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Yamaha XV16AL Service Manual

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Table of Contents
XV16AL
XV16ATL
SERVICE MANUAL
LIT-11616-12-56
XV16ALC
/
XV16ATLC
/
4WM-28197-E0

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Table of Contents
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  Summary of Contents for Yamaha XV16AL

  • Page 1 XV16AL XV16ALC XV16ATL XV16ATLC SERVICE MANUAL LIT-11616-12-56 4WM-28197-E0...
  • Page 2 EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the tech- niques to repair these types of vehicles.
  • Page 3: 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. Compre- hensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 4 ******** SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system CARB 8 Troubleshooting...
  • Page 5 ******** TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETION CARB – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 6: Table Of Contents

    INFO CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL CODE ..................1-1 FEATURES ....................1-2 IMPORTANT INFORMATION ..............1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY ....... 1-6 REPLACEMENT PARTS ................ 1-6 GASKETS, OIL SEALS AND O-RINGS ..........1-6 LOCK WASHERS/PLATES AND COTTER PINS ........
  • Page 7: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is affixed to the frame.
  • Page 8: Features

    FEATURES INFO EAS00019 FEATURES Twin spark plugs For this model, two spark plugs are incor- porated in each cylinder. By using two spark plugs, the combustion time in the combustion chamber is short- ened in an attempt to improve torque. Speed sensor The speed sensor is installed to the crank- case and it detects the number of passing...
  • Page 9 FEATURES INFO Auto decompression mechanism The auto decompression mechanism occurs when the engine is started. When the engine is started, the decompression cam and pin raise the exhaust valve lifters, push the push rods, move the rocker arms, and lower the exhaust valves which compress the cylinder. When the cylinder is compressed, pressure is released immediately, resulting in smoother engine start- ing capabilities and smoother crankshaft revolutions.
  • Page 10 FEATURES INFO Operation 1. When the starter switch is pushed, elec- tricity is run to the decompression sole- noid 1 causing it to push out the decompression solenoid rod 2. 2. When the decompression solenoid rod is pushed out, the decompression connec- tor 3 moves the decompression levers 4 in the direction indicated by the arrows, and then the levers push the...
  • Page 11 FEATURES INFO Hydraulic valve lifters Since the hydraulic valve-lifting mechanism maintains a valve clearance of zero, periodic valve clearance adjustments are unnecessary. The advantages of this system as compared to conventional techniques include the follow- ing: mechanical noise is reduced, the camshaft action on the valves remains unaffected by engine speed or temperature, and the valve timing is kept stable.
  • Page 12: Important Information

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

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1.
  • Page 14: Checking The Connections

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

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers, or both may differ depending on the country.
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve guide remover (6 mm) YM-4064-A This tool is used to remove or install the valve guides. Valve guide installer YM-4065-A This tool is used to install the valve guides. Valve guide reamer YM-4066 This tool is used to rebore the new valve guides.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Compression Compression gauge gauge YU-33223 Compression These tools are used to measure engine gauge adapter compression. YU-33223-3 Steering nut wrench YU-33975 This tool is used to loosen or tighten the steering stem ring nuts. Oil filter wrench YU-38411 This tool is needed to loosen or tighten...
  • Page 18 SPEC CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ............... 2-11 ELECTRICAL SPECIFICATIONS ..............2-15 TIGHTENING TORQUES ................2-18 GENERAL TIGHTENING TORQUES ..........2-18 ENGINE TIGHTENING TORQUES ............. 2-19 CHASSIS TIGHTENING TORQUES ........... 2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....
  • Page 19: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,500 mm (98.4 in) ---- Overall width 980 mm (38.6 in) ---- Overall height 1,140 mm (44.9 in): XV16A ---- 1,500 mm (59.1 in): XV16AT ---- Seat height 710 mm (28.0 in) ---- Wheelbase...
  • Page 20: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, OHV ---- Displacement 1,602 cm ---- Cylinder arrangement V-type 2-cylinder ---- Bore × stroke 95 × 113 mm (3.74 × 4.45 in) ---- Compression ratio 8.3:1 ---- Engine idling speed 850 ~ 950 r/min ----...
  • Page 21 SPEC ENGINE SPECIFICATIONS Item Standard Limit Engine oil pump Oil pump type Trochoidal ---- Inner rotor to outer rotor tip clear- 0.00 ~ 0.12 mm (0.000 ~ 0.005 in) 0.17 mm ance (0.007 in) Inner rotor outer rotor 2 to oil pump 0.03 ~ 0.08 mm (0.001 ~ 0.003 in) 0.13 mm housing clearance (feed pump)
  • Page 22 SPEC ENGINE SPECIFICATIONS Item Standard Limit Measurement A 36.594 ~ 36.649 mm 36.494 mm (1.4407 ~ 1.4429 in) (1.4368 in) Measurement B 31.950 ~ 32.050 mm 31.850 mm (1.2579 ~ 1.2618 in) (1.2539 in) Camshaft exhaust cam dimen- sions Measurement A 36.554 ~ 36.654 mm 36.454 mm (1.4391~ 1.4431 in)
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve margin thickness D Intake 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 0.4 mm (0.016 in) Exhaust 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 0.4 mm (0.016 in) Valve stem diameter Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm (0.2341 in)
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake ---- 2.5˚ /2.4 mm (2.5˚/0.094 in) Exhaust ---- 2.5˚ /2.4 mm (2.5˚/0.094 in) Winding direction (top view) Intake Counterclockwise ---- Exhaust Counterclockwise ---- Outer springs Free length Intake 43.25 mm (1.70 in) 41.26 mm (1.62 in) Exhaust...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Winding direction (top view) Intake Clockwise ---- Exhaust Clockwise ---- Valve lifters Valve lifter outside diameter 22.9680 ~ 22.9744 mm ---- (0.9043 ~ 0.9045 in) Valve lifter case inside diameter 22.990 ~ 23.010 mm ---- (0.9051 ~ 0.9059 in) Valve lifter-to-valve lifter case...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Ring type Barrel ---- Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---- End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.65 mm (0.026 in) Ring side clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Big end radial clearance E 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) 0.09 mm (0.0035 in) Crankshaft journal-to-crankshaft- 0.030 ~ 0.062 mm (0.0012 ~ 0.0024 in) 0.1 mm journal bearing clearance (0.0040 in) Clutch Clutch type Wet, multiple disc...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Shifting mechanism Shift mechanism type Guide bar ---- Max. shift fork guide bar bending ---- 0.025 mm (0.001 in) Shift fork thickness 6.26 ~ 6.39 mm (0.246 ~ 0.252 in) ---- Air filter type Dry element ---- Fuel pump...
  • Page 29: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle ---- Caster angle 32˚ ---- Trail 142 mm (5.59 in) ---- Front wheel Wheel type Spoke wheel ---- 16 × MT3.00 Size ---- Material Steel ---- Wheel travel 140 mm (5.51 in) ---- Wheel runout...
  • Page 30 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type With tube ---- Size 150/80 B16 71H ---- Model (manufacturer) D404 (DUNLOP)/ ---- G702 (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm , 36 psi) ---- 90 kg (198 lb) ~ Maximum load* 280 kPa (2.8 kg/cm...
  • Page 31 0 ~ 140 mm (0 ~ 5.51 in) ---- Optional spring available ---- Fork oil Recommended oil Yamaha fork oil 5WT ---- Quantity (each front fork leg) 554 cm (19.5 Imp oz, 18.7 US oz) ---- Level (from the top of the inner 110 mm (4.33 in)
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Drive belt Model (manufacturer) UBD-0568 ---- Drive belt slack (on a sidestand) 7.5 ~ 13 mm (0.30 ~ 0.51 in) ---- Drive belt slack 14 ~ 21 mm (0.55 ~ 0.83 in) ---- (on a suitable stand) 2 - 14...
  • Page 33: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (TCI) ---- Ignition timing 10˚ BTDC at 1,000 r/min ---- Advanced timing 40˚ BTDC at 4,000 r/min ---- Advancer type Throttle position sensor and electrical ---- 248 ~ 372 Ω...
  • Page 34 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit 12 V 1.7 W × 1 Neutral indicator light 12 V 1.7 W × 1 Turn signal indicator light 12 V 1.7 W × 1 High beam indicator light Fuel level indicator light Engine trouble indicator light Electric starting system System type Constant mesh...
  • Page 35 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage × quantity) 30 A × 1 Main fuse ---- 15 A × 1 Headlight fuse ---- 10 A × 1 Signaling system fuse ---- 15 A × 1 Ignition fuse ---- 10 A × 1 Carburetor heater fuse ---- 5 A ×...
  • Page 36: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES GENERAL TIGHTENING TORQUES This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifica- tions for special components or assemblies are provided for each chapter of this man- ual. To avoid warpage, tighten multi-fas- tener assemblies in a crisscross pattern and progressive stages until the specified tight- ening torque is reached.
  • Page 37: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Spark plug – Cylinder head Cylinder head Cylinder head (exhaust pipe) Stud bolt Camshaft driven gear Camshaft drive gear Bolt Connecting rod Bolt 38.5 3.85 Rocker arm adjusting screw...
  • Page 38 SPEC TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Generator rotor Bolt 16.0 Generator shaft Bolt Pickup coil rotor Bolt 11.5 Baffle plate Bolt Use a lock Clutch boss washer. Clutch spring plate Bolt Pull lever Bolt Transfer gear oil drain bolt –...
  • Page 39: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kgf ft·lb Upper bracket and inner tube Upper bracket and steering shaft 13.0 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) See NOTE. Brake hose joint and lower bracket Front brake master cylinder cap Handlebar holder (lower) Front brake master cylinder...
  • Page 40 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kgf ft·lb Rear master cylinder and rear brake bracket Rear brake reservoir tank Union bolt (rear brake hose) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Front wheel axle Front wheel axle pinch bolt Rear wheel axle nut 15.0...
  • Page 41: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearings Connecting rod bolts and nuts Connecting rod small end and big end Crankshaft pins Crankshaft journals Piston surfaces Piston pins Camshaft cam lobes and camshaft journals...
  • Page 42: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal...
  • Page 43: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2 - 25...
  • Page 44: Engine Oil Flow Diagrams

    SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Oil strainer 3 Dipstick 4 Oil delivery pipe 5 Push rod 6 Oil filter cartridge 7 Engine oil drain bolt (oil tank) 2 - 26...
  • Page 45 SPEC ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 2 - 27...
  • Page 46 SPEC ENGINE OIL FLOW DIAGRAMS 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt (engine) 2 - 28...
  • Page 47 SPEC ENGINE OIL FLOW DIAGRAMS 1 Main axle 2 Drive axle 3 Engine oil pump 4 Oil strainer Å To oil tank ı From oil tank Ç To oil filter cartridge 2 - 29...
  • Page 48: Transfer Gear Oil Flow Diagrams

    SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 - 30...
  • Page 49 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 - 31...
  • Page 50: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Å Route the rear brake light switch lead in front of the 1 Throttle cables 2 Brake hose rectifier/regulator bracket on the frame. 3 Clutch cable 4 Left handlebar switch lead 5 Vacuum hose (air induction system) 6 Rear brake light switch lead 7 Rectifier/regulator 2 - 32...
  • Page 51 SPEC CABLE ROUTING 1 Spark plug cap #3 B Carburetor heater lead 2 Ignition coil (rear cylinder) C Throttle position sensor lead 3 Spark plug cap #1 D Horn lead 4 Fuse box E Sidestand switch lead 5 Starter relay F Sidestand switch 6 Thermo switch Å...
  • Page 52 SPEC CABLE ROUTING 1 Battery A Spark plug cap #2 2 Turn signal relay B Sidestand switch coupler 3 Relay unit C Pickup coil lead 4 Oil tank breather hose D Horn leads 5 Ignition coil (front cylinder) E Starter motor lead 6 Main switch coupler F Sidestand switch lead 7 Meter assembly couplers...
  • Page 53 SPEC CABLE ROUTING Å Fasten the fuel tank breather and oil tank Ï Fasten the starter motor lead, stator coil lead, breather hose with a plastic clamp and then decompression solenoid lead, pickup coil insert the clamp into the frame. lead speed sensor lead and neutral switch ı...
  • Page 54 SPEC CABLE ROUTING 1 Fuel tank breather hose B Spark plug lead #2 2 Oil tank breather hose C Spark plug lead #1 3 Relay unit D Spark plug lead #3 4 Turn signal relay 5 Tail/brake light and rear turn signal light sub- Å...
  • Page 55 SPEC CABLE ROUTING Evaporative emission control system (California only) 1 Main switch 6 Rollover valve 2 Fuel tank breather hose 7 Solenoid valve coupler 3 Charcoal canister to carburetor hose 8 Solenoid valve 4 Charcoal canister 9 Solenoid valve to air filter case hose 5 Charcoal canister to rollover valve hose 0 Solenoid valve to carburetor hose 2 - 37...
  • Page 56 CONTENTS PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ................... 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 SEATS AND SIDE COVERS ................. 3-3 XV16AT ACCESSORY PARTS ..............3-4 FUEL TANK ....................3-6 AIR FILTER CASE ..................3-7 ENGINE ......................
  • Page 57 CHECKING THE FRONT BRAKE PADS ..........3-35 CHECKING THE REAR BRAKE PADS ..........3-35 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-35 CHECKING THE BRAKE HOSE ............3-36 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........ 3-37 ADJUSTING THE SHIFT PEDAL ............3-39 ADJUSTING THE DRIVE BELT SLACK ..........
  • Page 58: Periodic Checks And Adjustments

    √ control system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4,000 mi...
  • Page 59 • Replace every 16,000 Replace Check Replace (See page 3- hypoid gear oil mi (25,000 km) or 26.) 24 months. Control Yamaha chain and cable • Apply chain lube thor- √ √ √ √ √ √ cable lube or SAE (See page 3- oughly.
  • Page 60: Seats And Side Covers

    SEATS AND SIDE COVERS SEATS AND SIDE COVERS Order Job/Part Q’ty Remarks Removing the seats and side covers Remove the parts in the order listed. Rider seat Passenger seat Left side cover Right side cover For installation, reverse the removal procedure.
  • Page 61: Xv16At Accessory Parts

    XV16AT ACCESSORY PARTS XV16AT ACCESSORY PARTS Order Job/Part Q’ty Remarks Accessory parts removal (front) Remove the parts in the order listed. Front windshield Chrome flasher bracket cover Windshield stay For installation, reverse the removal procedure. 3 - 4...
  • Page 62 XV16AT ACCESSORY PARTS Order Job/Part Q’ty Remarks Accessory parts removal (rear) Remove the parts in the order listed. Emblem Backrest holder Backrest Backrest stay Saddlebag Passenger footrest Saddlebag stay Grip For installation, reverse the removal procedure. 3 - 5...
  • Page 63: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS AND SIDE COVERS”. Meter assembly Meter assembly coupler Disconnect. Fuel tank breather hose Fuel hose Disconnect.
  • Page 64: Air Filter Case

    AIR FILTER CASE AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Vacuum chamber breather hose Disconnect. (air filter case to solenoid valve hose) Cylinder head breather hose Disconnect. Air filter case For installation, reverse the removal procedure.
  • Page 65: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00047 Å ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times that the valve clearance is needed to be adjusted manu- ı...
  • Page 66 ADJUSTING THE VALVE CLEARANCE 4. Remove: • shift rod 1 5. Remove: • rider footrest (left) bolts 1 6. Remove: • engine left side cover 1 7. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 8. Remove: •...
  • Page 67 ADJUSTING THE VALVE CLEARANCE 9. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0 ~ 0.04 mm (0 ~ 0.0016 in) Exhaust valve 0 ~ 0.04 mm (0 ~ 0.0016 in) CAUTION: ACHTUNG: Be sure to check the intake and exhaust valves.
  • Page 68 ADJUSTING THE VALVE CLEARANCE 10.Adjust: • valve clearance ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Loosen the locknut 1. b.
  • Page 69: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1.
  • Page 70: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 8. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4 ~ 8 mm (0.16 ~ 0.31 in) EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 71: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS e. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction a increased. Throttle cable free play is Direction b decreased.
  • Page 72 CHECKING THE SPARK PLUGS 2. Disconnect: • spark plug cap 3. Remove: • spark plug CAUTION: ACHTUNG: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4.
  • Page 73: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”.
  • Page 74 CHECKING THE IGNITION TIMING 7. Remove: • timing mark accessing screw 1 8. Install: • timing light 1 • inductive tachometer 2 (onto the spark plug lead of cylinder #1) Timing light YU-33277-A Inductive tachometer YU-8036-A 9. Check: • ignition timing ▼...
  • Page 75: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 11.Adjust: • installed shift rod length Refer “ADJUSTING SHIFT PEDAL”. EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1.
  • Page 76 MEASURING THE COMPRESSION PRESSURE 8. Install: • compression gauge 1 • compression gauge adapter 2 Compression gauge YU-33223 Compression gauge adapter YU-33223-3 9. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,000 kPa (10 kg/cm...
  • Page 77: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than with- Piston wear or dam- age → Repair. out oil Piston rings, valves, cylinder Same as without oil head gasket, or pis- ton possibly defec-...
  • Page 78 CHECKING THE ENGINE OIL LEVEL 3. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”. 4. Remove: • dipstick 1 5. Check: • engine oil level The engine oil level should be between the minimum level mark a and maxi- mum level mark b.
  • Page 79: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00073 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • dipstick 1 • engine oil drain bolt (oil tank) 2 •...
  • Page 80 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m • kg, 12 ft • lb) ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 6.
  • Page 81 CHANGING THE ENGINE OIL NOTE: After the engine has been disassembled, pour the specified amount of engine oil into the crankcase and the oil tank. When pour- ing engine oil into the crankcase, pour it into the hole of the removed bolt 1. 10.Install: •...
  • Page 82: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several minutes, and then turn it off. CAUTION: ACHTUNG: When the engine is cold, the engine oil will have a higher viscosity, causing the engine...
  • Page 83: Checking The Transfer Gear Oil Level

    MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL Out of specification → Adjust. Engine oil pressure Possible causes • Faulty oil pump • Clogged oil filter Below specification • Leaking oil pas- sage • Leaking oil pas- Broken or damaged sage oil seal...
  • Page 84: Changing The Transfer Gear Oil

    CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL CAUTION: ACHTUNG: Do not allow foreign materials to enter the transfer case. 4. Install: • checking bolt 8 Nm (0.8 m · kg, 5.8 ft · lb) CHANGING THE TRANSFER GEAR OIL 1.
  • Page 85: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2.
  • Page 86: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: • air filter case Refer to “AIR FILTER CASE”. 2. Remove: • air filter case cover 1 • air filter element 2 3. Clean: • air filter element Apply compressed air to the outer sur- face of the air filter element.
  • Page 87: Checking The Carburetor Joint

    CHECKING THE CARBURETOR JOINT/ CHECKING THE FUEL HOSES AND FUEL FILTER EAS00094 CHECKING THE CARBURETOR JOINT 1. Remove: • carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Check: • carburetor joint 1 Cracks/damage → Replace. Refer to “CARBURETOR” in chapter 6. 3.
  • Page 88: Checking The Cylinder Head Breather Hose And Transfer Gear Case Breather Hose

    CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE 1. Remove: • rider seat • fuel tank Refer to “SEATS AND SIDE COVERS” and “FUEL TANK”.
  • Page 89: Chassis

    ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2.
  • Page 90: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Measure: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 100 mm (3.9 in) 2.
  • Page 91: Checking The Brake Fluid Level

    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 the motorcycle is upright. 2. Check: Å • brake fluid level Below the minimum level mark a →...
  • Page 92: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00120 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • brake pad Wear indicator groove 1 almost disap- peared →...
  • Page 93: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSE 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 94: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING WARNING Bleed the hydraulic brake system when- ever: • the brake system was disassembled, • a brake hose was loosened, discon- nected, or replaced, • the brake fluid level is very low, •...
  • Page 95 BLEEDING THE HYDRAULIC BRAKE SYSTEM c. Connect a clear plastic hose 1 tightly to the bleed screw 2. Å Front ı Rear d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f.
  • Page 96: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 374.4 ~ 378.4 mm (14.74 ~ 14.90 in) 2.
  • Page 97 ADJUSTING THE DRIVE BELT SLACK 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated.
  • Page 98: Checking And Adjusting The Steering Head

    ADJUSTING THE DRIVE BELT SLACK/ CHECKING AND ADJUSTING THE STEERING HEAD a. Loosen the brake caliper bracket bolt 1. b. Loosen the wheel axle nut 2. c. Loosen both locknuts 3. Å Right ı Left d. Turn both adjusting bolts 4 in direction a or b until the specified drive chain slack is obtained.
  • Page 99 CHECKING AND ADJUSTING THE STEERING HEAD 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: • meter assembly Refer to “FUEL TANK”. 4.
  • Page 100: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.
  • Page 101: Adjusting The Rear Shock Absorber Assembly

    CHECKING THE FRONT FORK/ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 2. Check: • inner tube Damage/scratches → Replace. • oil seal Oil leakage → Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar sev- eral times and check if the front fork rebounds smoothly.
  • Page 102: Checking The Tires

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHECKING THE TIRES Adjusting length a Minimum 42.5 mm (1.67 in) Standard 42.5 mm (1.67 in) Maximum 51.5 mm (2.03 in) CAUTION: ACHTUNG: Never turn the adjusting ring beyond the maximum or minimum setting. ▲...
  • Page 103 CHECKING THE TIRES Basic weight 332 kg (732 lb): XV16A (with oil and a 347 kg (765 lb): XV16AT full fuel tank) Maximum 196 kg (432 lb): XV16A load* 181 kg (399 lb): XV16AT Cold tire pres- Front tire Rear tire sure 250 kPa 250 kPa...
  • Page 104 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 105: Checking And Tightening The Spokes

    CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES WARNING WARNING • After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or dam- age to the motorcycle.
  • Page 106: Checking And Lubricating The Cables

    CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES 2. Tighten: • spokes (with a spoke wrench 1) 3 Nm (0.3 m · kg, 2.2 ft · lb) NOTE: Be sure to tighten the spokes before and after break-in. EAS00170 CHECKING AND LUBRICATING THE CABLES...
  • Page 107: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to- metal moving parts of the levers and ped- als. Recommended lubricant Lithium soap base grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to- metal moving parts of the sidestand.
  • Page 108: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 109 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not pos- sible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the bat- tery has to be checked by measuring the voltage at the battery terminals.
  • Page 110 CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer appropriate charging method illustration) WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate...
  • Page 111 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger 3 - 54...
  • Page 112 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger 3 - 55...
  • Page 113: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery • battery band 7. Connect: • battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: •...
  • Page 114 CHECKING THE FUSES NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester YU-03112 b. If the pocket tester indicates “∞”, replace the fuse. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 3.
  • Page 115: Replacing The Headlight Bulb

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB 4. Install: • left side cover Refer to “SEATS AND SIDE COVERS”. EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • screws 1 • headlight lens unit 2 2. Disconnect: • headlight coupler 1 3.
  • Page 116: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 6. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: ACHTUNG: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected.
  • Page 117 ADJUSTING THE HEADLIGHT BEAM 2. Adjust: • headlight beam (horizontally) ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Turn the adjusting knob 2 in direction a or b.
  • Page 118: Instrument Functions

    ” This indicator light will come on or flash if trouble occurs in a monitoring circuit. In such a case, take the motorcycle to a Yamaha dealer to have the self-diagnos- tic systems checked. COMBINATION METER 1 Combination meter 2 Clock...
  • Page 119 INSTRUMENT FUNCTIONS To reset the trip meter to “0”, push the set button until it displays “TRIP A” or “TRIP B”, then push mode button and hold it down for at least one second. NOTE: This motorcycle does not have a tachome- ter.
  • Page 120 CHAS CONTENTS CHASSIS FRONT WHEEL AND BRAKE DISCS ............4-1 REMOVING THE FRONT WHEEL ............4-3 DISASSEMBLING THE FRONT WHEEL ..........4-3 CHECKING THE FRONT WHEEL ............4-4 CHECKING THE BRAKE DISCS ............4-6 ASSEMBLING THE FRONT WHEEL ............ 4-7 INSTALLING THE FRONT WHEEL ............
  • Page 121 CHAS FRONT AND REAR BRAKES ..............4-22 REPLACING THE FRONT BRAKE PADS ..........4-24 REPLACING THE REAR BRAKE PADS ..........4-27 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ..4-35 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER .... 4-35 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS ..................
  • Page 122 CHAS DRIVE BELT AND DRIVE PULLEY ............. 4-90 REMOVING THE DRIVE BELT AND DRIVE PULLEY ......4-91 CHECKING THE DRIVE BELT ............. 4-91 INSTALLING THE DRIVE BELT AND DRIVE PULLEY ....... 4-92...
  • Page 123: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Reflector (left and right) Brake caliper (left and right) Wheel axle pinch bolt...
  • Page 124 CHAS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. 4 - 2...
  • Page 125: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING 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 126: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00526 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING WARNING Do not attempt to straighten a bent wheel axle. 2. Check: •...
  • Page 127 CHAS FRONT WHEEL AND BRAKE DISCS 6. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 7. Replace: • wheel bearings • oil seals ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 128: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
  • Page 129: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 23 Nm (2.3 m • kg, 17 ft • lb)  LOCTITE d. Measure the brake disc deflection. e.
  • Page 130 CHAS FRONT WHEEL AND BRAKE DISCS 2. Install: • brake discs • brake disc covers 23 Nm (2.3 m · kg, 17 ft · lb) NOTE:  • Apply locking agent (LOCTITE 648) to the threads of the brake disc bolts. •...
  • Page 131: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel, or both, the front wheel static balance should be adjusted. • Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 132 CHAS FRONT WHEEL AND BRAKE DISCS 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. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 4.
  • Page 133: Rear Wheel, Brake Disc And Rear Wheel Pulley

    CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Order Job/Part Q’ty Remarks Removing the rear fender and muf- Remove the parts in the order listed. fler Rider seat Refer to “SEATS AND SIDE COVERS” in chapter 3.
  • Page 134 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY EAS00550 Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is ele- vated.
  • Page 135 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Order Job/Part Q’ty Remarks Rear wheel Collar (left and right) Brake caliper bracket For installation, reverse the removal procedure. 4 - 13...
  • Page 136 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY EAS00556 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel pulley Brake disc Rear wheel pulley Oil seal Collar Circlip Bearing Collar Bearing Rear wheel drive hub Rear wheel drive hub damper...
  • Page 137 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly procedure. 4 - 15...
  • Page 138: Removing The Rear Wheel

    CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING 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 139: Checking The Rear Wheel Drive Hub

    CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY 3. Check: • spokes Refer to “FRONT WHEEL AND BRAKE DISCS”. 4. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISCS”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1.
  • Page 140: Assembling The Rear Wheel

    CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Rear wheel pulley self-locking nut 95 Nm (9.5 m • kg, 68 ft • lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ASSEMBLING THE REAR WHEEL 1.
  • Page 141 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY 4. Install: • rear wheel pulley 1 95 Nm (9.5 m · kg, 68 ft · lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. 5. Install: •...
  • Page 142 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY 9. Tighten: • wheel axle nut 150 Nm (15.0 m · kg, 110 ft · lb) • brake caliper bracket bolt 48 Nm (4.8 m · kg, 35 ft · lb) 10.Install: •...
  • Page 143: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY 17.Install: • rider seat Refer to “SEATS AND SIDE COVERS” in chapter 3. EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel, or both, the rear wheel static balance should be adjusted.
  • Page 144: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake hose holder bolt Retaining bolt Brake caliper...
  • Page 145 CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Muffler Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Brake caliper bolt Brake pad cover Brake pad clip Brake pad pin Brake pad spring...
  • Page 146: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: ACHTUNG: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 147 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pads 1 (along with the brake pad shim) • brake pad springs 3. Measure: • brake pad thickness a Out of specification → Replace the brake pads as a set. Minimum brake pad thickness 0.5 mm (0.02 in) 4.
  • Page 148 CHAS FRONT AND REAR BRAKES 5. Lubricate: • brake caliper retaining bolt Recommended lubricant Lithium soap base grease CAUTION: ACHTUNG: • Do not allow grease to contact the brake pads. • Remove any excess grease. 6. Install: • brake caliper •...
  • Page 149: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: • brake caliper 1 • brake pad cover 2 2.
  • Page 150 CHAS FRONT AND REAR BRAKES b. Loosen the bleed screw and push the brake caliper pistons into the brake cali- per with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m • kg, 4.3 ft • lb) d.
  • Page 151 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia- phragm...
  • Page 152 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake master cylinder holder Brake master cylinder Front brake light switch For installation, reverse the removal procedure. 4 - 30...
  • Page 153: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4 - 31...
  • Page 154 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Brake fluid Drain. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir...
  • Page 155 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Left footrest assembly Cotter pin Brake master cylinder For installation, reverse the removal procedure. 4 - 33...
  • Page 156 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4 - 34...
  • Page 157: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake mas- ter cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 •...
  • Page 158: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 Å CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...
  • Page 159: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 5. Check: • brake hoses • brake fluid reservoir hose Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 160 CHAS FRONT AND REAR BRAKES 4. Install: • copper washers • brake hose • union bolt 30 Nm (3.0 m · kg, 22 ft · lb) WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 161 CHAS FRONT AND REAR BRAKES WARNING 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 162: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • brake master cylinder kit 1 • circlip 2 • dust boot 3 2. Install: • brake master cylinder 1 23 Nm (2.3 m · kg, 17 ft · lb) 3.
  • Page 163 CHAS FRONT AND REAR BRAKES CAUTION: ACHTUNG: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. 6. Install: • brake fluid reservoir hose 1 • brake fluid reservoir 2 7.
  • Page 164 CHAS FRONT AND REAR BRAKES 8. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 9. Install: • brake fluid reservoir diaphragm • brake fluid reservoir diaphragm holder • brake fluid reservoir cap • brake fluid reservoir cover 10.Check: •...
  • Page 165 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain. Reflector Brake hose holder bolt Union bolt Copper washer...
  • Page 166 CHAS FRONT AND REAR BRAKES EAS00615 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers. Retaining bolt Brake caliper Brake caliper bracket Brake pad Brake pad spring Brake pad spring...
  • Page 167 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Muffler Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper bolt...
  • Page 168 CHAS FRONT AND REAR BRAKES EAS00617 Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.
  • Page 169: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00624 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 •...
  • Page 170: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a con- tainer and pump out the brake fluid care- fully. 2. Remove: •...
  • Page 171: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Check: Å • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper cylinders 2 Scratches/wear → Replace the brake cali- per. • brake calipers Cracks/damage → Replace. • brake fluid delivery passages (brake caliper body) ı...
  • Page 172 CHAS FRONT AND REAR BRAKES • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassem- bled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1.
  • Page 173 CHAS FRONT AND REAR BRAKES 6. Install: • copper washers • brake hose • union bolt 30 Nm (3.0 m · kg, 22 ft · lb) WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 174: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 8. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 9. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 175 CHAS FRONT AND REAR BRAKES 1. Install: • bleed screw • brake caliper piston seals 1 • brake caliper pistons 2 2. Install: • brake pads • brake pad spring 1 • brake pad pins 2 • brake pad clips 3 NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation.
  • Page 176 CHAS FRONT AND REAR BRAKES 6. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 177: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 178 CHAS FRONT FORK Order Job/Part Q’ty Remarks Lower bracket pinch bolt Loosen. Front fork leg Bolt Brake hose guide Lower fork cover For installation, reverse the removal procedure. 4 - 56...
  • Page 179 CHAS FRONT FORK EAS00648 Order Job/Part Q’ty Remarks Disassembling the front fork leg Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Fork spring Dust seal Oil seal clip Cartridge cylinder bolt Copper washer Cartridge cylinder...
  • Page 180 CHAS FRONT FORK Order Job/Part Q’ty Remarks Oil seal Seal spacer Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly procedure. 4 - 58...
  • Page 181: 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 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 182: Checking The Front Fork Legs

    CHAS FRONT FORK 3. Remove: • cartridge cylinder bolt NOTE: While holding the cartridge cylinder with the damper rod holder 1 and T-handle 2, loosen the cartridge cylinder bolt. Damper rod holder YM-1300-1 T-Handle YM-01326 4. Remove: • inner tube ▼...
  • Page 183: Assembling The Front Fork Legs

    CHAS FRONT FORK 2. Measure: • spring free length a Out of specification → Replace. Spring free length limit 566 mm (22.3 in) 3. Check: • cartridge cylinder 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air.
  • Page 184 2. Install: • oil flow stopper 3 3. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 5WT or equivalent 4. Install: • outer tube (onto the inner tube) • copper washer •...
  • Page 185 CHAS FRONT FORK 6. Install: • outer tube bushing 1 • seal spacer 2 (with the fork seal driver weight 3 and adapter 4) Fork seal driver weight YM-33963 Adapter YM-8020 7. Install: • oil seal 1 (with the fork seal driver weight 2 and adapter 3) CAUTION: ACHTUNG:...
  • Page 186: Installing The Front Fork Legs

    110 mm (4.33 in) Recommended oil Yamaha fork and shock oil 5WT or equivalent NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil.
  • Page 187 CHAS FRONT FORK 3. Install: • Upper bracket • Steering stem nut 130 Nm (13.0 m · kg, 94 ft · lb) NOTE: Make sure the inner fork tube is flush with the top of the upper bracket. 4. Tighten: •...
  • Page 188 CHAS FRONT FORK 8. Tighten: • upper bracket pinch bolts 1 10 Nm (1.0 m · kg, 7.2 ft · lb) 9. Install: • brake hose holder • front fender 23 Nm (2.3 m · kg, 17 ft · lb) 10.Install: •...
  • Page 189: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Right handlebar switch Throttle cable holder Throttle cable Disconnect.
  • Page 190 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Clutch cable Disconnect. Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure. 4 - 68...
  • Page 191: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handle- bar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 192 CHAS HANDLEBAR NOTE: • The upper handlebar holders should be installed with the arrows a facing for- ward Å. • Align the match marks b on the handle- bar with the upper surface of the lower handlebar holders. 3. Tighten: •...
  • Page 193 CHAS HANDLEBAR 8. Install: • handlebar grip ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.
  • Page 194 CHAS HANDLEBAR • First, tighten the upper bolt, then the lower bolt. 13.Connect: • front brake light switch connector 14.Install: • plastic clamp • rear view mirrors 15.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 ~ 15 mm (0.39 ~ 0.59 in)
  • Page 195: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Meter assembly Refer to “FUEL TANK” in chapter 3. Front fork legs/fork covers Refer to “FRONT FORK”. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 196 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Brake hose joint Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Upper bearing Lower bearing Bearing outer race For installation, reverse the removal procedure. 4 - 74...
  • Page 197: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • lower ring nut 1 (with the special tool 2) Ring nut wrench YU-33975 WARNING...
  • Page 198: Installing The Steering Head

    CHAS STEERING HEAD c. Install a new rubber seal and new bear- ing races. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ CAUTION: ACHTUNG: If the bearing race is not installed properly,...
  • Page 199 CHAS STEERING HEAD 3. Install: • lower ring nut 1 • rubber washer 2 • upper ring nut 3 • lock washer 4 Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 4. Install: • brake hose joint 1 7 Nm (0.7 m ·...
  • Page 200 CHAS STEERING HEAD 10.Install: • upper bracket • steering stem nut • front fork legs Refer to “FRONT FORK”. 11.Install: • handlebar Refer to “HANDLEBAR”. • front fork legs Refer to “FRONT FORK”. • meter assembly Refer to “FUEL TANK” in chapter 3. 4 - 78...
  • Page 201: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM ******** REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Adjusting bolt Locknut Mud guard...
  • Page 202 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Pivot shaft Rear shock absorber and swingarm assembly For installation, reverse the removal procedure. 4 - 80...
  • Page 203 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm 1/1/1 Bolt R= 53 mm (2.19 in) Self-locking nut/washer/bolt 1/1/1 Bolt R= 124 mm (4.88 in) Self-locking nut/washer/bolt Connecting arm O-ring...
  • Page 204 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Spacer/bearing Swingarm Dust cover Washer Spacer Bearing For installation, reverse the removal procedure. 4 - 82...
  • Page 205: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.
  • Page 206: Checking The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM 2. Remove: • bolt (shock absorber - connecting arm - frame) 1 NOTE: When removing the bolt (shock absorber - connecting arm - frame) 1, hold the swin- garm so that it does not drop down. 3.
  • Page 207: Checking The Replay Arm And Connecting Arm

    CHAS REAR SHOCK ABSORBER AND SWINGARM • spring Damage/wear → Replace the rear shock absorber assembly. • gas cylinder Damage/gas leaks → Replace. • bushings Damage/wear → Replace. • O-ring Damage/wear → Replace. • bolts Bends/damage/wear → Replace. CHECKING THE RELAY ARM AND CONNECTING ARM 1.
  • Page 208: Installing The Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Wash: • pivot shaft • dust covers • spacer • bearings Recommended cleaning solvent Kerosine 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM...
  • Page 209 CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Install: • bearings • oil seals 1 • spacers 2 4. Install: • relay arm 1 (onto the swingarm) 59 Nm (5.9 m · kg, 43 ft · lb) 5. Install: • o-rings 1 •...
  • Page 210 CHAS REAR SHOCK ABSORBER AND SWINGARM 8. Install: • rear shock absorber 1 (onto the relay arm) 40 Nm (4.0 m · kg, 29 ft · lb) 9. Install: • rear shock absorber and swingarm assembly • pivot shaft • washer •...
  • Page 211 CHAS REAR SHOCK ABSORBER AND SWINGARM 14.Install: • mud guard 1 15.Install: • locknut 1 • adjusting bolt 2 16.Install: • rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. 17.Adjust: • drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”...
  • Page 212: Drive Belt And Drive Pulley

    CHAS DRIVE BELT AND DRIVE PULLEY DRIVE BELT AND DRIVE PULLEY Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. pulley Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Rear shock absorber and swingarm Refer to “REAR SHOCK ABSORBER assembly...
  • Page 213: Checking The Drive Belt

    CHAS DRIVE BELT AND DRIVE PULLEY REMOVING THE DRIVE BELT AND DRIVE PULLEY NOTE: Loosen the drive pulley nut before remove the rear wheel. 1. Remove: • drive pulley cover bracket 1 • drive pulley cover 2 2. Straighten the lock washer tab. 3.
  • Page 214: Installing The Drive Belt And Drive Pulley

    CHAS DRIVE BELT AND DRIVE PULLEY 3. Check: • drive pulley • rear wheel pulley Bent teeth → Replace the drive belt and pulleys as a set. INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1. Install: • drive pulley 1 •...
  • Page 215 CHAS DRIVE BELT AND DRIVE PULLEY 6. Install: • dowel pins 1 • sliders 2 7. Install: • drive pulley cover 1 10 Nm (1.0 m · kg, 7.2 ft · lb) • drive pulley cover bracket 2 • bolts (M10) 53 Nm (5.3 m ·...
  • Page 216 CONTENTS ENGINE ENGINE ......................5-1 INSTALLING THE ENGINE ..............5-8...
  • Page 217 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ......5-12 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ................5-18 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ................. 5-18 CHECKING THE ROCKER ARM BASES ..........5-20 CHECKING THE PUSH RODS ............5-20 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES ................
  • Page 218 CLUTCH ...................... 5-60 REMOVING THE CLUTCH ..............5-65 REMOVING THE PRIMARY DRIVE GEAR ......... 5-65 CHECKING THE FRICTION PLATES ..........5-66 CHECKING THE CLUTCH PLATES ............ 5-66 CHECKING THE CLUTCH SPRING PLATE ........5-67 CHECKING THE CLUTCH HOUSING ..........5-67 CHECKING THE CLUTCH BOSS ............
  • Page 219 ENGINE OIL PUMP ................... 5-108 CHECKING THE OIL PUMP .............. 5-111 CHECKING THE RELIEF VALVE ............5-111 CHECKING THE OIL STRAINER ............5-112 ASSEMBLING THE OIL PUMP ............5-112 INSTALLING THE OIL PUMP ............5-113 INSTALLING THE OIL STRAINER ............ 5-113 CRANKSHAFT AND CONNECTING RODS ..........
  • Page 220 ENGINE EAS00188 ENGINE ENGINE Order Job/Part Q’ty Remarks Removing the muffler and exhaust Remove the parts in the order listed. pipes Muffler Front exhaust pipe Rear exhaust pipe Gasket For installation, reverse the removal procedure. 5 - 1...
  • Page 221 ENGINE Order Job/Part Q’ty Remarks Removing the oil filter bracket and horns Rider seat/side covers Refer to “SEATS AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Carburetor/carburetor joint Refer to “CARBURETOR”...
  • Page 222 ENGINE Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain. Transfer gear oil Drain. Transfer gear case Refer to “TRANSFER GEAR CASE”. Rider footrest (left) Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”. Rider footrest (right) Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 223 ENGINE Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Charcoal canister hose (carburetor to charcoal canister) Plastic clamp Stator coil coupler Decompression solenoid coupler Pickup coil coupler 5 - 4...
  • Page 224 ENGINE Order Job/Part Q’ty Remarks Neutral switch cover Neutral switch Speed sensor For connecting, reverse the disconnec- tion procedure. 5 - 5...
  • Page 225 ENGINE EAS00191 ENGINE Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. Self-locking nut Upper front mounting bolt Front engine bracket bolt Horn bracket Front engine bracket Self-locking nut Upper rear mounting bolt Rear engine bracket bolt...
  • Page 226 ENGINE Order Job/Part Q’ty Remarks Rear engine bracket Lower front mounting bolt Lower rear mounting bolt Engine Refer to “INSTALLING THE ENGINE”. For installation, reverse the removal procedure. 5 - 7...
  • Page 227 ENGINE INSTALLING THE ENGINE 1. Install: • lower rear mounting bolt 1 • lower front mounting bolt 2 • rear engine brackets 3 • rear engine bracket bolts 4 • upper rear mounting bolt 5 • self-locking nuts 6 • front engine brackets 7 •...
  • Page 228 ENGINE 5. Connect: • speed sensor coupler • neutral switch connector • pickup coil coupler • decompression solenoid coupler • stator coil coupler 6. Install: • plastic clamp 1 7. Connect: • charcoal canister hose (carburetor to charcoal canister) 1 8.
  • Page 229 ENGINE 11.Install: • horns 1 12.Connect: • horn couplers 13.Install: • oil filter bracket 1 10 Nm (1.0 m · kg, 7.2 ft · lb) • oil filter bolt 2 70 Nm (7.0 m · kg, 50 ft · lb) NOTE: ...
  • Page 230 ENGINE 18.Install: • starter motor Refer to “STARTER MOTOR” in chapter • air induction system parts Refer to “AIR INDUCTION SYSTEM” in chapter 6. • carburetor joint • carburetor Refer to “CARBURETOR” in chapter 6. • air filter case Refer to “AIR FILTER CASE” in chapter 3. •...
  • Page 231: Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Removing the engine left side cover Remove the parts in the order listed. and camshaft sprocket cover Rider seat/fuel tank/air filter case Refer to “SEATS AND SIDE COVER”, “FUEL TANK”...
  • Page 232 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Decompression solenoid cover Camshaft sprocket cover Camshaft sprocket cover gasket Dowel pin For installation, reverse the removal procedure. 5 - 13...
  • Page 233 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Cylinder head breather hose Oil tank breather hose R = 65 mm (2.56 in) Bolt R = 35 mm (1.38 in) Bolt R = 50 mm (1.97 in) Bolt...
  • Page 234 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Rear cylinder head cover spacer Front cylinder head cover spacer Cylinder head cover spacer gasket Dowel pin For installation, reverse the removal procedure. 5 - 15...
  • Page 235 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed. arms Push rod Rear rocker arm base Front rocker arm base Rocker arm base gasket Dowel pin Rocker arm shaft Rocker arm 1 Rocker arm 2...
  • Page 236 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover Oil seal O-ring Throttle stop screw Unhook. Throttle stop screw holder Rear valve lifter case cover Front valve lifter case cover Rear valve lifter case Front valve lifter case...
  • Page 237: Removing The Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark a on the pickup coil rotor (with the pointer b on the clutch/pickup coil rotor cover) ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 238 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pit- ting/scratches → Replace or check the lubrication system. 3. Measure: • rocker arm inside diameter a Out of specification → Replace. Rocker arm inside diameter 15.000 ~ 15.018 mm (0.5906 ~ 0.5913 in) 4.
  • Page 239: Checking The Rocker Arm Bases

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS CHECKING THE ROCKER ARM BASES 1. Check: • rocker arm base Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod • push rod end Bends/damage → Replace. 2. Measure: • push rod runout Out of specification →...
  • Page 240: Bleeding The Valve Lifter

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 3. Measure: • valve lifter outside diameter a Out of specification → Replace. Valve lifter case outside diameter 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 4. Measure: • valve lifter case inside diameter a Out of specification →...
  • Page 241 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Bleed: • valve lifter ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 242: Checking The Push Rod Covers

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS h. Rotate the crankshaft until the mark (on the camshaft driven gear) for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder #2 intake valve lifter, align mark 1 as shown.
  • Page 243: Installing The Rocker Arms And Push Rods

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: • oil seals 1 • O-rings 2 • push rod covers 3 3. Install: • valve lifter case covers 1 • throttle stop screw holder 2 4. Hook: • throttle stop screw 3 5.
  • Page 244 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: • dowel pins 1 • rocker arm gasket 2 3. Install: Å • rocker arm base (with rocker arms) • push rods ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 245: Installing The Cylinder Head Covers

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE CYLINDER HEAD COVERS The following procedure applies to both cylinders. 1. Install: • dowel pins 1 • cylinder head cover spacer gasket 2 2. Install: • cylinder head cover spacer 1 10 Nm (1.0 m ·...
  • Page 246: Installing The Camshaft Sprocket Cover And Engine Left Side Cover

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 1. Install: • dowel pins 1 gasket 2 • camshaft sprocket cover 2. Install: • camshaft sprocket cover 1 • decompression solenoid cover 2 3.
  • Page 247 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 7. Install: • shift rod 1 8. Install: • spark plugs 9. Connect: • spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. Å Forward 10.Fill: • oil tank (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL”...
  • Page 248: Camshafts

    CAMSHAFTS CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Valve lifters Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”. Muffler/exhaust pipes Refer to “ENGINE”. Decompression solenoid Long decompression push rod 92 mm (3.6 in) Short decompression push rod 78 mm (3.1 in) Camshaft drive gear Straight key Camshaft driven gear...
  • Page 249 CAMSHAFTS Order Job/Part Q’ty Remarks Camshaft cover Camshaft cover gasket Dowel pin Front cylinder camshaft end cover Front cylinder camshaft Rear cylinder camshaft For installation, reverse the removal procedure. 5 - 30...
  • Page 250: Removing The Camshafts

    CAMSHAFTS REMOVING THE CAMSHAFTS 1. Loosen: • front cylinder camshaft end cover bolts • camshaft drive gear bolt 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them.
  • Page 251: Checking The Camshafts

    CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: • cams Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • cam dimensions a and b Out of specification → Replace the cam- shaft. Minimum cam lobe dimensions Intake cam a 36.494 mm (1.4368 in) b 31.850 mm (1.2539 in) Exhaust cam a 36.454 mm (1.4352 in)
  • Page 252 CAMSHAFTS 5. Measure: • crankcase hole inside diameter c Out of specification → Replace the crank- case. Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 6. Measure: • camshaft cover hole inside diameter d Out of specification → Replace the cam- shaft cover.
  • Page 253: Checking The Decompression System

    CAMSHAFTS 9. Check: • camshaft drive gears • camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the camshaft.
  • Page 254: Checking The Oil Delivery Pipe

    CAMSHAFTS CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. • O-rings 2 Damage/wear → Replace. INSTALLING THE CAMSHAFTS 1. Install: • camshafts (to the camshaft cover) •...
  • Page 255 CAMSHAFTS 4. Install: • camshaft cover 1 (along with the camshafts) • oil delivery pipe 2 NOTE: Tighten the camshaft cover bolts in stages and in a crisscross pattern. 5. Install: • straight keys • camshaft drive gear 1 • camshaft driven gear 2 NOTE: •...
  • Page 256 CAMSHAFTS 8. Tighten: • camshaft drive gear bolt 1 30 Nm (3.0 m · kg, 22 ft · lb) • front cylinder camshaft end cover bolts NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them.
  • Page 257 CAMSHAFTS 12.Fill: • oil tank (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 13.Install: • air filter case • fuel tank • rider seat Refer to “AIR FILTER CASE”, “FUEL TANK”...
  • Page 258: Cylinder Heads

    CYLINDER HEADS CYLINDER HEADS Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Rider seat/fuel tank/air filter case Refer to “SEATS AND SIDE COVERS”, “FUEL TANK” and “AIR FILTER CASE” in chapter 3. Carburetor/carburetor joint Refer to “CARBURETOR”...
  • Page 259 CYLINDER HEADS Order Job/Part Q’ty Remarks Copper washer Rear cylinder head Front cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal procedure. 5 - 40...
  • Page 260: Removing The Cylinder Heads

    CYLINDER HEADS REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Follow the numerical order shown in the illustration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to each...
  • Page 261: Checking The Oil Delivery Pipe

    CYLINDER HEADS d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylin- der head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylin- der head several times. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ CHECKING THE OIL DELIVERY PIPE 1.
  • Page 262 CYLINDER HEADS 3. Install: • copper washers • oil delivery pipe 1 • oil delivery pipe bolts (M10) 21 Nm (2.1 m · kg, 15 ft · lb) • oil delivery pipe bolt (M8) 18 Nm (1.8 m · kg, 13 ft · lb) 4.
  • Page 263: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs The following procedure applies to both cylinders. Cylinder head Refer to “CYLINDER HEADS”. Valve cotter Upper spring seat Outer valve spring Inner valve spring...
  • Page 264: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.
  • Page 265: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS NOTE: Identify the position of each part very care- fully so that it can be reinstalled in its origi- nal place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
  • Page 266 VALVES AND VALVE SPRINGS ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Remove the valve guide with the valve guide remover 1.
  • Page 267: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm (0.0004 in) EAS00240...
  • Page 268 VALVES AND VALVE SPRINGS d. Measure the valve seat width. NOTE: Where the valve seat and valve face con- tacted one another, the blueing will have been removed. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 4.
  • Page 269: Checking The Valve Springs

    VALVES AND VALVE SPRINGS g. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression.
  • Page 270: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake and exhaust inner valve spring 6.3 ~ 7.3 kg at 29.0 mm (13.9 ~ 16.1 lb at 1.14 in) Intake and exhaust outer valve spring...
  • Page 271 VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • lower spring seat 1 • oil seal 2 • valve 3 • inner valve spring 4 •...
  • Page 272: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00251 CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEAD”. Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring...
  • Page 273: Removing The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: ACHTUNG: Do not use a hammer to drive the piston pin out.
  • Page 274 CYLINDERS AND PISTONS 2. Measure: • piston-to-cylinder clearance ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Measure cylinder bore “C” with the cyl- inder bore gauge.
  • Page 275: Checking The Piston Rings

    CYLINDERS AND PISTONS Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) <Limit>: 0.15 mm (0.006 in) f. If out of specification, replace the cylin- der, and the piston and piston rings as a set. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ EAS00263 CHECKING THE PISTON RINGS 1.
  • Page 276: Checking The Piston Pins

    CYLINDERS AND PISTONS Piston ring end gap Top ring 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) <Limit>: 0.65 mm (0.026 in) 2nd ring 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) <Limit>: 0.80 mm (0.031 in) Oil ring 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of...
  • Page 277: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS 4. Calculate: • piston pin-to-piston pin bore clearance Out of specification → Replace the piston pin. Piston pin-to-piston pin bore clearance = Piston pin bore diameter (in the pis- ton) b – Piston pin outside diameter a Piston pin-to-piston pin bore clearance 0.004 ~ 0.024 mm...
  • Page 278 CYLINDERS AND PISTONS 3. Install: • dowel pins 1 • gasket 2 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: • piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring Å...
  • Page 279: Clutch

    CLUTCH EAS00273 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Left side cover Refer to “SEATS AND SIDE COVERS” in chapter 3. Engine left side cover Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”.
  • Page 280 CLUTCH Order Job/Part Q’ty Remarks Clutch cover gasket Dowel pin For installation, reverse the removal procedure. 5 - 61...
  • Page 281 CLUTCH Order Job/Part Q’ty Remarks Removing the pull lever shaft and Remove the parts in the order listed. pickup coil Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Pickup coil lead holder Pickup coil For installation, reverse the removal procedure.
  • Page 282 CLUTCH EAS00274 Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Generator rotor cover Refer to “GENERATOR”. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Clutch plate Lock washer Wire circlip Clutch plate...
  • Page 283 CLUTCH Order Job/Part Q’ty Remarks Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key For installation, reverse the removal procedure. 5 - 64...
  • Page 284: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: • clutch cable holder 1 • clutch cover 2 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. 2.
  • Page 285: Checking The Friction Plates

    CLUTCH NOTE: While holding the generator rotor 2 with the sheave holder 3, loosen the pickup coil rotor bolt. Sheave holder YS-01880 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: • friction plate Damage/wear →...
  • Page 286: Checking The Clutch Spring Plate

    CLUTCH EAS00283 CHECKING THE CLUTCH SPRING PLATE 1. Check: • clutch spring plate 1 Damage → Replace. 2. Check: • clutch spring plate seat 2 Damage → Replace. EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs → Damage/pitting/wear Deburr clutch housing dogs or replace the clutch...
  • Page 287: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth a • pull rod teeth b Damage/wear → Replace the pull lever shaft and pull rod as a set. 2. Check: •...
  • Page 288: Installing The Primary Drive Gear

    CLUTCH 3. Install: • bearings • oil seals 1 NOTE: Lubricate the oil seal lips with lithium soap base grease. 4. Install: • pull lever shaft 1 • washer • circlip EAS00303 INSTALLING THE PRIMARY DRIVE GEAR 1. Install: • straight key 1 •...
  • Page 289: Installing The Clutch

    CLUTCH EAS00296 INSTALLING THE CLUTCH 1. Install: • dowel pin 1 • oil pump drive gear 2 • plate 3 • circlip 4 2. Install: • clutch housing 1 • thrust washer 2 NOTE: • Lubricate the clutch housing bearings with engine oil.
  • Page 290 CLUTCH Universal clutch holder YM-91042 5. Bend the lock washer tab along a flat side of the nut. 6. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • friction plates • clutch plates NOTE: •...
  • Page 291 CLUTCH 9. Install: • clutch spring plate seat 1 • clutch spring plate 2 • clutch spring plate retainer 3 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 10.Install: •...
  • Page 292 CLUTCH 14.Install: • pull lever spring • pull lever NOTE: If there is no free play in the clutch, install the pull lever to the pull lever shaft in order to get the distance a between the pull lever and clutch cable holder to 31.8 mm (1.25 in). 15.Connect: •...
  • Page 293: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft and stop- Remove the parts in the order listed. per lever Engine oil Drain. Clutch housing Refer to “CLUTCH”. Circlip Shift shaft spring Shift shaft Shift shaft spring stopper Lock washer Stopper lever Stopper lever spring...
  • Page 294: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift lever spring 2 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stop- per lever.
  • Page 295 SHIFT SHAFT 4. Install: • shift shaft spring • circlips • shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2. 5. Install: • clutch housing Refer to “CLUTCH”. 6. Fill: •...
  • Page 296: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat/left side cover/fuel tank Refer to “SEATS AND SIDE COVERS” and “FUEL TANK” in chapter 3. Muffler/exhaust pipes Refer to “ENGINE”.
  • Page 297 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal procedure. 5 - 78...
  • Page 298 GENERATOR AND STARTER CLUTCH EAS00343 Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Starter clutch gear For installation, reverse the removal...
  • Page 299: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover 1 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 300: Installing The Generator

    GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear counterclockwise ı, it should turn freely, otherwise the starter clutch is faulty and must be replaced. ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ EAS00354 INSTALLING THE GENERATOR 1.
  • Page 301 GENERATOR AND STARTER CLUTCH 4. Apply: • sealant (onto the stator coil assembly lead grom- met)  Quick Gasket ACC-11001-05-01 5. Install: • stator coil assembly 1 7 Nm (0.7 m · kg, 5.1 ft · lb) • stator coil assembly lead holder 7 Nm (0.7 m ·...
  • Page 302 GENERATOR AND STARTER CLUTCH 9. Connect: • decompression solenoid couplers • stator coil assembly coupler NOTE: Refer to “CABLE ROUTING” in chapter 2. 10.Install: • rider footrest (right) 1 48 Nm (4.8 m · kg, 35 ft · lb) 11.Connect: •...
  • Page 303 GENERATOR AND STARTER CLUTCH 14.Install: • exhaust pipes • muffler Refer to “ENGINE”. 15.Install: • fuel tank • left side cover • rider seat Refer to “FUEL TANK” and “SEATS AND SIDE COVERS” in chapter 3. 5 - 84...
  • Page 304: Transfer Gear Case

    TRANSFER GEAR CASE TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Removing the battery box Remove the parts in the order listed. Rider seat/side covers Refer to “SEATS AND SIDE COVERS” in chapter 3. Negative battery lead Positive battery lead Disconnect. Tool kit holder Tool kit Battery holder...
  • Page 305 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Ignitor unit Battery box Relay unit coupler Disconnect. Turn signal relay coupler Disconnect. Plastic clamp Relay bracket For installation, reverse the removal procedure. 5 - 86...
  • Page 306 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Removing the oil tank cover Remove the parts in the order listed. Muffler/exhaust pipes Refer to “ENGINE”. Engine oil Drain. Oil tank breather hose Disconnect. Dipstick Dipstick joint Oil pipe #1 Oil pipe #2 Oil tank cover Oil tank cover gasket Dowel pin...
  • Page 307 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Removing the transfer gear case Remove the parts in the order listed. Transfer gear oil Drain. Drive pulley Refer to “DRIVE BELT AND DRIVE PUL- LEY” in chapter4. Drive pulley case Dowel pin Cover Dowel pin Transfer gear oil pump...
  • Page 308 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Lock washer Primary chain Middle drive gear Middle driven shaft Transfer gear case Spacer Dowel pin Oil seal Bearing For installation, reverse the removal procedure. 5 - 89...
  • Page 309 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Disassembling the transfer gear Remove the parts in the order listed. case oil pump Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
  • Page 310: Removing The Battery

    TRANSFER GEAR CASE REMOVING THE BATTERY 1. Disconnect: • battery leads (from the battery terminals) WARNING WARNING First, disconnect the negative battery lead, then the positive battery lead. REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before removing the drive pulley.
  • Page 311: Checking The Oil Strainer

    TRANSFER GEAR CASE 2. Check: • primary chain 1 Damage/stiffness → Replace the primary chain, middle drive gear and middle driven shaft as a set. CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. CHECKING THE OIL PUMP 1.
  • Page 312: Checking The Oil Pipe

    TRANSFER GEAR CASE 3. Check: • oil pump operation Unsmooth → Repair or replace the defec- tive part(s). CHECKING THE OIL PIPE 1. Check: • oil pipe Damage → Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor •...
  • Page 313: Installing The Transfer Gear Case

    TRANSFER GEAR CASE 3. Install: • pins 1 • oil pump cover 2 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE:  Apply locking agent (LOCTITE ) to the threads of the oil pump cover screws. 4. Check: •...
  • Page 314 TRANSFER GEAR CASE 4. Install: • transfer gear case cover 1 10 Nm (1.0 m · kg, 7.2 ft · lb) 5. Install: • dowel pins 1 6. Install: • transfer gear case assembly 1 NOTE: • While installing the middle drive gear 2 onto the drive axle, install the transfer gear case assembly onto the engine.
  • Page 315 TRANSFER GEAR CASE 10.Remove: • drive pulley nut 11.Install: • transfer gear oil pump gasket • transfer gear oil pump 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE:  Apply locking agent (LOCTITE ) only to the threads of the transfer gear oil pump bolts 2 (M6 ×...
  • Page 316: Installing The Oil Tank Cover

    TRANSFER GEAR CASE 15.Install: • drive pulley case 1 30 Nm (3.0 m · kg, 22 ft · lb) 16.Install: • drive pulley Refer to “DRIVE BELT AND DRIVE PUL- LEY” in chapter 4. 17.Fill: • transfer gear case (with the specified amount of the recom- mended transfer gear oil) Refer to “CHANGING THE TRANSFER GEAR OIL”...
  • Page 317: Installing The Battery

    TRANSFER GEAR CASE 3. Install: • dipstick joint 1 • dipstick 2 NOTE: Finger tighten the dipstick joint bolt. 4. Connect: • oil tank breather hose 3 5. Install: • oil pipes 1 10 Nm (1.0 m · kg, 7.2 ft · lb) INSTALLING THE BATTERY 1.
  • Page 318 TRANSFER GEAR CASE 6. Install: • plastic bracket 7. Install: • negative battery lead 1 (to the dipstick joint) 8. Install: • battery 1 • battery holder 2 • tool kit 3 • tool kit holder 4 9. Connect: • battery leads (to the battery terminals) CAUTION: ACHTUNG:...
  • Page 319 CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Camshaft Refer to “CAMSHAFTS”. Piston Refer to “CYLINDERS AND PISTONS”. Shift shaft Refer to “SHIFT SHAFT”. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 320 CRANKCASE Order Job/Part Q’ty Remarks Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase For installation, reverse the removal procedure. 5 - 101...
  • Page 321 CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and bear- Remove the parts in the order listed. ings Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Baffle plate Oil seal Bearing Installation, reverse the removal proce- dure. 5 - 102...
  • Page 322 CRANKCASE EAS00386 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before removing the generator rotor. 1. Remove: • generator shaft bolt 1 NOTE: While the holding the generator rotor 2 with the sheave holder 3, loosen the gen- erator shaft bolt. Sheave holder YS-01880 2.
  • Page 323: Crankcase

    CRANKCASE 4. Remove: • right crankcase CAUTION: ACHTUNG: • First check that the shift drum segment’s teeth then remove the right crankcase. • Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces.
  • Page 324: Checking The Oil Delivery Pipe

    CRANKCASE CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. • O-rings 2 Damage/wear → Replace. CHECKING THE ENGINE OIL PUMP DRIVE 1. Check: • oil pump drive gear 1 •...
  • Page 325 CRANKCASE 4. Install: Å • crankcase bolts NOTE: • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • Tighten the bolts in numerical order (refer to the numbers in the illustration).
  • Page 326 CRANKCASE 8. Install: • washer • generator shaft bolt 1 28 Nm (2.8 m · kg, 20 ft · lb) NOTE:  • Apply locking agent (LOCTITE ) to the threads of the generator shaft bolt. • While holding the generator rotor 2 with the sheave holder 3, tighten the genera- tor shaft bolt.
  • Page 327: Engine Oil Pump

    ENGINE OIL PUMP ENGINE OIL PUMP Order Job/Part Q’ty Remarks Removing the engine oil pump Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Oil strainer Engine oil pump assembly Installation, reverse the removal proce- dure. 5 - 108...
  • Page 328 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Disassembling the engine oil pump Remove the parts in the order listed. Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Ball Oil pump outer rotor 1 Oil pump inner rotor 1 5 - 109...
  • Page 329 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2 Oil pump outer rotor 2 Oil seal Oil pump housing For assembly, reverse the disassembly procedure. 5 - 110...
  • Page 330: Checking The Oil Pump

    ENGINE OIL PUMP EAS00363 CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump housing covers 2 → Cracks/damage/wear Replace defective part(s). 2. Measure: • inner rotor-to-outer rotor tip clearance a • outer rotor-to-oil pump housing clear- ance b Out of specification →...
  • Page 331: Checking The Oil Strainer

    ENGINE OIL PUMP 2. Check: • ball 1 • spring 2 • oil seal 3 Damage/wear → Replace the defective part(s). EAS00368 CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 Damage → Replace. Contaminants → Clean with engine oil. EAS00374 ASSEMBLING THE OIL PUMP 1.
  • Page 332: Installing The Oil Pump

    ENGINE OIL PUMP • spring G • spring retainer H 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor. 3.
  • Page 333: Crankshaft And Connecting Rods

    CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS Order Job/Part Q’ty Remarks Removing the crankshaft and con- Remove the parts in the order listed. necting rods Crankcase Separate. Refer to “CRANKCASE”. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal...
  • Page 334: Removing The Crankshaft

    CRANKSHAFT AND CONNECTING RODS REMOVING THE CRANKSHAFT 1. Remove: • crankshaft journal bearing 1 NOTE: Remove the crankshaft journal bearing with the bearing remover and installer 2 and bearing driver 3. Bearing remover and installer YM-28898 Bearing driver YM-04058 EAS00391 REMOVING THE CONNECTING RODS 1.
  • Page 335 CRANKSHAFT AND CONNECTING RODS 3. Measure: • crankshaft pin-to-big end bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft pin-to-big end bearing clearance 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) <Limit>: 0.09 mm (0.0035 in) ▼...
  • Page 336 CRANKSHAFT AND CONNECTING RODS e. Tighten the connecting rod bolts. CAUTION: ACHTUNG: • When tightening the connecting rod bolts, be sure to use an F-type torque wrench. • Without pausing, tighten the connecting rod bolts to the specified torque. Apply continuous torque between 3.3 and 4.0 m •...
  • Page 337 CRANKSHAFT AND CONNECTING RODS 4. Select: • big end bearings (P NOTE: • The numbers a stamped into the crank- shaft web and the numbers b on the con- necting rods are used to determine the replacement big end bearing sizes. •...
  • Page 338: Installing The Connecting Rods

    CRANKSHAFT AND CONNECTING RODS 6. Measure: • crankshaft journal bearing inside diame- ter a Out of specification → Replace the crankcase assembly. Crankshaft journal bearing inside diameter 50.01 ~ 50.03 mm (1.969 ~ 1.970 in) NOTE: Measure the inside diameter of each crank- shaft journal bearing at two places.
  • Page 339 CRANKSHAFT AND CONNECTING RODS 2. Lubricate: • crankshaft pins • big end bearings • connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. Install: • big end bearings • connecting rods • connecting rod caps (onto the crankshaft pins) NOTE: •...
  • Page 340: Installing The Crankshaft

    CRANKSHAFT AND CONNECTING RODS INSTALLING THE CRANKSHAFT 1. Install: • generator shaft 1 2. Install: • crankshaft NOTE: • Make sure that the generator shaft drive gear teeth and generator shaft driven gear teeth mesh correctly. • Align the right connecting rod with the front cylinder sleeve hole.
  • Page 341 TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the shift forks, shift drum Remove the parts in the order listed. assembly and transmission Crankcase Separate. Refer to “CRANKCASE”. Shift fork guide bar Shift fork “L” Shift fork “R” Shift fork “C” Shift drum assembly Drive axle assembly Main axle assembly...
  • Page 342 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle assem- Remove the parts in the order listed. Circrip Washer 5th pinion gear 2nd/3rd pinion gear Circlip Washer 4th pinion gear Main axle/1st pinion gear For assembly, reverse the disassembly procedure. 5 - 123...
  • Page 343: Transmission

    TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle assem- Remove the parts in the order listed. 5th wheel gear Circlip Washer 2nd wheel gear Circlip Washer 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle For assembly, reverse the disassembly procedure.
  • Page 344: Checking The Shift Forks

    TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat sur- face.
  • Page 345: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge Out of specification → Replace the main axle. Maximum main axle runout 0.08 mm (0.003 in) 2. Measure: • drive axle runout (with a centering device and dial gauge Out of specification →...
  • Page 346 TRANSMISSION 2. Install: • shift drum assembly 1 • shift fork “R” • shift fork “C” • shift fork “L” • shift fork guide bars NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”.
  • Page 347 CARB CONTENTS CARBURETOR CARBURETOR ....................6-1 CHECKING THE CARBURETOR ............6-6 CHECKING THE CARBURETOR JOINT ..........6-8 ASSEMBLING THE CARBURETOR ............. 6-8 INSTALLING THE CARBURETOR JOINT .......... 6-12 INSTALLING THE CARBURETOR ............6-12 MEASURING AND ADJUSTING THE FUEL LEVEL ......6-14 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..................
  • Page 348 CARB CHECKING THE AIR INDUCTION SYSTEM ........6-26 INSTALLING THE AIR INDUCTION SYSTEM ........6-26...
  • Page 349 CARB CARBURETOR EAS00480 CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Rider seat Refer to “SEATS AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE”...
  • Page 350: Carburetor

    CARB CARBURETOR Order Job/Part Q’ty Remarks Charcoal canister hose Disconnect. (carburetor to charcoal canister) Carburetor heater connector Disconnect. Carburetor Fuel pump bracket assembly (with fuel pump) Vacuum hose Disconnect. Carburetor joint For installation, reverse the removal procedure. 6 - 2...
  • Page 351 CARB CARBURETOR EAS00483 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Throttle stop screw Vacuum chamber air vent hose Fuel strainer Throttle cable holder Throttle position sensor bracket Carburetor heater Coasting enricher cover Coasting enricher spring Coasting enricher 6 - 3...
  • Page 352 CARB CARBURETOR Order Job/Part Q’ty Remarks Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit Piston valve Float chamber Float chamber rubber gasket Drain bolt Accelerator plunger Float pivot pin 6 - 4...
  • Page 353 CARB CARBURETOR Order Job/Part Q’ty Remarks Float Needle valve Needle valve seat Main jet Spacer Needle jet Pilot jet Starter jet Pilot air jet For assembly, reverse the disassembly procedure. 6 - 5...
  • Page 354: Checking The Carburetor

    CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 355 CARB CARBURETOR 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage →...
  • Page 356: Checking The Carburetor Joint

    CARB CARBURETOR 13.Check: • coasting enricher cover 1 • coasting enricher spring 2 Cracks/damage → Replace. • coasting enricher 3 Cracks/tears/damage → Replace. 14.Check: • accelerator plunger 1 • accelerator plunger spring 2 Bends/cracks/damage → Replace. • O-ring 3 Damage/wear → Replace. 15.Check: •...
  • Page 357 CARB CARBURETOR 1. Install: • pilot air jet 1 2. Install: • starter jet • pilot jet 2 3. Install: • needle jet 1 NOTE: Align the slot a on the needle jet with the projection b on the carburetor body. 4.
  • Page 358 CARB CARBURETOR 6. Install: • needle valve • float 1 • float pin 2 7. Install: • accelerator plunger 1 • drain bolt 2 • float chamber rubber gasket 3 8. Install: • float chamber 1 9. Install: • piston valve 1 •...
  • Page 359 CARB CARBURETOR 10.Install: • coasting enricher 1 • coasting enricher spring • coasting enricher cover 2 NOTE: Align the tab a on the coasting enricher with the recess b in the carburetor body. 11.Install: • terminal 1 • washer • carburetor heater 2 2.5 Nm (0.25 m ·...
  • Page 360: Installing The Carburetor Joint

    CARB CARBURETOR 13.Install: • throttle stop screw • drain hose INSTALLING THE CARBURETOR JOINT 1. Install: • carburetor joint 1 12 Nm (1.2 m · kg, 8.7 ft · lb) 2. Connect: • vacuum hose 2 EAS00492 INSTALLING THE CARBURETOR 1.
  • Page 361 CARB CARBURETOR 5. Connect: • fuel hose 1 6. Connect: • throttle cables 1 7. Connect: • float chamber breather hose (carburetor to solenoid valve) 1 8. Hook: • throttle stop screw 1 9. Install: • carburetor NOTE: Align the projection a of the carburetor with slot of the carburetor joint.
  • Page 362: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR 11.Adjust: • engine idling speed Engine idling speed 850 ~ 950 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 12.Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 4 ~ 8 mm (0.16 ~ 0.31 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
  • Page 363: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETOR 2. Adjust: • fuel level ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Remove the carburetor. b. Check the needle valve seat and needle valve.
  • Page 364 CARB CARBURETOR d. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → yellow terminal 3 Negative tester probe → black terminal 2 e. While slowly opening the throttle, check that the throttle position sensor resis- tance is within the specified range.
  • Page 365 CARB CARBURETOR d. Measure the maximum throttle position sensor resistance. Out of specification → Replace the throt- tle position sensor. Maximum throttle position sen- sor resistance 4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F) (blue — black/blue) e. Connect the pocket tester (Ω × 1k) to the throttle position sensor coupler.
  • Page 366 CARB CARBURETOR 3. Adjust: • throttle position sensor angle ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a. Disconnect the throttle position sensor coupler from the wire harness.
  • Page 367: Checking The Fuel Pump

    CARB CARBURETOR EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ a.
  • Page 368: Checking The Fuel Cock Operation

    CARB CARBURETOR 6. Install: • fuel cock 7. Connect: • fuel hose EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its oper- ation. 1. Set the fuel cock to “OFF”. 2. Disconnect: • fuel hose (from the fuel cock) 3.
  • Page 369: Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (sec- ondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allow- ing secondary air to flow into the exhaust port.
  • Page 370 CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve Å To the carburetor joint ı To the front cylinder head 2 Air cut valve Ç To the rear cylinder head 3 Air cleaner Î To the air cut valve 4 Carburetor joint 6 - 22...
  • Page 371 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Removing the air induction system Remove the parts in the order listed. fuel tank Refer to “FUEL TANK” in chapter 3. Reed valve case to rear cylinder head hose Reed valve case to rear cylinder head pipe Reed valve case to front cylinder head hose...
  • Page 372 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Air filter Air filter cover Air filter hose Air cut valve to air filter hose Plastic locking tie Vacuum hose Bracket Air cut valve holder Air cut valve Air cut valve to reed valve cover hose Reed valve cover Reed valve case...
  • Page 373 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Reed valve base Reed valve stopper Reed valve For installation, reverse the removal procedure. 6 - 25...
  • Page 374 CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: • fibre reed 1 • fibre reed stopper • reed valve seat Cracks/damage →...
  • Page 375 CARB AIR INDUCTION SYSTEM 2. Install: • reed valve case 1 • reed valve cover • bracket 2 3. Install: • air cut valve to reed valve cover hose 1 • air cut valve 2 • air cut valve holder 3 4.
  • Page 376 CARB AIR INDUCTION SYSTEM 7. Install: • air filter 1 • air filter hose 2 • air filter cover 3 8. Install: • air filter bracket 1 9. Install: • air filter case assembly 1 10.Install: • rectifier/regulator 1 11.Connect: •...
  • Page 377 CARB AIR INDUCTION SYSTEM 13.Install: • fuel tank Refer to “FUEL TANK” in chapter 3. 6 - 29...
  • Page 378 – ELEC CONTENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..............7-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ....................7-2 SWITCHES ....................7-6 CHECKING SWITCH CONTINUITY ............7-6 CHECKING THE SWITCHES ................ 7-7 CHECKING THE BULBS AND BULB SOCKETS .......... 7-9 TYPES OF BULBS ................. 7-9 CHECKING THE CONDITION OF THE BULBS ........
  • Page 379 – ELEC IGNITION SYSTEM ..................7-12 CIRCUIT DIAGRAM ................7-12 TROUBLESHOOTING ................. 7-13 ELECTRIC STARTING SYSTEM ..............7-17 CIRCUIT DIAGRAM ................7-17 STARTING CIRCUIT CUTOFF SYSTEM OPERATION ...... 7-18 TROUBLESHOOTING ................. 7-19 STARTER MOTOR ..................7-23 CHECKING THE STARTER MOTOR ..........7-25 ASSEMBLING THE STARTER MOTOR ..........
  • Page 380: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ESA00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS A Battery K Stator coil assembly 1 Wire harness B Starter relay L Rear brake light switch 2 Main switch C Main fuse M Rectifier/regulator 3 Front brake light switch D Thermo switch 4 Ignition coils E Fuse box 5 Throttle position sensor...
  • Page 381: Arrangement Of The Electrical Components And Couplers

    ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Right handlebar switch coupler, left handlebar switch couplers and front turn signal connectors 2 Headlight coupler 1 Tail/brake light connectors and rear turn signal connectors 7 - 2...
  • Page 382 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Spark plug cap #3 5 Carburetor heater sub-wire 8 Spark plug cap #2 2 Rear brake light switch cou- 9 Spark plug cap #1 harness coupler pler 6 Throttle position sensor 0 Fuel pump 3 Ignition coil (front cylinder) A Fuel pump coupler...
  • Page 383 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Fuse box 2 Stator coil coupler, decompression solenoid couplers, pickup coil coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler 3 Battery negative lead 4 Battery positive lead 5 Battery 6 Ignitor unit 7 Tail/brake light and rear turn signal light sub-wire harness coupler...
  • Page 384 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Carburetor heater 5 Main switch 9 Rear brake light switch 2 Throttle position sensor 6 Solenoid valve coupler 3 Ignition coil (rear cylinder) 7 Solenoid valve 4 Main switch coupler 8 Spark plug cap #4 1 Diode 5 Decompression solenoid...
  • Page 385: Switches

    – ELEC SWITCHES EAS00730 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: ACHTUNG: Never insert the tester probes into the cou- pler terminal slots 1.
  • Page 386: 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 terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 387 – ELEC CHECKING THE SWITCHES 1 Dimmer switch 9 Fuse 2 Horn switch 0 Rear brake light switch 3 Turn signal switch A Sidestand switch 4 Clutch switch B Neutral switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch 7 - 8...
  • Page 388: 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 dam- age or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 389 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: ACHTUNG: • Be sure to hold the socket firmly when removing the bulb.
  • Page 390: 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 YU-03112 NOTE:...
  • Page 391: Ignition System

    – ELEC IGNITION SYSTEM EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 7 - 12...
  • Page 392: Troubleshooting

    – ELEC IGNITION SYSTEM EB802401 EB802011 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: Minimum open-circuit voltage 1.
  • Page 393 – ELEC IGNITION SYSTEM EB802405 4.Ignition spark gap The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the dynamic spark tester 1 as shown. 2 Spark plug cap •...
  • Page 394 – ELEC IGNITION SYSTEM EB802411 8.Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Replace the main Secondary coil resistance switch. 12 ~ 18 kΩ at 20 ˚C (68 ˚F) •...
  • Page 395 – ELEC IGNITION SYSTEM EB802415 12.Diode 13.Relay unit (diode) • Remove the diode from the coupler. • Remove the relay unit from the coupler. • Connect the pocket tester (Ω × 1) to the • Connect the pocket tester (Ω × 1) to the diode terminals as shown.
  • Page 396: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7 - 17...
  • Page 397: Starting Circuit Cutoff System Operation

    – ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 398: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB802401 EB803020 TROUBLESHOOTING 2.Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2.
  • Page 399 – ELEC ELECTRIC STARTING SYSTEM EB803403 EB803402 4.Relay unit (starting circuit cutoff relay) 5.Relay unit (diode) • Disconnect the relay unit from the cou- • Disconnect the relay unit from the cou- pler. pler. • Connect the pocket tester (Ω × 1) and •...
  • Page 400 – ELEC ELECTRIC STARTING SYSTEM EB802412 EB803404 6.Starter relay 8.Engine stop switch • Disconnect the starter relay from the • Check the engine stop switch for conti- coupler. nuity. • Connect the pocket tester (Ω × 1) and Refer to “CHECKING THE SWITCHES”. •...
  • Page 401 – ELEC ELECTRIC STARTING SYSTEM EB803406 11.Diode 13.Start switch • Remove the diode from the coupler. • Check the start switch for continuity. • Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”. diode terminals as shown. •...
  • Page 402 – ELEC STARTER MOTOR EB803500 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. 7 - 23...
  • Page 403 – ELEC STARTER MOTOR EB803501 Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Circlip Starter motor Starter motor rear cover Lock washer Oil seal Bearing Washer set Starter motor front cover Washer set O-ring Armature assembly Brush seat (along with the brushes)
  • Page 404: Checking The Starter Motor

    – ELEC STARTER MOTOR EB803511 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. Minimum commutator diameter 27 mm (1.06 in) 3.
  • Page 405: Assembling The Starter Motor

    – ELEC STARTER MOTOR 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Minimum brush length 5 mm (0.20 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.
  • Page 406: Installing The Starter Motor

    – ELEC STARTER MOTOR 3. Install: • armature assembly 4. Install: • bearing • oil seal • lock washer 1 5. Install: • O-rings 1 • starter motor rear cover 2 • starter motor front cover 3 • bolts 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the...
  • Page 407: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM (BLACK) Br/L (BLACK) Br/L Br/L (BLACK) 1 Generator 2 Rectifier/regulator 4 Battery 5 Main fuse 7 - 28...
  • Page 408: Troubleshooting

    – ELEC CHARGING SYSTEM EB802401 EB804010 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse Open-circuit voltage 2. battery 12.8 V or more at 20 ˚C (68 ˚F) 3.
  • Page 409 – ELEC CHARGING SYSTEM EB804404 NOTE: 5.Wiring Make sure that the battery is fully • Check the wiring connections of the charged. entire charging system. • Is the charging voltage within specifica- Refer to “CIRCUIT DIAGRAM”. tion? • Is the charging system’s wiring properly connected and without defects? The charging circuit is OK.
  • Page 410: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 - 31...
  • Page 411: Troubleshooting

    – ELEC LIGHTING SYSTEM EB802401 EB805010 TROUBLESHOOTING 2.Battery Any of the following fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING position light or meter light. THE BATTERY” in chapter 3. Open-circuit voltage Check: 12.8 V or more at 20 ˚C (68 ˚F)
  • Page 412: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805404 EB805410 CHECKING THE LIGHTING SYSTEM 5.Wiring 1. The headlight and the high beam indica- • Check the entire lighting system’s wir- tor light fail to come on. ing. 1.Headlight bulb and socket Refer to “CIRCUIT DIAGRAM”. •...
  • Page 413 – ELEC LIGHTING SYSTEM EB805411 Headlight 2. A meter light fails to come on. Tester positive probe → yellow 1 or green 2 1.Meter light bulb and socket Tester negative probe → black 3 • Check the meter light bulb and socket High beam indicator light Tester positive probe →...
  • Page 414 – ELEC LIGHTING SYSTEM 4. The front turn signal/position light fails EB805412 3. A tail/brake light fails to come on. to come on. 1.Tail/brake light bulb and socket 1.Front turn signal/position light bulb and • Check the tail/brake light bulb and socket socket for continuity.
  • Page 415: Signaling System

    – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 - 37...
  • Page 416 – ELEC SIGNALING SYSTEM 3 Main switch 4 Battery 5 Main fuse 8 Backup fuse B Ignitor unit G Neutral switch J Engine trouble indicator light K Turn signal indicator light L Neutral indicator light M Speedometer assembly (speedometer, combination meter and fuel level meter) N Fuel level indicator light Q Fuel sender R Turn signal relay...
  • Page 417: Troubleshooting

    – ELEC SIGNALING SYSTEM EB802401 EB806010 TROUBLESHOOTING 2.Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING THE BATTERY” in light. chapter 3. •...
  • Page 418: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EB806410 3.Horn CHECKING THE SIGNALING SYSTEM 1.The horn fails to sound. • Disconnect the horn coupler at the horn. • Connect a jumper lead 1 to the brown 1.Horn switch terminal in the horn coupler and the •...
  • Page 419 – ELEC SIGNALING SYSTEM EB806411 • Set the main switch to “ON”. 2. A tail/brake light fails to come on. • Pull in the brake lever or push down on 1.Tail/brake light bulb and socket the brake pedal. • Measure the voltage (12 V) of yellow at •...
  • Page 420 – ELEC SIGNALING SYSTEM 3.Turn signal switch • Check the turn signal switch for continu- ity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? Replace the left han- • Set the main switch to “ON”. dlebar switch. •...
  • Page 421 – ELEC SIGNALING SYSTEM ı 2.Neutral switch • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? Replace the neutral switch. • Set the main switch to “ON”. • Set the turn signal switch to “ ”...
  • Page 422 – ELEC SIGNALING SYSTEM EB806417 3.Voltage 5. The fuel level indicator light, fuel level meter or both fail to come on. • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire har- 1.Fuel level indicator light LED ness side) as shown.
  • Page 423 – ELEC SIGNALING SYSTEM EAS00843 2.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? Replace the ignitor Repair or replace unit. the wire harness. 7 - 45...
  • Page 424: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7 - 46...
  • Page 425: Fuel Pump Circuit Operation

    – ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump 7 - 47...
  • Page 426: Troubleshooting

    – ELEC FUEL PUMP SYSTEM EAS00739 EB808020 TROUBLESHOOTING 2.Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open circuit voltage 2.
  • Page 427 – ELEC FUEL PUMP SYSTEM 5.Relay unit (fuel pump relay) • Measure the fuel pump resistance. • Disconnect the relay unit from the cou- Fuel pump resistance 1.6 ~ 2.2 Ω at 20 ˚C (68 ˚F) pler. • Connect the pocket tester (Ω × 1) and •...
  • Page 428: Checking The Fuel Pump

    – ELEC FUEL PUMP SYSTEM EB808410 CHECKING THE FUEL PUMP WARNING WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refuelling. •...
  • Page 429: Carburetor Heating System

    – ELEC CARBURETOR HEATING SYSTEM EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM 7 - 51...
  • Page 430: Troubleshooting

    – ELEC CARBURETOR HEATING SYSTEM EAS00739 EAS00821 TROUBLESHOOTING 2.Battery The carburetor heating system fails to • Check the condition of the battery. operate. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Minimum open circuit voltage 1. Main and carburetor heater fuses 12.8 V or more at 20 ˚C (68 ˚F) 2.
  • Page 431 – ELEC CARBURETOR HEATING SYSTEM WARNING WARNING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. • Does the thermo switch operate prop- erly? Replace the thermo switch.
  • Page 432 – ELEC CARBURETOR HEATING SYSTEM EAS00754 6.Wiring • Check the entire carburetor heating sys- tem’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the carburetor heating system’s wir- ing properly connected and without defects? This circuit is OK. Properly connect or repair the carbu- retor heating sys- tem’s wiring.
  • Page 433 – ELEC SELF-DIAGNOSIS EB812000 SELF-DIAGNOSIS The XV16AL/XV16ALC/XV16ATL/XV16ATLC features a self-diagnosing system for the follow- ing circuit(s): • throttle position sensor • speed sensor • decompression solenoid • fuel level meter If any of these circuits is defective, the respective condition code will be displayed by the engine trouble indicator light or fuel level indicator light when the main switch is set to “ON”...
  • Page 434: Self-Diagnosis

    – ELEC SELF-DIAGNOSIS Display order on the engine trouble indicator light and fuel level indicator light 1 Engine trouble indicator light 2 Fuel level indicator light 1 Indicator lights check.......1.4 seconds 2 Light off ............3 seconds 3 Condition code.........First fault code (3 = throttle position sensor) 4 Condition code.........Next fault code (4 = speed sensor) 5 Light on ............0.5 second 6 Light off ............0.5 second...
  • Page 435 – ELEC SELF-DIAGNOSIS EB812010 EAS00843 TROUBLESHOOTING 1.Wire harness The engine trouble indicator light or the • Check the wire harness for continuity. fuel level indicator light starts to blink, Refer to “CIRCUIT DIAGRAM”. display the self-diagnosis sequence. • Is the wire harness OK? Check: 1.
  • Page 436 – ELEC SELF-DIAGNOSIS 2. Speed sensor CIRCUIT DIAGRAM B Ignitor unit H Speed sensor EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? Replace the speed sensor. Replace the ignitor Repair or replace unit.
  • Page 437 – ELEC SELF-DIAGNOSIS 3. Decompression solenoid CIRCUIT DIAGRAM B Ignitor unit E Decompression solenoid EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? • Measure the decompression solenoid resistance. Repair replace the wire harness.
  • Page 438 – ELEC SELF-DIAGNOSIS EB812403 • Check the decompression solenoid for 1.Fuel level indicator light LED continuity. • Check the LED of the fuel level indicator • Is the decompression solenoid OK? light. Refer to “CHECKING THE LEDs”. • Is the fuel level indicator light LED OK? Replace the ignitor Replace the decom- unit.
  • Page 439 – ELEC SELF-DIAGNOSIS EAS00843 3.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? Replace the meter Replace or replace assembly. the wire harness. 7 - 61...
  • Page 440: Troubleshooting

    TRBL SHTG CONTENTS TROUBLESHOOTING STARTING PROBLEMS ................8-1 ENGINE ....................8-1 FUEL SYSTEM ..................8-1 ELECTRICAL SYSTEMS ............... 8-2 INCORRECT ENGINE IDLING SPEED ............8-2 ENGINE ....................8-2 FUEL SYSTEM ..................8-2 ELECTRICAL SYSTEMS ............... 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........ 8-3 ENGINE ....................
  • Page 441 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM ........... 8-5 HEADLIGHT DOES NOT LIGHT ............8-5 HEADLIGHT BULB BURNT OUT ............8-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ..........8-5 TAIL/BRAKE LIGHT BULB BURNT OUT ..........8-5 TURN SIGNAL DOES NOT LIGHT ............8-5 TURN SIGNAL BLINKS SLOWLY ............
  • Page 442 TRBL STARTING PROBLEMS SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative proce- dure in this manual for checks, adjustments, and replacement of parts. STARTING PROBLEMS ENGINE FUEL SYSTEM...
  • Page 443: Incorrect Engine Idling Speed

    STARTING PROBLEMS/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Ignition system (See page 7-12 to 7-16) Battery (See page 3-51 to 3-56) • Faulty ignitor unit • Faulty battery • Faulty pickup coil • Discharged battery Switches and wiring (See page 7-7 to 7-8) Fuses (See page 3-56 to 3-58) •...
  • Page 444: Faulty Gear Shifting

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE FUEL SYSTEM Air filter (See page 3-7 and 3-29) Carburetor (See page 6-1 to 6-20) • Clogged air filter element • Faulty diaphragm •...
  • Page 445 OVERHEATING/POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00855 OVERHEATING ENGINE CHASSIS Cylinder heads and pistons (See page 5-53 Brakes (See page 3-34 to 3-38 and 4-22 to to 5-59) 4-54) • Heavy carbon buildup • Dragging brake Engine oil (See page 3-20 to 3-21) ELECTRICAL SYSTEMS •...
  • Page 446: Unstable Handling

    UNSTABLE HANDLING/FAULTY LIGHTING OR TRBL SIGNALING SYSTEM SHTG EAS00864 UNSTABLE HANDLING Handlebar (See page 4-67 to 4-72) Rear shock absorber assembly • Bent or incorrectly installed handlebar (See page 4-79 to 4-89) Steering head components (See page 3-41 • Faulty rear shock absorber spring to 3-43 and 4-73 to 4-78) •...
  • Page 448 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 449 EAS00001 XV16AL/XV16ALC XV16ATL/XV16ATLC SERVICE MANUAL  1998 by Yamaha Motor Corporation, U.S.A. First Edition, October 1998 All rights reserved. Any reproduction or unautho- rized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.

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