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Table of Contents

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Table of Contents

   Summary of Contents for Yamaha XV1600A1999

  • Page 3 EB000000 XV1600A (L) SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. First Edition, December 1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4: Important Manual Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 ******** SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system CARB 8 Troubleshooting...
  • Page 7 ******** TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETION CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9: Table Of Contents

    INFO CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
  • Page 10 INFO...
  • Page 11: Motorcycle Identification

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 12: Features

    FEATURES INFO EAS00019 FEATURES Twin spark plugs For this model, two spark plugs are incorpo- rated per each cylinder. By using two spark plugs, the combustion time in the combustion chamber is shortened in an attempt to improve torque. Speed sensor The speed sensor is installed to the crankcase and it detects the number of passing gears while the vehicle is running in 5th gear and sends the...
  • Page 13 FEATURES INFO Auto decompression mechanism The auto decompression mechanism occurs when the engine is started. When the engine is started the decompression cam and pin raise the exhaust valve lifters, push the push rods, move the rocker arms, and lower the exhaust valves which compress the cylinder. When the cylinder is compressed, pressure is released immediately, resulting in smoother engine starting capabilities and smoother crankshaft revolutions.
  • Page 14 FEATURES INFO Operation 1. When the starter switch is pushed, electricity is run to the decompression solenoid 1 causing it to push out the decompression so- lenoid rod 2 . 2. When the decompression solenoid rod is pushed out, the decompression connector 3 moves the decompression levers 4 in the direction indicated by the arrows, and then the levers push the decompression rods 5...
  • Page 15 FEATURES INFO Oil-pressure-operated valve lifters Since the oil-pressure-operated valve-lifting mechanism maintains a valve clearance of zero, periodic valve clearance adjustments are unnecessary. The advantages of this system as compared to conventional techniques include the following: me- chanical noise is reduced, the camshaft action on the valves remains unaffected by engine speed or temperature, and the valve timing is kept stable.
  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and ap- pearance, but inferior in quality.
  • Page 17: Lock Washers/plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut.
  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
  • Page 19: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers, or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 20 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve guide remover (6 mm) 90890-04064 This tool is used to remove or install the Valve guides. Valve guide installer 90890-04065 This tool is used to install the valve guides. Valve guide reamer 90890-04066 This tool is used to rebore the new valve guides.
  • Page 21 This tool is needed to loosen or tighten the oil filter cartridge. Engine tachometer 90890-03113 This tool is used to check engine speed. Yamaha bond No.1215 90890-85505 This sealant is used to seal two mating surfaces (e.g., crank case mating surfaces). Oil pressure gauge...
  • Page 22 INFO...
  • Page 23 SPEC CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
  • Page 24 SPEC...
  • Page 25: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,500 mm Overall width 980 mm Overall height 1,140 mm Seat height 710 mm Wheelbase 1,685 mm Minimum ground clearance 145 mm Minimum turning radius 3,200 mm Weight Wet (with oil and a full fuel tank) 332 kg Dry (without oil and fuel)
  • Page 26: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, OHV Displacement 1,602 cm Cylinder arrangement V-type 2-cylinder Bore stroke 113 mm Compression ratio 8.3:1 Engine idling speed 950 r/min Vacuum pressure at engine idling 52 kPa (390 mm Hg) speed Standard compression pressure 1,200 kPa...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Engine oil pump Oil pump type Trochoidal Inner rotor to outer rotor tip clearance 0.00 0.12 mm 0.17 mm Inner rotor outer rotor 2 to oil pump 0.03 0.08 mm 0.13 mm housing clearance (feed pump) Inner rotor outer rotor 1 to oil 0.06 0.11 mm...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Measurement A 36.594 36.649 mm 36.494 mm Measurement B 31.950 32.050 mm 31.850 mm Camshaft exhaust lobe dimensions Measurement A 36.554 36.654 mm 36.454 mm Measurement B 31.950 32.050 mm 31.850 mm Rocker arms, Rocker arm shafts Rocker arm inside diameter 15.000 15.018 mm...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve margin thickness D Intake 1.3 mm 0.4 mm Exhaust 1.3 mm 0.4 mm Valve stem diameter Intake 5.975 5.990 mm 5.945 mm Exhaust 5.960 5.975 mm 5.920 mm Valve guide inside diameter Intake 6.000 6.012 mm 6.05 mm...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake 2.5_/2.4 mm Exhaust 2.5_/2.4 mm Winding direction (top view) Intake Counter clockwise Exhaust Counter clockwise Outer springs Free length Intake 43.25 mm 41.26 mm Exhaust 43.25 mm 41.26 mm Installed length (valve closed) Intake 31.0 mm Exhaust...
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Winding direction (top view) Intake Clockwise Exhaust Clockwise VALVE LIFTERS Valve lifter outside diameter 22.9680 22.9744 mm Valve lifter case inside diameter 22.990 23.010 mm Valve lifter-to-valve lifter case clear- 0.0156 0.0420 mm ance VALVE PUSH RODS Valve push rod length 293.45...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Ring type Barrel Dimensions (B 3.8 mm End gap (installed) 0.30 0.45 mm 0.65 mm Ring side clearance 0.03 0.08 mm 0.12 mm 2nd ring Ring type Taper Dimensions (B 3.8 mm End gap (installed) 0.30...
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Big end radial clearance E 0.037 0.074 mm 0.09 mm Crankshaft journal-to-crankshaftjour- 0.030 0.062 mm 0.1 mm nal bearing clearance Clutch Clutch type Wet, multiple disc Clutch release method Rack and pinion (pull rod type) Clutch release method operation Cable operation Operation...
  • Page 34: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Shifting mechanism Shift mechanism type Guide bar Max. shift fork guide bar bending 0.025 mm Shift fork thickness 6.26 6.39 mm Air filter type Dry element Fuel pump Pump type Electrical Model (manufacturer) 4WM (MITSUBISHI) Output pressure 20 kPa...
  • Page 35 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle Caster angle Trail 142 mm Front wheel Wheel type Spoke wheel Size MT3.00 Material Steel Wheel travel 140 mm Wheel runout Max. radial wheel runout 1 mm Max. lateral wheel runout 0.5 mm Rear wheel Wheel type...
  • Page 36 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type With tube Size 150/80 B16 71H Model (manufacturer) D404 (DUNLOP)/ G702 (BRIDGESTONE) Tire pressure (cold) 90 kg 250 kPa (2.5 kg/cm 90 kg Maximum load* 280 kPa (2.8 kg/cm High-speed riding 280 kPa (2.8 kg/cm *Load is the total weight of the cargo, rider, passenger and accessories.
  • Page 37 6.8 N/mm (0.7 kg/mm) Spring stroke (K1) 140 mm Optional spring available Fork oil Recommended oil Yamaha fork oil 5WT Quantity (each front fork leg) 554 cm Level (from the top of the inner tube, 110 mm with the inner tube fully compressed,...
  • Page 38 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Drive belt Model (manufacturer) UBD-0568 Drive belt slack (on a sidestand) 13 mm Drive belt slack 21 mm (on a suitable stand) 2-14...
  • Page 39 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignitions system Ignition system type Transistorized coil ignition (TCI) Ignition timing 10_ BTDC at 1,000 r/min Advanced timing 40_ BTDC at 4,000 r/min Advancer type Throttle position sensor and electrical 372 Ω/Gy-B Pickup coil resistance/color Transistorized coil ignition unit...
  • Page 40 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Neutral indicator light 12 V 1.7 W Turn signal indicator light 12 V 1.7 W High beam indicator light 12 V 1.7 W Fuel level indicator light Engine trouble indicator light Electric starting system System type Constant mesh Starter motor...
  • Page 41: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 30 A Headlight fuse 15 A Signaling system fuse 10 A Ignition fuse 15 A Carburetor heater 10 A Backup fuse (odometer) Reserve 30 A, 15 A, 10 A, 5 A 2-17...
  • Page 42: Conversion Table

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 EAS00029 CONVERSION TABLE TIGHTENING TORQUES All specification data in this manual are listed in GENERAL TIGHTENING TORQUES SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread pitch.
  • Page 43: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Item Fastener Fastener Thread size Thread size Q’ty Q ty Remarks Remarks mSkg Spark plug – Cylinder head Cylinder head Cylinder head (exhaust pipe) Stud bolt Camshaft driven gear Camshaft driven gear Bolt Connecting rod Bolt...
  • Page 44 SPEC TIGHTENING TORQUES Tightening torque Item Item Fastener Fastener Thread size Q’ty Thread size Q ty Remarks Remarks mSkg Generator rotor Bolt 16.0 Generator shaft Bolt Pickup coil rotor Bolt 11.5 Buffle plate Bolt Clutch boss Use a lock washer. Clutch spring plate Bolt Pull lever...
  • Page 45: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Item Thread size Thread size Remarks Remarks mSkg Upper bracket and inner tube Upper bracket and steering shaft 13.0 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) See NOTE. Brake hose joint and lower bracket Front brake master cylinder cap Handlebar holder (lower)
  • Page 46 SPEC TIGHTENING TORQUES Tightening torque Item Item Thread size Thread size Remarks Remarks mSkg Rear master cylinder and brake bracket Rear brake reservoir tank Union bolt (rear brake hose) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Front wheel axle Front wheel axle pinch bolt Rear wheel axle nut...
  • Page 47: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearings Connecting rod bolts and nuts Connecting rod small end and big end Crankshaft pins Crankshaft journals Piston surfaces Piston pins Camshaft cam lobes and camshaft journals...
  • Page 48: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal...
  • Page 49: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Pressure feed Rear cylinder intake valve Front cylinder intake valve Rear cylinder Crankshaft journal Piston Connecting rod Crank Pin (left) Valve stem Rocker Valve Push Rear lifter camshaft Front cylinder Valve stem Rocker Push Valve...
  • Page 50: Engine Oil Flow Diagrams

    SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS Oil tank Oil strainer Dipstick Oil delivery pipe Push rod Oil filter cartridge Engine oil drain bolt (oil tank) 2-26...
  • Page 51 SPEC ENGINE OIL FLOW DIAGRAMS Valve lifter Push rod Rocker arm shaft Crankshaft 2-27...
  • Page 52 SPEC ENGINE OIL FLOW DIAGRAMS Engine oil pump Oil strainer Engine oil drain bolt (engine) 2-28...
  • Page 53 SPEC ENGINE OIL FLOW DIAGRAMS Main axle Drive axle Engine oil pump Oil strainer A To oil tank B From oil tank C To oil filter cartridge 2-29...
  • Page 54: Transfer Gear Oil Flow Diagrams

    SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS Middle drive shaft Transfer gear oil pump 2-30...
  • Page 55 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS Transfer gear oil pump Middle driven shaft 2-31...
  • Page 56: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Throttle cable A Pull the wire harness into the inside of the head light from through the Clutch cable hole on the back. Left handlebar switch lead B Clamp the wire harness. Rectifier/ regulator lead C Clamp the AIS vacuum hose.
  • Page 57 SPEC CABLE ROUTING Turn signal lead Headlight bracket A Route the left handlebar switch Ignition coil sub-wireharness Front brake light switch lead lead under the guide of handle Seat lock cable Rectifire/ regulator lead upper bracket. A.I.S vacuum hose High tension code B Clamp the wireharness.
  • Page 58 SPEC CABLE ROUTING F Route the seat lock cable on the wire harness. O Cover the sidestand switch lead, horn lead start- G Through the seat lock cable on the wireharness. er lead and pickup coil lead and then align the H Clamp the wireharness, seat lock cable to the clamp to the cover.
  • Page 59 SPEC CABLE ROUTING V Clamp the pickup coil lead. W Clamp the starter lead side stand switch lead horn lead with a band and then cut of the end. Locate the end of band outside. X Clamp the fuel pump lead to the engine stay with a band and cut the end of band.
  • Page 60 SPEC CABLE ROUTING Battery negative lead Side stand switch relay High tension code #2 Flasher relay Main switch lead To starter relay Fuel tank breather hose Starter lead Meter lead Pick up coil lead Right handlebar switch lead Horn lead Throttle cable Side stand switch lead Front brake hose...
  • Page 61 SPEC CABLE ROUTING A Dont clamp the hoses. G Connect the sidestand coupler under the clamp. B Clamp the fuel tank breather hose and oil tank H The terminal must be put in the way that the wire breather hose. lead comes out dounward through the terminal C Clamp the throttle cable and fuel tank breather along the body forward the lower side.
  • Page 62 SPEC CABLE ROUTING Stay High tension code #4 Front brake hose To main switch Throttle cable To meter Left handlebar switch lead High tension code #2 Fuel tank breather hose High tension code #1 Meter lead Wireharness Throttle cable Ignition coil lead Fuel sender lead High tension code #3 Seat lock cable...
  • Page 63 SPEC CABLE ROUTING A Clamp the wireharness. F Hang the thermo switch lead to the hook. B Position the white tape on the wireharness with G Set the wireharness along a dent of stay. the hole on battery box, as shown. H Pull the front flasher lead from through flasher C Fix the wireharness negative lead coupler to stay senter hole and pass on stay and pull the...
  • Page 64 SPEC...
  • Page 65 CONTENTS PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
  • Page 66 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..3-43 CHECKING THE TIRES ........3-44 CHECKING AND TIGHTENING THE SPOKES .
  • Page 67: Periodic Checks And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 68 PERIODIC MAINTENANCE/LUBRICATION INTERVALS EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) S Check operation. 17 * Sidestand switch S Replace if necessary. S Check operation and for oil leakage. 18 * Front fork S Correct accordingly.
  • Page 69: Seats And Side Covers

    SEATS AND SIDE COVERS SEATS AND SIDE COVERS Order Job/Part Q’ty Remarks Removing the seats and side covers Remove the parts in the order listed. Rider seat Passenger seat Left side cover Right side cover For installation, reverse the removal procedure.
  • Page 70: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS AND SIDE COVERS”. Meter assembly Meter assembly coupler Disconnect. Fuel tank breather hose Fuel hose Disconnect.
  • Page 71: Air Filter Case

    AIR FILTER CASE AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Vacuum chamber breather hose Disconnect. (air filter case to solenoid valve hose) Cylinder head breather hose Disconnect. Air filter case For installation, reverse the removal pro- cedure.
  • Page 72: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00047 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S The valve clearance is automatically adjusted by the oil pressure valve lifter. However, there are times that the valve clearance is needed to be adjusted manually.
  • Page 73 ADJUSTING THE VALVE CLEARANCE 4. Remove: S shift rod 1 5. Remove: S rider footrest (left) bolts 1 6. Remove: S engine left side cover 1 7. Remove: S timing mark accessing screw 1 S crankshaft end cover 2 8. Remove: S decompression solenoid cover 1 S camshaft sprocket cover 2...
  • Page 74 ADJUSTING THE VALVE CLEARANCE 9. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.04 mm Exhaust valve 0.04 mm CAUTION: Be sure to check the intake and exhaust valves. piston #1 TDC (rear cylinder) a.
  • Page 75 ADJUSTING THE VALVE CLEARANCE 10. Adjust: S valve clearance a. Loosen the locknut 1 . b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw 3 in direction a or b until the specified valve clearance is ob- tained.
  • Page 76: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compres- sion.
  • Page 77 ADJUSTING THE ENGINE IDLING SPEED Carburetor angle driver 90890-03158 Pilot screw 2-1/2 turns out c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Engine idling speed Direction is increased. Engine idling speed Direction is decreased.
  • Page 78: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Measure: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 8 mm...
  • Page 79: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS e. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free Direction play is increased. Throttle cable free Direction play is decreased.
  • Page 80 CHECKING THE SPARK PLUGS 2. Disconnect: S spark plug cap 3. Remove: S spark plug CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal- ling into the cylinders. 4.
  • Page 81: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: S rider seat Refer to “SEATS AND SIDE COVERS”.
  • Page 82 CHECKING THE IGNITION TIMING 7. Remove: S timing mark accessing screw 1 8. Install: S timing light 1 S inductive tachometer 2 (onto the spark plug lead of cylinder #1) Timing light 90890-03141 Engine tachometer 90890-03113 9. Check: S ignition timing a.
  • Page 83: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 11. Adjust: S installed shift rod length Refer to “ADJUSTING THE SHIFT PEDAL”. EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 84 MEASURING THE COMPRESSION PRESSURE 8. Install: S compression gauge 1 S compression gauge adapter 2 Compression gauge 90890-03081 Compression gauge adapter 90890-04082 9. Measure: S compression pressure Out of specification ! Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,000 kPa (10 kg/cm...
  • Page 85: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than Piston wear or damage ! Repair. without oil Piston ring(-s), valves, cylinder Same as without oil head gasket, or piston possibly defective ! Repair.
  • Page 86 CHECKING THE ENGINE OIL LEVEL 3. Remove: S rider seat Refer to “SEATS AND SIDE COVERS”. 4. Remove: S dipstick 1 5. Check: S engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b .
  • Page 87: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00073 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: S dipstick 1 S engine oil drain bolt (oil tank) 2 S engine oil drain bolt (engine) 3 4.
  • Page 88 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 mSkg) 6. Check: S engine oil drain bolt gasket Damage ! Replace. 7. Install: S engine oil drain bolt 43 Nm (4.3 mSkg,) 8.
  • Page 89 CHANGING THE ENGINE OIL NOTE: After the engine has been disassembled, pour the specified amount of engine oil into the crankcase and the oil tank. When pouring en- gine oil into the crankcase, pour it into the hole of the removed bolt 1 . 10.
  • Page 90: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several min- utes, and then turn it off. CAUTION: When the engine is cold, the engine oil will have a higher viscosity, causing the engine...
  • Page 91: Checking The Transfer Gear Oil Level

    MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL Out of specification ! Adjust. Engine oil pressure Possible causes S Faulty oil pump S Clogged oil filter Below specification S Leaking oil passage S Leaking oil Broken or damaged passage S Faulty oil filter oil seal Above...
  • Page 92: Changing The Transfer Gear Oil

    CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL CAUTION: Do not allow foreign materials to enter the transfer case. 4. Install: S checking bolt 8 Nm (0.8 mSkg) CHANGING THE TRANSFER GEAR OIL 1. Place a container under the transfer gear oil drain bolt.
  • Page 93: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 15 mm 2. Adjust: S clutch cable free play Handlebar side a.
  • Page 94: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S air filter case Refer to “AIR FILTER CASE”. 2. Remove: S air filter case cover 1 S air filter element 2 3. Clean: S air filter element Apply compressed air to the inner surface of the air filter element.
  • Page 95: Checking The Carburetor Joint

    CHECKING THE CARBURETOR JOINT/ CHECKING THE FUEL HOSES AND FUEL FILTER EAS00094 CHECKING THE CARBURETOR JOINT 1. Remove: S carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Check: S carburetor joint 1 Cracks/damage ! Replace. Refer to “CARBURETOR” in chapter 6. 3.
  • Page 96: Checking The Cylinder Head Breather Hose And Transfer Gear Case Breather Hose

    CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE CYLINDER HEAD BREATH- ER HOSE AND TRANSFER GEAR CASE BREATHER HOSE 1. Remove: S rider seat S fuel tank Refer to “SEATS AND SIDE COVERS” and “FUEL TANK”.
  • Page 97: Chassis

    ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: S brake lever free play a Out of specification ! Adjust. Brake lever free play (at the end of the brake lever) 5 mm 2. Adjust: S brake lever free play a.
  • Page 98: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Measure: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ³ Adjust. Brake pedal position (below the top of the rider footrest) 100 mm 2.
  • Page 99: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 100: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00120 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S brake pad Wear indicator groove 1 almost disap- peared ! Replace the brake pads as a set.
  • Page 101: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSE 1. Check: S rear brake light operation timing Incorrect ! Adjust. 2. Adjust: S rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.
  • Page 102: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenever: S the brake system was disassembled, S a brake hose was loosened, disconnected, or replaced, S the brake fluid level is very low, S brake operation is faulty.
  • Page 103 BLEEDING THE HYDRAULIC BRAKE SYSTEM c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . A Front B Rear d. Place the other end of the hose into a con- tainer. e. Slowly apply the brake several times. f.
  • Page 104: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a . 1. Measure: S installed shift rod length a Incorrect ! Adjust. Installed shift rod length 374.4 378.4 mm...
  • Page 105 ADJUSTING THE DRIVE BELT SLACK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a sidestand and or on a suitable stand so that the rear wheel is elevated. 2.
  • Page 106: Checking And Adjusting The Steering Head

    ADJUSTING THE DRIVE BELT SLACK/ CHECKING AND ADJUSTING THE STEERING HEAD a. Loosen the brake caliper bracket bolt 1 . b. Loosen the wheel axle nut 2 . c. Loosen both locknuts 3 . A Right B Left d. Turn both adjusting bolts 4 in direction a or b until the specified drive chain slack is ob- tained.
  • Page 107 CHECKING AND ADJUSTING THE STEERING HEAD 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness ! Adjust the steering head. 3. Remove: S meter assembly Refer to “FUEL TANK”. 4.
  • Page 108: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 4. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.
  • Page 109: Adjusting The Rear Shock Absorber Assembly

    CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 2. Check: S inner tube Damage/scratches ! Replace. S oil seal Oil leakage ! Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: S front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.
  • Page 110 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES Adjusting length a Minimum 42.5 mm Standard 42.5 mm Maximum 51.5 mm CAUTION: Never turn the adjusting ring beyond the maximum or minimum setting. EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires.
  • Page 111: Checking The Tires

    CHECKING THE TIRES Basic weight (with oil and a 332 kg full fuel tank) Maximum 196 kg load* Cold tire pres- Front tire Rear tire sure 250 kPa 250 kPa Up to 90 kg (2.5 (2.5 load* kgf/cm kgf/cm 250 kPa 280 kPa 90 kg maxi-...
  • Page 112 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Size...
  • Page 113: Checking And Tightening The Spokes

    CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES WARNING S After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with pos- sible injury to the rider or damage to the motorcycle.
  • Page 114: Checking And Lubricating The Cables

    CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES 2. Tighten: S spokes (with a spoke wrench 1 ) 3 Nm (0.3 mSkg) NOTE: Be sure to tighten the spokes before and after break-in. EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables.
  • Page 115: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium soap base grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
  • Page 116: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 117 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 118 CHECKING AND CHARGING THE BATTERY 5. Charge: S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. CAUTION: S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat- tery overheating and battery plate damage.
  • Page 119 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Charger Measure the open-circuit NOTE: Ammeter voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16...
  • Page 120 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- meter to the battery and start charging.
  • Page 121: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: S battery S battery band 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , then the negative battery lead 2 . 8.
  • Page 122 CHECKING THE FUSES NOTE: Set the pocket tester selector to “Ω 1”. Pocket tester 90890-03112 b. If the pocket tester indicates “ ”, replace the fuse. 3. Replace: S blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c.
  • Page 123: Replacing The Headlight Bulb

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB 4. Install: S left side cover Refer to “SEATS AND SIDE COVERS”. EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S screws 1 S headlight lens unit 2 2. Disconnect: S head light coupler 1 3.
  • Page 124: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 6. Install: S headlight bulb Secure the new headlight bulb with the head- light bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected.
  • Page 125 ADJUSTING THE HEADLIGHT BEAM 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or Headlight beam moves to Direction the right. Headlight beam moves to Direction the left. 3-59...
  • Page 126: Instrument Functions

    Engine trouble indicator light “ ” This indicator light will come on or flash if trouble occurs in a monitoring circuit. In such a case, take the motorcycle to a Yamaha dealer to have the self-diagnostic systems checked. COMBINATION METER...
  • Page 127 INSTRUMENT FUNCTIONS To reset the trip meter “0”, push the set button until it displays “TRIP A” or “TRIP B”, then push mode button and hold it down for at least one se- cond. NOTE: This motorcycle does not have a tachometer. However, it is equipped with an engine revolu- tion limiter, which prevents the engine revolu- tion from exceeding approximately 4,400 r/min.
  • Page 129: Chassis Chas

    CHAS CONTENTS CHASSIS FRONT WHEEL AND BRAKE DISCS ......REMOVING THE FRONT WHEEL .
  • Page 130 CHAS FRONT AND REAR BRAKES ........4-22 REPLACING THE FRONT BRAKE PADS .
  • Page 131 CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 78 Nm (7.8 mSkg) 20 Nm (2.0 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.
  • Page 132 CHAS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.
  • Page 133 CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 134 CHAS FRONT WHEEL AND BRAKE DISCS EAS00526 CHECKING THE FRONT WHEEL 1. Check: S wheel axle Roll the wheel axle on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: S tire S front wheel Damage/wear ! Replace.
  • Page 135 CHAS FRONT WHEEL AND BRAKE DISCS 6. Check: S wheel bearings Front wheel turns roughly or is loose ! Re- place the wheel bearings. S oil seals Damage/wear ! Replace. 7. Replace: S wheel bearings S oil seals a. Clean the outside of the front wheel hub. b.
  • Page 136 CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc.
  • Page 137 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 mSkg) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
  • Page 138: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS 2. Install: S brake discs S brake disc covers 23 Nm (2.3 mS kg) NOTE: S Apply locking agent (LOCTITE 648) to the threads of the brake disc bolts. S Tighten the brake disc in stages and in a criss- cross pattern.
  • Page 139 CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel, or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 140 CHAS FRONT WHEEL AND BRAKE DISCS c. If the heavy spot does not stay in that posi- tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: S front wheel static balance a.
  • Page 141 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg) 25 Nm (2.5 mSkg) 88 Nm (8.8 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Removing the rear fender and muffler Remove the parts in the order listed.
  • Page 142 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET EAS00550 32 Nm (3.2 mSkg) 10 Nm (1.0 mSkg) 150 Nm (15.0 mSkg) 32 Nm (3.2 mSkg) 48 Nm (4.8 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.
  • Page 143 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET 32 Nm (3.2 mSkg) 10 Nm (1.0 mSkg) 150 Nm (15.0 mSkg) 32 Nm (3.2 mSkg) 48 Nm (4.8 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Rear wheel Collar (left and right) Brake caliper bracket For installation, reverse the removal procedure.
  • Page 144 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET EAS00556 23 Nm (2.3 mSkg) 95 Nm (9.5 mSkg) Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket Oil seal Collar Circlip...
  • Page 145 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure. 4-15...
  • Page 146 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 147 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET 3. Check: S spokes Refer to “FRONT WHEEL AND BRAKE DISCS”. 4. Measure: S radial wheel runout S lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISCS”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1.
  • Page 148 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET Rear wheel sprocket self-locking 95 Nm (9.5 mSkg) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. ASSEMBLING THE REAR WHEEL 1. Install: S bearings S spacer S bearing S oil seal Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 149 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET 4. Install: S rear wheel sprocket 1 95 Nm (9.5 mSkg) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. 5. Install: S brake disc NOTE: S Apply locking agent (LOCTITE 648) to the threads of the brake disc bolts.
  • Page 150 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET 9. Tighten: S wheel axle nut 150 Nm (15.0 mSkg) S brake caliper bracket bolt 48 Nm (4.8 mSkg) 10. Install: S brake caliper 1 40 Nm (4.0 mSkg) 11. Install: S upper drive belt cover 1 10 Nm (1.0 mSkg) 12.
  • Page 151 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS SPROCKET 17. Install: S rider seat Refer to “SEATS AND SIDE COVERS” in chapter 3. EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel, or both, the rear wheel static balance should be adjusted.
  • Page 152: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
  • Page 153 CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Muffler Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET”. Brake caliper bolt Brake pad cover Brake pad clip...
  • Page 154: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 155 CHAS FRONT AND REAR BRAKES 2. Remove: S brake pads 1 (along with the brake pad shim) S brake pad springs 3. Measure: S brake pad thickness a Out of specification ! Replace the brake pads as a set. Minimum brake pad thickness 0.5 mm 4.
  • Page 156 CHAS FRONT AND REAR BRAKES 5. Lubricate: S brake caliper retaining bolt Recommended lubricant Lithium soap base grease CAUTION: S Do not allow grease to contact the brake pads. S Remove any excess grease. 6. Install: S brake caliper S brake caliper retaining blots 27 Nm (2.7 mSkg) S brake hose holder bolt 7.
  • Page 157 CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: S brake caliper 1 S brake pad cover 2 2.
  • Page 158 CHAS FRONT AND REAR BRAKES b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 mSkg) d. Install new brake pads and a new brake pad spring.
  • Page 159 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder...
  • Page 160 CHAS FRONT AND REAR BRAKES 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Brake master cylinder holder Brake master cylinder Front brake light switch For installation, reverse the removal procedure. 4-30...
  • Page 161 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4-31...
  • Page 162 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 23 Nm (2.3 mSkg) 48 Nm (4.8 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 163 CHAS FRONT AND REAR BRAKES 23 Nm (2.3 mSkg) 48 Nm (4.8 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Left footrest assembly Cotter pin Brake master cylinder For installation, reverse the removal procedure. 4-33...
  • Page 164 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4-34...
  • Page 165: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: To collect any remaining brake fluid, place a...
  • Page 166: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.
  • Page 167: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 5. Check: S brake hoses S brake fluid reservoir hose Cracks/damage/wear ! Replace. EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 168 CHAS FRONT AND REAR BRAKES 4. Install: S copper washers S brake hose S union bolt 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. NOTE: S While holding the brake hose, tighten the union bolt as shown.
  • Page 169 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
  • Page 170: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: S brake master cylinder kit 1 S circlip 2 S dust boot 3 2. Install: S brake master cylinder 1 23 Nm (2.3 mSkg) 3.
  • Page 171 CHAS FRONT AND REAR BRAKES CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches projection a as shown. 6. Install: S brake fluid reservoir hose 1 S brake fluid reservoir 2 7. Fill: S brake fluid reservoir (to the maximum level mark) Recommended brake fluid...
  • Page 172 CHAS FRONT AND REAR BRAKES 8. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 9. Install: S brake fluid reservoir diaphragm S brake fluid reservoir diaphragm holder S brake fluid reservoir cap S brake fluid reservoir cover 10.
  • Page 173 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
  • Page 174 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers. Retaining bolt Brake caliper Brake caliper bracket Brake pad...
  • Page 175 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Muffler Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET”.
  • Page 176 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw...
  • Page 177: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00624 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE:...
  • Page 178: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a.
  • Page 179: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. S brake caliper cylinders 2 Scratches/wear ! Replace the brake cali- per. S brake calipers Cracks/damage ! Replace. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air.
  • Page 180 CHAS FRONT AND REAR BRAKES S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1.
  • Page 181 CHAS FRONT AND REAR BRAKES 6. Install: S copper washers S brake hose S union bolt 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. CAUTION: When installing the brake hose onto the brake caliper, make sure the brake pipe touches the projection a on the brake cali- per.
  • Page 182: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 8. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 9. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 183 CHAS FRONT AND REAR BRAKES 1. Install: S bleed screw S brake caliper piston seals 1 S brake caliper pistons 2 2. Install: S brake pads S brake pad spring 1 S brake pad pins 2 S brake pad clips 3 NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation.
  • Page 184 CHAS FRONT AND REAR BRAKES 6. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 185: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 130 Nm (13.0 mSkg) 10 Nm (1.0 mSkg) 23 Nm (2.3 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
  • Page 186 CHAS FRONT FORK 130 Nm (13.0 mSkg) 10 Nm (1.0 mSkg) 23 Nm (2.3 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Lower bracket pinch bolt Loosen. Front fork legs Bolt Brake hose guide Lower fork cover For installation, reverse the removal...
  • Page 187 CHAS FRONT FORK EAS00648 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork leg Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Fork spring Dust seal...
  • Page 188 CHAS FRONT FORK 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Oil seal Seal spacer Outer tube busing Inner tube busing Oil flow stopper Outer tube For assembly, reverse the disassembly procedure. 4-58...
  • Page 189: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 190: Checking The Front Fork Legs

    CHAS FRONT FORK 3. Remove: S cartridge cylinder bolt NOTE: While holding the cartridge cylinder with the damper rod holder 1 and T-handle 2 , loosen the cartridge cylinder bolt. Damper rod holder 90890-01294 T-Handle 90890-01326 4. Remove: S inner tube a.
  • Page 191: Assembling The Front Fork Legs

    CHAS FRONT FORK 2. Measure: S spring free length a Out of specification ! Replace. Spring free length limit 566 mm 3. Check: S cartridge cylinder 1 Damage/wear ! Replace. Obstruction ! Blow out all of the oil pas- sages with compressed air. S oil flow stopper 2 Damage ! Replace.
  • Page 192 2. Install: S oil flow stopper 3 3. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 5WT or equivalent 4. Install: S outer tube (onto the inner tube) S copper washer S cartridge cylinder bolt 5.
  • Page 193 CHAS FRONT FORK 6. Install: S outer tube bushing 1 S seal spacer 2 (with the fork seal driver weight 3 and adapter 4 ) Fork seal driver weight 90890-01367 Adapter 90890-01374 7. Install: S oil seal 1 (with the fork seal driver weight 2 and adapter 3 ) CAUTION: Make sure the numbered side of the oil seal...
  • Page 194: Installing The Front Fork Legs

    110 mm Recommended oil Yamaha fork shock oil 5WT or equivalent NOTE: S While filling the front fork leg, keep it upright. S After filling, slowly pump the front fork leg up and down to distribute the fork oil.
  • Page 195 CHAS FRONT FORK 3. Install: S Upper bracket S Steering stem nut 130 Nm (13.0 mSkg) NOTE: Make sure the inner fork tube is flush with the top of the upper bracket. 4. Tighten: S lower bracket pinch bolt 1 20 Nm (2.0 mSkg) S cap bolt 23 Nm (2.3 mSkg)
  • Page 196 CHAS FRONT FORK 8. Tighten: S upper bracket pinch bolts 1 10 Nm (1.0 mSkg) 9. Install: S brake hose holder S front fender 23 Nm (2.3 mSkg) 10. Install: S front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. 4-66...
  • Page 197: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 10 Nm (1.0 mSkg) 23 Nm (2.3 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect.
  • Page 198 CHAS HANDLEBAR 10 Nm (1.0 mSkg) 23 Nm (2.3 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Clutch cable Disconnect. Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure.
  • Page 199: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 200 CHAS HANDLEBAR NOTE: S The upper handlebar holders should be installed with the arrows a facing forward A . S Align the match marks b on the handlebar with the upper surface of the lower handlebar holders. 3. Tighten: S lower handlebar holder nuts 40 Nm (4.0 mSkg) 4.
  • Page 201 CHAS HANDLEBAR 8. Install: S handlebar grip a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
  • Page 202 CHAS HANDLEBAR S First, tighten the upper bolt, then the lower bolt. 13. Connect: S front brake light switch connector 14. Install: S plastic clamp S rear view mirrors 15. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY”...
  • Page 203: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 130 Nm (13.0 mSkg) 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 20 Nm (2.0 mSkg) 1st. 52 Nm (5.2 mSkg) 2nd. 3 Nm (0.3 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed.
  • Page 204 CHAS STEERING HEAD 130 Nm (13.0 mSkg) 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 20 Nm (2.0 mSkg) 1st. 52 Nm (5.2 mSkg) 2nd. 3 Nm (0.3 mSkg) Order Job/Part Q’ty Remarks Brake hose joint Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket...
  • Page 205: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S lower ring nut 1 (with the special tool 2 ) Ring nut wrench 90890-01443 WARNING...
  • Page 206: Installing The Steering Head

    CHAS STEERING HEAD b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set.
  • Page 207 CHAS STEERING HEAD 3. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 4. Install: S brake hose joint 1 7 Nm (0.7 mSkg) 5.
  • Page 208 CHAS STEERING HEAD 10. Install: S upper bracket S steering stem nut S front fork legs Refer to “FRONT FORK”. 11. Install: S handlebar Refer to “HANDLEBAR”. S front fork legs Refer to “FRONT FORK”. S meter assembly Refer to “FUEL TANK” in chapter 3. 4-78...
  • Page 209: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM ******** REAR SHOCK ABSORBER AND SWINGARM 7 Nm (0.7 mSkg) 59 Nm (5.9 mSkg) 7 Nm (0.7 mSkg) 125 Nm (12.5 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm Rear wheel Refer to “REAR WHEEL, BRAKE DISC...
  • Page 210 CHAS REAR SHOCK ABSORBER AND SWINGARM 7 Nm (0.7 mSkg) 59 Nm (5.9 mSkg) 7 Nm (0.7 mSkg) 125 Nm (12.5 mSkg) Order Job/Part Q’ty Remarks Pivot shaft Rear shock absorber and swingarm assembly For installation, reverse the removal procedure. 4-80...
  • Page 211 CHAS REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.0 mSkg) 59 Nm (5.9 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm Self-locking nut/washer/bolt 1/1/1 Bolt = 53 mm Self-locking nut/washer/bolt 1/1/1 Bolt = 124 mm...
  • Page 212 CHAS REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.0 mSkg) 59 Nm (5.9 mSkg) Order Job/Part Q’ty Remarks Spacer/bearing Swingarm Dust cover Washer Spacer Bearing For installation, reverse the removal procedure. 4-82...
  • Page 213: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.
  • Page 214: Checking The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM 2. Remove: S bolt (shock absorber-connecting arm-frame) NOTE: When removing the bolt (shock absorber-con- necting arm-frame) 1 , hold the swingarm so that it does not drop down. 3. Measure: S swingarm free play S swingarm vertical movement a.
  • Page 215: Checking The Replay Arm And Connecting Arm

    CHAS REAR SHOCK ABSORBER AND SWINGARM S spring Damage/wear ! Replace the rear shock ab- sorber assembly. S gas cylinder Damage/gas leaks ! Replace. S bushings Damage/wear ! Replace. S O-ring Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. CHECKING THE REPLAY ARM AN CON- NECTING ARM 1.
  • Page 216: Installing The Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Wash: S pivot shaft S dust covers S spacer S bearings Recommended cleaning solvent Kerosine 4. Check: S dust covers S spacer S oil seals Damage/wear ! Replace. S bearings Damage/pitting ! Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORB- ER AND SWINGARM...
  • Page 217 CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Install: S bearings S oil seals 1 S spacers 2 4. Install: S relay arm 1 (onto the swingarm) 59 Nm (5.9 mSkg) 5. Install: S O-rings 1 S spacer 2 6. Install: S connecting arms 1 (onto the rear shock absorber) 7.
  • Page 218 CHAS REAR SHOCK ABSORBER AND SWINGARM 8. install: S rear shock absorber 1 (onto the relay arm) 40 Nm (4.0 mSkg) 9. Install: S rear shock absorber and swingarm assem- S pivot shaft S washer S pivot shaft nut 125 Nm (12.5 mSkg) S covers 10.
  • Page 219 CHAS REAR SHOCK ABSORBER AND SWINGARM 13. Install: S locknut 1 S adjusting bolt 2 14. Install: S rear wheel Rear to “REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET”. 15. Adjust: S drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”...
  • Page 220: Drive Belt And Drive Sprocket

    CHAS DRIVE BELT AND DRIVE SPROCKET DRIVE BELT AND DRIVE SPROCKET 85 Nm (8.5 mSkg) 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) 53 Nm (5.3 mSkg) Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. sprocket Rear wheel Refer to “REAR WHEEL, BRAKE DISC...
  • Page 221: Removing The Drive Belt And Drive Sprocket

    CHAS DRIVE BELT AND DRIVE SPROCKET REMOVING THE DRIVE BELT AND DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before remove the rear wheel. 1. Remove: S drive sprocket bracket 1 S drive sprocket cover 2 2. Straighten the lock washer tab. 3.
  • Page 222: Installing The Drive Belt And Drive Sprocket

    CHAS DRIVE BELT AND DRIVE SPROCKET 3. Check: S drive sprocket S rear wheel sprocket Bent teeth ! Replace the drive belt and sprockets as a set. INSTALLING THE DRIVE BELT AND DRIVE SPROCKET 1. Install: S drive sprocket 1 S lock washer 2 S drive sprocket nut 3 2.
  • Page 223 CHAS DRIVE BELT AND DRIVE SPROCKET 6. Install: S dowel pins 1 S sliders 2 7. Install: S drive sprocket cover 1 10 Nm (1.0 mSkg) S drive sprocket cover bracket 2 S bolts (M10) 53 Nm (5.3 mSkg) S bolts (M8) 30 Nm (3.0 mSkg) 4-93...
  • Page 224 CHAS...
  • Page 225 CONTENTS ENGINE ENGINE ............INSTALLING THE ENGINE .
  • Page 226 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ... . . 5-12 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ..........5-18 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS...
  • Page 227 CLUTCH ............5-60 REMOVING THE CLUTCH .
  • Page 228 ENGINE OIL PUMP ..........5-108 CHECKING THE OIL PUMP .
  • Page 229 ENGINE EAS00188 ENGINE ENGINE 30 Nm (3.0 mSkg) 20 Nm (2.0 mSkg) 25 Nm (2.5 mSkg) Order Job/Part Q’ty Remarks Removing the muffler and exhaust Remove the parts in the order listed. pipes Muffler Front exhaust pipe Rear exhaust pipe Gasket For installation, reverse the removal procedure.
  • Page 230 ENGINE 40 Nm (4.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 70 Nm (7.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil filter bracket and horn Rider seat/side covers Refer to “SEATS AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK”...
  • Page 231 ENGINE 40 Nm (4.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 70 Nm (7.0 mSkg) Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain. Transfer gear oil Drain. Transfer gear case Refer to “TRANSFER GEAR CASE”. Rider footrest (left) Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”.
  • Page 232 ENGINE Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Sparks plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Charcoal canister hose (carburetor to charcoal canister) Plastic clamp Stator coil coupler Decompression solenoid coupler Pickup coil coupler...
  • Page 233 ENGINE Order Job/Part Q’ty Remarks Neutral switch over Neutral switch Speed sensor For connecting, reverse the disconnection procedure.
  • Page 234 ENGINE EAS00191 ENGINE 48 Nm (4.8 mSkg) 88 Nm (8.8 mSkg) 88 Nm (8.8 mSkg) 88 Nm (8.8 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
  • Page 235 ENGINE 48 Nm (4.8 mSkg) 88 Nm (8.8 mSkg) 88 Nm (8.8 mSkg) 88 Nm (8.8 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Rear engine bracket Lower front mounting bolt Lower rear mounting bolt Engine Refer to “INSTALLING THE ENGINE”. For installation, reverse the removal procedure.
  • Page 236 ENGINE INSTALLING THE ENGINE 1. Install: S lower rear mounting bolt 1 S lower front mounting bolt 2 S rear engine brackets 3 S rear engine bracket bolts 4 S upper rear mounting bolt 5 S self-locking nuts 6 S front engine brackets 7 S horn bracket 8 S front engine bracket bolts 9 S upper front mounting bolt...
  • Page 237 ENGINE 5. Connect: S speed sensor coupler S neutral switch connector S pickup coil coupler S decompression solenoid coupler S stator coil coupler 6. Install: S plastic clamp 1 7. Connect: S charcoal canister hose (carburetor to char- coal canister) 1 8.
  • Page 238 ENGINE 11. Install: S oil filter bracket 1 10 Nm (1.0 mSkg) S oil filter bolt 2 70 Nm (7.0 mSkg) NOTE: Apply locking agent (LOCTITE ) to the threads of the oil filter bracket bolts. 12. Install: S rider footrest (right) Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 239 ENGINE 16. Install: S starter motor Refer to “STARTER MOTOR” in chapter 7. S air induction system parts. Refer to “AIR INDUCTION SYSTEM” in chapter 6. S carburetor joint S carburetor Refer to “CARBURETOR” in chapter 6. S air filter case Refer to “AIR FILTER CASE”...
  • Page 240: Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Removing the engine left side cover Remove the parts in the order listed.
  • Page 241 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 48 Nm (4.8 mSkg) Order Job/Part Q’ty Remarks Decompression solenoid cover Camshaft sprocket cover Camshaft sprocket cover gasket Dowel pin For installation, reverse the removal procedure.
  • Page 242 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Cylinder head breather hose Oil tank breather hose Bolt = 65 mm Bolt = 35 mm Bolt = 50 mm Bolt...
  • Page 243 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Rear cylinder head cover spacer Front cylinder head cover spacer Cylinder head cover spacer gasket Dowel pin For installation, reverse the removal procedure. 5-15...
  • Page 244 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed. arms Push rod Rear rocker arm base Front rocker arm base Rocker arm base gasket Dowel pin Rocker arm shaft...
  • Page 245 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover Oil seal O-ring Throttle stop screw Unhook. Throttle stop screw holder Rear valve lifter case cover Front valve lifter case cover...
  • Page 246: Removing The Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: S TDC mark a on the pickup coil rotor (with the pointer b on the clutch/pickup coil rotor cov- a. Turn the crankshaft clockwise. b.
  • Page 247 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Check: S rocker arm shaft Blue discoloration/excessive wear/pit- ting/scratches ! Replace or check the lu- brication system. 3. Measure: S rocker arm inside diameter a Out of specification ! Replace. Rocker arm inside diameter 15.000 15.018 mm 4.
  • Page 248: Checking The Rocker Arm Bases

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS CHECKING THE ROCKER ARM BASES 1. Check: S rocker arm base Cracks/damage ! Replace. CHECKING THE PUSH RODS 1. Check: S push rod S push rod end Bends/damage ! Replace. 2. Measure: S push rod runout Out of specification ! Replace.
  • Page 249: Bleeding The Valve Lifter

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 3. Measure: S valve lifter outside diameter a Out of specification ! Replace. Valve lifter case outside diameter 22.9680 22.9744 mm 4. Measure: S valve lifter case inside diameter a Out of specification ! Replace. Valve lifter case inside diameter 22.990 23.010 mm...
  • Page 250 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Bleed: S valve lifter a. Fill the container with kerosene and place the valve lifter into the container. On the plunger side of the valve lifter use a hand press and pump it a number of times and pour in the kerosene.
  • Page 251: Checking The Push Rod Covers

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS h. Rotate the crankshaft and align the position of the highest lifted point of the valve lifters, which need to be bled, to the camshaft drive gear. <Example: when bleeding the valve lifter of the #2 cylinder on the intake side of the.>...
  • Page 252: Installing The Rocker Arms And Push Rods

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: S oil seals 1 S O-rings 2 S push rod covers 3 3. Install: S valve lifter case covers 1 S throttle stop screw holder 2 4. Hook: S throttle stop screw 3 5.
  • Page 253 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: S dowel pins 1 S rocker arm gasket 2 3. Install: S rocker arm base (with rocker arms) S push rods a. Put the rocker arm base on the cylinder head. b.
  • Page 254: Installing The Cylinder Head Covers

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE CYLINDER HEAD COV- The following procedure applies to both cylin- ders. 1. Install: S dowel pins 1 S cylinder head cover spacer gasket 2 2. Install: S cylinder head cover spacer 1 10 Nm (1.0 mSkg) 3.
  • Page 255: Installing The Camshaft Sprocket Cover And Engine Left Side Cover

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 1. Install: S dowel pins 1 S camshaft sprocket cover gasket 2 2. Install: S camshaft sprocket cover 1 S decompression solenoid cover 2 3.
  • Page 256 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 7. Install: S shift rod 1 8. Install: S spark plugs 9. Connect: S spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. A Forward 10. Fill: S oil tank (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL”...
  • Page 257: Camshafts

    CAMSHAFTS CAMSHAFTS 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) 52 Nm (5.2 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Valve lifters Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”. Muffler/exhaust pipes Refer to “ENGINE”.
  • Page 258 CAMSHAFTS 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) 52 Nm (5.2 mSkg) Order Job/Part Q’ty Remarks Camshaft cover Camshaft cover gasket Dowel pin Front cylinder camshaft end cover Front cylinder camshaft Rear cylinder camshaft For installation, reverse the removal procedure.
  • Page 259: Removing The Camshafts

    CAMSHAFTS REMOVING THE CAMSHAFTS 1. Loosen: S front cylinder camshaft end cover bolts 1 S camshaft drive gear bolt 2 NOTE: S Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. S Do not damage the teeth of the camshaft drive and camshaft driven gears.
  • Page 260: Checking The Camshafts

    CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Minimum camshaft lobe dimen- sions Intake lobe a 36.494 mm b 31.850 mm Exhaust lobe...
  • Page 261 CAMSHAFTS 5. Measure: S crankcase hole inside diameter c Out of specification ! Replace the crank- case. Crankcase hole inside diameter 25.000 25.021 mm 6. Measure: S camshaft caver hole inside diameter d Out of specification ! Replace the camshaft cover.
  • Page 262: Checking The Decompression System

    CAMSHAFTS 9. Check: S camshaft drive gears S camshaft driven gears Chips/pitting/roughness/wear Replace the defective part(-s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: S decompression system NOTE: S Check the decompression system while the decompression push rod is installed in the camshaft.
  • Page 263: Checking The Oil Delivery Pipe

    CAMSHAFTS CHECKING THE OIL DELIVERY PIPE 1. Check: S oil delivery pipe 1 Damage ! Replace. Obstruction ! Wash and blow out with com- pressed air. S O-rings 2 Damage/wear ! Replace. INSTALLING THE CAMSHAFTS 1. Install: S camshafts (to the camshaft cover) S front cylinder camshaft end cover NOTE: S Lubricate molybdenum disulfide oil onto the...
  • Page 264 CAMSHAFTS 4. Install: S camshaft cover 1 (along with the camshafts) S oil delivery pipe 2 NOTE: Tighten the camshaft cover bolts in stages and in a crisscross pattern. 5. Install: S straight keys S camshaft drive gear 1 S camshaft driven gear 2 NOTE: S Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the...
  • Page 265 CAMSHAFTS 8. Tighten: S camshaft drive gear bolt 1 30 Nm (3.0 mSkg) S front cylinder camshaft end cover bolts 2 NOTE: S Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. S Do not damage the teeth of the camshaft drive and camshaft driven gear.
  • Page 266 CAMSHAFTS 12. Fill: S oil tank (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 13. Install: S air filter case S fuel tank S rider seat Refer to “AIR FILTER CASE”, “FUEL TANK” and “SEATS AND SIDE COVERS”...
  • Page 267: Cylinder Heads

    CYLINDER HEADS CYLINDER HEADS 50 Nm (5.0 mSkg) 39 Nm (3.9 mSkg) 18 Nm (1.8 mSkg) 21 Nm (2.1 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Rider seat/fuel tank/air filter case Refer to “SEATS AND SIDE COVERS”, “FUEL TANK”...
  • Page 268 CYLINDER HEADS 50 Nm (5.0 mSkg) 39 Nm (3.9 mSkg) 18 Nm (1.8 mSkg) 21 Nm (2.1 mSkg) Order Job/Part Q’ty Remarks Copper washer Rear cylinder head Front cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal procedure.
  • Page 269: Removing The Cylinder Heads

    CYLINDER HEADS REMOVING THE CYLINDER HEADS 1. Remove: S cylinder head NOTE: S Loosen the nuts in the proper sequence. S Follow the numerical order shown in the il- lustration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cyl-...
  • Page 270: Checking The Oil Delivery Pipe

    CYLINDER HEADS d. Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. CHECKING THE OIL DELIVERY PIPE 1.
  • Page 271 CYLINDER HEADS 3. Install: S copper washers S oil delivery pipe 1 S oil delivery pipe bolts (M10) 21 Nm (2.1 mSkg) S oil delivery pipe bolt (M8) 18 Nm (1.8 mSkg) 4. Install: S gaskets S reed valve case to front cylinder pipe 1 S reed valve case to rear cylinder pipe 2 5.
  • Page 272: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs The following procedure applies to both cylinders. Cylinder head Refer to “CYLINDER HEADS”. Valve cotter Upper spring seat Outer valve spring Inner valve spring...
  • Page 273: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 274: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
  • Page 275 VALVES AND VALVE SPRINGS a. Remove the valve guide with the valve guide remover 1 . b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance.
  • Page 276: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always re- place the oil seal. Valve stem runout 0.01 mm EAS00240...
  • Page 277 VALVES AND VALVE SPRINGS d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.
  • Page 278: Checking The Valve Springs

    VALVES AND VALVE SPRINGS g. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. h. Install the valve into the cylinder head. i. Press the vlve through the valve guide and onto the valve seat to make a clear impres- sion.
  • Page 279: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: S compressed valve spring force a Out of specification ! Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake and exhaust inner valve spring 7.3 kg at 29.0 mm Intake and exhaust outer valve spring 13.9 16.1 kg at 31.0 mm...
  • Page 280 VALVES AND VALVE SPRINGS 2. Lubricate: S valve stem 1 S oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S lower spring seat 1 S oil seal 2 S valve 3 S inner valve spring 4 S outer valve spring 5 S upper spring seat 6 (into the cylinder head)
  • Page 281: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00251 CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEAD”. Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring...
  • Page 282: Removing The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
  • Page 283 CYLINDERS AND PISTONS 2. Measure: S piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cyl- inder. Then, find the average of the measure- ments.
  • Page 284: Checking The Piston Rings

    CYLINDER AND PISTONS Piston-to-cylinder clearance 0.025 0.050 mm <Limit>: 0.15 mm f. If out of specification, replace the cylinder, and the piston and piston rings as a set. EAS00263 CHECKING THE PISTON RINGS 1. Measure: S piston ring side clearance Out of specification ! Replace the piston and piston rings as a set.
  • Page 285: Checking The Piston Pins

    CYLINDERS AND PISTONS Piston ring end gap Top ring 0.30 0.45 mm <Limit>: 0.65 mm 2nd ring 0.30 0.45 mm <Limit>: 0.80 mm Oil ring 0.7 mm EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins.
  • Page 286: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS 4. Calculate: S piston pin-to-piston pin bore clearance Out of specification ! Replace the piston pin. Piston pin-to-piston pin bore clearance = Piston pin bore diameter (in the piston) b – Piston pin outside diameter a Piston pin-to-piston pin bore clearance 0.004 0.024 mm...
  • Page 287 CYLINDERS AND PISTONS 3. Install: S dowel pins 1 S gasket 2 4. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Front of the motorcycle...
  • Page 288: Clutch

    CLUTCH EAS00273 CLUTCH 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Left side cover Refer to “SEATS AND SIDE COVERS” in chapter 3. Engine left side cover Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”.
  • Page 289 CLUTCH 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Clutch cover gasket Dowel pin For installation, reverse the removal procedure. 5-61...
  • Page 290 CLUTCH 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the pull lever shaft and Remove the parts in the order listed. pickup coil Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Pickup coil lead holder Pickup coil For installation, reverse the removal procedure.
  • Page 291 CLUTCH EAS00274 70 Nm (7.0 mSkg) 115 Nm (11.5 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Generator rotor cover Refer to “GENERATOR”. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod...
  • Page 292 CLUTCH 70 Nm (7.0 mSkg) 115 Nm (11.5 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key For installation, reverse the removal procedure.
  • Page 293: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: S clutch cable holder 1 S clutch cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 294: Checking The Friction Plates

    CLUTCH NOTE: While holding the generator rotor 2 with the sheave holder 3 , loosen the pickup coil rotor bolt. Sheave holder 90890-01701 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: S friction plate Damage/wear ! Replace the friction plates as a set.
  • Page 295: Checking The Clutch Spring Plate

    CLUTCH EAS00283 CHECKING THE CLUTCH SPRING PLATE 1. Check: S clutch spring plate 1 Damage ! Replace. 2. Check: S clutch spring plate seat 2 Damage ! Replace. EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing.
  • Page 296: Checking The Pull Lever Shaft And Pull Rod

    INSTALLING THE PICKUP COIL AND PULL LEVER SHAFT 1. Apply S sealant (onto the pickup coil lead grommet) Yamaha bond No.1215 90890-85505 2. Install: S pickup coil 7 Nm (0.7 mSkg) S pickup coil lead holder 7 Nm (0.7 mSkg)
  • Page 297: Installing The Primary Drive Gear

    CLUTCH 3. Install: S bearings S oil seals 1 NOTE: Lubricate the oil seal lips with lithium soap base grease. 4. Install: S pull lever shaft 1 S washer S circlip EAS00303 INSTALLING THE PRIMARY DRIVE GEAR 1. Install: S straight key 1 S primary drive gear 2 S pickup coil rotor 3 S spacer 4...
  • Page 298: Installing The Clutch

    CLUTCH EAS00296 INSTALLING THE CLUTCH 1. Install: S dowel pin 1 S oil pump drive gear 2 S plate 3 S circlip 4 2. Install: S clutch housing 1 S thrust washer 2 NOTE: S Lubricate the clutch housing bearings with en- gine oil.
  • Page 299 CLUTCH Clutch holding tool 90890-04066 5. Bend the lock washer tab along a flat side of the nut. 6. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: S friction plates S clutch plates NOTE: S First, install a friction plate and then alternate between a clutch plate and a friction plate.
  • Page 300 CLUTCH 9. Install: S clutch spring plate seat 1 S clutch spring plate 2 S clutch spring plate retainer 3 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 10. Install: S dowel pins 1 S clutch cover gasket 2 11.
  • Page 301 CLUTCH 14. Install: S pull lever spring S pull lever NOTE: If there is no free play in the clutch, install the pull lever to the pull lever shaft in order to get the dis- tance a between the pull lever and clutch cable holder to 31.8 mm.
  • Page 302: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT 22 Nm (2.2 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Engine oil Drain. Clutch housing Refer to “CLUTCH”. Circlip Shift shaft spring Shift shaft Shift shaft spring stopper...
  • Page 303: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift lever spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
  • Page 304 SHIFT SHAFT 4. Install: S shift shaft spring S circlips S shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2 . 5. Install: S clutch housing Refer to “CLUTCH”. 6. Fill: S oil tank Refer to “CHANGING THE ENGINE OIL”.
  • Page 305: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat/left side cover/fuel tank Refer to“SEATS AND SIDERS”...
  • Page 306 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal procedure.
  • Page 307 GENERATOR AND STARTER CLUTCH EAS00343 160 Nm (16.0 mSkg) Order Job/Part Q’ty Remarks Removing the generator rotor and Remove the parts in the order listed. starter clutch Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Starter clutch gear...
  • Page 308: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: S generator cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 309: Installing The Generator

    GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear counter- clockwise B , it should turn freely, otherwise the starter clutch is faulty and must be re- placed. EAS00354 INSTALLING THE GENERATOR 1. Install: S starter clutch gear 1 S generator rotor 2 S washer S generator rotor bolt 3...
  • Page 310 GENERATOR AND STARTER CLUTCH 4. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505 5. Install: S stator coil assembly 1 7 Nm (0.7 mSkg) S stator coil assembly lead holder 7 Nm (0.7 mSkg)
  • Page 311 GENERATOR AND STARTER CLUTCH 9. Connect: S decompression solenoid couplers S stator coil assembly coupler NOTE: Refer to “CABLE ROUTING” in chapter 2. 10. Install: S rider footrest (right) 1 48 Nm (4.8 mSkg) 11. Connect: S rear brake light switch coupler 1 NOTE: Refer to “CABLE ROUTING”...
  • Page 312 GENERATOR AND STARTER CLUTCH 14. Install: S exhaust pipes S muffler Refer to “ENGINE”. 15. Install: S fuel tank S left side cover S rider seat Refer to “FUEL TANK” and “SEATS AND SIDE COVERS” in chapter 3. 5-84...
  • Page 313: Transfer Gear Case

    TRANSFER GEAR CASE TRANSFER GEAR CASE 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the battery box Remove the parts in the order listed. Rider seat/sider covers Refer to “SEATS AND SIDE COVERS” in chapter 3. Negative battery lead Positive battery lead Disconnect.
  • Page 314 TRANSFER GEAR CASE 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Ignitor unit Battery box Relay unit coupler Disconnect. Turn signal relay coupler Disconnect. Plastic clamp Relay bracket For installation, reverse the removal procedure. 5-86...
  • Page 315 TRANSFER GEAR CASE 10 Nm (1.0 mSkg) 43 Nm (4.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil tank cover Remove the parts in the order listed. Muffler/exhaust pipes Refer to “ENGINE”. Engine oil Drain. Oil tank breather hose Disconnect.
  • Page 316 TRANSFER GEAR CASE 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 85 Nm (8.5 mSkg) 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) 8 Nm (0.8 mSkg) 30 Nm (3.0 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks...
  • Page 317 TRANSFER GEAR CASE 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 85 Nm (8.5 mSkg) 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) 8 Nm (0.8 mSkg) 30 Nm (3.0 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks...
  • Page 318 TRANSFER GEAR CASE 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Disassembling the transfer gear case Remove the parts in the order listed. oil pump Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
  • Page 319: Removing The Battery

    TRANSFER GEAR CASE REMOVING THE BATTERY 1. Disconnect: S battery leads (from the battery terminals) WARNING First, disconnect the negative battery lead, then the positive battery lead. REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before remove the drive sprocket.
  • Page 320: Checking The Oil Strainer

    TRANSFER GEAR CASE 2. Check: S primary chain 1 Damage/stiffness ! Replace the primary chain, middle drive gear and middle driven shaft as a set. CHECKING THE OIL STRAINER 1. Check: S oil strainer Damage ! Replace. Contaminants ! Clean with engine oil. CHECKING THE OIL PUMP 1.
  • Page 321: Checking The Oil Pipe

    TRANSFER GEAR CASE 3. Check: S oil pump operation Unsmooth ! Repair or replace the defective part(-s). CHECKING THE OIL PIPE 1. Check: S oil pipe Damage ! Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant...
  • Page 322: Installing The Transfer Gear Case

    TRANSFER GEAR CASE 3. Install: S pins 1 S oil pump cover 2 7 Nm (0.7 mSkg) NOTE: Apply locking agent (LOCTITE ) to the threads of the oil pump cover screws. 4. Check: S oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE TRANSFER GEAR CASE 1.
  • Page 323 TRANSFER GEAR CASE 4. Install: S transfer gear case cover 1 10 Nm (1.0 mSkg) 5. Install: S dowel pins 1 6 Install: S transfer gear case assembly 1 NOTE: S While installing the middle drive gear 2 onto the drive axle, install the transfer gear case as- sembly onto the engine.
  • Page 324 TRANSFER GEAR CASE 10. Remove: S drive sprocket nut 11. Install: S transfer gear oil pump gasket S transfer gear oil pump 1 10 Nm (1.0 mSkg) NOTE: Apply locking agent (LOCTITE ) only to the threads of the transfer gear oil pump bolts (M6 25 mm) bolts 2 .
  • Page 325: Installing The Oil Tank Cover

    TRANSFER GEAR CASE 15. Install: S drive sprocket case 1 30 Nm (3.0 mSkg) 16. Install: S drive sprocket Refer to “DRIVE BELT AND DRIVE SPROCKET” in chapter 4. 17. Fill: S transfer gear case (with the specified amount of the recom- mended transfer gear oil) Refer to “CHANGING THE TRANSFER GEAR OIL”...
  • Page 326: Installing The Battery

    TRANSFER GEAR CASE 3. Install: S dipstick joint 1 S dipstick 2 NOTE: Finger tighten the dipstick joint bolt. 4. Connect: S oil tank breather hose 3 5. Install S oil pipes 1 10 Nm (1.0 mSkg) INSTALLING THE BATTERY 1.
  • Page 327 TRANSFER GEAR CASE 6. Install: S plastic bracket 7. Install: S Negative battery lead 1 (to the dipstick joint) 8. Install: S battery 1 S battery holder 2 S tool kit 3 S tool kit holder 4 9. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 5 ,...
  • Page 328: Crankcase

    CRANKCASE CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 43 Nm (4.3 mSkg) 28 Nm (2.8 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”.
  • Page 329 CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 43 Nm (4.3 mSkg) 28 Nm (2.8 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase For installation, reverse the removal procedure.
  • Page 330 CRANKCASE 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the buffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Buffle plate Oil seal Bearing Installation, reverse the removal procedure. 5-102...
  • Page 331: Disassembling The Crankcase

    CRA