Table of Contents
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Chapters
Table of Contents
Related Manuals for Yamaha 1998 FZS600 5DM1-AE1
Summarization of Contents
NOTICE AND IMPORTANT INFORMATION
NOTICE
Manual's purpose and target audience. Assumes basic mechanical knowledge for repairs.
IMPORTANT INFORMATION
Defines symbols used for important information: DANGER, WARNING, CAUTION, NOTE.
HOW TO USE THIS MANUAL AND SYMBOLS
HOW TO USE THIS MANUAL
Guide on manual structure: chapters, sections, diagrams, job charts, and numbering.
SYMBOLS
Explanation of symbols used for chapters, maintenance, and lubricant types.
CHAPTER 1 GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
Locates vehicle identification number and model code label for parts ordering.
IMPORTANT INFORMATION
General preparation advice for removal and disassembly, including cleanliness and part handling.
REPLACEMENT PARTS
Recommends using genuine Yamaha parts and specified oils/greases for reliability.
GASKETS, OIL SEALS AND O-RINGS
Guidelines for replacing and properly installing gaskets, oil seals, and O-rings.
LOCK WASHERS/PLATES AND COTTER PINS
Instructions for replacing lock washers, plates, and cotter pins after tightening.
BEARINGS AND OIL SEALS
Proper installation of bearings and oil seals, including lubrication and handling precautions.
CIRCLIPS
Checks for circlip damage and proper installation techniques to ensure secure fit.
CHECKING THE CONNECTIONS
Procedure for checking electrical leads, couplers, and connectors for corrosion or moisture.
SPECIAL TOOLS
Lists necessary special tools for accurate tune-up and assembly to prevent damage.
CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS
Key specifications: model code, dimensions, engine type, displacement, bore/stroke, compression ratio.
GENERAL SPECIFICATIONS
Specifications for carburetor, spark plug, transmission, chassis, tires, and tire pressure.
GENERAL SPECIFICATIONS
Specifications for brakes, suspension, electrical system components, and bulb types.
MAINTENANCE SPECIFICATIONS ENGINE
Detailed engine specifications for cylinder head, cylinder, camshaft, and valve train.
MAINTENANCE SPECIFICATIONS ENGINE
Engine specifications for piston, rings, connecting rod, crankshaft, and oil clearance.
MAINTENANCE SPECIFICATIONS ENGINE
Engine specifications for clutch, transmission, and carburetor settings.
MAINTENANCE SPECIFICATIONS CHASSIS
Chassis specifications for lubrication system, cooling system, and water pump.
TIGHTENING TORQUES ENGINE
Specific torque values for engine fasteners to ensure proper assembly and function.
TIGHTENING TORQUES CHASSIS
Specific torque values for chassis fasteners, including steering, suspension, and frame components.
ELECTRICAL
Specifications for ignition system, T.C.I., spark plug, charging, and voltage regulator.
ELECTRICAL
Specifications for starter motor, relays, horn, flasher, gauges, and switches.
ELECTRICAL
Amperage ratings for various electrical circuits, including main, lighting, and ignition.
GENERAL TIGHTENING TORQUE SPECIFICATIONS
Standard torque values for common fasteners based on thread pitch and size.
LUBRICATION POINT AND LUBRICATION TYPES ENGINE
Identifies lubrication points for engine components with corresponding symbols.
LUBRICATION POINT AND LUBRICATION TYPES CHASSIS
Identifies lubrication points for chassis components with corresponding symbols.
COOLING SYSTEM DIAGRAMS
Schematic diagrams illustrating the layout of the cooling system components.
LUBRICATION DIAGRAMS ENGINE
Schematic diagrams showing lubrication points and oil flow within the engine.
CABLE ROUTING
Diagrams showing the correct routing for throttle, clutch, and brake cables.
CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
Table detailing recommended maintenance and lubrication intervals for key vehicle components.
FRONT COWLING
Procedure for removing the front cowling, including mirrors, inner panels, and headlight assembly.
SEAT, SIDE COVER AND FUEL TANK
Procedure for removing the seat, side covers, and fuel tank assembly.
ADJUSTING THE VALVE CLEARANCE
Step-by-step guide for adjusting valve clearance, emphasizing cold engine conditions.
SYNCHRONIZING THE CARBURETORS
Procedure for synchronizing carburetors using vacuum gauges and adjusting idling speed.
ADJUSTING THE ENGINE IDLING SPEED
Instructions for adjusting engine idling speed using pilot screws and throttle stop screws.
ADJUSTING THE THROTTLE CABLE FREE PLAY
Procedure for adjusting throttle cable free play at both carburetor and handlebar sides.
CHECKING THE SPARK PLUGS
Guide to inspecting spark plug condition, type, gap, and electrode wear.
CHECKING THE IGNITION TIMING
Method for checking ignition timing using specialized tools and engine idling speed.
MEASURING THE COMPRESSION PRESSURE
Procedure for measuring engine compression pressure and diagnosing potential issues.
CHECKING THE ENGINE OIL LEVEL
Instructions for checking engine oil level with the engine warm and upright.
CHANGING THE ENGINE OIL
Detailed procedure for draining engine oil, replacing the oil filter, and refilling.
MEASURING THE ENGINE OIL PRESSURE
Procedure for measuring engine oil pressure under specified conditions.
ADJUSTING THE CLUTCH CABLE FREE PLAY
Steps for adjusting clutch cable free play at handlebar and engine sides.
CLEANING THE AIR FILTER ELEMENT
Procedure for cleaning the air filter element using compressed air.
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS
Procedure to check carburetor joints and intake manifolds for cracks or damage.
CHECKING THE FUEL HOSES AND FUEL FILTER
Procedure to check fuel hoses for cracks and fuel filter for damage or dirt.
CHECKING THE CRANKCASE BREATHER HOSE
Procedure to check the crankcase breather hose for cracks, damage, or loose connections.
CHECKING THE EXHAUST SYSTEM
Procedure to check exhaust pipes and mufflers for damage and verify tightening torques.
CHECKING THE COOLANT LEVEL
Procedure for checking the coolant level in the radiator and reservoir.
CHECKING THE COOLING SYSTEM
Procedure to check cooling system components like radiator and hoses for damage.
CHANGING THE COOLANT
Procedure for draining and changing the engine coolant, including radiator cap safety.
ADJUSTING THE FRONT BRAKE
Procedure for adjusting the front brake lever position using the adjusting dial.
ADJUSTING THE REAR BRAKE
Procedure for adjusting the rear brake pedal position using the adjusting bolt.
CHECKING THE BRAKE FLUID LEVEL
Procedure for checking the brake fluid level and adding fluid if necessary.
ADJUSTING THE REAR BRAKE LIGHT SWITCH
Procedure for adjusting the rear brake light switch timing for proper operation.
CHECKING THE BRAKE HOSES
Procedure to check brake hoses and clamps for cracks, damage, or loose connections.
BLEEDING THE HYDRAULIC BRAKE SYSTEM
Procedure for bleeding the hydraulic brake system to remove air.
ADJUSTING THE SHIFT PEDAL
Procedure for adjusting the shift pedal position relative to the shift rod.
ADJUSTING THE DRIVE CHAIN SLACK
Procedure for checking and adjusting the drive chain slack within specified limits.
LUBRICATING THE DRIVE CHAIN
Recommendations for cleaning and lubricating the drive chain, especially O-ring chains.
CHECKING AND ADJUSTING THE STEERING HEAD
Procedure for checking steering head for looseness or binding and adjusting as needed.
CHECKING THE FRONT FORK
Procedure for checking the front fork's inner tubes, seals, and overall operation.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
Procedure for adjusting the spring preload on the rear shock absorber assembly.
CHECKING THE TIRES
Procedure for checking tire pressure, tread depth, wear indicators, and tire condition.
CHECKING THE WHEELS
Procedure for checking wheels for damage, out-of-roundness, and balancing.
CHECKING AND LUBRICATING THE CABLES
Procedure for checking cable sheaths and operation, and lubricating cables.
LUBRICATING THE LEVERS AND PEDALS
Lubrication points for levers and pedals, recommending lithium soap base grease.
LUBRICATING THE SIDESTAND
Lubrication points for the sidestand, recommending lithium soap base grease.
LUBRICATING THE CENTER STAND
Lubrication points for the center stand, recommending lithium soap base grease.
LUBRICATING THE REAR SUSPENSION
Lubrication points for the rear suspension, recommending molybdenum disulfide grease.
CHECKING AND CHARGING THE BATTERY
Safety precautions for handling and charging batteries, including warning about explosive gas.
CHECKING AND CHARGING THE BATTERY
Procedure for checking battery charge state by measuring open-circuit voltage.
CHECKING AND CHARGING THE BATTERY
Detailed warnings and instructions for battery charging, including charger types and overheating.
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) type charger with step-by-step instructions.
CHECKING AND CHARGING THE BATTERY
Charging method using a constant-voltage type charger, with specific voltage and time settings.
CHECKING THE FUSES
Procedure for checking fuses for continuity using a pocket tester.
REPLACING THE HEADLIGHT BULBS
Procedure for replacing headlight bulbs, including disconnecting the lead and removing the bulb.
ADJUSTING THE HEADLIGHT BEAMS
Procedure for adjusting headlight beams vertically using an adjusting screw.
ADJUSTING THE HEADLIGHT BEAMS
Procedure for adjusting headlight beams horizontally using adjusting knobs.
CHAPTER 4 OVERHAULING THE ENGINE
REMOVING THE ENGINE
Procedure for removing the drive sprocket and exhaust pipe assembly.
REMOVING THE ENGINE
Procedure for disconnecting leads and hoses from the engine.
REMOVING THE ENGINE
Procedure for removing the engine bracket and engine assembly.
INSTALLING THE ENGINE
Steps for installing the engine, tightening bolts, and installing the shift arm.
CAMSHAFT
Procedure for removing the cylinder head covers.
REMOVING THE CAMSHAFTS
Steps for aligning timing marks, removing timing chain guides, and camshaft caps.
CHECKING THE CAMSHAFTS
Procedure for checking camshaft lobes, dimensions, and runout for wear or damage.
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES
Procedure for checking timing chain, sprockets, and chain guides for wear or damage.
CHECKING THE TIMING CHAIN TENSIONER
Procedure for checking the timing chain tensioner for cracks, damage, or operation.
INSTALLING THE CAMSHAFTS
Steps for installing camshafts, caps, and related components with correct alignment.
CYLINDER HEAD
Procedure for removing the cylinder head, including nuts, bolts, and gasket.
CHECKING THE CYLINDER HEADS
Procedure for cleaning carbon deposits and checking cylinder head for damage or warpage.
INSTALLING THE CYLINDER HEAD
Steps for installing the cylinder head gasket, head, and camshafts with proper torque.
VALVES AND VALVE SPRINGS
Parts list and procedure for removing valves and valve springs.
REMOVING THE VALVES
Steps for removing valve lifters, pads, cotters, springs, and seals.
CHECKING THE VALVES AND VALVE GUIDES
Procedure for measuring valve-to-guide clearance and replacing valve guides.
CHECKING THE VALVE SEATS
Procedure for checking valve seats for wear and measuring valve seat width.
CHECKING THE VALVE SPRINGS
Procedure for measuring valve spring free length, compressed force, and tilt.
CHECKING THE VALVE LIFTERS
Procedure for checking valve lifters for damage or scratches.
CHECKING THE CAMSHAFT CAP
Procedure for checking camshaft case and caps for cracks or damage.
INSTALLING THE VALVES
Steps for installing valves, springs, seals, and cotters with correct orientation.
CYLINDERS AND PISTONS
Procedure for removing the cylinders and pistons.
CHECKING THE CYLINDERS AND PISTONS
Procedure for checking cylinder and piston condition and measuring clearance.
CHECKING THE PISTON RINGS
Procedure for measuring piston ring side and end gap clearance.
CHECKING THE PISTON PINS
Procedure for checking piston pin diameter and clearance.
INSTALLING THE PISTON AND CYLINDER
Steps for installing piston rings, piston, pin, and cylinder with correct orientation.
CLUTCH
Procedure for removing the clutch cover.
REMOVING THE CLUTCH
Steps for removing clutch boss nut, spacer, and bearing.
CHECKING THE FRICTION PLATES
Procedure for checking friction plate thickness.
CHECKING THE CLUTCH PLATES
Procedure for checking clutch plate warpage.
CHECKING THE CLUTCH SPRINGS
Procedure for checking clutch spring free length.
CHECKING THE CLUTCH HOUSING
Procedure for checking clutch housing dogs and bearing for damage.
CHECKING THE CLUTCH BOSS
Procedure for checking clutch boss splines for damage or wear.
CHECKING THE PRESSURE PLATE
Procedure for checking the pressure plate and bearing for damage.
CHECKING THE CLUTCH PUSH RODS
Procedure for checking clutch push rods and measuring bending limit.
INSTALLING THE CLUTCH
Steps for installing bearing and spacer into the clutch assembly.
INSTALLING THE CLUTCH
Steps for tightening clutch boss nut, lubricating, and installing clutch plates.
INSTALLING THE CLUTCH
Steps for installing pressure plate, clutch springs, and bolts with correct sequence.
SHIFT SHAFT
Parts list for shift shaft removal.
CHECKING THE SHIFT SHAFT
Procedure for checking shift shaft, lever, springs, and stopper lever for bends or wear.
CHECKING THE SHIFT DRUM ASSEMBLY
Procedure for checking shift drum grooves, segments, and bearings.
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY
Steps for installing shift drum assembly, forks, and guide bars with correct alignment.
AC MAGNETO AND STARTER CLUTCH
Procedure for removing the stator coil.
AC MAGNETO AND STARTER CLUTCH
Parts list for starter clutch removal.
AC MAGNETO AND STARTER CLUTCH
Procedure for removing the AC magneto rotor.
REMOVING THE STARTER CLUTCH
Steps for removing starter clutch cover and bolt.
REMOVING THE STARTER CLUTCH
Procedure for removing the starter clutch using a flywheel puller.
REMOVING THE AC MAGNETO
Procedure for removing the AC magneto rotor and Woodruff key.
CHECKING THE STARTER CLUTCH
Procedure for checking starter clutch gears and operation.
INSTALLING THE AC MAGNETO
Steps for installing Woodruff key, AC magneto rotor, and tightening bolts.
INSTALLING THE STARTER CLUTCH
Steps for installing starter clutch while holding generator rotor.
OIL PAN AND OIL STRAINER
Procedure for removing the oil strainer.
OIL PAN AND OIL STRAINER
Procedure for removing the oil pump assembly.
Disassembling the oil pump
Parts list for oil pump disassembly.
CHECKING THE OIL PUMP
Procedure for checking oil pump gears, housing, and clearances.
CHECKING THE RELIEF VALVE
Procedure for checking the relief valve components.
CHECKING THE OIL STRAINER
Procedure for checking the oil strainer for damage and contaminants.
CHECKING THE OIL NOZZLE
Procedure for checking oil nozzle, ball, and passage.
ASSEMBLING THE OIL PUMP
Lubricating and assembling oil pump components.
INSTALLING THE OIL PUMP
Steps for installing the oil pump assembly and checking rotation.
INSTALLING THE OIL STRAINER
Steps for installing the oil strainer housing and cover.
INSTALLING THE OIL PAN
Steps for installing dowel pins, gasket, oil pan, and related components.
INSTALLING THE OIL PAN
Tightening oil pan bolts and lubricating oil level switch O-ring.
CRANKCASE
Parts list for crankcase disassembly.
DISASSEMBLING THE CRANKCASE
Steps for removing crankcase bolts and halves, including careful separation.
CHECKING THE CRANKCASE
Procedure for washing, cleaning, and checking crankcase for damage and obstructions.
ASSEMBLING THE CRANKCASE
Lubricating crankshaft bearings and applying sealant for crankcase assembly.
ASSEMBLING THE CRANKCASE
Installing dowel pins, bearings, setting transmission gears, and installing upper crankcase.
ASSEMBLING THE CRANKCASE
Tightening crankcase bolts and checking transmission gear shifting.
CRANKSHAFT
Parts list for crankshaft removal.
REMOVING THE CRANKSHAFT
Steps for removing crankshaft assembly and bearings.
CONNECTING ROD
Parts list for connecting rod removal.
REMOVING THE CONNECTING RODS
Steps for removing connecting rods and big end bearings.
CHECKING THE CRANKSHAFT AND CONNECTING RODS
Procedure for measuring crankshaft runout and checking journal surfaces.
CHECKING THE CRANKSHAFT AND CONNECTING RODS
Procedure for measuring crankshaft journal-to-bearing clearance.
CHECKING THE CRANKSHAFT AND CONNECTING RODS
Installing crankshaft journal bearings and checking clearance with Plastigauge.
CHECKING THE CRANKSHAFT AND CONNECTING RODS
Tightening crankcase bolts and selecting replacement crankshaft journal bearings.
INSTALLING THE CONNECTING RODS
Lubricating and installing connecting rods and bearings onto the crankshaft.
INSTALLING THE CONNECTING RODS
Aligning connecting rod bolts and tightening rod nuts to specified angles.
INSTALLING THE CRANKSHAFT
Steps for installing crankshaft journal bearings, timing chain, and timing chain guide.
TRANSMISSION
Parts list for transmission removal.
Disassembling the transmission
Parts list for transmission disassembly.
CHECKING THE TRANSMISSION
Procedure for measuring axle runout and checking gear engagement and movement.
INSTALLING THE TRANSMISSION
Steps for installing oil baffle plate, breather hose, main axle, and drive axle assemblies.
SHIFT DRUM AND SHIFT FORKS
Parts list for shift drum and shift forks removal.
CHECKING THE SHIFT FORKS
Procedure for checking shift forks, guide bars, and movement for damage or wear.
CHECKING THE SHIFT DRUM ASSEMBLY
Procedure for checking shift drum grooves, segments, and bearings.
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY
Steps for installing shift drum assembly, forks, and guide bars with correct alignment.
CHAPTER 5 COOLING SYSTEM
RADIATOR
Procedure for removing the radiator, including fan motor leads and hoses.
CHECKING THE RADIATOR
Procedure for checking radiator fins, hoses, and measuring cap opening pressure.
INSTALLING THE RADIATOR
Procedure for filling the cooling system with coolant and checking for leaks.
THERMOSTAT
Parts list for thermostat removal.
Disassembling the thermostat
Parts list for thermostat disassembly.
CHECKING THE THERMOSTAT
Procedure for checking thermostat operation, housing, and radiator cap pressure.
ASSEMBLING THE THERMOSTAT
Steps for assembling thermostat housing, thermostat, O-ring, and cover.
WATER PUMP
Parts list for water pump removal.
REMOVING THE WATER PUMP
Procedure for removing water pump housing and checking seals.
CHECKING THE WATER PUMP
Procedure for checking water pump housing, impeller, seals, bearing, and installing cover.
CHAPTER 6 CARBURETORS
AIR FILTER CASE
Procedure for removing the air filter case and related components.
CARBURETORS
Procedure for removing the carburetors from the motorcycle.
Disassembling the carburetors
Parts list for carburetor disassembly.
CHECKING THE CARBURETORS
Procedure for checking carburetor body, float chamber, and fuel passages.
CHECKING THE CARBURETORS
Procedure for checking piston valve, vacuum chamber, jets, and fuel hoses.
ASSEMBLING THE CARBURETORS
Steps for assembling pilot screw, jet needle, and piston valve.
INSTALLING THE CARBURETORS
Procedure for adjusting carburetor synchronization and engine idling speed.
INSTALLING THE CARBURETORS
Procedure for adjusting throttle cable free play.
CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR
Procedure for checking and adjusting the throttle position sensor angle.
CHAPTER 7 CHASSIS
FRONT WHEEL AND BRAKE DISCS
Parts list for front wheel and brake discs removal.
REMOVING THE FRONT WHEEL
Steps for removing brake calipers, axle pinch bolt, and front wheel.
CHECKING THE FRONT WHEEL
Procedure for measuring wheel axle runout and checking bearings/seals.
CHECKING THE BRAKE DISCS
Procedure for checking brake disc deflection and thickness.
INSTALLING THE FRONT WHEEL
Steps for lubricating and installing the front wheel, sensor, and tightening bolts.
ADJUSTING THE FRONT WHEEL STATIC BALANCE
Procedure for finding and adjusting front wheel static balance with brake discs installed.
REMOVING THE REAR WHEEL
Steps for removing brake caliper, axle nuts, axle, and rear wheel.
CHECKING THE REAR WHEEL
Checks for wheel axle, bearings, oil seals, and tire condition.
CHECKING AND REPLACING THE REAR WHEEL SPROCKET
Procedure for checking and replacing the rear wheel sprocket.
INSTALLING THE REAR WHEEL
Lubricating and tightening wheel axle and brake caliper bolts.
ADJUSTING THE REAR WHEEL STATIC BALANCE
Procedure for adjusting rear wheel static balance.
FRONT AND REAR BRAKES
Procedure for removing front brake pads.
REAR BRAKE PADS
Procedure for removing rear brake pads.
REPLACING THE FRONT BRAKES PADS
Steps for replacing front brake pads, including bleeding the system.
REPLACING THE REAR BRAKE PADS
Steps for replacing rear brake pads, including bleeding the system.
FRONT BRAKE MASTER CYLINDER
Procedure for removing the front brake master cylinder.
Disassembling the front brake master cylinder
Parts list for front brake master cylinder disassembly.
REAR BRAKE MASTER CYLINDER
Procedure for removing the rear brake master cylinder.
Disassembling the rear brake master cylinder
Parts list for rear brake master cylinder disassembly.
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS
Checking master cylinders, passages, and kits for damage or wear.
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER
Steps for installing copper washers, brake hose, union bolt, and filling brake fluid.
ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER
Bleeding brake system, checking fluid level, and adjusting pedal position.
FRONT BRAKE CALIPERS
Procedure for removing the front brake calipers.
Disassembling the front brake calipers
Parts list for front brake caliper disassembly.
REAR BRAKE CALIPER
Procedure for removing the rear brake caliper.
Disassembling the rear brake caliper
Parts list for rear brake caliper disassembly.
DISASSEMBLING THE FRONT BRAKE CALIPERS
Steps for removing union bolt, washers, hoses, pistons, and seals.
DISASSEMBLING THE REAR BRAKE CALIPER
Steps for removing union bolt, washers, hoses, pistons, and seals.
CHECKING THE FRONT AND REAR BRAKE CALIPERS
Checking caliper pistons, cylinders, brackets, and passages for damage.
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS
Steps for installing caliper, washers, hose, and union bolt.
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS
Removing caliper, installing pads, springs, pins, and checking brake fluid.
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER
Installing copper washers, brake hose, union bolt, and filling brake fluid.
FRONT FORK
Parts list for front fork removal.
REMOVING THE FRONT FORK LEGS
Steps for removing upper bracket pinch bolt, cap bolt, lower bracket pinch bolt, and fork leg.
DISASSEMBLING THE FRONT FORK LEGS
Steps for removing dust seal, oil seal clip, and damper rod bolt.
CHECKING THE FRONT FORK LEGS
Procedure for checking inner tube, outer tube, spring, damper rod, and stopper.
ASSEMBLING THE FRONT FORK LEGS
Steps for installing bushings, oil seals, and damper rod.
ASSEMBLING THE FRONT FORK LEGS
Installing spring, seat, spacer, cap bolt, and front fork legs.
HANDLEBAR
Parts list for handlebar removal.
REMOVING THE HANDLEBAR
Steps for removing throttle cable housing, grip, and handlebar.
CHECKING THE HANDLEBAR
Procedure for checking the handlebar for bends, cracks, or damage.
INSTALLING THE HANDLEBAR
Steps for installing handlebar, holders, grips, switches, and master cylinder bracket.
INSTALLING THE HANDLEBAR
Steps for installing throttle grip, housing, cables, and adjusting clutch/throttle play.
STEERING HEAD
Parts list for steering head lower bracket removal.
REMOVING THE LOWER BRACKET
Steps for removing upper and lower ring nuts to remove the lower bracket.
CHECKING THE STEERING HEAD
Procedure for washing and checking steering head bearings and races.
INSTALLING THE STEERING HEAD
Steps for installing bearings, races, ring nuts, and upper bracket.
REAR SHOCK ABSORBER AND RELAY ARM
Parts list for removing rear shock absorber and relay arm.
HANDLING THE REAR SHOCK ABSORBER
Safety warnings and information regarding handling the rear shock absorber.
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY
Steps for removing battery, side covers, and rear shock absorber assembly.
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
Procedure for checking rear shock absorber for bends, leaks, bushings, and bolts.
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
Steps for lubricating and installing rear shock absorber assembly and connecting arm.
SWINGARM AND DRIVE CHAIN
Parts list for removing swingarm and drive chain.
REMOVING THE SWINGARM
Steps for removing side covers, connecting plate bolt, and rear shock absorber bolt.
CHECKING THE SWINGARM
Procedure for checking swingarm for bends/damage, pivot shaft, and bearings.
CHECKING THE DRIVE CHAIN
Procedure for measuring chain length, checking stiffness, and cleaning.
INSTALLING THE SWINGARM
Steps for lubricating and installing swingarm, relay arm, and connecting plates.
INSTALLING THE DRIVE CHAIN
Procedure for installing drive chain, sprocket, and washer, and adjusting slack.
CHAPTER 8 ELECTRICAL
ELECTRICAL COMPONENTS
Diagram showing the location of major electrical components.
CIRCUIT DIAGRAM
Overall electrical system circuit diagram.
CIRCUIT DIAGRAM
Key for electrical circuit diagram symbols and color codes.
CHECKING SWITCHES
Procedure for checking switch continuity using a pocket tester.
SWITCH POSITION AND TERMINAL CONNECTION
Charts showing switch positions and terminal connections for troubleshooting.
IGNITION SYSTEM
Circuit diagram for the ignition system.
TROUBLESHOOTING
Troubleshooting guide for ignition system failures like no spark or intermittent spark.
Spark plugs
Procedure for checking spark plug condition, type, and gap.
Ignition spark gap
Procedure for checking ignition spark gap using an ignition checker.
Spark plug cap resistance
Procedure for checking spark plug cap resistance.
Ignition coil resistance
Procedure for checking primary and secondary coil resistance.
Main switch
Procedure for checking main switch continuity.
Engine stop switch
Procedure for checking engine stop switch continuity.
Neutral switch
Procedure for checking neutral switch continuity.
Sidestand switch
Procedure for checking sidestand switch continuity.
Diode (starting circuit cut-off relay unit)
Procedure for checking diode continuity.
Pickup coil resistance
Procedure for checking pickup coil resistance.
Wiring connection
Check for proper wiring connections in the ignition system.
ELECTRIC STARTING SYSTEM
Circuit diagram for the electric starting system.
STARTING CIRCUIT OPERATION
Explanation of how the starting circuit operates based on switch conditions.
TROUBLESHOOTING
Troubleshooting guide if the starter motor fails to operate.
Starter motor
Procedure for checking starter motor operation.
Starting circuit cut-off relay (relay unit)
Procedure for checking the starting circuit cut-off relay for continuity.
Starter relay
Procedure for checking the starter relay for continuity.
Main switch
Procedure for checking the main switch continuity.
Engine stop switch
Procedure for checking the engine stop switch continuity.
Neutral switch
Procedure for checking the neutral switch continuity.
Sidestand switch
Procedure for checking the sidestand switch continuity.
Clutch switch
Procedure for checking the clutch switch continuity.
Start switch
Procedure for checking the start switch continuity.
Diode (starting circuit cut-off relay)
Procedure for checking the diode for continuity.
Wiring connection
Check for proper wiring connections in the starting system.
STARTER MOTOR
Parts list for starter motor removal and disassembly.
CHECKING THE STARTER MOTOR
Procedure for measuring brush length, spring force, and inspecting commutator.
CHECKING THE STARTER MOTOR
Procedure for inspecting armature coil resistances and commutator mica undercut.
CHARGING SYSTEM
Circuit diagram for the charging system.
TROUBLESHOOTING
Troubleshooting guide if the battery is not charging.
Charging voltage
Procedure for checking charging voltage using tachometer and pocket tester.
Stator coil resistance
Procedure for checking stator coil resistance.
Wiring connections
Check for proper wiring connections in the charging system.
LIGHTING SYSTEM
Circuit diagram for the lighting system.
TROUBLESHOOTING
Troubleshooting guide for headlight, high beam, taillight, auxiliary, and meter lights.
Main switch
Procedure for checking main switch continuity.
Lights switch
Procedure for checking lights switch continuity.
Dimmer switch
Procedure for checking dimmer switch continuity.
Pass switch
Procedure for checking pass switch continuity.
Wiring connections
Check for proper wiring connections in the lighting system.
Bulb and bulb socket
Check bulb and socket for continuity if headlight/high beam lights fail.
Voltage
Check voltage at headlight and high beam indicator connectors.
Bulb and bulb socket
Check bulb and socket for continuity if meter light fails.
Voltage
Check voltage at bulb socket connector for meter light.
Bulb and bulb socket
Check bulb and socket for continuity if taillight fails.
Voltage
Check voltage at bulb socket connector for taillight.
Bulb and bulb socket
Check bulb and socket for continuity if auxiliary light fails.
Voltage
Check voltage at bulb socket connector for auxiliary light.
SIGNAL SYSTEM
Circuit diagram for the signal system.
TROUBLESHOOTING
Troubleshooting guide for turn signals, brake light, indicator lights, and horn.
Main switch
Procedure for checking main switch continuity.
Wiring connections
Check for proper wiring connections in the signal system.
Horn switch
Procedure for checking horn switch continuity and voltage.
Horn
Procedure for checking horn operation by direct connection.
Bulb and bulb socket
Check bulb and socket for continuity if brake light fails.
Brake switch
Procedure for checking front and rear brake switch continuity.
Voltage
Check voltage at bulb socket connector for brake light.
Bulb and bulb socket
Check bulb and socket for continuity if turn signal fails.
Turn switch
Procedure for checking left handlebar switch continuity.
Voltage
Check voltage at flasher relay terminal for turn signals.
Voltage
Check voltage at bulb socket connector for turn signals.
Bulb and bulb socket
Check bulb and socket for continuity if neutral indicator light fails.
Neutral switch
Procedure for checking neutral switch continuity.
Diode (starting circuit cut-off relay)
Procedure for checking diode continuity.
Voltage
Check voltage at bulb socket connector for oil level warning light.
Starting circuit cut-off relay
Procedure for checking starting circuit cut-off relay resistance.
Fuel sender
Procedure for checking fuel sender continuity and resistance.
Fuel meter
Procedure for checking fuel meter operation by moving the float.
Voltage
Check voltage at bulb socket connector for fuel level warning light/meter.
CHAPTER 8 ELECTRICAL
ELECTRICAL COMPONENTS
Diagram showing the location of major electrical components.
CIRCUIT DIAGRAM
Overall electrical system circuit diagram.
CHECKING SWITCHES
Procedure for checking switch continuity using a pocket tester.
SWITCH POSITION AND TERMINAL CONNECTION
Charts showing switch positions and terminal connections for troubleshooting.
IGNITION SYSTEM
Circuit diagram for the ignition system.
TROUBLESHOOTING
Troubleshooting guide for ignition system failures like no spark or intermittent spark.
ELECTRIC STARTING SYSTEM
Circuit diagram for the electric starting system.
STARTING CIRCUIT OPERATION
Explanation of how the starting circuit operates based on switch conditions.
TROUBLESHOOTING
Troubleshooting guide if the starter motor fails to operate.
Starter motor
Procedure for checking starter motor operation.
Starting circuit cut-off relay (relay unit)
Procedure for checking the starting circuit cut-off relay for continuity.
Starter relay
Procedure for checking the starter relay for continuity.
Main switch
Procedure for checking main switch continuity.
Engine stop switch
Procedure for checking engine stop switch continuity.
Neutral switch
Procedure for checking neutral switch continuity.
Sidestand switch
Procedure for checking sidestand switch continuity.
Clutch switch
Procedure for checking clutch switch continuity.
Start switch
Procedure for checking start switch continuity.
Diode (starting circuit cut-off relay)
Procedure for checking diode continuity.
Wiring connection
Check for proper wiring connections in the starting system.
CHARGING SYSTEM
Circuit diagram for the charging system.
TROUBLESHOOTING
Troubleshooting guide if the battery is not charging.
Charging voltage
Procedure for checking charging voltage.
Stator coil resistance
Procedure for checking stator coil resistance.
Wiring connections
Check for proper wiring connections in the charging system.
LIGHTING SYSTEM
Circuit diagram for the lighting system.
TROUBLESHOOTING
Troubleshooting guide for headlight, high beam, taillight, auxiliary, and meter lights.
Main switch
Procedure for checking main switch continuity.
Lights switch
Procedure for checking lights switch continuity.
Dimmer switch
Procedure for checking dimmer switch continuity.
Pass switch
Procedure for checking pass switch continuity.
Wiring connections
Check for proper wiring connections in the lighting system.
Bulb and bulb socket
Check bulb and socket continuity if headlight/high beam lights fail.
Voltage
Check voltage at headlight and high beam indicator connectors.
Bulb and bulb socket
Check bulb and socket continuity if meter light fails.
Voltage
Check voltage at bulb socket connector for meter light.
Bulb and bulb socket
Check bulb and socket continuity if taillight fails.
Voltage
Check voltage at bulb socket connector for taillight.
Bulb and bulb socket
Check bulb and socket continuity if auxiliary light fails.
Voltage
Check voltage at bulb socket connector for auxiliary light.
SIGNAL SYSTEM
Circuit diagram for the signal system.
TROUBLESHOOTING
Troubleshooting guide for turn signals, brake light, indicator lights, and horn.
Main switch
Procedure for checking main switch continuity.
Wiring connections
Check for proper wiring connections in the signal system.
Horn switch
Procedure for checking horn switch continuity and voltage.
Horn
Procedure for checking horn operation by direct connection.
Bulb and bulb socket
Check bulb and socket continuity if brake light fails.
Brake switch
Procedure for checking front and rear brake switch continuity.
Voltage
Check voltage at bulb socket connector for brake light.
Bulb and bulb socket
Check bulb and socket continuity if turn signal fails.
Turn switch
Procedure for checking left handlebar switch continuity.
Voltage
Check voltage at flasher relay terminal for turn signals.
Voltage
Check voltage at bulb socket connector for turn signals.
Bulb and bulb socket
Check bulb and socket continuity if neutral indicator light fails.
Neutral switch
Procedure for checking neutral switch continuity.
Diode (starting circuit cut-off relay)
Procedure for checking diode continuity.
Voltage
Check voltage at bulb socket connector for oil level warning light.
Starting circuit cut-off relay
Procedure for checking starting circuit cut-off relay resistance.
FUEL PUMP SYSTEM
Circuit diagram for the fuel pump system.
FUEL PUMP CIRCUIT OPERATION
Explanation of the fuel pump circuit components and operation.
TROUBLESHOOTING
Troubleshooting guide if the fuel pump fails to operate.
Main switch
Procedure for checking main switch continuity.
Engine stop switch
Procedure for checking engine stop switch continuity.
Fuel pump relay (starting circuit cut-off relay)
Procedure for checking fuel pump relay continuity.
Fuel pump resistance
Procedure for checking fuel pump resistance.
Wiring connections
Check for proper wiring connections in the fuel pump system.
FUEL PUMP TEST
Procedure for testing fuel pump operation by connecting to the battery.
SELF-DIAGNOSIS
Overview of the self-diagnosis feature and monitored items.
TROUBLESHOOTING
Troubleshooting for throttle position sensor failure.
TROUBLESHOOTING
Troubleshooting for speed sensor failure.
CHAPTER 9 TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
Lists common causes for starting failure related to fuel, electrical, compression, and carburetor systems.
POOR ENGINE IDLE SPEED PERFORMANCE
Lists common causes for poor engine idle speed related to carburetor and electrical systems.
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
Lists common causes for poor performance at medium/high speeds.
FAULTY GEAR SHIFTING
Lists causes for hard shifting, stuck shift pedal, and jumping out of gear.
FAULTY CLUTCH PERFORMANCE
Lists causes for clutch slipping and dragging.
OVERHEATING
Lists common causes for engine overheating.
OVERCOOLING
Lists common causes for engine overcooling.
POOR BRAKING EFFECT
Lists common causes for poor braking performance related to discs, fluid, and calipers.
FAULTY FRONT FORK LEGS
Lists common causes for front fork malfunction and oil leakage.
UNSTABLE HANDLING
Lists common causes for unstable handling related to handlebar, steering, swingarm, tires, and frame.
FAULTY LIGHTING AND SIGNAL SYSTEMS
Troubleshooting for lighting and signal system issues like burnt-out bulbs or faulty relays.
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