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Yamaha XJR1300(L) 99 Service Manual

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  • Page 3 EAS00000 XJR1300(L) ’99 SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. 1st Edition, August 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS00002 NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology.
  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 EAS00009 SYMBOLS SPEC The following symbols are not relevant to every INFO vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) CHAS CARB 6 Chassis 7 Electrical system 8 Troubleshooting TRBL...
  • Page 7 EAS00013 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETORS CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9: Table Of Contents

    INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
  • Page 10 INFO...
  • Page 11: Chapter 1. General Information

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

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 13: Lock Washers/plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut.
  • Page 14: Checking Of The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
  • Page 15: Special Tools

    SPECIAL TOOLS INFO EB104000 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. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration 90890-03113 Engine tachometer This tool is used to check engine speed. 90890-03141 Timing light This tool is used to check the ignition tim- ing. 90890-03158 Carburetor angle driver This tool is used to turn the pilot screw when adjusting the engine idling speed.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration 90890-06754 gnition checker This tool is used to check the ignition sys- tem components. 90890-85505 Yamaha bond No. 1215 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces).
  • Page 18 INFO...
  • Page 19: Specifications

    SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .
  • Page 20 SPEC...
  • Page 21: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model XJR1300(L) Model code: 5EA2/5EA3/5EA4 Dimensions: Overall length 2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR) (SF) (AUS) 2250 mm (N) (SF) (G) (A) Overall width 775 mm Overall height 1115 mm Seat height 775 mm Wheelbase...
  • Page 22 SPEC GENERAL SPECIFICATIONS Model XJR1300(L) Carburetor: Type/quantity BS36/4 Manufacturer MIKUNI Spark plug: Type quantity DPR8EA-9/X24EPR-U9 Manufacturer NGK/DENSO 0.8 X 0.9 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 98/56 (1.750) Secondary reduction system Chain drive Secondary reduction ratio 38/17 (2.235)
  • Page 23 SPEC GENERAL SPECIFICATIONS Model XJR1300(L) Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm Shock absorber: Front shock absorber Coil spring/Oil Damper Rear shock absorber Coil spring/Gas-oil damper Wheel travel:...
  • Page 24: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Standard Limit Cylinder head: Warp limit 0.1 mm Cylinder: 79.00 X 79.01 mm Bore size Taper limit 0.05 mm Out of round limit 0.05 mm Wear limit 79.1 mm Camshaft: Drive method Chain drive (Center) 25.000 X 25.021 mm Cam cap inside diameter 24.967 X 24.980 mm...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Cam chain: Cam chain type/No. of links 79RH2015/156 Cam chain adjustment method Automatic Valve, valve seat, valve guide: 0.11 X 0.15 mm Valve clearance (cold) 0.16 X 0.20 mm Valve dimensions: Head Dia. Face Width Seat Width Margin Thickness 28.9 X 29.1 mm...
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Valve spring: Inner spring Free length 39.65 mm 37.5 mm 39.65 mm 37.5 mm Set length (valve closed) 32.8 mm 32.8 mm 61.7 X 72.5 N (6.29 X 7.39 kg) Compressed pressure (installed) 61.7 X 72.5 N (6.29 X 7.39 kg) Tilt limit 2.5_/1.7 mm 2.5_/1.7 mm...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Piston rings: Top ring: Type Barrel Dimensions (B 1.00 3.05 mm 0.20 X 0.35 mm End gap (installed) 0.6 mm 0.045 X 0.080 mm Side clearance (installed) 0.1 mm 2nd ring: Type Taper Dimensions (B 3.0 mm 0.35 X 0.50 mm End gap (installed)
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Clutch: 2.9 X 3.1 mm Friction plate thickness 2.8 mm Quantity 8 pcs 1.9 X 2.1 mm Clutch plate thickness 0.1 mm <Warp limit> Quantity 7 pcs Clutch spring height 6 mm Quantity 1 pc 0 X 0.2 mm Clutch housing thrust clearance 0.004 X 0.048 mm...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Lubrication system: Oil filter type Paper type Oil pump type Trochoid type 0.12 X 0.17 mm Tip clearance 0.2 mm 0.03 X 0.08 mm Housing and rotor clearance 0.15 mm 0.03 X 0.08 mm Side clearance 0.15 mm 180 X 220 kPa...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Camshaft cap Bolt Oil gallery bolt Screw Spark plug – 1.25 Cylinder head Cap nut 1.25 Cylinder head cover Bolt Cylinder Stud bolt 1.25 Cylinder...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Crankcase Bolt 1.25 Crankcase Bolt 1.25 Main gallery Plug Oil buffle plate Bolt Stopper plate Bolt Bearing housing Screw HY-VO chain guide Bolt Clutch boss Clutch pressure plate Bolt...
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Tightening sequence Cylinder head Crankcase 2-12...
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Model XJR1300(L) Lubrication chart: Pressure feed Splashed Ex. camshaft Lifter Timing chain area Generator IN. camshaft Lifter shaft Piston, Cylinder Clutch Transmission Connecting rod bearing Crankshaft bearings Main gallery Oil filter Oil cooler Relief valve Oil pump Oil pan / Oil strainer 2-13...
  • Page 34: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel 130 mm Fork spring free length 407.3 mm 395 mm Fitting length 363.3 mm Collar length 150 mm Spring rate (K1) 4.9 N/mm (0.5 kg/mm) (K2) 8.8 N/mm (0.9 kg/mm)
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Front disc brake: Type Dual Disc outside diameter thickness 5 mm Disc deflection limit 0.2 mm Pad thickness 5.5 mm 0.5 mm Master cylinder inside diameter 14 mm Caliper cylinder inside diameter 30.2 mm and 27 mm Brake fluid type DOT #4 Rear disc brake:...
  • Page 36 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mSkg Handle crown and inner tube Bolt 1.25 Handle crown and steering stem 11.0 Handle crown and handlebar holder 1.25 (lower) Upper handlebar holder Bolt 1.25 Lower bracket and inner tube...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mSkg Hook Screw Helmet holder Bolt Tail light bracket Bolt 1.25 Side stand Bolt 1.25 Side stand 1.25 Side stand switch Screw Footrest bracket Bolt 1.25 Rear footrest bracket...
  • Page 38: Electrical

    Advanced timing (B.T.D.C.) 50_ /5000 r/min Advancer type TPS & Electrical type T.C.I.: 248 X 372 Ω/W/R-W/G Pickup coil resistance/color T.C.I. unit model/manufacturer 5EA20/YAMAHA Ignition coil: Model/manufacturer 83R/YAMAHA Minimum spark gap 6 mm 1.9 X 2.9 Ω Primary winding resistance 9.5 X 14.3 kΩ...
  • Page 39 SPEC MAINTENANCE SPECIFICATIONS Model Standard Limit Mica undercut 0.7 mm Starter relay: Model/manufacturer MS5E-491/JIDECO Amperage rating 100 A 4.2 X 4.6 Ω Coil winding resistance Horn: Type Plane type Quantity 2 pcs Model/manufacturer YF12/NIKKO Maximum amperage Flasher relay: Type Full transistor type Model/manufacturer FE246BH/DENSO Self cancelling device...
  • Page 40: General Torque Specifications

    CONVERSION TABLE/ SPEC GENERAL TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUES All specification data in this manual are listed in This chart specifies tightening torques for stan- SI and METRIC UNITS. dard fasteners with a standard ISO thread pitch. Use this table to convert METRIC unit data to Tightening torque specifications for special IMPERIAL unit data.
  • Page 41: Lubrication Point And Grade Of Lubricant

    Starter clutch (outer/roller) Crankcase cover (push rod hole) Primary drive gear/damper Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Crankcase mating surfaces Yamaha bond No. 1215 Blind plug and oil seal (crankcase main gallery) Yamaha bond No. 1215 2-21...
  • Page 42: Chassis

    SPEC LUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Symbol Steering bearing (upper/lower) and bearing cover lip Front wheel oil seal (left/right) Rear wheel oil seal (left/right) Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever bolt, sliding surface...
  • Page 43: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Camshaft (intake) Camshaft (exhaust) Main gallery Oil strainer Oil pump Main axle Crankshaft 2-23...
  • Page 44 SPEC LUBRICATION DIAGRAMS Oil cooler Starter clutch Main axle Drive axle Oil pump Oil pan Relief valve Main gallery 2-24...
  • Page 45 SPEC LUBRICATION DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 2-25...
  • Page 46: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Starter motor cable Throttle position sensor A Fasten the wireharness to the Battery negative (–) lead Ignition coil lead (#2, 3) seat rail with a plastic band. Make Battery negative (–) lead con- Throttle cable sure that the end of band down nector Engine ground lead...
  • Page 47 SPEC CABLE ROUTING D Route the wireharness and start- F Fasten the wireharness to the I Fasten the high tension cables er motor cable in front of the res- frame with a plastic band. Make and throttle cables with a plastic ervoir tank bracket and the bat- sure that the end of band down clamp.
  • Page 48 SPEC CABLE ROUTING L Route the wireharness and start- er motor cable behind the side cover bracket and fasten them with a plastic band at front of the bracket. M Align the white paint marks of the fuel tank drain hose, fuel tank breather hose and air filter case drain hose.
  • Page 49 SPEC CABLE ROUTING Clutch hose A Insert the plastic band through E Fasten the high tension cables Starter cable the hole of plastic panel and then (#1, 2) with a plastic clamp. Posi- Air filter case drain hose fasten the clutch hose with it. tion the clamp at 50 –...
  • Page 50 SPEC CABLE ROUTING H Fasten the seat lock cable to the K Fasten the sidestand switch lead N Route the speedometer cable seat real with a plastic band. with steel clamp on the frame through the guide. Make sure that the end of band and then route it between the O Touch the brake pipe to the bra- down ward.
  • Page 51 SPEC CABLE ROUTING Throttle cables Starter relay Taillight lead Ignition coil (#2, 3) Seat lock cable Starter cable Throttle position sensor Seat lock Neutral switch connector Battery positive (+) lead A Position the horn (high) to right Pickup coil connector Fuse box side.
  • Page 52 SPEC CABLE ROUTING E Connect the fuel sender connec- G Fasten the battery positive (+) J Position the seat lock cable in- tor, neutral switch connector, lead and battery positive (+) lead side under the seat lock bracket. pickup coil connector and side- connector on the groove of the K Fasten the wireharness to the stand switch connector above...
  • Page 53 SPEC CABLE ROUTING N Fasten the wireharness, taillight lead and rear turn signal light leads (left and right) with steel clamp on the frame make sure that the end of clamp forward. O Route the rear turn signal light leads (left and right) through the each holes of the rear fender.
  • Page 54 SPEC CABLE ROUTING Meter leads A Route the throttle cables through D Route the handlebar switch lead Main switch lead the guide on the headlight stay. (left) and front turn signal light Starter cable B Route the meter leads, main lead (left) into the left under hole Handlebar switch lead (left) switch lead into the upper hole of...
  • Page 55 SPEC CABLE ROUTING H Touch the brake pipe to the stop- per. I Route the handlebar switch lead (right) and front turn signal light lead (right) into the right under hole of the headlight stay. J Fasten the handlebar switch lead (right) and front brake hose with a plastic band.
  • Page 56 SPEC...
  • Page 57 CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
  • Page 58 LUBRICATING THE SIDE STAND ......3-40 LUBRICATING THE CENTERSTAND ......3-40 LUBRICATING THE REAR SUSPENSION .
  • Page 59: Chapter 3. Periodic Inspection And Adjustment

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa- tion applies to vehicles already in service as well as new vehicles that are being prepared for sale.
  • Page 60 PERIODIC MAINTENANCE/LUBRICATION INTERVALS It is recommended that these items be serviced by a Yamaha dealer. **: Molybdenum disulfide grease. ***: Lithium soap base grease. NOTE: Brake fluid replacement: 1. When disassembling the master cylinder, caliper cylinder or clutch release cylinder, replace the brake fluid.
  • Page 61: Seat Side Cover And Fuel Tank

    SEAT, SIDE COVER AND FUEL TANK SEAT, SIDE COVER AND FUEL TANK 30 Nm (3.0 mSkg) 19 Nm (1.9 mSkg) Order Job/Part Q’ty Remarks Removing the seat, side cover and Remove the parts in the order listed. fuel tank Seat Side cover (left) Side cover (right) NOTE:...
  • Page 62: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE the following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 63 ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the timing plate with the mark b on the pickup coil base plate. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from...
  • Page 64 ADJUSTING THE VALVE CLEARANCE 5. Adjust: S Valve clearance a. Align the intake and exhaust valve lifter slots with each other. b. Slowly turn the crankshaft until the cam lifted at maximum. c. Install the tappet adjusting tool 1 as shown. Tappet adjusting tool: P/N 90890-04110 NOTE:...
  • Page 65 ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 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 CLEARANCE 0.00 X 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 X 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 X 0.15...
  • Page 66 ADJUSTING THE VALVE CLEARANCE EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm (0.098 in)) Rounded value = 250 h. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row inter- sect is the new valve pad number.
  • Page 67: Synchronizing The Carburetor

    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 68: Adjusting The Idling Speed

    SYNCHRONIZING THE CARBURETORS ADJUSTING THE ENGINE IDLING SPEED b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in ei- ther direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in ei- ther direction until both gauges read the same.
  • Page 69: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY Engine tachometer 90890-03113 3. Measure: S engine idling speed Out of specification ! Adjust. Engine idling speed 1,000 X 1,100 r/min 4. Adjust: S engine idling speed a. Turn the pilot screw 1 in or out until it is light- ly seated.
  • Page 70 ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Remove: S seat S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. 3. Adjust: S throttle cable free play NOTE: When the motorcycle is accelerating, the acceler- ator cable 1 is pulled. Carburetor side a.
  • Page 71: Checking The Spark Plugs

    CHECKING THE SPARK PLUGS CHECKING THE IGNITION TIMING EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: S spark plug cap 2. Remove: S spark plug CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal- ling into the cylinders.
  • Page 72: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE 2. Install: S timing light 1 S engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light 90890-03141 Engine tachometer 90890-03113 3. Check: S ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.
  • Page 73 MEASURING THE COMPRESSION PRESSURE 3. Disconnect: S spark plug cap 4. Remove: S spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders.
  • Page 74: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL a. Turn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.
  • Page 75: Checking The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled “ENERGY CONSERV- ING II”...
  • Page 76: Measuring The Engine Oil Pressure

    CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE Quantity Total amount 4.2 L Without oil filter element re- placement With oil filter element replace- ment 3.35 L 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 77: Adjusting The Clutch Lever

    MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH LEVER Engine oil pressure 80 kPa (0.8 kg/cm , 0.8 bar) Engine speed Approx. 1000 r/min Engine oil temperature 70 X 80_C (158 X 176_F) Out of specification ! Adjust. Engine oil pressure Possible causes Faulty oil pump Clogged oil filter Below specification...
  • Page 78: Checking The Clutch Fluid Level

    CHECKING THE CLUTCH FLUID LEVEL/ BLEEDING THE HYDRAULIC CLUTCH SYSTEM EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper lev- Recommended clutch fluid Brake fluid DOT 4...
  • Page 79 BLEEDING THE HYDRAULIC CLUTCH SYSTEM NOTE: S Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over- flow. S When bleeding the hydraulic clutch system, make sure that there is always enough clutch fluid before applying the clutch lever.
  • Page 80: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00087 CLEANING THE AIR FILTER ELEMENT 1. Remove: S side cover (right) Refer to “SEAT, SIDE COVER AND FUEL TANK”. S air filter case cover 1 2. Remove: S air filter element 2 3. Clean: S air filter element 1 Apply compressed air to the inner surface of the air filter element.
  • Page 81: Checking The Carburetor Joints And Intake Manifolds

    CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/ CHECKING THE FUEL AND VACUUM HOSES EAS00095 CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the car- buretor joints and intake manifolds. 1. Remove: S seat S side cover S fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”.
  • Page 82: Checking The Crankcase Breather Hose

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE CRANKCASE BREATHER HOSE EAS00100 1. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex-...
  • Page 83: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
  • Page 84: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL EAS00110 c. Tighten the locknut 1 to specification. Locknut 18 Nm (1.8 mSkg) WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system.
  • Page 85: Checking The Brake Pads

    CHECKING THE BRAKE FLUID LEVEL / CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH S When refilling, be careful that water does not enter the reservoir. Water will signifi- cantly lower the boiling point of the brake fluid and could cause vapor lock. CAUTION: Brake fluid may damage painted surfaces and plastic parts.
  • Page 86: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenev- S the system was disassembled, S a brake hose was loosened or removed, S the brake fluid level is very low, S brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake...
  • Page 87: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK Bleed screw 6 Nm (0.6 mSkg) k. Fill the reservoir to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING After bleeding the hydraulic brake system, check the brake operation.
  • Page 88: Adjusting The Drive Chain Slack

    ADJUSTING THE DRIVE CHAIN SLACK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2.
  • Page 89: Lubricating The Drive Chain

    ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN CAUTION: Do not loosen the wheel axle nut after tight- ening it to the specified torque. If the groove in the wheel axle nut is not aligned with the cotter pin hole in the wheel axle, tighten the nut further until they are aligned.
  • Page 90: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEER- ING 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 91 CHECKING AND ADJUSTING THE STEERING HEAD 8. Remove: S upper handleber holder 1 S handleber 2 –0.2po 9. Remove: S handle crown 1 10. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b.
  • Page 92: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK e. Install the rubber washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.
  • Page 93: Adjusting The Front Fork Legs

    ADJUSTING THE FRONT FORK LEGS ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over.
  • Page 94: Adjusting The Rear Shock Absorber Assemblies

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES EAS00161 ADJUSTING THE REAR SHOCK ABSORB- ER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. WARNING S Securely support the motorcycle so that there is no danger of it falling over. S Always adjust both rear shock absorber assemblies evenly.
  • Page 95 CHECKING THE TIRES EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 96: Checking The Tires

    Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. 3-38...
  • Page 97: Checking The Wheels

    CHECKING THE TIRES/CHECKING THE WHEELS Front tire Manufacturer Size Type MICHELIN 120 / 70ZR17 MACADAM 90X DUNLOP 120 / 70ZR17 D207F BRIDGESTONE 120 / 70ZR17 BT57F Rear tire Manufacturer Size Type MICHELIN 180/ 55ZR17 MACADAM 90X DUNLOP 180 / 55ZR17 D207 BRIDGESTONE 180 / 55ZR17 BT57R...
  • Page 98: Checking And Lubricating The Cables

    CHECKING ANDLUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE SIDE STAND/LUBRICATING THE CENTERSTAND LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment.
  • Page 99 CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 100 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 101 CHECKING AND CHARGING THE BATTERY WARNING Do not quick charge a battery. CAUTION: S Make sure that the battery vent is free of ob- structions. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
  • Page 102 CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger Charger Measure the open-circuit NOTE: Ammeter voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16 X 17 V.
  • Page 103 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger Measure the open-circuit NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- meter to the battery and start charging.
  • Page 104 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Check: S battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery 8. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 .
  • Page 105 CHECKING THE FUSES Pocket tester 90890-03112 b. If the pocket tester indicates “ ”, replace the fuse. 3. Replace: S blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational.
  • Page 106 REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S headlight unit 1 2. Disconnect: S headlight lead 1 S auxiliary light lead 2 3. Remove: S cover 3 4. Remove: S headlight bulb holder 1 5. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot,...
  • Page 107 REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Install: S headlight bulb holder 8. Install: S cover 9. Connect: S auxiliary light lead S headlight lead 10. Install: S headlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a.
  • Page 109 CHAPTER 4. ENGINE OVERHAUL ENGINE ............LEADS, HOSES AND EXHAUST PIPES .
  • Page 110 CHECKING THE PRESSURE PLATE ......4-37 CHECKING THE CLUTCH PUSH RODS ..... . . 4-38 INSTALLING THE CLUTCH .
  • Page 111 CHECKING THE BEARINGS AND OIL SEALS ....4-79 CHECKING THE CIRCLIPS AND WASHERS ....4-79 INSTALLING THE CONNECTING RODS .
  • Page 113: Engine

    ENGINE EAS0018 ENGINE OVERHAULE ENGINE LEADS, HOSES AND EXHAUST PIPES 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 25 Nm (2.5 mSkg) 25 Nm (2.5 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty...
  • Page 114 ENGINE 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 25 Nm (2.5 mSkg) 25 Nm (2.5 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks O-ring NOTE: Ground lead Disconnect ground lead.
  • Page 115: Leads And Drive Sprocet

    ENGINE EAS00190 LEADS AND DRIVE SPROCKET 10 Nm (1.0 mSkg) 85 Nm (8.5 mSkg) 10 Nm (1.0 mSkg) 25 Nm (2.5 mSkg) 10.Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the leads and drive Remove the parts in the order listed. sprocket NOTE: Starter motor lead...
  • Page 116 ENGINE 10 Nm (1.0 mSkg) 85 Nm (8.5 mSkg) 10 Nm (1.0 mSkg) 25 Nm (2.5 mSkg) 10.Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Lock washer Drive sprocket Drive chain For installation, reverse the removal procedure.
  • Page 117: Engine

    ENGINE ENGINE 48 Nm (4.8 mSkg) 88 Nm (8.8 mSkg) 64 Nm (6.4 mSkg) 28 Nm (2.8 mSkg) 30 Nm (3.0 mSkg) 55 Nm (5.5 mSkg) 64 Nm (6.4 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed.
  • Page 118: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Tighten the bolts in the following order. Bolt 1 : 88 Nm (8.8 mSkg) Bolt 2 : 48 Nm (4.8 mSkg) Bolt 3 : 55 Nm (5.5 mSkg) Bolt 4 : 30 Nm (3.0 mSkg) Bolt 5 : 64 Nm (6.4 mSkg) Nut 6 :...
  • Page 119: Camshaft

    CAMSHAFT CAMSHAFT CYLINDER HEAD COVER 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed. Seat, fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK”. Bolts Air duct (left/right) Plug cap...
  • Page 120: Camshafts

    CAMSHAFTS EAS00196 CAMSHAFTS 12 Nm (1.2 mSkg) 20 Nm (2.0 mSkg) 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Spark plugs Timing plate cover/Gasket Timing chain guide (top side) Timing chain tensioner assembly Timing chain guide (exhaust side)
  • Page 121: Removing The Camshafts

    CAMSHAFTS EAS00199 REMOVING THE CAMSHAFTS 1. Align: S “T” mark on the timing plate (with the stationary pointer on the pickup coil base plate) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark a with the pickup coil mark b .
  • Page 122: Checking The Camshafts

    CAMSHAFTS EAS000204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Camshaft lobe dimension limit Intake/exhaust a Wear limit <28.15 mm> b Wear limit <35.85 mm>...
  • Page 123: Checking The Camshaft Sprockets And Timing Chain Guides

    CAMSHAFTS 5. Measure: S camshaft journal diameter a Out of specification ! Replace the cam- shaft. Within specification ! Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.967 X 24.980 mm EAS00208 CHECKING THE CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshafts sprockets and timing chain guides.
  • Page 124: Installing The Camshafts

    CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: S camshaft sprockets NOTE: S Be sure to set the sprockets in the specified position as shown in the figure. S Temporarily tighten the bolts in this stage. A Exhaust side B Intake side 2.
  • Page 125 CAMSHAFTS CAMSHAFTS d. Check if the punched marks c on both cam- shafts are inside the holes of camshaft caps d . If they are not in the position, repeat the above steps. e. Tighten the bolts (camshaft cap) in a criss- cross pattern from the inside outwards.
  • Page 126 CAMSHAFTS a. Turn the crankshaft counterclockwise sever- al times until the TDC mark on the timing plate is aligned with the stationary pointer. b. Check if both the camshaft timing punch marks a are aligning with the camshaft cap hole b . 5.
  • Page 127: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 35 Nm (3.5 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. NOTE: Remove the engine mount (front) and move the engine to front side.
  • Page 128: Removing The Cylinder Head

    CYLINDER HEAD EAS00223 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head nuts 1 X NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00228 CHECKING THE CYLINDER HEAD The following procedure applies to all of the cyl-...
  • Page 129: Installing The Cylinder Head

    CYLINDER HEAD NOTE: To ensure an even surface, rotate the cylinder head several times. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: S gasket (New) 1 S dowel pins 2 2. Install: S cylinder head S washers S copper washers S cylinder head nuts NOTE: S Apply engine oil onto the threads of the cylin- der head nuts.
  • Page 130: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Camshaft Refer to “CAMSHAFTS”. Cylinder head Refer to “CYLINDER HEAD”. Valve pads Valve lifters Valve cotters Upper springs seats Valve springs (outer)
  • Page 131: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 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 that the valves properly seal. 1.
  • Page 132: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: S upper spring seat 1 S valve springs 2 S oil seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the...
  • Page 133 VALVES AND VALVE SPRINGS a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem to valve-guide clearance.
  • Page 134: Checking The Valve Seats

    VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: S carbon deposits (from the valve face and valve seat) 2. Check: S valve seat Pitting/wear ! Replace the cylinder head. 3.
  • Page 135: Checking The Valve Springs

    VALVES AND VALVE SPRINGS d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hand.
  • Page 136: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS Valve spring free length (intake and exhaust) Inner spring <Limit> 39.65 mm <37.5 mm> Outer spring <Limit> 41.1 mm <39 mm> 2. Measure: S compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force Intake and exhaust inner spring...
  • Page 137 VALVES AND VALVE SPRINGS Recommended lubricant Molybdenum disulfide oil 2. Install: S valve 1 S lower spring seat 2 S oil seal 3 S valve springs 4 S upper spring seat 5 (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up.
  • Page 138: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00252 CYLINDERS AND PISTONS 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Cylinder block Dowel pins Gasket Refer to “REMOVING/INSTALLING THE Piston pin clips CYLINDERS AND PISTONS”.
  • Page 139: Removing The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
  • Page 140 CYLINDERS AND PISTONS a. Measure cylinder bore “C” with the cylinder bore gauge. 1 20 mm from the top of the cylinder NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cyl- inder. Then, find the average of the measure- ments.
  • Page 141: Checking The Piston Rings

    CYLINDERS AND PISTONS EAS00263 CHECKING THE PISTON RINGS 1. Measure: S piston ring side clearance Out of specification ! Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.
  • Page 142: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS EAS00270 INSTALLING THE PISTONS AND CYLIN- DERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: S top ring 1 S 2nd ring 2 S lower oil ring rail 3 S upper oil ring rail 4 S oil ring expander 5 NOTE: S Be sure to install the piston rings so that the...
  • Page 143 CYLINDERS AND PISTONS 3. Install: S gasket (New) 1 S dowel pins 2 4. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring...
  • Page 144: Clutch

    CLUTCH EAS00273 CLUTCH CLUTCH COVER 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover. Remove the parts in the order listed. Engine oil Drain Clutch cover Gasket Dowel pins For installation, reverse the removal procedure. 4-32...
  • Page 145: Clutch

    CLUTCH EAS00274 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Pressure plate Clutch spring Spring housing Pressure plate Clutch push rod (short) Ball Refer to “INSTALLING THE CLUTCH”. Clutch push rod (long) O-ring Friction plates...
  • Page 146 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Clutch boss Stopper ring Clutch plate Clutch spring plate Clutch spring plate seat Refer to “REMOVING/INSTALLING Friction plates (narrow) THE CLUTCH”. Thrust washer Spacer Bearing Clutch housing For installation, reverse the removal procedure.
  • Page 147: Removing The Clutch

    CLUTCH EAS00275 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder, loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3.
  • Page 148: Checking The Clutch Plates

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge Out of specification ! Replace the clutch plates as a set.
  • Page 149: Checking The Clutch Housing

    CLUTCH EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S 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 er- ratic clutch operation. 2. Check: S bearing Damage/wear ! Replace the clutch hous- ing.
  • Page 150: Installing The Clutch

    CLUTCH EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: S O-ring 1 S short clutch push rod 2 S long clutch push rod 3 S ball 4 S bearing 5 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Measure: S long clutch push rod bending limit Out of specification ! Replace the long clutch push rod.
  • Page 151 CLUTCH 3. Tighten: S clutch boss nut 1 NOTE: While holding the clutch boss with the universal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 Clutch boss nut 70 Nm (7.0 mSkg) 4. Bend the lock washer tab along a flat side of the nut.
  • Page 152 CLUTCH 7. Install: S Friction plates (narrow type) 1 S Clutch plates 2 S Stopper ring 3 S Friction plates (wide type) 4 a. Install the friction plate of narrow contact face 1 and one of the clutch plate to the clutch boss.
  • Page 153: Clutch Master Cylinder

    CLUTCH EAS00305 CLUTCH MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch master Remove the parts in the order listed. cylinder NOTE: Clutch lever Clutch switch lead Before removing the clutch master cylin- Clutch switch der, drain the clutch fluid from the entire clutch system.
  • Page 154 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch master Disassembly the parts in the order listed. cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 4-42...
  • Page 155: Checking The Clutch Master Cylinder

    CLUTCH EAS00307 CAUTION: Clutch components rarely require disas- sembly. Therefore, always follow these preventive measures: S Never disassemble clutch components un- less absolutely necessary. S 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 156: Assembling The Clutch Master Cylinder

    CLUTCH 2. Check: S clutch master cylinder 1 S clutch master cylinder kit 2 Rust/scratches/wear ! Replace the clutch master cylinder and clutch master cylinder kit as a set. S clutch hose 3 Cracks/damage/wear ! Replace. EAS00309 ASSEMBLING THE CLUTCH MASTER CYL- INDER WARNING S Before installation, all internal clutch com-...
  • Page 157 CLUTCH Union bolt 30 Nm (3.0 mSkg) 3. Install: S clutch lever 1 NOTE: Lubricate the clutch lever pivot bolt with lithium soap base grease. 4. Fill: S clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING...
  • Page 158 CLUTCH 6. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper lev- Refer to “CHECKING THE CLUTCH FLUID LEVEL” in chapter 3. 7. Check: S clutch lever operation Soft or spongy feeling ! Bleed the clutch system.
  • Page 159: Clutch Release Cylinder

    CLUTCH EAS00311 CLUTCH RELEASE CYLINDER 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch release Remove the parts in the order listed. cylinder Refer to “INSTALLING THE CLUTCH RELEASE CYLINDER”. Bolt NOTE: Before removing the clutch releace cylin- der, drain the clutch fluid from the entire clutch system.
  • Page 160 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch release Disassembly the parts in the order listed. cylinder Clutch release cylinder Piston seal Refer to “DISASSEMBLING THE Clutch release cylinder piston CLUTCH RELEASE CYLINDER”. Piston seal Spring For assembly, reverse the disassembly procedure.
  • Page 161: Disassembling The Clutch Release Cylinder

    CLUTCH EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove: S piston seal 1 S clutch release cylinder piston 2 S spring 3 S piston seal 4 a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder.
  • Page 162: Installing The Clutch Release Cylinder

    CLUTCH EAS00315 INSTALLING THE CLUTCH RELEASE CYL- INDER 1. Check: S copper washers (New) S clutch hose 1 S union bolt 2 WARNING Proper clutch hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. Union bolt 30 Nm (3.0 mSkg) 2.
  • Page 163 CLUTCH NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reser- voir is horizontal. 3. Bleed: S clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 4.
  • Page 164: Oil Pump

    OIL PUMP OIL PUMP 4 Nm (0.4 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pump. Remove the parts in the order listed. Clutch Refer to “INSTALLING THE CLUTCH”. Oil pump drive gear Collar Washer Oil buffer plate Circlip Oil pump driven gear Washer...
  • Page 165 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Disassembly the parts in the order listed. Oil pump housing Inner rotor Outer rotor Dowel pin Refer to “ASSEMBLING THE OIL Oil pump housing PUMP”. Inner rotor Outer rotor Oil pump shaft Oil pump cover For assembly, reverse the disassembly procedure.
  • Page 166: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: S oil pump drive gear 1 S oil pump driven gear 2 S oil pump housing 3 S oil pump housing cover 4 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Measure: S inner-rotor to outer-rotor tip clearance A S outer-rotor to oil-pump-housing clearance B S oil-pump-housing to inner-rotor and outer-...
  • Page 167: Assembling The Oil Pump

    OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5...
  • Page 168: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft and Remove the parts in the order listed. stopper lever Oil pump Refer to “OIL PUMP”. Drive sprocket cover Refer to “ENGINE”. Circlip Washer Shift shaft Washer...
  • Page 169: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift lever spring Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
  • Page 170 SHIFT SHAFT NOTE: S Lubricate the oil seal lips with lithium soap base grease. S Hook the end of the shift lever spring onto the shift lever spring stopper 4 . 4-58...
  • Page 171: Timing Plate And Pickup Coil

    TIMING PLATE AND PICKUP COIL TIMING PLATE AND PICKUP COIL 45 Nm (4.5 mSkg) 4 Nm (0.4 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the timing plate and Remove the parts in the order listed. pickup coil Seat, side cover, fuel tank Pickup coil read Timing plate cover...
  • Page 172: Oil Pan

    OIL PAN OIL PAN 10 Nm(1.0 mSkg) 10 Nm(1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pan Remove the parts in the order listed. Engine Refer to “ENGINE”. Oil level switch/O-ring Oil pan Refer to “REMOVING/INSTALLING Dowel pin THE OIL PAN”. Gasket Relief valve/O-ring Relief valve/O-ring...
  • Page 173: Removing The Oil Pan

    OIL PAN EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S gasket S 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 174: Installing The Oil Strainer

    OIL PAN EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer housing 1 Oil strainer housing bolt 10 Nm (1.0 mSkg) LOCTITE NOTE: The arrow a on the oil strainer housing must point towards the front of the engine. 2.
  • Page 175: Crankcase

    CRANKCASE CRANKCASE 35 Nm (3.5 mSkg) 12Nm (1.2 mSkg) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) 35 Nm (3.5 mSkg) 12Nm (1.2 mSkg) 10Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pan Remove the parts in the order listed. Engine Refer to “ENGINE”.
  • Page 176 CRANKCASE 35 Nm (3.5 mSkg) 12 Nm (1.2 mSkg) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) 35 Nm (3.5 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Bearing cover Crankcase (lower) Refer to “DISASSEMBLING/ASSEM- BLING THE CRANKCASE”.
  • Page 177: Disassembling The Crankcase

    CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts NOTE: S 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. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
  • Page 178: Checking The Crankcase

    Recommended lubricant Engine oil 2. Apply: S 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 X 3 mm of the crankshaft journal bearings.
  • Page 179 CRANKCASE 5. Set the shift drum assembly and transmis- sion gears in the neutral position. 6. Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand.
  • Page 180: Starter Clutch

    STARTER CLUTCH EAS00342 STARTER CLUTCH 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Crankcase Refer to “CRANKCASE”. Bearing housing O-ring Oil seal Nozzle Generator shaft Bearing Starter clutch drive gear Refer to “INSTALLING THE STARTER...
  • Page 181 STARTER CLUTCH 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Idle gear shaft Starter clutch idle gear Bearing For installation, reverse the removal pro- cedure. 4-69...
  • Page 182: Checking The Starter Clutch

    STARTER CLUTCH EAS00350 CHECKINHG THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 2 S starter clutch drive gear 3 S starter clutch gear 4 Burrs/chips/roughness/wear Replace the defective part(-s). 3.
  • Page 183: Checking The Generator Shaft

    STARTER CLUTCH EAS00352 CHECKING THE GENERATOR SHAFT 1. Check: S generator shaft 1 S generator shaft splines 2 Damage/wear ! Replace the generator shaft. S oil passages 3 Dirt/obstruction ! Wash the generator shaft and then blow out the oil passages with com- pressed air.
  • Page 184: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Refer to “CRANKCASE”. Starter clutch Refer to “STARTER CLUTCH”. Crankshaft Oil seal Refer to “INSTALLING THE Cover CRANKSHAFT ASSEMBLY”. Timing chain HY-VO chain Crankshaft journal bearings Refer to “REMOVING/INSTALLING THE...
  • Page 185: Crankshaft

    CRANKSHAFT CONNECTING ROD 36 Nm (3.6 mSkg) Order Job/Part Q’ty Remarks Removing the connecting rod. Remove the parts in the order listed Refer to ”INSTALLING THE Connecting rod bolt CONNEECTING RODS.” Coonecting rod Refer to ”REMOVING/INSTALLING THE Connecting rod cap CONNECTING RODS.”...
  • Page 186: Removing The Crankshaft Assembly

    CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly 1 S 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. EAS00391 REMOVING THE CONNECTING RODS 1.
  • Page 187 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 1 and the crankshaft into the upper crank- case.
  • Page 188 CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings. h. Measure the compressed Plastigauge width 1 on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 4. Select: S Crankshaft journal bearings (J For example, if the crankcase “J ”...
  • Page 189 CRANKSHAFT CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crank- shaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bear- ings must be installed in their original posi- tions. a. Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods.
  • Page 190 CRANKSHAFT Refer to “INSTALLING THE CONNECTING RODS”. Connecting rod nut 36 Nm (3.6 mSkg) f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS”. g. Measure the compressed Plastigauge width 1 on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings.
  • Page 191: Checking The Timing Chain

    CRANKSHAFT CHECKING THE TIMING CHAIN 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2. Check S timing chain guide (intake side) Damage/wear ! Replace. EAS00400 CHECKING THE HY-VO CHAIN 1. Check: S HY-VO chain 1 Damage/stiffness ! Replace the HY-VO chain and sprockets as a set.
  • Page 192 CRANKSHAFT Recommended lubricant Engine oil 3. Install: S big end bearings 1 S connecting rods 2 S connecting rod caps 3 (onto the crankshaft pins) NOTE: S Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
  • Page 193: Installing The Crankshaft

    CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
  • Page 194: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks. Crankcase Refer to “CRANKCASE”. Main axle assembly Oil seal Refer to “INSTALLING THE TRANSMIS- Bearing SION”. Drive axle assembly Collar O-ring Oil seal...
  • Page 195 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the transmission Disassembly the parts in the order listed. Washer 1st wheel gear/Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear/collar Washer 5th wheel gear Circlip Washer 2nd wheel gear/collar Drive axle 4-83...
  • Page 196 TRANSMISSION Order Job/Part Q’ty Remarks 2nd pinion gear 5th pinion gear/collar Washer 3rd pinion gear Circlip Washer 4th pinion gear Main axle (1st pinion gear) For assembly, reverse the disassembly procedure. 4-84...
  • Page 197: Shift Cam And Shift Fork

    TRANSMISSION SHIFT CAM AND SHIFT FORK Order Job/Part Q’ty Remarks Removing the shift cam and shift Remove the parts in the order listed. fork. Refer to ”CRANKCASE” Crankcase Shif fork quide bar Shift fork (L) Refer to ”INSTALLING THE Shift fork (C) TRANSMISSION Shift fork (R) Stopper plate...
  • Page 198: Checking The Shift Fork

    TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: S shift fork cam follower 1 S shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork. 2. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface.
  • Page 199: Installing The Shift Forks And Shift Drum Assembly

    TRANSMISSION 2. Measure: S drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. Drive axle runout limit 0.06 mm 3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s). S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s).
  • Page 200: Installing The Transmission

    TRANSMISSION EAS00429 INSTALLING THE TRANSMISSION 1. Install: S main axle assembly 1 S drive axle assembly 2 NOTE: S Make sure that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase. S The drive axle bearing pin 5 must face to- wards the rear of the crankcase and the main axle bearing pin 6 must face towards the front of the crankcase.
  • Page 201 CARB CHAPTER 5. CARBURETORS CARBURETORS ..........CHECKING THE CARBURETORS .
  • Page 202 CARB...
  • Page 203: Chapter 5. Carburetors

    CARB CARBURETORS EAS00481 CARBURETORS CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Seat, fuel tank Refer to “SEAT, SIDE COVER AND FUEL TANK” in Chapter 3. Battery negative lead Battery positive lead Battery Carburetor joint screws Loosen Air filter joint screws...
  • Page 204 CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Disassembly the parts in the order listed. Starter shaft/Starter levers NOTE: Upper bracket The following procedure applies to all of the carburetors. Lower bracket Throttle stop screw set Carburetors Throttle cable bracket Starter plunger set Vacuum chamber cover Piston valve spring...
  • Page 205 CARB CARBURETORS EAS00484 Order Job/Part Q’ty Remarks Float chamber Float chamber gasket Float pin Float Refer to “ASSEMBLING THE CARBURE- Needle valve ass’y TORS”. Pilot jet Main jet Needle jet For assembly, reverse the disassembly procedure.
  • Page 206: Checking The Carburetors

    CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent.
  • Page 207: Assembling The Carburetors

    CARB CARBURETORS 10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S pilot jet 4 S pilot screw 5 Bends/damage/wear ! Replace. Obstruction ! Clean. Blow out the jets with compressed air. 11. Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down.
  • Page 208 CARB CARBURETORS EAS00489 2. Measure: S float height a Out of specification ! Adjust. Float height 21.3 X 23.3 mm a. Hold the carburetor upside down. b. Measure the distance from the mating sur- face of the float chamber (with the gasket re- moved) to the top of the float.
  • Page 209: Installing The Carburetors

    CARB CARBURETORS EAS00493 INSTALLING THE CARBURETORS 1. Adjust: S carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in chapter 3. 2. Adjust: S engine idling speed Engine idling speed 1,000 X 1,100 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3.
  • Page 210: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETORS a. Remove the carburetor assembly. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slight- ly bending the float tang 1 . e.
  • Page 211 CARB CARBURETORS Out of specification ! Replace the throttle position sensor. Throttle position sensor resistance 0 to 4 X 6 kΩ at 20_C (68_F) (Yellow – Black/Blue) 2. Adjust: S throttle position sensor angle a. Turn the main switch to “ON”. b.
  • Page 212: Checking The Fuel Cock

    CARB CARBURETORS EAS00505 CHECKING THE FUEL COCK 1. Check: S fuel cock Cracks/damage/wear ! Replace. EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its opera- tion. 1. Check that the fuel cock lever is positioned to “ON”...
  • Page 213 CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISCS ......REMOVING THE FRONT WHEEL .
  • Page 214 CHAS FRONT FORK ..........6-41 REMOVING THE FRONT FORK LEGS .
  • Page 215: Chapter 6. Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 73 Nm (7.3 mSkg) 19 Nm (1.9 mSkg) 40 Nm (4.0 mSkg) 20 Nm (2.0 mSkg) 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...
  • Page 216 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel. Disassembly the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure.
  • Page 217: 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 218: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4. Check: S wheel bearings Front wheel turns roughly or is loose ! Re- place the wheel bearings. S oil seals Damage/wear ! Replace.
  • Page 219 CHAS FRONT WHEEL AND BRAKE DISCS Brake disc deflection limit (maximum) Front: 0.2 mm Rear: 0.15 mm 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 station- ary.
  • Page 220: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2. Install: S brake disc 1 NOTE: S Apply LOCTITE 648 to the threads of the...
  • Page 221: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS 6. Install: S brake caliper Brake caliper bolt 40 Nm (4.0 mSkg) WARNING Make sure that the brake hose is routed properly. EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
  • Page 222 CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rim ex- actly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b. Turn the front wheel 90_ so that the heavy spot is positioned as shown.
  • Page 223: Rear Wheel, Brake Disc And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC AND CHAS REAR WHEEL SPROCKET EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 150 Nm (15.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 224: Brake Disc And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC AND CHAS REAR WHEEL SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET 20 Nm (2.0 mSkg) 60 Nm (6.0 mSkg) Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Collar Brake disc...
  • Page 225: Removing The Rear Wheel

    REAR WHEEL, BRAKE DISC AND CHAS REAR WHEEL SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 226: Checking The Rear Wheel Drive Hub

    REAR WHEEL, BRAKE DISC AND CHAS REAR WHEEL SPROCKET EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub Cracks/damage ! Replace. S rear wheel dive hub dampers Damage/wear ! Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1.
  • Page 227: Installing The Rear Wheel

    REAR WHEEL, BRAKE DISC AND CHAS REAR WHEEL SPROCKET EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: S wheel axle nut Wheel axle nut 150 Nm (15.0 mSkg) EAS00575 ADJUSTING THE REAR WHEEL STATIC...
  • Page 228: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Clip Pad pin Refer to “REPLACING THE FRONT Pad support BRAKE PADS”. Brake pad For installation, reverse the removal procedure.
  • Page 229: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Caliper Cover Clip Refer to “REPLACING THE REAR Pad pin BRAKE PADS”. Pad spring Brake pad Caliper shim...
  • Page 230: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 231 CHAS FRONT AND REAR BRAKES 3. Remove: S brake pads 7 4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: S brake pads S brake pad spring NOTE: Always install new brake pads, and a brake pad...
  • Page 232: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 6. Install: S brake pad pins S brake pad clips S brake caliper Brake caliper bolt 40 Nm (4.0 mSkg) 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 233 CHAS FRONT AND REAR BRAKES 5. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 .
  • Page 234: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master cylinder Brake fluid Remove the parts in the order listed. Drain Brake lever Brake switch lead Front brake switch Union bolt...
  • Page 235: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake Disassembly the parts in the order listed. master cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 6-21...
  • Page 236 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg) 28 Nm (2.8 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain Bolts Brake pedal...
  • Page 237: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake Disassembly the parts in the order listed. master cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 6-23...
  • Page 238 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: S rear view mirror (right) S brake lever 1 2.
  • Page 239: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages 2 (brake master cylinder body) Obstruction ! Blow out with compressed air.
  • Page 240 CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 241 CHAS FRONT AND REAR BRAKES 3. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 242: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S copper washers (New) 1 S brake hose 2 Union bolt 3 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 243 CHAS FRONT AND REAR BRAKES 3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 244: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPER 7 Nm (0.7 mSkg) 40 Nm (4.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Brake fluid Drain Union bolts Refer to “DISASSEMBLING/ Copper washers...
  • Page 245 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake cali- Disassembly the parts in the order listed. pers. The following procedure applies to both of the front brake calipers. Clips Pad pin Pad spring Brake pads/shims Caliper pistons...
  • Page 246: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES ESA00616 REAR BRAKE CALIPER 40 Nm (4.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain Union bolt Refer to “DISASSEMBLING/ Copper washers ASSEMBLING AND INSTALLING THE Brake hose...
  • Page 247 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassembly the parts in the order listed. Cover Clips Pad pins Pad support Brake pads/shims Caliper pistons Refer to “DISASSEMBLING THE REAR Dust seals BRAKE CALIPER.”...
  • Page 248: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE:...
  • Page 249: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00629 DISASSEMBLING THE REAR BRAKE CAL- IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
  • Page 250: 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 two years and Brake fluid whenever the brake is disassembled.
  • Page 251 CHAS FRONT AND REAR BRAKES S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1.
  • Page 252 CHAS FRONT AND REAR BRAKES Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system.
  • Page 253: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 254 CHAS FRONT AND REAR BRAKES 4. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 255: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE Brake calipers DISCS”.
  • Page 256 CHAS FRONT FORK 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork Disassembly the parts in the order listed. Cap bolts O-rings Plates Spacers Spring seats Fork springs Refer to “DISASSEMBLING/ Dust seals ASSEMBLING THE FRONT FORK LEGS”.
  • Page 257 CHAS FRONT FORK 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Inner tubes Inner tube bushings Oil flow stoppers Refer to “DISASSEMBLING/ Damper rods ASSEMBLING THE FRONT FORK Damper rod springs LEGS”. Outer tubes For assembly, reverse the disassembly procedure.
  • Page 258: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 259 CHAS FRONT FORK 4. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5. Remove: S damper rod bolt 1 NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3 , loosen the damper rod bolt.
  • Page 260: 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: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
  • Page 261: Assembling The Front Fork Legs

    Be careful not to damage the inner tube. 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 10W or equivalent 3. Tighten: S damper rod bolt 1 Damper rod bolt 30 Nm (3.0 mSkg)
  • Page 262 CHAS FRONT FORK 4. Install: S outer tube bushing 1 S seal spacer 2 S oil seal 3 (with the fork seal driver weight 4 and adapter 5 ) Fork seal driver weight 90890-01367 Adapter 90890-01374 CAUTION: Make sure that the numbered side of the oil seal faces up.
  • Page 263 CHAS FRONT FORK 7. Fully compress the front fork leg. 8. Fill: S front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 538 cm Recommended oil Fork oil 10w or equivalent CAUTION: S Be sure to use the recommended fork oil.
  • Page 264: Installing The Front Fork Legs

    CHAS FRONT FORK NOTE: S Install the fork spring with its smaller pitch up- ward. S Before installing the cap bolt, apply grease to the O-ring. S Temporarily tighten the cap bolt. EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
  • Page 265: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) 26 Nm (2.6 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Master cylinder bracket Master cylinder (front brake) Throttle cable housing Refer to “REMOVING/INSTALLING THE...
  • Page 266 CHAS HANDLEBAR 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) 26 Nm (2.6 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Handlebar grip Refer to “REMOVING THE HANDLEBAR”. Collar Upper handlebar holders Refer to “INSTALLING THE Handlebar HANDLEBAR”.
  • Page 267: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S throttle cable housing 1 NOTE: While removing the throttle cable housing, pull back the rubber cover 2 .
  • Page 268: Installing The Handlebar

    CHAS HANDLEBAR 3. Install: S handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
  • Page 269 CHAS THE HANDLEBAR 3. Install: S handlebar grip 1 S left grip end 2 NOTE: There should be 1 X 3 mm of clearance a be- tween the handlebar grip and the left grip end. 4. Install: S left handlebar switch 1 NOTE: Align the pin on the left handlebar switch with the hole a in the handlebar.
  • Page 270 CHAS THE HANDLEBAR NOTE: S Align the pin on the right handlebar switch with the hole a in the handlebar. S There should be 1 X 3 mm of clearance b be- tween the throttle grip and the right grip end. 8.
  • Page 271: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD LOWER BRACKET 110 Nm (11.0 mSkg) 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 272 CHAS STEERING HEAD 110 Nm (11.0 mSkg) 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Bearing Dust seal Lower handlebar holders For installation, reverse the removal procedure. 6-58...
  • Page 273: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S upper ring nut 1 S lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring...
  • Page 274: Installing The Steering Head

    CHAS STEERING HEAD 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. Install a new dust seal and new bearing races.
  • Page 275: Rear Shock Absorber, Swingarm And Drive Chain

    REAR SHOCK ABSORBER, CHAS SWINGARM AND DRIVE CHAIN REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) 125 Nm (12.5 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks...
  • Page 276 REAR SHOCK ABSORBER, CHAS SWINGARM AND DRIVE CHAIN 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) 125 Nm (12.5 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Bearings Drive chain For installation, reverse the removal procedure.
  • Page 277: Handling The Rear Shock Absorber And Gas Cylinder

    REAR SHOCK ABSORBER, CHAS SWINGARMAND DRIVE CHAIN EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.
  • Page 278: Removing The Swingarm

    REAR SHOCK ABSORBER, CHAS SWINGARMAND DRIVE CHAIN EAS00703 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.
  • Page 279: Checking The Rear Shock Absorber Assembly And Gas Cylinder

    REAR SHOCK ABSORBER, CHAS SWINGARM AND DRIVE CHAIN EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: S rear shock absorber rod 1 Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly.
  • Page 280: Checking The Drive Chain

    REAR SHOCK ABSORBER, CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S washers 2 Damage/Wear ! Replace. S bearings 3 Damage/Pitting ! Replace. S bush 4 Damage/Scratches ! Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain.
  • Page 281 REAR SHOCK ABSORBER, CHAS SWINGARM AND DRIVE CHAIN 4. Check: S O-rings 1 Damage ! Replace the drive chain. S drive chain rollers 2 Damage/wear ! Replace the drive chain. S drive chain side plates 3 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose is proper- ly routed away from the drive chain and be-...
  • Page 282 CHAS...
  • Page 283 ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS ........SWITCHES .
  • Page 284 ELEC...
  • Page 285: Chapter 7. Electrical

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Main switch Rear brake switch Fuel sender Oil level switch Starter relay Horns Starting circuit cutoff relay Ignition coils Battery Oil level relay Flasher relay Ignitior unit Neutral switch Sidestand switch...
  • Page 286: Switches

    ELEC SWITCHES EAS0010 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .
  • Page 287: 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 termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
  • Page 288 ELEC CHECKING THE SWITCHES Horn switch Start switch Clutch switch Lights switch (for Europe) Dimmer switch Rear brake switch Pass switch Fuse Turn signal switch Side stand switch Main switch Neutral switch Front brake switch Oil level switch Engine stop switch : for Europe : for AUS...
  • Page 289: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect.
  • Page 290 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: S Be sure to hold the socket firmly when re- moving the bulb.
  • Page 291: Checking The Condition Of The Bulb Sockets

    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: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...
  • Page 292: Ignition System

    ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 293: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING THE spark or intermittent spark). BATTERY” in chapter 3. Check: Min. open-circuit voltage 1.
  • Page 294 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C The following procedure applies to all of the S Is the spark plug cap OK? spark plugs. S Disconnect the spark plug cap from the spark plug.
  • Page 295 ELEC IGNITION SYSTEM EAS00749 8. Main switch S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? Replace the main switch. Secondary coil resistance 9.5 X 14.3 kΩ at 20_C S Is the ignition coil OK? EAS00750 9.
  • Page 296 ELEC IGNITION SYSTEM EAS00754 13. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Properly connect or Replace the ignitor repair the ignition unit. system’s wiring. 7-12...
  • Page 297: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-13...
  • Page 298: 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: S The transmission is in neutral (the neutral switch is closed).
  • Page 299: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Open-circuit voltage 2.
  • Page 300 ELEC ELECTRIC STARTING SYSTEM EAS00759 EAS00760 4. Starting circuit cutoff relay 5. Diode S Disconnect the relay unit from the coupler. S Disconnect the starting circuit cutoff relay S Connect the pocket tester (Ω 1) and bat- from the coupler. S Connect the pocket tester (Ω...
  • Page 301 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch S Disconnect the starter relay from the coupler. S Check the engine stop switch for continuity. S Connect the pocket tester (Ω 1) and bat- Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? tery (12 V) to the starter relay coupler as shown.
  • Page 302 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch S Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the start switch OK? Replace the right handlebar switch. EAS00766 13. Wiring S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
  • Page 303: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. Disassembling the starter motor Disassembly the pats in the order listed.
  • Page 304 ELEC ELECTRIC STARTING SYSTEM EAS00769 Checking The Starter Motor 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade...
  • Page 305 ELEC ELECTRIC STARTING SYSTEM 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Min. brush length 5 mm 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set. Brush spring force 7.65 X 10.01 N (0.780 X 1.021 kg) 7.
  • Page 306: Charging System

    ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM Generator Main fuse Battery Main switch 7-22...
  • Page 307: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse Open-circuit voltage 2. battery 12.8 V or more at 20_C 3.
  • Page 308 ELEC CHARGING SYSTEM EAS00777 5. Brush check NOTE: S Remove the brush holder Make sure that the battery is fully charged. S Is the charging voltage within specification? The charging circuit is OK. EAS00776 4. Stator coil assembly resistances S Check the brush spring. S Remove the generator cover.
  • Page 309 ELEC CHARGING SYSTEM EAS00778 6. Field coil resistance S Connect the pocket tester (Ω 1) to the rotor as shown. S Measure the field coil resistance. Field coil resistance 2.8 X 3.0 Ω at 20_C S Is the field coil OK? Replace the field coil.
  • Page 310: A.c. Generator

    ELEC CHARGING SYSTEM A.C. GENERATOR 7 Nm (0.7 mSkg) 25 Nm (2.5 mSkg) Order Job/Part Q’ty Remarks Disassembling the A.C. Generator Disassembly the parts in the order list. Cover Brush holder Regulator Rectifier cover Rectifier Rear cover Rotor assembly Bearing cover Bearing Bearing Stator assembly...
  • Page 311: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7-27...
  • Page 312: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING THE light, high beam indicator light, taillight, BATTERY” in chapter 3. auxiliary light (for Europe) or meter light. Open-circuit voltage Check: 12.8 V or more at 20_C...
  • Page 313: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00784 EAS00788 CHECKING THE LIGHTING SYSTEM 5. Dimmer switch 1. The headlight and the high beam indicator S Check the dimmer switch for continuity. light fail to come on. Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? 1.
  • Page 314 ELEC LIGHTING SYSTEM Headlight 2. Voltage Tester positive probe ! S Connect the pocket tester (20 V) to the meter yellow or green assembly coupler (wire harness side) as Tester negative probe ! black shown. High beam indicator light Tester positive probe ! yellow Tester positive probe ! blue Tester negative probe ! black Tester negative probe ! black...
  • Page 315 ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage S Connect the pocket tester (DC 20 V) to the S Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as auxiliary light couplers (wire harness side) as shown.
  • Page 316: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7-32...
  • Page 317: Troubleshooting

    ELEC SIGNALING SYSTEM EB806010 EAS00739 TROUBLESHOOTING 2. Battery S Any of the following fail to light: turn sig- S Check the condition of the battery. nal light, brake light or an indicator light. Refer to “CHECKING THE BATTERY” in S The horn fails to sound. chapter 3.
  • Page 318: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. S Disconnect the black connector at the horn terminal. 1. Horn switch S Connect a jumper lead to the horn terminal S Check the horn switch for continuity. and ground the jumper lead.
  • Page 319 ELEC SIGNALING SYSTEM EAS00797 S Set the main switch to “ON”. 2. A tail/brake light fails to come on. S Pull in the brake lever or push down on the 1. Tail/brake light bulb and socket brake pedal. S Measure the voltage (12 V) of yellow at the S Check the tail/brake light bulb and socket for tail/brake light coupler (wire harness side).
  • Page 320 ELEC SIGNALING SYSTEM Tester positive probe ! brown/white 2. Turn signal switch Tester negative probe ! ground S Check the turn signal for continuity. Refer to “CHECKING THE SWITCHES”. S Is the turn signal switch OK? Replace the left han- dlebar switch.
  • Page 321 ELEC SIGNALING SYSTEM EAS00760 S Set the main switch to “ON”. 3. Diode S Set the turn signal switch to “ ” or “ ”. S Disconnect the starting circuit cutoff relay S Measure the voltage (12 V) of chocolate from the coupler.
  • Page 322 ELEC SIGNALING SYSTEM 4. Voltage 2. Oil level switch S Connect the pocket tester (DC 20 V) to the S Drain the engine oil and remove the oil level meter assembly coupler (wire harness side) switch from the oil pan. S Check the oil level switch for continuity.
  • Page 323 ELEC SIGNALING SYSTEM S Set the main switch to “ON”. 4. Starting circuit cutoff relay S Measure the voltage (12 V) of brown S Disconnect the relay unit from the coupler. black/red at the meter assembly coupler. S Connect the pocket tester (Ω 1) to the relay S Is the voltage within specification? unit terminals as shown.
  • Page 324 ELEC SIGNALING SYSTEM S Check that the fuel level gauge needle move to 2. Voltage “F” to “E”. Connect the pocket tester (DC 20 V) to the me- NOTE: ter assembly coupler (wire harness side) as Before reading the fuel level gauge, leave the shown.
  • Page 325: Self-diagnosis

    ELEC SELF-DIAGNOSIS EAS00834 SELF-DIAGNOSIS The XJR1300 (L) features a self-diagnosing system for the following circuit(-s): S throttle position sensor S ignition circuit If any of these circuits are defective, their respective condition codes will be displayed on the tachome- ter when the main switch is set to “ON” (irrespective of whether the engine is running or not). The engine is not operated condition code at 2,000 r/min.
  • Page 326 ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The tachometer starts to display the Refer to “CIRCUIT DIAGRAM”. self-diagnosis sequence. S Is the wire harness OK? Check: 1. throttle position sensor 2. ignition circuit NOTE: Repair or replace the S Before troubleshooting, remove the following...
  • Page 327 ELEC SELF-DIAGNOSIS EAS00749 2. Ignition circuit 3. Main switch CIRCUIT DIAGRAM S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? Replace the main switch. EB812400 4. Wire harness S Check the ire harness for continuity. Refer to “CIRCUIT DIAGRAM”.
  • Page 328 ELEC SELF-DIAGNOSIS NOTE: When you switch the “–” and “+” leads of the digital pocket tester the readings in the above chart will be reversed. S Are the tester readings correct? Replace the ignitor Replace the relay unit. unit. 7-44...
  • Page 329: Troubleshooting

    TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING PROBLEMS ........ENGINE .
  • Page 330 TRBL SHTG...
  • Page 331: Starting Problems

    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 manual for checks, adjustments, and replacement of parts.
  • Page 332: Incorrect Engine Idling Speed

    INCORRECT ENGINE IDLING SPEED/POOR MEDIUM AND- TRBL HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Cylinders and cylinder head Battery S Incorrect valve clearance S Faulty battery S Damaged valve train components S Discharged battery Air filter Spark plugs S Clogged air filter element...
  • Page 333: Faulty Clutch

    TRBL FAULTY CLUTCH/OVERHEATING SHTG EAS00852 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch S Improperly assembled clutch S Unevenly tensioned clutch springs S Improperly assembled clutch master cylinder S Warped pressure plate S Improperly assembled clutch release cylinder S Bent clutch plate S Loose or fatigued clutch spring S Swollen friction plate S Loose union bolt...
  • Page 334: Poor Braking Performance

    POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL LEGS/UNSTABLE HANDLING SHTG EAS00857 POOR BRAKING PERFORMANCE S Worn brake pad S Loose union bolt S Worn brake disc S Damaged brake hose S Air in hydraulic brake system S Oil or grease on the brake disc S Leaking brake fluid S Oil or grease on the brake pad S Faulty brake caliper piston seal...
  • Page 335: Faulty Lighting And Signaling System

    TRBL FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG EAS00866 FAULTY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT TURN SIGNAL BLINKS SLOWLY S Wrong headlight bulb S Faulty turn signal relay S Too many electrical accessories S Faulty main switch S Hard charging S Faulty turn signal switch S Incorrect connection S Wrong turn signal bulb...
  • Page 336 TRBL SHTG...
  • Page 337 XJR1300’99 WIRING DIAGRAM for EUR AC generator Fuse (main) Battery Starter relay Main switch Fuse (ignition) Starter motor Starting circuit cut-off relay Ignitor unit Ignition coil Spark plug Pickup coil TPS (throttle position sensor) Neutral switch Sidestand switch Oil level relay Start switch Engine stop switch Front brake switch...
  • Page 338 XJR1300L WIRING DIAGRAM for AUS AC generator Fuse (main) Battery Starter relay Main switch Fuse (ignition) Starter motor Starting circuit cut-off relay Ignitor unit Ignition coil Spark plug Pickup coil TPS (throttle position sensor) Neutral switch Sidestand switch Oil level relay Start switch Engine stop switch Front brake switch...

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Xjr1300 (l) '99Xjr1300(l) 1999

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