Yamaha VMX12 2001 Service Manual
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Yamaha VMX12 2001 Service Manual

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VMX12
SERVICEMANUAL
2001
3LRD-AE1

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Summary of Contents for Yamaha VMX12 2001

  • Page 1 VMX12 2001 3LRD-AE1 SERVICEMANUAL...
  • Page 3 EAS00000 VMX12 2001 SERVICE MANUAL © 2000 by Yamaha Motor Co., Ltd. First edition, June 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. 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 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: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis COOL CARB...

  • Page 7: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB CHASSIS CHAS – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9 INFO...
  • Page 10 INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ............ 1-1 MODEL CODE ..................1-1 IMPORTANT INFORMATION ................ 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-2 REPLACEMENT PARTS ................1-2 GASKETS, OIL SEALS AND O-RINGS ........... 1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ............
  • Page 11 INFO...

  • Page 12: General Information

    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.

  • Page 13: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 14: 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 tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 15: Checking The Connections

    IMPORTANT INFORMATION INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...
  • Page 16 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Flywheel puller Attachment Puller 90890-01362 Attachment 90890-04089 These tools are needed to remove the rotor. Fork seal driver weight Attachment (f40) Weight 90890-01367 Attachment These tools are needed when installing 90890-01373 the slide metal, oil seal and dust seal into the fork.
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Vacuum gauge 90890-03094 This gauge is needed for carburetor synchronization. Dial gauge 90890-03097 This tool is used to measure the middle gear backlash. Pocket tester 90890-03112 This instrument is needed for checking the electrical system.
  • Page 19 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Bearing retainer wrench 90890-04050 This tool is needed when removing or installing the final drive shaft bearing. Middle drive shaft nut wrench (55 mm) 90890-04054 This tool is needed when removing or installing the middle drive shaft nut.

  • Page 20: Special Tools

    This tool is used to compress the piston rings when installing the piston into the cylinder. Ignition checker 90890-06754 Yamaha Bond No. 1215 90890-85505 This sealant (bond) is used on crank- case mating surfaces, etc. Ring gear fix bolt (M14) 90890-01524 M14×P1.5...
  • Page 22 SPEC...
  • Page 23 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ............... 2-11 ELECTRICAL SPECIFICATIONS ..............2-14 CONVERSION TABLE ................. 2-17 GENERAL TIGHTENING TORQUE SPECIFICATION .........2-17 TIGHTENING TORQUES ................2-18 ENGINE TIGHTENING TORQUES ............2-18 CHASSIS TIGHTENING TORQUES ............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........
  • Page 24 SPEC...

  • Page 25: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,300 mm ---- Overall width 795 mm ---- Overall height 1,160 mm ---- Seat height 765 mm ---- Wheelbase 1,590 mm ---- Minimum ground clearance 145 mm ---- Minimum turning radius 2,900 mm ----...

  • Page 26: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 1,198 cm ---- Cylinder arrangement V-type 4-cylinder ---- Bore × stroke 76 × 66 mm ---- Compression ratio 10.5 : 1 ---- Engine idling speed 950 ~ 1,050 r/min ---- Vacuum pressure at engine idling...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 170 ~ 240 kPa (1.7 ~ 2.4 kgf/cm ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0 ~ 0.12 mm 0.17 mm Outer-rotor-to-oil-pump-housing 0.03 ~ 0.08 mm...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (center) ---- Camshaft cap inside diameter 25.000 ~ 25.021 mm ---- Camshaft journal diameter 24.967 ~ 24.980 mm ---- Camshaft-journal-to-camshaft-cap 0.020 ~ 0.054 mm ---- clearance Intake camshaft lobe dimensions Measurement A 36.25 ~ 36.35 mm 36.15 mm...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 219FTS/117 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.15 mm ---- Exhaust 0.26 ~ 0.30 mm ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Inner springs Free length Intake 39.65 mm 37.45 mm Exhaust 39.65 mm 37.45 mm Installed length (valve closed) Intake 31.8 mm ---- Exhaust 31.8 mm ---- Compressed spring force (installed) Intake 61.7 ~ 72.5 N (6.29 ~ 7.39 kgf) ---- Exhaust 61.7 ~ 72.5 N (6.29 ~ 7.39 kgf)
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake ---- 2.5° /1.8 mm Exhaust ---- 2.5° /1.8 mm Winding direction (top view) Intake Clockwise ---- Exhaust Clockwise ---- Cylinders Cylinder arrangement V-type 4-cylinder ---- Bore × stroke 76 × 66 mm ---- Compression ratio 10.5 : 1...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Ring type Barrel ---- Dimensions (B × T) 1.0 × 3.1 mm ---- End gap (installed) 0.35 ~ 0.50 mm 0.75 mm Ring side clearance 0.03 ~ 0.07 mm 0.12 mm 2nd ring Ring type Taper...
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Hydraulic inner push ---- Operation Left-hand operation ---- Friction plates Thickness 2.9 ~ 3.1 mm 2.8 mm Plate quantity ---- Clutch plates Thickness 2.2 ~ 2.4 mm ---- Plate quantity ----...
  • Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetors Model (manufacturer) × quantity BDS35 (MIKUNI) × 4 ---- Throttle cable free play (at the flange 3 ~ 5 mm ---- of the throttle grip) ID mark 3LRC 10 ---- Main jet #150 ---- Main air jet ----...

  • Page 35: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle ---- Caster angle 29° ---- Trail 119 mm ---- Front wheel Wheel type Cast wheel ---- 18 × MT2.15 Size ---- Material Aluminum ---- Wheel travel 140 mm ---- Wheel runout Max.
  • Page 36 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Dual-disc brake ---- Operation Right-hand operation ---- Brake lever free play (at lever end) 2 ~ 5 mm ---- Recommended fluid DOT 4 ---- Brake discs Diameter × thickness 298 × 5 mm ---- Min.
  • Page 37 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Fork oil Yamaha fork oil 10 WT ---- Recommended oil Fork oil 10 W or equivalent ---- Quantity (each front fork leg) 621 cm ---- Level (from the top of the inner 123 mm...

  • Page 38: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 3° BTDC at 1,000 r/min ---- Advanced timing 31° BTDC at 9,000 r/min ---- Advancer type Vacuum and electrical ---- 80.8 ~ 121.2 Ω/O–B...
  • Page 39 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) SM-13 (MITSUBA) ---- Power output 0.65 kW ---- Brushes Overall length 10 mm 5 mm Spring force 8.82 N (899 gf) ---- 0.025 ~ 0.035 Ω...
  • Page 40 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage × quantity) 30 A × 1 Main fuse ---- 15 A × 1 Headlight fuse ---- 10 A × 1 Signaling system fuse ---- 10 A × 1 Ignition fuse ---- 10 A × 1 Radiator fan fuse ---- 30 A, 15 A, 10 A ×...

  • Page 41: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATION EB201000 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATION All specification data in this manual are listed in 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 IMPERIAL unit data.

  • Page 42: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Part to be tightened Part name Thread size Q’ty Remarks m·kgf Camshaft caps Bolt Blind plug Plug Cylinder head (exhaust pipe) Stud bolt Spark plugs Cylinder head Cylinder head cover Bolt Connecting rod caps AC magneto...
  • Page 43 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Part name Thread size Q’ty Remarks m·kgf Exhaust pipe joint clamp (#2 and #4) Bolt Exhaust pipe clamp bolt (exhaust Bolt chamber) Exhaust pipes Exhaust pipe cover Bolt Exhaust pipe cover Bolt Muffler bracket Bolt...
  • Page 44 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Part name Thread size Q’ty Remarks m·kgf Bearing housing Bolt Drain plug (final gear case) Plug Filler plug (final gear case) Plug Stator coil Screw Pickup coil Screw Starter motor Bolt Neutral switch Screw Oil level switch...

  • Page 45: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks m·kgf Upper bracket and inner tube Upper bracket and steering shaft 11.0 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) See NOTE Brake hose joint and lower bracket Front master cylinder cap (brake and clutch) Handlebar holder (lower)
  • Page 46 SPEC TIGHTENING TORQUES NOTE: 1.First, tighten the ring nut approximately 52 Nm (5.2 m • kg) by using the torque wrench, then loosen the ring nut completely. 2.Retighten the ring nut to specification. 2 - 22...

  • Page 47: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Balancer shaft journal Piston surface Piston pin Camshaft cam lobe/journal Timing chain tensioner...

  • Page 48: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication Point Symbol Steering bearing (upper/lower) Steering bearing cover Steering lock Steering head pipe lower oil seal Front wheel oil seal (right/left) Rear wheel oil seal Clutch hub fitting area Rear brake pedal shaft Shift pedal Sidestand sliding surface Centerstand sliding surface...

  • Page 49: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator cap È To coolant reservoir tank 2 Conduit É To thermostatic valve 3 Radiator hose Ê To coolant drain cock 4 Radiator 5 Thermostatic valve 6 Coolant drain cock 7 Water pump 2 - 25...
  • Page 50 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator cap È To thermostatic valve 2 Conduit É To coolant drain cock 3 Radiator hose 4 Radiator 5 Coolant drain cock 6 Thermostatic valve housing 7 Water pump 2 - 26...

  • Page 51: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft (intake) 8 Oil strainer 2 Camshaft (exhaust) 9 Oil pump 3 Water pump impeller shaft 0 Main axle 4 Water pump drive gear A Drive axle 5 Oil filter 6 Main gallery 7 Crankshaft 2 - 27...
  • Page 52 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Main gallery 3 Crankshaft 4 Oil level switch 2 - 28...
  • Page 53 SPEC OIL FLOW DIAGRAMS 1 Oil pump 2 Oil strainer 3 Main axle 4 Drive axle 5 Middle driven pinion gear 6 Middle drive pinion gear 2 - 29...
  • Page 54 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil pipe 3 Oil filter 2 - 30...

  • Page 55: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Front brake hose È Insert the wire harness, speedometer light lead 2 Clutch hose and front flasher light leads (left and right) 3 Front flasher light lead (left) through the hole in the housing at the back of the 4 Speedometer cable headlight.
  • Page 56 SPEC CABLE ROUTING 1 Main switch coupler A Battery negative lead 2 Handlebar switch coupler B Coolant breather hose 3 Fuel switch coupler C Conduit 4 Ignition coil lead D Rear brake reservoir tank 5 Ground lead E Battery 6 Rear brake switch lead F Wire harness 7 Coolant reservoir tank breather hose 8 Battery breather hose...
  • Page 57 SPEC CABLE ROUTING È Fasten the wire harness with a plastic locking Ì Pass the battery breather hose through the tie. clamp. É To the conduit. Í Fasten the rear brake switch lead with a plastic Ê Pass the ground lead outside the coolant reser- locking tie.
  • Page 58 SPEC CABLE ROUTING 1 Clutch hose A Speedometer cable 2 Handlebar switch lead (left) B Front brake hose 3 Clutch hose clump C Fuel pump control unit 4 Throttle cable holder D Relay unit 5 Throttle cables 6 Fuse box 7 Ignitor unit 8 Ignition coil 9 Radiator fan lead coupler...
  • Page 59 SPEC CABLE ROUTING È Pass the handlebar switch lead inside the clutch Ð Pass the clutch hose under the throttle cable hose. guide. É Pass the meter lead outside the clutch hose. Ñ Pass the throttle cables through the guide. Ê...
  • Page 60 SPEC CABLE ROUTING 1 Starter relay É Fasten the oil level switch lead, neutral switch 2 Main fuse lead, ground lead, sidestand switch lead, overflow 3 Ignition coil hose and AC generator lead with plastic band. 4 Oil level switch lead Ê...
  • Page 61 SPEC CABLE ROUTING 1 Coolant reservoir tank É Fasten the oil level switch lead, neutral switch 2 Spring lead, ground lead, sidestand switch lead, over- 3 Filler cover flow hose and AC generator lead with a plastic 4 Drain hose band.
  • Page 62 SPEC CABLE ROUTING 1 Fuel pump È Pass the fuel pipe and overflow hose through 2 Fuel pipe the hose holder. 3 Fuel filter bracket 4 Fuel filter 5 Over flow hose 6 Filler cover 7 Filler cap 8 Battery band 2 - 38...
  • Page 63 SPEC CABLE ROUTING 1 Diode B Pick up coil lead coupler 2 Ignitor unit C Ground lead coupler 3 Ignition coil lead coupler D Side stand switch lead coupler 4 Starter relay E Rectifier/regulator lead coupler 5 Battery negative lead F Oil level switch lead 6 Ignition coil G Neutral switch lead...
  • Page 64 SPEC CABLE ROUTING L Fuse box È To the conduit. M Meter lead coupler É Fasten the wire harness with a plastic locking N Handlebar switch lead coupler tie. Ê Clamp the taillight lead and rear flasher light lead (right). Ë...
  • Page 66 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 SEATS AND SIDE COVERS ................3-3 TOP COVER AND COVERS ................3-4 AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD ....3-5 ENGINE ......................3-6 ADJUSTING THE VALVE CLEARANCE ..........3-6 SYNCHRONIZING THE CARBURETORS ..........
  • Page 67 CHASSIS ...................... 3-32 ADJUSTING THE FRONT BRAKE ............3-32 ADJUSTING THE REAR BRAKE ............3-33 CHECKING THE BRAKE FLUID LEVEL ..........3-34 CHECKING THE BRAKE PADS ............3-35 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-35 CHECKING THE BRAKE HOSES ............3-36 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........3-36 ADJUSTING THE SHIFT PEDAL ............

  • Page 68: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 69 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Make sure that all nuts, bolts and screws are √ √ √ √ √ 16 * Chassis fasteners properly tightened. Sidestand/center- • Check operation. √...

  • Page 70: 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 Tool cover Tool band Tool kit Passenger seat Side covers (left and right) For installation, reverse the removal pro- cedure.

  • Page 71: Top Cover And Covers

    TOP COVER AND COVERS TOP COVER AND COVERS Order Job/Part Q’ty Remarks Removing the top cover and covers Remove the parts in the order listed. Top cover Covers (left and right) For installation, reverse the removal pro- cedure. 3 - 4...

  • Page 72: Air Filter Case And Electrical Components Board

    AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD Order Job/Part Q’ty Remarks Removing the air filter case and Remove the parts in the order listed. electrical components board Top cover and covers Refer to “TOP COVER AND COVERS”. Fuel pump control unit Disconnect.

  • Page 73: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00044 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 74 ADJUSTING THE VALVE CLEARANCE 8. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.15 mm Exhaust valve 0.26 ~ 0.30 mm a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a with the stationary pointer b.
  • Page 75 ADJUSTING THE VALVE CLEARANCE 9. Adjust: • valve clearance a. Align the intake and exhaust valve lifter slots with each other. b. Install the tappet adjusting tool 1 between the camshaft and the valve lifter. Tappet adjusting tool 90890-04105 NOTE: Make sure the tappet adjusting tool touches only the valve lifter 2, not the valve pad 3.
  • Page 76 ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 0.00 ~ 0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 0.06 ~ 0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 0.11 ~ 0.15...
  • Page 77 ADJUSTING THE VALVE CLEARANCE f. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm) Rounded value = 250 g. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table.

  • Page 78: Synchronizing The Carburetors

    SYNCHRONIZING THE CARBURETORS EAS00050 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
  • Page 79 SYNCHRONIZING THE CARBURETORS 6. Adjust: • carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.

  • Page 80: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00053 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 com- pression.

  • Page 81: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00057 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor syn- chronization should be adjusted properly. 1. Check: • throttle cable free play a Out of specification →...

  • Page 82: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS c. Tighten the locknut. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

  • Page 83: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 7. Install: • spark plug 18 Nm (1.8 m · kg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug cap EAS00064 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition sys-...

  • Page 84: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Check that the stationary pointer a is within the firing range b on the generator rotor. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable. 4.
  • Page 85 MEASURING THE COMPRESSION PRESSURE Compression pressure (at sea level) Minimum 1,200 kPa (12 kg/cm , 12 bar) Standard 1,400 kPa (14 kg/cm , 14 bar) Maximum 1,600 kPa (16 kg/cm , 16 bar) a. Set the main switch to “ON”. b.

  • Page 86: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 87: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00074 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: • engine oil filler cap 1 •...

  • Page 88: Measuring The Engine Oil Pressure

    CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount 4.0 L Without filter cartridge replacement 3.2 L With oil filter cartridge replace- ment 3.4 L 9.
  • Page 89 MEASURING THE ENGINE OIL PRESSURE 3. Remove: • main gallery bolt WARNING The engine, muffler and engine oil are extremely hot. 4. Install: • pressure gauge 1 • oil pressure adapter B 2 Pressure gauge 90890-03153 Oil pressure adapter B 90890-03124 5.

  • Page 90: Checking The Clutch Fluid Level

    CHECKING THE CLUTCH FLUID LEVEL EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Check: • clutch fluid level Below the minimum level mark 1 → Add the recommended clutch fluid to the proper level.

  • Page 91: Bleeding The Hydraulic Clutch System

    BLEEDING THE HYDRAULIC CLUTCH SYSTEM EAS00085 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING Bleed the hydraulic clutch system when- ever: • the system was disassembled, • a clutch hose was loosened or removed, • the clutch fluid level is very low, •...

  • Page 92: Cleaning The Air Filter Element

    BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the clutch fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m •...

  • Page 93: Checking The Carburetor Joints

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINTS/ CHECKING THE VACUUM HOSES NOTE: When installing the air filter element into the air filter case cover, make sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install: •...

  • Page 94: Checking The Fuel Hoses And Fuel Filter

    CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”. 2.

  • Page 95: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM/ CHECKING THE COOLANT LEVEL EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes, mufflers and gaskets. 1. Check: • exhaust pipe 1 • muffler 2 Cracks/damage → Replace. • gasket 3 Exhaust gas leaks →...

  • Page 96: Checking The Cooling System

    CHECKING THE COOLANT LEVEL/CHECKING THE COOLING SYSTEM/CHANGING THE COOLANT 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles. 6.

  • Page 97: Changing The Coolant

    CHANGING THE COOLANT Place a thick rag or a towel over the radia- tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
  • Page 98 CHANGING THE COOLANT Handling notes for coolant Coolant is potentially harmful and should be handled with special care. WARNING • If coolant splashes in your eyes, thor- oughly wash them with water and consult a doctor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

  • Page 99: Chassis

    ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm 2. Adjust: •...

  • Page 100: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 20 mm 2.

  • Page 101: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. •...

  • Page 102: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00119 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad • rear brake pad Wear indicators 1 almost touch the brake disc →...

  • Page 103: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose 1 Cracks/damage/wear → Replace. 2. Check: • brake hose clamp Loose →...
  • Page 104 BLEEDING THE HYDRAULIC BRAKE SYSTEM È 1. Bleed: • hydraulic brake system a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2.

  • Page 105: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ CHECKING THE FINAL DRIVE OIL LEVEL EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Check: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 30 ~ 34 mm 2.

  • Page 106: Changing The Final Drive Oil

    CHECKING THE FINAL DRIVE OIL LEVEL/ CHANGING THE FINAL DRIVE OIL 2. Remove: • final drive housing oil filler bolt 1 3. Check: • final drive oil level The final drive oil level should be to the bot- tom brim 2 of the filler hole. Below the top brim →...

  • Page 107: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 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 108 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 3.0 Nm (0.3 m • kg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.

  • Page 109: Checking The Front Fork

    CHECKING THE FRONT FORK/ ADJUSTING THE FRONT FORK LEGS EAS00150 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Check: • inner tube Damage/scratches →...
  • Page 110 ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3. Regulate: • air pressure a. Check the front fork leg air pressure with an air pressure gauge 1. Spring preload Supplying air increased (suspension is harder). Spring preload Releasing air decreased (suspension is softer).

  • Page 111: Adjusting The Rear Shock Absorber Assemblies

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES Spring preload CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • spring preload a. Insert a screwdriver into the hole 1 in the spring seat. b. Turn the spring seat 2 in direction a or b. Spring preload Direction a...

  • Page 112: Checking The Tires

    CHECKING THE TIRES EAS00164 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: • tire pressure Out of specification → Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 113 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.

  • Page 114: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Manufacturer Model Size 110/90 METZELER ME33 V18 (61V) Rear tire Manufacturer Model Size 150/90B- METZELER 15MC (74V) WARNING • New tires have a relatively low grip on the road surface until they have been slightly worn.

  • Page 115: Checking And Lubricating The Cables

    CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.

  • Page 116: Lubricating The Sidestand

    LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND/ LUBRICATING THE REAR SUSPENSION EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium soap base grease EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.

  • Page 117: Chk Adj

    CHECKING THE BATTERY EAS00176 ELECTRICAL SYSTEM CHECKING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 118 CHECKING THE BATTERY 4. Check: • electrolyte level The electrolyte level should be between the minimum level mark 1 and the maximum level mark 2. Below the minimum level mark → Add dis- tilled water to the proper level. CAUTION: Add only distilled water.
  • Page 119 CHECKING THE BATTERY • To reduce the chance of sparks, do not plug in the battery charger until the bat- tery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
  • Page 120 CHECKING THE BATTERY CAUTION: • When checking the battery, make sure the battery breather hose is properly installed and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the bat- tery to contact the frame, the motorcycle and its finish may be damaged.

  • Page 121: Checking The Fuses

    CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”.

  • Page 122: Replacing The Headlight Bulb

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB Amperage Items Q’ty rating Main fuse 30 A Headlight fuse 15 A Signaling system 10 A fuse Ignition fuse 10 A Radiator fan motor 10 A fuse Reserve fuse 30 A Reserve fuse 15 A Reserve fuse 10 A...
  • Page 123 REPLACING THE HEADLIGHT BULB 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4. Detach: • headlight bulb holder 1 5. Remove: • headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 124: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Headlight beam Direction a raised. Headlight beam is low- Direction b ered. 2. Adjust: • headlight beam (horizontally) a.
  • Page 127 CHAPTER 4 ENGINE ENGINE REMOVAL ..................4-1 EXHAUST PIPE, MUFFLER AND AIR BAFFLE PLATES .......4-1 BRAKE PEDAL, FOOTLEST (RIGHT), MASTER CYLINDER AND GROUND LEAD ................4-2 LEADS, CABLES AND HOSES ............... 4-3 ENGINE MOUNTING BOLTS ..............4-4 INSTALLING THE ENGINE ..............4-6 CAMSHAFT ....................4-7 CYLINDER HEAD COVERS ..............
  • Page 128 SHIFT SHAFT ....................4-42 GENERATOR ROTOR COVER ............. 4-42 SHIFT SHAFT AND STOPPER LEVER ..........4-43 CHECKING THE SHIFT SHAFT ............4-44 CHECKING THE STOPPER LEVER .............4-44 INSTALLING THE SHIFT SHAFT ............4-44 GENERATOR ....................4-46 STATOR COIL ASSEMBLY ..............4-46 GENERATOR ..................4-48 REMOVING THE GENERATOR ............
  • Page 129 MIDDLE GEAR ..................... 4-92 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....4-94 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY ....4-94 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY ......4-95 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY ......4-96 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....4-96 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY ....

  • Page 131: Engine Removal

    ENGINE REMOVAL ENGINE ENGINE REMOVAL EXHAUST PIPES, MUFFLER AND AIR BAFFLE PLATES Order Job/Part Q’ty Remarks Removing the exhaust pipes, muf- Remove the parts in the order listed. fler and air baffle plates Carburetors Refer to “REMOVING THE CARBURE- TOR” in chapter 6. Radiator Refer to “REMOVING THE RADIATOR”...

  • Page 132: Brake Pedal, Footlest (Right), Master Cylinder And Ground Lead

    ENGINE REMOVAL BRAKE PEDAL, FOOTREST (RIGHT), MASTER CYLINDER AND GROUND LEAD Order Job/Part Q’ty Remarks Removing the brake pedal, footrest Remove the parts in the order listed. (right), master cylinder and ground lead Brake pedal Footrest (right) Rear brake hose Disconnect.

  • Page 133: Leads, Cables And Hoses

    ENGINE REMOVAL LEADS, CABLES AND HOSES Order Job/Part Q’ty Remarks Removing the leads, cables and Remove the parts in the order listed. hoses Spark plug leads Disconnect. Vacuum hose Disconnect. Horn lead Disconnect. Starter lead (starter motor) Disconnect. Plastic locking tie Plastic band Starter lead (starter relay) Disconnect.

  • Page 134: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS 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. WARNING Securely support the motorcycle so there is no danger of it falling over. Bolts (front-lower) Bolts (engine bracket) Engine bracket...
  • Page 135 ENGINE REMOVAL Order Job/Part Q’ty Remarks Down tube (right side) Bolts (engine stay) Engine stay Engine assembly NOTE: Remove the engine assembly from the right side of the motorcycle. For installation, reverse the removal pro- cedure. 4 - 5...

  • Page 136: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine stay 1 • bolt (engine stay) 2 16 Nm (1.6 m · kg) • down tube (right) 3 • bolt (down tube) 4 45 Nm (4.5 m · kg) • bolt (rear) 5 70 Nm (7.0 m ·...

  • Page 137: Camshaft

    CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVERS Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over. Top cover and covers Refer to “TOP COVER AND COVERS”...
  • Page 138 CAMSHAFTS Order Job/Part Q’ty Remarks Spark plug cap Disconnect. Coolant hoses (to cylinder head) Disconnect. Spark plugs Cylinder head covers bolts Cylinder head covers Cylinder head covers gaskets For installation, reverse the removal pro- cedure. 4 - 8...

  • Page 139: Camshafts

    CAMSHAFTS EAS00196 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Cylinder head covers Refer to “CYLINDER HEAD COVERS”. Crankcase cover plate Timing plug Tensioners cap bolts Timing chain tensioners Gaskets Timing chain guides Refer to “Rear cylinder”.

  • Page 140: Removing The Camshafts

    CAMSHAFTS EAS00199 REMOVING THE CAMSHAFTS 1. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 2. Align: • “T1” mark on the flywheel (with the stationary pointer on the crank- case cover) a. Turn the crankshaft counterclockwise. b.

  • Page 141: Checking The Camshafts

    CAMSHAFTS 7. Remove: • timing chain guide (exhaust side) • camshaft caps 1 • dowel pins NOTE: For reference during installation, put identifica- tion marks on each camshaft cap. CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
  • Page 142 CAMSHAFTS 3. Measure: • camshaft runout Out of specification → Replace. Camshaft runout limit 0.03 mm 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of specification → Measure the cam- shaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.020 ~ 0.054 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).

  • Page 143: Checking The Timing Chain, Camshaft Sprockets

    CAMSHAFTS EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprockets as a set. 2.

  • Page 144: Installing The Camshafts

    CAMSHAFTS EAS00218 INSTALLING THE CAMSHAFTS 1. Align: • “T1” marks on the flywheel (with the stationary pointer on the crank- case cover) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T1” marks 1 on the generator rotor with the stationary pointer CAUTION: Do not turn the crankshaft when installing...
  • Page 145 CAMSHAFTS b. First, install the exhaust camshaft, and then the intake camshaft. NOTE: • Be sure to install the camshafts in the correct place as shown. “IN” mark = intake camshaft “EX” mark = exhaust camshaft • Make sure the timing marks 6 (o: small hole) in the camshaft face up.
  • Page 146 CAMSHAFTS CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Camshaft cap bolt 10 Nm (1.0 m • kg) g. Lubricate the camshaft bearing surfaces, camshaft lobes, and camshaft journals with engine oil.
  • Page 147 CAMSHAFTS g. Turn the exhaust camshaft so that the mark (o: small hole) on the camshaft is aligned with the mark on the camshaft cap. h. To remove the timing chain slack, force the exhaust camshaft clockwise. i. Insert your finger into the timing chain ten- sioner hole and push the timing chain guide (intake side) in.
  • Page 148 CAMSHAFTS 5. Check: • TDC mark a Make sure the TDC mark on the generator rotor is aligned with the stationary pointer • camshaft timing punch mark c (o: small hole) Make sure the punch marks in the cam- shafts are aligned with the marks d on the camshaft caps.
  • Page 149 CAMSHAFTS 1. Install: • exhaust camshaft • intake camshaft a. From the “T1” marks, turn the crankshaft counterclockwise 430° (i.e., 360° plus an additional 70°). b. When piston #2 is at TDC on the compres- sion stroke, align the “T2” mark a with the stationary pointer b.
  • Page 150 CAMSHAFTS 4. Install: • timing mark accessing screw 1 • crankshaft end cover 2 7 Nm (0.7 m · kg) 4 - 20...

  • Page 151: Cylinder Heads

    CYLINDER HEADS CYLINDER HEADS Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head covers Refer to “CYLINDER HEAD COVERS”. Camshafts Refer to “CAMSHAFTS”. Intake manifold Lock pins Water jacket joints Oil delivery pipes Cylinder heads...

  • Page 152: Checking The Cylinder Heads

    CYLINDER HEADS EAS00223 REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 153: Installing The Cylinder Head

    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. EAS00233 INSTALLING THE CYLINDER HEAD 1.

  • Page 154: 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 Engine assembly Refer to “ENGINE REMOVAL”. Camshafts Refer to “CAMSHAFTS”. Cylinder heads Refer to “CYLINDER HEADS”. Valve pads Valve lifters Valve cotters...

  • Page 155: 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 156: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • spring retainer 1 • inner valve springs 2 • outer valve springs 3 • valve 4 • spring seat 5 • oil seal 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 157 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C in an oven. a. Remove the valve guide with the valve guide remover 1.

  • Page 158: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm EAS00240...
  • Page 159 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. 4. Lap: • valve face • 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 160: 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 valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 161: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Spring tilt limit Intake and exhaust inner valve spring 1.7 mm Intake and exhaust outer valve spring 1.8 mm EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters.
  • Page 162 VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and attachment 3. Valve spring compressor 90890-04019 Attachment 90890-04114 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 163: Clutch

    CLUTCH CLUTCH CRANKCASE COVER (RIGHT SIDE) Order Job/Part Q’ty Remarks Removing the crankcase (right side) Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over. Engine oil Refer to “CHANGING THE ENGINE OIL”...

  • Page 164: Clutch Assembly

    CLUTCH CLUTCH ASSEMBLY Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Short clutch push rod O-ring Ball Friction plates Clutch plates Lock washer Clutch boss Wire circlip...
  • Page 165 CLUTCH Order Job/Part Q’ty Remarks Clutch plate Friction plate Clutch damper spring Clutch damper spring seat Thrust washer Clutch housing Long clutch push rod Circlip Oil pump drive gear Dowel pins For installation, reverse the removal pro- cedure. 4 - 35...

  • Page 166: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1 NOTE: While holding the clutch boss 2 with the uni- versal clutch holder 3, loosen the clutch boss nut. Clutch holding tool 90890-04086 3.

  • Page 167: Checking The Clutch Plates

    CLUTCH NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 ~ 3.1 mm <Limit>: 2.8 mm EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set.

  • Page 168: Checking The Clutch Housing

    CLUTCH EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: • bearing Damage/wear →...

  • Page 169: Checking The Clutch Push Rods

    CLUTCH EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: • O-ring 1 • short clutch push rod 2 • long clutch push rod 3 • ball 4 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • long clutch push rod bending limit Out of specification →...
  • Page 170 CLUTCH 2. Install: • clutch boss assembly 1 NOTE: • If the wire circlip 2 has been removed, care- fully install a new one as shown. • Install the clutch spring plate 3 with the “OUTSIDE” mark facing out. 3. Install: •...
  • Page 171 CLUTCH 7. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • friction plates • clutch plates NOTE: • First, install a friction plate and then alternate between a clutch plate and a friction plate. •...

  • Page 172: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT GENERATOR ROTOR COVER Order Job/Part Q’ty Remarks Removing the generator rotor cover Remove the parts in the order listed. Engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. Shift pedal Middle gear case cover NOTE: Loosen the bolts in stages and in a criss- cross pattern.

  • Page 173: Shift Shaft And Stopper Lever

    SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER Order Job/Part Q’ty Remarks Removing the shift shaft and stop- Remove the parts in the order listed. per lever Clutch assembly Refer to “CLUTCH”. Shift shaft assembly Circlip Washer Torsion spring Stopper lever Return spring For installation, reverse the removal pro- cedure.

  • Page 174: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift lever 2 Bends/damage/wear → Replace. • shift lever spring 3 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly →...
  • Page 175 SHIFT SHAFT 3. Install: • shift shaft 1 NOTE: • Lubricate the oil seal lips with lithium soap base grease. • Hook the end of the shift shaft spring onto the shift shaft spring stopper 2. 4. Install: • clutch •...

  • Page 176: Generator

    GENERATOR GENERATOR STATOR COIL ASSEMBLY Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. Muffler and exhaust pipes Refer to “ENGINE REMOVAL”. Thermostat assembly Refer to “THERMOSTAT ASSEMBLY AND CONDUIT”...
  • Page 177 GENERATOR Order Job/Part Q’ty Remarks Plate (stator coil) Stator coil assembly For installation, reverse the removal pro- cedure. 4 - 47...

  • Page 178: Generator

    GENERATOR GENERATOR Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Starter clutch idle gear shaft Starter clutch idle gear Generator rotor Woodruff key Starter clutch gear Starter motor lead Disconnect. Starter motor For installation, reverse the removal pro- cedure.

  • Page 179: Removing The Generator

    GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: • generator rotor bolt 1 • washer NOTE: • While holding the generator rotor 2 with the sheave holder 3, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the projection on the generator rotor.

  • Page 180: Checking The Starter Clutch

    GENERATOR EAS00350 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 Damage/wear → Replace. • starter clutch spring cap 2 • starter clutch spring 3 2. Check: • starter clutch idle gear 1 • starter clutch gear 2 Burrs/chips/roughness/wear →...

  • Page 181: Installing The Generator

    GENERATOR EAS00354 INSTALLING THE GENERATOR 1. Install: • starter clutch gear 1 • woodruff key 2 • generator rotor 3 • pin 4 • washer 5 • generator rotor bolt 6 NOTE: • Clean the tapered portion of the crankshaft and the generator rotor hub.

  • Page 182: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Muffler and exhaust pipes Refer to “ENGINE REMOVAL”.
  • Page 183 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Bracket tabs Straighten. Oil pipe Oil gallery pipe Oil filter For installation, reverse the removal pro- cedure. 4 - 53...

  • Page 184: Oil Pump

    OIL PAN AND OIL PUMP OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Oil pan and oil pump assembly Refer to “OIL PAN AND OIL PUMP”.
  • Page 185 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Dowel pins Oil pump housing cover 1 Inner rotor 2 Outer rotor 2 Oil pump shaft Oil pump housing cover 2 Dowel pin Oil pump housing For assembly, reverse the disassembly procedure.

  • Page 186: Removing The Oil Pan

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins 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.

  • Page 187: Checking The Relief Valve

    OIL PAN AND OIL PUMP 3. Check: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: • relief valve 1 • spring 2 Damage/wear → Replace the defective part(s).

  • Page 188: Assembling The Oil Pump

    OIL PAN AND OIL PUMP ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor 1 • outer rotor 1 • inner rotor 2 • outer rotor 2 • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: •...

  • Page 189: Installing The Oil Pan

    OIL PAN AND OIL PUMP NOTE: • When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor. • The arrow a on the gear housing faces toward the front of the engine. 3.
  • Page 190 CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEAD COVERS”. Water pump Refer to “WATER PUMP” in chapter 5. Clutch assembly Refer to “CLUTCH ASSEMBLY”.
  • Page 191 CRANKCASE Order Job/Part Q’ty Remarks Retainer (main axle bearing) Retainers (middle gear bearing) Middle driven gear assembly Shims Crankcase (upper) Refer to “SEPARATING THE CRANK- CASE”. Crankcase (lower) For installation, reverse the removal pro- cedure. 4 - 61...

  • Page 192: Crankcase

    CRANKCASE Order Job/Part Q’ty Remarks Disassembling the crankcase Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Crankcase separation Refer to “CRANKCASE”. Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Crankcase breather cover Crankcase breather spacer Rubber gaskets Oil pipe Drain plugs (cylinders)

  • Page 193: Separating The Crankcase

    CRANKCASE È SEPARATING THE CRANKCASE 1. Remove: • crankcase bolts 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. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustra- tion).

  • Page 194: Assembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 ~ 3 mm of the crankshaft journal bearings.
  • Page 195 CRANKCASE 5. Install: • middle driven shaft bearing housing bolts 30 Nm (3.0 m · kg) NOTE: The bolt with the washer goes in the lower right hole a of the middle driven shaft bearing housing. 6. Tighten: È • upper crankcase bolts •...
  • Page 196 CRANKCASE 7. Install: • middle driven shaft bearing housing retain- ers 1 25 Nm (2.5 m · kg) • main axle bearing retainer 2 7 Nm (0.7 m · kg) WARNING Always use new screws. NOTE: ® Apply LOCTITE to the middle gear and main bearing retainer screws.

  • Page 197: Crankshaft

    CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Crankcase separation Refer to “CRANKCASE”. Crankshaft Timing chains Main journal bearings Balancer shaft Main journal bearings For installation, reverse the removal pro- cedure.

  • Page 198: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft assembly • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00396 CHECKING THE CRANKSHAFT 1.
  • Page 199 CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings and the crankshaft into the upper crank- case. NOTE: Align the projections a of the crankshaft jour- nal upper bearings with the notches b in the...
  • Page 200 CRANKSHAFT 4. Select: • crankshaft journal bearings (J NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J ” refer to the bearings shown in the crankshaft illustration.

  • Page 201: Checking The Balancer Shaft

    CRANKSHAFT CHECKING THE BALANCER SHAFT 1. Measure: • balancer shaft-journal-to-balancer shaft- journal-bearing clearance Out of specification → Replace the balancer shaft journal bearings. balancer shaft-journal-to-bal- ancer shaft-journal-bearing clear- ance 0.020 ~ 0.048 mm MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CAUTION: Do not interchange the balancer shaft jour- nal bearings.
  • Page 202 CRANKSHAFT NOTE: • Align the projections of the balancer shaft journal lower bearings with the notches in the lower crankcase. • Do not move the crankshaft until the clear- ance measurement has been completed. f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase.
  • Page 203 CRANKSHAFT Bearing size of J “J ” (crankcase) – “J ” (balancer shaft web) 6 – 2 = 4 (green) BEARING COLOR CODE blue black brown green yellow pink NOTE: If the size is the same for all “J and J ”, one digit for that size is indicated.

  • Page 204: Installing The Balancer Shaft

    CRANKSHAFT 2. Install: • timing chain 1 (onto the crankshaft sprocket) • crankshaft assembly 2 NOTE: • Pass the timing chain through the timing chain cavity. • To prevent the timing chain from falling into the crankcase, fasten it with a wire. EAS00410 INSTALLING THE BALANCER SHAFT 1.

  • Page 205: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS Order Job/Part Q’ty Remarks Removing the connecting rod and Remove the parts in the order listed. piston Engine assembly Refer to “ENGINE REMOVAL”. Cylinder heads Refer to “CYLINDER HEAD COVERS”. Oil pan and oil pump assembly Refer to “OIL PAN AND OIL PUMP”.

  • Page 206: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 207: Checking The Cylinders And Pistons

    CONNECTING RODS AND PISTONS EAS00255 CHECKING THE CYLINDERS AND PISTONS 1. Check: • piston wall • cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance a.

  • Page 208: Checking The Piston Rings

    CONNECTING RODS AND PISTONS d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.055 ~ 0.075 mm <Limit>: 0.15 mm f.

  • Page 209: Checking The Piston Pins

    CONNECTING RODS AND PISTONS 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.35 ~ 0.50 mm...
  • Page 210 CONNECTING RODS AND PISTONS 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 18.991 ~ 19.000 mm 3. Calculate: • piston-pin-to-piston clearance Out of specification → Replace the piston pin.
  • Page 211 CONNECTING RODS AND PISTONS NOTE: Align the projections a on the big end bear- ings with the notches b in the connecting rod and connecting rod cap. ® c. Put a piece of Plastigauge on the crank- shaft pin. d. Assemble the connecting rod halves. NOTE: •...

  • Page 212: Installing The Pistons And Cylinders

    CONNECTING RODS AND PISTONS 5. Select: • big end bearings (P NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. • “P ”...
  • Page 213 CONNECTING RODS AND PISTONS 2. Position: • top ring • 2nd ring • oil ring Offset the piston ring end gaps as shown. a Top ring end b Lower oil ring end c Upper oil ring end d 2nd ring end 3.
  • Page 214 CONNECTING RODS AND PISTONS 6. Attach: • piston ring compressors 1 Piston ring compressor 90890-05158 7. Install: • connecting rod and piston assembly NOTE: • The stamped “Y” mark 2 on the No. 2 and No. 4 connecting rods should face towards È...

  • Page 215: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Drive axle assembly Main axle assembly Push rod bearing Oil seal Bearing stoppers Shift fork guide bars Shift forks Neutral switch Shift drum retainer Shift drum...
  • Page 216 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the transmission Remove the parts in the order listed. Middle drive pinion gear assembly Refer to “MIDDLE GEAR”. Bearing Shim 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle Plug 2nd wheel gear Washer Circlip...
  • Page 217 TRANSMISSION Order Job/Part Q’ty Remarks 5th wheel gear Bearing Circlip Bearing Main axle 4th pinion gear Washer Circlip 2nd, 3rd pinion gear 5th pinion gear Washer Circlip Bearing For assembly, reverse the disassembly procedure. 4 - 87...

  • Page 218: Checking The Shift Forks

    TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface.

  • Page 219: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge 1) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm 2. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification →...

  • Page 220: Installing The Transmission

    TRANSMISSION EAS00430 INSTALLING THE TRANSMISSION 1. Install: • shift drum assembly 1 • shift drum retainer 2 7 Nm (0.7 m · kg) NOTE: ® • Apply LOCTITE #648 to the shift drum retainer screws. • Turn the shift drum assembly to the neutral position.
  • Page 221 TRANSMISSION 5. Install: • bearing stoppers 1 NOTE: Insert the bearing stoppers completely into the grooves in the lower crankcase. 6. Lubricate: • oil seal lips (with a thin coat of the recommended lubri- cant) Recommended lubricant Lithium soap base grease 7.
  • Page 222 MIDDLE GEAR MIDDLE GEAR Order Job/Part Q’ty Remarks Removing the middle gear Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Drive axle assembly Refer to “TRANSMISSION”. Washer Universal joint (yoke) Dust seal Middle driven shaft bearing housing Shims O-ring Bearing...
  • Page 223 MIDDLE GEAR Order Job/Part Q’ty Remarks Middle driven shaft Retainer Thrust washer Middle drive pinion gear Damper cam Damper spring Spring seat Bearing Bearing For installation, reverse the removal pro- cedure. 4 - 93...

  • Page 224: Disassembling The Middle Drive Shaft Assembly

    MIDDLE GEAR EAS00435 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • spring retainers NOTE: While holding the spring with the middle drive gear holder 1, compress the spring with the damper spring compressor 2, and then remove the spring retainers. Middle gear backlash tool 90890-04080 Damper spring compressor...

  • Page 225: Checking The Middle Drive Shaft Assembly

    MIDDLE GEAR 1. Remove: • universal joint a. Remove the circlips 1. b. Place the universal joint in a press. c. With a pipe of the proper diameter posi- tioned beneath the universal joint driven yoke as shown, press the bearing into the pipe.

  • Page 226: Checking The Middle Driven Shaft Assembly

    MIDDLE GEAR EAS00439 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • middle driven gear Galling/pitting/wear → Replace the middle driven shaft assembly. 2. Check: • bearings Damage/pitting → Replace the middle drive shaft bearing housing assembly. 3. Check: • O-ring •...

  • Page 227: Assembling The Middle Driven Shaft Assembly

    MIDDLE GEAR 3. Measure: • drive axle assembly length a Out of specification → Add shim 1. Drive axle assembly length 253.81 ~ 254.37 mm Length a Shim thickness 252.66 ~ 253.00 mm 1.3 mm 253.01 ~ 253.40 mm 0.9 mm 253.41 ~ 253.80 mm 0.5 mm EAS00443...
  • Page 228 MIDDLE GEAR 2. Tighten: • middle driven shaft nut 90 Nm (9.0 m · kg) While holding the universal joint driven yoke with the universal joint holder, tighten the middle driven shaft nut. Universal joint holder 90890-04062 CAUTION: Tighten the middle driven shaft nut in small increments, checking the torque it takes to keep the middle driven gear turning in the middle driven shaft bearing housing - not...

  • Page 229: Installing The Middle Gear

    MIDDLE GEAR 4. Install: • universal joint driven yoke/cross joint (into the universal joint drive yoke) CAUTION: Do not hammer the universal joint drive yoke or the collapsible collar may be dis- torted. This will result in a change in the standard spinning torque,...

  • Page 230: Adjusting The Middle Gear Backlash

    MIDDLE GEAR 2. Tighten: • crankcase bolts 24 Nm (2.4 m · kg) • middle driven shaft housing bolts 30 Nm (3.0 m · kg) NOTE: Before tightening the bolts: 1. Adjust the middle gear backlash. Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH”.
  • Page 231 MIDDLE GEAR 2. Loosen: • middle driven shaft bearing housing bolts 3. Remove: • shim(s) 4. Tighten: • middle driven shaft bearing housing bolts CAUTION: Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too little middle gear backlash, and damage the middle gears and collapsible collar.
  • Page 232 MIDDLE GEAR 6. Turn: • universal joint drive yoke NOTE: While carefully tightening the middle driven shaft bearing housing bolts in stages and in a crisscross pattern, turn the universal joint drive yoke back and forth until the dial gauge reads 0.05 ~ 0.12 mm.

  • Page 233: Aligning The Middle Gear

    MIDDLE GEAR 9. Loosen: • middle driven shaft bearing housing bolts 10.Install: • shim(s) 11.Tighten: • middle driven shaft bearing housing bolts 30 Nm (3.0 m · kg) NOTE: Before tightening the middle driven shaft bear- ing housing bolts, make sure the arrow on the middle driven shaft bearing housing points towards the upper crankcase.
  • Page 234 MIDDLE GEAR b. To find drive pinion gear shim thickness “T”, use the following formula: Drive pinion gear shim thickness T = A – B Where: A = 54.5 + (constant number) B = 53 + (a/100) a = a numeral stamped on the left-side of the upper crankcase, divided by 100.
  • Page 235 MIDDLE GEAR Since the shims are only available in 0.10- or 0.15-mm increments, round off the hun- dredths’ digit. Hundredth’s digit Rounded value 0, 1, 2 3, 4, 5, 6 7, 8, 9 In the example above, the calculated drive pin- ion gear shim thickness is 0.54 mm.

  • Page 237: Cool

    COOL...
  • Page 238 COOL CHAPTER 5 COOLING SYSTEM RADIATOR AND RADIATOR HOSES ............5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR ..............5-3 THERMOSTAT ASSEMBLY AND CONDUIT ..........5-4 CHECKING THE THERMOSTAT ............. 5-8 CHECKING THE RADIATOR CAP ............5-9 ASSEMBLING THE THERMOSTAT ASSEMBLY ........5-9 INSTALLING THE THERMOSTAT ASSEMBLY ........
  • Page 239 COOL...

  • Page 240: Cooling System

    COOL RADIATOR AND RADIATOR HOSES EAS00454 COOLING SYSTEM RADIATOR AND RADIATOR HOSES Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Top cover and covers Refer to “TOP COVER AND COVERS” in chapter 3. Coolant Drain.
  • Page 241 COOL RADIATOR AND RADIATOR HOSES Order Job/Part Q’ty Remarks Removing the radiator hoses Remove the parts in the order listed. Radiator inlet hose Coolant drain cock assembly hose Radiator outlet hose Thermostat assembly breather hose Conduit breather hose Conduit inlet hoses Coolant breather hose For installation, reverse the removal pro- cedure.

  • Page 242: Checking The Radiator

    COOL RADIATOR AND RADIATOR HOSES EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 243: Thermostat Assembly And Conduit

    COOL THERMOSTAT ASSEMBLY AND CONDUIT EAS00460 THERMOSTAT ASSEMBLY AND CONDUIT Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Top cover and covers Refer to “TOP COVER AND COVERS” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT”...
  • Page 244 COOL THERMOSTAT ASSEMBLY AND CONDUIT Order Job/Part Q’ty Remarks Spring O-ring For installation, reverse the removal pro- cedure. 5 - 5...
  • Page 245 COOL THERMOSTAT ASSEMBLY AND CONDUIT Order Job/Part Q’ty Remarks Disassembling the thermostat Remove the parts in the order listed. assembly Thermostat housing cover O-ring Thermostat Thermostat housing For assembly, reverse the disassembly procedure. 5 - 6...
  • Page 246 COOL THERMOSTAT ASSEMBLY AND CONDUIT Order Job/Part Q’ty Remarks Removing the conduit assembly Remove the parts in the order listed. Thermo switch coupler Disconnect. Temperature sender lead Disconnect. Ground lead Disconnect. Conduit Temperature sender Thermo switch O-ring Conduit board For installation, reverse the removal pro- cedure.

  • Page 247: Checking The Thermostat

    COOL THERMOSTAT ASSEMBLY AND CONDUIT EAS00463 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 80 ~ 84°C → Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.

  • Page 248: Checking The Radiator Cap

    COOL THERMOSTAT ASSEMBLY AND CONDUIT CHECKING THE RADIATOR CAP 1. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 75 ~ 105 kPa (0.75 ~ 1.05 kg/cm , 0.75 ~ 1.05 bar) a.

  • Page 249: Installing The Thermostat Assembly

    COOL THERMOSTAT ASSEMBLY AND CONDUIT EAS00467 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3.

  • Page 250: Water Pump

    COOL WATER PUMP EAS00468 WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless coolant level extremely low or the coolant contains engine oil.
  • Page 251 COOL WATER PUMP Order Job/Part Q’ty Remarks O-ring Gasket Dowel pins For installation, reverse the removal pro- cedure. 5 - 12...
  • Page 252 COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. Circlip Driven gear Gear stopper pin Circlip Impeller Bearing Oil seal Refer to “DISASSEMBLING THE Water pump seal WATER PUMP”. Rubber damper Rubber damper holder For assembly, reverse the disassembly procedure.

  • Page 253: Disassembling The Water Pump

    COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: • bearing 1 • oil seal 2 NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing. 2. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.
  • Page 254 COOL WATER PUMP 2. Check: • water pump seal 1 • oil seal 2 Cracks/damage/wear → Replace. 3. Check: • bearing Rough movement → Replace. 4. Check: • water pump driven gear Pitting/wear → Replace. 5. Check: • water pump inlet pipe Cracks/damage/wear →...

  • Page 255: Assembling The Water Pump

    COOL WATER PUMP EAS00476 ASSEMBLING THE WATER PUMP 1. Install: • rubber damper 1 • rubber damper holder 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 2. Measure: • impeller shaft tilt Out of specification →...

  • Page 256: Installing The Water Pump

    COOL WATER PUMP 4. Install: • oil seal • bearing 1 NOTE: • Install the oil seal and bearing from the inside of the water pump housing. • Make sure the side of the bearing with the number faces up. •...
  • Page 257 COOL WATER PUMP 2. Install: • O-ring • water pump housing cover 1 • O-rings • water pump inlet pipe 2 NOTE: Before installing the water pump outlet pipe 2, lubricate the O-rings with a thin coat of lithium soap base grease. Water pump housing cover bolt 10 Nm (1.0 m •...

  • Page 258: Carb

    CARB...
  • Page 259 CARB CHAPTER 6 CARBURETION CARBURETORS .................... 6-1 CHECKING THE CARBURETORS ............6-6 ASSEMBLING THE CARBURETORS .............6-8 INSTALLING THE CARBURETORS ............6-9 MEASURING AND ADJUSTING THE FUEL LEVEL ......6-10 CHECKING THE FUEL PUMP ...............6-11...
  • Page 260 CARB...
  • Page 261 CARB CARBURETORS CARBURETION CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Top cover and covers Refer to “TOP COVER AND COVERS” in chapter 3. Air filter case and electrical compo- Refer to “AIR FILTER CASE AND ELEC- nents board TRICAL COMPONENTS BOARD”...
  • Page 262 CARB CARBURETORS Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Fuel overflow hose Fuel feed joint Upper bracket (left) Upper bracket (right) Throttle stop screw bracket Throttle stop screw Throttle stop screw spring Lower bracket Side bracket (front) Side bracket (rear) Starter lever shaft...
  • Page 263 CARB CARBURETORS Order Job/Part Q’ty Remarks Synchronization screw Synchronization screw spring Synchronization rod Throttle cable Carburetor For installation, reverse the removal pro- cedure. 6 - 3...
  • Page 264 CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: The remaining steps should be followed for all four of the carburetors. Pilot air jet No. 1 Starter plunger assembly Starter body Gasket Coasting enricher cover Coasting enricher spring Coasting enricher...
  • Page 265 CARB CARBURETORS Order Job/Part Q’ty Remarks Needle jet screw Main jet Jet block Gasket Main bleed pipe Pilot jet Vacuum chamber cover Piston valve spring Pilot screw assembly Pilot air jet No. 2 Plastic screw Jet needle kit Piston valve Needle jet For assembly, reverse the disassembly procedure.
  • Page 266 CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. a. Wash the carburetor in a petroleum-based solvent.
  • Page 267 CARB CARBURETORS 8. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage → Replace. 9. Check: • jet needle kit 1 • needle jet 2 • main jet 3 •...
  • Page 268 CARB CARBURETORS EAS00488 ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. CAUTION: • Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent. • Always use a new gasket. 1. Install: • O-ring •...
  • Page 269 CARB CARBURETORS 4. Install: • coasting enricher 1 • coasting enricher spring • coasting enricher cover 2 NOTE: Align the tab a on the coasting enricher with the recess b in the carburetor body. EAS00493 INSTALLING THE CARBURETORS 1. Adjust: •...
  • Page 270 CARB CARBURETORS EAS00495 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (below the line on the vacuum chamber) 15 ~ 17 mm a. Stand the motorcycle on a level surface. b.
  • Page 271 CARB CARBURETORS EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump a. Remove the top cover and air filter case. Refer to “TOP COVER AND COVERS” and “AIR FILTER CASE AND ELECTRICAL COMPONENTS BOARD” in chapter 3. b. Disconnect the fuel hose (fuel pump to car- buretor) 1 from the carburetor.

  • Page 273: Chas

    CHAS...
  • Page 274 CHAS CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS ............7-1 REMOVING THE FRONT WHEEL ............7-4 DISASSEMBLING THE FRONT WHEEL ..........7-4 CHECKING THE FRONT WHEEL ............7-5 CHECKING THE BRAKE DISCS ............. 7-6 CHECKING THE SPEEDOMETER GEAR UNIT ........7-8 ASSEMBLING THE FRONT WHEEL ............7-8 INSTALLING THE FRONT WHEEL ............7-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......
  • Page 275 CHAS FRONT FORK ....................7-65 REMOVING THE FRONT FORK LEGS ..........7-68 DISASSEMBLING THE FRONT FORK LEGS ........7-69 CHECKING THE FRONT FORK LEGS ..........7-70 ASSEMBLING THE FRONT FORK LEGS ..........7-71 INSTALLING THE FRONT FORK LEGS ..........7-74 HANDLEBAR ....................7-75 REMOVING THE HANDLEBAR .............

  • Page 276: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Speedometer cable Brake hose holder (left and right) Brake caliper (left and right)
  • Page 277 CHAS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Speedometer gear unit Refer to “INSTALLING THE FRONT Collar WHEEL”. Brake disc (left and right) For installation, reverse the removal pro- cedure. 7 - 2...
  • Page 278 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) Refer to “DISASSEMBLING THE FRONT WHEEL” and “ASSEMBLING THE FRONT WHEEL”. Speedometer clutch retainer Speedometer clutch Wheel bearing (left and right) Refer to “DISASSEMBLING THE FRONT...

  • Page 279: Removing The Front Wheel

    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 280: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00525 CHECKING THE FRONT WHEEL 1. Check: • front wheel axle Roll the front wheel axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent front wheel axle. 2.

  • Page 281: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS 6. Replace: • wheel bearings • oil seals a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel sur- face.
  • Page 282 CHAS FRONT WHEEL AND BRAKE DISCS a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is sta- tionary.

  • Page 283: Checking The Speedometer Gear Unit

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: • speedometer clutch Bends/damage/wear → Replace. 2. Check: • speedometer gear unit Damage/wear → Replace. EAS00539 ASSEMBLING THE FRONT WHEEL 1. Install: • wheel bearings • oil seals a.

  • Page 284: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Install: • speedometer gear unit NOTE: Make sure the speedometer gear unit and the wheel hub are installed with the two projec- tions 1 meshed into the two slots 2 respec- tively. 4. Install: •...
  • Page 285 CHAS FRONT WHEEL AND BRAKE DISCS 1. Remove: • balancing weight(s) 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. a. Spin the front wheel. b. When the front wheel stops, put an “X” mark at the bottom of the wheel.
  • Page 286 CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: • front wheel static balance a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. 7 - 11...

  • Page 287: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. disc NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Brake caliper Wheel axle nut Refer to “REMOVING THE...
  • Page 288 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Dust cover Hub dust seal Circuit Clutch hub O-ring Damper Oil seal Circlip Bearing Flange spacer 7 - 13...
  • Page 289 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Spacer Collar Oil seal Bearing For assembly, reverse the disassembly procedure. 7 - 14...

  • Page 290: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00562 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 291: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “FRONT WHEEL AND BRAKE DISC”. 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES”...

  • Page 292: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.

  • Page 293: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES 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. Brake caliper bolt Brake hose holder bolt Brake pad cover Brake pad clip...
  • Page 294 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper bolt Brake pad cover Brake pad clip Refer to “REPLACING THE REAR Brake pad pin BRAKE PADS”. Brake pad spring Brake pad Brake pad shim (left and right)

  • Page 295: 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: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 296 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit a Out of specification →...

  • Page 297: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES d. Install a new brake pad shim onto the new brake pads. e. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. 6.
  • Page 298 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit a Out of specification →...
  • Page 299 CHAS FRONT AND REAR BRAKES d. Install a new brake pad shim 3 onto each new brake pad 4. NOTE: The arrow a on the brake pad shim must point in the direction of disc rotation. e. Install new brake pads and a new brake pad spring 5.
  • Page 300 CHAS FRONT AND REAR BRAKES 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 dia- phragm Brake lever Brake lever spring Front brake light switch connector Disconnect.
  • Page 301 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake master cylinder holder Refer to “ASSEMBLING AND INSTALL- Brake master cylinder ING THE FRONT BRAKE MASTER CYLINDER”. Front brake light switch For installation, reverse the removal pro- cedure. 7 - 26...
  • Page 302 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7 - 27...
  • Page 303 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Right side cover Refer to “SEATS AND SIDE COVERS” in chapter 3. Right rider footrest Refer to “ENGINE” in chapter 4. Brake fluid Drain.
  • Page 304 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake master cylinder For installation, reverse the removal pro- cedure. 7 - 29...
  • Page 305 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Hose joint Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 306: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...

  • Page 307: Checking The Front And Rear Brake

    CHAS FRONT AND REAR BRAKES È EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...

  • Page 308: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components.
  • Page 309 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 310: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER WARNING •...
  • Page 311 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • 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 performance.
  • Page 312 CHAS FRONT AND REAR BRAKES 5. Adjust: • brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in chapter 3. Brake pedal position (below the top of the rider footrest) 20 mm 6. Adjust: • rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”...
  • Page 313 CHAS FRONT AND REAR BRAKES EAS00615 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. Brake fluid Drain. Brake hose holder bolt Refer to “DISASSEM- Union bolt BLING THE FRONT...
  • Page 314 CHAS FRONT AND REAR BRAKES 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. Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim (left and right)
  • Page 315 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Refer “DISASSEM- BLING THE REAR BRAKE Copper washer CALIPER” and “ASSEM- Brake hose Disconnect. BLING AND INSTALLING Brake caliper bolt THE REAR BRAKE CALI-...
  • Page 316 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim (left and right) Brake caliper piston Refer to “DISASSEMBLING THE REAR Brake caliper piston seal...

  • Page 317: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake sys- tem. 1. Remove: • union bolt 1 •...

  • Page 318: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00629 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 319: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every years and whenever the Brake fluid brake is disassem- bled È...

  • Page 320: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 321 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 322: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 323 CHAS FRONT AND REAR BRAKES 2. Remove: • brake caliper 3. Install: • brake pads • brake pad spring • brake caliper 40 Nm (4.0 m · kg) Refer to “REPLACING THE REAR BRAKE PADS”. 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid...
  • Page 324 CHAS FRONT AND REAR BRAKES 6. Check: • 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” in chapter 3. 7. Check: • brake pedal operation Soft or spongy feeling →...

  • Page 325: Hydraulic Clutch

    CHAS HYDRAULIC CLUTCH EAS00305 HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Removing the clutch master cylinder Remove the parts in the order listed. Clutch fluid Drain. Rear view mirror Clutch master cylinder reservoir cap Clutch master cylinder reservoir dia- phragm Clutch lever Refer to “ASSEMBLING AND INSTALL- Clutch push rod holder ING THE CLUTCH MASTER CYLINDER”.
  • Page 326 CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Clutch master cylinder holder Refer to “ASSEMBLING AND INSTALL- ING THE CLUTCH MASTER CYLINDER”. Clutch master cylinder Clutch switch For installation, reverse the removal pro- cedure. 7 - 51...
  • Page 327 CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch master Remove the parts in the order listed. cylinder Clutch master cylinder push rod Dust boot Spring Circlip Washer Clutch master cylinder kit Clutch master cylinder For assembly, reverse the disassembly procedure.

  • Page 328: Disassembling The Clutch Master Cylinder

    CHAS HYDRAULIC CLUTCH EAS00307 CAUTION: Clutch components rarely require disas- sembly. Therefore, always follow these preventive measures: • Never disassemble clutch components unless absolutely necessary. • If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.

  • Page 329: Checking The Clutch Master Cylinder

    CHAS HYDRAULIC CLUTCH EAS00308 CHECKING THE CLUTCH MASTER CYLINDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every two years Every years and whenever the Clutch fluid clutch is disassem- bled 1. Check: • clutch master cylinder 1 Damage/scratches/wear →...

  • Page 330: Assembling And Installing The Clutch Master Cylinder

    CHAS HYDRAULIC CLUTCH EAS00309 ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER WARNING • Before installation, all internal clutch components should be cleaned and lubri- cated with clean or new clutch fluid. • Never use solvents on internal clutch components. Recommended clutch fluid Brake fluid DOT 4 1.
  • Page 331 CHAS HYDRAULIC CLUTCH NOTE: • While holding the clutch hose, tighten the union bolt as shown. • Turn the handlebar to the left and to the right to make sure the clutch hose does not touch other parts (e.g., wire harness, cables, leads).
  • Page 332 CHAS HYDRAULIC CLUTCH CAUTION: Clutch fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt clutch fluid immediately. 5. Bleed: • clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 6. Check: • clutch fluid level Below the minimum level mark a →...
  • Page 333 CHAS HYDRAULIC CLUTCH EAS00311 Order Job/Part Q’ty Remarks Removing the clutch release cylin- Remove the parts in the order listed. Engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. Middle gear case cover, shift pedal Refer to “SHIFT SHAFT” in chapter 4. assembly Clutch fluid Drain.
  • Page 334 CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Joint Refer to “ASSEMBLING AND INSTALL- Copper washer ING THE CLUTCH RELEASE CYLIN- DER”. Clutch release cylinder For installation, reverse the removal pro- cedure. 7 - 59...
  • Page 335 CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch release Remove the parts in the order listed. cylinder Oil seal Clutch release cylinder piston Refer to “DISASSEMBLING THE Spring CLUTCH RELEASE CYLINDER”. Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 336: Disassembling The Clutch Release Cylinder

    CHAS HYDRAULIC CLUTCH EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER NOTE: Before disassembling the clutch release cylin- der, drain the clutch fluid from the entire clutch system. 1. Remove: • union bolt 1 • copper washers • clutch hose 2 NOTE: Put the end of the clutch hose into a container and pump out the clutch fluid carefully.

  • Page 337: Checking The Clutch Release Cylinder

    CHAS HYDRAULIC CLUTCH EAS00314 CHECKING THE CLUTCH RELEASE CYLINDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every two years Every years and whenever the Clutch fluid clutch is disassem- bled 1. Check: • clutch release cylinder body 1 Cracks/damage →...

  • Page 338: Assembling And Installing The Clutch Release Cylinder

    CHAS HYDRAULIC CLUTCH ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER WARNING • Before installation, all internal clutch components should be cleaned and lubri- cated with clean or new clutch fluid. • Never use solvents on internal clutch components as they will cause the piston seal to swell and distort.
  • Page 339 CHAS HYDRAULIC CLUTCH 4. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.

  • Page 340: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 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. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 341 CHAS FRONT FORK Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Refer to “ASSEMBLING THE FRONT Collar FORK LEGS”. Spring seat Fork spring Dust seal...
  • Page 342 CHAS FRONT FORK Order Job/Part Q’ty Remarks Damper rod Refer to “DISASSEMBLING THE FRONT Damper rod spring FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”. Inner tube Oil seal Seal spacer Outer tube bushing Refer to “ASSEMBLING THE FRONT FORK LEGS”. Inner tube bushing Oil flow stopper Outer tube...

  • Page 343: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00650 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 344: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 2. Remove: • dust seal 1 •...

  • Page 345: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 346: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 347 CHAS FRONT FORK 5. Tighten: • damper rod bolt 30 Nm (3.0 m · kg) NOTE: ® • Apply the locking agent (LOCTITE ) to the threads of the damper rod bolt. • While holding the damper rod assembly with the damper rod holder 1 and T-handle 2, tighten the damper rod assembly bolt.
  • Page 348 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 621 cm Recommended oil Yamaha fork oil 10W or equiva- lent Front fork leg oil level a (from the top of the inner tube, with the inner tube fully com-...

  • Page 349: Installing The Front Fork Legs

    CHAS FRONT FORK 11.Install: • fork spring • spring seat • collar • cap bolt NOTE: • Install the spring with the smaller pitch a facing up È. • Before installing the cap bolt, lubricate its O-ring with grease. • Temporarily tighten the cap bolt. EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the...

  • Page 350: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the master cylinders, Remove the parts in the order listed. handlebar switches and handlebar grips Rear view mirror (left and right) Plastic band Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Refer to “INSTALLING THE HANDLE- Right handlebar switch...
  • Page 351 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Clutch master cylinder holder Clutch master cylinder Refer to “INSTALLING THE HANDLE- BAR”. Left handlebar switch Handlebar grip Refer to “REMOVING THE HANDLE- BAR” and “INSTALLING THE HANDLE- BAR”. For installation, reverse the removal pro- cedure.
  • Page 352 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Upper handlebar holder Handlebar Refer to “INSTALLING THE HANDLE- Turn signal light bracket assembly BAR”. Speedometer assembly Lower handlebar holder For installation, reverse the removal pro- cedure.

  • Page 353: 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: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

  • Page 354: Installing The Handlebar

    CHAS HANDLEBAR EAS00670 INSTALLING THE HANDLEBAR 1. Install: • lower handlebar holder 1 40 Nm (4.0 m · kg) • turn signal light bracket assembly 2 • speedometer assembly 3 2. Install: • handlebar 1 • upper handlebar holder 2 20 Nm (2.0 m ·...
  • Page 355 CHAS HANDLEBAR 4. Install: • left handlebar switch NOTE: Install the left handlebar switch as shown. 5. Install: • clutch master cylinder Refer to “HYDRAULIC CLUTCH”. 6. Install: • right handlebar switch NOTE: Install the right handlebar switch as shown. 7.

  • Page 356: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Handlebar/handlebar holders Refer to “HANDLEBAR”. Front fork legs Refer to “FRONT FORK”. Headlight lens unit Lead (in the headlight body) Disconnect.
  • Page 357 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Upper bracket Lock washer Refer to “INSTALLING THE STEERING HEAD”. Upper ring nut Rubber washer Lower ring nut Refer to “REMOVING THE LOWER BRACKET” and “INSTALLING THE Lower bracket STEERING HEAD”. Bearing cover Upper bearing Lower bearing Bearing outer race...

  • Page 358: 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: • lower ring nut 1 (with the steering nut wrench 2) •...

  • Page 359: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearings • bearing races a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c.
  • Page 360 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 1 110 Nm (11.0 m ·...

  • Page 361: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER Order Job/Part Q’ty Remarks Removing the rear shock absorbers Remove the parts in the order listed. Nut (left and right) Refer to “REMOVING THE REAR Washer (left and right) SHOCK ABSORBER ASSEMBLIES” Bolt (left and right) and “INSTALLING THE REAR SHOCK Spacer (left and right) ABSORBER ASSEMBLIES”.

  • Page 362: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER 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 informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.

  • Page 363: Checking The Rear Shock Absorber Assemblies

    CHAS REAR SHOCK ABSORBER EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...

  • Page 364: Swingarm

    CHAS SWINGARM EAS00701 SWINGARM Order Job/Part Q’ty Remarks Removing the swingarm Remove the parts in the order listed. Muffler Refer to “ENGINE” in chapter 4. Rear shock absorbers Refer to “REAR SHOCK ABSORBER”. Final drive assembly Refer to “SHAFT DRIVE”. Pinch bolt Brake torque rod Refer to “INSTALLING THE SWINGARM”.
  • Page 365 CHAS SWINGARM Order Job/Part Q’ty Remarks Rubber boot/spring Refer to “INSTALLING THE SWINGARM”. Spacer (left and right) Oil seal (left and right) Bearing (left and right)/ bearing race (left and right) For installation, reverse the removal pro- cedure. 7 - 90...

  • Page 366: Removing The Swingarm

    CHAS SWINGARM EAS00702 REMOVING THE SWINGARM 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. 2.

  • Page 367: Checking The Swingarm

    CHAS SWINGARM EAS00708 CHECKING THE SWINGARM 1. Check: • swingarm Bends/cracks/damage → Replace. 2. Check: • left pivot bolt • right pivot bolt Damage/wear → Replace. 3. Check: • spacers • oil seals • bearings • pivot bolt covers Damage/wear → Replace. EAS00712 INSTALLING THE SWINGARM 1.
  • Page 368 CHAS SWINGARM 3. Tighten: • left pivot bolt 1 • right pivot bolt 2 • locknut 3 a. Tighten the left pivot bolt 1 to specification. Left pivot bolt 100 Nm (10.0 m • kg) b. Tighten the right pivot bolt 2 to specifica- tion.

  • Page 369: Shaft Drive

    CHAS SHAFT DRIVE EAS00715 SHAFT DRIVE TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sustained B. Improper gear backlash speeds. (not to be confused with engine surg- C. Damaged gear teeth ing or transmission-related movements.) D.
  • Page 370 CHAS SHAFT DRIVE Inspection notes 1. Inves tigate any unusual noises. The following noises may indicate a mechanical defect: a. A rolling “rumble” during coasting, accelera- tion or deceleration (increases with the rear wheel speed, but does not increase with higher engine or transmission speeds).
  • Page 371 CHAS SHAFT DRIVE EAS00716 Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section exist, check the following points. Place the motorcycle on a suitable stand so YES Replace the wheel bearing. that the front wheel is elevated and then Refer to “FRONT WHEEL AND BRAKE spin the front wheel.

  • Page 372: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks

    CHAS SHAFT DRIVE EAS00717 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 1. Drain: • final drive oil (from the final drive housing) Refer to “CHANGING THE FINAL DRIVE OIL” in chapter 3. 2. Check: •...

  • Page 373: Measuring The Ring Gear Backlash

    CHAS SHAFT DRIVE EAS00719 MEASURING THE RING GEAR BACKLASH 1. Secure the final drive assembly in a vise. 2. Remove: • final drive oil drain bolt 3. Drain: • final drive oil (from the final drive assembly) 4. Measure: • ring gear backlash Out of specification →...

  • Page 374: Adjusting The Ring Gear Backlash

    CHAS SHAFT DRIVE EAS00720 ADJUSTING THE RING GEAR BACKLASH 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts.

  • Page 375: Measuring The Ring-Gear-To-Stopper-Bolt Clearance

    CHAS SHAFT DRIVE EAS00721 MEASURING THE RING-GEAR-TO- STOPPER-BOLT CLEARANCE 1. Remove: • ring gear bearing housing (along with the ring gear) Refer to “ADJUSTING THE RING GEAR BACKLASH”. 2. Measure: • ring-gear-to-stopper-bolt clearance a Out of specification → Adjust. Ring-gear-to-stopper-bolt clear- ance 0.30 ~ 0.60 mm 1 Stopper bolt...
  • Page 376 CHAS SHAFT DRIVE 3. Install: • stopper bolt shim(s) 1 • stopper bolt 2 9 Nm (0.9 m · kg) • ring gear 3 • ring gear bearing housing CAUTION: • The stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise.
  • Page 377 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed. Final gear oil Drain. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. Rear shock absorber (left) Refer to “REAR SHOCK ABSORBER”. Final drive assembly Refer to “INSTALLING THE FINAL DRIVE ASSEMBLY”.
  • Page 378 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Disassembling the final drive Remove the parts in the order listed. assembly Circlip Oil seal Drive shaft Spring Ring gear bearing housing/oil seal Dust cover Ring gear/bearing Refer to “ALIGNING THE FINAL DRIVE Ring gear shim(s) PINION GEAR AND RING GEAR”.
  • Page 379 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Left-hand threads. Refer to “DISAS- Gear coupling SEMBLING THE Bearing retainer/oil seal Left-hand threads. FINAL DRIVE Final drive pinion gear/bearing ASSEMBLY” and “ALIGNING THE Final drive pinion gear shim(s) FINAL DRIVE PIN- Bearing ION GEAR AND Bearing RING GEAR”.

  • Page 380: Disassembling The Final Drive Assembly

    CHAS SHAFT DRIVE EAS00724 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts.

  • Page 381: Removing And Installing The Ring Gear Bearings

    CHAS SHAFT DRIVE CAUTION: The final drive pinion gear should only be removed if ring gear replacement is neces- sary. NOTE: Lightly tap on the end of the final drive pinion gear with a soft hammer. EAS00725 REMOVING AND INSTALLING THE RING GEAR BEARINGS 1.

  • Page 382: Aligning The Final Drive Pinion Gear And Ring Gear

    • bearing 3 (with a suitable press tool 4 and an appro- priate support for the final drive housing) NOTE: The bearing can be reused, but Yamaha rec- ommends installing a new one. EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR...
  • Page 383 CHAS SHAFT DRIVE 1. Select: • final drive pinion gear shim(s) 1 • ring gear shim(s) 2 a. Position the final drive pinion gear and the ring gear with shims 1 and 2. Calculate the respective thicknesses from information marked on the final drive housing and the drive pinion gear.
  • Page 384 CHAS SHAFT DRIVE Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 In the example above, the calculated final drive pinion gear shim thickness is 0.51 mm.
  • Page 385 CHAS SHAFT DRIVE Example: If the final drive housing is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “– 05”, and “f” is 13.00: B = (45 + 51/100) + (3 + 35/100) – [(35.40 –...
  • Page 386 CHAS SHAFT DRIVE 2. Install: • shims (as calculated) • final drive pinion gear • bearing retainer 110 Nm (11.0 m · kg) (with the bearing retainer wrench 1) CAUTION: The bearing retainer has left-hand threads. To tighten the bearing retainer, turn it counterclockwise.
  • Page 387 CHAS SHAFT DRIVE 7. Measure: • ring-gear-to-thrust-washer clearance a. Remove the ring gear bearing housing (along with the ring gear). ® b. Place four pieces of Plastigauge between the original thrust washer and the ring gear. c. Install the ring gear bearing housing and tighten the bolts and nuts to specification.

  • Page 388: Checking The Drive Shaft

    CHAS SHAFT DRIVE EAS00727 CHECKING THE DRIVE SHAFT 1. Check: • drive shaft splines Damage/wear → Replace the drive shaft. EAS00728 INSTALLING THE FINAL DRIVE ASSEMBLY 1. Lubricate: • drive shaft splines Recommended lubricant Molybdenum disulfide grease 2. Install: • final drive assembly NOTE: Align the drive shaft splines with the driven yoke of the universal joint.

  • Page 390: Elec

    – ELEC...
  • Page 391 – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ............... 8-1 SWITCHES ..................... 8-3 CHECKING SWITCH CONTINUITY ............8-3 CHECKING THE SWITCHES ................. 8-5 CHECKING THE BULBS AND BULB SOCKETS ......... 8-7 TYPES OF BULBS ................... 8-7 CHECKING THE CONDITION OF THE BULBS ........8-7 CHECKING THE CONDITION OF THE BULB SOCKETS ......8-9 IGNITION SYSTEM ..................8-10 CIRCUIT DIAGRAM ................
  • Page 392 – ELEC COOLING SYSTEM ..................8-43 CIRCUIT DIAGRAM ................8-43 TROUBLESHOOTING ................8-44 FUEL PUMP SYSTEM .................. 8-47 CIRCUIT DIAGRAM ................8-47 FUEL PUMP CIRCUIT OPERATION .............8-48 TROUBLESHOOTING ................8-49 CHECKING THE FUEL PUMP ...............8-52...

  • Page 393: Electrical System

    – ELEC ELECTRICAL COMPONENTS tEAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Ignitor unit 2 Pressure sensor 3 Ignition coil (#1 & #3) 4 Neutral switch 5 Oil level gauge 6 Ignition coil (#2 & #4) 7 Fuel pump relay 8 Thermo switch 9 Temperature sender 8 - 1...
  • Page 394 – ELEC ELECTRICAL COMPONENTS 1 Starter relay 2 Main fuse 3 Battery 4 Rectifier/regulator 5 Sidestand switch 6 Rear brake light switch 7 Horn 8 Turn signal relay 9 Starting circuit cutoff relay 0 Diode assembly A Main switch B Wire harness 8 - 2...

  • Page 395: Switches

    – ELEC SWITCHES EAS00730 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.
  • Page 396 – ELEC SWITCHES 8 - 4...

  • Page 397: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 398 – ELEC CHECKING THE SWITCHES 1 Dimmer switch 2 Pass switch 3 Horn switch 4 Turn signal switch 5 Clutch switch 6 Light switch 7 Engine stop switch 8 Start switch 9 Fuel reserve switch 0 Front brake light switch A Main switch B Fuse C Rear brake light switch...

  • Page 399: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 400 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.

  • Page 401: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE:...

  • Page 402: Ignition System

    – ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 10...

  • Page 403: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING THE BATTERY” in spark or intermittent spark). chapter 3. Check: Minimum open-circuit voltage 1. main and ignition fuses 12.8 V or more at 20 °C 2.
  • Page 404 – ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. 2 Spark plug cap •...
  • Page 405 – ELEC IGNITION SYSTEM EAS00749 8. Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Replace main switch. • Measure the secondary coil resistance. EAS00750 Secondary coil resistance 9. Engine stop switch 10.56 ~ 15.84 kΩ...
  • Page 406 – ELEC IGNITION SYSTEM 12.Diode assembly 13.Vacuum pressure sensor • Disconnect the diode assembly coupler • Disconnect the vacuum pressure sensor from the wire harness. coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 407: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 15...

  • Page 408: Starting Circuit Cutoff System Operation

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 409: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 410 – ELEC ELECTRIC STARTING SYSTEM EAS00759 EAS00761 4. Starting circuit cutoff relay 5. Starter relay • Disconnect the starting circuit cutoff relay • Disconnect the starter relay coupler from coupler from the wire harness. the coupler. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 411 – ELEC ELECTRIC STARTING SYSTEM EAS00750 EAS00764 7. Engine stop switch 11.Start switch • Check the engine stop switch for continuity. • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? •...
  • Page 412 – ELEC ELECTRIC STARTING SYSTEM 13.Wiring connections • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly con- nected and without defects? This circuit is OK. Properly connect or repair starting system’s wiring. 8 - 20...

  • Page 413: Starter Motor

    – ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Coolant drain cock assembly Refer to “THERMOSTAT ASSEMBLY AND CONDUIT” in chapter 5. Starter motor lead Starter motor assembly For installation, reverse the removal pro- cedure.
  • Page 414 – ELEC STARTER MOTOR EAS00768 Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Starter motor front cover Washer kit Starter motor rear cover Washer kit Armature coil Brush seat Brush holder Starter motor yoke For assembly, reverse the disassembly procedure.

  • Page 415: Checking The Starter Motor

    – ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm 3. Measure: •...

  • Page 416: Assembling The Starter Motor

    – ELEC STARTER MOTOR 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 5 mm 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 8.82 N (899 gf) 7.
  • Page 417 – ELEC STARTER MOTOR 3. Install: • O-rings 1 • bolts 2 5 Nm (0.5 m · kg) 8 - 25...

  • Page 418: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM R/W G/Y L/B L/W 2 Rectifier/regulator 3 Generator 4 Main fuse 5 Battery 8 - 26...

  • Page 419: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The battery is not being charged. Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. main fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C 3.
  • Page 420 – ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring connections Make sure the battery is fully charged. • Check the wiring connections of the entire charging system. • Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? The charging circuit is OK.

  • Page 421: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 29...

  • Page 422: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING THE BATTERY” in light, high beam indicator light, taillight, chapter 3. auxiliary light or meter light. Minimum open-circuit voltage Check: 12.8 V or more at 20 °C...

  • Page 423: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00784 EAS00788 CHECKING THE LIGHTING SYSTEM 5. Dimmer switch 1. The headlight and the high beam indicator • Check the dimmer switch for continuity. light fail to come on. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? 1.
  • Page 424 – ELEC LIGHTING SYSTEM Headlight 2. Voltage Positive tester probe → • Connect the pocket tester (DC 20 V) to the yellow 1 or green 2 meter light coupler (wire harness side) as Negative tester probe → black 3 shown. High beam indicator light Positive tester probe →...
  • Page 425 – ELEC LIGHTING SYSTEM EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The auxiliary light fails to come on. 1. Tail/brake light bulb and socket 1. Auxiliary light bulb and socket • Check the tail/brake light bulb and socket •...

  • Page 426: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 34...
  • Page 427 – ELEC SIGNALING SYSTEM 1 Main switch 4 Main fuse 5 Battery 0 Front brake light switch B Engine stop switch N Fuel level indicator light O Oil level warning light R Neutral indicator light S Turn signal indicator light W Diode assembly X Fuel sender Y Engine oil level switch...

  • Page 428: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • Any of the following fail to light: flasher Refer to “CHECKING THE BATTERY” in light, brake light or an indicator light. chapter 3. •...

  • Page 429: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the pink connector at the horn terminal. 1. Horn switch • Connect a jumper lead 1 to the horn termi- • Check the horn switch for continuity. nal and ground the jumper lead.
  • Page 430 – ELEC SIGNALING SYSTEM EAS00797 • Set the main switch to “ON”. 2. The tail/brake light fails to come on. • Pull in the brake lever or push down on the 1. Tail/brake light bulb and socket brake pedal. • Measure the voltage (12 V) of yellow 1 on •...
  • Page 431 – ELEC SIGNALING SYSTEM 3. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (12 V) on brown/white turn signal relay coupler (wire harness side) 1 at the turn signal relay coupler (wire har- as shown.
  • Page 432 – ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 3. Voltage • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (12 V) of the chocolate tachometer coupler (wire harness side) as 1 or dark green 2 at the turn signal light shown.
  • Page 433 – ELEC SIGNALING SYSTEM 2. Engine stop switch 4. Voltage • Check the engine stop switch for continuity. • Connect the pocket tester (DC 20 V) to the Refer to “CHECKING THE SWITCHES”. tachometer coupler (wire harness side) as • Is the engine stop switch OK? shown.
  • Page 434 – ELEC SIGNALING SYSTEM EAS00803 • Measure the fuel sender resistances. 6. The fuel level indicator light fails to come Fuel sender resistance (Ω × 100) 1. Fuel level indicator light bulb and socket 700 ~ 1,100 Ω at 25 °C •...

  • Page 435: Cooling System

    – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 43...
  • Page 436 – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The radiator fan motor fails to turn. Refer to “CHECKING THE BATTERY” in • The water temperature gauge needle chapter 3. fails to move when the engine is warm. Minimum open-circuit voltage Check: 12.8 V or more at 20 °C...
  • Page 437 – ELEC COOLING SYSTEM • Does the radiator fan motor turn? radiator motor is faulty and must be replaced. EAS00811 5. Thermo switch • Remove the thermo switch from the con- duit. • Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown.
  • Page 438 – ELEC COOLING SYSTEM EAS00812 6. Temperature sender WARNING • Handle the temperature sender with spe- • Remove the temperature sender from the cial care. radiator. • Connect the pocket tester (Ω × 10) to the • Never subject the temperature sender to temperature sender 1 as shown.

  • Page 439: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 8 - 47...

  • Page 440: Fuel Pump Circuit Operation

    – ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Fuel level indicator light 7 Fuel sender 8 Fuel reserve switch 9 Fuel pump relay...

  • Page 441: Troubleshooting

    – ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. If the fuel pump fails to operate. Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 442 – ELEC FUEL PUMP SYSTEM 5. Fuel reserve switch Fuel sender resistance (Ω × 100) • Check the fuel reserve switch for continuity. 700 ~ 1,100 Ω at 25 °C Refer to “CHECKING THE SWITCHES”. • Is the fuel reserve switch OK? •...
  • Page 443 – ELEC FUEL PUMP SYSTEM EAS00817 9. Fuel pump resistance • Disconnect the fuel pump coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the fuel pump coupler as shown. Positive tester probe → blue/black 1 Negative tester probe →...

  • Page 444: Checking The Fuel Pump

    – ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •...

  • Page 445: Trbl Shtg

    TRBL SHTG...

  • Page 446: Troubleshooting Trbl

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING PROBLEMS ................9-1 ENGINE ....................9-1 FUEL SYSTEM ..................9-1 ELECTRICAL SYSTEMS ................. 9-2 INCORRECT ENGINE IDLING SPEED ............9-2 ENGINE ....................9-2 FUEL SYSTEM ..................9-2 ELECTRICAL SYSTEMS ................. 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........9-3 ENGINE ....................
  • Page 447 TRBL SHTG FAULTY FRONT FORK LEGS ............... 9-5 LEAKING OIL ................... 9-5 MALFUNCTION ..................9-5 UNSTABLE HANDLING ................. 9-5 FAULTY LIGHTING OR SIGNALING SYSTEM ..........9-6 HEADLIGHT DOES NOT LIGHT .............. 9-6 HEADLIGHT BULB BURNT OUT ............. 9-6 TAIL/BRAKE LIGHT DOES NOT LIGHT ..........9-6 TAIL/BRAKE LIGHT BULB BURNT OUT ..........
  • Page 448 TRBL STARTING PROBLEMS SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.

  • Page 449: Starting Problems

    STARTING PROBLEMS/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ignitor unit • Faulty battery • Faulty pickup coil Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...

  • Page 450: Engine

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE FUEL SYSTEM Air filter Carburetor(s) • Clogged air filter element • Faulty diaphragm Air intake system • Incorrect fuel level • Bent, clogged or disconnected carburetor •...

  • Page 451: Overheating

    OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Carburetor(s) • Cylinder head(s) and piston(s) • Incorrect main jet setting • Heavy carbon buildup • Incorrect fuel level Engine oil • Damaged or loose carburetor joint •...
  • Page 452 FAULTY FRONT FORK LEGS/ TRBL UNSTABLE HANDLING SHTG EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION • Bent, damaged or rusty inner tube • Bent or damaged inner tube • Cracked or damaged outer tube • Bent or damaged outer tube •...
  • Page 453 TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •...
  • Page 454 VMX12 WIRING DIAGRAM 1 Main switch 2 Rectifier/regulator 3 Generator 4 Main fuse (YELLOW) (YELLOW) 5 Battery R/B B/R 6 Starter relay 7 Starter motor 8 Starting circuit cutoff relay (YELLOW) (YELLOW) R/G R/B 9 Right handlebar switch 0 Front brake light switch A Light switch B Engine stop switch (YELLOW) (YELLOW)

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