Page 3 EB000000 XVS650 SERVICE MANUAL 1996 by Yamaha Motor Co.Ltd. First edition, September 1996 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4: Important Information
It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Page 5: How To Use This Manual
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section.
Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting...
Page 7 E004000 CHAPTER TITLES GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENTS ENGINE OVERHAUL CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
Page 9: Table Of Contents
INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
Page 10 INFO...
Page 11: Motorcycle Identification
MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 12: Important Information
5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 13: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.
Page 14: Checking Of Connections
CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1. Disconnect: S Connector 2. Check: S Connector Moisture ! Dry each terminal with an air blower. Stains/rust ! Connect and disconnect the terminals several times. 3.
Page 15: Special Tools
SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.
Page 16 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Sheave holder This tool is needed to hold the rotor 90890-01701 when removing or installing the rotor bolt. Compression gauge set 90890-03081 These tools are needed to measure engine compression. Vacuum gauge 90890-03094 This gauge is needed for carburetor...
Page 17 Damper spring compressor 90890-04090 This tool is needed when removing or installing the damper spring. Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Yamaha bond No.1215 90890-85505 This sealant (bond) is used on crankcase mating surfaces, etc.
Page 18 INFO...
Page 19: Specifications Spec
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .
Page 20 SPEC...
Page 21: Chapter 2. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: XVS650: 4VR1, 4VR2 Dimensions: Overall length 2,340 mm Overall width 2,880 mm Overall height 1,065 mm Seat height 2,695 mm Wheelbase 1,610 mm Minimum ground clearance 2,140 mm Minimum turning radius 3,100 mm Basic weight: With oil and a full fuel tank...
Page 22 SPEC GENERAL SPECIFICATIONS Item Standard Carburetor: Type/quantity BDS28/2 Manufacturer MIKUNI Spark plug: Type DPR7EA-9/X22EPR-U9 Manufacturer NGK/DENSO 0.8 X 0.9 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 68/38 (1.789) Secondary reduction system Shaft drive Secondary reduction ratio 19/18 32/11 (3.071)
Page 23 SPEC GENERAL SPECIFICATIONS Item Standard Suspension: Front suspension Telescopic fork Rear suspension Swingarm (Monocross) Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Gas-oil damper Wheel travel: Front wheel travel 140 mm Rear wheel travel 86 mm Electrical: Ignition system T.C.I.
Page 24: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm Cylinder: 80.945 X 80.995 mm Bore size 81.1 mm Measuring point* 40 mm Camshaft: Drive method Chain drive (left & right) 28.000 X 28.021 mm Cam cap inside diameter 27.96 X 27.98 mm Camshaft outside diameter...
Page 25 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links SILENT CHAIN/118 Timing chain adjustment method Automatic Rocker arm/rocker arm shaft: 14.000 mm X 14.018 mm Bearing inside diameter 13.980 mm X 13.991 mm Shaft outside diameter 0.009 mm X 0.038 mm Arm-to-shaft clearance Valve, valve seat, valve guide:...
Page 26 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 21.8 X 25.6 kg Compressed pressure (installed) 21.8 X 25.6 kg Tilt limit 2.5_/1.9 2.5_/1.9 Direction of winding (top view)IN Counter clockwise Counter clockwise Piston: 0.035 X 0.055 mm Piston to cylinder clearance 0.15 mm 80.90 X 80.95 mm Piston size “D”...
Page 27 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring: Type Dimensions (B Taper End gap (installed) 3.6 mm 0.30 X 0.45 mm Side clearance 0.8 mm 0.02 X 0.06 mm Oil ring: 0.12 mm Dimensions (B End gap (installed) 3.1 mm 0.2 X 0.7 mm Connecting rod: 0.026 X 0.050 mm...
Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: Main axle deflection limit 0.06 mm Drive axle deflection limit 0.06 mm Shifter: Shifter type Guide bar Carburetor: I. D. mark 4VR 00 Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) 4CP10-3 Needle jet (N.J)
Page 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Pressure feed Splashed Camshaft Rocker arm shaft Piston Middle gear housing Drive axle Starter clutch Crankshaft Main axle Oil filter Oil pump Relief valve Oil strainer...
Page 30 SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence: Crankcase tightening sequence: Left crankcase Right crankcase 2-10...
Page 31 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Cylinder head Cylinder head Cylinder head Bolt Cylinder head cover bracket Cylinder head (exhaust pipe) Stud bolt Camshaft sprocket cover Bolt Tappet cover Bolt Rocker arm shaft (oil passage)
Page 32 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Clutch spring Bolt Clutch adjuster Clutch boss Use lock washer Push lever axle Screw Middle drive pinion gear 12.0 Stake Bearing retainer (middle driven —...
Page 33: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball & taper roller bearing No./size of steel ball (upper) 19 pcs/0.25 in Front suspension: Front fork travel 140 mm Fork spring free length 295 mm 289 mm Fitting length 249.9 mm Spring rate...
Page 34 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Master cylinder inside diameter 12.7 mm Caliper cylinder inside diameter 30.1 mm Caliper cylinder inside diameter 33.3 mm Brake fluid type DOT 4 Rear brake: Type Leading, trailing Brake drum inside diameter 200 mm 201 mm Lining thickness 4 mm...
Page 35 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks mSkg Upper bracket and inner tube Lower bracket and inner tube Upper bracket and steering shaft 11.0 Ring nut (steering shaft) — See NOTE Handlebar holder (lower) and upper bracket Handlebar holder (lower) and handlebar holder (upper) Master cylinder (front brake)
Page 36 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks mSkg Passenger footrest and frame Sidestand bracket and frame Sidestand and sidestand bracket Sidestand switch Brake pedal/footrest and frame Front wheel axle Front wheel axle pinch bolt Brake caliper Brake disc and front wheel Caliper bleed screw Rear wheel axle nut...
Page 37: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 12_ at 1,200 r/min Advancer type TPS and electrical type T.C.I.: 182 X 222 Ω at 20_C/Gray – Black Pickup coil resistance/color T.C.I. unit model/manufacturer J4T079/MITSUBISHI Ignition coil: Model/manufacturer...
Page 38 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn: Type Plane type Quantity Model/manufacturer YF-12/NIKKO Maximum amperage 1.5 A Flasher relay: Type Full transistor type Model/manufacturer FE246BH/DENSO Self cancelling device 75 X 95 cycle/min Flasher frequency Wattage 21 W 2 + 3W Fuel pump relay: Model/manufacturer G8R-30Y/OMRON...
Page 39: General Torque Specifications
SPEC GENERAL TORQUE SPECIFICATIONS EB202001 General torque GENERAL TORQUE specifications SPECIFICATIONS (nut) (nut) (Bolt) (Bolt) mSkg This chart specifies torque for standard fasten- 10 mm 6 mm ers with standard I.S.O. pitch threads. Torque specifications for special components or as- 12 mm 8 mm semblies are provided for each chapter of this...
Page 40: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Symbol Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX)
Page 41: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203010 CHASSIS Lubrication point Symbol Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface...
Page 42: Lubrication Diagrams
SPEC LUBRICATION DIAGRAMS EB205000 LUBRICATION DIAGRAMS 1 Rocker arm (intake) 4 Drain bolt 7 Push rod 1 2 Rocker arm (exhaust) 5 Oil strainer 8 Oil pump 3 Camshaft 6 Push lever 2-22...
Page 43 SPEC LUBRICATION DIAGRAMS 1 Rocker arm shaft (intake) 4 Drive axle 7 Oil filter 2 Rocker arm shaft (exhaust) 5 Relief valve 8 Crankshaft 3 Camshaft 6 Oil pump 2-23...
Page 44 SPEC LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter 3 Oil pump 2-24...
Page 45 SPEC LUBRICATION DIAGRAMS 1 Camshaft 4 Drive axle 2 Rocker arm 5 Main axle 3 Starter idle gear 2-25...
Page 46: Cable Routing
SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Clutch cable Horn 2 Left handlebar switch lead Headlight lead 3 Fuel tank breather hose Right handlebar switch lead 4 Speedometer cable Spark plug lead 5 Speedometer Fuel hose 6 Speedometer light leads Main switch lead 7 Rectifier/ regulator Fuel pump lead...
Page 47 SPEC CABLE ROUTING A Pass the front flasher light leads (left and E Connect the rear brake switch coupler in front right) and headlight lead through the of the roll over valve stay. headlight cover hole. F To the speedometer light leads. B Pass the left handlebar switch lead behind G Pass the right handlebar switch lead and head- the upper bracket.
Page 48 SPEC CABLE ROUTING L Fasten the sidestand switch lead with a metal Q Fasten the rear brake switch lead and rectifier/ clamp. regulator lead with a plastic locking tie. M Fasten the rear brake switch lead, sidestand R Place the couplers behind the steering head. switch lead and rectifier / regulator lead with S Pass the speedometer cable through the a metal clamp.
Page 49 SPEC CABLE ROUTING 1 Frame bracket Starter relay A Pass the tail/brake light lead 2 Wire harness Carburetor heater relay between the frame bracket and 3 Fuse box Neutral switch lead battery box. 4 Battery positive (+) lead Pickup coil lead B Fasten the tail/brake light lead 5 Spark plug lead A.C.
Page 50 SPEC CABLE ROUTING E Fasten the right handlebar switch lead with a K Fasten the fuse box lead with a plastic locking plastic locking tie. tie. F Pass the right handlebar switch lead behind L Fasten the battery positive (+) lead with a bat- the upper bracket.
Page 51 SPEC CABLE ROUTING Q Fasten the pickup coil lead, A.C. magneto V Fasten the starter cable with a plastic locking lead, neutral switch lead and starter motor tie. lead with a plastic locking tie. W Inside the motorcycle. R Fasten the battery negative (–) lead, starter X Pass the fuel tank breather hose through the motor lead and wire harness with a plastic holder.
Page 52 SPEC CABLE ROUTING b Fasten the wire harness and leads with a h To the flasher light relay. metal clamp. i To the rear fender. c To the carburetor heater relay. To the battery negative (–) lead. d Fasten the wire harness and leads with a k Pass the ignitor unit leads through the plastic locking tie.
Page 53 SPEC CABLE ROUTING 1 Front flasher light (right) Speedometer cable A Pass the throttle cables 2 Throttle cables Neutral switch lead through the cable guide. 3 Brake hose Pickup coil lead B Pass the brake hose in front 4 Right handlebar switch lead A.C.
Page 54 SPEC CABLE ROUTING G To the ignition coil. N 20 mm H Pass the starter cable between the ignition O Pass the thermo switch lead inside of the coil and spark plug lead. silencer breather hose. I To the throttle position sensor (TPS). P Place the end of the plastic locking tie as J To the carburetor.
Page 55 INSP CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
Page 56 INSP ELECTRICAL ..........3-37 BATTERY INSPECTION .
Page 57: Periodic Inspections And Adjustments
INTRODUCTION/PERIODIC MAINTENANCE/ INSP LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa- tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
Page 58 S Change every 24,000 km or 24 months. Items marked with an asterisk (*) require special tools, data and technical skills for servicing. Take the motorcycle to a Yamaha dealer or refer to the Service Manual when servicing these items. NOTE: Brake fluid replacement: 1.
Page 59: Fuel Tank And Seats
INSP FUEL TANK AND SEATS FUEL TANK AND SEATS 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Fuel tank and seats removal Remove the parts in the order below. NOTE: Fuel hose Set the fuel cock to “OFF”...
Page 60: Engine
INSP VALVE CLEARANCE ADJUSTMENT EB303003 ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: D Valve clearance adjustment should be made with the engine cool, at room temperature. D When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression stroke.
Page 61 INSP VALVE CLEARANCE ADJUSTMENT 8. Remove: S Camshaft sprocket covers 1 9. Remove: S Timing plug 1 S Straight plug 2 10. Measure: S Valve clearance Out of specification ! Adjust. Valve clearance (cold): Intake valve: 0.07 X 0.12 mm Exhaust valve: 0.12 X 0.17 mm *****************************************************...
Page 62 INSP VALVE CLEARANCE ADJUSTMENT D Measure the valve clearance using a thick- ness gauge 1 . ***************************************************** 11. Adjust: S Valve clearance ***************************************************** Adjustment steps: D Loosen the locknut 1 . D Insert a thickness gauge between the adjust- er end and the valve end. D Turn the adjuster 2 in or out until the speci- fied clearance is obtained.
Page 63: Carburetor Synchronization
VALVE CLEARANCE ADJUSTMENT/ INSP CARBURETOR SYNCHRONIZATION 13. Install: S Camshaft sprocket covers 10 Nm (1.0 mSkg) S Tappet covers 10 Nm (1.0 mSkg) S Cylinder head cover 10 Nm (1.0 mSkg) S Spark plugs 18 Nm (1.8 mSkg) EB303010 CARBURETOR SYNCHRONIZATION NOTE: Prior to synchronizing the carburetors, the valve clearance should be properly adjusted and the...
Page 64 INSP CARBURETOR SYNCHRONIZATION 6. Adjust: S Carburetor synchronization ***************************************************** Adjustment steps: D Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 until both gauges read the same. D Rev the engine two or three times, each time for less than a second, and check the syn- chronization again.
Page 65: Idling Speed Adjustment
INSP IDLING SPEED ADJUSTMENT EB303021 IDLING SPEED ADJUSTMENT NOTE: Prior to adjusting the idling speed, the carbure- tor synchronization should be adjusted proper- ly, the air filter should be clean and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.
Page 66: Throttle Cable Adjustment
IDLING SPEED ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT 5. Adjust: S Throttle cable free play Refer to “THROTTLE CABLE ADJUST- MENT”. Free play (throttle cable): 4 X 6 mm At throttle grip flange EB303030 THROTTLE CABLE ADJUSTMENT NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchro- nization should be adjusted properly.
Page 67: Spark Plug Inspection
THROTTLE CABLE ADJUSTMENT/ INSP SPARK PLUG INSPECTION 1st step: D Loosen the locknut 3 on throttle cable #1. D Turn the adjuster 4 in or out until the speci- fied free play is obtained. Turning in: free play is increased. Turning out: free play is decreased.
Page 68: Ignition Timing Check
INSP SPARK PLUG INSPECTION/IGNITION TIMING CHECK 2. Check: S Spark plug type Incorrect ! Replace. Standard spark plug: DPR7EA-9 (NGK) X22EPR-U9 (DENSO) 3. Inspect: S Electrode 1 Wear/damage ! Replace. S Insulator 2 Abnormal color ! Replace. Normal color is a medium-to-light tan col- 4.
Page 69 INSP IGNITION TIMING CHECK 1. Remove: S Timing plug 1 2. Attach: S Timing light 1 S Engine tachometer 2 (to the #1 spark plug lead) Timing light: 90890-03141 Engine tachometer: 90890-03113 3. Check: S Ignition timing ***************************************************** Checking steps: D Start the engine and let it warm up for several minutes.
Page 70: Compression Pressure Measurement
INSP COMPRESSION PRESSURE MEASUREMENT EB303060 COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in a loss of performance. 1. Check: S Valve clearance Out of specification ! Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT”. 2. Start the engine and let it warm up for sev- eral minutes.
Page 71 INSP COMPRESSION PRESSURE MEASUREMENT Compression pressure (with oil applied in the cylinder) Reading Diagnosis Higher than Worn or damaged pistons ! Repair. without oil Possible defective ring(s), Same as valves, cylinder head gas- without oil ket or piston ! Repair. Compression pressure (at sea level) Standard:...
Page 72: Engine Oil Level Inspection
INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: D Make sure the motorcycle is upright when in- specting the oil level. D Place the motorcycle on a suitable stand. 2. Inspect: S Oil level Oil level should be between the maximum a and minimum b marks.
Page 73: Engine Oil Replacement
INSP ENGINE OIL REPLACEMENT EB303080 ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for sev- eral minutes. 2. Turn off the engine and place a container under the drain bolt. 3. Remove: S Oil filler plug 1 S O-ring 2 S Drain bolt 3 S Gasket...
Page 74 INSP ENGINE OIL REPLACEMENT 6. Fill: S Crankcase Refer to “ENGINE OIL LEVEL INSPEC- TION”. Oil quantity: Total amount: 3.2 L (2.8 Imp qt) Periodic oil change: 2.6 L (2.3 Imp qt) With oil filter replacement: 2.8 L (2.6 Imp qt) 7.
Page 75: Clutch Adjustment
INSP CLUTCH ADJUSTMENT/AIR FILTER CLEANING EB303090 CLUTCH ADJUSTMENT 1. Check: S Clutch cable free play a Out of specification ! Adjust. Free play (clutch cable): 10 X 15 mm At clutch lever end 2. Adjust: S Clutch cable free play ***************************************************** Adjustment steps: D Loosen the locknuts 1 .
Page 76: Carburetor Joint Inspection
AIR FILTER CLEANING/CARBURETOR JOINT INSP INSPECTION/FUEL LINE INSPECTION 3. Inspect: S Air filter element Damage ! Replace. 4. Clean: S Air filter element Blow off the dust from the outside of the element using compressed air. 5. Install: S Air filter element S Air filter case cover NOTE: When installing the element in its case, make...
Page 77: Breather Hose Inspection
BREATHER HOSE INSPECTION/ INSP EXHAUST SYSTEM INSPECTION BREATHER HOSE INSPECTION 1. Remove: S Cylinder head cover (rear cylinder) Refer to “ENGINE REMOVAL” in CHAP- TER 4. 2. Inspection: S Breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly.
Page 78: Chassis
INSP FRONT BRAKE ADJUSTMENT EB304002 CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: S Brake lever free play a Out of specification ! Adjust. Free play (brake lever): 10 X 15 mm (at brake lever end) 2. Adjust: S Brake lever free play ***************************************************** Adjustment steps: D Loosen the locknut 1 .
Page 79: Rear Brake Adjustment
INSP REAR BRAKE ADJUSTMENT EB304012 REAR BRAKE ADJUSTMENT 1. Check: S Brake pedal height a Out of specification ! Adjust. Brake pedal height: 85 mm (above the top of the footrest) 2. Adjust: S Brake pedal height ***************************************************** Adjustment steps: D Loosen the locknut 1 .
Page 80: Brake Fluid Level Inspection
REAR BRAKE ADJUSTMENT/ INSP BRAKE FLUID LEVEL INSPECTION 5. Adjust: S Brake light switch Refer to “BRAKE LIGHT SWITCH AD- JUSTMENT”. EB304020 BRAKE FLUID LEVEL INSPECTION 1. Stand the motorcycle on a level surface. NOTE: D When inspecting the brake fluid level, make sure the motorcycle is upright.
Page 81: Brake Pad Inspection
BRAKE PAD INSPECTION/BRAKE SHOE INSPECTION/ INSP BRAKE LIGHT SWITCH ADJUSTMENT EB304030 BRAKE PAD INSPECTION 1. Operate the brake lever. 2. Inspect: S Brake pad Wear indicators 1 almost touch the brake disc ! Replace the brake pads as a set. Refer to “REAR WHEEL AND REAR BRAKE”...
Page 82: Brake Hose Inspection
BRAKE HOSE INSPECTION INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) EB304060 BRAKE HOSE INSPECTION 1. Inspect: S Brake hose(s) Cracks/wear/damage ! Replace. 2. Check: S Brake hose clamp(s) Loose ! Tighten. 3. Hold the motorcycle upright and apply the front or rear brake. 4.
Page 83: Shift Pedal Adjustment
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP SHIFT PEDAL ADJUSTMENT g. Loosen the bleed screw and allow the lever to travel towards its limit. h. Tighten the bleed screw when the lever limit has been reached, then release the lever. Repeat steps (e) to (h) until all the air bubbles have disappeared from the brake fluid.
Page 84: Final Gear Oil Level Inspection
SHIFT PEDAL ADJUSTMENT/ INSP FINAL GEAR OIL LEVEL INSPECTION 2. Adjust: S Shift pedal position ***************************************************** Adjustment steps: D Loosen both locknuts 1 . D To obtain the correct pedal position turn the shift pedal rod 2 in or out. Turning in: shift pedal is lowered.
Page 85: Final Gear Oil Replacement
FINAL GEAR OIL REPLACEMENT/ INSP STEERING HEAD INSPECTION EB304120 FINAL GEAR OIL REPLACEMENT 1. Place a container under the final gear case. 2. Remove: S Oil filler bolt 1 S Drain plug 2 Drain the final gear case of its oil. 3.
Page 86 INSP STEERING HEAD INSPECTION 4. Loosen S Front fork pinch bolts (upper) 1 5. Remove S Steering stem nut 2 S Upper bracket 3 6. Adjust: S Steering head ***************************************************** Adjustment steps: D Remove the lock washer 1 , the upper ring nut 2 and the rubber washer 3 .
Page 87: Front Fork Inspection
STEERING HEAD INSPECTION/ INSP FRONT FORK INSPECTION D Check the steering head for looseness or binding by turning it all the way, in both direc- tions. If it binds, remove the steering stem as- sembly and inspect the steering bearings. Refer to “STEERING HEAD AND HAN- DLEBAR”...
Page 88: Rear Shock Absorber Adjustment
REAR SHOCK ABSORBER ADJUSTMENT/ INSP TIRE INSPECTION EB304160 REAR SHOCK ABSORBER ADJUSTMENT Securely support the motorcycle so that there is no danger of it falling over. Spring preload 1. Adjust: S Spring preload NOTE: Use the special wrench and extension bar in- cluded in the owner’s tool kit to adjust the spring preload.
Page 89 INSP TIRE INSPECTION D Tire inflation pressure should only be checked and adjusted when the tire tem- perature equals the ambient air tempera- ture. Tire inflation pressure and suspen- sion must be adjusted according to the total weight of the cargo, rider, passenger and accessories (fairing, saddlebags, etc.if approved for this model), and ac- cording to whether the motorcycle will be...
Page 90 Co., Ltd. for this model. No guarantee concerning handling characteristics can be given if a tire combination, other than one approved by Yamaha, is used on this motorcycle. The front and rear tires should always be by the same manufac- turer and of the same design.
Page 91: Wheel Inspection
WHEEL INSPECTION/SPOKE INSPECTION AND INSP TIGHTENING/CABLE INSPECTION AND LUBRICATION EB304180 WHEEL INSPECTION 1. Inspect: S Wheels Bends/damage ! Replace. NOTE: After a tire or wheel has been changed or re- placed always balance the wheel. Never attempt to make any repairs to the wheels.
Page 92: Lever And Pedal Lubrication
CABLE INSPECTION AND LUBRICATION/LEVER AND INSP PEDAL LUBRICATION/SIDESTAND LUBRICATION 1. Inspect: S Cable sheaths Damage ! Replace. 2. Check: S Cable operation Unsmooth operation ! Lubricate. Recommended lubricant: Engine oil NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath.
Page 93: Electrical
INSP BATTERY INSPECTION EB305000 ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the bat- tery has to be checked by measuring the volt- age at the battery terminals.
Page 94 INSP BATTERY INSPECTION Batteries generate explosive hydrogen gas. Always follow these preventive measures: D Charge batteries in a well-ventilated area. D Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) D DO NOT SMOKE when charging or han- dling batteries.
Page 95 INSP BATTERY INSPECTION D Check the condition of the battery using the Relationship between open-circuit following charts. voltage and charging time at 20_C Example: D Open-circuit voltage = 12.0V D Charging time = 6.5 hours D Charge condition of the battery = 20 X 30% D Charging method for MF batteries Charging time (Hours) CAUTION:...
Page 96 INSP BATTERY INSPECTION Charging method using a variable-current (voltage) type charger Charger Measure the open-circuit NOTE: AMP meter voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
Page 97 INSP BATTERY INSPECTION Charging method using a constant-voltage type charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Make sure the current is higher than the standard charging current written on...
Page 98: Fuse Inspection
BATTERY INSPECTION/ INSP FUSE INSPECTION 5. Inspect: S Battery terminals Dirty ! Clean with a wire brush. Poor connection ! Correct. NOTE: After cleaning the terminals, apply a light coat of grease. 6. Install: S Battery S Battery band 7. Connect: S Battery leads CAUTION: First, connect the positive lead 1 , then con-...
Page 99 INSP FUSE INSPECTION NOTE: Set the tester selector to “Ω 1”. Pocket tester: 90890-03112 D If the tester indicates , replace the fuse. ************************************* 3. Replace: S Blown fuse ***************************************************** Replacement steps: D Turn off the main switch. D Install a new fuse with the proper current rat- ing.
Page 100: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT/ INSP HEADLIGHT BULB REPLACEMENT EB305020 HEADLIGHT BEAM ADJUSTMENT 1. Adjust: S Headlight beam (vertically) Turn the adjuster 1 in or out. Turning in: headlight beam is raised. Turning out: headlight beam is lowered. 2. Adjust: S Headlight beam (horizontally) Turn the adjuster 2 in or out.
Page 101 INSP HEADLIGHT BULB REPLACEMENT CAUTION: 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 the lu- minous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
Page 102 INSP...
Page 103 CHAPTER 4. ENGINE ENGINE REMOVAL ..........MUFFLERS, BRAKE PEDAL AND SIDE COVER .
Page 104 OIL PUMP ........... . 4-45 OIL PUMP INSPECTION .
Page 105: Chapter 4. Engine
ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLERS, BRAKE PEDAL AND SIDE COVER 64 Nm (6.4 m S kg) 25 Nm (2.5 m S kg) 20 Nm (2.0 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) Order Job name/Part name Q’ty...
Page 106 ENGINE REMOVAL 64 Nm (6.4 m S kg) 25 Nm (2.5 m S kg) 20 Nm (2.0 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) Order Job name/Part name Q’ty Remarks Battery cover Side cover (right) For installation, reverse the removal procedure.
Page 107: Cylinder Head Covers
ENGINE REMOVAL CYLINDER HEAD COVERS 5 Nm (0.5 m S kg) 5 Nm (0.5 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Cylinder head covers removal Remove the parts in the order below.
Page 108 ENGINE REMOVAL 5 Nm (0.5 m S kg) 5 Nm (0.5 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Lower cylinder head cover (front) For installation, reverse the removal procedure.
Page 109: Sidestand And Crankcase Cover (Left)
ENGINE REMOVAL SIDESTAND AND CRANKCASE COVER (LEFT) 64 Nm (6.4 m S kg) 30 Nm (3.0 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 13 Nm (1.3 m S kg) Order Job name/Part name Q’ty Remarks Side stand and crankcase cover...
Page 110: Engine Mounting Bolts
ENGINE REMOVAL ENGINE MOUNTING BOLTS 74 Nm (7.4 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 30 Nm (3.0 m S kg) 40 Nm (4.0 m S kg) 30 Nm (3.0 m S kg)
Page 111 ENGINE REMOVAL 74 Nm (7.4 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 40 Nm (4.0 m S kg) 30 Nm (3.0 m S kg) 40 Nm (4.0 m S kg) 30 Nm (3.0 m S kg) Order...
Page 112: Shift Pedal Installation
ENGINE REMOVAL SHIFT PEDAL INSTALLATION 1. Connect S Shift pedal link 1 10 Nm (1.0 mSkg) NOTE: Align the punch mark a on the shift rod with the slot b on the shift pedal link BRAKE PEDAL INSTALLATION 1. Connect S Brake pedal link 1 10 Nm (1.0 mSkg) NOTE:...
Page 113: Cylinder Heads
CYLINDER HEADS CYLINDER HEADS 35 Nm (3.5 m S kg) 35 Nm (3.5 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) 12 Nm (1.2 m S kg) 55 Nm (5.5 m S kg) 20 Nm (2.0 m S kg)
Page 114 CYLINDER HEADS 35 Nm (3.5 m S kg) 35 Nm (3.5 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) 12 Nm (1.2 m S kg) 55 Nm (5.5 m S kg) 20 Nm (2.0 m S kg) Order...
Page 115: Cylinder Head Removal
CYLINDER HEADS CYLINDER HEAD REMOVAL Rear cylinder head 1. Align: S “T” mark (with the stationary pointer) ***************************************************** Removal steps: D Temporarily install the AC magneto cover without the pickup coil and stator coil. D Turn the crankshaft clockwise. D Align the “T” mark a with the stationary pointer b on the crankcase cover (left) when the rear piston is at TDC on the compression stroke.
Page 116: Cylinder Head Inspection
CYLINDER HEADS 6. Remove: S Cylinder head NOTE: D Loosen the bolts and nuts in the proper se- quence. D Follow the numerical order shown in the il- lustration. Loosen each bolt 1/4 of a turn at a time until all of the bolts are loose. Front cylinder head NOTE: When removing the front cylinder head cam-...
Page 117 CYLINDER HEADS 3. Measure: S Cylinder head warpage Out of specification ! Resurface. Cylinder head warpage: Less than 0.03 mm ***************************************************** Warpage measurement and resurfacement steps: D Place a straightedge 1 and a feeler gauge 2 across the cylinder head. D Use a feeler gauge to measure the warpage.
Page 118: Cylinder Head Installation
CYLINDER HEADS CYLINDER HEAD INSTALLATION Rear cylinder head 1. Install: S Nuts (cylinder head) (M10: 1 X 4) 35 Nm (3.5 mSkg) S Bolts (cylinder head) (M8: 5 X 7) 20 Nm (2.0 mSkg) NOTE: D Tighten the bolts and nuts in the proper se- quence.
Page 119 CYLINDER HEADS 3. Install: S Timing chain tensioner ***************************************************** Installation steps: D Remove the tensioner cap bolt 1 , washer 2 and spring 3 . D Release the timing chain tensioner one-way cam 4 and push the tensioner rod 5 all the way in.
Page 120 CYLINDER HEADS Front cylinder head NOTE: When installing the front cylinder head cam- shafts, repeat the rear cylinder head camshafts installation procedure. However, note the fol- lowing points. 1. Install: S Camshaft sprocket ***************************************************** Installation steps: D Turn the crankshaft clockwise 290_. D Align the “I”...
Page 121: Rocker Arms And Camshaft
ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m S kg) 38 Nm (3.8 m S kg) 20 Nm (2.0 m S kg) 14 Nm (1.4 m S kg) Order Job name/Part name Q’ty Remarks Rocker arm and camshaft removal Remove the parts in the order below.
Page 122: Rocker Arm And Camshaft Removal
ROCKER ARMS AND CAMSHAFT ROCKER ARM AND CAMSHAFT REMOVAL 1. Remove: S Rocker arm shafts (intake and exhaust) 1 S Rocker arms 2 NOTE: Use a slide hammer 3 to remove the rocker arm shafts. Slide hammer bolt (M8): 90890-01085 Weight: 90890-01084 2.
Page 123: Rocker Arm And Camshaft Installation
ROCKER ARMS AND CAMSHAFT 4. Inspect: S Rocker arms S Rocker arm shafts Damage/wear ! Replace. ***************************************************** Inspection steps: D Inspect the two contact areas on the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole. 2) Camshaft lobe contact surface. Excessive wear ! Replace.
Page 124 ROCKER ARMS AND CAMSHAFT NOTE: D The dowel pin a on the end of the camshaft must align with the timing mark b on the cyl- inder head. D Make sure that the No.1 camshaft 6 is installed in the rear cylinder head and the No.2 camshaft 7 is installed in the front cyl- inder head.
Page 125: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Valve and valve spring removal Remove the parts in the order below. Cylinder heads Refer to “CYLINDER HEADS”. Rocker arms and camshafts Refer to “ROCKER ARMS AND CAM- SHAFT”.
Page 126: Valve And Valve Spring Removal
VALVES AND VALVE SPRINGS VALVE AND VALVE SPRING REMOVAL 1. Check: S Valve sealing Leakage at the valve seat ! Inspect the valve face, valve seat and valve seat width. Refer to “INSPECTION”. ***************************************************** Checking steps: D Pour a clean solvent 1 into the intake and exhaust ports.
Page 127 VALVES AND VALVE SPRINGS 2. Replace: S Valve guide ***************************************************** Replacement steps: NOTE: To ease guide removal, installation and to main- tain correct fit heat the cylinder head in an oven to 100_C. D Remove the valve guide using a valve guide remover 1 .
Page 128 VALVES AND VALVE SPRINGS 5. Measure: S Runout (valve stem) Out of specification ! Replace. Runout limit: 0.03 mm NOTE: D When installing a new valve always replace the guide. D If the valve is removed or replaced always re- place the oil seal.
Page 129 VALVES AND VALVE SPRINGS 9. Lap: S Valve face S Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. ***************************************************** Lapping steps: D Apply a coarse lapping compound to the valve face.
Page 130: Valve And Valve Spring Installation
VALVES AND VALVE SPRINGS 10. Measure: S Valve spring free length a Out of specification ! Replace. Free length (valve spring): 43.2 mm <Limit>: 42.0 mm 11. Measure: S Compressed spring force a Out of specification ! Replace. b Installed length Compressed spring force: 21.8 X 25.6 kg at 37.1 mm 12.
Page 131 VALVES AND VALVE SPRINGS 3. Install: S Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: 90890-04019 4. To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood.
Page 132: Cylinders And Pistons
CYLINDERS AND PISTONS CYLINDERS AND PISTONS 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Cylinder and piston removal Remove the parts in the order below. Cylinder heads Refer to “CYLINDER HEADS”. Timing chain guide The “up” mark should face towards the cylinder head.
Page 133: Piston Removal
CYLINDERS AND PISTONS PISTON REMOVAL 1. Remove: S Piston pin clips 1 S Piston pin 2 S Piston 3 NOTE: D Put identification marks on each piston head for reference during reinstallation. D Before removing each piston pin, deburr the clip groove and pin hole area.
Page 134 CYLINDERS AND PISTONS NOTE: Measure the cylinder bore “C” horizontally and laterally. Wear Standard limit Cylinder 80.965 X 81.015 mm 81.1 mm bore C: X + Y D Find the average of the measurements. D If out of specification, rebore or replace the cylinder and replace the piston and piston rings as a set.
Page 135: Piston Ring Inspection
CYLINDERS AND PISTONS PISTON RING INSPECTION 1. Measure: S Side clearance (piston to piston rings) Out of specification ! Replace the piston and the piston rings as a set. NOTE: Before measuring the side clearance remove the carbon deposits from the piston ring grooves and rings.
Page 136: Piston Pin Inspection
CYLINDERS AND PISTONS PISTON PIN INSPECTION 1. Inspect: S Piston pin Blue discoloration/grooves ! Replace, then inspect the lubrication system. 2. Measure: S Piston pin-to-piston clearance ***************************************************** Measurement steps: D Measure the piston pin outside diameter a . If out of specification, replace the piston pin. Outside diameter (piston pin): 19.995 X 20.000 mm D Measure the piston inside diameter b .
Page 137: Cylinder And Piston Installation
CYLINDER AND PISTONS CYLINDER AND PISTON INSTALLATION 1. Install: S Piston ring (top ring) 1 S Piston ring (second ring) 2 NOTE: D Be sure to install the piston rings so that the manufacturer’s marks or numbers are lo- cated on the upper side of the rings. D Lubricate the piston and piston rings liberally with engine oil.
Page 138: Clutch
CLUTCH CLUTCH CRANKCASE COVER (RIGHT) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Crankcase cover (right) removal Remove the parts in the order below. Stand the motorcycle on a level surface.
Page 139 CLUTCH 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Dowel pins Crankcase cover gasket For installation, reverse the removal procedure. 4-35...
Page 140: Clutch Assembly
CLUTCH CLUTCH ASSEMBLY 70 Nm (7.0 m S kg) 70 Nm (7.0 m S kg) 8 Nm (0.8 m S kg) 8 Nm (0.8 m S kg) Order Job name/Part name Q’ty Remarks Clutch assembly removal Remove the parts in the order below. Oil pump driven gear Refer to “OIL PUMP”.
Page 141 CLUTCH 70 Nm (7.0 m S kg) 70 Nm (7.0 m S kg) 8 Nm (0.8 m S kg) 8 Nm (0.8 m S kg) Order Job name/Part name Q’ty Remarks Lock washer Claw washer Drive gear (oil pump) Primary drive gear Straight key For installation, reverse the removal procedure.
Page 142: Clutch Removal
CLUTCH CLUTCH REMOVAL 1. Straighten: S Lock washer tab 2. Loosen: S Nut (clutch boss) 1 NOTE: Loosen the nut (clutch boss) 1 while holding the clutch boss 2 with the clutch holding tool Clutch holding tool: 90890-04086 PRIMARY DRIVE GEAR REMOVAL 1.
Page 143 CLUTCH 5. Inspect: S Primary drive gear teeth Wear/damage ! Replace the clutch housing. 6. Check: S Circumferential play Free play ! Replace the clutch housing. 7. Inspect: S Clutch spring Damage ! Replace the clutch spring. 8. Measure: S Clutch spring free length Out of specification ! Replace the clutch springs as a set.
Page 144: Push Rod Inspection
CLUTCH PUSH ROD INSPECTION 1. Inspect: S Push rod #1 1 S O-ring S Ball 2 S Push rod #2 3 Cracks/wear/damage ! Replace. PRIMARY DRIVE GEAR INSTALLATION 1. Install: S Drive gear (oil pump) 1 S Claw washer S Lock washer S Nut (primary drive gear) 70 Nm (7.0 mSkg) NOTE:...
Page 145 CLUTCH NOTE: D Apply engine oil onto the friction plates. D Align the two slots a on the friction plates with the two punch marks b on the clutch housing. ***************************************************** 4. Install: S Push rod #2 S Ball S Push rod #1 1 S O-ring 2 S Push plate 3 S Washer 4...
Page 146: Shift Shaft
SHIFT SHAFT SHIFT SHAFT Order Job name/Part name Q’ty Remarks Shift shaft removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT” in CHAPTER 3. Clutch assembly Refer to “CLUTCH”. Crankcase cover (left) Refer to “ENGINE REMOVAL”. Circlip Washer Shift shaft...
Page 147: Shift Shaft Inspection
SHIFT SHAFT SHIFT SHAFT INSPECTION 1. Inspect: S Shift shaft 1 S Shift pawls 2 S Return spring (shift arm) 3 Bends/wear/damage ! Replace. 2. Inspect: S Stopper lever Roller turns roughly ! Replace. Bends/damage ! Replace. 3. Inspect: S Torsion spring (shift shaft) 1 S Torsion spring (stopper lever) 2 Wear/damage ! Replace.
Page 148 SHIFT SHAFT 2. Install: S Shift lever NOTE: Insert the shift arm 1 between the pins on the shift cam segment. 4-44...
Page 149: Oil Pump
OIL PUMP OIL PUMP 7 Nm (0.7 m S kg) Order Job name/Part name Q’ty Remarks Oil pump removal Remove the parts in the order below. Crankcase cover (right) Refer to “CLUTCH”. Circlip Driven gear (oil pump) Oil pump assembly O-rings/collar For installation, reverse the removal procedure.
Page 150 OIL PUMP Order Job name/Part name Q’ty Remarks Oil pump disassembly Disassembly the parts in the order below. Spring retainer Spring Relief valve Oil pump cover Shaft Inner rotor Outer rotor Dowel pins Oil pump housing For assembly, reverse the disassembly procedure.
Page 151: Oil Pump Inspection
OIL PUMP OIL PUMP INSPECTION 1. Inspect: S Drive gear (oil pump) 1 S Driven gear (oil pump) 2 Cracks/wear/damage ! Replace. 2. Measure: S Tip clearance a (between the inner rotor 1 and the outer rotor 2 ) S Side clearance b (between the outer rotor 2 and the pump housing 3 ) Out of specification ! Replace the oil...
Page 152: Ac Magneto And Starter Clutch
AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH STATOR COIL AND PICKUP COIL 7 Nm (0.7 m S kg) 7 Nm (0.7 m S kg) Order Job name/Part name Q’ty Remarks Stator removal Remove the parts in the order below. Engine oil Refer to “ENGINE OIL REPLACE- MENT”...
Page 153: Ac Magneto And Starter Clutch
AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH 20 Nm (2.0 m S kg) 80 Nm (8,0 m S kg) Order Job name/Part name Q’ty Remarks AC magneto and starter clutch Remove the parts in the order below. removal Shaft Starter idler gear...
Page 154: Ac Magneto Removal
AC MAGNETO AND STARTER CLUTCH AC MAGNETO REMOVAL 1. Remove: S Rotor S Woodruff key ***************************************************** Removal steps: D Remove the starter clutch bolts 1 . D Remove the rotor bolt 2 and washer 3 . NOTE: Loosen the starter clutch bolts 1 and rotor bolt 2 while holding the rotor with a sheave holder Sheave holder: 90890-01701...
Page 155: Ac Magneto Installation
AC MAGNETO AND STARTER CLUTCH 2. Inspect: S Oil passage (rotor bolt) Clogged ! Blow out with compressed air. 3. Inspect: S Stator coil Damage ! Replace. 4. Check: S Starter clutch assembly operation ***************************************************** Clutch operation checking steps: D Install the starter wheel gear to the starter clutch, and hold the starter clutch.
Page 156 AC MAGNETO AND STARTER CLUTCH 2. Tighten: S Bolt (rotor) 1 80 Nm (8.0 mSkg) S Bolts (starter clutch) 2 20 Nm (2.0 mSkg) NOTE: Tighten the rotor bolt 1 and starter clutch bolts 2 while holding the magneto rotor with a sheave holder 3 .
Page 157: Crankshaft And Connecting Rods Crankcase
CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS CRANKCASE 10 Nm (1.0 m S kg) 24 Nm (2.4 m S kg) 24 Nm (2.4 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 24 Nm (2.4 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name...
Page 158 CRANKSHAFT AND CONNECTING RODS 10 Nm (1.0 m S kg) 24 Nm (2.4 m S kg) 24 Nm (2.4 m S kg) 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg) 24 Nm (2.4 m S kg) 10 Nm (1.0 m S kg) Order Job name/Part name...
Page 159 CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS 36 Nm (3.6 m S kg) Order Job name/Part name Q’ty Remarks Crankshaft and connecting rod Remove the parts in the order below. removal Crankshaft assembly Main journal bearings Nuts (connecting rod caps) Refer to “CRANKSHAFT Connecting rod bolts REMOVAL/INSTALLATION”.
Page 160: Crankcase Separation
CRANKSHAFT AND CONNECTING RODS CRANKCASE SEPARATION 1. Separate: S Left crankcase S Right crankcase ***************************************************** Separation steps: D Remove the crankcase bolts. NOTE: D Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. D Loosen the bolts in numerical order (see numbers on the illustration).
Page 161: Crankshaft Removal
CRANKSHAFT AND CONNECTING RODS CRANKSHAFT REMOVAL 1. Remove: S Main journal bearings 1 NOTE: Remove the main journal bearings by the plane bearing installer/remover 2 middle driven shaft bearing driver 3 . Plane bearing installer/remover: 90890-04074 Middle driven shaft bearing driver: 90890-04058 2.
Page 162 CRANKSHAFT AND CONNECTING RODS 5. Inspect: S Crank pin surfaces S Bearing surfaces Wear/scratches ! Replace. 6. Inspect: S Timing chain sprockets 1 Damage/wear ! Replace the crankshaft. 7. Measure: S Oil clearance (crank pin) Out of specification ! Replace the bear- ing.
Page 163 CRANKSHAFT AND CONNECTING RODS D The stamped “Y” mark 2 on the connect- ing rods should face towards the left side of the crankcase. D Be sure that the characters 3 on the side of the cap and connecting rod are aligned. D Tighten the nuts.
Page 164 CRANKSHAFT AND CONNECTING RODS BEARING COLOR CODE blue black brown green ***************************************************** 9. Measure: S Oil clearance (main journal) Out of specification ! Replace the bear- ing. Oil clearance (main journal): 0.020 X 0.052 mm ***************************************************** Measurement steps: CAUTION: On the journal, the larger value is used as a basis for calculation of the oil clearance, and on the journal bearing, the smaller value is used.
Page 165 CRANKSHAFT AND CONNECTING RODS D If journal bearing inside diameter is “45.03” and crankshaft journal outside diameter is “44.98”, then the main journal oil clearance Main journal oil clearance: Journal bearing inside diameter – Main journal outside diameter = 45.03 – 44.98 = 0.05 mm If the oil clearance is out of specification, se- lect a replacement bearings.
Page 166: Crankshaft Installation
CRANKSHAFT AND CONNECTING RODS CRANKSHAFT INSTALLATION 1. Attach: S Main journal bearings 1 NOTE: D Attach the main journal bearing to the plane bearing installer/remover 2 middle driven shaft bearing driver 3 . D Align the projection a on the bearing with the projection b and slot c on the special tools.
Page 167: Crankcase Assembly
S Crankshaft 1 NOTE: Align the left connecting rod with the rear cylin- der sleeve hole. CRANKCASE ASSEMBLY 1. Apply: S Engine oil (onto the main journal bearings) S Sealant (onto the crankcase mating surfaces) Yamaha Bond No.1215: 90890-85505 4-63...
Page 168 CRANKSHAFT AND CONNECTING RODS 2. Install: S Right crankcase (onto the left crankcase) NOTE: Turn the shift cam to the position shown in the figure so that it does not contact the crankcase when installing the crankcase. 3. Tighten: S Crankcase bolts (follow the proper tightening sequence) NOTE: The numbers embossed on the crankcase indi-...
Page 169: Transmission
TRANSMISSION TRANSMISSION 25 Nm (2.5 m S kg) Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in the order below. Crankcase separation Refer to “CRANKSHAFT”. Guide bar 1 Guide bar 2 Shift fork 2 “C” Shift fork 3 “R” Refer to “TRANSMISSION Shift fork 1 “L”...
Page 170: Shift Fork Inspection
TRANSMISSION SHIFT FORK INSPECTION 1. Inspect: S Shift fork cam follower 1 S Shift fork pawl 2 Scoring/bends/wear/damage place. 2. Inspect: S Guide bar Roll the guide bar on a flat surface. Bends ! Replace. Do not attempt to straighten a bent guide bar.
Page 171 TRANSMISSION 2. Inspect: S Gear teeth Blue discoloration/pitting/wear ! Replace. S Mated dogs Rounded edges/cracks/missing portions ! Replace. 3. Check: S Proper pinion gear engagement (each gear to its counter part) Incorrect ! Reassemble. S Gear movement Roughness ! Replace. ************************************* Transmission gear reassembling point: Press the 2nd pinion gear 1 into the 1st pinion...
Page 172: Transmission Installation
TRANSMISSION TRANSMISSION INSTALLATION 1. Tighten: S Torx screws (bearing retainer) 1 25 Nm (2.5 mSkg) Use #40 torx screw wrench. 2. Lock the torx screw head with drift punch. 3. Install: S Shift cam 1 S Shift fork 2 “C” 2 S Shift fork 3 “R”...
Page 173: Middle Gear
MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVEN PINION GEAR 25 Nm (2.5 m S kg) 90 Nm (9.0 m S kg) Order Job name/Part name Q’ty Remarks Middle driven pinion gear removal Remove the parts in the order below. Engine assembly Refer to “ENGINE REMOVAL”.
Page 174 MIDDLE GEAR 25 Nm (2.5 m S kg) 90 Nm (9.0 m S kg) Order Job name/Part name Q’ty Remarks Middle driven pinion gear Refer to “MIDDLE DRIVEN PINION Middle driven shaft GEAR REMOVAL/INSTALLATION”. For installation, reverse the removal procedure. 4-70...
Page 175: Middle Drive Pinion Gear
MIDDLE GEAR MIDDLE DRIVE PINION GEAR 12 Nm (1.2 m S kg) 120 Nm (12.0 m S kg) Order Job name/Part name Q’ty Remarks Middle drive pinion gear removal Remove the parts in the order below. Middle gear cover/O-ring Refer to “MIDDLE DRIVE PINION Middle drive pinion gear GEAR REMOVAL/INSTALLATION”.
Page 176: Middle Driven Pinion Gear Removal
MIDDLE GEAR MIDDLE DRIVEN PINION GEAR REMOVAL 1. Remove: S Universal joint ***************************************************** Disassembly steps: D Remove the circlips 1 . D Place the universal joint in a press. D Using a suitable diameter pipe beneath the yoke, press the bearing into the pipe as shown.
Page 177: Middle Drive Pinion Gear Removal
MIDDLE GEAR 4. Remove: S Spring retainers NOTE: Attach the damper spring compressor 1 on the spring seat 2 and compress the damper spring, then remove the spring retainers. Damper spring compressor: 90890-04090 5. Remove: S Bearing retainer 1 S Bearing ***************************************************** Removal steps: D Attach the folded rag 2 .
Page 178: Middle Gear Inspection
MIDDLE GEAR MIDDLE GEAR INSPECTION 1. Inspect: S Damper cam surface Wear/scratches ! Replace the damper cam as a set. 2. Inspect: S Damper spring Damage/cracks ! Replace. 3. Inspect: S Middle driven pinion gear teeth 1 S Middle drive pinion gear teeth 2 Pitting/galling/wear Replace middle gear as a set.
Page 179: Middle Driven Pinion Gear Installation
MIDDLE GEAR MIDDLE DRIVEN PINION GEAR INSTALLATION 1. Install: S Spring retainers NOTE: Attach the damper spring compressor 1 on the spring seat 2 and compress the damper spring, then install the spring retainers. Damper spring compressor: 90890-04090 2. Install: S Bearing ***************************************************** Installation steps:...
Page 180 MIDDLE GEAR 4. Install: S Middle driven shaft assembly ***************************************************** Install steps: D Clean the outside of the middle driven shaft and the inside of the bearing. D Fit the middle driven shaft assembly onto the bearing housing. D Place the middle driven shaft assembly onto a hydraulic press.
Page 181 MIDDLE GEAR 7. Install: S Bearings 1 (onto the cross joint) CAUTION: The needles can easily fall out of their races, so check each bearing. Slide the universal joint yoke back and forth on the bearings. If a needle is out of place the yoke will not go all the way onto the bearing.
Page 182: Middle Drive Gear Shim Selection
MIDDLE GEAR NOTE: Before tightening the bolts: 1. Adjust the gear lash of the middle gear. Refer to “GEAR BACKLASH ADJUST- MENT”. 2. Check the operation of the middle driven gear. MIDDLE DRIVE GEAR SHIM SELECTION NOTE: Gear positioning is necessary when any of the following parts are replaced.
Page 183: Gear Backlash Adjustment
MIDDLE GEAR A = 44.03 – 43.45 = 0.58 6) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.58 mm. The chart instructs you, however, to round off 8 to Hundredths Round value 0, 1, 2, 3, 4 5, 6, 7, 8, 9...
Page 184 MIDDLE GEAR 3. Position: S Dial gauge (onto the outside edge of the universal joint) NOTE: Be sure that the gauge is positioned over the centerline of the yoke bearing hole. 4. Rotate: S Universal joint 1 NOTE: Move the universal joint gently back and forth. 5.
Page 185 MIDDLE GEAR 6. Tighten: S Bolts (driven gear bearing housing) 1 25 Nm (2.5 mSkg) NOTE: Tighten the bolts carefully, one thread turn at a time, only. Push in the bearing housing and tighten the bearing housing bolts. CAUTION: Do not overtighten the bearing housing bolts or you may obtain too little gear back- lash and cause damage to the gears.
Page 186 MIDDLE GEAR D Shims are supplied in the following thick- nesses. Middle drive pinion gear shim: Thickness (mm) 0.10, 0.15, 0.20 ***************************************************** 10. Tighten: S Bolts (driven gear bearing housing) 1 25 Nm (2.5 mSkg) 11. Measure: S Gear backlash 4-82...
Page 187 CARB CHAPTER 5. CARBURETION CARBURETOR ..........CARBURETOR INSPECTION .
Page 188 CARB...
Page 189: Chapter 5. Carburetion
CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in the order below. Fuel tank Refer to “FUEL TANK AND SEATS” in CHAPTER 3. Air filter case assembly Air duct Cylinder head breather hose Disconnect Throttle position sensor lead Thermo switch lead...
Page 190 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Carburetor disassembly Disassemble the parts in the order below. Carburetor heater lead Carburetor heaters 1 12V 15W Carburetor heaters 2 12V 30W Float chamber Float Needle valve set Main jet Jet holder Pilot jet Refer to “CARBURETOR Jet needle set...
Page 191 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Diaphragm set Refer to “CARBURETOR ASSEMBLY”. Throttle position sensor Refer to “THROTTLE POSITION SENSOR (TPS) INSPECTION AND ADJUSTMENT”. Pilot screw Refer to “CARBURETOR ASSEMBLY”. Main air jet For assembly, reverse the disassembly procedure.
Page 192: Carburetor Inspection
CARB CARBURETOR EB600030 CARBURETOR INSPECTION 1. Inspect: S Carburetor body S Float chamber S Jet housing Cracks/damage ! Replace. S Fuel passage Blockage ! Clean as indicated. S Carburetor float chamber body Contamination ! Clean. ***************************************************** Cleaning steps: D Wash the carburetor in a petroleum based solvent.
Page 193: Carburetor Assembly
CARB CARBURETOR 5. Inspect: S Vacuum chamber cover 1 S Springs 2 S Plastic bushing 3 S Plastic screw cap 4 Cracks/damage ! Replace. 6. Inspect: S Jet needle 1 S Main jet 2 S Main jet holder 3 S Pilot jet 4 S Needle jet 5 S Pilot air jet 6 S Pilot screw 7...
Page 194 CARB CARBURETOR 1. Install: S Needle jet 1 NOTE: D Align the groove on the needle jet with the projection on the carburetor body. D Install the needle jet from the piston valve side. 2. Install: S Pilot screw 1 Pilot screw (turns out): 3.
Page 195: Fuel Level Adjustment
CARB CARBURETOR FUEL LEVEL ADJUSTMENT 1. Measure: S Fuel level a Out of specification ! Adjust Fuel level: 7.5 X 8.5 mm (below the float chamber line) ***************************************************** Measurement and adjustment steps: D Place the motorcycle on a level surface. D Put the motorcycle on a suitable stand to en- sure that the carburetor assembly is posi- tioned vertically.
Page 196: Throttle Position Sensor (Tps) Inspection
CARB CARBURETOR THROTTLE POSITION SENSOR (TPS) IN- SPECTION AND ADJUSTMENT NOTE: Before adjusting the TPS, the idling speed should be properly adjusted. 1. Inspect: S TPS resistance ***************************************************** Inspect steps: D Disconnect the TPS coupler. D Remove the TPS from the carburetor. D Connect the pocket tester (Ω...
Page 197 CARB CARBURETOR 2. Adjust: S TPS position ***************************************************** Adjustment steps: D Loosen the TPS mounting screws 1 . D Adjust the TPS resistance by turning the sen- sor body to the right or left. Stop turning the sensor body when the specified resistance is indicated on the tester.
Page 198 CARB...
Page 199: Chassis Chas
CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISC ......FRONT WHEEL DISASSEMBLY .
Page 200 CHAS STEERING HEAD ..........6-43 STEERING HEAD REMOAL .
Page 201: Chapter 6. Chassis
CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 59 Nm (5.9 m S kg) 20 Nm (2.0 m S kg) 23 Nm (2.3 m S kg) Order Job name/Part name Q’ty Remarks Front wheel and brake disc removal Remove the parts in the order below.
Page 202 CHAS FRONT WHEEL AND BRAKE DISC Order Job name/Part name Q’ty Remarks Front wheel disassembly Disassemble the parts in the order below. Oil seals Clutch retainer Speedometer clutch Oil seal Bearing Refer to “FRONT WHEEL Collar DISASSEMBLY/ASSEMBLY”. Bearing For assembly, reverse the disassembly procedure.
Page 203: Front Wheel Disassembly
CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL DISASSEMBLY 1. Remove: S Oil seals S Bearings 1 S Collar ***************************************************** Removal steps: D Clean the outside of the front wheel hub. D Use a flat-head screwdriver to remove the oil seals.
Page 204: Brake Disk Inspection
CHAS FRONT WHEEL AND BRAKE DISC 4. Tighten: S Loose spokes 3 Nm (0.3 mSkg) NOTE: After tightening the spokes check the front wheel runout. 5. Measure: S Front wheel runout Over the specified limits ! Replace. Front wheel runout limits: Radial 1 : 2.0 mm Lateral 2 : 2.0 mm 6.
Page 205: Front Wheel Assembly
CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL ASSEMBLY 1. Install: S Collar S Bearings S Oil seals ***************************************************** Installation steps: D Install the new bearings and oil seals by re- versing the removal steps. NOTE: Use a socket 1 that matches the diameter of the outer bearing race and the oil seal.
Page 206: Front Wheel Static Balance Adjustment
CHAS FRONT WHEEL AND BRAKE DISC EB700040 FRONT WHEEL STATIC BALANCE ADJUSTMENT NOTE: D After replacing the tire and/or rim, the wheel static balance should be adjusted. D Adjust the front wheel static balance with the brake discs installed. 1. Remove: S Balancing weight 2.
Page 207 CHAS FRONT WHEEL AND BRAKE DISC 5. Check: S Front wheel static balance ***************************************************** Checking steps: D Turn the wheel so that it comes to each point as shown. D Check that the wheel is at rest at each point. If not, readjust the front wheel static balance.
Page 208: Front Brake
CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS 40 Nm (4.0 m S kg) 23 Nm (2.3 m S kg) Order Job name/Part name Q’ty Remarks Front brake pad removal Remove the parts in the order below. Retaining bolt Brake caliper Refer to “BRAKE PAD Brake pads REPLACEMENT”.
Page 209: Brake Pad Replacement
CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: D disassemble components unless abso- lutely necessary; D use solvents on internal brake compo- nents; D use spent brake fluid for cleaning; (use only clean brake fluid) D allow brake fluid to come in contact with the eyes, as this may cause eye injury;...
Page 210 CHAS FRONT BRAKE D Loosen the brake caliper bleed screw and us- ing a finger push the caliper pistons into the brake caliper. D Tighten the brake caliper bleed screw 2 . Brake caliper bleed screw: 6 Nm (0.6 mSkg) D Install new brake pads and a new brake pad spring.
Page 211: Master Cylinder
CHAS FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 m S kg) 30 Nm (3.0 m S kg) Order Job name/Part name Q’ty Remarks Master cylinder removal Remove the parts in the order below. Brake fluid Drain Rear view mirror (right) Brake lever/compression spring Front brake switch Union bolt...
Page 212 CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Master cylinder disassembly Disassemble the parts in the order below. Dust boot Circlip Refer to “MASTER CYLINDER ASSEMBLY”. Master cylinder cup kit Spring For assembly, reverse the disassembly procedure. 6-12...
Page 213: Master Cylinder Inspection
CHAS FRONT BRAKE MASTER CYLINDER INSPECTION 1. Inspect: S Master cylinder Wear/scratches ! Replace the master cylinder assembly. S Master cylinder body Cracks/damage ! Replace. S Oil delivery passage (master cylinder body) Blockage ! Blow out with compressed air. 2. Inspect: S Master cylinder cup kit 1 Scratches/wear/damage ! Replace as a set.
Page 214: Master Cylinder Installation
CHAS FRONT BRAKE 2. Install: S Circlip 1 S Dust boot 2 MASTER CYLINDER INSTALLATION 1. Install: S Master cylinder 1 S Master cylinder bracket 2 10 Nm (1.0 mSkg) CAUTION: D Install the master cylinder holder with the “UP” mark facing upward. D Align the end of the holder with the punch mark a on the handlebar.
Page 215 CHAS FRONT BRAKE 3. Fill: S Reservoir tank Recommended brake fluid: DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. D Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
Page 216: Front Brake Caliper
CHAS FRONT BRAKE FRONT BRAKE CALIPER 7 Nm (0.7 m S kg) 30 Nm (3.0 m S kg) 6 Nm (0.6 m S kg) 40 Nm (4.0 m S kg) 23 Nm (2.3 m S kg) Order Job name/Part name Q’ty Remarks Front brake caliper removal...
Page 217 CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Front brake caliper disassembly Disassemble the parts in the order below. Brake pads Refer to “FRONT BRAKE PADS”. Pad spring Brake caliper pistons Refer to “CALIPER DISASSEMBLY/ Dust seals ASSEMBLY”. Caliper piston seals Bleed screw For assembly, reverse the disassembly procedure.
Page 218: Caliper Disassembly
CHAS FRONT BRAKE CALIPER DISASSEMBLY 1. Remove: S Brake caliper pistons S Dust seals 1 S Caliper piston seals 2 ***************************************************** Removal steps: D Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. D Never try to pry out the caliper pistons.
Page 219: Caliper Assembly
CHAS FRONT BRAKE S Oil delivery passage (brake caliper body) Blockage ! Blow out with compressed air. Replace the caliper piston seal and dust seal whenever the brake caliper is disas- sembled. CALIPER ASSEMBLY D All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
Page 220 CHAS FRONT BRAKE CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake cali- per. Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”.
Page 221: Rear Wheel And Rear Brake
CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE MUFFLER AND REAR BRAKE ROD 20 Nm (2.0 m S kg) 25 Nm (2.5 m S kg) 20 Nm (2.0 m S kg) Order Job name/Part name Q’ty Remarks Muffler and rear brake rod removal Remove the parts in the order below.
Page 222: Rear Wheel
CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL 70 Nm (7.0 m S kg) 92 Nm (9.2 m S kg) Order Job name/Part name Q’ty Remarks Rear wheel removal Remove the parts in the order below. Stand the motorcycle on a level surface.
Page 223 CHAS REAR WHEEL AND REAR BRAKE 62 Nm (6.2 m S kg) Order Job name/Part name Q’ty Remarks Rear wheel disassembly Disassemble the parts in the order below. Lock washers Clutch hub Dampers O-rings Bearing Refer to “REAR WHEEL Spacer/collar DISASSEMBLY/ASSEMBLY”.
Page 224 CHAS REAR WHEEL AND REAR BRAKE 10 Nm (1.0 m S kg) Order Job name/Part name Q’ty Remarks Rear brake disassembly Disassemble the parts in the order below. Brake shoes Tension springs Bolt Camshaft lever Refer to “REAR BRAKE Wear indicator ASSEMBLY”.
Page 225: Rear Wheel Removal
CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL REMOVAL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so there is no danger of it falling over. 2. Remove: S Bolts (final gear case) 3. Loosen: S Rear axle nut 1 4.
Page 226: Rear Brake Inspection
CHAS REAR WHEEL AND REAR BRAKE 2. Check: S Spokes Refer to “FRONT WHEEL”. 3. Tighten: S Loose spokes Refer to “FRONT WHEEL”. 4. Measure: S Rear wheel runout Refer to “FRONT WHEEL”. 5. Inspect: S Rear wheel bearings Refer to “FRONT WHEEL”. REAR BRAKE INSPECTION 1.
Page 227: Rear Wheel Assembly
CHAS REAR WHEEL AND REAR BRAKE 3. Measure: S Brake drum inside diameter a Out of specification ! Replace the wheel. Brake drum inside diameter: 200 mm Wear limit: 201 mm 4. Inspect: S Brake drum inner surface Oil/scratches ! Repair. Use a rag soaked in lacquer thinner or solvent.
Page 228: Rear Brake Assembly
CHAS REAR WHEEL AND REAR BRAKE REAR BRAKE ASSEMBLY 1. Install: S Brake shoe plate 1 S Camshaft 2 S Wear indicator 3 S Camshaft lever 4 10 Nm (1.0 mSkg) NOTE: Apply lithium soap base grease onto the cam- shaft and pin.
Page 229: Rear Wheel Static Balance Adjustment
CHAS REAR WHEEL AND REAR BRAKE EB701040 REAR WHEEL STATIC BALANCE ADJUSTMENT NOTE: D After replacing the tire and/or wheel, the stat- ic wheel balance should be adjusted. D Adjust the static wheel balance with the rear brake disc and hub installed. 1.
Page 230: Front Fork
CHAS FRONT FORK FRONT FORK 20 Nm (2.0 m S kg) 23 Nm (2.3 m S kg) 7 Nm (0.7 m S kg) 30 Nm (3.0 m S kg) 10 Nm (1.0 m S kg) 40 Nm (4.0 m S kg) Order Job name/Part name Q’ty...
Page 231 CHAS FRONT FORK 23 Nm (2.3 m S kg) 30 Nm (3.0 m S kg) Order Job name/Part name Q’ty Remarks Front fork disassembly Disassemble the parts in the order below. Cap bolt O-ring Spacer collar Refer to “FRONT FORK ASSEMBLY”. Spring seat Fork spring Dust seal...
Page 232 CHAS FRONT FORK 23 Nm (2.3 m S kg) 30 Nm (3.0 m S kg) Order Job name/Part name Q’ty Remarks Seal spacer Slide metal Inner tube/piston metal Refer to “FRONT FORK ASSEMBLY”. Oil lock piece Outer tube For assembly, reverse the disassembly procedure.
Page 233: Front Fork Disassembly
CHAS FRONT FORK FRONT FORK DISASSEMBLY 1. Remove: S Dust seal 1 S Retaining clip 2 (use a slotted-head screwdriver) CAUTION: Take care not to scratch the inner tube. 2. Remove: S Damper rod bolt 1 NOTE: Loosen the damper rod bolt while holding the damper rod with the T-handle 2 and the damp- er rod holder 3 .
Page 234: Front Fork Inspection
CHAS FRONT FORK EB703030 FRONT FORK INSPECTION 1. Inspect: S Inner tube 1 S Outer tube 2 Scratches/bends/damage ! Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. 2. Measure: S Fork spring length a Over the specified limit ! Replace.
Page 235 2. Lubricate: S Inner tube (outer surface) Recommended lubricant: Yamaha fork oil 10WT or equivalent 3. Install: S Inner tube 1 (to outer tube 2 ) 4. Install:...
Page 236 CHAS FRONT FORK 6. Install: S Slide metal 1 S Seal spacer Use the fork seal driver weight 2 and the adapter 3 . 7. Install: S Oil seal 1 Use the fork seal driver weight 2 and the adapter 3 . Fork seal driver weight: 90890-01367 Adapter:...
Page 237: Front Fork Installation
FRONT FORK 10. Fill: S Fork oil Each fork: 0.454L (454 cm Yamaha fork oil 10WT or equiv- alent. After filling up, slowly pump the fork up and down to distribute the fork oil. Oil level a : 114 mm...
Page 238: Handlebar
CHAS HANDLEBAR HANDLEBAR 23 Nm (2.3 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order below. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over.
Page 239 CHAS HANDLEBAR 23 Nm (2.3 m S kg) 10 Nm (1.0 m S kg) 20 Nm (2.0 m S kg) Order Job name/Part name Q’ty Remarks Throttle grip assembly Cable guide Refer to “HANDLEBAR INSTALLA- Handlebar holder (upper) TION”. Handlebar Handlebar holder (lower) For installation, reverse the removal procedure.
Page 240: Handlebar Inspection
CHAS HANDLEBAR HANDLEBAR INSPECTION 1. Inspect: S Handlebar Bends/cracks/damage ! Replace. CAUTION: Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. ***************************************************** Left handlebar grip replacement steps: D Remove the handlebar grip. D Apply a light coat of rubber adhesive on the end of the handlebar.
Page 241 CHAS HANDLEBAR D Align the match marks b on the handlebar with the lower handlebar holder bolt hole. D Apply a light coat of lithium soap base grease onto the right end of the handlebar. CAUTION: D First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.
Page 242 CHAS HANDLEBAR 7. Install: S Handlebar switch (left) 1 NOTE: Align the matching surface of the handlebar switch (left) with the punch mark a on the han- dlebar. 8. Adjust: S Throttle cable free play Refer to “THROTTLE CABLE ADJUST- MENT”...
Page 243: Steering Head
CHAS STEERING HEAD STEERING HEAD 52 Nm (5.2 m S kg) 18 Nm (1.8 m S kg) 110 Nm (11.0 m S kg) 32 Nm (3.2 m S kg) Order Job name/Part name Q’ty Remarks Steering head removal Remove the parts in the order below. Stand the motorcycle on a level surface.
Page 244 CHAS STEERING HEAD 52 Nm (5.2 m S kg) 18 Nm (1.8 m S kg) 110 Nm (11.0 m S kg) 32 Nm (3.2 m S kg) Order Job name/Part name Q’ty Remarks Rubber washer Lower ring nut Refer to “STEERING HEAD REMOVAL/INSTALLATION”.
Page 245: Steering Head Remoal
CHAS STEERING HEAD STEERING HEAD REMOAL 1. Remove: S Lower ring nut 1 Use the ring nut wrench 2 . Ring nut wrench: 90890-01403 Support the lower bracket so that it does not fall down. EB704020 STEERING HEAD INSPECTION 1. Wash the bearings and the bearing races with a solvent.
Page 246: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 100 Nm (10.0 m S kg) 7 Nm (0.7 m S kg) 62 Nm (6.2 m S kg) 62 Nm (6.2 m S kg) 100 Nm (10.0 m S kg) Order Job name/Part name Q’ty...
Page 247 CHAS REAR SHOCK ABSORBER AND SWINGARM 100 Nm (10.0 m S kg) 7 Nm (0.7 m S kg) 62 Nm (6.2 m S kg) 62 Nm (6.2 m S kg) 100 Nm (10.0 m S kg) Order Job name/Part name Q’ty Remarks Tool box...
Page 248: Handling Notes
CHAS REAR SHOCK ABSORBER AND SWINGARM HANDLING NOTES This shock absorber contains highly com- pressed nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer can- not be held responsible for property dam- age of personal injury that may result from improper handling.
Page 249: Swingarm Inspection
CHAS REAR SHOCK ABSORBER AND SWINGARM SWINGARM INSPECTION 1. Check: S Swingarm free play ***************************************************** Inspection steps: D Check the tightening torque of the swingarm pivot shaft securing nuts. Securing nut (swingarm pivot shaft): Left: 100 Nm (10 mSkg) Right: 7 Nm (0.7 mSkg) Right - nut: 100 Nm (10 mSkg)
Page 250: Swingarm Installation
CHAS REAR SHOCK ABSORBER AND SWINGARM 4. Inspect: S Collars 1 S Oil seals 2 S Bearings 3 S Rubber boot 4 Wear/damage ! Replace. SWINGARM INSTALLATION 1. Install: S Swingarm S Pivot shaft (left) 1 S Pivot shaft (right) 2 S Pivot shaft nut 3 ***************************************************** Tightening steps:...
Page 251: Shaft Drive
CHAS SHAFT DRIVE SHAFT DRIVE EB707010 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible causes 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration, or sus- B. Improper gear lash tained speeds (This must not be confused C.
Page 252 CHAS SHAFT DRIVE Inspection notes 1. Investigate any unusual noises. ***************************************************** The following noises may indicate a me- chanical defect: a. A rolling “rumble” during coasting, accel- eration, or deceleration. The noise in- creases with rear wheel speed, but does not increase with higher engine or trans- mission speeds.
Page 253 CHAS SHAFT DRIVE 3. Inspect: S Oil leakage ***************************************************** Inspection steps: D Clean the entire motorcycle thoroughly, then dry it. D Apply a leak-locating compound or dry pow- der spray to the shaft drive. D Road test the motorcycle for the distance necessary to locate the leak.
Page 254 CHAS SHAFT DRIVE Troubleshooting chart When causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist, check the following points: Elevate and spin the front wheel. Feel for Replace the wheel bearing. wheel bearing damage. Refer to “FRONT WHEEL”.
Page 255: Final Gear Backlash Measurement
CHAS SHAFT DRIVE EB707030 FINAL GEAR BACKLASH MEASUREMENT 1. Secure the final drive gear case in a vise or a similar supporting device. 2. Remove: S Drain plug Drain the oil. 3. Install: S Specified bolt 1 (into the drain plug hole) 4.
Page 256: Final Gear Backlash Adjustment
CHAS SHAFT DRIVE EB707031 FINAL GEAR BACKLASH ADJUSTMENT 1. Remove: S Bolts (bearing housing) NOTE: Working in a crisscross pattern, loosen each nut 1 /4 of a turn. After all the nuts are loosened, re- move them. 2. Remove: S Bearing housing 1 S Ring gear 2 S Thrust washer 3 S Shim(s) 4...
Page 257: Drive Shaft
CHAS SHAFT DRIVE DRIVE SHAFT 23 Nm (2.3 m S kg) 115 Nm (11.5 m S kg) 23 Nm (2.3 m S kg) 42 Nm (4.2 m S kg) Order Job name/Part name Q’ty Remarks Drive shaft removal Remove the parts in the order below. Stand the motorcycle on a level surface.
Page 258: Final Gear
CHAS SHAFT DRIVE FINAL GEAR 23 Nm (2.3 m S kg) Order Job name/Part name Q’ty Remarks Final gear disassembly Disassemble the parts in the order below. NOTE: Bolts (bearing housing) Bolt (bearing housing) Working in a crisscross pattern, loosen each bolt 1/4 of a turn.
Page 259: Final Drive Gear Disassembly
Use a suitable press tool 4 and an ap- propriate support for the final gear case. 2. Inspect: S Final drive roller bearing NOTE: The roller bearing can be reused, but Yamaha recommends installation of a new bearing. Do not reuse the oil seal. 6-59...
Page 260 CHAS SHAFT DRIVE 3. Remove: S Final drive roller bearing 1 ***************************************************** Removal steps: D Heat the final gear case to 150_C. D Using an appropriately shaped punch 2 re- move the roller bearing outer races. D Remove the inner race from the final drive shaft.
Page 261: Final Drive/Ring Gear Positioning
CHAS SHAFT DRIVE EB707034 FINAL DRIVE/RING GEAR POSITIONING NOTE: Ring gear positioning is necessary when any of the following parts are replaced: D Final gear case D Ring gear bearing housing D Bearing(s) 1. Select: S Final drive gear shim 1 S Ring gear shim 2 ***************************************************** Selection steps:...
Page 262 CHAS SHAFT DRIVE Since final drive gear shims can only be se- lected in 0.10 mm increments, round off the hundredths digit and select the appropriate shim(s). Hundredths Rounded value 0, 1, 2, 3, 4 5, 6, 7, 8, 9 In the example above, the calculated final drive gear shim thickness is 0.51 mm.
Page 263 CHAS SHAFT DRIVE Therefore, the ring gear shim thickness is 0.55 mm. Shim sizes are supplied in the fol- lowing thickness. Ring gear shim Thickness (mm) 0.25, 0.30, 0.40 Since ring gear shims can only be selected in 0.10 mm increments, round off the hundredths digit and select the appropriate shim(s).
Page 264 CHAS SHAFT DRIVE ***************************************************** Ring gear thrust washer clearance mea- surement steps: D Remove the ring gear assembly. D Place four pieces of Plastigauge between the originally installed ring gear thrust washer and the ring gear. D Install the ring gear assembly and tighten the bolts to specification.
Page 265: Deive Shaft Inspection
CHAS SHAFT DRIVE EB707040 DEIVE SHAFT INSPECTION 1. Inspect: S Drive shaft splines Wear/damage ! Replace. FINAL GEAR CASE INSTALLATION 1. Apply: S Sealant (onto the mating surface of both final gear case halves) Yamaha Bond No. 1215: 90890-85505 6-65...
Page 266 CHAS...
Page 267 ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS ........SWITCH INSPECTION .
Page 268 ELEC SELF-DIAGNOSIS ..........7-49 TROUBLESHOOTING .
Page 269: Chapter 7. Electrical
ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Thermo switch 9 Starter relay IGNITION COIL: 2 Main switch Igniter unit PRIMARY WINDING RESISTANCE: 3 Ignition coil Flasher relay 3.8 X 4.6 Ω at 20_C 4 Fuse Neutral switch SECONDARY WINDING RESISTANCE: 5 Carburetor heater relay Rear brake switch 10.1 X 15.1 kΩ...
Page 270: Switch Inspection
ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty as any point, replace the switch. Pocket tester: 90890-03112 NOTE: D Set the pocket tester to “0” before starting the test.
Page 271: Switch Continuity Inspection
ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity ! Correct or replace. : The coupler locations are circled.
Page 272 ELEC SWITCH INSPECTION 1 Clutch switch 8 Engine stop switch 2 Horn switch 9 Lights switch 3 Dimmer switch Start switch 4 Pass switch Fuse 5 Turn switch Rear brake switch 6 Main switch Sidestand switch 7 Front brake switch Neutral switch...
Page 273: Ignition System
ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM...
Page 274: Troubleshooting
ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 8. Main switch 1. Fuses (main and ignition) 9. Engine stop switch 2. Battery 10. Neutral switch 3. Spark plugs 11. Sidestand switch 4.
Page 275 ELEC IGNITION SYSTEM EB802013 Standard spark plug: 3. Spark plugs DPR7EA-9/NGK S Check the spark plug condition. X22EPR-U9/DENSO S Check the spark plug type. S Check the spark plug gap. Refer to “SPARK PLUG INSPECTION” in CHAPTER3. INCORRECT Spark plug gap: 0.8 X 0.9 mm Repair or replace the spark plugs.
Page 276 ELEC IGNITION SYSTEM OUT OF SPECIFICATION S Check if the spark plug cap has the specified resistance. Spark plug cap resistance: Replace the spark plug cap. 10 kΩ at 20_C MEETS SPECIFICATION EB802016 Tester (+) lead ! Red/Black terminal 6. Ignition coil resistance Tester (–) lead ! Orange (Gray) terminal S Disconnect the ignition coil connector from the wire harness.
Page 277 ELEC IGNITION SYSTEM EB80201C 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal. Tester (+) lead ! Gray terminal Tester (–) lead ! Black terminal S Check if the pickup coil has the specified re- OUT OF SPECIFICATION sistance.
Page 278 ELEC IGNITION SYSTEM 12. Relay unit (diode) S Remove the relay unit from the wire har- ness. S Check for continuity as follows: Sky blue – Blue/Yellow Tester (+) lead ! Sky blue Conti- Tester (–) lead ! Blue/Yellow nuity Tester (+) lead ! Blue/Yellow No Con- Tester (–) lead ! Sky blue...
Page 279: Electric Starting System
ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-11...
Page 280: Starting Circuit Operation
ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting cir- cuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can op- erate only if: The transmission is in neutral (the neutral...
Page 281: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 8. Engine stop switch 2. Battery 9. Neutral switch 3. Starter motor 10. Sidestand switch 4. Relay unit (starting circuit cut-off relay) 11.
Page 282 ELEC ELECTRIC STARTING SYSTEM EB803021 3. Starter motor D A wire that is used as a jumper lead must S Connect the battery positive terminal have the equivalent capacity or more as starter motor cable using a jumper lead that of the battery lead, otherwise the S Check the operation of the starter motor.
Page 283 ELEC ELECTRIC STARTING SYSTEM 5. Relay unit (diode) S Remove the relay unit from the wire har- ness. S Check for continuity as follows: Sky blue – Black/Yellow Sky blue – Blue/Yellow Tester (+) lead ! Sky blue Conti- Tester (–) lead ! Black/Yellow nuity Tester (+) lead ! Black/Yellow No Con-...
Page 284 ELEC ELECTRIC STARTING SYSTEM INCORRECT 7. Main switch Refer to “SWITCH INSPECTION”. Replace main switch. CORRECT INCORRECT 8. Engine stop switch Refer to “SWITCH INSPECTION”. Replace handlebar switch (right). CORRECT INCORRECT 9. Neutral switch Refer to “SWITCH INSPECTION”. Replace neutral switch. CORRECT INCORRECT 10.
Page 285: Starter Motor
ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. Exhaust pipe assembly Refer to “ENGINE ASSEMBLY” in CHAPTER 4. Starter motor/O-ring Starter motor lead Disassemble the parts in the order Starter motor disassembly below.
Page 286: Starter Motor Inspection
ELEC ELECTRIC STARTING SYSTEM EB803034 STARTER MOTOR INSPECTION 1. Inspect: S Commutator Dirty ! Clean it with #600 grit sandpaper. 2. Measure: S Commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit: 27 mm 3. Measure: S Mica undercut b Out of specification ! Scrape the mica to the proper measurement using a hacksaw...
Page 287: Starter Motor Assembly
ELEC ELECTRIC STARTING SYSTEM 5. Measure: S Brush length a Out of specification ! Replace. Brush length wear limit: 4 mm 6. Measure: S Brush spring force Fatigue/out of specification ! Replace as a set. Brush spring force: 520 X 920 g 7.
Page 288 ELEC ELECTRIC STARTING SYSTEM 3. Install: S Gasket 1 S Yoke 2 S Washer kit 3 S Brackets 4 NOTE: Align the match marks a on the yoke with the match marks b on the brackets. 7-20...
Page 289: Charging System
ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 AC magneto (stator coil) 2 Rectifier/ regulator 4 Battery 5 Main fuse 7-21...
Page 290: Troubleshooting
ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 4. Stator coil resistance 2. Battery 5. Wiring connections (the entire charging 3. Charging voltage system) NOTE: D Remove the following part(s) before trouble- Engine tachometer: shooting: 90890-03113...
Page 291 ELEC CHARGING SYSTEM S Start the engine and accelerate to about 5,000 r/min. Charging voltage: MEETS SPECIFICATION 14 V at 5,000 r/min NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4. Stator coil resistance S Disconnect the AC magneto coupler from the wire harness.
Page 292: Lighting System
ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 7-24...
Page 293: Troubleshooting
ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAIL/BRAKE LIGHT, AUXILIARY LIGHT AND/OR METER LIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main and head light) 5. Dimmer switch 2. Battery 6. Pass switch 3. Main switch 7.
Page 294 ELEC LIGHTING SYSTEM INCORRECT 3. Main switch Refer to “SWITCH INSPECTION”. Replace main switch. CORRECT 4. Lights switch Refer to “SWITCH INSPECTION”. Lights switch is faulty, replace handlebar CORRECT switch (right). INCORRECT 5. Dimmer switch Refer to “SWITCH INSPECTION”. Dimmer switch is faulty, replace handlebar CORRECT switch (left).
Page 295: Lighting System Check
ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on: NO CONTINUITY 1. Bulb and bulb socket S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY Headlight: 2.
Page 296 ELEC LIGHTING SYSTEM EB805021 2. If the meter light fails to come on: NO CONTINUITY 1. Bulb and bulb socket S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (20 V) to the bulb socket coupler.
Page 297 ELEC LIGHTING SYSTEM OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V) of the “blue” lead on the bulb socket connector. The wiring circuit from the main switch to the MEETS bulb socket connector is faulty, repair it. SPECIFICATION This circuit is not faulty.
Page 298: Signal System
ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 7-30...
Page 299 ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse Ignitor unit Neutral switch Engine indicator light Turn indicator light Neutral indicator light Front turn signal Rear turn signal Horn switch Turn switch Flasher relay Horn Rear brake switch Tail / brake light Signal system fuse Front brake switch...
Page 300: Troubleshooting
ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE TURN SIGNAL, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON: IF THE HORN FAILS TO SOUND: Procedure Check: 1. Fuses (main and signals) 2. Battery 3. Main switch 4. Wiring connections (the entire signal system) NOTE: D Remove the following part(s) before trouble-...
Page 301 ELEC SIGNAL SYSTEM INCORRECT 3. Main switch Refer to “SWITCH INSPECTION”. Replace main switch. CORRECT EB806011 4. Wiring connections POOR CONNECTION S Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal sys- tem’s circuits.
Page 302: Signal System Check
ELEC SIGNAL SYSTEM EB806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound: NO CONTINUITY 1. Horn switch Refer to “SWITCH INSPECTION”. Replace the handlebar switch (left). CONTINUITY 2. Voltage S Connect the pocket tester (DC 20 V) to the horn lead.
Page 303 ELEC SIGNAL SYSTEM EB806022 2. If the brake light fails to come on: INCORRECT 1. Brake switch (front, rear) Refer to “SWITCH INSPECTION”. Replace brake switch. CORRECT 2. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead ! Yellow terminal Tester (–) lead ! Black terminal OUT OF SPECIFICATION...
Page 304 ELEC SIGNAL SYSTEM OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V) of the “Brown” lead at the flasher relay terminal. The wiring circuit from the main switch to the MEETS flasher relay connector is faulty, repair it. SPECIFICATION 3.
Page 305 ELEC SIGNAL SYSTEM OUT OF SPECIFICATION S Turn the main switch to “ON”. S Turn the turn switch to “L” or “R”. S Check the voltage (12 V) of the “Chocolate” lead or “Dark green” lead on the bulb socket connector.
Page 306: Fuel Pump System
ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7-38...
Page 307: Fuel Pump Circuit Operation
ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION 1 Battery The fuel pump circuit consists of the fuel pump 2 Main fuse relay, fuel pump, engine stop switch and ignitor 3 Main switch unit. 4 Ignition fuse The ignitor unit includes the control unit for the 5 Engine stop switch fuel pump.
Page 308: Troubleshooting
ELEC FUEL PUMP SYSTEM EB808020 TROUBLESHOOTING IF THE FUEL PUMP FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 5. Relay unit (fuel pump relay) 2. Battery 6. Fuel pump 3. Main switch 7. Wiring connections (the entire fuel system) 4.
Page 309 ELEC FUEL PUMP SYSTEM INCORRECT 3. Main switch Refer to “SWITCH INSPECTION”. Replace main switch. 4. Engine stop switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace handlebar switch (right). EB803023 5. Relay unit (fuel pump relay) S Remove the relay unit from the wire har- ness.
Page 310 ELEC FUEL PUMP SYSTEM OUT OF SPECIFICATION S Check if the fuel pump has the specified re- sistance. Fuel pump resistance: Replace the fuel pump. 1.6 X 2.2 Ω at 20_C MEET SPECIFICATION EB808022 POOR CONNECTION 7. Wiring connections S Check the connections of the entire fuel pump system.
Page 311: Fuel Pump Test
ELEC FUEL PUMP SYSTEM EB808030 FUEL PUMP TEST Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or combustion. Be ex- tremely careful and note the following points: D Stop the engine before refuelling. D Do not smoke and keep away from open flames, sparks, or any other source of fire.
Page 312: Carburetor Heater System
ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM 7-44...
Page 313: Troubleshooting
ELEC CARBURETOR HEATER SYSTEM TROUBLESHOOTING IF THE CARBURETER HEATER FAILS TO OPERATE: Procedure Check: 1. Fuses (main and carburetor heater) 5. Carburetor heater relay 2. Battery 6. Thermo switch 3. Main switch 7. Carburetor heater 4. Neutral switch 8. Wiring connections (the entire carburetor heater system) NOTE: D Remove the following part(s) before trouble-...
Page 314 ELEC CARBURETOR HEATER SYSTEM INCORRECT 3. Main switch Refer to “SWITCH INSPECTION”. Replace main switch. CORRECT 4. Neutral switch INCORRECT Refer to “SWITCH INSPECTION”. CORRECT Replace neutral switch. 5. Caburetor heater relay. S Remove the carburetor heater relay from the wire harness. S Connect the pocket tester (Ω...
Page 315 ELEC CARBURETOR HEATER SYSTEM 6. Thermo switch S Remove the thermo switch from the thermo switch plate. S Connect the pocket tester to the thermo switch lead. Tester (+) lead ! Brown/Yellow terminal Tester (–) lead ! Black/Yellow terminal S Immerse the thermo switch in the water S Check the thermo switch for continuity.
Page 316 ELEC CARBURETOR HEATER SYSTEM INCORRECT S Measure the heater resistance. Carburetor heater resistance: 12V15W: 6 X 12 Ω at 20_C Replace carburetor heater. 12V30W: 6 X 10 Ω at 20_C CORRECT POOR CONNECTION 1. Wiring connection S Check the connections of the carburetor heater system.
Page 317 ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The XVS650 features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the engine indicator light (irrespective of whether the engine is running or not). 1 NOTE: The XVS650 features a self-diagnosing system.
Page 318 ELEC SELF-DIAGNOSIS TROUBLESHOOTING The engine indicator light starts to display the self-diagnosis sequence. NOTE: Use the following special tool in this trouble- Pocket tester: shooting. 90890-03112 1. Throttle position sensor (TPS) CIRCUIT DIAGRAM Throttle position sensor (TPS) Ignitor unit NO CONTINUITY 1.
Page 319 TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ......FUEL SYSTEM ..........ELECTRICAL SYSTEM .
Page 320 TRBL SHTG...
Page 321: Chapter 8. Troubleshooting
TRBL STARTING FAILURE/HARD STARTING SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for in- spection, adjustment and replacement of parts.
Page 322: Compression System
TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston ring D Loose spark plug D Improperly installed piston ring D Loose cylinder head or cylinder D Worn, fatigued or broken piston ring D Faulty cylinder head gasket D Seized piston ring D Worn, damaged or seized cylinder...
Page 323: Faulty Gear Shifting
FAULTY GEAR SHIFTING/ TRBL CLUTCH SLIPPING/DRAGGING SHTG EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission D Improperly adjusted shift pedal link D Seized transmission gear D Bent shift shaft D Jammed impurities D Incorrectly assembled transmission Shift cam, shift fork D Groove jammed with impurities...
Page 324: Overheating
OVERHEATING/FAULTY BRAKE/FRONT FORK OIL TRBL LEAKAGE AND FRONT FORK MALFUNCTION SHTG EB905000 OVERHEATING OVERHEATING Ignition system Compression system D Improper spark plug gap D Heavy carbon build-up D Improper spark plug heat range Engine oil D Faulty ignitor unit D Improper oil level D Improper oil viscosity Fuel system D Improper carburetor main jet setting...
Page 325: Unstable Handling
UNSTABLE HANDLING/ TRBL FAULTY LIGHTING AND SIGNAL SYSTEMS SHTG EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Front fork D Improperly installed or bent D Uneven oil levels on both sides D Uneven spring tension Steering D Improperly installed handlebar crown (uneven damping force adjuster position) D Bent steering stem D Broken spring D Improperly installed steering shaft...
Page 326 TRBL SHTG...
Page 327 XVS650 ’97 WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/ regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Relay unit 9 Fuel pump Sidestand switch Throttle position sensor (TPS) Ignitor unit Ignition coil Spark plug Pickup coil Neutral switch...

Yamaha XVS6501997 Service Manual

Section 1

Section 2

Table of Contents

Insp Adj

Carburetor

Chassis Chas

Table of Contents

Trbl Shtg

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha XVS6501997