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Yamaha XVS1100(L) Service Manual

1999 motorcycle
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  • Page 2 EB000000 XVS1100 (L) SERVICE MANUAL 1998 by Yamaha Motor Co.,Ltd. First edition, October 1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
  • Page 4: How To Use This Manual

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Chassis 8 Electrical 9 Troubleshooting...
  • Page 6 CHAPTER TITLES GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENTS ENGINE OVERHAUL CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...
  • Page 8: Table Of Contents

    INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
  • Page 9: General Information

    MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 10: Important Information

    5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 11: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.
  • Page 12: Checking Of Connections

    CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1. Disconnect: S Connector 2. Check: S Connector Moisture ! Dry each terminal with an air blower. Stains/rust ! Connect and disconnect the terminals several times. 3.
  • Page 13: Special Tools

    SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.
  • Page 14 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration T-handle/damper rod holder T-handle 90890-01326 Holder These tools are needed to loosen and tighten 90890-01460 the damper rod holding bolt. Flywheel puller/adapter Puller 90890-01362 Adapter 90890-04131 These tools are needed to remove the rotor. Fork seal driver weight/adapter Weight 90890-01367...
  • Page 15 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Timing light 90890-03141 This tool is necessary for checking ignition timing. Valve guide remover & installer 90890-04014 This tool is needed to remove and install the valve guide. Valve spring compressor 90890-04019 This tool is needed to remove and install the valve assemblies.
  • Page 16 This tool is needed when removing or instal- ling the damper spring. Dynamic spark tester Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Yamaha bond No.1215 90890-85505 This sealant (bond) is used on crankcase mat- ing surfaces, etc.
  • Page 17 SPEC...
  • Page 18 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .
  • Page 19: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: XVS1100: 5EL1 (For Europe) 5EL2 (For D, A, FIN) 5EL3 (For Australia) Dimensions: Overall length 2,405 mm Overall width 895 mm Overall height 1,095 mm Seat height 690 mm Wheelbase 1,640 mm Minimum ground clearance 145 mm...
  • Page 20 SPEC GENERAL SPECIFICATIONS Item Standard Carburetor: Type/quantity BSR37/2 Manufacturer MIKUNI Spark plug: Type BPR7ES/W22EPR–U Manufacturer NGK/DENSO 0.7 X 0.8 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 78/47 (1.660) Secondary reduction system Shaft drive Secondary reduction ratio 44/47...
  • Page 21 SPEC GENERAL SPECIFICATIONS Item Standard Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link suspension) Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Gas-oil damper Wheel travel: Front wheel travel 140 mm Rear wheel travel 113 mm Electrical: Ignition system T.C.I.
  • Page 22: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm Cylinder: 95.00 X 95.01 mm Bore size 95.1 mm Measuring point 40 mm Camshaft: Drive method Chain drive (left & right) 25.000 X 25.021 mm Cam cap inside diameter 24.96 X 24.98 mm Camshaft outside diameter...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links SILENT CHAIN/98L Timing chain adjustment method Automatic Rocker arm/rocker arm shaft: 14.000 mm X 14.018 mm Bearing inside diameter 14.036 mm 13.985 mm X 13.991 mm Shaft outside diameter 13.95 mm 0.009 mm X 0.033 mm Arm-to-shaft clearance...
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit 0.03 mm 1.2 X 1.4 mm Valve seat width 2.0 mm 1.2 X 1.4 mm 2.0 mm Valve spring: Free length 44.6 mm 43.5 mm 44.6 mm 43.5 mm Set length (valve closed) 40 mm 40 mm Compressed pressure...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 22.004 X 22.015 mm Piston pin bore inside diameter 21.991 X 22.000 mm Piston pin outside diameter Piston rings: Top ring: Type Plain Dimensions (B 3.8 mm 0.3 X 0.5 mm End gap (installed) 0.8 mm 0.04 X 0.08 mm Side clearance (installed)
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: 2.9 X 3.1 mm Friction plate thickness 2.8 mm Quantity 2.5 X 2.7 mm Clutch plate thickness 0.1 mm Quantity 1.9 X 2.1 mm Clutch plate thickness 0.1 mm Quantity Clutch spring free length 7.2 mm 6.5 mm Quantity...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type Oil pump type Trochoid type 0.03 X 0.09 mm Tip clearance “A” or “B” 0.15 mm 0.03 X 0.08 mm 0.15 mm Side clearance 450 X 550 kPa (4.5 X 5.5 kg/cm Relief valve operating pressure Shaft drive: 0.1 X 0.2 mm...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: 2-10...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence: Crankcase tightening sequence: Left crankcase Right crankcase 2-11...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Cylinder head Cylinder head Plate Bolt Cylinder head cover Screw Cylinder head (exhaust pipe) Stud bolt 12.5 1.25 Rocker arm shaft Union bolt 37.5 3.75...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Clutch spring Bolt Clutch adjuster Clutch boss Use lock washer Push lever axle Screw Stake Middle drive pinion gear 11.0 Stake Bearing retainer (middle driven shaft) 11.0 Stake Yoke (middle driven shaft)
  • Page 32: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing Front suspension: Front fork travel 140 mm Fork spring free length 356.9 mm 350 mm Fitting length 319.4 mm Collar length 183 mm Spring rate (K1) 8.8 N/mm (0.9 kg/mm) (K2) 12.7 N/mm (1.3 kg/mm)
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front brake: Type Dual disc Disc outside diameter thickness 5 mm 4.5 mm Disc deflection limit 0.15 mm Pad thickness inner 6.2 mm 0.8 mm Pad thickness outer 6.2 mm 0.8 mm Master cylinder inside diameter 14.0 mm Caliper cylinder inside diameter 25.4 mm...
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks mSkg Upper bracket and inner tube Lower bracket and inner tube Upper bracket and steering shaft 11.0 Ring nut (steering shaft) — See NOTE Handlebar holder (lower) and upper bracket Handlebar holder (lower) and handlebar holder (upper) Master cylinder (front brake)
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size size mSkg Passenger footrest and frame Sidestand bracket and frame Sidestand and sidestand bracket Sidestand switch Brake pedal/footrest and frame Rear brake master cylinder and master cylinder bracket Master cylinder bracket and down tube Footrest and frame Front wheel axle...
  • Page 36: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 10_ at 1,000 r/min Advancer type Digital type T.C.I.: 189 X 231 Ω at 20_C/Gray – Black Pickup coil resistance/color T.C.I. unit model/manufacturer J4T101/MITSUBISHI Ignition coil: Model/manufacturer F6T507 /MITSUBISHI 3.57 X 4.83 Ω...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn: Type Plane type Quantity Model/manufacturer YF-12/NIKKO Maximum amperage Flasher relay: Type Full transistor type Model/manufacturer FE246BH/DENSO Self cancelling device 75 X 95 cycle/min Flasher frequency Wattage 21 W 2 + 3.4W Oil level gauge: Model/manufacturer 5EL/DENSO Starting circuit cut-off relay...
  • Page 38: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS SPEC /CONVERSION TABLE EB202001 EAS00028 GENERAL TORQUE CONVERSION TABLE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies torque for standard fasten- Use this table to convert METRIC unit data to ers with standard I.S.O.
  • Page 39: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Symbol Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX)
  • Page 40: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203010 CHASSIS Lubrication point Symbol Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface...
  • Page 41: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EB205000 LUBRICATION DIAGRAMS Rocker arm shaft (intake) Oil pump Rocker arm shaft (exhaust) Drive axle Oil filter Middle drive shaft 2-23...
  • Page 42 SPEC LUBRICATION DIAGRAMS Oil pump Middle drive shaft Releaf valve Oil filter 2-24...
  • Page 43 SPEC LUBRICATION DIAGRAMS Camshaft Middle drive shaft Crankshaft Drive axle Main axle Connecting rod big end 2-25...
  • Page 44 SPEC CABLE ROUTING EB206000 CABLE ROUTING Clutch cable Alarm connector Fuel hose (carburetor-fuel pump) Starter cable Fuel pump lead Brake hose Handlebar switch lead (left) Speed sensor lead Heat protector Handlebar switch lead (right) Sidestand switch lead Fuel breather hose (fuel tank- High tension code Neutral switch lead roll over valve) (for California)
  • Page 45: Cable Routing

    SPEC CABLE ROUTING Purge hose (carburetor-solenoid B Position the throttle cable and F Push the wire harness inside valve) (for California) starter cable as shown, and of the tool box plate. A Fasten the handlebar switch clamp them with holder. G Route the sidestand lead leads (left and right) to the C Clamp the wire harness with...
  • Page 46 SPEC CABLE ROUTING J Fasten the handlebar switch M Fasten the AC magneto lead leads (left and right) under the and sidestand switch lead with a handle crown with a plastic plastic locking tie. band. N Fasten the alarm lead with a Set the band at four notches, plastic band on the lid.
  • Page 47 SPEC CABLE ROUTING Battery Ignition coil Handlebar switch lead (left) Battery positive (+) lead Master cylinder reservoir hose Throttle position sensor lead Starter motor positive (+) lead Breather hose Carburetor heater lead Speedometer lead Air filter drain hose Thermo switch lead Fuel hose (carburetor-fuel pump) Battery negative (–) lead Starting circuit cutoff relay...
  • Page 48 SPEC CABLE ROUTING A Clamp the battery positive (+) D Connect the purge hose H Fasten the rear brake switch lead to the battery with battery (carburetor side-solenoid valve lead and master cylinder band. side) with joint. (for California) reservoir hose to the down B Connect the battery negative E Route the front turn signal light tube with a plastic locking tie.
  • Page 49 SPEC CABLE ROUTING K To rear brake caliper L Clamp the handlebar switch lead (right) and main switch lead to the frame with a holder. M Arrange the throttle position sensor connector, carburetor heater connector and thermo switch connector between the starting circuit cutoff relay and high tension code.
  • Page 50 SPEC CABLE ROUTING Brake hose Battery negative (–) lead Starter cable Throttle cable connector Fuel hose (fuel cock-fuel filter) Master cylinder reservoir hose Battery Carburetor heater lead High tension code Battery positive (+) lead Thermo switch lead Purge hose (carburetor-solenoid Taillight lead Igniter unit valve) (for California)
  • Page 51 SPEC CABLE ROUTING B Route the rear brake switch F Route the battery positive (+) J Fasten the wire harness with a lead under the master cylinder lead through the slit of the band on the tool box plate. reservoir hose. battery box.
  • Page 52 SPEC CABLE ROUTING L Route wire harness outside of P Route the igniter lead through the guide on the frame. the igniter plate hole to the wire M Clamp the clutch cable and harness. starter cable with a holder. Q Clamp the taillight lead with Position the end of holder down mud guard clamp.
  • Page 53 SPEC CABLE ROUTING Throttle cable Starter cable Clutch cable Handlebar switch lead (left) Headlight lead Brake hose A Route the handlebar switch lead (right) rear side of the throttle cable. 2-35...
  • Page 54 INSP...
  • Page 55 INSP CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
  • Page 56 INSP ELECTRICAL SYSTEM ......... 3-37 CHECKING AND CHARGING THE BATTERY .
  • Page 57: Periodic Inspections And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE/ INSP LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa- tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 58 Final gear oil 24,000 km or 24 months (whichever comes first). * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
  • Page 59: Fuel Tank And Seats

    INSP FUEL TANK AND SEATS FUEL TANK AND SEATS 23Nm (2.3mSkg) 7 Nm (0.7mSkg) 7 Nm (0.7mSkg) Order Job name/Part name Q’ty Remarks Fuel tank and seats removal Remove the parts in the order below. Passenger seat Seat bracket Rider’s seat Fuel hose NOTE: Set the fuel cock to “OFF”...
  • Page 60: Removal

    INSP FUEL TANK AND SEATS REMOVAL 1. Remove: S Ignitor plate NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S Ignitor plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver.
  • Page 61: Engine

    INSP ADJUSTING THE VALVE CLEARANCE EAS00047 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 62 INSP ADJUSTING THE VALVE CLEARANCE 6. Remove: S tappet covers 1 7. Remove: S camshaft sprocket cover (rear cylinder) 1 S camshaft sprocket cover (front cylinder) 8. Remove: S timing plug 1 S straight plug 2 9. Measure: S valve clearance Out of specification ! Adjust.
  • Page 63 INSP ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align either the camshaft sprock- et plate hole a with the stationary pointer b on the cylinder head. When the camshaft sprocket plate hole or camshaft sprocket punch mark is aligned with the stationary pointer, the piston is at top dead center...
  • Page 64: Synchronizing The Carburetors

    ADJUSTING THE VALVE CLEARANCE/ INSP SYNCHRONIZING THE CARBURETORS Locknut: 27 Nm (2.7 mSkg) e. Measure the valve clearance again. f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.
  • Page 65 INSP SYNCHRONIZING THE CARBURETORS 5. Install: S vacuum gauge 1 S engine tachometer 2 (to the spark plug lead of cyl. #2) Vacuum gauge: 90890-03094 Engine tachometer: 90890-03113 6. Start the engine and let it warm up for several minutes. 7.
  • Page 66: Adjusting The Engine Idling Speed

    SYNCHRONIZING THE CARBURETORS/ INSP ADJUSTING THE ENGINE IDLING SPEED Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm 12. Install: S vacuum plugs S air duct S fuel tank S seat EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted...
  • Page 67: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ INSP ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 68: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ INSP CHECKING THE SPARK PLUGS Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction increased.
  • Page 69: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ INSP CHECKING THE IGNITION TIMING 7. Measure: S spark plug gap a (with a wire gauge) Out of specification ! Regap. Spark plug gap 0.7 X 0.8 mm 8. Install: S spark plug 20 Nm (2.0 mSkg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface.
  • Page 70: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ INSP MEASURING THE COMPRESSION PRESSURE 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. Engine idling speed: 950 X 1,050 r/min b.
  • Page 71 INSP MEASURING THE COMPRESSION PRESSURE 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. 5. Install: S compression gauge 1 Compression gauge set: 90890-03081 6.
  • Page 72: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ INSP CHECKING THE ENGINE OIL LEVEL 7. Install: S spark plug 20 Nm (2.0 mSkg) 8. Connect: S spark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand.
  • Page 73: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ INSP CHANGING THE ENGINE OIL 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 74: Adjusting The Clutch Cable Free Play

    CHANGING THE ENGINE OIL/ INSP ADJUSTING THE CLUTCH CABLE FREE PLAY Quantity Total amount 3.6 L Without oil filter element replacement 3.0 L With oil filter element replacement 3.1 L 9. Install: S o-ring S engine oil filter cap 10. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 75: Cleaning The Air Filter Element

    ADJUSTING THE CLUTCH CABLE FREE PLAY/ INSP CLEANING THE AIR FILTER ELEMENT 4. Adjust: S clutch mechanism Engine side a. Loosen the locknut 1 . b. Turn in the adjusting screw 2 until it is lightly seated. c. Turn the adjusting screw out 1/4 of a turn. d.
  • Page 76: Checking The Carburetor Joint And Intake Manifold

    CLEANING THE AIR FILTER ELEMENT / INSP CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD / CHECKING THE BREATHER HOSE CAUTION: Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
  • Page 77: Checking The Exhaust System

    INSP CHECKING THE EXHAUST SYSTEM EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes, mufflers and gaskets. 1. Check: S exhaust pipes 1 S muffler 2 Cracks/damage ! Replace. S gaskets 3 Exhaust gas leaks ! Replace. 2.
  • Page 78: Chassis

    INSP ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: S brake lever free play a Out of specification ! Adjust. Brake lever free play (at the end of the brake lever) 5 X 8 mm 2. Adjust: S brake lever free play a.
  • Page 79: Adjusting The Rear Brake

    INSP ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 81.8 mm 2.
  • Page 80: Checking The Brake Fluid Level

    INSP CHECKING THE BRAKE FLUID LEVEL EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check; S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 81: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ INSP CHECKING THE BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
  • Page 82: Bleeding The Hydraulic Brake System

    INSP BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenever: 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.
  • Page 83: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ INSP ADJUSTING THE SHIFT PEDAL h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
  • Page 84: Checking The Final Drive Oil Level

    CHECKING THE FINAL DRIVE OIL LEVEL/ INSP CHANGING THE FINAL DRIVE OIL EAS00144 CHECKING THE FINAL DRIVE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2.
  • Page 85: Checking And Adjusting The Steering Head

    CHANGING THE FINAL DRIVE OIL/ INSP CHECKING AND ADJUSTING THE STEERING HEAD Quantity 0.2 L Refer to “CHECKING THE FINAL DRIVE OIL LEVEL”. 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.
  • Page 86 INSP CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01403 Lower ring nut (initial tightening...
  • Page 87: Checking The Front Fork

    CHECKING THE FRONT FORK/ INSP ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00149 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Check: S inner tube Damage/scratches ! Replace.
  • Page 88: Checking The Tires

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ INSP CHECKING THE TIRES Ring nut wrench 1HX-28135-00 a. Turn the adjusting knob 1 in direction a or ! Spring preload is Direction increased (suspension is harder). ! Spring preload is Direction decreased (suspension is softer). Adjusting position Standard: 3 Minimum: 1 (soft)
  • Page 89 INSP CHECKING THE TIRES Basic weight: (with 274 kg oil and full fuel tank) Maximum 201 kg load*: Cold tire Front Rear pressure: Up to 90 kg 200 kPa 225 kPa load* (2.00 kgf/cm (2.25 kgf/cm 90 kg 225 kPa 250 kPa X maximum (2.25 kgf/cm...
  • Page 90 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire: Manufactur- Type...
  • Page 91: Checking And Tightening The Spokes

    CHECKING THE TIRES/ INSP CHECKING AND TIGHTENING THE SPOKES NOTE: For tires with a direction of rotation mark 1 : S Install the tire with the mark pointing in the direction of wheel rotation. S Align the mark 2 with the valve installation point.
  • Page 92: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES / INSP LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may causes the cable to corrode and interfere with its move- ment.
  • Page 93: Electrical System

    INSP CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 94 INSP 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 95 INSP CHECKING AND CHARGING THE BATTERY WARNING Ambient temperature 20_C Do not quick charge a battery. CAUTION: S Make sure that the battery breather hose and battery vent are free of obstructions. S Never remove the MF battery sealing caps. Condition of charge in battery (%) S Do not use a high-rate battery charger.
  • Page 96 INSP CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Charger Measure the open-circuit NOTE: AMP meter voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
  • Page 97 INSP CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 98 INSP CHECKING AND CHARGING THE BATTERY 6. Check: S battery breather hose and battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery CAUTION: S When inspecting the battery, make sure that the battery breather hose is properly attached and routed correctly.
  • Page 99: Checking The Fuses

    INSP CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a fuse. 1. Remove: S rider’s seat S ignitor plate Refer to “FUEL TANK AND SEATS”.
  • Page 100: Replacing The Headlight Bulb

    CHECKING THE FUSES/ INSP REPLACING THE HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
  • Page 101: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ INSP ADJUSTING THE HEADLIGHT BEAM CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 103 CHAPTER 4 ENGINE ENGINE REMOVAL ..........MUFFLERS, BRAKE PEDAL AND SIDE COVER .
  • Page 104 CLUCTH ............4-38 RIGHT CRANKCASE COVER .
  • Page 105 MIDDLE GEAR ..........4-72 MIDDLE DRIVE PINION GEAR .
  • Page 106: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL MUFFLERS, BRAKE PEDAL AND SIDE COVER 23 Nm (2.3 mSkg) 64 Nm (6.4 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 25 Nm (2.5 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the muffler, brake pedal Remove the parts in the order listed.
  • Page 107 ENGINE REMOVAL 23 Nm (2.3 mSkg) 64 Nm (6.4 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 25 Nm (2.5 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Rear brake master cylinder/bracket Battery cover Battery leads Disconnect NOTE: First, disconnect the negative lead, then...
  • Page 108: Leads, Shift Pedal And Clutch Cable

    ENGINE REMOVAL LEADS, SHIFT PEDL AND CLUTCH CABLE 64 Nm (6.4 mSkg) 64 Nm (6.4 mSkg) Order Job name/Part name Q’ty Remarks Removing the leads, shift pedal and Remove the parts in the order listed. clutch cable Tool box cover Left side cover AC magneto lead/pickup lead/side 1/1/1...
  • Page 109: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS 48 Nm (4.8 mSkg) 74 Nm (7.4 mSkg) 48 Nm (4.8 mSkg) 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Engine mounting bolt removal Remove the parts in the order below. Place a suitable stand under the frame and engine.
  • Page 110: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Tighten the bolts in the following order. Bolt 1 : 48 Nm (4.8 mSkg) Bolt 2 : 48 Nm (4.8 mSkg) Bolt 3 : 48 Nm (4.8 mSkg) Bolt 4 : 48 Nm (4.8 mSkg) Bolt 5 : 48 Nm (4.8 mSkg) 2.
  • Page 111: Cylinder Heads

    CYLINDER HEADS CYLINDER HEADS REAR CYLINDER HEAD 50 Nm (5.0 mSkg) 35 Nm (3.5 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 55 Nm (5.5 mSkg) Order Job name/Part name Q’ty Remarks...
  • Page 112 CYLINDER HEADS 50 Nm (5.0 mSkg) 35 Nm (3.5 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 55 Nm (5.5 mSkg) Order Job name/Part name Q’ty Remarks Timing chain tensioner/gasket Refer to “REMOVING/INSTALLING THE Camshaft sprocket...
  • Page 113: Front Cylinder Head

    CYLINDER HEADS FRONT CYLINDER HEAD 35 Nm (3.5 mSkg) 50 Nm (5.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 55 Nm (5.5 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Cylinder head removal...
  • Page 114 CYLINDER HEADS 35 Nm (3.5 mSkg) 50 Nm (5.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 55 Nm (5.5 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Timing chain tensioner/gasket Camshaft sprocket plate Refer to “REMOVING/INSTALLING...
  • Page 115: Removing The Cylinder Heads

    CYLINDER HEADS EAS00226 REMOVING THE CYLINDER HEADS Rear cylinder head 1. Remove: S camshaft sprocket cover S tappet covers 2. Align: S “T” mark a (with the stationary pointer b ) a. Temporarily install the left crankcase cover without the pickup coil and stator coil. b.
  • Page 116 CYLINDER HEADS 4. Remove: S timing chain tensioner S gasket 5. Remove: S bolt (camshaft sprocket) 1 S camshaft sprocket 2 NOTE: To prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: S cylinder head NOTE: S Loosen the bolts and nuts in the proper se- quence.
  • Page 117: Checking The Cylinder Heads

    CYLINDER HEADS EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cyl- inder heads. 1. Eliminate: S combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: S spark plug threads S valve seats 2.
  • Page 118: Checking The Timing Chain Tensioner

    CYLINDER HEADS EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: S timing chain tensioner Cracks/damage/rough movement ! Re- place. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
  • Page 119 CYLINDER HEADS 3. Install: S camshaft sprocket a. Temporarily install the rotor nut and left crankcase cover without the pickup coil and stator coil. b. Turn the crankshaft clockwise. c. Align the “T” mark a with the stationary pointer b on the crankcase cover (left). d.
  • Page 120 CYLINDER HEADS d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Cap bolt 8 Nm (0.8 mSkg) 5. Install: S bolt (camshaft sprocket) 1 55 Nm (5.5 mSkg) NOTE: S Be sure the projection on the camshaft sprock- et plate is aligned with the hole in the sprocket.
  • Page 121: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 37.5 Nm (3.75 mSkg) 27 Nm (2.7 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rocker arm and Remove the parts in the order listed. camshaft Cylinder heads Refer to “CYLINDER HEAD”.
  • Page 122: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Remove: S rocker arm shafts (intake and exhaust) 1 S rocker arms 2 NOTE: Use a slide hammer 3 and weight 4 to remove the rocker arm shafts. Slide hammer bolt (M8): 90890-01085 Weight:...
  • Page 123: Checking The Rocker Arms And Rocker Arm

    ROCKER ARMS AND CAMSHAFTS EB401410 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: S rocker arm Damage/wear ! Replace. S rocker arm lobe 1 S valve adjuster 2 Excessive wear ! Replace.
  • Page 124: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFTS EAS00220 INSTALLING THE CAMSHAFT AND ROCK- ER ARMS 1. Lubricate: S camshaft Recommended lubricant Camshaft/Bushing Molybdenum disulfide oil 2. Install: S camshaft 1 S camshaft bushing 2 NOTE: S The dowel pin a on the end of the camshaft must align with the timing mark b on the cylin- der head.
  • Page 125 ROCKER ARMS AND CAMSHAFTS 5. Install: S rocker arms S rocker arm shafts NOTE: Make sure that the rocker arm shafts is com- pletely pushed into the cylinder head. 4-20...
  • Page 126: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs. Cylinder heads Refer to “CYLINDER HEADS”. Rocker arms and camshafts Refer to “ROCKER ARMS AND CAMSHAFT”.
  • Page 127: Removing The Valves

    VALVE 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 128 VALVE AND VALVE SPRINGS Out of specification ! Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 X 0.037 mm <Limit>: 0.08 mm Exhaust 0.025 X 0.052 mm <Limit>: 0.10 mm 2. Replace. S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_K) in an oven.
  • Page 129: Checking The Valve Seats

    VALVE AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness limit 0.8 mm 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide.
  • Page 130 VALVE AND VALVE SPRINGS 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound to the valve face.
  • Page 131: Checking The Valve Springs

    VALVE AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length (intake and exhaust) 44.6 mm <Limit>: 43.5 mm...
  • Page 132 VALVE AND VALVE SPRINGS NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch 4. Install: S valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 . Valve spring compressor 90890-04019 5.
  • Page 133: Cylinders And Pistons

    CYLINDERS AND PISTONS CYLINDERS AND PISTONS 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEADS”. Timing chain guide The “5EL” mark should face towards the cylinder head.
  • Page 134: Checking The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE PISTONS The following procedure applies to all of the pis- tons. 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 135 CYLINDER AND PISTONS 2. Measure: S piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. a 40 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.
  • Page 136: Checking The Piston Rings

    CYLINDER AND PISTONS EB404410 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 137: Checking The Piston Pins

    CYLINDERS AND PISTONS EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins. 1. CHECK: S piston pin Blue discoloration/grooves ! Replace, then inspect the lubrication system. 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin.
  • Page 138 CYLINDERS AND PISTONS 2. Install: S piston 1 S piston pin 2 S piston pin clip (New) 3 NOTE: S Apply engine oil onto the piston pin. S Make sure that the “EX” mark a on the piston faces towards the exhaust side of the engine. S Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
  • Page 139: Timing Gears

    TIMING GEARS TIMING GEARS 10 Nm (1.0 mSkg) 110 Nm (11.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the timing gears Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEAD”. Cylinders Refer to “CYLINDERS AND PISTONS”. Clutch assembly Refer to “CLUTCH”.
  • Page 140: Removing The Timing Drive Gears

    TIMING GEARS REMOVING THE TIMING DRIVE GEAR Front cylinder 1. Straighten the lock washer tab. 2. Remove: S primary drive gear nut 1 NOTE: While holding the generator rotor with the sheave holder, loosen the primary drive gear nut. 3. Remove: S timing drive gear 2 S dowel pins S springs...
  • Page 141: Checking The Primary Drive

    TIMING GEARS EAS00292 CHECKING THE PRIMARY DRIVE 1. Check: S primary drive gear S primary driven gear Damage/wear ! Replace the primary drive and primary driven gears as a set. Excessive noise during operation ! Re- place the primary drive and primary driven gears as a set.
  • Page 142 TIMING GEARS Front cylinder 1. Install: (Front cylinder) S springs 1 S dowel pins S timing drive gear 2 NOTE: S Insert the suitable pin 3 into the hole of timing chain drive gear sprocket and match the gear teeth. S Push the projections a on the timing drive gear into the spaces b .
  • Page 143: Right Crankcase Cover

    CLUTCH CLUTCH RIGHT CRANKCASE COVER 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the right clutch cover Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
  • Page 144 CLUTCH 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Dowel pins Crankcase cover gasket For installation, reverse the removal procedure. 4-39...
  • Page 145: Clutch Assembly

    CLUTCH CLUTCH ASSEMBLY 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring bolts Clutch spring plate Clutch spring Clutch spring seat Refer to “INSTALLING THE CLUTCH”. Clutch pressure plate Bearing/shart clutch push rod Friction plates...
  • Page 146 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Thrust washer Clutch housing Long clutch push rod For installation, reverse the removal procedure. 4-41...
  • Page 147: Removing The Clutch

    CLUTCH EAS00278 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 clutch holding tool 3 , loosen the clutch boss nut. Clutch holding tool 90890-04086 3.
  • Page 148: Checking The Pressure Plate

    CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: S pressure plate Cracks/damage ! Replace. S bearing Damage/wear ! Replace. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: S clutch boss splines Damage/pitting/wear ! Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause er- ratic clutch operation.
  • Page 149: 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 1 ) Out of specification ! Replace the clutch plates as a set.
  • Page 150: Installing The Clutch

    CLUTCH EAS00295 INSTALLING THE CLUTCH 1. Install: S clutch housing 1 NOTE: S If the wire circlip 2 has been removed, care- fully install a new one as shown. 2. Tighten: S lock washer S clutch boss nut 1 70 Nm (7.0 mSkg) NOTE: While holding the clutch boss with the clutch holding tool 2 , tighten the clutch boss nut.
  • Page 151 CLUTCH NOTE: Make sure that the semicircular slot a in the friction plate is aligned with the mark b on the clutch housing. 7. Install: S clutch pressure plate S clutch spring plate seat S clutch spring 1 S clutch spring plate 2 S clutch spring bolts 3 NOTE: Tighten the clutch spring bolts in stages and in a...
  • Page 152: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL 7 Nm (0.7 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the startor coil Remove the parts in the order listed Engine oil Refer to “ENGINE OIL REPLACEMENT”...
  • Page 153: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH 12 Nm (1.2 mSkg) 175 Nm (17.5 mSkg) Order Job name/Part name Q’ty Remarks Removing the generator and starter Remove the parts in the order listed clutch. Rotor Dowel pins Refer to “REMOVING/INSTALLING Springs THE GENERATOR.”...
  • Page 154: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: S camshaft sprocket cover S tappet covers Refer to “REAR CYLINDER HEAD.” 2. Align: S “T” mark a (with the stationary pointer b ) a. Temporarily install the AC magneto cover without the pickup coil and stator coil.
  • Page 155: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH NOTE: S Remove the rotor by pushing back the rotor, the flywheel puller 2 and the adapter 3 . S Install the flywheel puller bolts and tighten the center bolt, making sure that the tool body stays parallel to the rotor.
  • Page 156: Installing The Generator

    GENERATOR AND STARTER CLUTCH INSTALLING THE GENERATOR 1. Install: S starter clutch assembly NOTE: Align the hole a on the starter clutch housing with the hole b on the rotor. Starter clutch bolt: 12 Nm (1.2 mSkg) LOCTITE 2. Install: S timing drive gear 1 S springs 2 S dowel pins 3...
  • Page 157 GENERATOR AND STARTER CLUTCH 4. Check: S TDC on the compression stroke If the marks do not align ! Adjust. a. Align the “T” mark a with the stationary pointer b on the left crankcase cover. b. When the “T” mark is aligned with the station- ary pointer, the punch mark c on the cam- shaft sprocket should be aligned with the sta- tionary pointer d on the cylinder head.
  • Page 158: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT Order Job name/Part name Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever. Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Left crankcase cover Refer to “GENERATOR AND STARTER Rotor assembly CLUTCH”.
  • Page 159: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 S shift lever 2 Bends/damage/wear ! Replace. S shift lever spring 3 Damage/wear ! Replace. EB408410 CHECKING THE STOPPER LEVER 1. Check: S stopper lever Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
  • Page 160: Oil Pump

    OIL PUMP OIL PUMP 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 12 Nm (1.2 mSkg) Order Job name/Part name Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Rotor assembly Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 161 OIL PUMP 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the oil pump Disassembly the parts in the order listed. Oil pump cover Oil pump body Oil pump rotor (inner) Refer to “ASSEMBLING THE OIL Oil pump rotor (outer) PUMP”.
  • Page 162: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: S oil pump driven gear S oil pump body S oil pump driven gear cover 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-body-side clearance S oil-pump-body-to-inner-rotor-and-outer-ro- tor clearance c Out of specification ! Replace the oil pump.
  • Page 163 OIL PUMP EAS00376 ASSEMBLING THE OIL PUMP 1. Assemble: S oil pump 10 Nm (1.0 mSkg) CAUTION: After tightening the bolts, make sure that the oil pump turns smoothly. NOTE: Align the pin a with the slots b on the inner ro- tor.
  • Page 164: Crankshaft And Connecting Rods

    CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS CRANKCASE 38.5 Nm (3.85 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”.
  • Page 165 CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the crankshaft and Remove the parts in the order listed. connecting rod Crankshaft assembly Refer to “REMOVING/INSTALLING THE CRANKSHAFT”. Oil pump drive sprocket Bearing Nuts (connecting rod caps) Refer to “INSTALLING THE...
  • Page 166: Disassembling The Crankcase

    CRANKSHAFT AND CONNECTING RODS EAS00386 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.) A Right crankcase...
  • Page 167: Removing The Connecting Rods

    CRANKSHAFT AND CONNECTING RODS EB412111 REMOVING THE CRANKSHAFT 1. Remove: S crankshaft assembly 1 NOTE: S Remove the crankshaft assembly with the crankcase separating tool 2 . S Make sure that the crankcase separating tool is centered over the crankshaft assembly. Crankcase separating tool 90890-01135 EB412121...
  • Page 168 CRANKSHAFT AND CONNECTING RODS CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves.
  • Page 169 CRANKSHAFT AND CONNECTING RODS Refer to “INSTALLING THE CONNECTING RODS”. Connecting rod nut 48 Nm (4.8 mSkg) f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS”. g. Measure the compressed Plastigauge width 1 on each crankshaft pin. If the clearance is out of specification, select replacement big end bearings.
  • Page 170: Checking The Bearing And Oil Seals

    CRANKSHAFT AND CONNECTING RODS EB412440 CHECKING THE BEARINGS AND OIL SEALS 1. Check: S bearings Clean and lubricate the bearings, then rotate the inner race with your finger Rough movement ! Replace. 2. Check: S oil seals Damage/wear ! Replace. INSTALLING THE CRANKSHAFT 3.
  • Page 171: Assembling The Crankcase

    S crankshaft 1 NOTE: Align the left connecting rod with the rear cylin- der sleeve hole. ASSEMBLING THE CRANKCASE 1. Apply: S engine oil (onto the main journal bearings) S sealant (onto the crankcase mating surfaces) Yamaha Bond No. 1215: 90890-85505 4-66...
  • Page 172 CRANKSHAFT AND CONNECTING RODS 2. Tighten: S crankcase bolts (follow the proper tightening sequence) NOTE: The numbers embossed on the crankcase indi- cate the crankcase tightening sequence. 4 X 6 (M10) 38.5Nm (3.85 mSkg) 1 X 3 , 7 X (M6) 10 Nm (1.0 mSkg) NOTE:...
  • Page 173: Transmission

    TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in the order listed. Crankcase separation Refer to “CRANKSHAFT”. Guide bar Shift fork 1 “R” Shift fork 2 “C” Refer to “INSTALLING THE Shift fork 3 “L” TRANSMISSION”.
  • Page 174: Checking The Shift Forks

    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 175: Checking The Transmission

    TRANSMISSION EAS00424 CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge) Out of specification ! Replace the main axle. Main axle runout limit 0.08 mm 2. Measure: S drive axle runout (with a centering device and dial gauge) Out of specification ! Replace the drive axle.
  • Page 176: Installing The Transmission

    TRANSMISSION EAS00430 INSTALLING THE TRANSMISSION 1. Install: S shift drum assembly NOTE: Turn the shift drum assembly to the neutral posi- tion. 2. Install: S main axle assembly 1 S drive axle assembly 2 S shift fork “L” 3 S shift fork “C” 4 S shift fork “R”...
  • Page 177: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE PINION GEAR 110 Nm (11.0 mSkg) 110 Nm (11.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the middle drive pinion Remove the parts in the order listed. gear Sepalate the crankcase Refer to “CRANKSHAFT AND CONNECTING ROD.”...
  • Page 178: Middle Driven Pinion Gear

    MIDDLE GEAR MIDDLE DRIVEN PINION GEAR Order Job name/Part name Q’ty Remarks Removing the middle driven Remove the parts in the order listed. pinion gear. Bolts Refer to “REMOVING THE MIDDLE Circlips DRIVEN SHAFT ASSEMBLY/ Bearings INSTALLING THE UNIVERSAL JOINT”. Driven yoke Refer to “REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY/INSTALING...
  • Page 179 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Collapsible collar Refer to “INSTALLING THE MIDDLE Middle driven shaft GEAR ASSEMBLY AND ADJUSTING THE BACKLASH”. Oil seal Refer to “ASSEMBLING THE MIDDLE Bearing DRIVEN SHAFT ASSEMBLY”. Bearing For installation, reverse the removal procedure.
  • Page 180: Removing The Middle Drive Shaft Assembly

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT AS- SEMBLY 1. Remove: S bearing retainer S middle drive shaft assembly a. Straighten the thread on the bearing retainer. b. Attach the bearing retainer wrench 1 . Bearing retainer wrench: 90890-04137 c. Remove the bearing retainer and middle drive shaft assembly.
  • Page 181: Removing The Middle Driven Shaft Assembly

    MIDDLE GEAR REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Remove: S universal joint a. Remove the circlips 1 . b. Place the universal joint in a press. c. With a pipe of the proper diameter positioned beneath the universal joint driven yoke as shown, press the bearing into the pipe.
  • Page 182: Assembling The Middle Drive Shaft Assembly

    MIDDLE GEAR 3. Check: S O-ring S oil seal Damage ! Replace the defective part(-s). 4. Check: S universal joint movement Rough movement ! Replace the universal joint. EAS00441 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Tighten: S middle drive shaft nut 1 110 Nm (11.0 mSkg) NOTE: S Set the torque wrench at a right angle to the...
  • Page 183: Assembling The Middle Driven Shaft Assembly

    MIDDLE GEAR ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following points are critical when assem- bling the middle gears: S The collapsible collar must be replaced when- ever the middle driven shaft assembly is re- moved from the middle driven shaft bearing housing.
  • Page 184 MIDDLE GEAR 2. Install: S shim S middle drive shaft assembly 3. Install: S bearing retainer Install steps: S Attach the bearing retainer wrench 1 . Bearing retainer wrench: 90890-04137 S Tighten the bearing retainer. Bearing retainer: 110 Nm (11.0 mSkg) S Lock the threads on the bearing retainer by staking them with a center punch.
  • Page 185: Installing The Universal Joint

    MIDDLE GEAR CAUTION: Do not over tighten the middle driven pinion gear nut. If over tighten the middle driven pinion gear nut, replace the collapsible col- lar and adjust the backlash. f. Stake the middle driven pinion gear shaft thread. INSTALLING THE UNIVERSAL JOINT 4.
  • Page 186: Aligning The Middle Gear

    MIDDLE GEAR EAS00452 ALIGNING THE MIDDLE GEAR NOTE: Aligning the middle gear is necessary when any of the following parts are replaced: S Crankcase S Middle drive shaft 1. Select: S middle drive gear shim(-s) 1 NOTE: Select the middle drive gear shim(-s) 1 by cal- culating the middle drive gear shim thickness and then measuring the middle gear backlash.
  • Page 187 MIDDLE GEAR Hundredths Rounded value 0, 1, 2 3, 4, 5, 6, 7, 8, 9 Shims are supplied in the following thickness. Middle drive pinion gear shim: Thickness (mm) 0.10, 0.15, 0.20 4-82...
  • Page 188 CARB...
  • Page 189 CARB CHAPTER 5 CARBURETION CARBURETOR ..........CHECKING THE CARBURETORS .
  • Page 190: Carburetor

    CARB CARBURETOR CARBURETION CARBURETOR 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK AND SEATS” in CHAPTER 3. Air filter case assembly Air ducts Cylinder head breather hose Disconnect Air chamber...
  • Page 191 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Disassembling the carburetor. Disassemble the parts in the order listed. Carburetor heater leads Carburetor heaters 12V 30W Float chamber/gasket Float Needle valve set Main jet Jet holder Pilot jet Starter jet Refer to “CARBURETOR ASSEMBLY”. Jet needle set Starter plunger set...
  • Page 192 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Diaphragm set Refer to “ASSEMBLING THE CARBURE TORS”. Throttle position sensor Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR (TPS)”. Pilot screw Main air jet Pilot air jet 1 Pilot air jet 2 Throttle stop screw set For assembly, reverse the disassembly procedure.
  • Page 193: Checking The Carburetors

    CARB CARBURETORS EB600031 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 petroleumbased solvent.
  • Page 194 CARB CARBURETOR 8. Check: S vacuum chamber cover 1 S piston valve spring 2 S plastic cap 3 S O-ring 4 S spring 5 Cracks/damage ! Replace. 9. Check: S jet needle 1 S needle jet 2 S main jet 3 S pilot screw 4 S pilot jet 5 S main air jet 6...
  • Page 195: Assembling The Carburetors

    CARB CARBURETOR EB600042 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent. S Always use a new gasket. 1. Install: S coasting enricher diaphragm S coasting enricher spring S coasting enricher cover NOTE:...
  • Page 196: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR EB600063 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (above the line on the float chamber) 4 X 5 mm a. Stand the motorcycle on a level surface. b.
  • Page 197: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETOR EB600071 CHECKING ADJUSTING THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Inspect: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. b. Connect the pocket tester (Ω 1k) to the throttle position sensor.
  • Page 198 CARB CARBURETOR Closed-throttle resistance 0.56 X 0.84 kΩ at 20 C (yellow – black) c. Tighten the throttle position sensor screws. NOTE: Remove the pocket tester leads and connect the throttle position sensor coupler.
  • Page 199: Air Induction System (Ais)

    CARB AIR INDUCTION SYSTEM (AIS) EB601000 AIR INDUCTION SYSTEM (AIS) AIR INDUTION This system burns the unburned exhaust gases by injecting fresh air (secondary air) at the ex- haust port. This is to reduce the output of the hy- drocarbons. When there is negative pressure around the ex- haust port, the reed valve opens and the sec- ondary air flows into the exhaust port.
  • Page 200: Air Induction System Inspection

    CARB AIR INDUCTION SYSTEM (AIS) AIR INDUCTION SYSTEM INSPECTION Reed valve 1. Inspect: Air filter S hose connections Orifice Poor connections ! Properly connect. Carburetor joint (near cylinder) S hoses To the front cylinder head S reed valves To the rear cylinder head S air cut-off valve To the orifice S air filter...
  • Page 201 CARB...
  • Page 202 CHAS...
  • Page 203 CHAS CHAPTER 6 CHASSIS FRONT WHEEL AND BRAKE DISCS ......REMOVING THE FRONT WHEEL .
  • Page 204 CHAS HANDLEBAR ..........6-52 REMOVING THE HANDLEBAR .
  • Page 205: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS CHASSIS FRONT WHEEL AND BRAKE DISCS 59 Nm (5.9 mSkg) 20 Nm (2.0 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.
  • Page 206 CHAS FRONT WHEEL AND BRAKE DISCS Order Job name/Part name Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seals Bearings Collar For assembly, reverse the disassembly procedure.
  • Page 207: 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 208 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: S spokes 3 Nm (0.3mSkg) NOTE: After tightening the spokes, measure the front wheel runout. 5. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace.
  • Page 209: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag be- tween the screwdriver and the wheel surface. c.
  • Page 210 CHAS FRONT WHEEL AND BRAKE DISCS c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 2 – 3 mm below the edge of the brake disc. 3.
  • Page 211: 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 seallips Recommended lubricant Lithium soap base grease 2. Install: S front wheel assembly NOTE: The arrow mark a on the tire must point in the direction of the wheel.
  • Page 212: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance shourd be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 213 CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: S front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.
  • Page 214: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC MUFFLER AND BRAKE CALIPER 20 Nm (2.0mSkg) 30 Nm (3.0mSkg) 40 Nm (4.0mSkg) 20 Nm (2.0mSkg) 25 Nm (2.5mS kg) Order Job name/Part name Q’ty Remarks Removing the muffler and brake Remove the parts in the order listed.
  • Page 215: Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL 23 Nm (2.3mSkg) 40 Nm (4.0mSkg) 23 Nm (2.3mSkg) 90 Nm (9.0mSkg) 107 Nm (10.7mSkg) Order Job name/Part name Q’ty Remarks Remove the parts in the order listed. Removing the rear wheel WARNING Securely support the motorcycle so there is no danger of it falling over.
  • Page 216 CHAS REAR WHEEL AND BRAKE DISC 62 Nm (6.2mSkg) Order Job name/Part name Q’ty Remarks Rear wheel disassembly Remove the parts in the order listed. Disassembling the rear wheel Lock washers Clutch hub Dampers O-rings Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure.
  • Page 217: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00562 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 218: Checking The Rear Wheel Drive Hub

    CHAS REAR WHEEL AND BRAKE DISC EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub Cracks/damage ! Replace. S rear wheel drive hub dampers Damage/wear ! Replace. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S drive shaft splines Recommended lubricant Molydenum disulfide grease 2.
  • Page 219: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC f. Tighten the rear axle holder with specified torque. Rear axle end nut 23 Nm (2.3 mSkg) g. Tighten the rear brake caliper bracket bolt with specified tightening torque. Brake caliper bracket bolt 40 Nm (4.0 mSkg) h.
  • Page 220: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Retaining bolt Brake caliper Refer to “REPLACING THE FRONT Brake pads BRAKE PADS”.
  • Page 221: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Muffler Refer to “REAR WHEEL AND BRAKE Muffler stay DISC”.
  • Page 222: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 223 CHAS FRONT AND REAR BRAKES 2. Remove: S brake pads 1 (along with the brake pad shims) 3. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.8 mm 4.
  • Page 224: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 6. Check: S brake fluid level Below the minimum lever mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system.
  • Page 225 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 226: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder. Brake fluid Drain Rear view mirror (right) Brake lever/compression spring Front brake switch Union bolt...
  • Page 227 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Master cylinder cup Spring For assembly, reverse the disassembly procedure. 6-23...
  • Page 228: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 64 Nm (6.4 mSkg) 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain...
  • Page 229 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake master Disassembly the parts in the order listed. cylinder Master cylinder boot Circlip Master cylinder cup Spring For assembly, reverse the disassembly procedure. 6-25...
  • Page 230: Removing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before removing the front brake master cylin- der, drain the brake fluid from the entire brake system. 1. Remove: S rear view mirror (right) S brake lever/compression spring S brake switch 1 2.
  • Page 231: Checking The Front And Rear Brake Master Cylinder

    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 232: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00598 INSTALLING THE 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 233 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
  • Page 234: Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00610 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: S copper washers (New) S brake hose Union bolt 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 235 CHAS FRONT AND REAR BRAKES 5. Adjust: S brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in chapter 3. Brake pedal position (below the top of the rider footrest) 81.8 mm 6. Adjust: S rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”...
  • Page 236: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg) 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Brake fluid Drain Brake hose holder Union bolt...
  • Page 237 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers Pad spring Brake caliper pistons Refer to “REMOVING THE FRONT Dust seals BRAKE CALIPERS”. Caliper piston seals Bleed screw For assembly, reverse the disassembly procedure.
  • Page 238: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES ESA00616 REAR BRAKE CALIPER 40 Nm (4.0 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Muffler Refer to “REAR WHEEL AND BRAKE Muffler stay DISC”.
  • Page 239 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake caliper Disassembly the parts in the order listed. Cover Clips Pad pins Pad spring Brake pads Caliper pistons Refer to “DISASSEMBLING THE REAR Dust seals BRAKE CALIPER”.
  • Page 240: Removing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00624 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before removing either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S brake hose holder S union bolt 1 S copper washers 2 S brake hose...
  • Page 241: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Remove: S union bolt 1 S copper wachers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper pistons 1 S brake caliper pistons seals 2 a.
  • Page 242: Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper piston assembly. S brake caliper cylinders 2 Scratches/wear ! Replace the brake cali- per. S brake calipers 3 Cracks/damage ! Replace. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air.
  • Page 243 CHAS FRONT AND REAR BRAKES 1. Install: S brake caliper 1 (temporarily) S copper washers (New) 2 S brake hose 3 S union bolt 4 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 244: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 245 CHAS FRONT AND REAR BRAKES 1. Install: S brake caliper 1 (temporarily) S copper washers S brake hose 2 S 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 246 CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 247: Front Fork

    CHAS FRONT FORK FRONT FORK 20 Nm (2.0 mSkg) 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 248 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Refer to “DISASSEMBLING/ASSEM- Dust seal BLING THE FRONT FORK LEGS”.
  • Page 249 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Seal spacer Outer tube bushing Refer to “DISASSEMBLING/ASSEM- Inner tube/inner tube bushing BLING THE FRONT FORK LEGS”. Oil lock piece Outer tube For assembly, reverse the disassembly procedure.
  • Page 250: 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 251: Checking The Front Fork Legs

    CHAS FRONT FORK NOTE: S Do not remove the front fork leg protector from the outer tube. S If the front fork leg protector must be removed, always install a new one. 4. Remove: S damper rod bolt S copper washer NOTE: While holding the damper rod with the T-handle 1 and damper rod holder 2 , loosen the damp-...
  • Page 252: Assembling The Front Fork Legs

    CHAS FRONT FORK 3. Check: S damper rod 1 Damage/wear ! Replace. Obstruction ! Blow out all of the oil pas- sages with compressed air. S oil lock piece 2 Damage ! Replace. CAUTION: When disassembling and assembling the front fork leg, do not allow any foreign mate- rial to enter the front fork.
  • Page 253 CHAS FRONT FORK 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 10 W or equivalent 3. Tighten: S damper rod bolt 1 30 Nm (3.0 mSkg) NOTE: While holding the damper rod with the T-handle 1 and damper rod holder 2 , tighten the damp- er rod bolt 3 .
  • Page 254 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.464 L Recommended oil Yamaha fork and shock oil 10W or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 255 CHAS FRONT FORK NOTE: S Install the fork spring with its smaller pitch up- word. 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 fllowing procedure applies to both of the front fork legs.
  • Page 256: Handlebar

    CHAS HANDLEBAR HANDLEBAR 28 Nm (2.8 mSkg) 10 Nm (1.0 mSkg) 32 Nm (3.2 mSkg) Order Job name/Part name Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 257 CHAS HANDLEBAR 28 Nm (2.8 mSkg) 10 Nm (1.0 mSkg) 32 Nm (3.2 mSkg) Order Job name/Part name Q’ty Remarks Throttle grip assembly Handlebar holders (upper) Refer to “INSTALLING THE Handlebar HANDLEBAR”. Cable guide Handlebar holders (lower) For installation, reverse the removal procedure.
  • Page 258: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S handlebar grip (left) 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 259: Installing The Handlebar

    CHAS HANDLEBAR 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. WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried.
  • Page 260 CHAS HANDLEBAR S Align the match marks b on the handlebar with the upper surface of the lower handlebar holders. 3. Install: S throttle grip S throttle cable WARNING Make sure that the pin a on the throttle cable housing is aligned with the hole b in the handlebar.
  • Page 261 CHAS HANDLEBAR 9. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 5 X 10 mm 10. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
  • Page 262: Steering Head

    CHAS STEERING HEAD STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 263 CHAS STEERING HEAD 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) 110 Nm (11.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Rubber washer Lower ring nut Refer to “REMOVING THE LOWER Bearing cover BRACKET/INSTALLING THE Lower bracket STEERING HEAD”.
  • Page 264: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S 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 265: Installing The Steering Head

    CHAS STEERING HEAD a. Remove the bearing reces 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 rubber seal and new bearing re- ces.
  • Page 266 CHAS STEERING HEAD NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to “FRONT FORK” NOTE: Temporarily tighten the upper and lower bracket pinch bolts. 6-62...
  • Page 267: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM RIGHT SIDE COVER AND BATTERY BOX 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the right side cover and Remove the parts in the order listed. battery box.
  • Page 268: Left Side Cover And Tool Box

    CHAS REAR SHOCK ABSORBER AND SWINGARM LEFT SIDE COVER AND TOOL BOX 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the left side cover and Remove the parts in order listed. tool box Tool box cover Left side cover Owner’s tool kit Connector’s –...
  • Page 269 CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) 90 Nm (9.0 mSkg) 48 Nm (4.8 mSkg) 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in order listed.
  • Page 270: Disposing Of A Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER AND SWINGARM 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 271: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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 272: Removing The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00702 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 273: Cylinder

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly.
  • Page 274: Installing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00698 INSTALLING THE REAR SHOCK ABSORB- ER ASSEMBLY 1. Install: S swingarm Refer to “INSTALLING THE SWINGARM”. 2. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 3. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm (4.0 mSkg)
  • Page 275 CHAS REAR SHOCK ABSORBER AND SWINGARM 2. Install: S relay arm S left connecting arm S right connecting arm Rear-shock-absorber-assembly lower nut 1 48 Nm (4.8 mSkg) Connecting arm nuts 2 48 Nm (4.8 mSkg) Relay-arm-to-frame-nut 3 48 Nm (4.8 mSkg) 3.
  • Page 276: Shaft Drive

    CHAS SHAFT DRIVE SHAFT DRIVE EAS00715 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible causes 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration, or sus- B. Improper gear lash tained speeds. (not to be confused with engine C.Damaged gear teeth surging or transmissionrelated D.Broken drive shaft...
  • Page 277 CHAS SHAFT DRIVE Inspection notes 1. Investigate any unusual noises. The following noises may indicate a me- chanical defect: a. A rolling “rumble” during coasting, accelera- tion, or deceleration, (increases with the rear wheel speed, but does not increase with higher engine or transmission speeds).
  • Page 278 CHAS SHAFT DRIVE EAS00716 Troubleshooting chart When causes A and B shown in the chart at the beginning of the “TROUBLESHOOTING” section exist, check the following points: Place the motorcycle on a suitable stand so Replace the wheel bearing. that the front wheel is elevated and then spin Refer to “FRONT WHEEL AND BRAKE the front wheel.
  • Page 279: Checking The Final Drive Oil For Contamination And Inspecting The Shaft Drive For Leaks

    CHAS SHAFT DRIVE EAS00717 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 1. Drain: S final drive oil (from the final drive housing) Refer to “CHARGING THE FINAL DRIVE OIL” in chapter 3. 2. Check: S final drive oil Large amount of metal particles ! Check for bearing seizure.
  • Page 280: Measuring The Ring Gear Backlash

    CHAS SHAFT DRIVE EAS00719 MEASURING THE RING GEAR BACKLASH 1. Secure the final drive assembly in a vise. 2. Remove: S final drive oil drain bolt 3. Drain: S final drive oil (from the final drive assembly) 4. Measure: S ring gear backlash Out of specification ! Adjust.
  • Page 281: Adjusting The Ring Gear Backlash

    CHAS SHAFT DRIVE g. Rotate the final drive pinion gear 90_. h. Reinstall the bolt, special tool, and dial gauge. i. Repeat steps (d) to (h) three more times (for a total of four measurements). j. If any of the readings are over specification, adjust the ring gear backlash.
  • Page 282 CHAS SHAFT DRIVE b. If it is necessary to increase the ring gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. c. If it is necessary to reduce the ring gear back- lash by more than 0.2 mm, increase the thrust washer thickness by 0.2 mm for every 0.2 mm decrease of ring gear shim thick-...
  • Page 283: Final Drive Assembly And Drive Shaft

    CHAS SHAFT DRIVE FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 23 Nm (2.3 mSkg) 115 Nm (11.5 mSkg) 23 Nm (2.3 mSkg) 130 Nm (13.0 mSkg) 42 Nm (4.2 mSkg) Order Job name/Part name Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed.
  • Page 284: Final Gear

    CHAS SHAFT DRIVE FINAL GEAR 23 Nm (2.3 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the final gear. Disassemble the parts in the order listed. Bolts (bearing housing) NOTE: Nuts (bearing housing) Working in a crisscross pattern, loosen each bolt and nut 1/4 of a turn.
  • Page 285: Disassembling The Final Drive Assembly

    CHAS SHAFT DRIVE EAS00724 DISASSEMBLING THE FINAL DRIVE AS- SEMBLY 1. Remove: S ring gear bearing housing nuts S ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each bolts and nuts 1/4 of a turn. After all of the bolts and nuts are fully loosened, and remove them.
  • Page 286: Removing And Installing The Ring Gear Bearings

    CHAS SHAFT DRIVE EAS06725 REMOVING AND INSTALLING THE RING GEAR BEARINGS 1. Remove: S collar 1 S oil seal 2 S bearing 3 (with an appropriate press tool 4 and an ap- propriate support for the final drive housing) 2. Check: S bearing Damage ! Replace.
  • Page 287: Aligning The Final Drive Pinion Gear And Ring Gear

    S collar 1 S oil seal 2 S bearing (with an appropriate press tool 3 and press) NOTE: The bearing can be reused, but Yamaha recom- mends installing a new one. EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR...
  • Page 288 CHAS SHAFT DRIVE Where: a = a numeral (positive or negative) on the ring gear, to be divided by 100 and added to “84” b = a numeral on the final drive housing. Example: If the final drive pinion gear is marked “+ 01” and the final drive housing is marked “83.50”: A = (84 + 1/100) –...
  • Page 289 CHAS SHAFT DRIVE f = the ring gear bearing thickness constant Ring gear bearing thickness“ f ” 13.00 mm Example: If the final drive housing is marked “45.51” the ring gear bearing housing is marked “3.35” the ring gear is marked “-05”, and “f” is 13.00: B = 45.51 + 3.35 –...
  • Page 290 CHAS SHAFT DRIVE Bearing retainer wrench 90890-04077 3. Install: S gear coupling S self-locking nut 130 Nm (13.0 mSkg) (with the special tool 1 ) Coupling gear/middle shaft tool 90890-01229 CAUTION: Apply LOCTITE to the self-locking nut. 4. Install: S ring gear bearing housing (along with the ring gear, but without the thrust washer) 5.
  • Page 291: Checking The Drive Shaft

    1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2. Apply: S sealant (onto both final drive housing mating sur- faces) Yamaha bond No. 1215 90890-85505 3. Install: S drive shaft (to the final drive pinion gear) 6-87...
  • Page 292 CHAS SHAFT DRIVE 4. Tighten: S final bearing housing nuts 42 Nm (4.3 mSkg) 5. Install: S rear wheel assembly Refer to “REAR WHEEL AND BRAKE DISC”. 6-88...
  • Page 293 – ELEC...
  • Page 294 ELEC CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS ........SWITCHES .
  • Page 295 ELEC CARBURETOR HEATER SYSTEM ......7-44 CIRCUIT DIAGRAM ......... 7-44 TROUBLESHOOTING .
  • Page 296: Electrical

    ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS Main switch Side stand switch Thermo switch Neutral switch Flasher relay Rectifier/ regulator Starting circuit cut off relay Oil lamp relay Ignition coil Battery Starter relay Rear brake switch Fuse Horn Igniter unit...
  • Page 297: 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 298: 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 299 ELEC CECKING THE SWITCHES Clutch switch Engine stop switch Pass switch Start switch Horn switch Fuse Dimmer switch Rear brake switch Turn switch Sidestand switch Main switch Neutral switch : for Europe Front brake switch : for AUS Lights switch (for Europe)
  • Page 300: 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 301 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 302: 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 303: Ignition System

    ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 304: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Min. open-circuit voltage 1.
  • Page 305 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 306 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 10.7 X 14.5 kΩ 20 _C EAS00750 S Is the ignition coil OK? 9.
  • Page 307 ELEC IGNITION SYSTEM 13. Starting circuit cut-off relay (diode) S Remove the relay unit from the wire har- ness. S Check for continuity as follows: 12. Diode Sky blue – Blue/Yellow 2 S Remove the diode from the wire harness. S Check for continuity as follows: Tester (+) lead ! SKy blue Continu-...
  • Page 308: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-13...
  • Page 309: Starting Circuit Operation

    ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting cir- cuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can op- erate only if: The transmission is in neutral (the neutral...
  • Page 310: 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 Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2.
  • Page 311 ELEC ELECTRIC STARTING SYSTEM EAS00759 EAS00760 4. Starting circuit cutoff relay 5. Starting circuit cutoff relay (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.
  • Page 312 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch S Check the engine stop switch for continuity. S Disconnect the starter relay from the cou- Refer to “CHECKING THE SWITCHES”. pler. S Is the engine stop switch OK? S Connect the pocket tester (Ω...
  • Page 313 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 right handlebar switch. 13. Diode S Check the diode for continuity. Refer to “IGNITION SYSTEM”. S Is the diode OK? Replace the diode.
  • Page 314: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 10 Nm (1.0 mSkg) Order Job name/Part name 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 315 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 316 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. Bruch spring force 7.65 X 10.01 N (780 X 1.020 g) 7.
  • Page 317 ELEC ELECTRIC STARTING SYSTEM 3. Install: S Starter motor rear cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover. 7-22...
  • Page 318: Charging System

    ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM AC magneto (stator coil) Rectifier/ regulator Battery Main fuse 7-23...
  • Page 319: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The battery is not being sharged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuses Open-circuit voltage 2. battery 12.8 V or more at 20_C 3.
  • Page 320 ELEC CHARGING SYSTEM EAS00779 5. Wiring NOTE: S Check the wiring connections of the entire Make sure that the battery is fully charged. charging system. S Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. S Is the charging system’s wiring properly con- ected and without defects? The charging circuit is OK.
  • Page 321: Lighting System

    ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 7-26...
  • Page 322: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, auxilia- THE BATTERY” in chapter 3. ry light (for Europe) or meter light. Open-circuit voltage Check: 12.8 V or more at 20_C...
  • Page 323: 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 came on. Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? 1.
  • Page 324 ELEC LIGHTING SYSTEM 2. Voltage S Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe ! blue Tester negative probe ! black S Set the main switch to “ON”. S Set the light switch to “ ”.
  • Page 325 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 326: Signal System

    ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 7-31...
  • Page 327 ELEC SIGNAL SYSTEM 4 Main switch 6 Ignition fuse 7 Battery 8 Main fuse Oil level gauge Oil lamp relay Neutral switch Oil warning light Turn signal indicator light Neutral indicator light Flasher relay Turn signal switch Rear turn signal light (R) Rear turn signal light (L) Front turn signal light (R) Front turn signal light (L)
  • Page 328: Troubleshooting

    ELEC SIGNALING SYSTEM EB806010 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S Any of the following fail to light: turn sig- Refer to “CHECKING THE BATTERY” in nal light, brake light or an indicator light. S The forn fails to sound. chapter 3.
  • Page 329: 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 forn switch for continuity. and ground the jumper lead.
  • Page 330: Signaling System

    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 331 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 332 ELEC SIGNALING SYSTEM S Set the main switch to “ON”. 3. Voltage S Set the turn signal switch to “ ” or “ ”. S Connect the pockt tester (DC 20V) to the me- S Measure the voltage (12 V) of chocolate ter assembly coupler (wire harness side) as dark green at the turn signal light connec-...
  • Page 333 ELEC SINGNAL SYSTEM 2. Oil level switch 4. Voltage S Connect the pocket tester (DC 20 V) to the S Drain the engine oil and remove the oil level switch from the oil pan. meter assembly coupler (wire harness side) S Check the oil level switch for continuity.
  • Page 334: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7-39...
  • Page 335: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump Battery Main fuse relay, fuel pump, engine stop switch and ignitor Main switch unit. Ignition fuse The ignitor unit includes the control unit for the Engine stop switch fuel pump.
  • Page 336: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The fuel pump fails to operate. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, and ignition fuses Open-circuit voltage 2.
  • Page 337 ELEC FUEL PUMP SYSTEM EB803023 EB808021 5. Starting circuit cutoff relay (fuel pump relay) 6. Fuel pump resistance S Disconnect the fuel pump coupler from the S Remove the relay unit from the wire har- wire harness. ness. S Connect the pocket tester (Ω S Connect the pocket tester (Ω...
  • Page 338: Fuel Pump Test

    ELEC FUEL PUMP SYSTEM EB808030 FUEL PUMP TEST WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or combustion. Be extreme- ly careful and note the following points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks, or any other source of fire.
  • Page 339: Carburetor Heater System

    ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM 7-44...
  • Page 340: Troubleshooting

    ELEC CARBURETOR HEATER SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The carburetor heater fails to operate. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, and carburetor heater Open-circuit voltage 2.
  • Page 341 ELEC CARBURETOR HEATER SYSTEM 5. Carburetor heater relay S Remove the carburetor heater relay from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the carburetor heater relay ter- minals. Battery (+) terminal ! Brown/Yellow terminal Battery (–) terminal ! Sky blue terminal 2...
  • Page 342 ELEC CARBURETOR HEATER SYSTEM 7. Carburetor heater S Remove the carburetor heater from the car- buretor body. S Connect the pocket tester to the carburetor heater. Tester (+) lead ! Heater terminal Tester (–) lead ! Heater body S Measure the heater resistance. Carburetor heater resistance: 12 V 30 W : 6 X 10 Ω...
  • Page 343: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The XVS1100 features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the engine indicator light (irrespective of whether the engine is running or not). NOTE: The XVS1100 features a self-diagnosing system.
  • Page 344 ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The engine warning light starts to display Refer to “CIRCUIT DIAGRAM”. the self-diagnosis sequence. S Is the wire harness OK? Check: 1. throttle position sensor 2. speed sensor Repair or replace the NOTE: wire harness.
  • Page 345 ELEC SELF-DIAGNOSIS 2. Speed sensor CIRCUIT DIAGRAM S Set the main switch to “ON”. S Turn the rear wheel slowly. S Check the tester voltage (0V - 5V - 0V). S Is the speed sensor OK? Replace the ignitor Replace the speed unit.
  • Page 346 TRBL SHTG...
  • Page 347: Troubleshooting

    TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ......FUEL SYSTEM ..........ELECTRICAL SYSTEM .
  • Page 348: Starting Failure/Hard Starting

    TRBL STARTING FAILURE/HARD STARTING SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...
  • Page 349: Compression System

    STARTING FAILURE/HARD STARTING/POOR IDLE SPEED TRBL PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston ring S Loose spark plug S Improperly installed piston ring S Loose cylinder head or cylinder S Worn, fatigued or broken piston ring S Faulty cylinder head gasket S Seized piston ring S Worn, damaged or seized cylinder...
  • Page 350: Faulty Gear Shifting

    FAULTY GEAR SHIFTING/ TRBL CLUTCH SLIPPING/DRAGGING SHTG EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission S Improperly adjusted shift pedal link S Seized transmission gear S Bent shift shaft S Jammed impurities S Incorrectly assembled transmission Shift cam, shift fork S Groove jammed with impurities...
  • Page 351: Overheating Overheating

    OVERHEATING/FAULTY BRAKE/FRONT FORK OIL TRBL LEAKAGE AND FRONT FORK MALFUNCTION SHTG EB905000 OVERHEATING OVERHEATING Ignition system Compression system S Improper spark plug gap S Heavy carbon build-up S Improper spark plug heat range Engine oil S Faulty ignitor unit S Improper oil level S Improper oil viscosity Fuel system S Improper carburetor main jet setting...
  • Page 352: Unstable Handling

    UNSTABLE HANDLING/ TRBL FAULTY LIGHTING AND SIGNAL SYSTEMS SHTG EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Front fork S Improperly installed or bent S Uneven oil levels on both sides S Uneven spring tension Steering S Improperly installed handlebar crown (uneven damping force adjuster position) S Bent steering stem S Broken spring S Improperly installed steering shaft...
  • Page 353 XVS1100 WIRING DIAGRAM (for Europe) Pickup coil A.C. magneto Rectifier/ regulator Main switch Alarm system (Option) Ignition fuse Battery Main fuse Starter relay Starter motor Oil level gauge Oil lamp relay Starting circuit cut-off relay Fuel pump Throttle position sensor Igniter unit Ignition coil Spark plug...
  • Page 354 XVS1100L WIRING DIAGRAM (for AUS) Pickup coil A.C. magneto Rectifier/ regulator Main switch Ignition fuse Battery Main fuse Starter relay Starter motor Oil level gauge Oil lamp relay Starting circuit cut-off relay Fuel pump Throttle position sensor Igniter unit Ignition coil Spark plug Speed sensor Neutral switch...
  • Page 355 SPEC CABLE ROUTING A Clamp the throttle cables with E Position the steel band end to I Connect the wireharness to the the holder. Position the end of right side. ignitar unit through the hole of clip downword. F Route the battery positive (+) LID.

This manual is also suitable for:

1999 xvs11001999 xvs1100l