. Remove: assembly Refer to engine removal section. NOTE: The V-boost can be inspected without the disassembly. It is not necessary to disassemble the V-boost. INSPECTION 1. Inspect: Contamination Clean. Use a petroleum based solvent. valves Replace V-boost assembly. ADJUSTMENT NOTE: These adjustments are only required when following is replaced. motor cable cable joint Carburetor joint Control Cable Adjustment 1.
V-BOOST 2. Measure: Between the pulley Out of specification . and the adjuster Adjust. m (0.012 0.004 in) Lockunt 3. Adjust: By the following adjustment steps. Clearance adjustment steps: First step: NOTE: Do not loosen the locknut in this stage. . the lock bolt on the main switch for the servo motor initial operation (valve closed position). NOTE: By performing these steps, and appropriate tension for the control cable 1 can be in the joint obtain with the spring .
V-BOOST V-boost Synchronization NOTE: Before synchronizing the V-boost, the control cable should be adjusted. a’ 0.4 0.1 mm (0.016 0.004 in) 2. Adjust: By the following adjustment steps. V-boost synchronization adjustment step: the locknut the adjuster clockwise or counterclockwise until proper clearance is attained. the clearance. If not, repeat above step. the locknut. Apply to the locknut. . I NSTAL ON 1. Install: V-boost assembly Reverse the removal steps.
AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR CLEANER AND CRANKCASE VENTILATION SYSTEM Refer to "CHAPTER 2" for t h e air cleaner maintenance.
CHAPTER 6 . CHASSIS FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.................................................. FREE PLAY INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 6-44 44 6-45 SHAFT DRIVE . . . . . . . . . . . . . . . .
FRONT W H E E L CHASSIS FRONT W H E E L Collar seal Bearing 6- 1 clutch @Clutch retainer seal unit assembly
REMOVAL Securely support the motorcycle so it won't fall over when the front wheel. 1. Place the motorcycle on i t s centerstand. 2. Remove: @Speedometercable 3. Remove: Fork brace Front fender 4. Loosen: bolt (front axle) Front axle 5. Elevate the front wheel by placing a suitable stand under the engine. 6. Remove: Front axle Front wheel Lower the wheel until the brake discs come off the calipers. Turn the brake calipers outward so they do not obstruct the wheel.
FRONT WHEEL 2. Inspect : F r o n t axle Bends Replace. Roll the axle on a f l a t surface. Do not attempt to straighten a dent axle. 3. Inspect: Wheel Replace. 4. Measure: Wheel Over specified limit Rim Radial Lateral 5. Check: Wheel balance O u t of balance Repalce. Limits: 2.0 mm (0.08 in) 2.0 mm (0.08 in) Adjust. Balance wheels with the brake discs installed. Be sure t h e valve stem locknut i s tightened securely after repairing or replacing a tire and/or wheel.
FRONT WHEEL Eye protection is recommended when using striking tools. -- the new bearing by reversing the previous steps. NOTE: Use a socket that matches the outside diameter of the race of the bearing. Do not strike the center race or balls of the bearing. Contact should be made only with the outer race. 7. Inspect : Brake disc specified limit Replace. Maximum Deflection (Front and Rear) : 0.15 mm (0.006 in) Minimum Disc Thickness (Front and Rear): 7.0 mm (0.
FRONT WHEEL 3. Install: Front wheel NOTE: sure that the projecting portion (torque stopper) of the gear unit housing is ed correctly. .Compress the front forks several times t o confirm proper fork operation before tightening the pinch bolt. 4. Tighten: Front axle 60 (6.0 43 5. Tighten: Pinch bolt (front axle) Fork brace Front fender 20 Nm (2.0 14 Nuts (Fork Brace): 9 Nrn (0.9 6.
R E A R W HEEL R E A R W HEEL seat Bearing Spacer Spacer Cylinder bearing seal Clutch hub Damper Hub dust seal T I R E SIZE: 1.0 mm (0.04 in) RIM SIZE: M73.50 x 15 RIM RADIAL: LATERAL: 2.0 mm (0.08 in) 120 Nm (12.
R E A R W HEEL REMOVAL 1. Place the motorcycle on its centerstand. 2. Remove: *Cotter pin *Axle nut Washer 3. Remove: Rear caliper Tension bar NOTE: Do not depress the brake pedal when the wheel is off the motorcycle as the brake pads will be forced. 4. Loosen: Pinch bolt (rear axle) 5. Remove: Rear axle While supporting the brake caliper, pull out the rear axle. Rear wheel Move the wheel to the right side to separate it from the final gear case.
INSTALLATION When installing the rear wheel, reverse the removal procedure. Note the following points. 1. Apply: Lithium base grease Lightly grease t o the final gear case splines. 2. Install: Rear wheel assembly NOTE: Be sure the splines on the wheel hub f i t into final gear case. 3. Tighten: Wheel axle 120 Nm (12.0 85 Pinch Bolt (Rear Wheel): 20Nm (2.0 14 I Always use a new cotter pin on the rear axle nut. 4. Tighten: *Tension bar Rear caliper 4 5 Nm (4.
FRONT AND REAR BRAKE FRONT AND REAR BRAKE Air bleed screw Retaining pin Dust seal Piston seal Piston A 6-9 F R O N T CALIPER : Install the pad spring with i t s longer disc rotating direction. 5 N m (0.5 3.
FRONT AND REAR BRAKE Air bleed screw Retaining pin Dust seal Piston seal Piston Shim E Install the pad spring with i t s longer tangs@ in the disc rotating direction. F -@: Be sure to position the shim that i t s arrow mark@ points in the rotating direction of the disc plate rotation. REAR CALIPER B 5 Nm (0.5 3.6 REPLACEASASET 45 Nm (4.
FRONT AND REAR BRAKE CALIPER PAD REPLACEMENT It is not necessary t o disassemble the brake caliper and brake hose t o replace the brake pads. 1. Remove: 2. Remove: Retaining clips Retaining pins spring 3. Remove: Pads NOTE: the pad spring if pad replacement is required. Replace the pads as a set if either is found to be worn to the wear limit. Wear Limit 0.5 mm (0.02 in) 4.
FRONT AND REAR BRAKE BRAKE ONLY: Be sure to position the shim so that i t s arrow mark points in the rotating direction of the disc plate rotation. CALIPE SASSE MB LY 1. Remove: Pads Refer to "CALIPER PAD ME section. 2. Remove: hose Place the open hose end into a container and pump the old fluid out carefully. 3. Remove: Caliper Never loosen the bridge bolts of the caliper. on either side 4. Remove: Dust seals Piston seals By the following removal steps.
FRONT AND REAR BRAKE MASTER CYLINDER DISASSEMBLY Master cylinder cap Rubber seal cylinder kit 4 Copper washer joint BRAKE FLUID TYPE: D O T # 3 Nm (0.9 m*kg, 6.5 ft-lb) 1 25 Nm (2.5 m-kg, 18 ft-lb) 25 Nm (2.5 m-kg, 18ft.
FR O N T A N D R EA R B R A K E Reservoir tank B and Copper washer M aster cylinder kit Locknut Adjusting rod (Forbrake pedalheight) D BR AKE H O SE R O U TIN G : W hen installing the rear brake hose, align the brake pipe w ith the front projection 2 on the m aster cylinder. A R EAR M ASTER C YLIN D ER B BR AKE FLU ID TYPE: D O T #3 25 N m (2.
FRONT AND REAR BRAKE Front Brake Master Cylinder Disassembly NOTE: Drain the brake fluid before removing master cylinder. Dust b o o t Piston Piston cups Return spring Washer Seat A MASTER CYLINDER KIT (Replace as a set) 1. Remove: Brake light switch leads Brake lever Lever spring 2. Disconnect: Brake hose Drain the fluid. 3. Remove: Master cylinder Master cylinder cap 4.
FRONT AND REAR BRAKE Rear Brake Master Cylinder Disassembly NOTE: Drain the brake fluid before removing master cyIinder . 1. Remove: cover (right) 2. Disconnect: Brake hose Spring Piston cup Piston Adjusting rod Circlip Dust boot MASTER C Y L I N D E R K I T (Replace as a set) 3. Remove: Master cylinder Fluid reservoir tank Drain the fluid. 4. Disconnect: hose 5. Remove: Dust boot rod Master cylinder kit Drain the excess fluid.
FR O N T A N D R EA R B R A K E All internal parts should be cleaned in new brake fluid only. D o not use solvents w ill cause seals to sw ell and distort. 1. Inspect: Brake pads Over specified lim it Replace. 2. Inspect: • Caliper piston Rust/W ear/Dam age Replace. Dust seal/Piston seal Dam age Replace. R eplace the piston and dust seals w henever a caliper is disassem bled. • M aster cylinder kit Master cylinder body Scratches/W ear Replace. N O TE : Clean all passages with new brake fluid.
I FRONT AND REAR BRAKE Caliper Reassembly When assembling the caliper, reverse the disassembly procedure. Note the following points. 1. Install: Brake calipers Brake hoses m-kg, 32 ft-lb) I 25 Nm (2.5 m-kg, 18 ft-lb) 2. Bleed the air completely from the brake system. Master Cylinder Reassembly When assembling the master cylinder, reverse the disassembly procedure. Note the following points. 1. Install: Master cylinder kit Internal parts should be lubricated with brake fluid when installed. 2.
FRONT AND REAR BRAKE 3. Fill: Master cylinders 4. Bleed the air completely from the brake system. AIR BLEEDING , Bleed the brake system it: The system has been disassembled. A brake hose has been loosened or removed. The brake fluid i s very low. brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. 1. Bleed: Brake fluid By the following steps. Air bleeding steps: a. Add proper brake fluid to the reservoir. b. Install the diaphragm.
FRONT AND REAR BRAKE NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have pered. j. Add brake fluid t o the level line on the reservoir. BRAKE DISC INSTALLATION 1. Install: Brake NOTE: brake disc should be installed with the face outward. arrow mark arrow mark on the disc must point of the wheel. toward the rotating direction 2. Tighten: Bolts (disc) Bolts (Brake Disc): 20 Nm (2.
HYDRAULIC CLUTCH HYDRAULIC CLUTCH Copper washer Master cylinder kit (Replace as a set) 1 Nm (0.1 0.
HYDRAULIC CLUTCH CLUTCH RELEASE DISASSEMBLY 1. Remove: Footrest Change pedal Middle gear case cover NOTE: When removing the middle gear case cover, be sure oil does not leak out of the case. 2. Remove: hose Drain the fluid. release assembly Remove: Dust seal Piston assembly MASTER CYLINDER DISASSEMBLY NOTE: Drain the clutch fluid before removing master cylinder.
HYDRAULIC CLUTCH 1 . Remove: switch leads lever hose Drain the fluid. 2.Remove: Master cylinder Drain the excess fluid. 3. Remove: boot rod Circlip Master cylinder k i t CLUTCH INSPECTION AND REPAIR Recommended Clutch Component Replacement Schedule: Piston seal, dust Clutch hoses Clutch fluid Every two years Every four years Replace only when clutch is disassmbled 1 . Inspect: Cylinder body Replace. NOTE: Clean a l l passages with new brake fluid. hoses Replace.
HYDRAULIC CLUTCH 3. Inspect: Replace. seal Wear Replace. CLUTCH REASSE MBLY internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Clutch Release Reassembly When assembling the clutch release, reverse the disassembly procedure. Note the following points. 1. Install: Clutch release assembly Clutch hose I Clutch Release Assembly: 8.7 1 2 N m (1.2 Clutch Hose: 2 5 N m (2.
HYDRAULIC CLUTCH 9 Nm (0.9 Clutch Hose: 6.5 2. Install: rod 0 Lever NOTE: Grease the pivot point 3. Fill: 0 Master cylinder 4. Bleed the air completely from the clutch system. AIR BLEEDING Bleed the clutch system it: 0 The system has been disassembled. A clutch hose has been loosened or removed. The clutch fluid is very low. clutch operation i s faulty. 1. Bleed: fluid (brake fluid) By the following steps. Air bleeding steps: a. Add proper brake fluid to the reservoir. b. Install the diaphragm.
HYDRAULIC CLUTCH i.R epeat steps (e) to (h) untilallof the air bubbles have been rem oved from the I system . NO TE: If bleeding is difficult, it m ay be necessary to let the clutch fluid system stabilize for a few hours. R epeat the bleeding procedure w hen the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir.
FRONT FORK FRONT FORK Damper Air joint O-ring Air valve Fork cap O-ring Cap bolt Spring seat Fork spring Rebound spring 6-27 complete Oil lock piece Inner fork tube @Guide bush Dust cover Retaining clip seal spacer bush @Outer fork tube Drain screw
FRONT FORK REMOVAL Securely support the motorcycle so it won't fall over when the front wheel and front forks are removed. 1. Remove: Front wheel Refer t o "FRONT WHEEL" seciton. 0 Brake calipers Cable holders 2. Remove: valve cap (left) cap Depress the valve until all of the air has been released. 3. Loosen: 0 Pinch bolt (steeringcrown) bolt Use the Front Fork Cap Socket 01104). 4. Loosen: bolts (under bracket) 5.
FRONTFORK D LY 1. Remove: bolt Use the Front Fork Cap Socket 01 104). Spring seat Fork spring Inner fork tube 2. Remove: Dust cover Retaining clip Use a thin screwdriver, and be careful not t o scratch the inner fork tube. 3. Remove: Bolt (cylinder complete) Use the Damper Rod Holder and the T-Handle t o lock the damper rod. 4. Remove: Damper rod (cylinder complete) Rebound spring 5. Remove: Inner fork tube By the following removal steps. inner fork tube removal steps: Hold fork leg horizontally.
FR O N T FO R K NO TE: • Excessive force will dam age the oil seal and/or the bushes, Dam aged oil seal and bushing m ust be repalced. bottom ing the inner tube in the outer tube during the above procedure, as the oil lock piece will be dam aged. 6. Rem ove: • Oilseal Sealspacer * Slide bush • Guide bush *Oil lock piece IN SPEC TIO N Inspect: Inner fork tube Scratches/Bends Replace. D o not attem pt to straighten a bent inner fork tuba as this m ay dangerously w eaken the tube.
FRONTFORK 3. Inspect: Damper rod Replace. Contamination Blow out all oil passages with compressed air. 4. Inspect: @O-ring(cap bolt) lock piece Damage Replace. Seals Replace. ASSEMBLY Before assembling, clean and inspect all parts and replace when necessary. NOTE: In front fork assembly, be sure to use following new parts. Do not reuse them. bush Guide bush seal Dust seal 1. Install: Rebound spring Damper rod Allow the rod t o slide slowly down the tube until the it protrudes from the bottom.
FRONT FORK 3. Tighten: Bolt (cylinder complete) Use the Damper Rod Holder and the T-Handle Bolt (Cylinder Complete): 40 Nm (4.0 29 4. Install: *Slide bush outer tube. Use the Fork Seal Driver Weight 33963) and the Adapter (YM-33964). @inner tube Outer tube 5. Install: spacer On top of the slide bush seal Use the Fork Seal Driver Weight 33963) and the Adapter and install with numbered side up. inner tube Outer tube 6.
FRONT FORK 8. Install: Fork spring With smaller pitch side up. *Spring seat bolt Temporarily tighten the cap bolt. INSTALLATION 1. Install: Front underbracket. Circlip Onto inner tube. Apply a light coat of lithium base grease to the O-rings in the air joint bracket. joint bracket Rubber damper Over inner fork tube. 2. Tighten: Pinch bolts (under bracket) Temporarily tighten the pinch bolts. NOTE: Position the inner tube end so that it i s flush with the top of the steering crown. 3.
FRONT FORK 5. Adjust: Front fork air pressure Refer to "CHAPTER 2. FRONT FORK A DJUSTM ENT" section. 6. Install: valve cap Fork cap Brake calipers *Cable holders Refer to "FRONT A N D REAR BRAKE" section. Front wheel Refer to "FRONT WHEEL" section.
STEERING H E A D STEERING HE AD @Steering stem nut Lock washer nut (Upper) @Washer Ring nut (Lower) Bearing cover Bearing (Upper) Bearing (Lower) Nrn (2.0 14 (11 20 40 (4.0 (2.0 14 29 1. TIGHTEN RING 50 (5.0 36 LOOSEN IT COMPLETY: 3. RETIGHTEN IT: 3 Nrn (0.3 2.
REMOVAL Securely support the motorcycle so there is no danger of it falling over. 1. Remove: Front wheel Front forks 2. Remove: Headlight lens unit 3. Disconnect: leads (in the headlight body) 4. Remove: *Bolt (headlight body bracket) Emblem 5. Remove: Flasher light bracket assembly 6.
STEER IN G H EA D 7. R em ove: • Brake hose joint R em ove: • N ut (steering crow n) • Steering crown 9. R em ove: Lock w asher (ring nut) • Ring nut (upper) • W asher R ing nut (low er) Support the under bracket so that it m ay not fall dow n. 10.
INSPECTION 1. Wash the bearing in a solvent. 2. Inspect: Bearings Bearing race Replace. NOTE: Always repalce bearing and race as a set. INSTA LLAT I 0N 1. Lubricate: Bearing and races 2. Install: (lower) Onto steering stem. stem Hold the steering stem until it is secured. Bearing (upper) Ball race cover Ring nut (lower) 3. Tighten: Ring nuts (lower and upper) B y the following tightening steps. Ring nuts tightening steps: Install the ring nut (lower)@.
STEERING HEAD @Checkthe steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings Install the washer Install the ring nut (upper) NOTE: The tapered side of ring nut must face downward. tighten the ring nut then align the slots of both ring nuts. If not aligned, and tighten the hold the lower ring nut other until they are aligned. Install the lock NOTE: Make sure the lock washer tab i s placed in the slots.
REAR SHOCK ABSORBER REAR SHOCK ABSORBER shock absorber assembly 20 Nm (2.0 14 SPRING PRELOAD POSITION (STANDARD): 1 DAMPING POSITION (STANDARD): 1 20 Nm (2.
REAR SHOCK ABSORBER REMOVAL 1. Remove: Bolt (shock absorber top) Special washer Nut (shock absorber bottom) *Plain washer 2. Pull out the shock absorber top, and turn the shock absorber clockwise. 3. Remove: Rear shock absorber INSPECTION 1. Inspect: Shock absorber rod . Replace the shock absorber assembly *Shock absorber Oil leakes Replace the shock absorber assembly. Spring Replace the shock absorber Fatigue assembly. Move the spring up and down.
REAR SHOCK ABSORBER 2. Install: Rear shock absorber NOTE: The rear shock absorber should be installed so that the damping match mark on the shock . absorber faces outward 3. Tighten: Bolt (shock absorber top) Nut (shock absorber bottom) I Bolt (Shock Absorber Top): 20 Nm (2.0 14 Nut (Shock Absorber Bottom): 30 Nm (3.0 22 I 4. Adjust: Spring preload Damping force Refer to "CHAPTER 2. REAR SHOCK ABSORB E R ADJUSTMENT" section.
SWI NGARM Locknut Pivot shaft (right) Collar seal Taper roller bearing Pivot shaft (left) Lock washer Collar seal Taper roller bearing Rubber boot 20Nm (2.0 6 Nm (0.6 100 Nm (10.0 4.3 72 100 Nm (10.
SW I NGARM FREE PLAY INSPECTION 1. Remove: Rear wheel Rear shock absorbers 2. Check: Swingarm (side play) Side play Replace taper roller bearings and collars. Move swingarm from side to side. There should be no noticeable side play. 3. Check: Swingarm (vertical movement) spots Replace bearings. Move the swingarm up and down. /-- REMOVAL 1. Remove: Rear wheel Rear shock absorbers Pivot shaft caps 2. Flatten: Lock washer tab Use a blunt chisel. I 3. Remove: shaft (left) Lock washer 4.
5. Remove: Rubber boot *Bolts (muffler) 6. Remove: Push down the muffler. 7. Remove: Final gear assembly INSPECTION 1. Wash the bearings in a solvent. 2. Inspect: Bearings Replace. seals Damage Replace. 3. Inspect: Rubber boot Damage Replace.
INSTALLATION When installing the swingarm, reverse the removal steps. Note the following points. 1. Lubricate: Bearing seals I Lithium Base Waterproof Wheel Bearing Grease 2. Install: Swingarm Pivot shafts 3. Tighten: Pivot shafts By the following tightening steps. Pivot shaft tightening steps: the pivot shaft (left) cation, Pivot Shaft (Left): 100 Nm (10.0 to specifi- 72 the pivot shaft (right) contacts the collar until Pivot Shaft (Right): 6 Nm (0.6 kg, 4.3 nut (right pivot shaft) to cation.
SHAFT DRIVE SHAFT DRIVE Dust cover Bearing housing Ring gear Stopper shim Ring gear stopper O-ring seal Ring gear shim Bearing Ring gear Thrust washer Bearing seal Bearing Drive pinion gear Bearing Bearing Bearing retainer O-ring seal Coupling gear Spring Drive shaft seal Washer Bearing 23 Nm (2.
SHAFT DRIVE TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Possible Causes Symptoms 1. A pronounced hesitation or "jerky" movement during acceleration, deceleration, or sustained speed. (This must not be confuse with engine surging or tansmission characteristics.) 2. A "rolling rumble" noticeable a t low speed; a high-piched whine; a "clunk" from a shaft drive component or area. /- 3.
SHAFT DRIVE Inspection Notes lnrestigate any unusual noises The following "Noises" may indicate a mechanical defect: a. A "rolling rumble" noise during coasting, acceleration, or deceleration. The noise increases with rear wheel speed, but it does not increase with higher engine or transmission speeds. Diagnosis: Possible wheel bearing damage. b. A "whining" noise that varies with acceleration and deceleration. Diagnosis: Possible incorrect reassembly, too-little gear lash.
I 3. Inspect: leakage By the following inspection steps. Oil leakage inspection steps: the entire motorcycle thoroughly, then dry it. a leak-localizing compound or dry powder spray t o the shaft drive. test the motorcycle for the distance necessary to locate the leak, 0 Clean Leakage Damage Inspect component housing, gasket, and/or seal for damage. Replace component.
SHAFT DRIVE TroubleshootingChart When basic conditions "a" and "b" above exist, check the following points: Elevate and spin the front wheel. Feel for wheel bearing damage. Replace the wheel bearing. (Refer to "CHAPTER 5. Check the rear wheel. Feel for bearing damage. Rear wheel bearings and shaft drive bearings probably not damaged. Repeat test or remove individual components. Remove the rear wheel. Check for wheel bearing damage. Replace the rear wheel bearing. 5. REAR WHEEL" (Refer section).
SHAFT DRIVE 1.5 mm (0.06 in) 14 (0.55 mm (3.94 in) FINAL DRIVE GEAR Gear Lash Measurement 1. Secure the gear case in a vise or other support. 2. Remove: Drain plug Drain the oil. 3. Install: A specified bolt the drain plug 4. Finger tighten the bolt until it holds the ring gear. NOTE: Do not over tighten the bolt; finger-tight is sufficient. 5. Attach: Lash Measurement Tool 01230) Dial Gauge (YU-03097) Position mark 6. Measure: lash Gently rotate the gear coupling from engagement t o engagement.
SH A FT D R IVE 2. R em ove: • Bearing housing • Dust cover • Ring gear • Shim (s) • Thrustw asher 3. Adjust: • G ear lash By the follow ing adjustm entsteps. G ear lash adjustm ent steps: • Selectthe suitable shim s and thrust washer by the follow ing chart. Too-little gear lash Reduce shim thickness. Too-large gear lash Increase shim thickness. To A dd or R educe R ing G ear Shim Thickness Increase by m ore than 0.1 m m (0.004 in) R educe by m ore than 0.1 m m (0.004 in) gear shim increase.
SHAFT DRIVE 2. Measure: Ring gear stopper clearance Use the Feeler Gauge O u t of specification Adjust. Ring Gear Stopper Clearance : 0.30 0.60 mm (0.012 0.024 in) - I Ring gear stopper R i n g gear 3. Install: Bearing housing with ring gear Ring Gear Stopper Clearance Adjustment 1. Remove: Ring gear Ring gear stopper Bearing housing Left-hand-threads 2. Select: By the following chart. Shim I Thickness 0.40 0.50 3. Install: in above list (step Ring Gear Stopper: 9 Nm (0.9 6.5 LOCT I T 4.
SHAFT DRIVE . . . . Final Drive Gear Disassembly 1. Remove: Nuts (bearing housing) Bolts (bearing housing) NOTE: Working in a crisscross pattern, loosen nut 1/4 turn each, Remove them after all loosened. 2. Remove: Bearing housing Dust cover washer 3. Remove: nut (coupling gear) Use a Final Drive Shaft Holder Coupling gear 4. Remove: Bearing retainer (final drive shaft) Use a Final Drive Shaft Bearing Retainer (YM-04050). Finaldr ng-retainer has Ieft-hand threads. Turn retainer clockwise to loosen it.
Bearing Removal and Reassembly 1. Remove: *Guide collar seal Roller bearing Use a suitable press tool and an appropriate support for the main housing. 2. Inspect: Roller bearing Damage Replace. NOTE: Reuse of roller bearing OK, but recommends installation of new bearing. Do not reuse the oil seal. 3. Remove: Final drive shaft roller bearing By the following removal steps.
I SHAFT DRIVE 5. Install: Guide collar (new) Roller bearing (outer race) Use a suitable press tool and a press to install the above components into the main housing. I Final Gear Positioning Gear positioning is necessary when any of the following parts are replaced: 0 Final gear case 0 Ring gear bearing housing 1. Select: Final drive gear shim Ring gear shim By the following selection steps.
SHAFT DRIVE W here: a = a num eral (usually a decim al num ber) on the gear is either added to or subtracted from “84”. b = a num eral on the gear case (i.e. 83.50) Example: ) If final drive shaft gear is m arked “+01” . . “a” is 84.01. !) If the gear case is m arked “83.50” , . , “b” is 83.50. A = 84.01 -83.50 = 0.51 I) Therefore, shim thickness is 0.51 m m . Shim sites are supplied in following thicknesses: Because shim s can only be selected in O.
SHAFT DRIVE c =numeral on gear case 45.52) d =numeral (usually a decimal number) on outside of ring gear bearing housing and added to 3. e =numeral (usually a decimal number) on inside of ring gear either added to or subtracted from 35.40. f bearing thickness (consideredconstant). Bearing Thickness "f" = 13.00 mm Example: 1) If gear case is marked "45.52" . . . "c" is 45.52. If ring gear bearing housing is marked "35" . . . "d" is 0.35 + 3 = 3.35. ... is 3) If ring gear is marked 35.40 + 0.01 = 35.41.
SHAFT DRIVE I Hundredths I Round I 0 In the example above, the calculated shim thickness i s 0.46 mm. The chart instructs however, t o round off the 6 t o 5. shims. Thus you should use a 2. Install: *Shims (proper size as calculated) Final drive shaft assembly Bearing retainer (final drive shaft) Use a Final Drive Shaft Bearing Retainer Wrench NOTE: The bearing retainer has left-hand threads; turn retainer counterclockwise t o tighten it. Bearing Retainer: 110 Nm (11.
SHAFT DRIVE Thrust clearance measurement steps: 0 Remove t h e ring gear assembly. Place four pieces of between originally f i t t e d thrust washer and r i n g gear. 0 Install t h e r i n g gear assembly and tighten t h e bolts and nuts to specification. Bolts (Bearing Housing): 40 Nm (4.0 kg, 29 N u t s (Bearing Housing): 23 Nm (2.3 17 Ib) NOTE: Do not turn t h e shaft drive and r i n g gear when measuring clearance with Remove t h e ring gear assembly. Measure t h e thrust clearance.
SHAFT DRIVE DRIVE SHAFT Removal 1. Remove: Rear wheel Final gear assembly Drive shaft Inspection 1. Inspect: Drive shaft splines Replace. Installation When installing the dirve shaft, reverse the removal procedure. Note the following points. 1. Lubricate: splines Molybdenum DisuIfide Grease 2. Install: Drive shaft Before installing, first set the universal joint in place on the middle case side. 3. Apply: *Sealant (Quick To the mating surfaces of both case halves. 4.
. . CHAPTER 7. ELECTR CIRCUIT DIAGRAM ................................. 7-1 .................................... 7-3 ELECTRICAL COMPONENTS ELECTRIC STARTING SYSTEM .................................. CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUT-OFF SYSTEM ........................ STARTER MOTOR TEST ....................................
COOLING SYSTEM ............................................ CIRCUIT DIAGRAM ........................................ 7-45 T R 0UBLESHOOTING ...................................... 7-47 ELECTRIC FAN AND THERMOSTATIC SWITCH . . . . . . . . . . . . . . . . . THERMO-UNIT AND THERMOMETER ......................... 7-49 FUEL PUMP SYSTEM .......................................... CIRCUIT DIAGRAM ........................................ FUEL PUMP CIRCUIT OPERATION ........................... T ROUBLESHOOTING ........
I I CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM w 7-1 w
CIRCUIT DIAGRAM Ignition coil Spark plug Ignition coil Spark plug Ignition Spark plug Ignition coil Temperature meter Thermo-unit Tachometer Horn "HORN" switch "FUEL" indicator light Fuel sender unit " OIL LEVEL" warning indicator light "NEUTRAL" indicator light Neutral switch Front brake switch Rear brake switch "LIGHTS" (Dimmer) switch Headlight "HIGH BEAM" indicator light Meter light light Fuse (HEAD) Fuse (SIGNAL) Relay unit Starting circuit cut-off relay Flasher relay Cancelling unit Starter switch "T
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (1) TCI unit Pressure sensor Ignition coil Neutral switch gauge Ignition coil Thermostatic switch Thermo-unit 7-3 IGNITION COIL: PRIMARY 2.
ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (2) Starter relay Main fuse Battery Rectifier with regulator Sidestand switch Rear brake switch Horn Relay unit Sidestand relay V-boost valve control unit Fuel pump relay Diode Main switch Wire harness BATTERY: CAPACITY: C 16AH SPECIFIC GRAVITY: 1.
I I ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-5
ELECTRIC STARTING SYSTEM I Aforementioned circuit diagram shows electrical starting circuit in wiring diagram. NOTE: For the encircled numbers and color cords, see page 7-2.
ELECTRIC STARTING SYSTEM TR O U B LESH O O TIN G Troubleshooting C hart (1) Rem ove the seat. , D isconnect the “L/W ” lead from the starter relay. C heck the battery voltage (12V) on the “L/W ” lead from the starter relay. t C orrect the battery term inal connection. I 12V C onnect the “LA N ” lead from the starter relay to the battery negative (-) term inal; use a jum per lead . If the starter relay does not click; replace the relay.
ELECTRIC STARTING SYSTE Troubleshooting C hart (2) TH E STA R TER M O TO R D O ES N O T O PERATE. relay and starter m otor; e m ain sw itc fram e; use a jum per lead . If the relay unit clicks, check the starter, clutch and neutral sw itches. R eplace sw itch (es) if necessary.
ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM A starting circuit cut-off system is employed, and operates as follows: Starting Circuit Operation The starting circuit on this model consist of the starter motor, starter relay, and the relay unit (starting circuit cut-off relay). I f the engine stop switch and the main switch are both on, the starter motor can operate only if: The transmission is in neutral (the neutral switch is on).
ELECTRIC STARTING SYSTEM STARTER MOTOR TEST O-ring Brush holder assembly seal Brush MINIMUM BRUSH LENGTH: 5.5 mm (0.
ELECTRIC STARTING SYSTEM Removal 1. Remove: motor Refer to "CHAPTER 3. ENGINE DISASSEMBLY" section. Inspection and Repair 1. Inspect: Commutator Dirty Clean with 2. Measure: Commutator diameter Out of specification motor. grit sandpaper. Replace starter 3. Measure: undercut (between commutator segments) Scrape mica to Out of specification proper valve. Use a hacksaw blade that is ground to fit. Mica Undercut: 0.7 mm (0.
ELECTRIC STARTING SYSTEM 5. Inspect: Replace 6. Inspect: Damage brushes Replace. 7. Measure: length Out of specification Replace. Minimum Brush Length: 5.5 mm (0.22 in) 8. springs Compare with new spring. Replace. Installation 1. Install: motor ,/- NOTE: Align the match marks on the brackets with on the housing.
B A T T E R Y INSPECTION 1. Inspect: Refer to "CHAPTER 2 B A T T E R Y INSPECTION" section. . . , STARTER R E L A Y TEST 1. Inspect: realy Poor condition Replace. B y the following inspection steps. Starter relay inspection steps: the seat. ignition switch to "ON", engine stop switch to " RUN" and shift pedal to RA L". the starter motor lead from the starter motor. the starter switch and check to see if the starter relay clicks. Starter relay clicking Starter relay OK.
ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF RELAY TEST 1. Remove: cover (left) unit 2. Disconnect: unit connector I I 22552 3. Measure: circuit out-off relay resistance Use the Pocket Tester Out of specification Replace. Starting Circuit Cut-off Relay Resist- + I I 225 I 10%a t 20°C I 4. Check: circuit cut-off relay contacts Use 12V battery and the Pocket Tester (YU-03112). Out of specification Replace. Battery Connected : Batterv Disconnected : SIDESTAND RELAY TEST 1.
ELECTRIC STARTING SYSTEM 2. Check: relay contacts U se 12V battery and the Pocket Tester (YU -03112). O utofspecification R eplace relay. Blue/Yellow Red/W hite Black/W hite Black D IO D E TEST 1. R em ove: cover panel *D iode 2. Check: continuity/discontinuity D efective elem ent(s) R eplace diode. P ocket tester C ontinuity X : D iscontinuity (Scale x 1 (Scale x N O TE: The results “0” or "X” should be reversed according to the P ocket Tester polarity.
ELECTRIC STARTING SYSTEM NEUTRAL SWITCH TEST 1. Disconnect: lead (Blue) 2. Check: switch contact Out of specification Replace switch. Blue Ground SIDESTAND SWITCH TEST 1. Remove: cover (left) 2. Disconnect: 02-pin connector (Blue/Yellow and Black) 3. Check: switch contacts Out of specification Replace switch.
CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7-1 7
CHARGING SYSTEM Afcrementioned circuit diagram shows charging circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2.
CHARG ING SYSTEM TR O U B LESH O O TIN G Battery voltage:M ore than 12V to m easure the generator voltage.
CHARGING SYSTEM CHARGING V O L T A G E TEST 1. Remove: *Seat 2. Connect: Tester To battery terminals. 3. Start the engine and accelerate to about 2,000 or more. 4. Measure: Generator v oItage O u t of specification Check battery, stator coil, and Generator Voltage: 14.5 Never disconnect the wires from the battery while the generator is operating, otherwise the voltage across the generator terminals will increase and damage the semiconductors.
CHARGING SYSTEM 4. Measure: coil resistance O u t of specification Replace stator coils. 15%of 20°C (68°F) (White - White) White RECTIFIER TEST 1. Check: element Replace rectifier. White White White Red Black Regulator Brown Rectifier Pocket Tester I I Continuity d a 0 a d X d b 0 b d X d C C d a e e a X 0 X I I 0 0 0 0 X X X X 0 0 0 0 X X X X X : Discontinuity NOTE: The results "0" or " X " should be reversed according to the Pocket Tester polarity.
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IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 7-23
IGNITION SYSTEM Aforementioned circuit diagram shows ignition circuit in wiring diagram.
IGNITION SYSTEM T OUBLESHOOTI NG The entire ignition system can be checked for misfire and weak spark by using the Electro Tester. 1. Warm up the engine so that all of the electrical componentsare a t operatingtemperature. 2. Connect: Tester 3. Start the engine, and increase the spark gap until misfire occurs. (Test a t various between idle and red line.) Spark plug lead Spark plug Do not run the engine in neutral above 6,000 for more than 1 or 2 seconds. Minimum Spark Gap: 6 mm (0.
IGNITION SYSTEM Troubleshooting Chart Check the entire ignition for connections. 1 Correct. Faulty Measure the battery voltage and ,specific gravity. Battery voltage: More than 12V Specific gravity: 1,280 I I Recharge the battery. I No Check the fuse "IGNITION" and wiring circuit. "ON". Check for voltage 2V) on the lead a t the TCI unit and ignition coils. 5A) No Measure the pickup coils resistance.
IGNITION SYSTEM DESC I PTION This model is equipped with a battery operated, fu transistorized, breakerless ignition system. By using magnetic pickup coils, the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition timing. The TCI (Transistor Control Ignition) unit incorporates an automatic advance circuit controlled by signals generated by the pickup coil.
IGNITION SYSTEM IGNITION SPARK GAP TEST 1. Remove: cover (left) component board 2. Disconnect: coil leads plug leads 3. Connect: Tester NOTE: Be sure to use a fully charge 12V battery . 4. Turn the spark plug gap adjuster and increase the gap to the maximum limit unless misfire occurs first. A Minimum Spark Gap: 6 mm (0.24 in) SO 13.2 1000 IGNITION COIL RESISTANCE TEST 1. Connect: Tester 2. Measure: coil resistance coil resistance O u t of specification Replace.
IGNITION SYSTEM PICKUP COIL RESISTANCE TEST 1. Remove: 2. Disconnect: connecter (Black, and Gray) Orange, 3. Measure coil resistance Use a Pocket Tester Out of specification Replace. Pickup Coil Resistance: 1 10% at 20°C - - Black Orange Gray SPARK PLUG INSPECTION Refer to "CHAPTER 2 SPARK PLUG INS PE CT N" section. I I 7-29 PRESSURE SENSOR Operation This pressure sensor unit consists of a semiconductor strain gauge and an amplifying circuit.
IGNITION SYSTEM Removal 1. Remove: cover (left) component board 2. Disconnect: connector hose 3. Remove: sensor Inspection 1. Connect: Tester 2. Measure: voltage Out of specification Replace. Output Voltage: About 2.0 DC Volt Output voltage Atmospheric pressure Pressure Installation 1. Install: sensor Reverse the removal procedure.
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 7-31
LIGHTING SYSTEM I I Aforementioned circuit diagram shows lighting circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2.
LIGHTING SYSTEM TESTS AND CHECKS The battery provides power for operation of the headlight, taillight, and meter lights. If none of the above fail to operate proceed further. Low battery voltage indicates either a faulty battery, low battery fluid level, or a defective charging system. Also check fuse condition. Replace any “open” fuses. There are individual fuses for various circuits (see complete Circuit Diagram). NOTE: Check each bulb first before performing the following check.
LIG HTING SYSTEM H eadlight Troubleshooting R eplace. Replace. Check m ain switch, replace if necessary. C heck “STAR T” sw itch,ifnecessary. n open Poor ground or poor connection of headlight w iring.
. LIGHTING SYSTEM Taillight Troubleshooting TAILLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING. Faulty Check taillight bulb. Replace. I Replace. I Faulty I Check main fuse. I t Measure voltage on Blue lead from main switch ("ON" position). 12v Measure voltage a t taillight terminal, Poor ground or poor connection of taillight wiring. 7-35 Novoltaae Check main switch, replace if necessary. - No voltage An open or poor connection between taillight and main switch terminal.
, MEMO - ............................................................................................................................................................................. ............................................................................................................................................................................. .......................................................................................................................................................
SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 7-37
SIGNAL SYSTEM Aforementioned circuit diagram shows signal circuit in wiring diagram. ,--- NOTE: For the encircled numbers and color codes, see page 7-2.
SIGNAL SYSTEM SIGNAL SYSTEM TESTS AND CHECKS The battery provides power for operation of the horn, brakelight, indicator lights and flasher lights. If none of the above operates, always check battery voltage before proceeding further. Battery 1. Check: voltage Defective components Check for: Replace. Faulty battery Low battery fluid level Defective charninn Faulty I Horn 1. Check: operation Defective components Replace. Brake Light 1. Check: light operation Defective components Replace.
SIGNAL SYSTEM "01L LEVEL" Warning Indicator Light 1. Check: light operation Defective components Replace. Check for: I Defective bulb Defective oil level gauge 1 2 V on Brown lead to indicator light I Flasher Light 1. Check: light operation Refer to " SELF-CANCELLING FLASHER SYSTEM section. O I L L E V E L GAUGE TEST 1. Drain: oil 2. Remove: level gauge 3. Measure: level gauge resistance Use the Pocket Tester O u t of specification Replace.
SIGNAL SYSTEM REED SWITCH TEST 1. Remove: *Headlight lens unit cover (left) 2. Disconnect: *Relay assembly coupler 3. Measure: Reed switch resistance Use the Pocket Tester Out of specification Replace. Lift the front wheel and rotate the wheel by hand. Then return back or when wheel is stopped Black FLASHER SYSTEM TEST Description The self-cancelling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes.
SIGNAL SYSTEM I Operation The handlebar switch has three positions: L (left), OFF, and R (right). The switch lever will return to the "OFF" position after being pushed to L or R, but the signal will function. By pushing the lever in, the signal may be cancelled manually. I f the flasher self-cancelling system should become inoperative, replace relay unit. Troubleshooting Flasher light and indicator light inoperative. Faulty Check buIb. Replace. Left circuit: for 12V on Chocolate lead to light.
SIGNAL SYSTEM . SWITCHES TEST Switches may be checked for continuity with a Pocket Tester on the "Ohm x 1" position.
I SIGNAL SYSTEM Switch Position Lead Color RIB OFF ON 0 "START" Switch Switch Position /-- OFF Color Code I 7-44
COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 7-45
COOLING SYSTEM Aforementioned circuit diagram shows cooling circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2.
COOLING SYSTEM TROUBLESHOOTING The electric fan will not turn at coolant temperatures of 105 3°C (221.0 37.4" or more: Defective I Check the connectors. Fan operative Check battery voltage on Blue leads. Correct. I Replace fan motor assembly. I No voltage I Check wiring circuit, and correct defective . Fan operative Replace the thermostatic switch. Replace the fan motor assembly.
CO O LING SYSTEM ELEC TR IC SW ITC H FA N AND TH ER M O STA TIC O peration The electric fan w ill be sw itched O N or O FF according to the coolant tem perature in the radiator. E lectric fan N O TE : The electric fan is controlled by the therm ostatic sw itch w hen the m ain sw itch is “O N ”. Thus, under certain operating conditions,this fan m ay continue to run until the engine tem perature has cooled dow n to about 91°C (195.
I 1 COOLING SYSTEM 2. Inspect: switch operation By the following inspection steps. Thermostatic switch inspectionsteps: I thermostatic switch in water. Thermometer Thermostatic switch Pocket Tester I- continuity as indicated. Note temperatures while heating the water. Malfunction Replace switch. Pocket Tester Water Temperature Step 0 - 98°C (32More than 105 (221.05 Discontinuity 3°C 105 to 98°C (221 to 208.4" 3" I Less than 98°C (208.
COOLING SYSTEM Thermo-unit.Inspection 1. Remove: cover (right) nit Handle the thermo-unit with special care. Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced. 2. operation By the following inspection steps. Thermo-unit inspectionsteps: Immerse thermo-unit in water. Temperature gauge Thermo-unit Pocket Tester Water Check continuity a t indicated Note temperatuers while heating the water. Malfunction Replace switch.
FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7-51
FUEL PUMP SYSTEM I Aforementioned circuit diagram shows fuel pump circuit in wiring diagram. /-- NOTE: For the encircled numbers and color codes, see page 7-2.
I 1 I I FUEL PUMP SYSTEM FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay, fuel pump, and fuel reserve switch. The fuel pump starts and stops as indicated in the chart below.
FUEL PUMP SYSTEM TROUBLESHOOTING TroubleshootingChart (1) Fuel pump fails to operate after engine is started. I t Start the engine and the fuel pump input voltage (Blue/Black lead). , More than 11V Less than 11V Check fuel pump, replace if necessary. I Check fuel pump relay ground lead. I OK Check ignitor unit output voltage condition (Orange lead) by testing No. 1 (rear) cylinder minimum spark gap.
FUEL PUMP SYSTEM Troubleshooting chart (2) Fuel pump fails to operate for a 5 interval when carburetor fuel level is low with the main/ engine stop switches turned t o "ON" and fuel reserve switch turned to "RES". More than Check fuel pump, replace if necessary. Stop the engine and turn on the main/ engine stop switches and measure the fuel pump input voltage lead). More than More than Turn the fuel reserve switch to "RES" and measure the fuel pump input voltage lead).
FUEL PUMP SYSTEM Troubleshooting Chart (3) Fuel pump does not stop after 30 seconds when fuel indicater light on while engine is running. pump input voltage 30 seconds after fuel sender Green lead is grounded (Blue/ Check fuel pump connections correct if necessary. Fuel sender unit resistance: 0.9 0.2 at 20°C Replace. /-- Check fuel pump relay ground lead. I Replace fuel pump relay. 1 Correct ground lead.
FUEL PUMP SYSTEM "FUEL" (RESERVE) SWITCH TEST may be checked for continuity with a Switch Pocket Tester on the "Ohm x 1" position. Switch Position Lead Color R/W R OFF ON 0 0 FUEL PUMP RELAY TEST 1. Remove: cover (left) 2. Check: pump operation Refer to "FUEL PUMP TEST" section. 3. Measure: *Battery voltage Use the Pocket Tester Out of specification Replace relay. Main and engine stop switches are "ON" position.
FUEL PUMP SYSTEM Cut-out switch Diaphragm Plunger Solenoid coil Fuel chamber Valve Outlet Inspection 1. Connect: 2V) 2. Check: pump operation Faulty operation Replace. 3. Inspect: pump Replace. FUEL SENDER UNIT TEST 1. Remove: r - cover 2. Measure: sender unit resistance Out of specification Replace. 7 Fuel Sender Unit Resistance: 0.9 0.
V-B O O ST V-B O O ST SYSTEM C IR C U IT D IA G R A M SYSTEM
Aforementioned circuit diagram shows V-boost circuit in wiring diagram. NOTE: For the encircled numbers and color codes, see page 7-2.
V-BOOST SYSTEM V-BOOST SYSTEM Description The V-Boost consists of a servomotor, a control cable, special intake joints and butterfly valves. The front and rear cylinders are connected by the special intake joint. In the middle of the intake joint is the butterfly valve. The butterfly valve is opened and closed by the servomotor. And this valve is securely closed by means of i t s return spring. The servomotor senses rpm from engine's ignition signals and controls the butterfly valve operation.
V-B O O ST SYSTEM O peration There is a lag in tim e betw een the starting ofthe servo m otor and the opening of the butterfly valves. This lag is caused by a slack provided w ith the controlcam e. Therefore, the servo m otor starts to operate at 5,730 engine r/m in but the valves begine to open at 6,000 r/m in.
Valve opens Valve closed Servo motor starts Main switch "ON" 1 second Engine starting Increased engine speed Time Initial operation 8,000 rlmin I I I I I I I I 5,730 7-63 I ----- - --
I V-BOOST SYSTEM TROUBLESHOOTING Troubleshooting Chart (1) OK When the main switch is turned on, the butterfly valves operate one cycle. Refer to "Troubleshooting Chart section. NO Check the battery voltage 0 I Recharge the battery. 16V). n When the main switch is turned on after the control cable is disconnected, the servo motor operate one cycle. I Check butterfly valves and control cable for mechanical faults. Correct any. I NO Check each couplers, and fuse. NU Correct.
V-B O O ST SYSTEM Troubleshooting C hart (2) W hen the m ain sw itch is turned on, the butterfly valves operate one cycle. unit and the V-b I C heck the ignitor and the ignition coil. I OK R eplace the V -boost valve control unit.
SERVO MOTOR TEST 1. Disconnect: motor coupler 2. Connect: Battery 3. Check: motor operation Not operation Replace. 4. Measure: .Potentiometer resistance Use the Pocket Tester Out of specification Replace. 7.
. CHAPTER 8 APPENDICES SPECIFICATIONS .............................................. GENERAL SPECIFICATIONS .................................. MAIWTENANCE FICATIONS ............................. 8-1 8-1 8-3 GENERAL TORQUE SPECIFICATIONS ............................. 8-18 ........................................ 8-18 CONVERSION TABLES......................................... 8-19 LUBRICATION DIAGRAMS ..................................... 8-20 ............................................. 8-24 .
SPECIFICATIONS APPENDICES SPECIFICATIONS GENERAL SPECIFICATIONS Engine Starting Number Vehicle Identification Number 1F K-000101 F Dimensions: I Length OveraII Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: Weight Oil and Full Fuel Tank Minimum Turning Radius: Engine: Engine Type CyIinder Arrangement Displacement Bore x Stroke Compression Ratio Compression Pressure Starting System Lubrication System: Oil Type or Grade: Engine Oil 30 40 50 1 2,300 mm (90.
FICATIONS Model Carburetor: BDS 34 x Spark Plug: Ty anufacturer G K ,X24EP IPPONDENSO DP 0.8 0.9 mm (0.031 0.035 in) Wet, multiple-disc Clutch Type: Transmission: Primary ReductionSystem Primary Reduction Ratio Secondary ReductionSystem Secondary Reduction Ratio Transmission Type Operation Gear Ratio: 1 2nd 3rd 4th 5th Chassis: Frame Type Caster Angle Trail Spar gear 87/49 (1.775) Shaft drive 21/27 x (2.851) Constant mesh, 5-speed Left foot operation 43/17 39/22 31/23 28/26 26/28 (2.529) (1.772) (1.
Model Shock Absorber: Front Shock Absorber Rear Shock Absorber Wheel Travel: Front Wheel Travel Rear Wheel Travel Electrical: Ignition System Generator System Battery Type or Model Battery Capacity ight Type: Bulb Wattage x Quantity: Headlight Ta rake Light Flasher Light Parking/ R unning Light Indicator Light: "NEUTRAL" "HIGH BEAM" "01L LEVEL" "TURN" "FUEL" Meter Light MAINTENANCE Engine spring, Oil damper Coil spring, Oil damper 140 mm (5.5 in) 100 mm (3.9 in) T.C. I. A.C.
Model Camshaft Runout Limit 0.03 mm (0.0012 in) Cam Chain: of Links Cam Chain Cam Chain Adjustment Method Valve, Valve Seat, Valve Guide: Valve Clearance (Cold): IN. EX. " A ' Head Dia. "B" Face Width "C"Seat Width Limit "D" Margin Thickness Limit> Stem Outside Dia. Limit Guide Inside Dia. < Limit> Stem-to-GuideClearance Limit> Stem Runout Limit IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. IN. EX. Automatic 0.1 1 0.26 0.15 mm (0.004 0.30 mm (0.010 0.
Model VMX Valve Spring: Inner Spring: Free Length IN. EX. Limit > IN. EX. Set Length (ValveClosed) IN. EX. Compressed Pressure (Installed) IN. EX. IN. Tilt EX. Direction of Winding 39.65 mm (1.561 in) 39.65 mm (1.561 in) 37.45 mm 1.474 in) 37.45 mm (1.474 in) 31.8 mm (1.25 in) 31.8 mm (1.25 in) 6.29 7.39 13.9 16.3 Ib) 6.29 7.39 (13.9 16.3 mm (0.067 in) mm (0.067 in) IN. EX. Left Left Outer Spring: Free Length IN. EX. Limit IN. EX. Set Length (Valve Closed) IN. EX.
Model Oversize: 1 2nd Piston Ring: Top Ring: Barrel 3.1 x 1.0 mm (0.122 x 0.040 in) 0.35 0.50 mm (0.0138 0.0197 in) 0.75 mm (0.0295 in) 0.03 0.07 mm (0.0012 0.0028 in) 0.12 mm (0.0047 in) Dimensions x End Gap (Installed) < Limit Side Clearance (Installed) Limit 2nd Ring: Taper 3.1 x 1.2 mm (0.122 x 0.047 in) 0.35 0.50 mm (0.0138 0.0197 in) 0.75 mm (0.0295 in) 0.02 0.06 mm (0.0008 0.0024 in) 0.12 mm (0.
SPECIFICATIONS VMX Model Shifter: Shifter Type Guide Bar Bending Limit Carburetor: I.D. Mark Main Jet Main Air Jet Jet Needle Needle Jet Pilot Jet Pilot Air Jet Pilot Screw Pilot Outlet Bypass Valve Seat Size Starter Jet Guide Bar 0.025 mm (0.001 in) 1FKOO 3: (N.J.) (P.A.J. (P.A.J. (B.P. (B.P. 2) (B.P. 3) Fuel Level Engine Idling Speed Vacuum Pressure a t Idling Speed Vacuum Synchronous Difference Fuel Pump: Consumption Amperage (Max.
FICATIONS Model Lubrication Chart: Intake camshaft Cylinder head I I -- I Crankcase Tightening Sequence: Lower Case With
SPECIFICATIONS Model Cooling System: Radiator Core Size: Radiator Cap Opening Pressure Reservoir Tank Capacity < From Low to Full Level Water Pump: Reduction Ratio , Shaft Drive: Middle Gear Backlash Limit Final Gear Backlash < Limit > Ring Gear Stopper Clearance 8-9 Width Height Thickness 363.8 rnrn (14.3 in) 240 mm (9.45 in) 16 rnrn (0.63 in) 73.6 103.0 (0.75 1.05 10.7 14.9 psi) 0.3 L (0.26 Imp qt, 0.32 US 0.2 L (0.18 Imp qt, 0.21 US - SingIe-suction 31/21 (1.476) trifugaI pump 0.05 0.12 mm (0.
TIGHTENING TORQUE Part to be Tightened Camshaft Cap Spark Plug Cylinder Head Cylinder Head Cover Connecting Rod AC Magneto Cam Sprocket Plate (Damper chain) Tensioner Tensioner Stopper Bolt Water Pump Cover Water Pump Housing Coolant Drain Plug Thermostatic Valve Housing Thermostatic Valve Cover Electric Fan Motor Electric Fan Radiator Assembly Breather Cover Radiator Cover Cover (Left and right) Conduit Oil Pump Cover Oil Strainer Housing Oil Pump Oil Filter Cover Engine Oil Drain Bolt Oil Pan Oil Baffle
1 I Part t o be Tightened Part Name Thread Size Q'ty Crankcase Crankcase Crankcase Dive Axle Bearing Retainer Main Axle Bearing Retainer Crankcase Cover (Left) Lead Clamp Crankcase Cover (Right) Middle Gear Case Cover Middle Gear Oil Drain Bolt One-way Clutch Clutch Boss Clutch Release Cylinder Clutch Pressure Plate Middle Drive Gear Middle Drive Shaft Middle Drive Shaft Bearing Housing Shift Cam Segment Shift Cam Plate (Neutral) Shift Cam Bearing Stopper Change Lever Adjuster Bolt Bolt Bolt Torx scr
Chassis Model Steering System: Steering Bearing Type Front Suspension: Front Fork Travel Fork Spring Free Length < Limit> Collar Length Spring Rate: Taper roller bearing K2 Stroke: Optional Spring Oil Capacity Oil Level Oil Grade Enclosed Air Pressure (Standard) < Min. Max. K2 Rear Suspension: Shock Absorber‘ Travel Spring Free Length < Limit Fitting Length Spring Rate: K2 Stroke : K2 Optional Spring Rear Arm: Free Play Limit: Vertical Lateral wheel x 18 Aluminum 2 mm (0.08 in) 2 mm (0.
Model Master Cylinder Inside Diameter Caliper Cylinder Inside Diameter Brake Fluid Type Rear Disc Brake: 15.87 mm (0.63 in) 45.4 mm (1.79 in) DOT Disc Outside Diameter x Thickness Pad Thickness Inner < Limit>* Pad Thickness Outer < .... . ......... .... . . . . Single 282 x 7.5 mm (11.1 x 0.30 in) 5.5 mm (0.22 in) 0.5 mm (0.02 in) 5.5 mm (0.22 in) 0.5 mm (0.02 in) I 12.7 mm (0.50 in) 42.85 mm (1.
SPECIFICATIONS TIGHTENING TORQUE: Part to be Tightened Thread Size Tightening Torque Remarks Nm 60 20 23 20 110 50 3 6.0 2.0 2.3 2.0 11.0 5.0 0.3 43 14 17 14 80 Steering Shaft Ring Nut (Lower) Steering Shaft Ring Nut (Lower) Steering Shaft Ring Nut (Upper) 1.5 M8 x 1.25 M8 x 1.25 M8 x 1.25 M22 x 1.0 M25 x 1.0 M25 x 1.0 M25 x 1.
FICATIONS Electrical Model Voltage: Ignition System: I Timing Advanced Timing (B.T.D.C.) Advancer Type .C E 12v 3" a t 1,000 43" a t 9,000 Vacuum and electrical 60 n 40 20 0 1 2 3 4 5 T.C. Pickup Coil Resistance 7 6 8 9 15% a t 20°C (68°F) (Orange - Black), (Orange - Gray) (Orange (Orange TID ITACHI T.C.I. Ignition Coil: CM11-61 I I 10% a t 20°C (68°F) 20% a t 20°C (68°F) 13.2 A.C. magneto generator Primary Winding Resistance Secondary Winding Resistance Charging pe: A.C.
Model /--- VMX Voltage ReguI No Load Regulated Voltage Rectifier: Capacity Withstand Voltage Battery: Capacity Specific Gravity Electric Starter System: Starter Motor: Short control SH INDENG EN 14- 15V SH 25A 200v INDENGEN 16AH 1.280 Constant mesh type BA o u t put Bush: Overall Length < Limit > Spring Pressure Commutator: Outside Diameter Wear Limit > Mica Undercut Starter Relay: Amperage Rating Coil Winding Resistance Horn: ty Ty 0.6 12.5 mm (0.49 in) 5.5 mm (0.22 in) 560 680 g (19.7 23.
SPECIFICATIONS ModeI Starting Circuit Cut-off Relay: Coil Winding Resistance Diode T- 100-Y 1 10% a t 20°C (68" Yes.
OF UNITS GENERAL TORQUE 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 tighten this book. To avoid fastener assemblies in a crisscross fashion, in progressive stages, until full torque i s reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be a t room temperature.
CONVERSION TABLES CONVERSION TABLES Metric t o inch system Known km m m cm mm Multiplier Inch t o metric system Known Result Multiplier 7.233 86.80 0.0723 0.8680 0.13826 0.01 152 13.831 1.1521 0.03527 0.4535 28.352 2.352 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.4252 1.609 1.609 0.3048 0.9141 2.54 25.4 cm mm cc cc lit (liter) Iit (liter lit (liter) Centigrade mi ft in in (US (US t (Iiter lit (liter) lit (liter) 0.03382 0.06102 2.1134 1.057 0.
LUBRICATION DIAGRAMS LUBRICATION AG RAMS LUBRICATION DIAGRAM 8-20
LUBRICATION DIAGRAMS LUBRICATION DIAGRAM (2) 8-21
LUBRICATION AG RAMS LUBRICATION DIAGRAM 8-22
LUBRICATION DIAGRAMS LUBRICATION DIAGRAM (4)
Headlight body Hose guide Front flasher light lead (Left) Clutch hose Speedometer cable Front brake hose @Brake joint Wireharness light lead @Front flasher light lead (Right) Front brake hose /-- 8-24
CABLE ROUTING Fuel pump control unit Relay unit V-boost valve control unit V-boost valve control unit lead Clamp hose clamp 7 Throttle cable joint Fuse box unit Ignition coil 8-25 Sidestand relay Radiator fan lead Horn lead (For speedometer cable) Clamp (For brake hose) 19 Guide (For throttle cable) Guide (For clutch hose) Handlebar switch lead (Left) A Pass the handlebar switch lead inside the clutch hose B Pass the meter lead outside the u tch hose. C Pass the clutch hose outside the throttle cable.
CABLE ROUTING Main fuse Ignition coil Oil level switch lead Neutral switch lead Regulater lead Sidestand switch lead A.C. generator lead Band Clamp lead (For clutch hose) Clamp (For sidestand switch lead) Clamp Clamp (For clutch hose) Starter relay Pass the band through the guide on frame on frame.
CABLE ROUTING Handlebar switch lead Diode Ignitor unit Ignition coil lead Conduit lead Band Battery negative Ignition coil ignition coil lead Starter relay lead Fuel filter 8-27 lead cover lead flasher light lead (Left) coil lead up coil lead @Starter relay lead @Starter motor lead switch lead Regulater lead level switch lead Neutral switch lead @Battery positive (+) lead fuse pump Fuse box V-boost valve control unit @Meter lead Clamp the taillight lead and rear flasher light lead (Right) Clamp the rear
@Earth lead /-- 'switch lead (Left) coil conduit Earth lead Rear brake switch lead Battery breather hose @Coolant reservoir tank breather hose Fuel sender lead Rear brake switch lead Band negative reservoir lead Band @Main switch lead switch brake reservoir tank @Battery box (For battery breather hose) (For reservoir tank breather hose and Battery breather hose) A Pass the wireharness outside the main switch stay. Earth lead: Pass the earth lead outside the reservoir tank breather hose.
CABLE ROUTING Fuel filter bracket Fuel filter Fuel pipe cover Filler cap Battery band Fuel pump Clamp Fuel pipe
CABLE ROUTING Reservoir tank clip Spring clip Filler cover Pipe joint clip Drain hose Band Over flow hose valve Holder Fuel sender Battery breather hose A 8-30
CABLE ROUTING CANISTER PIPE ROUTING To carburetor To fuel tank TO Canister
CONSUMER IN FORMATION CONSUMER IN ON NOTICE The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. These figures indicate braking performance that can be met or exceeded by the vehicles to which they apply, without locking the wheels, under different conditions of loading and with partial failures of the braking system.
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