Yamaha BT1100 2002 Service Manual
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Yamaha BT1100 2002 Service Manual

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BT1100
2002
5JN1-AE1
SERVICE MANUAL

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  • Page 1 BT1100 2002 5JN1-AE1 SERVICE MANUAL...
  • Page 2 EASB0000 BT1100 2002 SERVICE MANUAL © 2001 by Belgarda S.p.A. First edition, November 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Belgarda S.p.A. is expressly prohibited. Printed in Italy...
  • Page 3 EASB0001 NOTICE This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 5: General Information

    EB003000 ILLUSTRATED SYMBOLS The following symbols are not relevant to every SPEC INFO vehicle. Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. INSP 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS E004000 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION INSP AND ADJUSTMENTS ENGINE CARBURETION CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 8 INFO...
  • Page 9 INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER................1-1 MODEL LABEL ......................1-1 IMPORTANT INFORMATION ....................1-2 PREPARATION FOR REMOVAL PROCEDURES ............1-2 REPLACEMENT PARTS ....................1-2 GASKETS, OIL SEALS AND O-RINGS ................1-2 LOCK WASHERS/PLATES AND COTTER PINS ............1-3 BEARINGS AND OIL SEALS ..................1-3 CIRCLIPS ........................1-3 CHECKING OF CONNECTIONS ..................1-4 SPECIAL TOOLS........................1-5...
  • Page 10 INFO...

  • Page 11: Chapter 1. General Information

    INFO MOTORCYCLE IDENTIFICATION EB100010 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame under the seat. MODEL LABEL The model label 1 is affixed to the frame under the seat. This information will be needed to order spare parts.

  • Page 12: Important Information

    5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 13: Lock Washers/Plates And Cotter Pins

    INFO IMPORTANT INFORMATION EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter 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 14: Checking Of Connections

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

  • Page 15: Special Tools

    INFO SPECIAL TOOLS 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 16 INFO SPECIAL TOOLS Tool name/How to use Illustration Tool No. Flywheel puller/adapter Puller 90890-01362 Adapter These tools are needed to remove the 90890-04131 rotor. Fork seal driver weight/adapter Weight (Ø 43 mm) 90890-01367 These tools needed when Adapter installing the slide metal, oil seal and 90890-01374 dust seal into the fork.
  • Page 17 INFO SPECIAL TOOLS Tool name/How to use Illustration Tool No. 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 18 This tool is needed when removing or installing the damper spring. Dynamic spark tester Ignition checker 90890-06754 This instrument is necessary for checking the ignition system compo- nents. Yamaha bond No.1215 90890-85505 This sealant (bond) is used on crankcase mating surfaces, etc.
  • Page 19 SPEC...
  • Page 20 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS .................... 2-1 MAINTENANCE SPECIFICATIONS ..................2-4 ENGINE ........................2-4 CHASSIS ........................2-14 ELECTRICAL ......................2-18 GENERAL TORQUE SPECIFICATIONS................2-20 CONVERSION TABLE......................2-20 LUBRICATION POINTS AND LUBRICANT TYPES............2-21 ENGINE ........................2-21 CHASSIS ........................2-22 LUBRICATION DIAGRAMS ....................2-23 CABLE ROUTING ......................2-26...
  • Page 21 SPEC...

  • Page 22: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: BT1100: 5JN1 Dimensions: Overall length 2,200 mm Overall width 800 mm Overall height 1,140 mm Seat height 812 mm Wheelbase 1,530 mm Minimum ground clearance 168 mm Minimum turning radius 2,980 mm Basic weight: With oil and a full fuel tank...
  • Page 23 SPEC GENERAL SPECIFICATIONS Item Standard Carburetor: Type/quantity BSR37/2 Manufacturer MIKUNI Spark plug: Type BPR7ES/W22EPR-U Manufacturer NGK/DENSO Spark plug gap 0.8 mm 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 19/18...
  • Page 24 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/Spring preload adjustable Wheel travel: Front wheel travel 130 mm Rear wheel travel 113 mm Electrical system: Ignition system...

  • Page 25: Engine

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ••• 0.03 mm Cylinder: Bore size 95.00 95.01 mm 95.1 mm Measuring point 40 mm ••• Camshaft: Drive method Chain drive (left & right) ••• Cam cap inside diameter 25.000 25.021 mm •••...
  • Page 26 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: Bearing inside diameter 14.000 mm 14.018 mm 14.036 mm Shaft outside diameter 13.985 mm 13.991 mm 13.95 mm Arm-to-shaft clearance...
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ••• 0.03 mm Valve seat width 1.4 mm 2.0 mm 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 •••...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 22.004 22.015 mm 22.045 Piston pin outside diameter 21.991 22.000 mm 21.975 Piston rings: Top ring: Type Plain ••• Dimensions (B x T) 3.8 mm ••• End gap (installed) 0.5 mm 0.8 mm Side clearance (installed)
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 3.1 mm 2.8 mm Quantity ••• Clutch plate thickness 2.7 mm 0.1 mm Quantity ••• Clutch plate thickness 2.1 mm 0.1 mm Quantity ••• Clutch spring free length 7.2 mm 6.5 mm Quantity •••...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ••• Oil pump type Trochoid type ••• Tip clearance “A” or “B” 0.03 0.09 mm 0.15 mm Side clearance 0.03 0.08 mm 0.15 mm Relief valve operating pressure 550 kPa (4.5 5.5 kg/cm •••...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Needle bearing (starter) Connecting rod big end Main axle Crankshaft Drive axle Pressure feed Pinin drive Splashed Orifice Middle driveshaft Rocker arm (EX) Camshaft (EX) Rocker arm (EX) Rocker arm (IN) Camshaft (IN) Rocker arm (IN) Oil filter Oil pump...
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence: Crankcase tightening sequence: Left crankcase Right crankcase 2-11...
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Part Thread Part to be tightened Q’ty torque Remarks name size · · Cylinder head Cylinder head Plate Bolt Cylinder head cover Screw Cylinder head (exhaust pipe) Stud bolt 12.5 1.25 Rocker arm shaft Union 37.5 3.75...
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS Tightening Part Thread Part to be tightened Q’ty torque Remarks name size · · Exhaust pipe strap Screw Silencer fastener to passenger board support Screw Exhaust pipe guard fastener Screw Crankcase (cylinder) Stud bolt Crankcase (cylinder) Stud bolt Crankcase Bolt 38.5...

  • Page 35: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing ••• Front suspension: Front fork travel 130 mm ••• Fork spring free length 363.3 mm ••• Fitting length 339.8 mm ••• Collar length 150 mm ••• Spring rate (K1) 7.0 N/mm (0.71 kg/mm)
  • Page 36 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front brake: Type Dual disc ••• Disc outside diameter thickness 5 mm 4.5 mm Disc deflection limit ••• 0.2 mm Pad thickness inner 5.5 mm 0.5 mm outer 5.5 mm 0.5 mm Master cylinder inside diameter 14.0 mm •••...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Remarks size · · Headlight assembly/Cowling: Lower headlight support Upper headlight support (right and left) Headlight bracket (right and left) Plastic cover Front flasher lights (right and left) Handlebar/Front fork assembly: Upper bracket and inner tube Lower bracket and inner tube...
  • Page 38 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Rear brake/Footrests: Brake caliper torque rod Rear brake adjuster Rear brake pedal fastening screw (special) Rear master cylinder fastening screw Rear brake fluid reservoir fastening screw Special screw for fastening rear brake hose to brake caliper Special screw for fastening rear brake...

  • Page 39: 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.: 231 Ω at 20 °C / Gray–Black Pickup coil resistance/color ••• T.C.I. unit model/manufacturer J4T101/MITSUBISHI •••...
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn: Type Plane type ••• Quantity ••• Model/manufacturer K80 L-12V/LEB ••• Maximum amperage ••• Flasher relay: Type Semi-transistor ••• Model/manufacturer FB222M/NIPPONDENSO ••• Self cancelling device ••• Flasher frequency 95 cycle/min ••• Wattage 10 W 2 + 3.4 W •••...

  • Page 41: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC CONVERSION TABLE EB202001 EAS00028 GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE This chart specifies torque for standard fasteners All specification data in this manual are listed in SI with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.

  • Page 42: 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 43: 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 44: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EB205000 LUBRICATION DIAGRAMS Rocker arm shaft (intake) Oil filter Drive axle Rocker arm shaft (exhaust) Oil pump Middle drive shaft 2-23...
  • Page 45 SPEC LUBRICATION DIAGRAMS Oil pump Oil filter Releaf valve Middle drive shaft 2-24...
  • Page 46 SPEC LUBRICATION DIAGRAMS Camshaft Middle drive shaft Crankshaft Drive axle Main axle Connecting rod big end 2-25...

  • Page 47: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Relays group Carburetor heater Throttle cables Flasher relay Filler tank cap fuel drain pipe Wireharness Speed sensor Filler tank cap fuel drain pipe Clutch cable Sidestand switch Fuel hose (carburetor-3 way) Front brake cable (left) å...
  • Page 48 SPEC CABLE ROUTING Brake cable Front brake hose (right) Rear brake hose (front master cylinder) A.I.S. pipe to the front cylinder Brake fluid reservoir hose Thermo swicth Starter motor Ignition coil (rear cylinder) Rubber cap for front wiring Starter motor lead Starter relay assy connections Oil level gauge...
  • Page 49 SPEC CABLE ROUTING ç Check that the wires of the igni- Spark plug cap (rear cylinder) Ignition coil (front cylinder) tion coil do not remain tensioned. A.I.S. pipe to the rear cylinder Handlebar switch leads (right) ∂ Fix the wires of the right switch A.I.S.
  • Page 50 SPEC CABLE ROUTING Rubber cap for front wiring Spark plug lead (rear) Fuel pump connections & Battery positive (+) terminal Fuel sender Spark plug lead (front) Fuse box Air intake pipe (A.I.S. system) Throttle cable Battery negative (-) terminal Anti-theft alarm connectors Depression fuel cock ´...
  • Page 51 SPEC...
  • Page 52 INSP...

  • Page 53: Insp Adj

    INSP CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION......................3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........3-1 SEAT, SIDE COVERS AND FUEL TANK ..............3-3 REMOVAL ......................3-3 INSTALLATION ....................3-3 ENGINE ........................3-4 ADJUSTING THE VALVE CLEARANCE ..............3-4 SYNCHRONIZING THE CARBURETORS ............3-7 ADJUSTING THE ENGINE IDLING SPEED ............3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ..........3-10 CHECKING THE SPARK PLUGS ..............3-11 CHECKING THE IGNITION TIMING ..............3-12...
  • Page 54 INSP ELECTRICAL SYSTEM ....................3-37 CHECKING AND CHARGING THE BATTERY ..........3-37 CHECKING THE FUSES ..................3-43 REPLACING THE HEADLIGHT BULB ..............3-44 ADJUSTING THE HEADLIGHT BEAM ..............3-46...

  • Page 55: Chapter 3. Periodic Inspections And Adjustments

    INSP INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 56 • Check operation. and switches • Adjust headlight beam. * Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead.

  • Page 57: Seat, Side Covers And Fuel Tank

    INSP SEAT, SIDE COVERS AND FUEL TANK SEAT, SIDE COVERS AND FUEL TANK Order Q’ty Remarks Job name/Part name Seat, side covers and fuel tank Remove the parts in the order below. removal Seat Side cover Panel Fuel overflow pipe Fuel hose Fuel hose Fuel meter sender unit couper...

  • Page 58: Engine

    INSP ADJUSTING THE VALVE CLEARANCE EASB0045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 59 INSP ADJUSTING THE VALVE CLEARANCE 7. Remove: • camshaft sprocket cover (rear cylinder) 1 • camshaft sprocket cover (front cylinder) 8. Remove: • timing plug 1 • straight plug 2 9. Measure: • valve clearance Out of specification Adjust. Valve clearance (cold): Intake valve: 0.07 ~ 0.12 mm Exhaust valve:...
  • Page 60 INSP ADJUSTING THE VALVE CLEARANCE d. Measure the valve clearance with a thickness gauge 1. e. Turn the crankshaft crockwise 290° and then measure the front cylinder. 10. Adjust: • valve clearance a. Loosen the locknut 1. b. Insert a thickness gauge between the end of the adjusting screw and the valve tip.

  • Page 61: Synchronizing The Carburetors

    INSP SYNCHRONIZING THE CARBURETORS EASB0002 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Start the engine and let it warm up for several minutes, then stop the engine.
  • Page 62 INSP SYNCHRONIZING THE CARBURETORS 9. Check: • engine idling speed Out of specification Adjust. Refer to "ADJUSTING THE ENGINE IDLING SPEED". Engine idling speed: 950 ~ 1,050 r/min 10. Adjust: • carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same.

  • Page 63: Adjusting The Engine Idling Speed

    INSP ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the car- buretor synchronization should be adjusted prop- erly, the air filter should be clean, and the engine should have adequate compression. 1.

  • Page 64: Adjusting The Throttle Cable Free Play

    INSP ADJUSTING THE THROTTLE CABLE FREE PLAY EASB0003 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a Out of specification Adjust.

  • Page 65: Checking The Spark Plugs

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

  • Page 66: Checking The Ignition Timing

    INSP CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 8. Install: • spark plugs 20 Nm (2.0 m•kg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug caps 10. Install: • cylinder head covers EAS00064 CHECKING THE IGNITION TIMING NOTE:...

  • Page 67: Measuring The Compression Pressure

    INSP MEASURING THE COMPRESSION PRESSURE EAS00065 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylin- ders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Check: • valve clearance Out of specification Adjust.
  • Page 68 INSP MEASURING THE COMPRESSION PRESSURE Compression pressure (with oil applied in the cylinder) Reading Diagnosis Higher Piston wear or than without damage Repair Piston ring(s), valves, Same as cylinder head gasket without oil or piston possibly Repair defective Compression pressure (at sea level) Standard: 1,000 kPa (10 kg/cm...

  • Page 69: Checking The Engine Oil Level

    INSP CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3.

  • Page 70: Changing The Engine Oil

    INSP CHANGING THE ENGINE OIL EASB0005 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap 1 •...

  • Page 71: Adjusting The Clutch Cable Free Play

    INSP CHANGING THE ENGINE OIL/ 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: • O-ring • engine oil filter cap 10. Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 72: Cleaning The Air Filter Element

    INSP ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT 4. Adjust: • 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 73: Checking The Carburetor Joint And Intake Manifold

    INSP CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 5. Clean: • air filter element Apply compressed air to the outer surface of the air filter element. 6. Check: • air filter element Damage Replace. 7. Install: •...

  • Page 74: Checking The Breather Hose

    INSP CHECKING THE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE BREATHER HOSE 1. Remove: • cylinder head cover 2. Check: • cylinder head breather hose 1 Cracks/damage Replace. Connect properly. Loose connection CAUTION: Make sure that the cylinder head breather hose is routed correctly.

  • Page 75: Chassis

    INSP ADJUSTING THE FRONT BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a between the brake lever and the handlebar grip) a. Turn the adjusting dial 1 while holding the lever pushed away from the handlebar grip NOTE: Align the setting on the adjusting dial with the arrow mark 2...

  • Page 76: Adjusting The Rear Brake

    INSP ADJUSTING THE REAR BRAKE EASB0008 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Brake pedal position (below the top of the rider footrest) 43 mm Out of specification Adjust.

  • Page 77: 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: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: • brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper...

  • Page 78: Checking The Brake Hoses

    INSP CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: • brake hose Cracks/damage/wear Replace. 2. Check: • brake hose clamp Loose connection Tighten.
  • Page 79 INSP BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Bleed: • hydraulic brake system a. Add the recommended brake fluid to the prop- er level.

  • Page 80: Adjusting The Shift Pedal

    INSP ADJUSTING THE SHIFT PEDAL/ CHECKING THE FINAL DRIVE OIL LEVEL EASB0009 ADJUSTING THE SHIFT PEDAL 1. Check: • shift pedal position (distance a from the top of the rider footrest to the top of the shift pedal) Out of specification Adjust.

  • Page 81: Changing The Final Drive Oil

    INSP CHECKING THE FINAL DRIVE OIL LEVEL/ CHANGING THE FINAL DRIVE OIL Recommended final drive oil SAE 80 hypoid gear oil graded "GL-4", "GL-5" or "GL-6" multi-purpose SAE 80W90 hypoid gear oil 4. Install: • final drive housing oil filler bolt 23 Nm (2.3 m•kg) EAS00145 CHANGING THE FINAL DRIVE OIL...

  • Page 82: Checking And Adjusting The Steering Head

    INSP CHECKING AND ADJUSTING THE STEERING HEAD EASB0010 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 83 INSP CHECKING AND ADJUSTING THE STEERING HEAD NOTE: Set the torque wrench at a right angle to the ring nut wrench 5. Ring nut wrench 90890-01403 Lower ring nut (initial tightening torque) 52 Nm (5.2 m•kg) c. Loosen the lower ring nut 4 completely, then tighten it to specification.

  • Page 84: Checking The Front Fork

    INSP CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 12. Install: • handle 13. Install: • upper handle holder Refer to “INSTALLING THE HANDLEBAR” in chapter 6. Handle holder bolt 23 Nm (2.3 m•kg) 14. Connect: • main switch coupler 15.

  • Page 85: Adjusting The Front Fork Legs

    INSP ADJUSTING THE FRONT FORK EAS00155 ADJUSTING THE FRONT FORK The following procedure applies to both of the fork legs. WARNING • Always adjust both fork legs equally, other- wise poor handling and loss of stability may result. • Securely support the motorcycle so that there is no danger of it falling over.

  • Page 86: Adjusting The Rear Shock Absorber Assembly

    INSP ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EASB0011 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.

  • Page 87: Checking The Tires

    INSP CHECKING THE TIRES EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: • tire pressure Out of specification Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 88 INSP CHECKING THE TIRES 2. Check: • tire surfaces Damage/wear Replace the tire. Minimum tire tread depth 1.6 mm Tire tread depth Side wall Wear indicator WARNING • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire fail- ure and personal injury from sudden defla- tion.

  • Page 89: Checking The Wheels

    INSP CHECKING THE TIRES/CHECKING THE WHEELS Front tire (Tubeless) Manufacturer Size Type 120/70-ZR17 DUNLOP D205F TL (58W) 120/70-ZR17 METZELER MEZ3F TL (58W) Rear tire (Tubeless) Manufacturer Size Type 170/60-ZR17 DUNLOP D205 TL (72W) 170/60-ZR17 METZELER MEZ3 TL (72W) WARNING New tires have a relatively low grip on the road surface until they have been slightly worn.

  • Page 90: Checking And Lubricating The Cables

    INSP CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE 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 movement. Replace damaged cable sheaths and cables as soon as possible.

  • Page 91: 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: •...
  • Page 92 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 measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by meas- uring the voltage at the battery terminals.
  • Page 93 INSP CHECKING AND CHARGING THE BATTERY WARNING Ambient Do not quick charge a battery. temperature 20 °C CAUTION: • Make sure that the battery breather hose and battery vent are free of obstructions. • Never remove the MF battery sealing caps. 30 2520 •...
  • Page 94 INSP CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Charger NOTE: Measure the open-circuit meter Voltage should be measured 30 minutes voltage prior to charging. after the machine is stopped. NOTE: Set the charging voltage at 16 ~ 17 V (if Connect a charger and AMP the setting is lower, charging will be meter to the battery and start...
  • Page 95 INSP CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 96 INSP CHECKING AND CHARGING THE BATTERY 6. Check: • battery breather hose Obstruction Clean. 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1, then the negative lead 2. 8. Check: • battery terminals Dirt Clean with a wire brush.

  • Page 97: 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: • seat •...

  • Page 98: Replacing The Headlight Bulb

    INSP CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical sys- tem, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
  • Page 99 INSP REPLACING THE HEADLIGHT BULB CAUTION: Avoid touching the glass part of the headlight 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 affect- ed.

  • Page 100: Adjusting The Headlight Beam

    INSP ADJUSTING THE HEADLIGHT BEAM EASB0013 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction a Headlight beam is raised. Direction b Headlight beam is lowered. 3-46...
  • Page 102 CHAPTER 4. ENGINE ENGINE REMOVAL ....................4-1 SEAT, STORAGE COMPARTMENT, SIDE COVERS, FUEL TANK, AIR FILTER CASE ASSEMBLY, CARBURETOR ASSEMBLY AND EXHAUST SYSTEM ..................4-1 LEADS, SHIFT PEDAL AND CLUTCH CABLE ............4-3 ENGINE MOUNTING BOLTS ................4-4 INSTALLING THE ENGINE ..................4-5 CYLINDER HEADS......................4-6 REAR CYLINDER HEAD ..................4-6 FRONT CYLINDER HEAD..................4-8 REMOVING THE CYLINDER HEADS..............4-10...
  • Page 103 CLUCTH ........................4-38 RIGHT CRANKCASE COVER ................4-38 CLUTCH ASSEMBLY..................4-40 REMOVING THE CLUTCH ................4-42 CHECKING THE FRICTION PLATES ..............4-42 CHECKING THE PRESSURE PLATE ..............4-43 CHECKING THE CLUTCH BOSS ..............4-43 CHECKING THE CLUTCH PUSH RODS ............4-43 CHECKING THE CLUTCH PLATES ..............4-44 CHECKING THE CLUTCH SPRING AND CLUTCH SPRING SEAT PLATE ..4-44 CHECKING THE CLUTCH HOUSING..............4-44 INSTALLING THE CLUTCH................4-45 GENERATOR AND STARTER CLUTCH ..............4-47...
  • Page 104 TRANSMISSION ......................4-68 CHECKING THE SHIFT FORKS ................4-69 CHECKING THE SHIFT DRUM ASSEMBLY............4-69 CHECKING THE TRANSMISSION ..............4-70 INSTALLING THE TRANSMISSION ..............4-71 MIDDLE GEAR ......................4-72 MIDDLE DRIVE PINION GEAR ................4-72 MIDDLE DRIVEN PINION GEAR ..............4-73 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY ........4-75 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ......4-75 REMOVING THE MIDDLE DRIVEN SHAFT ASSEMBLY ........4-76 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY........4-76...

  • Page 106: Chapter 4. Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL SEAT, STORAGE COMPARTMENT, SIDE COVERS, FUEL TANK, AIR FILTER CASE ASSEMBLY, CARBURETOR ASSEMBLY AND EXHAUST SYSTEM 7 Nm (0.7 m•kg) 4 Nm (0.4 m•kg) Order Q’ty Remarks Job name/Part name Removing the seat, storage Remove the parts in the order listed. Stand the motorcycle on a level surface.
  • Page 107 ENGINE REMOVAL 7 Nm (0.7 m•kg) 4 Nm (0.4 m•kg) Order Job name/Part name Q’ty Remarks Battery leads Disconnect NOTE: First, disconnect the negative lead, then disconnect the positive lead. Side covers Refer to "SEAT, SIDE COVERS AND Fuel tank FUEL TANK"...

  • Page 108: Leads, Shift Pedal And Clutch Cable

    ENGINE REMOVAL LEADS, SHIFT PEDAL AND CLUTCH CABLE Order Job name/Part name Q’ty Remarks Removing the leads, shift pedal and Remove the parts in the order listed. clutch cable AC magneto lead/pickup lead/ 1/1/1/1 Disconnect side stand switch lead/ speed sensor lead/ neutral switch lead Shift rod Refer to "INSTALLING THE ENGINE".

  • Page 109: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS 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. Lift the front fork upper bracket. Engine ground lead connector Disconnect Main footrest brackets Engine stay bolt (upper)

  • Page 110: Installing The Engine

    ENGINE EASB0014 INSTALLING THE ENGINE 1. Tighten the bolts in the following order: Bolt 1: 65 Nm (6.5 m•kg) Bolt 2: 65 Nm (6.5 m•kg) Nut 3: 85 Nm (8.5 m•kg) Special screw 4: 18 Nm (1.8 m•kg) Bolt 5: 110 Nm (11.0 m•kg) CAUTION: Install the Ø...

  • Page 111: Cylinder Heads

    CYLINDER HEADS CYLINDER HEADS REAR CYLINDER HEAD 50 Nm (5.0 m•kg) 35 Nm (3.5 m•kg) 10 Nm (1.0 m•kg) 20 Nm (2.0 m•kg) 20 Nm (2.0 m•kg) 20 Nm (2.0 m•kg) 10 Nm (1.0 m•kg) 55 Nm (5.5 m•kg) Order Job name/Part name Q’ty Remarks...
  • Page 112 CYLINDER HEADS 50 Nm (5.0 m•kg) 35 Nm (3.5 m•kg) 10 Nm (1.0 m•kg) 20 Nm (2.0 m•kg) 20 Nm (2.0 m•kg) 20 Nm (2.0 m•kg) 10 Nm (1.0 m•kg) 55 Nm (5.5 m•kg) 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 m•kg) 50 Nm (5.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 55 Nm (5.5 m•kg) 20 Nm (2.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) Order Job name/Part name Q’ty Remarks Cylinder head removal...
  • Page 114 CYLINDER HEADS 35 Nm (3.5 m•kg) 50 Nm (5.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 55 Nm (5.5 m•kg) 20 Nm (2.0 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) Order Job name/Part name Q’ty Remarks Timing chain tensioner/gasket Camshaft sprocket plate Refer to "REMOVING/INSTALLING THE...

  • Page 115: Removing The Cylinder Heads

    CYLINDER HEADS EAS00226 REMOVING THE CYLINDER HEADS Rear cylinder head 1. Remove: • camshaft sprocket cover • tappet covers 2. Align: • "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: • timing chain tensioner • gasket 5. Remove: • bolt (camshaft sprocket) 1 • camshaft sprocket 2 NOTE: To prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: • cylinder head NOTE: •...

  • Page 117: Checking The Cylinder Heads

    CYLINDER HEADS EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylin- der heads. 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: •...

  • Page 118: Checking The Timing Chain Tensioner

    CYLINDER HEADS EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement Replace. 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: • 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 point- er 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 tight- en the cap bolt to the specified torque. Cap bolt 8 Nm (0.8 m•kg) 5. Install: • bolt (camshaft sprocket) 1 55 Nm (5.5 m•kg) NOTE: •...

  • Page 121: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 37.5 Nm (3.75 m•kg) 27 Nm (2.7 m•kg) 20 Nm (2.0 m•kg) 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 ROCKER ARMS CAMSHAFT 1. Remove: • rocker arm shafts (intake and exhaust) 1 • 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: 90890-01084...

  • Page 123: Checking The Rocker Arms And Rocker Arm Shafts

    ROCKER ARMS AND CAMSHAFTS EB401410 CHECKING THE ROCKER ARMS AND ROCK- ER ARM SHAFTS The following procedure applies to all of the rock- er arms and rocker arm shafts. 1. Check: • rocker arm Replace. Damage/wear • rocker arm lobe 1 •...

  • Page 124: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFTS EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • camshaft Recommended lubricant Camshaft/Bushing Molybdenum disulfide oil 2. Install: • camshaft 1 • camshaft bushing 2 NOTE: • 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: • rocker arms • rocker arm shafts NOTE: Make sure that the rocker arm shafts is completely 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 CAM- SHAFT".

  • 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 cylinder 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 ~ 0.037 mm <Limit>: 0.08 mm Exhaust 0.025 ~ 0.052 mm <Limit>: 0.10 mm 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °K) in an oven.

  • Page 129: Checking The Valve Seats

    VALVE AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification Replace the valve. Valve margin thickness limit 0.8 mm 6. Measure: • valve stem runout Out of specification Replace the valve. NOTE: • When installing a new valve, always replace the valve guide.
  • Page 130 VALVE AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. 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: • 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 2.
  • Page 132 VALVE AND VALVE SPRINGS NOTE: Install the valve spring with the larger pitch a fac- ing up. b Smaller pitch 4. Install: • 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 m•kg) 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: Removing The Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE PISTONS The following procedure applies to all of the pis- tons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: •...
  • Page 135 CYLINDER AND PISTONS 2. Measure: • 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 cylinder. Then, find the average of the measurements.

  • Page 136: Checking The Piston Rings

    CYLINDER AND PISTONS EB404410 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, 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 piston pins. 1. Check: • piston pin Blue discoloration/grooves Replace, then inspect the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification Replace the piston pin.
  • Page 138 CYLINDERS AND PISTONS 2. Install: • piston 1 • piston pin 2 • piston pin clip (New) 3 NOTE: • Apply engine oil onto the piston pin. • Make sure that the "EX" mark a on the piston faces towards the exhaust side of the engine. •...

  • Page 139: Timing Gears

    TIMING GEARS TIMING GEARS 10 Nm (1.0 m•kg) 110 Nm (11.0 m•kg) 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: • primary drive gear nut 1 NOTE: While holding the generator rotor with the sheave holder, loosen the primary drive gear nut. 3. Remove: •...

  • Page 141: Checking The Primary Drive

    TIMING GEARS EAS00292 CHECKING THE PRIMARY DRIVE 1. Check: • primary drive gear • primary driven gear Damage/wear Replace the primary drive and primary driven gears as a set. Excessive noise during operation Replace the primary drive and primary driven gears as a set.
  • Page 142 TIMING GEARS Front cylinder 1. Install: (front cylinder) • springs 1 • dowel pins • timing drive gear 2 NOTE: • Insert the suitable pin 3 into the hole of timing chain drive gear sprocket and match the gear teeth. •...

  • Page 143: Right Crankcase Cover

    CLUTCH CLUTCH RIGHT CRANKCASE COVER 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. Engine oil Refer to "ENGINE OIL REPLACEMENT"...
  • Page 144 CLUTCH 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 m•kg) 8 Nm (0.8 m•kg) 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 m•kg) 8 Nm (0.8 m•kg) 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: • 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: • pressure plate Cracks/damage Replace. • bearing Damage/wear Replace. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause errat- ic 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: • clutch plate Damage Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set.

  • Page 150: Installing The Clutch

    CLUTCH EAS00295 INSTALLING THE CLUTCH 1. Install: • clutch housing 1 NOTE: If the wire circlip 2 has been removed, carefully install a new one as shown. 2. Tighten: • lock washer • clutch boss nut 1 70 Nm (7.0 m•kg) NOTE: While holding the clutch boss with the clutch hold- ing tool 2, tighten the clutch boss nut.
  • Page 151 CLUTCH NOTE: Make sure that the semicircular slot a in the fric- tion plate is aligned with the mark b on the clutch housing. 7. Install: • clutch pressure plate • clutch spring plate seat • clutch spring 1 • clutch spring plate 2 •...

  • Page 152: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL 7 Nm (0.7 m•kg) 10 Nm (1.0 m•kg) 10 Nm (1.0 m•kg) 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 12 Nm (1.2 m•kg) 175 Nm (17.5 m•kg) 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 THE Springs GENERATOR".

  • Page 154: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: • camshaft sprocket cover • tappet covers Refer to "REAR CYLINDER HEAD". 2. Align: • "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: • Remove the rotor by pushing back the rotor, the flywheel puller 2 and the adapter 3. • 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: • 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 m•kg) LOCTITE ® 2. Install: •...
  • Page 157 GENERATOR AND STARTER CLUTCH 4. Check: • TDC on the compression stroke If the marks do not align Adjust. a. Align the "T" mark a with the stationary point- er b on the left crankcase cover. b. When the "T" mark is aligned with the station- ary pointer, the punch mark c on the camshaft sprocket should be aligned with the stationary 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: • shift shaft 1 • shift lever 2 Bends/damage/wear Replace. • shift lever spring 3 Damage/wear Replace. EB408410 CHECKING THE STOPPER LEVER 1. Check: • stopper lever Bends/damage Replace. Roller turns roughly Replace the stopper lever.

  • Page 160: Oil Pump

    OIL PUMP OIL PUMP 10 Nm (1.0 m•kg) 7 Nm (0.7 m•kg) 12 Nm (1.2 m•kg) 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 m•kg) 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) Oil pump rotor (outer) Refer to "ASSEMBLING THE OIL PUMP". Oil pump body Oil pump rotor (inner) Oil pump rotor (outer)

  • Page 162: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump driven gear • oil pump body • oil pump driven gear cover Cracks/damage/wear Replace the defec- tive part(-s). 2. Measure • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-body-side clearance • oil-pump-body-to-inner-rotor-and-outer- rotor clearance c Out of specification Replace the oil pump.
  • Page 163 OIL PUMP EAS00376 ASSEMBLING THE OIL PUMP 1. Assemble: • oil pump 10 Nm (1.0 m•kg) 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 rotor. 4-58...

  • Page 164: Crankshaft And Connecting Rods

    CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS CRANKCASE 38,5 Nm (3.85 m•kg) 10 Nm (1.0 m•kg) 20 Nm (2.0 m•kg) 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 m•kg) 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: • crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...

  • Page 167: Removing The Connecting Rods

    CRANKSHAFT AND CONNECTING RODS EB412111 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft assembly 1 NOTE: • Remove the crankshaft assembly with the crankcase separating tool 2. • 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 crank- shaft-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 m•kg) Remove the connecting rod and big end bear- ings. 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: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger Rough movement Replace. 2. Check: • oil seals Damage/wear Replace. INSTALLING THE CRANKSHAFT 1.

  • Page 171: Assembling The Crankcase

    • crankshaft 1 NOTE: Align the left connecting rod with the rear cylinder sleeve hole. ASSEMBLING THE CRANKCASE 1. Apply: • engine oil (onto the main journal bearings) • sealant (onto the crankcase mating surfaces) Yamaha Bond No. 1215: 90890-85505 4-66...
  • Page 172 CRANKSHAFT AND CONNECTING RODS 2. Tighten: • crankcase bolts (follow the proper tightening sequence) NOTE: The numbers embossed on the crankcase indi- cate the crankcase tightening sequence. 6 (M10) 38.5 Nm (3.85 m•kg) 3, 7 o (M6) 10 Nm (1.0 m•kg) 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” Shift fork 3 “L” Refer to "INSTALLING THE Shift drum 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: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface.

  • Page 175: Checking The Transmission

    TRANSMISSION EAS00424 CHECKING THE TRANSMISSION 1. Measure: • 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: • 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: • shift drum assembly NOTE: Turn the shift drum assembly to the neutral posi- tion. 2. Install: • main axle assembly 1 • drive axle assembly 2 • shift fork “L” 3 • shift fork “C” 4 •...

  • Page 177: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE PINION GEAR 110 Nm (11.0 m•kg) 110 Nm (11.0 m•kg) Order Job name/Part name Q’ty Remarks Removing the middle drive pinion Remove the parts in the order listed. gear Separate the crankcase Refer to "CRANKSHAFT AND CONNECTING ROD".

  • Page 178: Middle Driven Pinion Gear

    MIDDLE GEAR MIDDLE DRIVE PINION GEAR Order Job name/Part name Q’ty Remarks Removing the middle driven pinion Remove the parts in the order listed. 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/INSTALLING...
  • 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 ASSEMBLY 1. Remove: • bearing retainer • 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: • 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: • O-ring • oil seal Damage Replace the defective part(-s). 4. Check: • universal joint movement Rough movement Replace the universal joint. EAS00441 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Tighten: • middle drive shaft nut 1 110 Nm (11.0 m•kg) NOTE: •...

  • Page 183: Assembling The Middle Driven Shaft Assembly

    MIDDLE GEAR ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following points are critical when assembling the middle gears: • The collapsible collar must be replaced when- ever the middle driven shaft assembly is removed from the middle driven shaft bearing housing.
  • Page 184 MIDDLE GEAR 2. Install: • shim • middle drive shaft assembly 3. Install: • bearing retainer Install steps: • Attach the bearing retainer wrench 1 Bearing retainer wrench: 90890-04137 • Tighten the bearing retainer. Bearing retainer: 110 Nm (11.0 m•kg) •...

  • 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 collar and adjust the backlash. Stake the middle driven pinion gear shaft thread. INSTALLING THE UNIVERSAL JOINT 1.

  • 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: • Crankcase • Middle drive shaft 1. Select: • middle drive gear shim(-s) 1 NOTE: Select the middle drive gear shim(-s) 1 by calcu- lating 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

    CARB...
  • Page 189 CARB CHAPTER 5. CARBURETION CARBURETOR ......................5-1 CHECKING THE CARBURETORS ..............5-4 ASSEMBLING THE CARBURETORS ..............5-6 INSTALLING THE CARBURETORS ..............5-6 MEASURING AND ADJUSTING THE FUEL LEVEL ..........5-7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ....5-8 AIR INDUCTION SYSTEM (AIS) ................5-10 AIR INDUCTION ....................5-10 AIR CUT-OFF VALVE..................5-10 AIR INDUCTION SYSTEM INSPECTION ............5-11...
  • Page 190 CARB...

  • Page 191: Chapter 5. Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Seat Refer to "SEAT, SIDE COVERS AND Fuel tank FUEL TANK" in Chapter 3. Air filter case assembly Air ducts Cylinder head breather hose Disconnect Cover...
  • Page 192 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 193 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Diaphragm set Refer to "ASSEMBLING THE CARBURETORS". 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 194: Checking The Carburetors

    CARB CARBURETOR EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: • carburetor body • float chamber • jet housing Cracks/damage Replace. 2. Check: • fuel passages Obstruction Clean. a. Wash the carburetor in a petroleumbased sol- vent.
  • Page 195 CARB CARBURETOR 8. Check: • vacuum chamber cover 1 • piston valve spring 2 • plastic cap 3 • O-ring 4 • spring 5 Cracks/damage Replace. 9. Check: • jet needle 1 • needle jet 2 • main jet 3 •...

  • Page 196: Assembling The Carburetors

    CARB CARBURETOR EB600042 ASSEMBLING THE CARBURETORS The following procedure applies to both of the car- buretors. CAUTION: • Before assembling the carburetors, wash all of the parts in a petroleum-based solvent. • Always use a new gasket. 1. Install: • coasting enricher diaphragm •...

  • Page 197: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR EB600063 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification Adjust. Fuel level (above the line on the float chamber) 5 mm a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight c.

  • Page 198: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETOR EB600071 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Inspect: • throttle position sensor a. Disconnect the throttle position sensor cou- pler. b. Connect the pocket tester (Ω 1k) to the throttle position sensor.
  • Page 199 CARB CARBURETOR Closed-throttle resistance 0.56 ~ 0.84 kΩ at 20 °C (68 °F) (yellow – black) c. Tighten the throttle position sensor screws. NOTE: Remove the pocket tester leads and connect the throttle position sensor coupler.

  • Page 200: 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 exhaust port. This is to reduce the output of the hydrocar- bons. When there is negative pressure around the ex- haust port, the reed valve opens and the second- ary air flows into the exhaust port.

  • Page 201: Air Induction System Inspection

    CARB AIR INDUCTION SYSTEM (AIS) 1 Reed valve AIR INDUCTION SYSTEM INSPECTION 2 Air filter 1. Inspect: 3 Orifice • hose connections 4 Carburetor joint (near cylinder) Poor connections Properly connect. [A] To the front cylinder head • hoses [B] To the rear cylinder head •...
  • Page 202 CARB...

  • Page 203: Chas

    CHAS...
  • Page 204 CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISCS ................6-1 REMOVING THE FRONT WHEEL ..............6-3 CHECKING THE FRONT WHEEL ................6-3 CHECKING THE BRAKE DISCS................6-4 INSTALLING THE FRONT WHEEL ..............6-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE ........6-7 REAR WHEEL AND BRAKE DISC ................6-9 REAR WHEEL ......................6-9 REMOVING THE REAR WHEEL ................6-11 CHECKING THE REAR WHEEL ................6-12...
  • Page 205 CHAS HANDLEBAR ......................6-51 REMOVING THE HANDLEBAR................6-53 CHECKING THE HANDLEBAR ................6-53 INSTALLING THE HANDLEBAR ................6-54 STEERING HEAD ....................6-57 REMOVING THE LOWER BRACKET ..............6-59 CHECKING THE STEERING HEAD ..............6-59 INSTALLING THE STEERING HEAD ..............6-60 REAR SHOCK ABSORBER AND SWINGARM............6-61 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ....6-63 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ....6-63 REMOVING THE REAR SHOCK ABSORBER ..........6-64 REMOVING THE SWINGARM ................6-65...

  • Page 206: Chapter 6. Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job name/Part name Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs WARNING For installation, reverse the removal procedure. Brake hose holder (right/left) Brake caliper (right/left) Refer to “REMOVING/INSTALLING THE Front wheel axle pinch bolt...
  • Page 207 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 208: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EASB0015 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 209: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4. Check: • wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. • oil seals Damage/wear Replace.
  • Page 210 CHAS FRONT WHEEL AND BRAKE DISCS Brake disc deflection limit Front: 0.2 mm Rear: 0.15 mm a. Place the motorcycle on a suitable stand so that the wheel is elevated b. Before measuring the front brake disc deflec- tion, turn the handlebar to the left or right to ensure that the front wheel is stationary.

  • Page 211: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EASB0016 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: • wheel axle • oil seallips Recommended lubricant Lithium soap base grease 2. Install: • front brake disc 1 NOTE: •...

  • Page 212: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BAL- ANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance shourd be adjusted. • Adjust the front wheel static balance with the brake discs installed.
  • Page 213 CHAS FRONT WHEEL AND BRAKE DISCS b. Turn the front wheel 90° so that the heavy spot is positioned as shown c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.

  • Page 214: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL AND BRAKE DISC REAR WHEEL Order Job name/Part name Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. disc Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
  • Page 215 CHAS REAR WHEEL AND BRAKE DISC Order Job name/Part name Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Brake disc Oil seal Bearing Spacer Plate cover Hub clutch Bearings Damper Bearing Collar For assembly, reverse the disassembly procedure.

  • Page 216: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EASB0017 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 217: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EASB0018 CHECKING THE REAR WHEEL 1. Check: • rear wheel axle • rear wheel • wheel bearings • oil seals Refer to “FRONT WHEEL AND BRAKE DISCS”. 2. Check: • tire Damage/wear Replace. Refer to “CHECKING THE WHEELS” in Chapter 3.

  • Page 218: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC a. Install the rear wheel in the swingarm b. Install the spacers, brake caliper bracket and rear wheel axle 1. c. Tighten the rear wheel axle nut with specified torque. Rear wheel axle 110 Nm (11.0 m•kg) d.

  • Page 219: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake hose retainer Brake caliper Pad pin clip Pad pin Refer to "REPLACING THE FRONT Pad spring BRAKE PADS".

  • Page 220: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Caliper Cover Pad pin clip Refer to “REPLACING THE REAR Pad pin BRAKE PADS”. Pad spring Brake pads/shim For installation, reverse the removal...

  • Page 221: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EB702100 CAUTION: Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake sys- tem is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 222 CHAS FRONT AND REAR BRAKES 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5.

  • Page 223: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 7. Check: • brake fluid level Below the minimum lever mark a the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in Chapter 3. 8. Check: • brake lever operation Soft or spongy feeling Bleed the brake system.
  • Page 224 CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

  • Page 225: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 m•kg) 28 Nm (2.8 m•kg) Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain the brake fluid Brake lever Front brake switch lead Front brake switch...
  • Page 226 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. 6-21...
  • Page 227 CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER 24 Nm (2.4 m•kg) Order Job name/Part name Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Side cover (right) Drain the brake fluid Rear brake master cylinder bolts Rear brake master cylinder cover Union bolt/ brake switch Refer to “REMOVING/INSTALLING THE...
  • Page 228 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. 6-23...
  • Page 229 CHAS FRONT AND REAR BRAKES EB702210 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Disconnect: • brake switch leads 1 (from brake switch) 2.

  • Page 230: Checking The Front And Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EB702242 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder Damage/scratches/wear Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air.

  • Page 231: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EB702270 INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents.
  • Page 232 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. • Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 233: Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EASB0023 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers (New) 3 • brake hose 4 • union bolt 2 24 Nm (2.4 m•kg) • master cylinder cover 1 WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 234 CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in Chapter 3. 4. Check: •...

  • Page 235: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS 28 Nm (2.8 m•kg) Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Drain the brake fluid Union bolt Copper washers Refer to “REMOVING/INSTALLING THE Brake hose FRONT BRAKE CALIPERS”.
  • Page 236 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 pin clips Pad pin Refer to “REPLACING THE FRONT Pad spring BRAKE PADS”. Brake pads Bleed screw Brake caliper pistons Refer to “DISASSEMBLING THE FRONT Dust seals...

  • Page 237: Removing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER Order Job name/Part name Q’ty Remarks Removing the rear brake calipers Remove the parts in the order listed. Drain the brake fluid Union bolt Copper washers Refer to “REMOVING/INSTALLING THE Brake hose REAR BRAKE CALIPERS”.
  • Page 238 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 Pin clips Pad pins Pad spring Refer to “REPLACING THE REAR Brake pads/shim BRAKE PADS”. Bleed screw Caliper pistons Refer to “DISASSEMBLING THE REAR Dust seals...
  • Page 239 CHAS FRONT AND REAR BRAKES EB702317 DISASSEMBLING FRONT BRAKE CALIPER 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: • union bolt 1 •...
  • Page 240 CHAS FRONT AND REAR BRAKES EB702322 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 241: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replace- ment schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled.

  • Page 242: Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702374 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 243 CHAS FRONT AND REAR BRAKES Brake caliper retaining bolt 42 Nm (4.2 m•kg) 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. •...

  • Page 244: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EASB0024 INSTALLING THE REAR BRAKE CALIPER WARNING • Before installation, all internal brake compo- nents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 245 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. • Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 246: Front Fork

    CHAS FRONT FORK FRONT FORK Order Job name/Part name Q’ty Remarks Removing the front fork Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE Front wheel DISCS”. Brake caliper assembly Cowling Lift forward Bracket Front fender Upper bracket bolts Refer to “REMOVING/INSTALLING THE Cap bolts...
  • Page 247 CHAS FRONT FORK 30 Nm (3.0 m•kg) Order Job name/Part name Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Washer Spacer Spring seat Fork spring Refer to “DISASSEMBLING/ Piston ring ASSEMBLING THE FRONT FORK Rebound spring LEGS”.
  • Page 248 CHAS FRONT FORK 30 Nm (3.0 m•kg) Order Job name/Part name Q’ty Remarks Oil seal Oil seal washer Outer tube bushing Damper rod bolt Refer to “DISASSEMBLING/ Gasket ASSEMBLING THE FRONT FORK LEGS”. Outer tube Protector For assembly, reverse the disassembly procedure.

  • Page 249: 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 250 CHAS FRONT FORK 4. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5. Remove: • damper rod bolt 1 NOTE: While holding the damper rod with the T-handle 3 and damper rod holder 2, loosen the damper rod bolt.

  • Page 251: Checking The Front Fork Legs

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

  • Page 252: Assembling The Front Fork Legs

    Be careful not to dam- age the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 10W or equivalent 3. Tighten: • damper rod bolt 1 Damper rod bolt 30 Nm (3.0 m•kg)
  • Page 253 CHAS FRONT FORK 4. Install: • outer tube bushing 1 • oil seal spacer 2 • oil seal 3 (with the fork seal driver weight 4 and adapter 5) Fork seal driver weight 90890-01367 Adapter 90890-01374 CAUTION: Make sure that the numbered side of the oil seal faces up.
  • Page 254 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.525 L Recommended oil Yamaha fork and shock oil 10W or equivalent CAUTION: • Be sure to use the recommended fork oil. • Other oils may have an adverse effect on front fork performance.

  • Page 255: Installing The Front Fork Legs

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

  • Page 256: Handlebar

    CHAS HANDLEBAR HANDLEBAR 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. Plastic locking ties Clutch cable Handlebar switch (left)
  • Page 257 CHAS HANDLEBAR Order Job name/Part name Q’ty Remarks Throttle grip assembly Handlebar holders (upper) Refer to “INSTALLING THE HANDLEBAR”. Handlebar Handlebar holders (lower) For installation, reverse the removal procedure. 6-52...

  • 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: • 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 rub- ber adhesive has fully dried.
  • Page 260 CHAS HANDLEBAR 3. Install: • throttle grip 1 • throttle cable WARNING Make sure that the pin a on the throttle cable housing is aligned with the hole b in the han- dlebar. 4. Install: • master cylinder 1 Refer to “FRONT AND REAR BRAKES”. NOTE: Align the slit in the brake lever holder with the punch mark a in the handlebar.
  • Page 261 CHAS HANDLEBAR NOTE: Apply a thin coat of lithium soap base grease onto the end of the clutch cable. 10. Adjust: • 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) 10 mm 11.

  • Page 262: Steering Head

    CHAS STEERING HEAD STEERING HEAD LOWER BRACKET Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork legs Refer to “FRONT FORK”. Handlebar Refer to ”HANDLEBAR”.
  • Page 263 CHAS STEERING HEAD Order Job name/Part name Q’ty Remarks Bearing Dust seal Lower handlebar holder For installation, reverse the removal procedure. 6-58...

  • Page 264: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • upper ring nut 1 • 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 races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing races.

  • Page 266: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in order listed. and swingarm Stand the motorcycle on a level surface. Place a suitable stand under the engine. WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 267 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Rear master cylinder It is not necessary to disconnect the brake hose. Refer to “REAR BRAKE MASTER CYLINDER”. Rear brake pedal Main footrest (right and left) Main footrest cover (right) Passenger footrest holder (right and left) Brake caliper tension bar Rear shock absorber lower bolt...

  • Page 268: Handling The 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 the following information.

  • Page 269: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EASB0026 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 270: Removing The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM EASB0027 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 271: Checking The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: • rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly.

  • Page 272: Installing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EASB0028 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • swingarm Refer to “INSTALLING THE SWINGARM”. 2. Lubricate: • spacers • bearings Recommended lubricant Molybdenum disulfide grease 3. Install: • rear shock absorber assembly Rear shock absorber assembly: Upper nut 42 Nm (4.2 m•kg)

  • Page 273: Installing The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00712 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • oil seals Recommended lubricant Molybdenum disulfide grease 2. Install: • relay arm • left connecting arm • right connecting arm Rear-shock-absorber-assembly: Lower nut 1 50 Nm (5.0 m•kg) Connecting arm nuts 2 50 Nm (5.0 m•kg)

  • Page 274: 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 sustained B. Improper gear lash speeds (not to be confused with engine surging C.
  • Page 275 CHAS SHAFT DRIVE Inspection notes 1. Investigate any unusual noises. The following noises may indicate a mechani- cal defect: a. A rolling "rumble" during coasting, accelera- tion, or deceleration, (increases with the rear wheel speed, but does not increase with high- er engine or transmission speeds).
  • Page 276 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 DISC”.

  • Page 277: Checking The Final Drive Oil For Contamination And Inspecting The Shaft Drive For Leaks

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

  • Page 278: Measuring The Ring Gear Backlash

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

  • Page 279: 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. Repeat steps (d) to (h) three more times (for a total of four measurements). If any of the readings are over specification, adjust the ring gear backlash.
  • Page 280 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 thickness.

  • Page 281: Final Drive Assembly And Drive Shaft

    CHAS SHAFT DRIVE FINAL DRIVE ASSEMBLY AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed. and drive shaft Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.

  • Page 282: Final Gear

    CHAS SHAFT DRIVE FINAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the final gear Disassemble the parts in the order listed. NOTE: Bolts (bearing housing) Working in a crisscross pattern, loosen Nuts (bearing housing) each bolt and nut 1/4 of a turn. After all the bolts and nuts are loosened, remove them.

  • Page 283: Disassembling The Final Drive Assembly

    CHAS SHAFT DRIVE EASB0029 DISASSEMBLING THE FINAL DRIVE ASSEM- 1. Remove: • ring gear bearing housing nuts • 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 284: Removing And Installing The Ring Gear Bearings

    CHAS SHAFT DRIVE 5. Remove: • final drive pinion gear (with the special tools) Crankshaft installer bolt adapter 1 90890-01277 Armature shock puller 2 90890-01290 Weight 3 90890-01291 WARNING Always use new bearings. CAUTION: The final drive pinion gear should only be removed if ring gear replacement is neces- sary.

  • Page 285: Aligning The Final Drive Pinion Gear And Ring Gear

    • collar 1 • oil seal 2 • 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 286 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 287 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: A = 45.51 + 3.35 –...
  • Page 288 CHAS SHAFT DRIVE Bearing retainer wrench 90890-04050 3. Install: • gear coupling • self-locking nut 130 Nm (13.0 m•kg) (with the special tool 1) Coupling gear/middle shaft tool 90890-01229 4. Install: • ring gear bearing housing (along with the ring gear, but without the thrust washer) 5.

  • Page 289: Checking The Drive Shaft

    CHAS SHAFT DRIVE d. Remove the ring gear bearing housing. e. Measure width flattened Plastigauge ® Ring-gear-to-thrust-washer clearance 0.2 mm If the ring-gear-to-thrust-washer clearance is within specification, install the ring gear bear- ing housing (along with the ring gear). g. If the ring-gear-to-thrust-washer clearance is out of specification, select the correct thrust washer as follows.

  • Page 290: Installing The Drive Shaft

    Recommended lubricant Molybdenum disulfide grease 2. Apply: • sealant (onto both final drive housing mating sur- faces) Yamaha bond No. 1215 90890-85505 3. Install: • drive shaft (to the final drive pinion gear) 4. Tighten: • final bearing housing nuts 50 Nm (5.0 m•kg)

  • Page 292: Elec

    ELEC...
  • Page 293 ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS ..................7-1 SWITCHES ........................7-3 CHECKING SWITCH CONTINUITY ..............7-3 CHECKING THE SWITCHES ..................7-4 CHECKING THE BULBS AND BULB SOCKETS ............7-6 TYPES OF BULBS....................7-6 CHECKING THE CONDITION OF THE BULBS ..........7-6 CHECKING THE CONDITION OF THE BULB SOCKETS ........7-8 IGNITION SYSTEM......................7-9 CIRCUIT DIAGRAM ....................7-9 TROUBLESHOOTING ..................7-10...
  • Page 294 ELEC CARBURETOR HEATER SYSTEM ................7-46 CIRCUIT DIAGRAM ....................7-46 TROUBLESHOOTING ..................7-47 SELF-DIAGNOSIS ....................7-49 TROUBLESHOOTING ..................7-51...

  • Page 295: Chapter 7. Electrical

    ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Ignition coils 5 Neutral switch 2 Igniter unit 6 Oil level gauge assembly 3 Speed sensor 7 Horn 4 Sidestand switch...
  • Page 296 ELEC ELECTRICAL COMPONENTS 8 Main switch e Relay assembly 9 Thermo switch r Flasher relay 0 Fuel meter senser unit t Diode q Battery y Fuse assembly w Starter relay u Rectifier/regulator...

  • 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 coupler 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 CHECKING THE SWITCHES 1 Clutch switch 8 Lights switch 2 Pass switch 9 Engine stop switch 3 Horn switch 0 Start switch 4 Dimmer switch q Fuses 5 Turn switch w Rear brake switch 6 Main switch e Sidestand switch 7 Front brake switch r Neutral switch...

  • Page 300: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both.
  • 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: • Be sure to hold the socket firmly when removing 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: • bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same...

  • Page 303: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 304 ELEC IGNITION SYSTEM EASB0030 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. 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 k at 20°C (68 °F) The following procedure applies to all of the • Is the spark plug cap OK? spark plugs. • Disconnect the spark plug cap from the spark plug.
  • Page 306 ELEC IGNITION SYSTEM EAS00749 8. Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Replace the main switch. Secondary coil resistance 10.7 14.5 k at 20°C (68°F) EAS00750 • Is the ignition coil OK? 9.
  • Page 307 ELEC IGNITION SYSTEM Sky blue 1 Tester (+) lead Con- Blue/Yellow 2 Tester (–) lead tinuity Blue/Yellow 2 No Con- Tester (+) lead 12. Diode Sky blue 1 Tester (–) lead tinuity • Remove the diode from the wire harness. NOTE: •...

  • Page 308: Circuit Diagram

    ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-14...
  • Page 309 ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit 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 operate only if: The transmission is in neutral (the neutral switch is closed).

  • Page 310: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EASB0031 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in Chapter 3. 1. Main and ignition fuses Min. open-circuit voltage: 2.
  • Page 311 ELEC ELECTRIC STARTING SYSTEM EAS00739 EAS00760 4. Starting circuit cutoff relay 5. Starting circuit cutoff relay (diode) • Disconnect the relay unit from the coupler. • Disconnect the starting circuit cutoff relay from the coupler. • Connect the pocket tester ( 1) and bat- •...
  • Page 312 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch • Disconnect the starter relay from the coupler. • Check the engine stop switch for continuity. • Connect the pocket tester ( 1) and bat- Refer to “CHECKING THE SWITCHES”. tery (12V) to the starter relay coupler as •...
  • Page 313 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace right handlebar switch. 13. Diode • Check the diode for continuity. Refer to “IGNITION SYSTEM”. •...

  • Page 314: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 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. Disassembly the pats in the order listed. Disassembling the starter motor Circlip Starter motor drive gear...
  • Page 315 ELEC ELECTRIC STARTING SYSTEM Order Job name/Part name Q’ty Remarks Washer set End bracket Refer to “Assembling the starter motor.” Planetary gears Armature assembly Brush holder/brush Refer to “Assembling the starter motor.” Starter motor yoke For assembly, reverse the disassembly procedure.
  • Page 316 ELEC ELECTRIC STARTING SYSTEM EAS00769 Checking the starter motor 1. Check: • commutator Dirt Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: • mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw...
  • Page 317 ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification Replace the brushes as a set. Min. brush length 5 mm 6. Measure: • brush spring force Out of specification Replace the brush springs as a set. Bruch spring force 7.65 10.01 N (780...
  • Page 318 ELEC ELECTRIC STARTING SYSTEM 3. Install: • starter motor rear cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover. 7-24...

  • Page 319: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Pickup coil Rectifier/regulator Starter relay Battery Wire minus lead 7-25...

  • Page 320: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in Chapter 3. 1. main fuse Min. open-circuit voltage 2. battery 12.8 V or more at 20 °C (68 °F) 3.
  • Page 321 ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring Make sure that the battery is fully charged. • Check the wiring connections of the entire • Is the charging voltage within specification? charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly conected and without defects? The charging circuit is OK.

  • Page 322: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 7-28...

  • Page 323: Troubleshooting

    ELEC LIGHTING SYSTEM EASB0033 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: headlight, • Check the condition of the battery. high beam indicator light, license plate light Refer to “CHECKING AND CHARGING THE or meter light. BATTERY” in Chapter 3. Min.

  • Page 324: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00784 EAS00788 CHECKING THE LIGHTING SYSTEM 5. Dimmer switch 1. The headlight and the high beam indicator • Check the dimmer switch for continuity. light fail to came on. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? 1.
  • Page 325 ELEC LIGHTING SYSTEM 2. Voltage • Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Blue 1 Tester positive probe Black 2 Tester negative probe • Measure the voltage (12 V) of Yellow 1 or Green 2 on the headlight coupler (headlight side).
  • Page 326 ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as license plate light coupler (wire harness side) shown.

  • Page 327: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 7-33...
  • Page 328 ELEC SIGNALING SYSTEM Main switch Starter relay Battery Wire minus lead Ignition fuse Front brake switch Signal fuse Left handlebar switch Horn Flasher relay Speedometer Neutral switch lead Neutral switch Front turn signal light (L) Front turn signal light (R) Rear turn signal light (L) Rear turn signal light (R) Tail/brake light...

  • Page 329: Troubleshooting

    ELEC SIGNALING SYSTEM EASB0035 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn signal • Check the condition of the battery. light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE • The horn fails to sound. BATTERY”...

  • Page 330: Checking The Signaling System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM • Disconnect the Black connector at the horn 1. The horn fails to sound. terminal. • Connect a jumper lead 1 to the horn termi- 1. Horn switch nal and Ground the jumper lead. •...
  • Page 331 ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. A tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as 1. Tail/brake light bulb and socket shown. • Check the tail/brake light bulb and socket for Green/Yellow 1 Tester positive probe continuity.
  • Page 332 ELEC SIGNALING SYSTEM Brown/White 1 2. Turn signal switch Tester positive probe Tester negative probe Ground • Check the turn signal for continuity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? Replace the left han- dlebar switch. •...
  • Page 333 ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 3. Voltage • Set the turn signal switch to “Δ or “¥”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (12 V) of Chocolate 1 meter assembly coupler (wire harness side) or Dark green 2 at the turn signal light con- as shown.
  • Page 334 ELEC SIGNALING SYSTEM 2. Oil level switch • Drain the engine oil and remove the oil level switch from the oil pan. • Check the oil level switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the oil level switch OK? Replace the oil level switch.

  • Page 335: Fuel Pump System

    ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7-41...

  • Page 336: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION 1 Battery The fuel pump circuit consists of the fuel pump re- 2 Main fuse lay, fuel pump, engine stop switch and ignitor unit. 3 Main switch The ignitor unit includes the control unit for the fu- 4 Ignition fuse el pump.

  • Page 337: Troubleshooting

    ELEC FUEL PUMP SYSTEM EASB0037 EAS00739 TROUBLESHOOTING 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to "CHECKING AND CHARGING THE Check: BATTERY" in Chapter 3. 1. Main, and ignition fuses Open-circuit voltage 2.
  • Page 338 ELEC FUEL PUMP SYSTEM EB803023 EB808021 5. Starting circuit cutoff relay (fuel pump relay) 6. Fuel pump resistance • Remove the relay unit from the wire harness. • Disconnect the fuel pump coupler from the • Connect the pocket tester ( 1) and bat- wire harness.

  • Page 339: Fuel Pump Test

    ELEC FUEL PUMP SYSTEM EASB0038 FUEL PUMP TEST WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or combustion. Be extremely careful and note the following points: • Stop the engine before refuelling. •...
  • Page 340 ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM 7-46...
  • Page 341 ELEC CARBURETOR HEATER SYSTEM EASB0039 EAS00739 TROUBLESHOOTING 2. Battery The carburetor heater fails to operate. • Check the condition of the battery. Refer to "CHECKING AND CHARGING THE Check: BATTERY" in Chapter 3. 1. Main, and carburetor heater Open-circuit voltage 2.
  • Page 342 ELEC CARBURETOR HEATER SYSTEM EASB0041 5. Carburetor heater • Remove the carburetor heater from the car- buretor body. • Connect the pocket tester to the carburetor heater. Heater terminal 1 Tester (+) lead Heater body 2 Tester (–) lead • Immerse the thermo switch in the water 3. •...
  • Page 343 ELEC SELF-DIAGNOSIS EASB0043 SELF-DIAGNOSIS This model is equipped with a self-diagnosis device for the following electrical circuits: - tachometer - speedometer - oil level warning light - fuel level warning light - throttle position sensor - speed sensor. When the key is turned to "ON", the tachometer and speedometer needles should move to the maximum, then back to zero.
  • Page 344 ELEC SELF-DIAGNOSIS EASB0044 1. Wire harness TROUBLESHOOTING • Check the wire harness for continuity. The tachometer displays the throttle posi- Refer to "CIRCUIT DIAGRAM". tion sensor/speed sensor error code. • Is the wire harness OK? Check: 1. throttle position sensor 2.
  • Page 345 ELEC SELF-DIAGNOSIS 2. Speed sensor CIRCUIT DIAGRAM • Set the main switch to “ON”. • Turn the rear wheel slowly. • Check the tester voltage (0 V ~ 5 V ~ 0 V). • Is the speed sensor OK? Replace the ignitor Replace the speed unit.
  • Page 346 ELEC...

  • Page 347: Trbl Shtg

    TRBL SHTG...

  • Page 348: Troubleshooting Trbl

    TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ................8-1 FUEL SYSTEM ......................8-1 ELECTRICAL SYSTEM ....................8-1 COMPRESSION SYSTEM ....................8-2 POOR IDLE SPEED PERFORMANCE ................8-2 POOR IDLE SPEED PERFORMANCE ..............8-2 POOR MEDIUM-AND HIGH-SPEED PERFORMANCE ............ 8-2 POOR MEDIUM-AND HIGH-SPEED PERFORMANCE ..........8-2 FAULTY GEAR SHIFTING ....................
  • Page 349 TRBL SHTG...

  • Page 350: Starting Failure/Hard Starting

    TRBL SHTG STARTING FAILURE/HARD STARTING 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 inspec- tion, adjustment and replacement of parts.

  • Page 351: Compression System

    STARTING FAILURE/HARD STARTING/ TRBL POOR IDLE SPEED PERFORMANCE/ SHTG POOR MEDIUM-AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston ring • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder • Worn, fatigued or broken piston ring •...

  • Page 352: Faulty Gear Shifting

    TRBL FAULTY GEAR SHIFTING/ SHTG CLUTCH SLIPPING/DRAGGING EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission • Improperly adjusted shift pedal link • Seized transmission gear • Bent shift shaft • Jammed impurities Shift cam, shift fork •...

  • Page 353: Overheating

    TRBL OVERHEATING/FAULTY BRAKE/FRONT FORK OIL SHTG LEAKAGE AND FRONT FORK MALFUNCTION EB905000 OVERHEATING OVERHEATING Ignition system Compression system • Improper spark plug gap • Heavy carbon build-up • Improper spark plug heat range Engine oil • Faulty ignitor unit • Improper oil level Fuel system •...

  • Page 354: Unstable Handling

    TRBL UNSTABLE HANDLING/ SHTG FAULTY LIGHTING AND SIGNAL SYSTEMS EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Front fork • Improperly installed or bent • Uneven oil levels on both sides Steering • Uneven spring tension (uneven damping force • Improperly installed handlebar crown adjuster position) •...
  • Page 355 TRBL SHTG...
  • Page 356 ELECTRICAL SYSTEM BT1100 WIRING DIAGRAM Pickup coil Rectifier/regulator Main switch Starter relay Battery Wire minus lead Starter motor Starting circuit cut-off relay Fuel pump Igniter unit Ignition coil 1 Ignition coil 2 Throttle position sensor Sidestand switch Ignition fuse Right handlebar switch Front brake switch Headlight fuse Signal fuse...

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