Yamaha TDM850- User Manual

Page 4 - WARNING; NOTICE; PARTICULARY IMPORTANT INFORMATION; This material is distinguished by the following notation.

WARNING CAUTION: NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and theirqualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is as-sumed that persons using this book to perform maintenance and repairs on...

Page 5 - HOW TO USE THIS MANUAL

1 2 4 6 5 7 3 8 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicat...

Page 6 - ILLUSTRATED SYMBOLS

22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC CHAS COOL INSP ADJ TRBL SHTG EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on topright of each page and indicate the subject of eachchapter. 1 General information 2 Specifications 3 Pe...

Page 7 - INDEX

GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION ANDADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INSP ADJ INDEX

Page 9 - GENERAL INFORMATION; MOTORCYCLE IDENTIFICATION

GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRAME SERIAL NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER 1-1 . . . . . . . . . . . . . . . . . . . ....

Page 11 - GEN

1-1 MOTORCYCLE IDENTIFICATION GEN INFO NOTE: NOTE: EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head. The vehicle identification number is used to identi-fy the motorcycle and may...

Page 12 - IMPORTANT INFORMATION

1-2 IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL1. Remove all dirt, mud dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the motorcycle keep mated parts together. Thi...

Page 14 - CHECKING OF CONNECTIONS

1-4 CHECKING OF CONNECTIONS GEN INFO NOTE: NOTE: CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the con-nector.1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will no...

Page 15 - HOW TO USE THE CONVERSION TABLE

1-5 HOW TO USE THE CONVERSION TABLE GEN INFO HOW TO USE THE CONVERSIONTABLE All specification data in this manual are listed in SIand METRIC UNITS.Use this table to convert METRIC unit data to IM-PERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL **mm 0.03937 = **in 2 mm 0.03937 = 0.08 in CONVERSION T...

Page 16 - SPECIAL TOOLS; Tool name / How to use

1-6 SPECIAL TOOLS GEN INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly.Using the correct special tool will help prevent damage caused by the use of improper tools or improvisedtechniques. The shape and part number used for the special tool diff...

Page 19 - SPEC; SPECIFICATIONS; ENGINE

SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 21 - GENERAL SPECIFICATIONS

2-1 GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model: TDM850 Model code: 4TX1 Dimensions: Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius 2,165 mm, 2,200 mm (D, DK, SF, N, S)790 mm1,285 mm805 mm1,475 mm1...

Page 22 - Item

2-2 GENERAL SPECIFICATIONS SPEC Item Standard Air filter: Dry type element Fuel: TypeFuel tank capacityFuel reserve amount Regular unleaded gasoline20 L3.1 L Carburetor: Type / quantityManufacturer BDST38 / 2MIKUNI Spark plug: TypeManufacturerSpark plug gap DPR8EA-9 / X24EPR-U9NGK / NIPPONDENSO0.8 X...

Page 23 - * Load is total weight of cargo, rider, passenger and accessories

2-3 GENERAL SPECIFICATIONS SPEC Item Standard Tire pressure (cold tire): Maximum load-except motorcycleLoading condition A* frontrear Loading condition B* frontrear High speed riding frontrear 180 kg0 90 kg 225 kPa (2.25 kg / cm 2 , 2.25 bar) 275 kPa (2.75 kg / cm 2 , 2.75 bar) 90 180 kg 225 kPa (2....

Page 24 - MAINTENANCE SPECIFICATIONS

2-4 MAINTENANCE SPECIFICATIONS SPEC Head Dia Face Width Seat Width Margin Thickness MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm Cylinder: Bore sizeTaper limitOut of round limit 89.500 89.505 mm 89.6 mm0.05 mm0.03 mm Camshaft: Drive methodCamshaft cap insid...

Page 29 - Tightening torques; size

2-9 MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Part name Thread size Q’ty Tightening torque Remarks g size y Nm m S kg Camshaft capCylinder head Cylinder head coverCoolant drain bolt (cylinder body)Spark plugConnecting rodRotorCamshaft sprocketTiming chain tensionerRadia...

Page 30 - Crankcase tightening sequence:

2-10 MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Part name Thread size Q’ty Tightening torque Remarks g size y Nm m S kg Stator coilStarter motorThermo switchThermo switch housing Screw Flange bolt —— M6M6M6 PT1 / 8 3211 7 102815 0.71.02.81.5 Crankcase tightening sequence:

Page 31 - CHASSIS

2-11 MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travelFork spring free lengthSpring rate (K1) Stroke (K1) Optional springOil capacity (per fork tube)Oil levelOil grade 149 mm505 mm6.4 N / mm (0.64 kg...

Page 33 - See “NOTE”

2-13 MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Thread size Tightening torque Remarks g size Nm m S kg Upper bracket and inner tubeUpper bracket and steering stemSteering stem and ring nutInner tube and under bracketHorn bracket and brake hose holderBrake hose holder and...

Page 34 - kg) by using the torque wrench, then loosen the

2-14 MAINTENANCE SPECIFICATIONS SPEC NOTE: Part to be tightened Thread size Tightening torque Remarks g size Nm m S kg Caliper bracket and swingarmBrake disc and wheel hub (front and rear)Driven sprocket and rear hubBleed screw and brake caliperRear brake hose union boltFront wheel axle pinch boltBr...

Page 35 - ELECTRICAL

2-15 MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.)Advancer type 10 at 1,150 r / min Electrical type T.C.I.: Pickup coil resistance / color 192 288 Ω at 20 C/ Blue / Yellow – T.C.I. unit model / manufacturer Green / WhiteTNDF3...

Page 37 - GENERAL TORQUE SPECIFICATIONS; General torque

2-17 GENERAL TORQUE SPECIFICATIONS SPEC GENERAL TORQUESPECIFICATIONS This chart specifies torque for standard fastenerswith standard I.S.O. pitch threads.Torque specifications for special components orassemblies are included in the applicable sec-tions of this book. To avoid warpage, tighten multi-f...

Page 38 - LUBRICATION POINT AND GRADE OF LUBRICANT

2-18 LUBRICATION POINT AND GRADE OF LUBRICANT SPEC LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication point Lubricant type Oil seal lips O-ring Bearing Crankshaft (big end) Piston surface Piston pin Cylinder Piston ring, oil ring Connecting rod bolt Crankshaft journal Balancer (bearing / sh...

Page 40 - LUBRICATION DIAGRAMS

2-20 1 Oil pump (for pumping oil to the oil tank) 2 Oil pump (for lubricating the engine parts) 3 Oil strainer 4 Oil filter 5 Drain bolt 6 Oil tank LUBRICATION DIAGRAMS SPEC LUBRICATION DIAGRAMS

Page 45 - CABLE ROUTING

2-25 CABLE ROUTING SPEC 1 Throttle cable 2 Right handlebar switch lead 3 Brake hose 4 Main switch lead 5 Clutch cable 6 Left handlebar switch lead 7 Horn lead 8 Starter cable 9 Coolant reservoir hose 10 Headlight lead 11 Meter light lead 12 Thermo switch lead 13 Fan motor lead 14 Ignition coil (left...

Page 52 - CARBLE ROUTING

2-32 1 Headlight lead 2 Wire harness 3 Meter light lead 4 Throttle stop screw cable 5 Vacuum hose (#1) 6 Carburetor air vent hose 7 Carburetor breather hose 8 Starter motor lead 9 Battery positive lead 10 Battery negative lead 11 Coolant reservoir breather hose CARBLE ROUTING SPEC 12 Coolant reservo...

Page 55 - PERIODIC INSPECTION AND ADJUSTMENT; INTRODUCTION

INSP ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE / LUBRICATION INTERVALS 3-1 . . . . . . . . . . . . . . COWLINGS, SEAT, TAIL COVER AND FUEL TANK 3-3 . . . . ...

Page 57 - LUBRICATION INTERVALS; INSP; : If is recommended that these items be serviced by a Yamaha dealer.

3-1 INTRODUCTION / PERIODIC MAINTENANCE / LUBRICATION INTERVALS INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. Thesepreventive maintenance procedures, if followed, will ensure more reliable ...

Page 58 - PERIODIC MAINTENANCE / LUBRICATION INTERVALS; the brake fluid level and add the fluid as required.

3-2 PERIODIC MAINTENANCE / LUBRICATION INTERVALS INSP ADJ NOTE: Brake fluid replacement:1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. 2. On the inner parts of the master cylinder and caliper...

Page 59 - Order

3-3 COWLINGS, SEAT, TAIL COVER AND FUEL TANK INSP ADJ Order Job name / Part name Q’ty Remarks 123456789 10 11 Cowlings removalSide cowling (left and right)Meter panelDamperWind shieldInner panelFront flasher light leadFront flasher light (left and right)Auxiliary light lead couplerHeadlight lead cou...

Page 61 - AIR FILTER CASE; AIR FILTER CASE

3-5 AIR FILTER CASE INSP ADJ Order Job name / Part name Q’ty Remarks 1234 Air filter case removalSide cowling, seat, side cover and fueltankCylinder head breather hoseAir filter case breather hoseCarburetor clampAir filter case 1121 Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAILC...

Page 62 - VALVE CLEARANCE ADJUSTMENT; Side cowling

3-6 VALVE CLEARANCE ADJUSTMENT INSP ADJ NOTE: ENGINE VALVE CLEARANCE ADJUSTMENT The valve clearance should be adjusted whenthe engine is cool to touch. The piston must be at Top Dead Center (T.D.C.)on compression stroke to check or adjust thevalve clearance. 1. Remove: Side cowling Seat Side cover F...

Page 64 - Rotate the crankshaft 270

3-8 VALVE CLEARANCE ADJUSTMENT INSP ADJ NOTE: NOTE: NOTE: NOTE: S Measure the valve clearance using a feelergauge 2 . S Record the measured reading if the clearance isincorrect. S Rotate the crankshaft 270 _ counterclockwise and check the clearance of piston #2. Make sure that the camshaft lobes are...

Page 65 - Remove the valve lifters 1 and the pads 2 .; Pad range; Pads can only be selected in 0.05 mm increments.

3-9 VALVE CLEARANCE ADJUSTMENT INSP ADJ NOTE: NOTE: NOTE: Remove the valve lifters 1 and the pads 2 . Place a rag in the timing chain space to preventpads from falling into the crankcase. Identify each valve lifter 1 and pad 2 positionvery carefully so that they can be reinstalled intheir original p...

Page 66 - Install the new pads 1 and the valve lifters 2 .

3-10 VALVE CLEARANCE ADJUSTMENT INSP ADJ NOTE: NOTE: 10 Nm (1.0 m kg) NOTE: Locate the rounded-off value and the mea-sured valve clearance in the chart “PADSELECTION TABLE”. The field where thesetwo coordinates intersect shows the new padnumber to use. Use the new pad number only as a guide whenveri...

Page 67 - INTAKE

3-11 VALVE CLEARANCE ADJUSTMENT INSP ADJ VALVE CLEARANCE (cold): 0.15 0.20 mm Example: Installed is 175 Measured clearance is 0.27 mmReplace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm MEASURED CLEARANCE INSTALLED PAD NUMBER VALVE CLEARANCE (cold): 0.25 0.3...

Page 68 - Recheck the valve clearance.

3-12 VALVE CLEARANCE ADJUSTMENT INSP ADJ NOTE: 10 Nm (1.0 m kg) 18 Nm (1.8 m kg) Recheck the valve clearance. If the clearance is still incorrect, repeat all theclearance adjustment steps until the specifiedclearance is obtained. 10. Install: All removed parts Install all removed parts in reversed o...

Page 69 - CARBURETOR SYNCHRONIZATION

3-13 CARBURETOR SYNCHRONIZATION INSP ADJ NOTE: NOTE: CARBURETOR SYNCHRONIZATION Valve clearance and idling speed should be ad-justed properly before synchronizing the carbure-tors. 1. Place the motorcycle on a level surface. Place the motorcycle on its centerstand if a cen-terstand is equipped. If n...

Page 70 - Carburetor synchronization; Intake vacuum at idle speed:; Stop the engine and detach the measuring; At throttle grip flange; Fuel tank

3-14 CARBURETOR SYNCHRONIZATION INSP ADJ NOTE: 7. Adjust: Carburetor synchronization Adjustment steps: Synchronize carburetor #1 to carburetor #2 byturning synchronizing screw 1 until bothgauges read the same. Race the engine for less than a second, two orthree times and check the synchronizationaga...

Page 71 - IDLING SPEED ADJUSTMENT

3-15 IDLING SPEED ADJUSTMENT INSP ADJ NOTE: IDLING SPEED ADJUSTMENT The carburetor synchronization should be ad-justed properly before adjusting the idling speed. 1. Start the engine and let it warm up for several minutes. 2. Attach: Engine tachometer 1(to the #1 spark plug lead). Engine tachometer:...

Page 72 - Idling speed is increased.

3-16 IDLING SPEED ADJUSTMENT / THROTTLE CABLE ADJUSTMENT INSP ADJ NOTE: Turn the throttle stop screw 2 in or out untilspecified idling speed is obtained. Turnning in: Idling speed is increased. Turnning out: Idling speed is decreased. 6. Adjust: Throttle cable free playRefer to “THROTTLE CABLE FREE ...

Page 73 - THROTTLE CABLE ADJUSTMENT; Free play is increased.

3-17 THROTTLE CABLE ADJUSTMENT INSP ADJ NOTE: WARNING 3. Adjust: Throttle cable free play Adjustment steps:First step: Loosen the locknut 1 Turn the adjuster 2 in or out until the specifiedfree play is obtained. Turnning in: Free play is increased. Turnning out: Free play is decreased. Tighten the l...

Page 74 - SPARK PLUG INSPECTION; Spark plug caps

3-18 SPARK PLUG INSPECTION INSP ADJ CAUTION: 18 Nm (1.8 m kg) NOTE: SPARK PLUG INSPECTION1. Remove: Spark plug caps Spark plugs Before completely removing the spark plug,use compressed air to clean the cylinder headcover areas to prevent dirt from falling into theengine. 2. Inspect: Spark plug typeI...

Page 75 - IGNITION TIMING CHECK

3-19 IGNITION TIMING CHECK INSP ADJ NOTE: NOTE: IGNITION TIMING CHECK Carburetor synchronization, engine idle speedand throttle cable free play should be adjustedproperly before checking the ignition timing. 1. Remove: Timing plug 1 2. Attach: Timing light Engine tachometer(to the #1 spark plug lead...

Page 76 - COMPRESSION PRESSURE MEASUREMENT

3-20 COMPRESSION PRESSURE MEASUREMENT INSP ADJ NOTE: CAUTION: COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result inperformance loss. 1. Check: Valve clearanceOut of specification Adjust. Refer to “VALVE CLEARANCE ADJUST-MENT”. 2. Start the engine and let it warm up for se...

Page 77 - Spark plugs

3-21 COMPRESSION PRESSURE MEASUREMENT INSP ADJ WARNING NOTE: 18 Nm (1.8 m kg) Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher thanwithout oil Worn or damagedpistons / pistonrings Repair Same as without oil Defective ring(s),valves, cylinderhead gasket or pis-ton is pos...

Page 78 - ENGINE OIL LEVEL INSPECTION; Place the motorcycle on a level surface.

3-22 ENGINE OIL LEVEL INSPECTION INSP ADJ NOTE: NOTE: CAUTION: NOTE: ENGINE OIL LEVEL INSPECTION Position the motorcycle straight up when inspect-ing the oil level. 1. Place the motorcycle on a level surface. After idling the engine for 15 minutes, be sure themotorcycle is vertical, then check that ...

Page 79 - ENGINE OIL REPLACEMENT; New

3-23 ENGINE OIL REPLACEMENT INSP ADJ New 35 Nm (3.5 m kg) 30 Nm (3.0 m kg) ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: Oil filler plug 1 4. Remove: Drain bolt (with gasket) 1 Oil filter dra...

Page 80 - Crankcase

3-24 ENGINE OIL REPLACEMENT INSP ADJ CAUTION: 7. Fill: Crankcase The engine should be filled with oil in twosteps. First fill the engine with 3.2 liters of oil.Then start the engine and race it five or sixtimes. Stop the engine and fill it with oil to thespecified level. Oil quantity: Total amount: ...

Page 81 - CLUTCH ADJUSTMENT / AIR FILTER CLEANING; At clutch lever end

3-25 CLUTCH ADJUSTMENT / AIR FILTER CLEANING INSP ADJ A B CAUTION: CLUTCH ADJUSTMENT1. Check: Clutch cable free play aOut of specification Adjust. Free play: 10 15 mm At clutch lever end 2. Adjust: Clutch cable free play Adjustment steps: Loosen the locknut(s) 1 . Turn the adjuster(s) 2 in or out un...

Page 84 - Exhaust pipes; COOLANT LEVEL INSPECTION

3-28 EXHAUST SYSTEM INSPECTION / COOLANT LEVEL INSPECTION INSP ADJ 20 Nm (2.0 m kg) 24 Nm (2.4 m kg) 24 Nm (2.4 m kg) 20 Nm (2.0 m kg) NOTE: NOTE: EXHAUST SYSTEM INSPECTION1. Inspect: Exhaust pipes MufflersCracks / Damage Replace. GasketsExhaust gas leaks Replace. 2. Check: Exhaust pipe nut 1 Exhaus...

Page 85 - Place the motorcycle on a level surface.

3-29 COOLANT LEVEL INSPECTION / COOLANT REPLACEMENT INSP ADJ CAUTION: WARNING NOTE: NOTE: Hard water or salt water is harmful to the en-gine parts; use boiled or distilled water if youcan’t get soft water. COOLANT REPLACEMENT1. Remove: Side cowling (right) SeatRefer to “COWLINGS, SEAT, TAIL COVERAND...

Page 86 - COOLANT REPLACEMENT; Gaskets; Coolant and water mix ratio:

3-30 COOLANT REPLACEMENT INSP ADJ New 10 Nm (1.0 m kg) 10 Nm (1.0 m kg) NOTE: WARNING 5. Install: Gaskets Drain bolt 1 Cylinder drain bolt 6. Connect: Coolant reservoir hose 7. Fill: Cooling system (radiator and engine)(to specified level a ) Recommended coolant: High quality ethylene glycol anti-fr...

Page 87 - Do not use water containing impurities or oil.

3-31 COOLANT REPLACEMENT INSP ADJ CAUTION: NOTE: Hard water or salt water is harmful to the en-gine parts. Use boiled or distilled water if youcan’t get soft water. Do not use water containing impurities or oil. Take care that no coolant splashes ontopainted surfaces. If it does, wash it away withwa...

Page 88 - Radiator 1

3-32 COOLANT REPLACEMENT / COOLING SYSTEM INSPECTION INSP ADJ COOLING SYSTEM INSPECTION1. Inspect: Radiator 1 Hose 2 2 Hose 3 3Cracks / Damage Replace. Refer to “RADIATOR” in CHAPTER 5.

Page 89 - FRONT BRAKE ADJUSTMENT

3-33 FRONT BRAKE ADJUSTMENT INSP ADJ a a b c WARNING CAUTION: WARNING CHASSIS FRONT BRAKE ADJUSTMENT1. Adjust: Brake lever position(distance a from handle grip to front brake le-ver) Adjustment steps: Turn the adjuster 1 while pushing the frontbrake lever forward until the desired lever posi-tion is...

Page 90 - REAR BRAKE ADJUSTMENT; Below top of footrest.; Brake pedal height

3-34 REAR BRAKE ADJUSTMENT INSP ADJ WARNING CAUTION: WARNING REAR BRAKE ADJUSTMENT1. Check: Brake pedal height aOut of specification Adjust. Brake pedal height: 29 mm Below top of footrest. 2. Adjust: Brake pedal height Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out until the...

Page 91 - BRAKE FLUID LEVEL INSPECTION

3-35 BRAKE FLUID LEVEL INSPECTION INSP ADJ A B NOTE: NOTE: NOTE: CAUTION: WARNING BRAKE FLUID LEVEL INSPECTION Position the motorcycle straight up when inspect-ing the fluid level. 1. Place the motorcycle on a level surface. Place the motorcycle on its centerstand if a cen-terstand is equipped. If n...

Page 92 - Replace brake pad as a set.; BRAKE LIGHT SWITCH ADJUSTMENT; Brake light operating timing; Brake light on later.

3-36 BRAKE PAD INSPECTION / BRAKE LIGHT SWITCH ADJUSTMENT INSP ADJ A B NOTE: BRAKE PAD INSPECTION1. Activate the brake lever or brake pedal.2. Inspect: Brake padWear indicator 1 almost contacting the brakedisc Replace brake pad as a set. Refer to “FRONT AND REAR BRAKE” inCHAPTER 7. A Front B Rear BR...

Page 93 - BRAKE HOSE INSPECTION /; Brake hoses 1; Bleed the brake system if:; Brake system

3-37 A B BRAKE HOSE INSPECTION / AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ WARNING WARNING BRAKE HOSE INSPECTION1. Inspect: Brake hoses 1 Brake pipe 2Cracks / Wear / Damage Replace. The brake pipe must not be disassembled. Donot loosen the bolts 3 . 2. Check: Brake hose clampLoosen Tighten. 3. ...

Page 94 - SHIFT PEDAL ADJUSTMENT

3-38 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) / SHIFT PEDAL ADJUSTMENT INSP ADJ NOTE: WARNING d. Place the other end of the hose into a contain- er. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the...

Page 95 - Shift pedal is raised.; DRIVE CHAIN SLACK ADJUSTMENT

3-39 SHIFT PEDAL ADJUSTMENT / DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ NOTE: CAUTION: WARNING NOTE: 2. Adjust: Change pedal position Adjustment steps: Remove the drive sprocket cover 1 . Loosen both locknuts 2 . Turn the shift pedal link 3 in or out to obtain thecorrect pedal position. Turnning in: Shi...

Page 96 - Caliper bracket bolt 1; Caliper bracket bolt:; Tighten the locknuts.

3-40 DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ NOTE: 2. Check: Drive chain slack aOut of specification Adjust. Drive chain slack: 40 50 mm 3. Loosen: Caliper bracket bolt 1 Axle nut 2 4. Adjust: Drive chain slack Adjustment steps: Loosen both locknuts 3 . Turn the adjusters 4 in or out until the speci-f...

Page 97 - Recommended lubricant:; stand under the engine.

3-41 DRIVE CHAIN LUBRICATION / STEERING HEAD INSPECTION INSP ADJ WARNING DRIVE CHAIN LUBRICATIONThe chain consists of many parts that work witheach other. If the chain is not maintained properly,it will wear out rapidly.Therefore, form the habit of periodically servicingthe chain. This service is es...

Page 98 - STEERING HEAD INSPECTION

3-42 STEERING HEAD INSPECTION INSP ADJ NOTE: WARNING 4. Remove: Starter cable holder 1 Cable guide 2 Handlebar holder (upper) 3 (with plugs) Handlebar 4 5. Loosen: Upper bracket pinch bolts 1 6. Remove: Handle crown nut 2 Upper bracket 3 7. Adjust: Steering head Adjustment steps: Remove the special ...

Page 99 - FRONT FORK INSPECTION

3-43 STEERING HEAD INSPECTION / FRONT FORK INSPECTION INSP ADJ NOTE: 108 Nm (10.8 m kg) 23 Nm (2.3 m kg) 23 Nm (2.3 m kg) 7 Nm (0.7 m kg) 7 Nm (0.7 m kg) WARNING Check the steering head by turning it lock tolock. If it binds, remove the steering stem as-sembly and inspect the steering bearings.Refer...

Page 100 - Hold the motorcycle in an upright position and; FRONT FORK ADJUSTMENT

3-44 FRONT FORK INSPECTION / FRONT FORK ADJUSTMENT INSP ADJ WARNING a b CAUTION: 2. Check: Inner tube 1Scratches / Bent / Damage Replace. Oil sealExcessive oil leakage Replace. 3. Hold the motorcycle in an upright position and apply the front brake. 4. Check: OperationPump the front fork up and down...

Page 101 - REAR SHOCK ABSORBER ADJUSTMENT

3-45 FRONT FORK ADJUSTMENT / REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ a b CAUTION: WARNING Damping force1. Adjust: Damping forceTurn the adjuster 1 in or out. Turnningin : Damping force isincreased. Turnningout : Damping force isdecreased. Adjuster position: Standard: 4 clicks outMinimum: 5 clicks ou...

Page 102 - Loosen the locknut 1 .; Measurement length c :

3-46 REAR SHOCK ABSORBER ADJUSTMENT INSP ADJ a b CAUTION: a b CAUTION: 2. Adjust: Spring preloadFine adjustment (bottom) Adjustment steps: Loosen the locknut 1 . Turn the adjuster 2 in or out. Turnningin : Spring preload isincreased. Turnningout : Spring preload isdecreased. Measurement length c : S...

Page 103 - TIRE INSPECTION; NEVER OVERLOAD THE MOTORCYCLE.

3-47 TIRE INSPECTION INSP ADJ WARNING TIRE INSPECTION1. Measure: Tire pressureOut of specification Adjust. Tire inflation pressure should only bechecked and adjusted when the tire tempera-ture equals the ambient air temperature. Tireinflation pressure and suspension must beadjusted according to the ...

Page 105 - For tires with a “DRIVE” mark 1 :; CABLE INSPECTION AND LUBRICATION

3-49 TIRE INSPECTION / WHEEL INSPECTION / CABLE INSPECTION AND LUBRICATION INSP ADJ NOTE: WARNING NOTE: WARNING WARNING NOTE: For tires with a “DRIVE” mark 1 : Install the wheel with the “DRIVE” mark pointingin direction in which the wheel will rotate. After mounting a tire, ride conservatively for ...

Page 107 - Refer to “Battery removal”.; BATTERY

3-51 Order Job name / Part name Q’ty Remarks 123456 Battery removalSeat Brake hose guideRear master cylinderRear brake switchBattery negative lead terminalBattery positive lead terminalBattery assembly 111111 Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK”. Ref...

Page 108 - REMOVAL

3-52 REMOVAL INSP ADJ WARNING WARNING NOTE: REMOVAL Immediately after removing the battery leads,securely cover the terminals with the covers 1 to prevent the battery leads from being shorted. 1. Remove: SeatRefer to “COWLINGS, SEAT, TAIL COVERAND FUEL TANK”. 2. Remove: Negative terminal cover 1 Pos...

Page 109 - INSPECTION

3-53 INSPECTION INSP ADJ NOTE: CAUTION: WARNING INSPECTION Since the MF battery is a sealed type battery, it isnot possible to measure the specific gravity of theelectrolyte in order to check the charge state of thebattery. Therefore the charge of the battery has tobe checked by measuring the voltag...

Page 110 - Battery condition; Battery condition checking steps:; Charging time; Charge condition of the battery = 20; Charging method

3-54 INSPECTION INSP ADJ 1615 141312 1110 5 6.5 10 100 75 50 30 25 20 0 0 10 20 30 40 11.5 12.0 12.5 13.0 17 18 10 11 12 13 14 (V) 50 60 Volt meter Relationship between the open-circuit voltageand the charging time at 20 _ C Charging time (hours) S This varies depending on the temperature, the state...

Page 111 - Do not quick charge the battery.

3-55 INSPECTION INSP ADJ WARNING Before removing the clips from the batteryterminals, be sure to turn off the charger’spower switch. The open-circuit voltage variation for the MFbattery after charging is shown below. Asshown in the figure, the open circuit voltagestabilizes about 30 minutes after ch...

Page 112 - Monitor the amperage for 3; YES; Charging method using a variable-current (voltage) type charger

3-56 Connect a charger and AMPmeter to the battery and startcharging. Adjust the voltage so that thecurrent is at the standard charg-ing level. Set the timer according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps.” Set the charging voltage at 16 ...

Page 113 - Charging method using a constant-current type charger; This type of battery charger cannot charge the MF battery.; Charging method using a constant-voltage type charger

3-57 Make sure that the currentis higher than the standardcharging current writtenon the battery. Connect a charger andAMP meter to the batteryand start charging. Measure the open-circuitvoltage prior to charging. This type of battery charger cannotcharge the MF battery. A variable volt-age charger ...

Page 114 - INSPECTION / INSTALLATION / FUSE INSPECTION; FUSE INSPECTION

3-58 INSPECTION / INSTALLATION / FUSE INSPECTION INSP ADJ NOTE: NOTE: NOTE: CAUTION: 2. Inspect: Battery terminalDirty Clean with a wire brush. Poor connection Correct. After cleaning the terminals, grease them lightly. INSTALLATION1. Install: Battery assembly 1 During installation, be sure the proj...

Page 115 - FUEL INSPECTION

3-59 FUEL INSPECTION INSP ADJ NOTE: WARNING 2. Inspect: Fuses 1 Inspection steps: Connect the pocket tester to the fuse andcheck it for continuity. Set the tester selector to “ Ω 1” Pocket tester: 90890-03112 If the tester indicates ∞ , replace the fuse. 3. Replace: Blown fuse Replacement steps: Tur...

Page 116 - Headlight beam is raised.; Cover 1

3-60 HEADLIGHT BEAM ADJUSTMENT / HEADLIGHT BULB REPLACEMENT INSP ADJ WARNING EB305021 HEADLIGHT BEAM ADJUSTMENT1. Adjust: Headlight beam (vertically)Turn the adjuster 1 in or out. Turnning in: Headlight beam islowered. Turnning out: Headlight beam is raised. 2. Adjust: Headlight beam (horizontally)T...

Page 117 - HEADLIGHT BULB REPLACEMENT; Bulb holder

3-61 HEADLIGHT BULB REPLACEMENT INSP ADJ New CAUTION: 5. Install: Bulb Secure the new bulb with the bulb holder. Avoid touching the glass part of the bulb.Keep it free from oil; otherwise, the transpar-ency of the glass, life of the bulb, and luminousflux will be adversely affected. If oil gets on t...

Page 119 - ENG; ENGINE OVERHAUL

ENG CHAPTER 4. ENGINE OVERHAUL ENGINE ASSEMBLY 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE / MUFFL...

Page 120 - OIL PUMP

ENG A.C. MAGNETO AND STARTER WHEEL GEAR 4-37 . . . . . . . . . . . . . . . . . . . . . STATOR COIL 4-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.C. MAGNETO AND STARTER WHEEL GEAR 4-38 . . . . . . . . . . . . . . . . . . REMOVAL 4-39 . . . . . ...

Page 121 - ENGINE ASSEMBLY; LEADS

4-1 WARNING Order Job name / Part name Q’ty Remarks 12 3456 Leads disconnectSide cowling, seat, side cover and fueltank.Battery negative leadBattery positive lead Starter motor leadStartor coil lead / pickup coil lead couplerNeutral switch lead couplerClamp 11 1 1 / 1 11 Disconnect the parts in the ...

Page 122 - DRIVE SPROCKET AND EXHAUST PIPE / MUFFLER

4-2 Order Job name / Part name Q’ty Remarks 123456789 Drive sprocket and exhaust pipe / muffler removalAir filter caseCarburetor assemblyRadiator assemblyThermostatic valve assembly Drive sprocket cover 1Shift armDrive sprocket cover 2Nut / Lock washerDrive sprocket / Drive chainExhaust pipe / Muffl...

Page 123 - Engine removal

4-3 Order Job name / Part name Q’ty Remarks 123456789 10 11 Engine removal Starter motor Vacuum hoseBreather hoseBoltBoltBoltEngine bracket (left)Engine bracket (right)PlugBoltBoltEngine assembly 1 21211112111 Remove the parts in the order below. Place suitable stand under the frame andengine. Refer...

Page 125 - Bolt 1

4-5 ENGINE ASSEMBLY ENG NOTE: 1 2 3 4 5 6 12 Nm (1.2 m kg) NOTE: INSTALLATION1. Install: Bolt 1 X 6 Do not fully tighten. 2. Tighten: Tighten the bolts in the order below. 1 Bolt 30 Nm (3.0 m kg) 2 Bolt 30 Nm (3.0 m kg) 3 Bolt 64 Nm (6.4 m kg) 4 Bolt 89 Nm (8.9 m kg) 5 Bolt 60 Nm (6.0 m kg) 6 Bolt 3...

Page 126 - CAMSHAFT; CYLINDER HEAD COVER

4-6 Order Job name / Part name Q’ty Remarks 12345 Cylinder head cover removalSide cowling, seat, side cover and fueltankAir filter case Coolant RadiatorCarburetor assemblyThermostatic assembly Breather hoseSpark plug capBoltCylinder head coverCylinder head cover gasket 12 1 / 6 /1 13 Remove the part...

Page 129 - Camshaft cap 1; Cam lobes length limit:

4-9 CAMSHAFT ENG NOTE: CAUTION: 8. Remove: Timing chain guide (exhaust) Camshaft cap 1 Remove the camshaft cap bolts in a crisscrosspattern, working from the inside to the outside. The bolts (camshaft caps) must be removedevenly to prevent damage to the cylinder head,camshafts or camshaft caps. INSP...

Page 131 - Exhaust camshaft 1

4-11 CAMSHAFT ENG NOTE: 10 Nm (1.0 m kg) NOTE: CAUTION: NOTE: INSTALLATION1. Install: Exhaust camshaft 1 Intake camshaft 2(with camshaft sprocket temporarily tighten) Dowel pins 3 Install the camshaft with the punch mark a facingupward. 2. Install: Camshaft caps Install the camshaft cap with the arr...

Page 133 - CYLINDER HEAD

4-13 CYLINDER HEAD ENG Order Job name / Part name Q’ty Remarks 12345678 Cylinder head removalExhaust pipeCamshaftUnion boltCopper washerOil delivery pipeClipVacuum hoseCylinder headCylinder head gasketDowel pin 12122112 Remove the parts in the order below.Refer to “ENGINE ASSEMBLY”.Refer to “CAMSHAF...

Page 134 - Cylinder head warp limit:

4-14 CYLINDER HEAD ENG NOTE: NOTE: New 40 Nm (4.0 m kg) Nut 10 Nm (1.0 m kg) Bolt NOTE: INSPECTION1. Eliminate: Carbon deposit(from combustion chamber)Use rounded scraper. Do not use a sharp instrument to avoid damagingor scratching: Spark plug threads Valve seat 2. Inspect: Cylinder headScratches /...

Page 135 - VALVE AND VALVE SPRING

4-15 VALVE AND VALVE SPRING ENG Order Job name / Part name Q’ty Remarks 123456789 10 Valve and valve spring removalCylinder head coverCylinder headValve lifterAdjusting padValve cotterValve retainerValve springStem sealValve spring seatExhaust valveIntake valve (center)Intake valve (left and right) ...

Page 136 - VALVE AND VALE SPRING; Valve lifters 1; Valve spring compressor:

4-16 VALVE AND VALE SPRING ENG NOTE: NOTE: REMOVAL1. Remove: Valve lifters 1 Pads 2 Identify each lifter 1 and pad 2 position verycarefully so that they can be reinstalled in theiroriginal place. 2. Check: Valve sealingLeakage at valve seat Inspect the valve face, valve seat and the valve seat width...

Page 137 - Out of specification

4-17 VALVE AND VALVE SPRING ENG NOTE: NOTE: INSPECTION1. Measure: S Stem-to-guide clearance Stem-to-guide clearance = Valve guide inside diameter a –Valve stem diameter b Out of specification Replace valve guide. Stem-to-guide clearance: Intake: 0.010 X 0.037 mm <Limit>: 0.08 mm Exhaust: 0.025...

Page 138 - Always replace the guide if the valve is replaced.

4-18 VALVE AND VALVE SPRING ENG NOTE: 3. Eliminate: Carbon deposit(from valve face) 4. Inspect: Valve facePitting / Wear Reface the face. Valve stem endMushroom shape or diameter larger than restof stem Replace. 5. Measure: Margin thickness aOut of specification Replace. Margin thickness: 0.8 X 1.2 ...

Page 139 - Install the valve into the cylinder head.

4-19 VALVE AND VALVE SPRING ENG NOTE: CAUTION: Measurement steps: Apply the Mechanic’s blueing dye (Dykem) b tothe valve face. Install the valve into the cylinder head. Press the valve through the valve guide and ontothe valve seat to make a clear pattern. Measure the valve seat width. Where the val...

Page 141 - Stem seal

4-21 VALVE AND VALVE SPRING ENG New NOTE: 13. Measure: S Spring tilt aOut of specification Replace. Spring tilt limit: 2.5 _ / 1.7 mm INSTALLATION1. Install: S Stem seal S Valve S Spring seat S Valve spring S Valve retainer(into cylinder head) S Make sure that each valve is installed in its origi-na...

Page 142 - Valve spring compressor 2 :

4-22 VALVE AND VALVE SPRING ENG NOTE: NOTE: NOTE: 2. Install: Valve cotters 1 Install the valve cotters while compressing thevalve spring with the valve spring compressor. Valve spring compressor 2 : 90890-04019 Attachment 3 : 90890-04108 3. Secure the valve cotters 1 onto the valve stem by tapping ...

Page 143 - CYLINDER AND PISTON

4-23 CYLINDER AND PISTON ENG Order Job name / Part name Q’ty Remarks 123456789 10 11 Cylinder and piston removalCylinder headJointO-ringO-ringDowel pinCylinderCylinder gasketO-ringCirclipPiston pinPistonPiston ring set 11141124222 Remove the parts in the order below.Refer to “CYLINDER HEAD”. For ins...

Page 144 - Piston circlips 1

4-24 CYLINDER AND PISTON ENG NOTE: CAUTION: NOTE: REMOVAL1. Remove: Piston circlips 1 Piston pins 2 Pistons 3 Before removing the piston pin clip, cover thecrankcase with a clean rag to prevent the pistonpin clip from falling into the crankcase cavity. Put identification marks on each piston head fo...

Page 145 - or D

4-25 CYLINDER AND PISTON ENG Cylinder bore “C” 89.500 X 89.505 mm Taper limit “T” 0.05 mm Out of round “R” 0.03 mm “C” = Maximum D “T” = (Maximum D 1 , or D 2 ) – (Maximum D 5 or D 6 ) “R” = (Maximum D 1 , D 3 or D 5 ) – (Minimum D 2 , D 4 or D 6 ) If out of specification, rebore or replace the cyli...

Page 146 - Replace piston and

4-26 CYLINDER AND PISTON ENG NOTE: NOTE: NOTE: 3. Measure: Side clearanceOut of specification Replace piston and rings as a set. Eliminate the carbon deposits from the piston ringgrooves and rings before measuring the sideclearance. Side clearance: Top ring: 0.035 X 0.070 mm 2nd ring: 0.035 X 0.070 ...

Page 147 - inspect lubrication system.

4-27 CYLINDER AND PISTON ENG NOTE: 6. Inspect: Piston pinBlue discoloration / Grooves Replace, then inspect lubrication system. 7. Measure: Piston pin-to-piston clearance Measurement steps: Measure the piston pin outside diameter a .If out of specification, replace the piston pin. Outside diameter (...

Page 149 - CLUTCH

4-29 CLUTCH ENG Order Job name / Part name Q’ty Remarks Crankcase cover (right) removalEngine oil Clutch cableCrankcase cover (right) GasketDowel pinCirclipPlain washerPull leverTorsion springPlain washer 11 1211111 Remove the parts in the order below.Refer to “ENGINE OIL REPLACEMENT”in CHAPTER 3. F...

Page 151 - Universal clutch holder:

4-31 CLUTCH ENG NOTE: NOTE: REMOVAL1. Straighten the lock washer tab.2. Remove: Clutch boss nut 1 Lock washer 2 Clutch boss 3 Loosen the clutch boss nut 1 while holding theclutch boss 3 with the universal clutch holder. Universal clutch holder: 90890-04086 3. Remove: Spacer 1 Bearing 2 Install 6 mm ...

Page 154 - Loosen the bolts in a crisscross pattern.

4-34 Order Job name / Part name Q’ty Remarks 123 4567 Crankcase cover (left) removalEngine oil Drive sprocket cover 1 / 2Shift armCrankcase cover (left) GasketDowel pinCirclipPlain washer 1 / 1 11 1211 Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3. For installat...

Page 155 - Refer to “INSTALLATION”.; SHIFT SHAFT

4-35 SHIFT SHAFT ENG Order Job name / Part name Q’ty Remarks 1234567 Shift shaft removalClutchShift armShift shaftCirclipPlain washerTorsion springStopper levelBearing retainerTorsion spring 1111111 Remove the parts in the order below.Refer to “CLUTCH”.Refer to “CRANKCASE COVER (LEFT)”. For installa...

Page 156 - Shift shaft 1

4-36 SHIFT SHAFT ENG 12 Nm (1.2 m kg) 10 Nm (1.0 m kg) NOTE: INSPECTION1. Inspect: Stopper lever 1Roller turns roughly Replace. Bends / Damage Replace. 2. Inspect: Torsion spring (shift shaft) 1 Torsion spring (stopper lever) 2Wear / Damage Replace. 3. Inspect: Shift shaft 1 Shift pawls 2Bends / Wea...

Page 158 - Remove the parts in the order below.

4-38 A.C. MAGNETO AND STARTER WHEEL GEAR ENG Order Job name / Part name Q’ty Remarks 12 34 567 A.C. magneto and starter wheelgear removalRotorShaft Starter idle gearStarter clutch Plate washerWoodruff keyStarter wheel gear 11 11 111 Remove the parts in the order below. For installation, reverse the ...

Page 159 - Washer 2; Crankshaft protector:; Starter clutch operation; Clutch operation checking steps:; When turning the starter wheel gear clockwise

4-39 A.C. MAGNETO AND STARTER WHEEL GEAR ENG NOTE: NOTE: REMOVAL1. Remove: Bolt (rotor) 1 Washer 2 Loosen the bolt (rotor) 1 while holding the mag-neto with the sheave holder 3 . Do not allow the sheave holder 3 to touch theprojection on the rotor. Sheave holder: 90890-01701 2. Remove: A.C. magneto ...

Page 160 - Starter wheel gear 1

4-40 A.C. MAGNETO AND STARTER WHEEL GEAR ENG NOTE: 130 Nm (13.0m kg) NOTE: 2. Inspect: Starter wheel gear 1(contacting surfaces)Pitting / Wear / Damage Replace. INSTALLATION1. Install: Starter wheel gear 1 Woodruff key 2 2. Install: Plate washer Rotor 1 Washer Clean the tapered portions of the crank...

Page 161 - OIL PUMP COVER AND OIL PUMP DRIVEN GEARS

4-41 OIL PUMP ENG Order Job name / Part name Q’ty Remarks 123456789 Oil pump cover and oil pump drivengear removalEngine oil Oil pipeO-ringOil pump coverGasketDowel pinCollarGasketCirclipOil pump driven gear 1 11121122 Remove the parts in the order below. Refer to “ENGINE OIL REPLACE-MENT” in CHAPTE...

Page 163 - Replace the oil pump as-

4-43 OIL PUMP ENG INSPECTION1. Inspect: Oil pump driven gearsWear / Cracks / Damage Replace. 2. Measure: Tip clearance a(between the inner rotor 1 and the outer rotor 2 ) Side clearance b(between the outer rotor 2 and the pumphousing 3 )(between the inner rotor 1 / outer rotor 2 andthe pump housing ...

Page 164 - OIL TANK; OIL HOSE

4-44 OIL TANK ENG Order Job name / Part name Q’ty Remarks 1234567 Oil hose removalEngine oil EngineUnion boltCopper washerOil delivery pipeOil hoseO-ringOil pipeO-ring 2411212 Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”. For installa...

Page 166 - OIL PAN; OIL PAN

4-46 Order Job name / Part name Q’ty Remarks 1234 5678 Oil pan removalEngine oil EngineOil hoseOil filter coverO-ringCollarOil filter Oil panGasketDowel pinO-ring / collar 1211 112 2 / 2 Remove the parts in the order below.Refer to “ENGINE OIL REPLACE-MENT” in CHAPTER 3.Refer to “ENGINE ASSEMBLY”.Re...

Page 167 - BALANCER

4-47 OIL PAN ENG Order Job name / Part name Q’ty Remarks 123 Balancer weight removalEngine oil EnginePistonShift shaftA.C. magneto Oil pump assemblyOil tankOil panPlateRear balancer holder / Dowel pinRear balancer shaft / O-ring 2 1 / 21 / 1 Remove the parts in the order below.Refer to “ENGINE OIL R...

Page 171 - Install the rear balancer shaft.

4-51 OIL PAN ENG 10 Nm (1.0 m kg) Installing steps: Turn the crankshaft until the keyway a isaligned with embossed mark b on the crank-case. While holding the crankshaft, install the balancerweight and align the mark c on the rear balanc-er gear with the embossed mark d on the crank-case. Install th...

Page 172 - CRANKSHAFT; CRANKSHAFT ASSEMBLY

4-52 CRANKSHAFT ENG (M6) Order Job name / Part name Q’ty Remarks 123456789 Crankshaft removalBalancer weightWater pumpTiming chainCover plateLower crankcaseDowel pinNozzleCrankshaft assemblyMain journal bearingPinTiming chain guide (intake) 111111611 Remove the parts in the order below.Refer to “BAL...

Page 173 - CONNECTING ROD

4-53 CRANKSHAFT ENG Order Job name / Part name Q’ty Remarks 12345 Connecting rod removalNutConnecting rod boltConnecting rodConnecting rod capConnecting rod bearing 44224 Remove the parts in the order below. For installation, reverse the removalprocedure. Refer to “REMOVAL”, and“INSTALLATION”. 48 Nm...

Page 174 - Cover plate 1; Crankshaft assembly 1

4-54 A B CRANKSHAFT ENG NOTE: CAUTION: REMOVAL1. Remove: Cover plate 1 2. Remove: Upper crankcase Lower crankcase Dowel pins Loosen the bolts 1 / 4 turn each and remove themafter all are loosened. Remove the bolts starting with the highest num-bered one. The embossed numbers in the crankcase desig-n...

Page 176 - Put a piece of Plastigauge

4-56 CRANKSHAFT ENG CAUTION: NOTE: NOTE: NOTE: 3. Measure: Oil clearance (main journal)Out of specification Replace bearing. Oil clearance: 0.020 0.038 mm <Limit>: 0.1 mm Measurement steps: Do not interchange the bearings and connect-ing rod. They must be installed in their originalpositions, ...

Page 177 - Lubricate the threads of bolts 1

4-57 A B CRANKSHAFT ENG NOTE: CAUTION: Tighten the bolt to specification in the tighten-ing sequence cast on the crankcase. 1 6 (M10): 40 Nm (4.0 m kg) 7 10 , 13 , 15 , 20 25 (M8) 24 Nm (2.4 m kg) 11 , 12 , 14 , 16 19 , 26 , 27 (M6) 12 Nm (1.2 m kg) A Upper crankcase B Lower crankcase Lubricate the ...

Page 180 - Connecting rod bearings 1

4-60 CRANKSHAFT ENG NOTE: 48 Nm (4.8 m kg) CAUTION: INSTALLATION1. Apply: Molybdenum disulfide grease(onto threads of bolts and nut seats) Engine oil(onto crank pins and inner surfaces of connect-ing rod bearings) 2. Install: Connecting rod bearings 1 Connecting rods 2 Connecting rod caps 3(onto cra...

Page 181 - Pin

4-61 CRANKSHAFT ENG NOTE: NOTE: 5. Install: Timing chain guide (intake) Pin 6. Install: Main journal bearings Align the projection a of the bearing with thenotch b in the crankcase. Install each bearing in its original place. 7. Apply: Engine oil(onto inner surfaces of main journal bearings) Sealant...

Page 182 - Upper crankcase bolt; molybdenum disulfide motor oil.

4-62 A B CRANKSHAFT ENG CAUTION: NOTE: 10 Nm (1.0 m kg) 10. Install: Lower crankcase 1(onto upper crankcase 2 )Place the lower crankcase assembly onto theupper crankcase assembly. Before tightening the crankcase bolts, checkthe following point: Be sure the gears shift correctly when theshift cam is ...

Page 183 - TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-63 TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG Order Job name / Part name Q’ty Remarks 123456789 10 11 Transmission, shift cam and shiftfork removalLower crankcaseDrive axle assembly / Oil sealCirclipShift fork guide bar 2Shift fork “R”Shift fork “L”Shift fork guide bar 1Shift fork “C”Shift camBear...

Page 185 - Shift fork cam follower 1; Do not attempt to straighten a bent guide bar.; Replace the fork and

4-65 TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG WARNING INSPECTION1. Inspect: Shift fork cam follower 1 Shift fork pawl 2Scoring /Bends/ Wear / Damage Replace. 2. Inspect: Guide barRoll the guide bar on a flat surface.Bends Replace. Do not attempt to straighten a bent guide bar. 3. Check: Shift fork...

Page 186 - Main axle assembly 1

4-66 116.6 116.68 mm TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG NOTE: 12 Nm (1.2 m kg) NOTE: 6. Inspect: Gear teethBlue discoloration / Pitting / Wear Replace. Mated dogsRounded edges / Cracks / Missing portions Replace. 7. Check: Proper gear engagement (each gear)(with its counterpart)Incorrect Rea...

Page 187 - TRANSMISSION,SHIFT CAM AND SHIFT FORK

4-67 TRANSMISSION,SHIFT CAM AND SHIFT FORK ENG NOTE: NOTE: NOTE: 3. Install: Shift cam 1 Shift fork “C” 2 Shift fork “L” 3 Shift fork “R” 4 Shift for guide bars 5 Install the shift forks with the embossed mark tothe right and in sequence (R, C, L) beginningfrom the right. Install the shift fork guid...

Page 189 - COOL; COOLING SYSTEM; RADIATOR; THERMOSTATIC VALVE ASSEMBLY; WATER PUMP

COOL CHAPTER 5. COOLING SYSTEM RADIATOR 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 5-3 . . . . . . . . . . ...

Page 192 - Blow out with compressed air; Radiator cap opening pressure:

5-2 RADIATOR COOL INSPECTION1. Inspect: Radiator core 1Obstruction Blow out with compressed air through rear of the radiator.Flattened fin Repair / Replace. 2. Inspect: Fan 2 Cracks / Damage Replace. 3. Inspect: Radiator hosesCrancks / Damage Replace. 4. Measure: Radiator cap opening pressureRadiato...

Page 193 - Radiator assembly

5-3 RADIATOR COOL 7 Nm (0.7 m kg) CAUTION: INSTALLATIONReverse the “REMOVAL” procedure.Note the following points.1. Install: Radiator assembly 2. Fill: Cooling systemRefer to “COOLANT REPLACEMENT” inCHAPTER 3. 3. Inspect: Cooling systemDecrease of pressure (leaks) Repair as re- quired. Inspection st...

Page 194 - THERMOSTATIC VALVE

5-4 THERMOSTATIC VALVE COOL Order Job name / Part name Q’ty Remarks 123456 Thermostatic valve assemblyremovalCoolant Side cowling, seat, side cover andfuel tankAir filter caseRadiator assemblyGround leadThermo switch lead couplerThermo unit leadCoolant hose 1Coolant hose 4Thermostatic valve assembly...

Page 199 - CARB; CARBURETION; CARBURETOR; CARBURETOR ASSEMBLY

CARB CHAPTER 6. CARBURETION CARBURETOR 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR ASSEMBLY 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR 6-2 . . . . . . . . . . . . . . . . . . . . . . . ...

Page 201 - Air filter case

6-1 CARBURETOR CARB Order Job name / Part name Q’ty Remarks 12345678 Carburetor assembly removalSide cowling, seat, side cover andfuel tank Air filter case Throttle position sensor lead couplerCarburetor heater hose (inlet)Carburetor heater hose (outlet)Throttle stop screwFuel hoseStarter cableThrot...

Page 202 - Disassemble the parts in the order below.

6-2 CARBURETOR CARB Order Job name / Part name Q’ty Remarks Carburetor disassemblyCarburetor heater hoseFloat chamberNeedle valveFloatStarter jetMain jetPilot jetJet housingJet needleThrottle valve 1111111111 Disassemble the parts in the order below. Refer to ”INSTALLATION”. 1 2 3456789 10 CARBURETO...

Page 204 - ASSEMBLY

6-4 CARBURETOR CARB CAUTION: NOTE: ASSEMBLY Before reassembling, wash all parts in cleanpetroleum based solvent. Always use a new gasket. 1. Install: Main jet 1 Starter jet 2 Pilot jet 3 2. Install: Valve seat Make sure that projection a on the valve seat isaligned with the slot b on the carburetor ...

Page 205 - Below the MIKUNI mark

6-5 CARBURETOR CARB NOTE: NOTE: FUEL LEVEL ADJUSTMENT1. Measure: Fuel level a Fuel level: 15.8 16.8 mm Below the MIKUNI mark Out of specification Adjust. Adjust the float level by slightly bending the floattang 1 . Fuel level measurement and adjustmentsteps: Place the motorcycle on a level surface. ...

Page 206 - Turn the main switch to ”ON”.

6-6 CARBURETOR CARB NOTE: NOTE: 4 Nm (0.4 m kg) NOTE: 1. Adjust: TPS (throttle position sensor) position Adjustment steps: Turn the main switch to ”ON”. Disconnect the TPS (throttle position sensor)coupler. Reconnect the TPS (throttle position sensor)coupler. When the above procedure is commenced, t...

Page 207 - Blue terminal 1

6-7 CARBURETOR CARB 2. Inspect: S TPS (throttle position sensor) Inspection steps: S Disconnect the TPS (throttle position sensor)coupler. S Remove the TPS (throttle position sensor) fromcarburetor. S Connect the pocket tester ( Ω 1k) to the TPS (throttle position sensor) couplers. Tester (+) lead B...

Page 209 - CHAS

CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY 7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 210 - REAR SHOCK ABSORBER AND RELAY ARM; HANDLING NOTES; SWINGARM AND DRIVE CHAIN

CHAS REAR SHOCK ABSORBER AND RELAY ARM 7-50 . . . . . . . . . . . . . . . . . . . . . . HANDLING NOTES 7-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTES ON DISPOSAL 7-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWI...

Page 211 - FRONT WHEEL AND BRAKE DISCS

7-1 Order Job name / Part name Q’ty Remarks 123456789 Front wheel and brake disc removal Speedometer cablePinch bolt (front wheel axle)Cable guideBrake caliper (left / right)Front wheel axleFront wheelSpeedometer gear unitCollarBrake disc (left / right) 111 1 / 1 1111 1 / 1 Remove the parts in the o...

Page 212 - Disassemble the parts in order below.

7-2 FRONT WHEEL AND BRAKE DISCS CHAS Order Job name / Part name Q’ty Remarks Front wheel disassemblyOil sealClutch retainerMeter clutchOil sealBearingSpacerBearing 1111111 Disassemble the parts in order below. Refer to “ASSEMBLY”. For assembly, reverse the disassemblyprocedure. 1234567

Page 213 - Do not attempt to straighten a bent axle.; Wheel runout; Wheel bearing and oil seal replacement steps:; Clean the outside of the wheel hub.

7-3 FRONT WHEEL AND BRAKE DISCS CHAS WARNING NOTE: INSPECTION1. Inspect: Front wheel axle. Roll it on a flat surface.Bends Replace. Do not attempt to straighten a bent axle. 2. Measure: Wheel runout Over the specified limit Replace. Rim runout limits: Radial a : 1 mmLateral b : 0.5 mm 3. Inspect: Wh...

Page 214 - Replace collar and oil seal

7-4 FRONT WHEEL AND BRAKE DISCS CHAS NOTE: CAUTION: NOTE: NOTE: Use a socket 3 that matches the outside diame-ter of the race of the bearing and oil seal. Do not strike the center race 4 or balls 5 ofthe bearing. Contact should be made only withthe outer race 6 . 4. Inspect: CollarWear / Damage Repl...

Page 216 - STATIC WHEEL BALANCE ADJUSTMENT

7-6 FRONT WHEEL AND BRAKE DISCS CHAS NOTE: NOTE: STATIC WHEEL BALANCE ADJUSTMENT S After replacing the tire and / or rim, wheel balanceshould be adjusted. S Adjust the wheel balance with brake diskinstalled. 1. Remove: S Balancing weight 2. Set the wheel on a suitable stand. 3. Find: S Heavy spot Pr...

Page 217 - Turn the wheel so that the heavy spot is 90

7-7 FRONT WHEEL AND BRAKE DISCS CHAS S Turn the wheel so that the heavy spot is 90 _ up. S Check that the heavy spot is at rest there.If not, try another weight until the wheel is bal-anced. 5. Check: S Wheel balance Checking steps: S Turn the wheel so that is comes to each point asshown. S Check th...

Page 218 - REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET; REAR WHEEL

7-8 REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS Order Job name / Part name Q’ty Remarks 1234567 Rear wheel removal Brake caliperCaliper bracket boltRear wheel axle nutPlain washerRear wheel axleChain pullerRear wheel 1112121 Remove the parts in the order below. Loosen For installation, reverse t...

Page 219 - BRAKE DISC AND DRIVEN SPROCKET

7-9 REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS Order Job name / Part name Q’ty Remarks 12345678 Brake disc and driven sprocketremovalCollar (left / right)Brake discDriven sprocketClutch hubRubber damperCollarOil sealBearing 1 / 1 1116111 Remove the parts in the order below. For installation, re...

Page 220 - Disassembly the parts in the order below.

7-10 REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS Order Job name / Part name Q’ty Remarks Rear wheel disassemblyOil sealBearingCollarBearing 1111 Disassembly the parts in the order below. For assembly, reverse the disassemblyprocedure. 123 4

Page 221 - Wheel bearings

7-11 REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS NOTE: INSPECTION1. Inspect: Rear wheel axleRefer to “FRONT WHEEL AND BRAKE DISC”. 2. Measure: Wheel runoutRefer to “FRONT WHEEL AND BRAKE DISC”. 3. Install: Wheel bearings Oil seals CollarsRefer to “FRONT WHEEL AND BRAKE DISC”. 4. Measure: Brake d...

Page 222 - Replace; Driven sprocket replacement steps:; Remove the self locknuts and driven sprocket.

7-12 REAR WHEEL, BRAKE DISC AND DRIVEN SPROCKET CHAS NOTE: NOTE: 6. Inspect: Driven sprocketMore than 1 / 4 teeth a wear Replace sprocket.Bent teeth Replace sprocket. b Correct 1 Roller 2 Sprocket Driven sprocket replacement steps: Remove the self locknuts and driven sprocket. Clean the hub, especia...

Page 223 - FRONT AND REAR BRAKE; FRONT BRAKE PAD

7-13 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 12345678 Front brake pad removalCable guidePad coverRetaining clipRetaining pinPad springBrake padPad shimBleed screw 11221221 Remove the parts in the order below. For installation, reverse the removalprocedure. Refer to “BRAKE P...

Page 224 - REAR BRAKE PAD

7-14 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 1234567 Rear brake pad removalPad coverRetaining clipRetaining pinPad springBrake padPad shim (left / right)Bleed screw 12212 1 / 1 2 Remove the parts in the order below. For installation, reverse the removalprocedure. 40 Nm (4.0...

Page 225 - Use solvents on internal brake components.; Brake pads 1

7-15 FRONT AND REAR BRAKE CHAS CAUTION: NOTE: NOTE: Disc brake components rarely require disas-sembly. DO NOT: Disassemble components unless absolutelynecessary. Use solvents on internal brake components. Use contaminated brake fluid for cleaning.Use only clean brake fluid. Allow brake fluid to come...

Page 227 - Brake pads

7-17 FRONT AND REAR BRAKE CHAS New New New NOTE: NOTE: Replace the pads as a set if either is found to beworn to the wear limit a . Wear limit a : 0.5 mm 2. Install: Pad shims (onto brake pads) Brake pads Pad spring Installation steps: Connect a suitable hose 1 tightly to the caliperbleed screw 2 . ...

Page 228 - Disconnect; FRONT BRAKE MASTER CYLINDER

7-18 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 1234567 Front brake master cylinder removalBrake fluidBrake leverFront brake switch lead couplerFront brake switchUnion boltCopper washer / Brake hoseMaster cylinder bracketMaster cylinder assembly 1111 2 / 1 11 Remove the parts ...

Page 230 - Remove from the master cylinder side.; REAR BRAKE MASTER CYLINDER

7-20 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 123 4567 Rear brake master cylinder removalBrake fluidUnion boltCopper washer / Brake hoseBrake reservoir hose Cotter pinClevis pinPlain washerMaster cylinder 1 2 / 1 1 1111 Remove the parts in the order below.Drain Refer to “MAS...

Page 231 - Disconnect the parts in the order below.

7-21 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks Rear brake master cylinder discon-nectionBootCirclipMaster cylinder kitMaster cylinder body 1111 Disconnect the parts in the order below. For assembly, reverse the disconnectionprocedure. 1 234

Page 232 - Replace the master cylin-; Replace as a; MASTER CYLINDER ASSEMBLY

7-22 B A B A FRONT AND REAR BRAKE CHAS WARNING MASTER CYLINDER INSPECTION1. Inspect: Master cylinder 1Wear / Scratches Replace the master cylin- der assembly. Master cylinder body 2Cracks / Damage Replace. Oil delivery passage (master cylinder body)Blow out with compressed air. A Front B Rear 2. Ins...

Page 233 - Always use new copper washers.

7-23 FRONT AND REAR BRAKE CHAS 9 Nm (0.9 m kg) CAUTION: New 30 Nm (3.0 m kg) WARNING CAUTION: Front brake1. Install: Master cylinder 1 Master cylinder bracket 2 Align the end of the holder with the punchmark a on the handlebar. Tighten first the upper bolt, then the lowerbolt. 2. Install: Copper was...

Page 234 - Be careful that water does not enter the mas-; Copper washer 1

7-24 FRONT AND REAR BRAKE CHAS WARNING New 30 Nm (3.0 m kg) CAUTION: WARNING Use only the designated quality brake fluid:otherwise, the rubber seals may deteriorate,causing leakage and poor brake perfor-mance. Refill with the same type of brake fluid: mix-ing fluids may result in a harmful chemicalr...

Page 235 - Clevis pin 1

7-25 FRONT AND REAR BRAKE CHAS New 2. Install: Clevis pin 1 Washer Cotter pin 3. Fill: Brake reservoirRefer to “MASTER CYLINDER ASSEMBLY –Front brake”. 4. Inspect: Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3. 5. Check: Brake pedal operationA soft or spongy feeling Bleed br...

Page 236 - Refer to “CALIPER INSTALLATION”.; FRONT BRAKE CALIPER

7-26 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 1234 56 Front brake caliper removalBrake fluidCable guideUnion boltCopper washerStay Brake hose and brake pipeBrake caliper assembly 112 11 Remove the parts in the order below.Drain Refer to “CALIPER INSTALLATION”. For installati...

Page 238 - REAR BRAKE CALIPER

7-28 FRONT AND REAR BRAKE CHAS Order Job name / Part name Q’ty Remarks 1234 Rear brake caliper removalBrake fluidBrake hoseBrake hose jointCopper washerBrake caliper assembly 1111 Remove the parts in the order below.Drain For installation, reverse the removalprocedure. Refer to “CALIPER INSTALLATION...

Page 240 - CALIPER DISASSEMBLY

7-30 A B FRONT AND REAR BRAKE CHAS NOTE: WARNING CALIPER DISASSEMBLY Before disassembling the front brake caliper orrear brake caliper, drain the brake hose, mastercylinder, brake caliper and brake reservoir of theirbrake fluid. 1. Remove: Pistons Piston seals 1 Removal steps: Using a wood piece 2 ,...

Page 241 - CALIPER INSPECTION AND REPAIR; Replace caliper assembly.; CALIPER ASSEMBLY

7-31 FRONT AND REAR BRAKE CHAS WARNING WARNING WARNING CALIPER INSPECTION AND REPAIR Recommended brake component p replacement schedule: Brake pads As required Piston seal, Every two years dust seal Every two years Brake hoses Every two years Replace only when Brake fluid p y brakes aredisassembled....

Page 242 - When installing the brake hose on the caliper

7-32 FRONT AND REAR BRAKE CHAS New 30 Nm (3.0 m kg) CAUTION: NOTE: 40 Nm (4.0 m kg) 14 Nm (1.4 m kg) WARNING 40 Nm (4.0 m kg) CALIPER INSTALLATION1. Install: Front brake Brake caliper 1 (temporarily) Copper washers Brake hose 2 Union bolt 3 When installing the brake hose on the caliper 1 , take care...

Page 243 - FRONT FORK

7-33 FRONT FORK CHAS Order Job name / Part name Q’ty Remarks 1234567 Front fork removalFront wheel Cable guideFront fenderPlastic bandPinch bolt (upper bracket)Cap boltPinch bolt (lower bracket)Front fork (left / right) 114222 1 / 1 Remove the parts in the order below.Refer to “FRONT WHEEL ANDBRAKE ...

Page 246 - DISASSEMBLY

7-36 FRONT FORK CHAS NOTE: CAUTION: NOTE: CAUTION: DISASSEMBLY Do not reuse the front fork protector that was re-moved from the outer tube. When installing a new front fork protector, besure it is not twisted and will not come off easily. 1. Remove: Dust seal 1 Retaining clip 2Use a slotted-head scr...

Page 247 - Inner fork tube 1

7-37 FRONT FORK CHAS WARNING CAUTION: INSPECTION1. Inspect: Inner fork tube 1 Outer fork tube 2Scratches / Bends / Damage Replace. Do not attempt to straighten a bent inner forktube as this may dangerously weaken thetube. 2. Measure: Fork spring free length aOver specified limit Replace. Fork spring...

Page 248 - Piston metal 1; Fork seal driver weight:

7-38 FRONT FORK CHAS New 30 Nm (3.0 m kg) NOTE: New New 2. Lubricate: Inner fork tube (outer surface) Recommended lubricant: Fork oil 10W or equivalent 3. Install: Piston metal 1 Damper rod 2 Oil lock piece 3 4. Tighten: Damper bolt 1 Tighten the damper rod bolt while holding thedamper rod with the ...

Page 249 - Fork oil

7-39 NOTE: FRONT FORK CHAS CAUTION: NOTE: New NOTE: Before installing the oil seal, apply the lithium soapbase grease onto the oil seal lips. Be sure that the oil seal numbered side faceupward. 7. Install: Dust seal 1Use the fork seal driver weight. Fork seal driver weight: 90890-01367 8. Fill: Fork...

Page 250 - Cap bolts 2

7-40 FRONT FORK CHAS CAUTION: 30 Nm (3.0 m kg) 24 Nm (2.4 m kg) 23 Nm (2.3 m kg) WARNING INSTALLATION1. Install: Front fork(s)Temporarily tighten the pinch bolts. Make sure that the inner tube end is flush withthe top of the upper bracket. 2. Tighten: Pinch bolts (lower bracket) 1 Cap bolts 2 Pinch ...

Page 251 - HANDLEBAR

7-41 HANDLEBAR CHAS Order Job name / Part name Q’ty Remarks 123456789 10 11 Handlebar removalBandClutch cableClutch switch lead couplerClutch switchLeft handlebar switchClutch leverGrip endFront brake switch lead couplerMaster cylinder bracketMaster cylinder assemblyCollar 21111121111 Remove the par...

Page 253 - Remove the handlebar grip.

7-43 HANDLEBAR CHAS WARNING NOTE: WARNING 23 Nm (2.3 m kg) NOTE: CAUTION: INSPECTION1. Inspect: HandlebarBends / Crancks / Damage Replace. Do not attempt to straighten a bent handlebaras this may dangerously weaken the handle-bar. Handlebar grip (left) replacement steps: Remove the handlebar grip. A...

Page 255 - Left handlebar switch 1

7-45 HANDLEBAR CHAS NOTE: 6. Install: Left handlebar switch 1 Align the projection a on the handlebar switchwith the hole b on the handlebar. 7. Adjust: Clutch cable free playRefer to “CLUTCH ADJUSTMENT” in CHAP-TER 3. 8. Adjust: Throttle cable free playRefer to “THROTTLE CABLE ADJUSTMENT”in CHAPTER...

Page 256 - STEERING HEAD; LOWER BRACKET

7-46 STEERING HEAD CHAS Order Job name / Part name Q’ty Remarks 123456789 10 Lower bracket removalFront wheel Front forkHandlebarMain switch lead couplerStarter cable holderCable guideHorn / Horn lead couplerBrake hose holderSteering stem nutPlate washerUpper bracketSpecial washerRing nut (upper) 11...

Page 258 - Bearings; Bearing race replacement steps:; Install the new races.

7-48 STEERING HEAD CHAS WARNING NOTE: CAUTION: REMOVAL1. Remove: Ring nut (lower) 1Use the ring nut wrench 2 . Ring nut wrench: 90890-01403 Support the lower bracket so that it may notfall down. INSPECTION1. Wash the bearing and bearing races with a sol- vent. 2. Inspect: Bearings Bearing racesPitti...

Page 259 - Install the plate washer.

7-49 STEERING HEAD CHAS NOTE: WARNING NOTE: INSTALLATION1. Tighten: Ring nuts (lower and upper) Tightening steps: Tighten the ring nut (lower) 1 using the ring nutwrench 2 . Ring nut: 48 Nm (4.8 m kg) Set the torque wrench to the ring nut wrench sothat they form a right angle. Ring nut wrench: 90890...

Page 260 - REAR SHOCK ABSORBER

7-50 REAR SHOCK ABSORBER CHAS Order Job name / Part name Q’ty Remarks 12345678 Rear shock absorber removalSeat Self locknutPlain washerBoltCollarCapSelf locknutBoltRear shock absorber 11111111 Remove the parts in the order below.Refer to “COWLINGS, SEAT, TAILCOVER AND FUEL TANK” in CHAP-TER 3. For i...

Page 261 - hole through the cylinder wall at a point 15

7-51 REAR SHOCK ABSORBER CHAS WARNING WARNING HANDLING NOTES This shock absorber contains highly com-pressed nitrogen gas. Rear and understandthe following information before handling theshock absorber. The manufacturer cannot beheld responsible for property damage or per-sonal injury that may resul...

Page 264 - 0 link length limit:; Replace drive chain.

7-54 SWINGARM AND DRIVE CHAIN CHAS NOTE: CAUTION: INSPECTION1. Measure: 10 link length (drive chain) aOut of specification Replace drive chain. 10 link length limit: 159 mm For measurement make the chain tense by fin-ger. 10 link length is a measurement between the in-sides of the 1 and 11 rollers a...

Page 265 - Drive chain; Drive chain lubricant:; Clean and lubricate or replace.

7-55 SWINGARM AND DRIVE CHAIN CHAS 90 Nm (9.0 m kg) 4. Lubricate: Drive chain Drive chain lubricant: SAE 30 50W motor oil or chain lubricants suitable for “O-ring”chains 5. Inspect: Drive chain stiffnessStiff Clean and lubricate or replace. 6. Check: Swingarm free play Inspection steps: Check the ti...

Page 267 - ELEC

ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH INSPECTION 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH INSPECTION 8-2 . . . . . . . . . . . . . . . . . . . . ....

Page 269 - ELECTRICAL COMPONENTS

8-1 ELECTRICAL COMPONENTS ELEC Fuse boxBatteryRear brake switchSidestand switchNeutral switchIgnition coilHorn Ignitor unitStarting circuit cut-off relayRectifier / regulatorMain switchThermo switchThermo unitFlasher relayStarter relay 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ELECTRICAL ELECTRICAL COMPON...

Page 270 - SWITCH INSPECTION

8-2 SWITCH INSPECTION ELEC NOTE: SWITCH INSPECTION SWITCH INSPECTIONUse a pocket tester to check the terminals for con-tinuity. If the continuity is faulty as any point, re-place the switch. Pocket tester: 90890-03112 Set the pocket tester to “0” before starting thetest. The pocket tester should be ...

Page 272 - IGNITION SYSTEM; CIRCUIT DIAGRAM

8-4 A.C. magneto/Pickup coil Main switch Battery Main fuse Starting circuit cut-of f relay 1 3 4 5 8 9 10 12 13 14 45 Neutral switch Sidestand switch Ignitor unit Ignition coil Spark plug Engine stop switch Ignition fuse 47 IGNITION SYSTEM ELEC IGNITION SYSTEM CIRCUIT DIAGRAM

Page 273 - TROUBLESHOOTING

8-5 IGNITION SYSTEM ELEC NOTE: Refer to “SWITCH INSPECTION”. 1. Fuse (main and ignition) Replace fuse(s). NO CONTINUITY S Check the battery condition.Refer to “BATTERY INSPECTION” in CHAP-TER 3. 2. Battery CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C : S Clean battery terminals. S Recha...

Page 276 - Pickup coil resistance:

8-8 IGNITION SYSTEM ELEC INCORRECT MEETSPECIFICATION Replace main switch. S Disconnect the pickup coil coupler from thewire harness. S Connect the pocket tester ( Ω 100) to the pickup coil terminal. 7. Pickup coil resistance S Check the pickup coil for specified resistance. Pickup coil resistance: 1...

Page 277 - Wiring connection

8-9 IGNITION SYSTEM ELEC 12. Wiring connection : S Check the entire ignition system for connec-tions.Refer to “CIRCUIT DIAGRAM”. Replace ignitor unit. POOR CONNECTION Correct. CORRECT

Page 278 - ELECTRIC STARTING SYSTEM

8-10 Main switch Battery Main fuse Starter relay Starter motor Starting circuit cut-of f relay Neutral switch Sidestand switch Clutch switch Engine stop switch Start switch Ignition fuse 3 4 5 6 7 8 9 10 35 45 46 47 ELECTRIC STARTING SYSTEM ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

Page 279 - or if

8-11 ELECTRIC STARTING SYSTEM ELEC STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and the starting circuitcut-off relay. If the “ENGINE STOP” switch and themain switch are both closed, the starter motor canoperate only if: The transmission i...

Page 280 - Open circuit voltage:

8-12 ELECTRIC STARTING SYSTEM ELEC NOTE: Refer to “SWITCH INSPECTION”. 1. Fuse (main and ignition) Replace fuse(s). NO CONTINUITY S Check the battery condition.Refer to “BATTERY INSPECTION” in CHAP-TER 3. 2. Battery CONTINUITY Open circuit voltage: 12.8 V or more at 20 _ C : S Clean battery terminal...

Page 282 - Red / White terminal

8-14 ELECTRIC STARTING SYSTEM ELEC INCORRECT CONTINUITY Replace main switch. S Disconnect the relay unit coupler from the wireharness. S Connect the pocket tester ( Ω 1) and battery (12 V) to the relay unit coupler terminals. 5. Starter relay NO CONTINUITY Replace starter relay. : CORRECT Battery (+...

Page 284 - Armature coil; STARTER MOTOR

8-16 ELECTRIC STARTING SYSTEM ELEC Order Job name / Part name Q’ty Remarks 12 Starter motor removalExhaust pipe and muffler assembly Starter motor / O-ringStarter motor lead Starter motor disassembly Front bracketWasher kitRear bracketWasher kitBrush seat / Brush 1 Armature coil 1 / 1 1 1121 1 / 1 1...

Page 285 - Commutator wear limit:

8-17 ELECTRIC STARTING SYSTEM ELEC NOTE: Inspection and repair1. Inspect: CommutatorDirty Clean it with #600 grit sandpaper. 2. Measure: Commutator diameter aOut of specification Replace starter motor. Commutator wear limit: 27 mm 3. Measure: Mica undercut bOut of specification Scrape the mica to pr...

Page 287 - Gasket 1

8-19 ELECTRIC STARTING SYSTEM ELEC New New New NOTE: 3. Install: Gasket 1 Yoke 2 Washer kit 3 Gasket 4 Front bracket 5 O-ring 6 Align the match marks a on the yoke with thematch marks b on the brackets.

Page 288 - CHARGING SYSTEM

8-20 A.C. magneto/pickup coil Rectifier/refulator Battery Main fuse 1 2 4 5 CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM

Page 291 - POOR CONNECTION

8-23 CHARGING SYSTEM ELEC 5. Wiring connection : S Check the entire starting system for connec-tions.Refer to “CIRCUIT DIAGRAM”. Replace rectifier / regulator. POOR CONNECTION Correct. CORRECT

Page 292 - LIGHTING SYSTEM

8-24 Main switch Battery Main fuse Meter light 3 4 5 19 High beam indicator light 21 Headlight 25 Auxiliary light 26 Lights switch 30 Dimmer switch 31 Pass switch 32 T ail/brake light 39 Headlight fuse 40 Diode 48 LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM

Page 295 - Headlight

8-27 1. Voltage Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers. When dimmer switch is “LO” position.When dimmer switch is “HI” position. AB Headlight: Tester (+) lead Yellow or Green lead. Tester (–) lead Black lead. High beam indicator light: Tester (+) ...

Page 297 - Black lead; Turn the main switch to “ON”.

8-29 1. Voltage Connect the pocket tester (DC 20 V) to thebulb socket connector. Tester (+) lead Blue / Red lead Tester (–) lead Black lead 1 2 Turn the main switch to “ON”. Turn the light switch to “ON” or “PO” position. Check for voltage (12 V) on the “Blue / Red”lead at the bulb socket connector....

Page 299 - SIGNAL SYSTEM

8-31 SIGNAL SYSTEM ELEC SIGNAL SYSTEM CIRCUIT DIAGRAM

Page 302 - Frame ground

8-34 SIGNAL SYSTEM ELEC POOR CONNECTION Correct. INCORRECT Replace main switch. : MEETSSPECIFICATION : Refer to “SWITCH INSPECTION”. 3. Main switch CORRECT S Check the entire signal system for connec-tions.Refer to “WIRING DIAGRAM”. 4. Wiring connection CORRECT INCORRECT Replace handlebar switch (le...

Page 311 - Thermo unit resistance:; Handle the thermo unit with special care.

8-43 6. Thermo unit S Remove the thermo unit from the radiator. S Connect the pocket tester ( Ω 10) to the ther- mo unit . S Immerse the thermo unit in the water . S Measure the resistance. Thermo unit resistance: 80 _ C: 47 X 53 Ω 100 _ C: 26 X 30 Ω Replace thermo unit. BAD CONDITION 7. Wiring conn...

Page 312 - TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS; The above pattern is repeated.

8-44 Revolution( 10 3 r / min) Tachometer display Engine speed time(seconds) TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS ELEC 123 NOTE: TPS (THROTTLE POSITION SENSOR) SELF DIAGNOSIS CIRCUIT DIAGRAM If the needle of the tachometer shows the follow-ing pattern while the engine is running, the thrott...

Page 317 - TRBL; STARTING FAILURE / HARD STARTING

9-1 STARTING FAILURE / HARD STARTING TRBL SHTG NOTE: TROUBLESHOOTING The following troubleshooting does not cover all the possible causes of trouble. If should be helpful, howev-er, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustmentand replacemen...

Page 318 - POOR IDLE SPEED PERFORMANCE

9-2 STARTING FAILURE / HARD STARTING / POOR IDLE SPEED PERFORMANCE / POOR MEDIUM AND HIGH SPEED PERFORMANCE TRBL SHTG COMPRESSION SYSTEMCylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Worn, damaged or seized cylinder Improperly sealed valve Imp...

Page 319 - FAULTY GEAR SHIFTING

9-3 FAULTY GEAR SHIFTING / CLUTCH SLIPPING / DRAGGING TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTINGRefer to “Clutch dragging.” SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rod Bent shift shaft Shift cam, shift fork Groove jammed with impurities Seized shift fork Bent shift fork guid...

Page 320 - FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION; OVERHEATING

9-4 OVERHEATING/FAULTY BRAKE/ FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION TRBL SHTG OVERHEATING OVERHEATINGIgnition system Improper spark plug gap Improper spark plug heat range Faulty ignitor unit Fuel system Improper carburetor main jet (improper setting) Improperly adjusted fuel level Clogg...

Page 321 - FAULTY LIGHTING AND SIGNAL SYSTEM; INSTABLE HANDLING

9-5 INSTABLE HANDLING / FAULTY LIGHTING AND SIGNAL SYSTEM TRBL SHTG INSTABLE HANDLING INSTABLE HANDLINGHandlebar Improperly installed or bent Steering Improperly installed handlebar crown Bent steering stem Improperly installed steering shaft (Improperlytightened ring nut) Damaged ball bearing or be...

Page 322 - FLASHER KEEPS ON

9-6 FAULTY LIGHTING AND SIGNAL SYSTEM TRBL SHTG FLASHER KEEPS ON Faulty flasher relay Bulb burnt out FLASHER WINKS QUICKER Improper bulb Faulty flasher relay Bulb burnt out HORN IS INOPERATIVE Faulty battery Faulty fuse Faulty main and / or horn switch Improperly adjusted horn Faulty horn Broken wir...

Page 323 - COLOR CODE

COLOR CODE B Black . . . . . . Br Brown . . . . . Ch Chocolate . . . . Dg Dark green . . . . G Green . . . . . Gy Gray . . . . L Blue . . . . . . Lg Light green . . . . . O Orange . . . . . R Red . . . . . . Sb Sky blue . . . . . W White . . . . . Y Yellow . . . . . . B / L Black / Blue . . . . B / ...

Table of Contents:

Summary

Other Yamaha Models