TW125 RepairManual

EAS00000
TW125
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
1st Edition, July 1998
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTE:
WARNING
CAUTION:
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company 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,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo-
torcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
Yamaha Motor Company, Ltd., is continually striving to improve all its models. Modifications and signif-
icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person inspecting or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
1 2
5
7
6
4
3
8
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to SYMBOLS on the following page.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (Periodic Inspections and Adjustments), where the sub-section title(-s) appear.
(In Chapter 3, Periodic Inspections and Adjustments, the sub-section title appears at the top of each
page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS).
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
21
1
3
5
7
9
2
4
8
6
23 24
22 20
18 19 17
15
14 13
11 12
10
GEN
INFO
SPEC
ENG
CARB
ELEC
CHAS
CHK
ADJ
TRBL
SHTG
16
EAS00009
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Engine
5 Carburetor(-s)
6 Chassis
7 Electrical system
8 Troubleshooting
Symbols 9 to
16
indicate the following.
9 Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
Symbols
17
to
22
in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
Symbols
23
to
24
in the exploded diagrams indi-
cate the following:
23 Apply locking agent (LOCTITE
R
)
24 Replace the part
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
CARBURATION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
3
ENG
4
CARB
5
CHAS
6
ELEC
7
TRBL
SHTG
8
CHK
ADJ
INDEX
GEN
INFO

1
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 11 . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 12 . . . . . . . . . .
REPLACEMENT PARTS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 12 . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/ PLATES AND COTTER PINS 13 . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
MOTORCYCLE IDENTIFICATION
GEN
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.
EAS00018
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-2
GEN
INFO
EAS00020
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the SPECIAL TOOLS section.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
mated through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and apply grease onto
the oil seal lips.
1-3
GEN
INFO
OR
CAUTION:
EAS00023
LOCK WASHERS/ PLATES AND COTTER
PINS
1. After removal, replace all lock wash-
ers/ plates 1 and cotter pins. After the bolt or
nut has been tightened to specification, bend
the lock tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturers marks or numbers are vis-
ible. When installing oil seals, apply a light
coat of lithium soap base grease onto the oil
seal lips. Oil bearings liberally when instal-
ling, if appropriate.
1 Oil seal
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1 Bearing
EAS00025
CIRCLIPS
1. Before reassembly, check all circlips careful-
ly and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positioned op-
posite the thrust 3 that the circlip receives.
4 Shaft
1-4
CHECKING THE CONNECTIONS
GEN
INFO
NOTE:
NOTE:
NOTE:
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
S lead
S coupler
S connector
2. Check:
S lead
S coupler
S connector
Moisture ! Dry with an air blower.
Rust / stains ! Connect and disconnect sev-
eral times.
3. Check:
S all connections
Loose connection ! Connect properly.
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
S lead
S coupler
S connector
Make sure that all connections are tight.
5. Check:
S continuity
(with a pocket tester)
Pocket tester
90890-03112
S If there is no continuity, clean the terminals.
S When checking the wire harness, perform
steps 1 to 3.
S As a quick remedy, use a contact revitalizer
available at most part stores.
1-5
SPECIAL TOOLS
GEN
INFO
EAS00020
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/ Usage Illustration
90890-01080
90890-04052
Rotor puller
Attachment
These tools are used when removing the
generator rotor.
90890-01083
90890-01084
Rocker arm shaft puller bolt
Weight
These tools are used when removing or
installing the rocker arm shafts.
90890-01268 Ringnut wrench
This tool is used to loosen and tighten the ex-
haust and steering ringnut.
90890-01294
90890-01326
Damper rod holder
T-handle
This tool is used for disassembling or assem-
bling the front fork
90890-01311 Valve adjusting tool
This tool is necessary for adjusting valve
clearance.
90890-01312 Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01367
90890-01368
Fork seal driver weight
Fork seal driver attachment (33 mm)
This tool is used when installing the fork seal.
90890-01403 Ring nut wrench
This tool is used to loosen and tighten the
steering ring nut.
90890-01701 Sheave holder
This tool is used for holding the generator
rotor
1-6
SPECIAL TOOLS
GEN
INFO
90890-03079 Thickness gauge
This tool is used to measure the valve
clearance.
90890-03081
90890-04082
Compression gauge
Adaptor
These tools are used to measure the engine
compression.
90890-03112 Pocket tester
These instruments are invaluable for
checking the electrical system.
90890-03113 Engine tachometer
This tool is needed for detecting engine rpm.
90890-03141 Timing light
This tool is necessary for checking ignition
timing.
90890-04019
90890-04108
Valve spring compressor
Attachment
These tools are used when removing or
installing the valve and the valve spring.
90890-04064 Valve guide remover 6 mm
This tool is used to remove the valve guide.
90890-04065 Valve guide reamer 6 mm
This tool is used to rebore the valve guide.
90890-04066 Valve guide installer 6 mm
This tool is needed to install the valve guides
properly.
90890-04086 Clutch holding tool
This tool is used for holding the clutch boss.
1-7
SPECIAL TOOLS
GEN
INFO
90890-04101 Valve lapper
This tool is used for lapping the valve.
90890-06754 Ignition checker
This instrument is necessary for checking the
ignition system components.
90890-85505 Yamaha bond No.1215
This sealant (bond) is used for crankcase
mating surface, etc.
GEN
INFO
SPEC

2
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 2-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE 2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE 2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE SPECIFICATIONS 2-14 . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINT AND GRADE OF LUBRICANT 2-15 . . . . . . . . . . . . .
ENGINE 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAM 2-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
Model TW125
Model code: 5EK1/ 5EK2
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,140 mm
,810 mm
1,120 mm
,805 mm
1,330 mm
,260 mm
2,100 mm
Basic weight:
With oil and full fuel tank 125 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore stroke
Compression ratio
Compression pressure (STD)
Starting system
Lubrication system:
Air-cooled 4-stroke, SOHC
Forward-inclined single cylinder
0.124 L (124 cm
3
)
57.0 48.8 mm
10.0 : 1
1,200 kPa (12.0 kg/ cm
2
, 12.0 bar) at 1,000 r/ min
Electric starter
Wet sump
Oil type or grade:
Engine oil
API standard:
SE or higher grade
ACEA standard:
G4 or G5
Periodic oil change
With oil filter replacement
Total amount
1.0 L
1.1 L
1.3 L
Air filter: Wet type element
Fuel:
Type
Fuel tank capacity
Fuel reserve capacity
Regular unleaded gasoline
7.0 L
1.0 L
2-2
SPEC
Model TW125
Carburetor:
Type/ quantity
Manufacturer
Y24P/ 1
TEIKEI
Spark plug:
Type
Manufacturer
Spark plug gap
DR8EA
NGK
0.6 X 0.7 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
Spur gear
74/ 20 (3.700)
Chain drive
50/ 14 (3.571)
Constant mesh 5 speed
Left foot operation
36/ 16 (2.250)
31/ 21 (1.476)
27/ 24 (1.125)
25/ 27 (0.926)
23/ 29 (0.793)
Chassis:
Frame type
Caster angle
Trail
Diamond
26_
95 mm
Tire:
Type
Size front
rear
Manufacture front
rear
Type front
rear
Tube type
130/ 80-18 66P
180/ 80-14 M/ C 78P
BRIDGESTONE
BRIDGESTONE
TW31
TW34
Tire pressure (cold tire):
Maximum load-except motorcycle
Loading condition A *
front
rear
Loading condition B *
front
rear
Off road riding
front
rear
High speed riding
front
rear
180 kg
0 X 80 kg
150 kPa (1.5 kg/ cm
2
, 1.5 bar)
150 kPa (1.5 kg/ cm
2
, 1.5 bar)
80 X 180 kg
150 kPa (1.5 kg/ cm
2
, 1.5 bar)
175 kPa (1.75 kg/ cm
2
, 1.75 bar)
125 kPa (1.25 kg/ cm
2
, 1.25 bar)
125 kPa (1.25 kg/ cm
2
, 1.25 bar)
150 kPa (1.5 kg/ cm
2
, 1.5 bar)
175 kPa (1.75 kg/ cm
2
, 1.75 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-3
SPEC
Model TW125
Brake:
Front brake type
operation
Rear brake type
operation
Single disc brake
Right hand operation
Drum brake
Right foot operation
Suspension:
Front suspension
Rear suspension
Telescopic fork
Swingarm (Monocross)
Shock absorber:
Front shock absorber
Rear shock absorber
Coil spring/ Oil damper
Coil gas spring/ Oil damper
Wheel travel:
Front wheel travel
Rear wheel travel
160 mm
150 mm
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
C.D.I.
C.D.I. magneto
GM 7CZ-3D
12 V 7 AH
Headlight type: Bulb type
Bulb wattage quantity:
Headlight
Auxiliary light
Tail / brake light
Turn signal light
Meter light
High beam indicator
Neutral indicator
Turn signal indicator
12 V 45 W/ 40 W 1
12 V 4 W 1
12 V 5 W/ 21 W 1
12 V 21 W 4
12 V 3.4 W 1
12 V 3.4 W 1
12 V 3.4 W 1
12 V 3.4 W 1
2-4
MAINTENANCE SPECIFICATIONS
SPEC
Head Dia. Face Width Seat Width Margin Thickness
ENGINE
Item Standard Limit
Cylinder head:
Warp limit SSS 0.05 mm
Cylinder:
Bore size
Taper limit
Out of runout limit
57.00 X 57.02 mm
SSS
SSS
57.1 mm
0.05 mm
0.01 mm
Camshaft:
Cam dimensions
Intake A
B
C
Exhaust A
B
C
Camshaft runout limit
36.54 X 36.64 mm
30.13 X 30.23 mm
6.59 mm
36.58 X 36.68 mm
30.21 X 30.31 mm
6.63 mm
SSS
36.45 mm
30.05 mm
SSS
36.49 mm
30.13 mm
SSS
0.03 mm
Cam chain:
Cam chain type/ No. of links
Cam chain adjustment
DID 25SH/ 104 EDESOLES
Automatic
SSS
SSS
Rocker arm/ rocker armshaft:
Rocker arm inside diameter
Rocker shaft outside diameter
Rocker arm-to-rocker armshaft
clearance
12.000 X 12.018 mm
11.985 X 11.991 mm
0.009 X 0.033 mm
12.036 mm
11.950 mm
SSS
Valve, valve seat, valve guide:
Valve clearance (cold) IN
EX
0.05 X 0.09 mm
0.11 X 0.15 mm
SSS
SSS
Valve dimensions
A head diameter IN
EX
B face width IN
EX
C seat width IN
EX
D margin thickness IN
EX
Stem outside diameter IN
EX
28.9 X 29.1 mm
23.9 X 24.1 mm
2.4 X 2.8 mm
2.4 X 2.8 mm
0.9 X 1.1 mm
0.9 X 1.1 mm
0.8 X 1.2 mm
0.8 X 1.2 mm
5.975 X 5.990 mm
5.960 X 5.975 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
5.955 mm
5.940 mm
2-5
SPEC
Item Standard Limit
Guide inside diameter IN
EX
Stem-to-guide clearance IN
EX
Stem runout limit
Valve seat width IN
EX
6.000 X 6.012 mm
6.000 X 6.012 mm
0.010 X 0.037 mm
0.025 X 0.052 mm
SSS
0.9 X 1.1 mm
0.9 X 1.1 mm
6.042 mm
6.042 mm
0.08 mm
0.10 mm
0.03 mm
1.6 mm
1.6 mm
Valve spring:
Free length (inner) IN/ EX
(outer) IN/ EX
Set length (valve closed)
(inner) IN/ EX
(outer) IN/ EX
Compressed pressure
(inner) IN/ EX
(outer) IN/ EX
Tilt limit (inner) IN/ EX
Tilt limit (outer) IN/ EX
Direction of winding (inner) IN/ EX
Direction of winding (outer) IN/ EX
35.5 mm
37.2 mm
30.5 mm
32.0 mm
8.4 X 10.2kg
16.6 X 20.4 kg
SSS
SSS
Clockwise
Counterclockwise
33.5 mm
35.2 mm
SSS
SSS
SSS
SSS
2.5_/1.5 mm
2.5_/1.6 mm
SSS
SSS
Piston:
Piston to cylinder
clearance
Piston size D
Piston over size (1st)
Piston over size (2nd)
Measuring point H
Piston off-set
Piston off-set direction
Piston pin bore
inside diameter
Piston pin outside diameter
0.035 X 0.055 mm
56.960 X 56.975 mm
57.25 mm
57.50 mm
7.0 mm
0.5 mm
IN side
15.002 X 15.013 mm
14.987 X 14.992 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
15.045 mm
14.975 mm
Piston rings:
Top ring:
Type
Dimensions (B T)
End gap (installed)
Side clearance (installed)
2nd ring:
Type
Dimensions (B T)
End gap (installed)
Side clearance
Oil ring:
Dimensions (B T)
End gap (installed)
Plane
2.3 2.5 mm
0.15 X 0.35 mm
0.03 X 0.07 mm
Plane
2.3 2.5 mm
0.15 X 0.35 mm
0.02 X 0.06 mm
2.5 2.8 mm
0.3 X 0.9 mm
SSS
SSS
0.60 mm
0.15 mm
SSS
SSS
0.60 mm
0.15 mm
SSS
SSS
2-6
SPEC
F
Item Standard Limit
Crankshaft:
Crank width A
Runout limit C
Big end side clearance D
Big end radial clearance
Small end free play F
55.95 X 56.00 mm
SSS
0.35 X 0.65 mm
0.010 X 0.025 mm
0.8 X 1.0 mm
SSS
0.03 mm
1.0 mm
SSS
SSS
Clutch:
Friction plate thickness
Quantity
Clutch plate thickness
Quantity
Clutch spring free length
Quantity
Push rod bending limit
2.9 X 3.1 mm
4 pcs.
1.6 mm
3 pcs.
34.9 mm
4 pcs.
SSS
2.7 mm
SSS
0.05 mm
SSS
33.9 mm
SSS
0.2 mm
Transmission:
Main axle runout limit
Drive axle runout limit
SSS
SSS
0.08 mm
0.08 mm
Carburetor:
Type
I.D. mark
Main jet (M.J)
Main air jet (M.A.J)
Jet needle (J.N)
Needle jet (N.J)
Cut away (C.A)
Pilot air jet (P.A.J)
Pilot outlet (P.O)
Pilot jet (P.J)
Bypass 1 (B.P.1)
Pilot screw (P.S)
Valve seat size (V.S)
Starter jet 1 (G.S.1)
Starter jet 2 (G.S.2)
Float height (F.H)
Fuel level (F.L)
Engine idle speed
Intake vacuum
Y24P
5EK1 00
#118
1.4
4C78-3/ 5
T00
2.5
1.3
0.8
#38
1.0
2
2.0
#60
#60
0 X 2.0mm
1,300 X 1,500 r/ min
195 X 235 mmHg
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Oil pump:
Type
Tip clearance
Side clearance
Bypass valve setting pressure
Trochoid type
0.03 X 0.09 mm
0.10 X 0.15 mm
80 X 120 kPa
(0.8 X 1.2 kg/ cm
2
, 0.8 X 1.2 bar)
SSS
0.14 mm
0.35 mm
SSS
2-7
SPEC
TIGHTENING TORQUES
ENGINE
Th d
Tightening
Part to be tightened Part name
Thread
size
Qty
g g
torque
Remarks g
size
y
Nm mSkg
Cylinder head blind plug
Cylinder head and cylinder
Cylinder head
(Timing chain side)
Cam sprocket cover
Valve cover
Camshaft retainer
Spark plug
Cylinder
Balancer driven gear
C.D.I. magneto
Valve adjuster locknut
Cam sprocket
Timing chain tensioner
Timing chain guide (intake)
Oil pump
Oil pump and crankcase
Drain plug
Oil filter cover
Drain bolt (oil filter)
Carburetor joint and carburetor
Air filter case (front)
Air filter case (rear)
Muffler protector
Muffler and frame
Exhaust pipe and cylinder
Exhaust pipe and muffler
Crankcase (left and right)
Generator cover
Crankcase cover (left)
Clutch cover
Starter clutch
Primary drive gear
Clutch spring
Clutch boss
Push lever axle
Push lever adjuster
Drive sprocket
Shift cam (Segment)
Shift pedal
Pick up coil
Neutral switch
Stator coil
Starter motor
Screw
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Screw
Screw
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Screw
Screw
Screw
Screw
Screw
Bolt
Nut
Screw
Nut
Screw
Nut
Bolt
Screw
Bolt
Screw
Screw
Screw
Screw
M6
M8
M8
M6
M6
M6
M12
M6
M14
M10
M6
M10
M6
M6
M6
M6
M35
M6
M6
M6
M6
M6
M6
M8
M8
M6
M8
M6
M6
M4
M6
M8
M14
M5
M14
M8
M6
M5
M6
M6
M6
M10
M6
M6
2
4
2
2
5
2
1
2
1
1
2
1
2
2
2
3
1
2
1
2
1
2
4
2
1
2
1
13
10
1
11
3
1
4
1
1
1
2
1
1
2
1
3
1
7
22
20
7
10
8
18
10
50
50
14
60
10
8
7
7
43
7
10
12
10
10
7
20
27
12
20
7
7
2
7
30
50
6
70
12
8
6
12
10
7
20
7
7
0.7
2.2
2.0
0.7
1.0
0.8
1.8
1.0
5.0
5.0
1.4
6.0
1.0
0.8
0.7
0.7
4.3
0.7
1.0
1.2
1.0
1.0
0.7
2.0
2.7
1.2
2.0
0.7
0.7
0.2
0.7
3.0
5.0
0.6
7.0
1.2
0.8
0.6
1.2
1.0
0.7
2.0
0.7
0.7
Stake
2-8
SPEC
Tightening sequence
Cylinder head
Crankcase
Item Standard Limit
2-9
SPEC
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type (upper)
(lower)
No. / size of steel balls (upper)
Ball bearings
Angular ball bearing
22 pcs. 0.1875 in
SSS
SSS
SSS
Front suspension:
Front fork travel
Fork spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
Oil capacity
Oil level
Oil grade
Inner tube vend limit
160 mm
342 mm
337 mm
4.4 N / mm (0.44 kg/ mm)
0 X 160 mm
0.243 L (243 cm
3
)
135 mm
Fork oil 10 WT or equivalent
SSS
SSS
338 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.2 mm
Rear suspension:
Shock absorber stroke
Spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
48 mm
193 mm
185 mm
100 N/ mm (10.0 kg/ mm)
0 X 48 mm
SSS
173 mm
SSS
SSS
SSS
Front wheel:
Type
Rim size
Rim material
Rim runout limit radial
lateral
Spoke wheel
2.50 18
Aluminum
SSS
SSS
SSS
SSS
SSS
2 mm
2 mm
Rear wheel:
Type
Rim size
Rim material
Rim runout limit radial
lateral
Spoke wheel
14 M/ C MT 4.50
Steel
SSS
SSS
SSS
SSS
SSS
2 mm
2 mm
Drive chain:
Type/ manufacturer
No. of links
Chain free play
428HG/ DAIDO
109
35 X 60 mm
SSS
SSS
SSS
Front brake:
Type
Disc outside diameter
Disc thickness
Pad thickness (inner)
(outer)
Master cylinder inside diameter
Caliper cylinder 1 inside diameter
Caliper cylinder 2 inside diameter
Brake fluid type
Single disc
220 mm
3.5 mm
5.3 mm
5.3 mm
11 mm
26.9 mm
22.2 mm
DOT#4
SSS
SSS
3.0 mm
0.8 mm
0.8 mm
SSS
SSS
SSS
SSS
2-10
SPEC
Item Standard Limit
Rear brake:
Type
Drum inside diameter
Shoe thickness
Shoe spring free length
Leading, trailing
110 mm
4 mm
50.5 mm
SSS
111 mm
2 mm
SSS
Brake lever:
Brake lever free play (at lever end) 2 X 5 mm SSS
Brake pedal:
Brake pedal free play
Brake pedal position
20 X 30 mm
30 mm
SSS
SSS
Clutch lever:
Clutch lever free play (at lever end) 10 X 15 mm SSS
Throttle cable free play 3 X 5 mm SSS
2-11
SPEC
NOTE:
TIGHTENING TORQUES
CHASSIS
Part to be tightened Thread size
Tightening
torque
Remarks g
Nm mSkg
Handle crown and front fork
Handle crown and steering shaft
Handlebar holder (under and upper)
Steering ring nut
Master cylinder (front brake)
Brake hose union bolt (front brake)
Steering shaft and front fork
Engine and front engine stay
Front engine stay and frame
Engine and top engine stay
Top engine stay and frame
Engine and frame
Swingarm pivot shaft
Rear shock absorber and frame
Chain guide and swingarm
Sidestand
Footrest (left)
Footrest (right)
Rear footrest (left)
Front wheel axle and nut
Rear wheel axle and nut
Brake caliper and front fork
Brake disc and front wheel
Rear wheel sprocket and hub
Brake caliper bleed screw
Brake cam lever
M8
M14
M8
M25
M6
M10
M10
M8
M8
M8
M8
M8
M12
M10
M5
M10
M12
M10
M8
M14
M16
M10
M6
M8
M7
M6
23
90
20
18
7
26
30
33
33
33
33
33
80
56
5
40
60
45
15
90
90
30
13
35
6
9
2.3
9.0
2.0
1.8
0.7
2.6
3.0
3.3
3.3
3.3
3.3
3.3
8.0
5.6
0.5
4.0
6.0
4.5
1.5
9.0
9.0
3.0
1.3
3.5
0.6
0.9
Refer to NOTE
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving smooth-
ly.
2. First, tighten the ring nut approximately 38 Nm (3.8 mSkg) by using the torque wrench, then loosen
the ring nut one turn and retighten the ring nut to specification.
2-12
SPEC
ELECTRICAL
Item Standard Limit
Ignition timing:
Ignition timing (B.T.D.C.)
Advanced timing
Advanced type
9_ at 1,500 r/ min
30_ at 5,000 r/ min
Digital type
SSS
SSS
SSS
C.D.I.:
Pickup coil resistance/ color
Source coil resistance/ color
C.D.I. unit model / manufacturer
656 X 984 at 20_C/
Red White
624 X 936 at 20_C/
Brown Green
5EK/ YAMAHA
SSS
SSS
SSS
Ignition coil:
Model / manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
2JN/ YAMAHA
6 mm
0.18 X 0.28 at 20_C
6.32 X 9.48 k at 20_C
SSS
SSS
SSS
SSS
Spark plug cap:
Type
Resistance
Resin type
10 k
SSS
SSS
Charging system:
Type
Standard output
Stator coil resistance/ color
C.D.I. magneto
F5BT/ YAMAHA
12V 170 W/ 5,000 r/ min
0.48 X 0.72 at 20_C/
White White
SSS
SSS
SSS
SSS
SSS
Rectifier/ regulator:
Type (regulator)
No load regulated voltage
Capacity (rectifier)
Withstand voltage
SH629A-12/ SHINDENGEN
Semi conductor-short circuit type
14.5 V
10 A
200 V
SSS
SSS
SSS
SSS
SSS
Battery:
Specific gravity 1.280 SSS
Electric starter system:
Type
Starter motor:
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut (depth)
Constant mesh type
2JX/ YAMAHA
0.4 kW
0.0171 X 0.0209 at 20_C
10 mm
5.52 X 8.28 N (552 X 828 g)
22 mm
1.5 mm
SSS
SSS
SSS
3.5 mm
SSS
21 mm
SSS
2-13
SPEC
Item Standard Limit
Starter relay:
Amperage rating
Coil winding resistance
MS5F/ JIDECO
100 A
4.2 X 4.6 at 20_C
SSS
SSS
SSS
Horn:
Maximum amperage
YF-12/ NIKKO
3 A
SSS
SSS
Flasher relay:
Type
Flasher frequency
Full transistor type
FE 246 BH/ DENSO
85 cycle/ min
SSS
SSS
SSS
Circuit breaker:
Type
Main
Reserve
Fuse
20 A 1 pcs.
20 A 1 pcs.
SSS
SSS
SSS
2-14
CONVERSION TABLE/
GENERAL TORQUE SPECIFICATIONS
GEN
INFO
A: Distance across flats
B: Outside thread diameter
EAS00028
CONVERSION TABLE
All specification data in this manual are listed in Sl and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMP
** mm 0.03937 = ** in
2 mm 0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
Torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
Weight
kg
g
2.205
0.03527
lb
oz
Distance
km/ hr
km
m
m
cm
mm
0.6214
0.6214
3.281
1.094
0.3937
0.03937
mph
mi
ft
yd
in
in
Volume/
Capacity
cc (cm
3
)
cc (cm
3
)
lit (liter)
lit (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/ mm
kg/ cm
2
Centigrade
55.997
14.2234
9/ 5 (_C) + 32
lb/ in
psi (lb/ in
2
)
Fahrenheit (_F)
EAS00029
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifica-
tions for special components or assemblies are included in the applicable sections of this book. To
avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until
full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
Components should be at room temperature.
A
(Nut)
B
(Bolt)
General torque
specifications
(Nut) (Bolt)
Nm mSkg
10 mm 6 mm 6 0.6
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
2-15
LUBRICATION POINT AND GRADE OF LUBRICANT
SPEC
ENGINE
Lubrication Point Symbol
Oil seal lips (all)
Bearing retainer (all)
Bolt (cylinder head)
Crank pin
Connecting rod (big end)
Piston pin
Piston/ piston ring
Buffer boss
Valve stem/ valve guide (IN, EX)
Valve stem end (IN, EX)
Rocker arm shaft
Cam and bearing (camshaft)
Rocker arm inner surface
Crankcase mating surfaces Yamaha bond No.1215
O-ring (all)
Starter idle gear thrust surfaces
Starter clutch (outer/ roller)
Starter wheel gear inner surface
Push rod
Primary driven gear inner surface
Push lever axle
Transmission gear inner surface
Shift fork/ guide bar/ shaft
Shift cam
2-16
SPEC
CHASSIS
Lubrication Point Symbol
Steering head pipe bearing (upper/ lower)
Front wheel oil seal lips (left / right)
Rear wheel oil seal lips (left / right)
Rear brake shoe plate, camshaft and pivoting pin
Pivoting points (brake pedal shaft and frame)
Sidestand sliding surface/ mounting bolt
Tube guide (throttle grip) inner surface
Brake lever bolt / master cylinder sliding surface
Clutch lever bolt / collar/ cable sliding surface
Brake pedal shaft surface
Gear unit (speedometer)
Swigarm insert surface/ bush/ thrust cover
Pivot shaft surface
Rear shock absorber lower pin surface/ dust seal lips
2-17
1 Rocker arm (IN)
2 Rocker shaft
3 Rocker arm (EX)
4 Camshaft
5 Oil pump
6 Push lever
LUBRICATION DIAGRAM
SPEC
LUBRICATION DIAGRAM
2-18
1 Oil pump
2 Oil filter
3 Crankshaft
4 Main axle
5 Drive axle
6 Oil strainer
LUBRICATION DIAGRAM
SPEC
2-19
A Fasten the handlebar switch
lead, front brake switch lead and
clutch switch lead to the handle-
bar with a plastic clamp.
B The end of the plastic locking tie
must face down ward.
C To headlight
12 Meter lead
13 Headlight coupler
14 Wireharness
15 Front turn signal light (right)
16 Front turn signal light lead (right)
1 Brake hose
2 Throttle cable
3 Front brake switch lead
4 Handlebar switch lead (right)
5 Handlebar switch lead (left)
6 Clutch cable
7 Clutch switch lead
8 Main switch lead
9 Speedometer cable
10 Starter cable
11 Indicator light lead
CABLE ROUTING
SPEC
CABLE ROUTING
2-20
E Route the battery breather hose
through the hole of air cleaner
case.
F Fasten the rear brake switch
lead couplers and carburetor
heater lead to the frame with a
plastic locking tie.
The end of the plastic locking tie
must face front side.
A The end of the plastic locking tie
B Fasten the wire harness, han-
dlebar switch lead (right), front
brake switch lead, throttle cable,
starter cable, clutch switch lead
and main switch lead to the
frame with steel clamp.
C Route the wire harness, handle-
bar switch (right) and front brake
switch lead through the cable
guide.
D Route the battery breather hose
through the cable guide.
CABLE ROUTING
SPEC
1 Battery positive lead
2 Starter relay
3 Starter motor lead
4 Clamp
5 Front brake switch lead
6 Handlebar switch lead (right)
7 Ignition coil
8 Horn lead
9 High tension cable
10 Flasher relay
11 Rear brake switch lead
12 Neutral relay
13 CDI unit
2-21
E Route the carburetor air vent hose
and carburetor over flow hose be-
tween the engine and swingarm.
F Route the starter motor lead be-
tween the engine and swing arm.
A Fasten the CDI magneto leads,
starter motor lead, neutral switch
lead and ground lead to the frame
stay.
The end of plastic locking tie
B Fasten the side stand switch
lead with the steel clamp.
C Fasten the carburetor air vent
hose, carburetor over flow hose
and starter motor lead with a
plastic clamp.
D Route the side stand switch lead
through the guide.
CABLE ROUTING
SPEC
1 Starter cable
2 Throttle cable
4 Main switch lead
5 Thermo switch lead
6 Sidestand switch lead
7 Carburetor over flow hose
8 Carburetor air vent hose
9 Clutch cable
10 Brake hose
11 Speedometer cable
12 CDI magneto leads
13 Neutral switch lead
2-22
G Route the carburetor air vent
hose and carburetor over flow
hose through the guide.
H Route the clutch cable through
the cable guide.
I Route the brake hose and speed-
ometer cable through the cable
guide.
J Fasten the brake hose and spee-
dometer cable to the front fork
outer tube with a cable holder.
CABLE ROUTING
SPEC
2-23
E Route the rear turn signal light
lead (right) between the frame
and license bracket.
F Route the rear turn signal light
lead (left) between the frame and
license bracket.
A Fasten the wire harness with
steel clamp.
B Fasten the wire harness and rear
turn signal light lead to the frame
with a plastic locking tie.
must face in side.
C Route the rear turn signal light
lead inside of hose.
D Fasten the wire harness and rear
turn signal light (right) with a
steel clamp.
CABLE ROUTING
SPEC
2 Main switch lead
3 Starter motor lead
4 CDI magneto lead
5 Battery positive lead
6 Wire harness
7 Thermo switch lead
8 Sidestand switch lead
9 Battery negative lead
10 Rectifier/ Regulator
11 Ground lead
2-24
G Fasten the rear turn signal light
(left) to the frame with a plastic
locking tie.
must face rear ward.
H Fasten the thermo switch lead
connectors to the frame with a
plastic locking tie.
must face inside.
CABLE ROUTING
SPEC
CHK
ADJ

3
CHAPTER 3.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/ LUBRICATION INTERVALS 3-1 . . . . . . . . . . .
SEAT, FUEL TANK AND SIDE COVER 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE 3-4 . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED 3-6 . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-7 . . . . . . . . . . . . .
CHECKING THE SPARK PLUG 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION TIMING 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE 3-10 . . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL 3-11 . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL 3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-14 . . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT 3-15 . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3-16
CHECKING THE FUEL HOSES 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE 3-17 . . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM 3-17 . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-21 . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE PADS 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE SHOES 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-22 . . . . . . . . . . . . . . .
CHECKING THE BRAKE HOSE 3-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-23 . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-24 . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-26 . . . . . . . . . .
CHECKING THE FRONT FORK 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIRES 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND TIGHTENING THE SPOKES 3-31 . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-31 . . . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-32 . . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-32 . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BATTERY 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUSE 3-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULB 3-37 . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAM 3-38 . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera-
tion and a longer service life. The need for costly overhaul work will be greatly reduced. This informa-
tion applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
BRAKE
EVERY
No ITEM ROUTINE
BRAKE-
IN
1,000 KM
6,000 km
or
6 months
12,000 km
or
12 months
1 * Fuel line
S Check fuel hoses for cracks or damage.
S Replace if necessary.

2 Spark plugs
S Check condition.
S Clean, regap or replace if necessary.

3 * Valves
S Check valve clearance.
S Adjust if necessary.

4 Air filter S Clean or replace if necessary.
5 * Battery
S Check electrolyte level and specific gravity.
S Correct or recharge if necessary.
S Make sure that the breather hose is properly routed.

6 Clutch
S Check operation.
S Adjust or replace cable.

7 * Front brake
S Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
S Correct accordingly.
S Replace brake pads if necessary.

8 * Rear brake
S Check operation.
S Adjust cable and replace brake shoes if necessary.

9 * Wheels
S Check balance, runout spoke tightness and for damage.
S Tighten spokes and rebalance,replace if necessary.

10 * Tires
S Check tread depth and for damage.
S Check air pressure.
S Correct if necessary.

11 * Wheel bearings
S Check bearing for looseness or damage.

12 * Swingarm
S Check Swingarm pivoting point for play.
S Lubricate with lithium soap base grease.

13 Drive chain
S Check chain slack.
S Adjust if necessary. Make sure that the rear wheel is properly
aligned.
S Clean and lubricate.
Every 500 km and after washing the
motorcycle or riding in rain
14 * Steering bearings
S Check bearing play and steering for roughness.
S Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).

3-2
PERIODIC MAINTENACE/LUBRICATION INTERVALS
CHK
ADJ
NOTE:
EVERY
NO. ITEM ROUTINE
BRAKE-IN
1,000 KM
6,000 km
or
6 months
12,000 km
or
12 months
15 * Chassis fasteners
S Make sure that all nuts, bolts and screws are properly tightened.
S Tighten if necessary.

16 Sidestand
S Check operation.
S Lubricate and repair if necessary.

17 * Sidestand switch
S Check operation.

18 * Front fork
S Check operation and for oil leakage.

19 *
Rear shock absorber
assembly pivoting
points
S Check operation.
S Lubricate with lithium soap base grease every 24,000 km or 24
months (whichever comes first).

20 * Carburetor
S Check engine idling speed and starter operation.
S Adjust if necessary.

21 Engine oil
S Check oil level and vehicle for oil leakage.
S Change. (Warm engine before draining.)

22
Engine oil filter
element
S Clean or replace if necessary.
23 * Engine oil strainer S Clean or replace if necessary.
*: Since these items require special tools, date and technical skills,they should be serviced by a Ya-
maha dealer.
S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
S Hydraulic brake system.
When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check
the brake fluid level regularly and fill as required.
Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
Replace the brake hoses every four years or if cracked or damaged.
3-3
Order Job/ Part Qty Remarks
1
2
3
4
5
6
Removing the seat, fuel tank and
side cover
Seat
Fuel hose
Fuel tank
Tail cover
Side cover (left)
Side cover (right)
1
1
1
1
1
1
Remove the parts in the order listed.
Before disconnecting the fuel hose, turn
the fuel cock off.
For installation, reverse the removal
procedure.
NOTE:
SEAT, FUEL TANK AND SIDE COVER
CHK
ADJ
SEAT, FUEL TANK AND SIDE COVER
3-4
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00049
ENGINE
The following procedure applies to all of the
valves.
S Valve clearance adjustment should be made
on a cold engine, at room temperature.
S When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
S seat
S side cover (left and right)
S fuel tank
Refer to SEAT, FUEL TANK AND SIDE
COVER.
2. Remove:
S spark plug cap 1
S spark plug
S valve cover (intake side) 2
S valve cover (exhaust side) 3
3. Remove:
S timing check plug (with O-ring) 1
S center plug (with O-ring) 2
4. Measure:
S valve clearance
Out of specification ! Adjust.
Valve clearance (cold)
Intake valve
0.05 X 0.09 mm
Exhaust valve
0.11 X 0.15 mm
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the mark
a
on the genera-
tor rotor with the stationary pointer b on the
crankcase.
c. Measure the valve clearance with a thick-
ness gauge 1 .
3-5
A B
CHK
ADJ
a
b
10 Nm (1.0 mSkg)
New
10 Nm (1.0 mSkg)
New
18 N m (1.8 mSkg)
5. Adjust:
S valve clearance
a. Loosen the locknut 1 .
b. Insert a thickness gauge 2 between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 in direction
a
or
b until the specified valve clearance is ob-
tained.
Direction ! Valve clearance is
increased.
Direction ! Valve clearance is
decreased.
Valve adjusting tool
90890-01311
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut
14 Nm (1.4 mSkg)
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
6. Install:
S valve cover (intake side) 1
S o-ring 2
S valve cover (exhaust side) 3
S o-ring 4
A Intake side
B Exhaust side
7. Install:
S spark plug
S timing check plug 1
(with O-ring)
Scenter plug 2
(with O-ring)
3-6
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
NOTE:
a
b
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter should be clean, and the
engine should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:
S engine tachometer
(to the spark plug lead)
Engine tachometer
90890-03113
3. Measure:
S engine idling speed
Engine idling speed
1,300 X 1,500 r/ min
4. Adjust:
a. Turn the pilot screw 1 in or out until it is light-
ly seated.
b. Turn the pilot screw out the specified number
of turns.
Pilot screw
2 turns out
c. Turn the throttle stop screw 2 in direction
a
or b until the specified engine idling speed is
obtained.
Direction !Engine idling speed is
increased.
Direction ! Engine idling speed is
decreased.
5. Adjust:
S throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play (at the
flange of the throttle grip)
3 X 5 mm
3-7
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
NOTE:
a
b
NOTE:
a
b
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.
1. Check:
a
3 X 5 mm
2. Adjust:
Carburetor side
a. Loosen the locknut 1 on the throttle cable.
b. Turn the adjusting nut 2 in direction
a
or b
until the specified throttle cable free play is
obtained.
Direction ! Throttle cable free play is
increased.
decreased.
c. Tighten the locknut.
If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable,
use the adjusting nut on the handlebar side.
Handlebar side
a
or b
until the specified throttle cable free play is
obtained.
increased.
decreased.
3-8
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUG
CHK
ADJ
WARNING
CAUTION:
After adjusting the throttle cable free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
EAS00060
CHECKING THE SPARK PLUG
1. Disconnect:
S spark plug cap
2. Remove:
S spark plug
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fal-
ling into the cylinder.
3. Check:
S spark plug type
Incorrect ! Change.
Spark plug type (manufacturer)
DR8EA (NGK)
4. Check:
S electrode 1
Damage/ wear ! Replace the spark plug.
S insulator 2
Abnormal color ! Replace the spark plug.
Normal color is a medium-to-light tan color.
5. Clean:
S spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
S spark plug gap
a
(with a wire gauge)
Out of specification ! Regap.
Spark plug gap
0.6 X 0.7 mm
3-9
CHECKING THE SPARK PLUG/
CHECKING THE IGNITION TIMING
CHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:
S spark plug
Spark plug
18 Nm (1.8 mSkg)
S Before installing the spark plug, clean the
spark plug and gasket surface.
S Finger-tighten 1 the spark plug before torqu-
ing to specification 2 .
8. Connect:
S spark plug cap
EAS00064
CHECKING THE IGNITION TIMING
Prior to checking the ignition timing, check the wiring
connections of the entire ignition system. Make sure
that all connections are tight and free of corrosion.
1. Remove:
S timing check plug
2. Install:
S timing light 1
S engine tachometer 2
(to the spark plug lead of cylinder #1)
Timing light 1
90890-03141
Engine tachometer 2
90890-03113
3. Check:
S ignition timing
a. Start the engine, warm it up for several minutes,
and then let it run at the specified engine idling
speed.
Engine idling speed
1,300 X 1,500 r/ min
b. Check that the stationary pointer a is within the
firing range b on the generator rotor.
Incorrect firing range ! Check the ignition sys-
tem.
The ignition timing is not adjustable.
4. Remove:
S timing light
S engine tachometer
5. Install:
S timing check plug
3-10
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
NOTE:
CAUTION:
EAS00067
MEASURING THE COMPRESSIONPRES-
SURE
Insufficient compression pressure will result in a
loss of performance.
1. Check:
S valve clearance
Out of specification ! Adjust
Refer to ADJUSTING THE VALVE CLEAR-
ANCE .
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
S spark plug cap
4. Remove:
S spark plug
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it from
falling into the cylinder.
5. Install:
S compression gauge 1
Compression gauge 1
90890-03081
Adapter 2
90890-04082
6. Measure:
S compression pressure
Above the maximum pressure ! Inspect the
cylinder head, valve surfaces, and piston
crown for carbon deposits.
Below the minimum pressure ! Squirt a few
drops of oil into the cylinder and measure
again.
S Refer to the following table.
Compression pressure
(with oil applied into cylinder)
Reading Diagnosis
Higher than
without oil
Piston wear or damage
!Repair.
Same as
without oil
Piston ring(-s), valves,
cylinder head gasket or
piston possibly defec-
tive !Repair.
3-11
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
WARNING
18 Nm (1.8 mSkg)
NOTE:
Compression pressure
(at sea level)
Standard:
1,200 kPa (12.0 kg/ cm
2
, 12 bar)
Minimum:
1,100 kPa (11,0 kg/ cm
2
, 11 bar)
a. Turn the main switch to ON.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
To prevent sparking, ground the spark plug
lead before cranking the engine.
7. Install:
S spark plug
8. Connect:
S spark plug cap
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
S Place the motorcycle on a suitable stand.
S Make sure that the motorcycle is upright.
2. Let the engine idle for a few minutes.
3. Check:
S engine oil level
The engine oil level should be between the
minimum level marks
a
and maximum level
marks b .
Below the minimum level mark ! Add the
recommended engine oil to the proper level.
Recommended engine oil
Refer to the chart for the
engine oil grade which is
best suited for certain
atmospheric temperatures.
API standard
SE or higher grade
ACEA standard
G4 or G5
3-12
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
CAUTION:
NOTE:
43 Nm (4.3 mSkg)
S Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD
a
or higher and do
not use oils labeled ENERGY CONSERV-
ING II b or higher.
S Do not allow foreign materials to enter the
crankcase.
5. Check the engine oil level again.
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS00076
2. Place a container under the engine oil drain
bolt.
3. Remove:
S engine oil filler cap 1
S engine oil drain bolt 2
4. Drain:
S engine oil
(completely from the crankcase)
5. If the oil filter element is also to be replaced,
perform the following procedure.
a. Remove the oil filter element cover 1 and oil
filter element 2 .
b. Check the O-ring 3 and replace it if it is
cracked or damaged.
c. Install the new oil filter element and the oil fil-
ter element cover.
Oil filter element cover bolt
7 Nm (0.7 mSkg)
6. Check:
S engine oil drain bolt gasket
Damage ! Replace.
7. Install:
S engine oil drain bolt
3-13
CHK
ADJ
8. Fill:
S crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
1.3 L
Without oil filter element
replacement
1.0 L
With oil filter element
replacement
1.1 L
9. Install:
S engine oil filler cap
11. Check:
S engine
(for engine oil leaks)
12. Check:
S engine oil level
Refer to CHECKING THE ENGINE OIL
LEVEL.
13. Check:
S engine oil pressure
a. Slightly loosen the oil gallery bolt 1 .
b. Start the engine and keep it idling until the
engine oil starts to seep from the oil gallery
bolt.
If no engine oil comes out after one minute,
turn the engine off so that it will not seize.
c. Check engine oil passages and oil pump for
damage or leakage.
d. Start the engine after solving the problem(s),
and check the oil pressure again.
e. Tighten the oil gallery bolt to specification.
Oil gallery bolt:
7 Nm (0.7 mSkg)
3-14
ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK
ADJ
a
b
NOTE:
a
b
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
S clutch cable free play
a
Clutch cable free play (at the end
of the clutch lever)
10 X 15 mm
2. Adjust:
Handlebar side
b. Turn the adjusting screw 2 in direction
a
or
b until the specified clutch cable free play is
obtained.
Direction ! Clutch cable free play is
increased.
decreased.
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a
or b
until the specified clutch cable free play is ob-
tained.
increased.
decreased.
3-15
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
NOTE:
CAUTION:
EAS00090
CLEANING THE AIR FILTER ELEMENT
1. Remove:
S side cover (left)
S air filter case cover 1
2. Remove:
S air filter element 1
3. Clean:
S air filter element
(with solvent)
After cleaning, carefully pat the air filter element
on a clean cloth to remove the excess oil.
4. Check:
Damage ! Replace.
5. Apply the recommended oil to the entire sur-
face of the air filter element and then careful-
ly pat the air filter element on a clean cloth to
remove the excess oil. The air filter element
should be wet but not dripping.
Recommended oil
Engine oil
6. Install:
S air filter case cover
(along with the gasket)
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor en-
gine performance and possible overheat-
ing.
3-16
CLEANING THE AIR FILTER ELEMENT/ CHECKING
THE CARBURETOR JOINT AND INTAKE MANIFOLD/
CHECKING THE FUEL HOSES
CHK
ADJ
NOTE:
S Make sure that the air filter element is properly
installed in the air filter case.
S The air filter screen fits into the slots 2 in the
air filter case.
7. Install:
S side cover (left)
EAS00094
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Remove:
S seat
S side cover
S fuel tank
COVER.
2. Check:
S carburetor joint 1
S intake manifold 2
Cracks/ damage ! Replace.
Refer to CARBURETOR in chapter 5.
3. Install:
S fuel tank
S side cover
S seat
COVER.
EAS00096
CHECKING THE FUEL HOSES
The following procedure applies to all of the fuel
and vacuum hoses.
1. Remove:
S seat
S side cover
S fuel tank
COVER.
2. Check:
S fuel hose 1
3. Install:
S fuel tank
S side cover
S seat
COVER.
3-17
CHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
CAUTION:
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
S seat
S side cover
S fuel tank
COVER.
2. Check:
S crankcase breather hose 1
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
S fuel tank
S side cover
S seat
COVER.
EAS00100
The following procedure applies to all of the ex-
haust pipes, mufflers and gaskets.
1. Remove:
S seat
S rear cowling
S side cover (right)
2. Check:
S exhaust pipe 1
S silencer 2
S gasket 3
Exhaust gas leaks ! Replace.
3-18
CHK
ADJ
3. Check:
S tightening torque
Exhaust pipe 4
12 Nm (1.2 mSkg)
Exhaust pipe and muffler bolt 5
20 Nm (2.0 mSkg)
Muffler and muffler bracket bolt 6
20 Nm (2.7 mSkg)
Muffler and muffler bracket bolt 7
27 Nm (2.7 mSkg)
4. Install:
S rear cowling
S seat
3-19
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
b
c
WARNING
CAUTION:
EAS00108
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
S brake lever free play
a
Brake lever free play
(at the end of the brake lever):
2 X 5 mm
2. Adjust:
S brake lever free play
a Loosen the locknut 1 .
b Turn the adjusting bolt 2 in direction b or
c
until the specified free play is obtained.
Direction ! Brake lever free play is
increased.
Direction ! Brake lever free play is
decreased.
c Tighten the locknut.
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system . Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, inspect and, if nec-
essary, bleed the brake system.
After adjusting the brake lever position,
make sure that there is no brake drag.
EAS00112
1. Check:
S brake pedal position
(distance
a
from the top of the rider footrest
to the top of the brake pedal)
Brake pedal position (above the
top of the rider footrest)
30 mm
3-20
CHK
ADJ
a
b
a
b
CAUTION:
2. Adjust:
S brake pedal position
b. Turn the adjusting bolt 2 in direction
a
or b
until the specified brake pedal position is ob-
tained.
Direction ! Brake pedal is raised.
Direction ! Brake pedal is lowered.
c. Tighten the locknut to specification.
3. Measure:
S brake pedal free play
a
Brake pedal free play
20 X 30 mm
4. Adjust:
S brake pedal free play
a. Turn the adjusting nut 2 in direction
a
or b
until the specified brake pedal free play is ob-
tained.
Direction ! Brake pedal free play is
increased.
Direction ! Brake pedal free play is
decreased.
After adjusting the brake pedal position and
free play, make sure that there is no brake
drag.
5. Adjust:
S rear brake light switch
Refer to ADJUSTING THE REAR BRAKE
LIGHT SWITCH.
3-21
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL
S Place the motorcycle on a suitable stand.
S Make sure that the motorcycle is upright.
2. Check:
S brake fluid level
Below the minimum level mark
a
! Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
S When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser-
voir is horizontal.
3-22
CHECKING THE BRAKE PADS/ CHECKING THE BRAKE SHOES/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
NOTE:
a
b
EAS00117
CHECKING THE BRAKE PADS
brake pads.
1. Operate the brake.
2. Check:
S brake pad
Wear indicators 1 almost touch the brake
disc ! Replace the brake pads as a set.
Refer to FRONT BRAKE in chapter 7.
EAS00126
CHECKING THE BRAKE SHOES
1. Operate the brake.
2. Check:
S wear indicator 1
Reaches the wear limit line 2 ! Replace
the brake shoes as a set.
Refer to REAR WHEEL in chapter 7.
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
S rear brake light operation timing
Incorrect ! Adjust.
2. Adjust:
S rear brake light operation timing
a. Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction
a
or b until the
rear brake light comes on at the proper time.
Direction ! Brake light comes on
sooner.
Direction ! Brake light comes on
later.
3-23
CHECKING THE BRAKE HOSE/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
WARNING
NOTE:
EAS00129
CHECKING THE BRAKE HOSE
1. Check:
S brake hose 1
Cracks/ damage/ wear ! Replace.
2. Check:
S brake hose clamp
Loose connection ! Tighten.
3. Hold the motorcycle upright and apply the
front or rear brake.
4. Check:
S brake hose
Activate the brake several times.
Brake fluid leakage ! Replace the damaged
hose.
Refer to FRONT BRAKE in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE SYS-
TEM
Bleed the hydraulic brake system whenev-
er:
S The system was disassembled.
S A brake hose was loosened or removed.
S The brake fluid level is very low.
S Brake operation is faulty.
S Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to over-
flow.
S When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydrau-
lic brake system, considerably lengthening the
bleeding procedure.
S If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
3-24
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
WARNING
NOTE:
CAUTION:
1. Bleed:
S hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake master cylinder reservoir di-
aphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
d. Place the other end of the hose into a con-
tainer.
e. Slowly squeeze the brake lever several
times.
f. Fully squeeze the brake lever without releas-
ing it.
g. Loosen the bleed screw.
This will release the tension and cause the
brake lever to contact the throttle grip.
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 mSkg)
k. Fill the reservoir to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL.
After bleeding the hydraulic brake system,
check the brake operation.
56EAS00141
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
3-25
CHK
ADJ
WARNING
NOTE:
a
b
NOTE:
CAUTION:
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.
3. Measure:
S drive chain slack
Drive chain slack
35 X 60 mm
4. Adjust:
S drive chain slack
a. Loosen the wheel axle nut 1 .
b. Turn the chain pullers 2 in direction
a
or b
until the specified drive chain slack is ob-
tained.
Direction ! Drive chain is tightened.
Direction ! Drive chain is loosened.
To maintain the proper wheel alignment, adjust
both sides evenly.
c. Tighten the wheel axle nut.
Wheel axle nut
90 Nm (9.0 mSkg)
Do not loosen the wheel axle nut after tight-
ening it to the specified torque. If the groove
in the wheel axle nut is not aligned with the
cotter pin hole in the wheel axle, tighten the
nut further until they are aligned.
3-26
LUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
EAS00143
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained prop-
erly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas. Use only ker-
osine to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with engine
oil or chain lubricant that is suitable for non-O-
ring chains.
Recommended lubricant
Engine oil or chain lubricant sui-
table for non-O-ring chains
EAS00146
CHECKING AND ADJUSTING THE STEER-
ING HEAD
the front wheel is elevated.
2. Check:
S steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding ! Adjust the steering
head.
3. Remove:
S handlebar
S upper bracket
4. Adjust:
S steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
3-27
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
NOTE:
WARNING
NOTE:
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
Set the torque wrench at a right angle to the ring
nut wrench.
Ring nut wrench
90890-01403
Lower ring nut
(initial tightening torque)
38 Nm (3.8 mSkg)
c. Loosen the lower ring nut completely, then
tighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
18 Nm (1.8 mSkg)
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 inspect the upper and
lower bearings.
Refer to STEERING HEAD AND HAN-
DLEBAR in chapter 6.
e. Install the rubber washer .
f. Install the upper ring nut 6 .
g. Finger tighten the upper ring nut 6 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 7 .
Make sure that the lock washer tabs
a
sit cor-
rectly in the ring nut slots b .
5. Install:
S upper bracket
S handlebar
Steering stem nut
90 Nm (9.0 mSkg)
Upper bracket pinch bolt
23 Nm (2.3 mSkg)
Handlebar holder bolt
20 Nm (2.0 mSkg)
3-28
CHECKING THE FRONT FORK
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
EAS00149
CHECKING THE FRONT FORK
2. Check:
S inner tube
Damage/ scratches ! Replace.
S oil seal
Oil leakage ! Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
S operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation ! Repair.
Refer to FRONT FORK in chapter 6.
EAS00166
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:
S tire pressure
Out of specification ! Regulate.
S The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
S The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
S Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
3-29
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
Basic weight
(with oil and a full
fuel tank)
125 kg
Maximum load* 180 kg
Cold tire pressure Front tire Rear tire
Up to 80 kg load*
150 kPa
(1.50kgf / cm
2
,
1.5 bar)
150 kPa
(1.50kgf / cm
2
,
1.5 bar)
80 kg X
maximum load*
150 kPa
(1.50 kgf / cm
2
,
1.5 bar)
175 kPa
(1.75 kgf / cm
2
,
1.75 bar)
Off road riding
125 kPa
(1.25 kgf / cm
2
,
1.25 bar)
125kPa
(1.25 kgf / cm
2
,
1.25 bar)
*: total of cargo, rider, passenger and accesso
ries
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
2. Check:
S tire surfaces
Damage/ wear ! Replace the tire.
Minimum tire tread depth
1.6 mm
1 Tire tread depth
2 Side wall
3 Wear indicator
S Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.
S When using tube tires, be sure to install the
correct tube.
S Always replace a new tube tire and a new
tube as a set.
S To avoid pinching the tube, make sure that
the wheel rim band and tube are centered
in the wheel groove.
S Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
Tube wheel ! Tube tire only
Tubeless wheel !Tube or tubeless tire
3-30
CHECKING THE TIRES
CHK
ADJ
WARNING
NOTE:
S 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 manufactur-
er and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.
Front tire
Manufacturer Type Size
BRIDGESTONE TW31 130/ 80-18 66P
Rear tire
Manufacturer Type Size
BRIDGESTONE TW34
180/ 80-14
M/ C 78P
S 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 pos-
sible injury to the rider or damage to the
motorcycle.
S After a tire has been repaired or replaced,
be sure to tighten the tire valve stem lock-
nut 1 to specification.
For tires with a direction of rotation mark 1 :
S Install the tire with the mark pointing in the
direction of wheel rotation.
S Align the mark 2 with the valve installation
point.
Tire valve stem locknut
1.5 Nm (0.15 mSkg)
3-31
CHECKING AND TIGHTENING THE SPOKES/
CHECKING AND LUBRICATING THE CABLES
CHK
ADJ
NOTE:
NOTE:
WARNING
NOTE:
EAS00169
CHECKING AND TIGHTENING THE SPOKES
spokes.
1. Check:
S spoke 1
Bends/ damage ! Replace.
Loose ! Tighten.
Tap the spokes with a screwdriver.
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
2. Tighten:
S spoke
(with a spoke wrench 2 )
Be sure to tighten the spokes before and after
break-in.
Spoke nipple
2 Nm (0.2 mSkg)
EAS00170
CHECKING AND LUBRICATING THE
CABLES
cable sheaths and cables.
Damaged cable sheaths may cause the
cable to corrode and interfere with its move-
ment. Replace damaged cable sheaths and
cables as soon as possible.
1. Check:
S cable sheath
Damage ! Replace.
2. Check:
S cable operation
Unsmooth operation ! Lubricate.
Engine oil or a suitable cable
lubricant
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.
3-32
LUBRICATING THE LEVERS AND PEDALS/LUBRICATING
THE SIDESTAND/LUBRICATING THE REAR SUSPENSION
CHK
ADJ
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Engine oil
EAS00172
LUBRICATING THE SIDESTAND
moving parts of the sidestand.
Engine oil
EAS00174
LUBRICATING THE REAR SUSPENSION
moving parts of the rear suspension.
Molybdenum disulfide oil
3-33
CHECKING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
EAS00176
ELECTRICAL SYSTEM
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
S Wear protective eye gear when handling or
working near batteries.
S Charge batteries in a well-ventilated area.
S Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
S DO NOT SMOKE when charging or han-
dling batteries.
S KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
S Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
S SKIN Wash with water.
S EYES Flush with water for 15 minutes and
get immediate medical attention.
Internal
S Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
1. Remove:
S seat
2. Disconnect:
S battery leads
(from the battery terminals)
S battery breather hose
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
S battery
3-34
CHK
ADJ
CAUTION:
WARNING
CAUTION:
4. Check:
S electrolyte level
The electrolyte level should be between the
minimum level mark 1 and the maximum
level mark 2 .
Below the minimum level mark ! Add dis-
tilled water to the proper level.
Add only distilled water. Tap water contains
minerals which are harmful to the battery.
5. Check:
S specific gravity
Less than 1.280 ! Recharge the battery.
Specific gravity
1.280 at 20_C
6. Charge:
S battery
Battery charging amperage and time
0.7 amps/ 10 hrs
Do not quick charge a battery.
S Loosen the battery sealing caps.
S Make sure that the battery breather hose
and battery vent are free of obstructions.
S To ensure maximum performance, always
charge a new battery before using it.
S Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
S If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
S When charging a battery, be sure to re-
move it from the motorcycle. (If charging
has to be done with the battery mounted on
the motorcycle, disconnect the negative
lead from the battery terminal.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
3-35
CHK
ADJ
NOTE:
CAUTION:
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure that the battery charger lead
clips are in full contact with the battery ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate heat in the contact area and a weak clip
spring may cause sparks.
S If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
Replace the battery whenever:
S battery voltage does not rise to specification or
bubbles fail to rise during charging,
S sulphation of one or more battery cells occurs
(as indicated by the battery plates turning
white or material accumulating in the bottom of
the battery cell),
S specific gravity readings after a long, slow
charge indicate that one battery cells charge
is lower than the rest,
S warpage or buckling of the battery plates or in-
sulators is evident.
7. Check:
S battery breather hose and battery vent
Obstruction ! Clean.
Damage ! Replace.
8. Install:
S battery
9. Connect:
S battery breather hose 1
S When inspecting the battery, make sure
that the battery breather hose is properly
attached and routed correctly. If the battery
breather hose is positioned so as to allow
electrolyte or hydrogen gas from the bat-
tery to contact the frame, the motorcycle
and its finish may be damaged.
S Make sure that the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.
3-36
CHECKING THE BATTERY/CHECKING THE FUSES
CHK
ADJ
CAUTION:
CAUTION:
NOTE:
10. Check:
S battery terminals
Dirt ! Clean with a wire brush.
11. Connect:
S battery leads
(to the battery terminals)
First, connect the positive lead 1 , then the
negative lead 2 .
12. Lubricate:
S battery terminals
Dielectric grease
13. Install:
S seat
EAS00181
CHECKING THE FUSE
fuses.
To avoid a short circuit, always turn the main
switch to OFF when checking or replacing
a fuse.
1. Remove:
S seat
2. Check:
S fuse
a. Connect the pocket tester to the fuse and
check it for continuity.
Set the pocket tester selector to 1.
Pocket tester
90890-03112
b. If the pocket tester indicates , replace the
fuse.
3-37
CHECKING THE FUSE/
REPLACING THE HEADLIGHT BULB
CHK
ADJ
WARNING
3. Replace:
blown fuse
a. Turn off the ignition.
b. Install a new fuse of the correct amperage
rating.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
S seat
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
S headlight cover 1
S headlight unit 2
2. Disconnect:
S headlight coupler 1
S headlight bulb cover 2
3-38
REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM
CHK
ADJ
WARNING
CAUTION:
a
b
3. Remove:
S headlight bulb holder 1
S headlight bulb 2
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:
S headlight bulb (New)
Secure the new headlight bulb with the head-
light bulb holder.
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. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install:
S headlight bulb holder
6. Connect:
S headlight coupler
7. Install:
S headlight unit
S headlight cover
EAS00184
1. Adjust:
S headlight beam (vertically)
a. Turn the adjusting screw 1 in direction
a
or
b .
Direction ! Headlight beam is
raised.
Direction ! Headlight beam is
lowered.
3-39
CHK
ADJ
a
b
2. Adjust:
S headlight beam (horizontally)
a. Turn the adjusting knob 2 in direction
a
or
b .
Direction ! Headlight beammoves to
the right.
Direction ! Headlight beammoves to
the left.
CHK
ADJ
ENG

4
CHAPTER 4.
OVERHAULING THE ENGINE
ENGINE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAD AND EXHAUST PIPE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR AND DRIVE SPROCKET 4-2 . . . . . . . . . . . . . . . . . . . . . .
ENGINE 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT SPROCKET COVER 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER 4-8 . . . . . . . . . . . . . . . . .
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFT SPROCKET 4-9 . . . . . . . . . . . . . . . . . . . .
CAMSHAFT 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE ROCKER ARMS AND CAMSHAFT 4-13 . . . . . . . . . . . .
CHECKING THE CAMSHAFTS 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4-14 .
INSTALLING THE CAMSHAFT AND ROCKER ARMS 4-15 . . . . . . . . . . .
VALVES AND VALVE SPRINGS 4-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE VALVES 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVES AND VALVE GUIDES 4-19 . . . . . . . . . . . . . . . .
CHECKING THE VALVE SEATS 4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE VALVE SPRINGS 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE VALVES 4-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER AND PISTON 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE PISTON AND PISTON RINGS 4-25 . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON 4-25 . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS 4-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PIN 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PISTON AND CYLINDER 4-28 . . . . . . . . . . . . . . . . . . .
CLUTCH 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 4-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS 4-34 . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING 4-34 . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS 4-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PUSH RODS 4-35 . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CLUTCH 4-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SEGMENT 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE PROMARY GEAR 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL PUMP 4-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PRIMARY DRIVE GEAR 4-46 . . . . . . . . . . . . . . . . . . . .
BALANCER GEAR 4-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE BALANCER DRIVEN GEAR 4-48 . . . . . . . . . . . . . . . . . .
CHECKING THE BALANCER DRIVE GEAR 4-48 . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE BALANCER DRIVE GEAR 4-48 . . . . . . . . . . . . . . . . .
INSTALLING THE BALANCER DRIVEN GEAR 4-49 . . . . . . . . . . . . . . . . .
STARTER CLUTCH AND GENERATOR 4-50 . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR COVER 4-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL 4-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH AND GENERATOR 4-52 . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR ROTOR 4-53 . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH 4-53 . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH 4-54 . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR ROTOR 4-55 . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT 4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE 4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND BALANCER WEIGHT 4-58 . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE 4-59 . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE PLUNGER SEAL 4-59 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT AND CONNECTING ROD 4-60 . . . . . .
CHECKING THE BEARINGS AND OIL SEALS 4-61 . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET, AND
TIMING CHAIN GUIDES 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PLUNGER SEAL 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CRANKSHAFT 4-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE 4-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION 4-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT
FORKS 4-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE AXLE AND MAIN AXLE 4-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION 4-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS 4-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY 4-65 . . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION 4-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION, SHIFT FORKS AND
SHIFT DRUM ASSEMBLY 4-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
ENGINE
ENG
1
2
3
4
5
Disconnecting the leads and hoses
Seat, fuel tank and side cover
Battery lead
Generator coupler/ starter motor
coupler
Plug cap
Muffler
Exhaust pipe
Gasket
1/ 1
1
1
1
1
Disconnect the parts in the order listed.
COVER in CHAPTER 3.
First, disconnect the negative lead,
then the positive lead.
For connecting, reverse the disconnection
procedure.
CAUTION:
12 Nm (1.2 mSkg)
20 Nm (2.0 mSkg)
27 Nm (2.7 mSkg)
20 Nm (2.0 mSkg)
EAS00188
OVERHAULING THE ENGINE
ENGINE
LEAD AND EXHAUST PIPE
4-2
ENGINE
ENG
1
2
3
4
5
6
7
8
Removing the carburetor and drive
sprocket
Carburetor
Clutch cable
Crankcase breather hose
Ground lead
Shift pedal
Generator cover
Rear wheel axle nut
Sprocket holder
Drive sprocket / drive chain
1
1
1
1
1
1
1
1/ 1
Refer to CARBURETOR in CHAPTER 5.
Loosen the axle nut and slacken the drive
chain.
For installation, reverse the removal pro-
cedure.
NOTE:
6 Nm (0.6 mSkg)
10 Nm (1.0 mSkg)
7 Nm (0.7 mSkg)
EAS00189
CARBURETOR AND DRIVE SPROCKET
4-3
1
2
3
4
5
Removing the engine
Engine stay (top)
Front engine stay
Pivot shaft
Engine mount bolt (rear under)
Engine
1
1
1
1
1
Securely support the motorcycle so
Refer to INSTALLING THE ENGINE.
cedure.
33 Nm (3.3 mSkg)
33 Nm (3.3 mSkg)
33 Nm (3.3 mSkg)
33 Nm (3.3 mSkg)
80 Nm (8.0 mSkg)
ENGINE
ENG
EAS00192
ENGINE
4-4
ENGINE
ENG
NOTE:
10 Nm (1.0 mSkg)
EAS00192
INSTALLING THE ENGINE
1. Install:
S pivot shaft 1
S engine mount bolt (rear) 2
S engine mount bolt (front) 3
S engine mount bolt (front) 4
S engine mount bolt (top) 5
S engine bracket bolt (front) 6
S engine bracket bolt (front) 7
S engien bracket bolt (top) 8
S engine bracket bolt (top) 9
Do not fully tighten the bolts.
2. Tighten the bolts in the following order.
Pivot shaft 1
80 Nm (8.0 mSkg)
Engine mount bolt (rear) 2
33 Nm (3.3 mSkg)
Engine mount bolt (front) 3
33 Nm (3.3 mSkg)
Engine mount bolt (front) 4
33 Nm (3.3 mSkg)
Engine mount bolt (top) 5
33 Nm (3.3 mSkg)
Engine bracket bolt (front) 6
33 Nm (3.3 mSkg)
Engine bracket bolt (front) 7
33 Nm (3.3 mSkg)
Engine bracket bolt (top) 8
33 Nm (3.3 mSkg)
Engine bracket bolt (top) 9
33 Nm (3/3 mSkg)
3. Install:
S shift pedal 1
4-5
CYLINDER HEAD
ENG
1
2
3
4
5
6
7
Removing the comshaft sprocket
cover
Side cover, seat and fuel tank
Exhaust pipe assembly
Carburetor assembly
Engine stay (top)
Spark plug
Camshaft sprocket cover/ O-ring
Valve cover (intake side)/ O-ring
Valve cover (exhaust side)/ O-ring
Intake manifold/ O-ring
Timing mark cap/ O-ring
Center cap/ O-ring
1
1/ 1
1/ 1
1/ 1
1/ 1
1/ 1
1/ 1
COVER in CHAPTER 3.
Refer to ENGINE.
procedure.
Refer to CARBURETOR in CHAPTER
5.
Refer to ENGINE.
10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg)
10 NM (1.0 mSkg)
7 Nm (0.7 mSkg)
CYLINDER HEAD
CAMSHAFT SPROCKET COVER
4-6
CYLINDER HEAD
ENG
1
2
3
4
5
6
Removing the cylinder head
Timing chain tensioner assembly
Camshaft sprocket / Timing chain
Cylinder head
Dowel pins
Gasket
Cylinder head gasket
1
1/ 1
1
3
1
1
Refer to REMOVEING THE CYLINDER
HEAD/INSTALLING THE CAMSHAFT
SPROCKET.
Refer to REMOVING/ INSTALLING THE
CYLINDER HEAD.
procedure.
22 Nm (2.2 mSkg)
20 Nm (2.0 mSkg)
60 Nm (6.0 mSkg)
10 Nm (1.0 mSkg)
EAS00221
CYLINDER HEAD
4-7
CYLINDR HEAD
ENG
NOTE:
EAS00225
REMOVING THE CYLINDER HEAD
1. Align:
S I mark
a
on the generator rotor (with the
stationary pointer b on the crankcase cov-
er)
a. Turn the primary pulley counterclockwise.
sion stroke, align the I mark
c
on the cam-
shaft sprocket with the mark d on the cylin-
der head.
2. Loosen:
S bolt 1
3. Remove:
S cap bolt 1
S timing chain tensioner 2
(along with the gasket)
Scamshaft sprocket 3
S timing chain 4
S To prevent the timing chain from falling into the
crankcase, fasten it with a wire
a
.
S While holding the generator rotor bolt with a
wrench, remove the bolt.
4-8
CYLINDER HEAD
ENG
NOTE:
NOTE:
NOTE:
4. Remove:
S cylinder head
S Loosen the nuts in the proper sequence.
S Loosen each nut 1/ 2 of a turn at a time.
After all of the nuts are fully loosened, remove
them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:
S combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:
S spark plug threads
S valve seats
2. Check:
S cylinder head
Damage/ scratches ! Replace.
3. Measure:
S cylinder head warpage
Out of specification ! Resurface the cylin-
der head.
Cylinder head warpage
Less than 0.05 mm
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 X 600 grit wet abrasive paper
on the surface plate and resurface the cylin-
der head using a figure-eight sanding pat-
tern.
To ensure an even surface, rotate the cylinder
head several times.
4-9
CYLINDER HEAD
ENG
NOTE:
NOTE:
EAS00216
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
S timing chain tensioner
EAS00212
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
tappet covers and O-rings.
1. Check:
S tappet cover
S camshaft sprocket cover
S O-ring
Damage/ wear ! Replace the defective
part(-s).
EAS00233
INSTALLING THE CYLINDER HEAD
1. Install:
S dowel pins 1
S O-ring 2
S gasket (New) 3
The UP mark on the gasket must face up.
2. Install:
S cylinder head
S Apply engine oil onto the threads of the cylin-
der head nuts.
S Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
Cylinder head nut
M8 ( 1 X 4 ) 22Nm (2,2mSkg)
M8 ( 5 X 6 ) 20Nm (2,0mSkg)
4-10
CYLINDER HEAD
ENG
NOTE:
NOTE:
CAUTION:
60 Nm (6.0 mSkg)
EAS00213
INSTALLING THE CAMSHAFT SPROCKET
1. Align:
S I mark on the generator rotor
(with the mark on the generator rotor cover)
a. Turn the crankshaft counterclockwise.
sion stroke, align the I mark
a
on the gen-
erator rotor with the mark b on the genera-
tor rotor cover.
Be sure to keep the timing chain as tight as pos-
sible.
2. Install:
S timing chain
(onto the camshaft sprocket)
S camshaft sprocket
(onto the camshaft)
The notch
a
on the camshaft should face to-
wards the intake side of the engine.
Align the camshaft marks
a
with the edge of
the cylinder head as shown.
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
3. Install:
S washer 1
S camshaft sprocket bolts 2
4-11
CYLINDER HEAD
ENG
WARNING
NOTE:
5. Install:
S timing chain tensioner
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver 1 .
b. with the timing chain tensioner rod turned
all the way into the timing chain tensioner
housing (with the thin screwdriver still
installed),install the gasket and the timing
chain tensioner 2 onto the cylinder block.
Always use a new gasket.
c. Tighten the timing chain tensioner bolts to
the specified torque.
Timing chain tensioner bolt
10 Nm (1,0 mSkg)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and
then tighten the cap bolt 3 to the specified
torque.
6. Turn:
S crankshaft
Turn the crankshaft several full turns to make
sure that the camshaft is properly timed.
7. Install:
S dowel pins
S camshaft end cap 1
8. Lubricate:
S cylinder head components
Engine oil
4-12
CAMSHAFT
ENG
1
2
3
4
5
6
7
8
9
Removing the camshaft
Cylinder head
Lock washer
Camshaft retainer
Camshaft bushing
Camshaft
Rocker arm shaft (intake side)
Rocker arm shaft (exhaust side)
Rocker arm
O-ring
Nut / Adjuster
1
1
1
1
1
1
2
1
2/ 2
Refer to CYLINDER HEAD.
Refer to REMOVING THE ROCKER
ARMS AND CAMSHAFT/ INSTALLING
THE CAMSHAFT AND ROCKER ARMS.
procedure.
14 Nm (1.4 mSkg)
14 Nm (1.4 mSkg)
8 Nm (0.8 mSkg)
EAS00195
CAMSHAFT
4-13
CAMSHAFT
ENG
NOTE:
NOTE:
EAS00202
REMOVING THE ROCKER ARMS AND CAM-
SHAFT
1. Loosen:
S locknuts 1
S adjusting screws 2
2. Remove:
S bolt 1
S lock washer 2
S camshaft retainer 3
3. Remove:
S camshaft 1
S camshaft bushing 2
Screw a 10-mm bolt 3 into the threaded end of
the camshaft and then pull out the camshaft.
4. Remove:
S intake rocker arm shaft
S exhaust rocker arm shaft
S intake rocker arm
S exhaust rocker arm
Attach a rocker arm shaft puller bolt 1 and
weight 2 to the rocker arm shaft and slide out
the shaft.
Rocker arm shaft puller bolt
90890-01083
Weight
90890-01084
EAS00205
CHECKING THE CAMSHAFTS
1. Check:
S camshaft bushings
Damage/ wear ! Replace.
2. Check:
S camshaft lobes
Blue discoloration/ pitting/ scratches ! Re-
place the camshaft.
4-14
CAMSHAFT
ENG
A B
3. Measure:
S camshaft lobe dimensions A and B
Out of specification ! Replace the cam-
shaft.
Camshaft lobe dimension limit
Intake
A 36.45 mm
B 30.05 mm
Exhaust
A 36.49 mm
B 30.13 mm
4. Check:
S camshaft oil passage
Obstruction ! Blow out with compressed air.
EAS00206
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
S rocker arm
2. Check:
S rocker arm shaft
Blue discoloration/ excessive wear/ pit-
ting/ scratches ! Replace or check the lu-
brication system.
3. Check:
S camshaft lobe
Excessive wear ! Replace the camshaft.
4. Measure:
S rocker arm inside diameter
Out of specification ! Replace.
Rocker arm inside diameter
12.000 X 12.018 mm
Limit 12.036 mm
5. Measure:
S rocker arm shaft outside diameter
Rocker arm shaft outside
diameter
11.985 X 11.991 mm
Limit 11.950 mm
4-15
CAMSHAFT
ENG
NOTE:
NOTE:
NOTE:
6. Calculate:
S rocker-arm-to-rocker-arm-shaft clearance
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification ! Replace the defective
part(-s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 X 0.033 mm
INSTALLING THE CAMSHAFT AND ROCK-
ER ARMS
1. Lubricate:
S rocker arm shaft
2. Install:
S exhaust rocker arm
S exhaust rocker arm shaft
Make sure that the exhaust rocker arm shaft is
completely pushed into the cylinder head.
3. Install:
S intake rocker arm
S intake rocker arm shaft 1
Insert a cylinder head bolt 2 into the hole in the
cylinder head and the intake rocker arm shaft as
shown.
4. Lubricate:
S Camshaft
Camshaft
Camshaft bearing
Engine oil
4-16
CAMSHAFT
ENG
New
8 Nm (0.8 mSkg)
NOTE:
5. Install:
S camshaft retainer 1
S Lock washer 2
S Bolt 3
Bend the lock washer tab along a flat side of the
bolt 3 .
4-17
1
2
3
4
5
6
7
8
Removing the valves and valve
springs
Cylinder head
Rocker arm, Camshaft
Valve cotters
Spring retainer
Valve spring (inner)
Valve spring (outer)
Valve (exhaust)
Valve (intake)
Valve guide (stem seal)
Spring seat
4
2
2
2
1
1
2
2
Refer to CAMSHAFT.
cedure.
VALVES.
VALVES AND VALVE SPRINGS
ENG
EAS00236
4-18
ENG
NOTE:
NOTE:
NOTE:
EAS00238
REMOVING THE VALVES
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.
1. Check:
S valve sealing
Leakage at the valve seat ! Check the valve
face, valve seat, and valve seat width.
Refer to CHECKING THE VALVE SEATS.
a. Pour a clean solvent
a
into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1 .
2. Remove:
S valve cotters 1
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3 .
90890-04019
Attachment
90890-04108
3. Remove:
S upper spring seat 1
S valve springs 2
S oil seal 3
S lower spring seat 4
S valve 5
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
4-19
ENG
NOTE:
NOTE:
EAS00239
CHECKING THE VALVES AND VALVE GUIDES
valves and valve guides.
1. Measure:
S valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter
a

Valve stem diameter b
Out of specification ! Replace the valve
guide.
Valve-stem-to-valve-guide clear-
ance
Intake
0.010 X 0.037 mm
Limit: 0.08 mm
Exhaust
0.025 X 0.052 mm
Limit: 0.10 mm
2. Replace:
S valve guide
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C in an oven.
a. Remove the valve guide with a valve guide
remover 1 .
b. Install the new valve guide with a valve guide
installer 2 and valve guide remover 1 .
c. After installing the valve guide, bore the
valve guide with a valve guide reamer 3 to
obtain the proper valve-stem-to-valve-guide
clearance.
After replacing the valve guide, reface the valve
seat.
Valve guide remover (6 mm)
90890-04064
Valve guide installer (6 mm)
90890-04065
Valve guide reamer (6 mm)
90890-04066
4-20
ENG
NOTE:
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/ wear ! Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem ! Replace the valve.
5. Measure:
S valve margin thickness
a
Out of specification ! Replace the valve.
Valve margin thickness
0.8 X 1.2 mm
6. Measure:
S valve stem runout
Out of specification ! Replace the valve.
S When installing a new valve, always replace
the valve guide.
S If the valve is removed or replaced, always re-
place the oil seal.
Valve stem runout
Limit: 0.03 mm
EAS00240
CHECKING THE VALVE SEATS
valves and valve seats.
1. Eliminate:
S carbon deposits
(from the valve face and valve seat)
2. Check:
S valve seat
Pitting/ wear ! Replace the cylinder head.
3. Measure:
S valve seat width
a
Out of specification ! Replace the cylinder
head.
Valve seat width
Intake: 0.9 X 1.1 mm
Limit: 1.6 mm
Exhaust: 0.9 X 1.1 mm
Limit: 1.6 mm
4-21
ENG
NOTE:
CAUTION:
NOTE:
a. Apply Mechanics blueing dye (Dykem) 1
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width. Where the
valve seat and valve face contacted one
another, the blueing will have been removed.
4. Lap:
S valve face
S valve seat
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound
a
to the
valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.
4-22
ENG
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanics 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 impres-
sion.
j. Measure the valve seat width
c
again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
valve springs.
1. Measure:
S valve spring free length
a
spring.
Valve spring free length (intake
and exhaust)
Inner spring
35.5 mm Limit: 33.5 mm
Outer spring
37.2 mm Limit: 35.2 mm
2. Measure:
S compressed spring force
a
spring.
b Installed length
Compressed spring force
Intake and exhaust inner
spring
8.4 X 10.2 kg at 30.5 mm
Intake and exhaust outer
spring
16.6 X 20.4 kg at 32.0 mm
3. Measure:
S valve spring tilt
a
spring.
Spring tilt limit
Intake and exhaust inner spring
2.5_/ 1.5 mm
Intake and exhaust outer spring
2.5_/ 1.6 mm
4-23
ENG
NOTE:
NOTE:
CAUTION:
EAS00246
INSTALLING THE VALVES
valves and related components.
1. Deburr:
S valve stem end
(with an oil stone)
2. Lubricate:
S valve stem
S oil seal
(with the recommended lubricant)
3. Install:
S valve 1
S lower spring seat 2
S oil seal 3
S valve springs 4
S upper spring seat 5
(into the cylinder head)
Install the valve springs with the larger pitch a
facing up.
4. Install:
S valve cotters 1
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3 .
90890-04019
Attachment
90890-04108
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
Hitting the valve tip with excessive force
could damage the valve.
4-24
CYLINDER AND PISTON
ENG
1
2
3
4
5
6
7
8
9
Removing the cylinder and piston
Cylinder head
Timing chain guide (exhaust side)
Cylinder/ O-ring
O-ring
Dowel pin
Cylinder gasket
Piston pin circlip
Piston pin
Piston
Piston ring set
1
1/ 1
1
2
1
2
1
1
1
procedure.
Refer to REMOVING THE PISTON
AND PISTON RINGS.
Refer to INSTALLING THE PISTON
AND CYLINDER.
Refer to INSTALLING THE PISTON
AND CYLINDER.
EAS00265
CYLINDER AND PISTON
4-25
CYLINDER AND PISTON
ENG
NOTE:
NOTE:
NOTE:
YP******
REMOVING THE PISTON AND PISTON
RINGS
1. Remove:
S piston pin circlip 1
S piston pin 2
S piston 3
Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the crank-
case cavity.
2. Remove:
S top ring
S 2nd ring
S oil ring
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
EAS00255
CHECKING THE CYLINDER AND PISTON
1. Check:
S piston wall
S cylinder wall
Vertical scratches ! Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
S piston-to-cylinder clearance
a. Measure cylinder bore C with the cylinder
bore gauge.
Measure cylinder bore C by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the measure-
ments.
Cylinder bore C 57.00 X 57.02 mm
Taper limit T 0.05 mm
Out of round R 0.01 mm
C = Maximum D
T = (Maximum D
1
or D
2
)
(Maximum D
5
or D
6
)
R = (Maximum D
1
, D
3
or D
5
)
(Minimum D
2
, D
4
or D
6
)
4-26
CYLINDER AND PISTON
ENG
NOTE:
b. If out of specification, rebore or replace the
rings as a set.
c. Measure piston skirt diameter P with the
micrometer.
1 7.0 mm from the bottom edge of the piston.
Piston size P
Standard 56.960 X 56.975 mm
Oversize 2 57.25 mm
Oversize 4 57.50 mm
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore C
Piston skirt diameter P
Piston-to-cylinder clearance
0.035 X 0.055 mm
f. If out of specification, rebore or replace the
rings as a set.
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
S piston ring side clearance
Out of specification ! Replace the piston
and piston rings as a set.
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance
Top ring
0.03 X 0.07 mm
<Limit>: 0.15 mm
2nd ring
0.02 X 0.06 mm
<Limit>: 0.15 mm
4-27
CYLINDER AND PISTON
ENG
NOTE:
NOTE:
2. Install:
S piston ring
(into the cylinder)
Level the piston ring in the cylinder with the pis-
ton crown as shown.
a 5.0 mm
3. Measure:
S piston ring end gap
ring.
The oil ring expander spacers end gap cannot
be measured. If the oil ring rails gap is exces-
sive, replace all three piston rings.
Piston ring end gap
Top ring
0.15 X 0.35 mm
<Limit>: 0.60 mm
2nd ring
0.15 X 0.35 mm
<Limit>: 0.60 mm
Oil ring
0.3 X 0.9 mm
EAS00265
CHECKING THE PISTON PIN
1. Check:
S piston pin
Blue discoloration/ grooves ! Replace the
piston pin and then check the lubrication sys-
tem.
2. Measure:
S piston pin outside diameter
a
pin.
14.987 X 14.992 mm
3. Calculate:
S piston-pin-to-piston clearance
Out of specification ! Replace the piston pin
and piston as a set.
4-28
CYLINDER AND PISTON
ENG
NOTE:
New
NOTE:
New
Piston-pin-to-piston clearance =
Piston pin bore size b
a
Piston-pin-to-piston clearance
0.010 X 0.026 mm
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
S top ring 1
S 2nd ring 2
S lower oil ring rail 3
S upper oil ring rail 4
S oil ring expander 5
Be sure to install the piston rings so that the
manufacturers marks or numbers face up.
2. Install:
S piston 1
S piston pin 2
S piston pin clip 3
S Apply engine oil onto the poston pin.
S Make sure that the arrow mark
a
on the piston
points towards the exhaust side of the cylinder.
S Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
3. Install:
S gasket 1
S dowel pins
2
4. Lubricate:
S piston
S piston rings
S cylinder
Engine oil
4-29
CYLINDER AND PISTON
ENG
NOTE:
5. Offset:
S piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
6. Install:
S cylinder 1
S While compressing the piston rings with one
hand, install the cylinder with the other hand.
S Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
4-30
CLUTCH
ENG
1
2
3
Removing the clutch cover
Drain the engine oil
Clutch cover
Clutch cover gasket
Dowel pins
1
1
2
Refer to CHANGING THE ENGINE OIL
in CHAPTER 3.
cedure.
7 Nm (0.7 mSkg)
EAS00273
CLUTCH
CLUTCH COVER
4-31
CLUTCH
ENG
1
2
3
4
5
6
7
8
9
10
11
4
1
4
3
1/ 1
1
1
1
1
1
1/ 1
Removing the clutch
Clutch springs
Pressure plate
Friction plates
Clutch plates
Nut / Lock washer
Clutch boss
Thrust washer
Clutch housing
Ball
Long clutch push rod
Push lever screw/ Gasket
6 Nm (0.6 mSkg)
8 Nm (0.8 mSkg)
70 Nm (7.0 mSkg)
12 Nm (1.2 mSkg)
Refer to REMOVING/INSTALLING
THE CLUTCH.
EAS00274
CLUTCH
4-32
12
13
14
15
16
17
18
Push lever axle
Torsion spring
Circlip
Oil seal
Nut / Washer
Short clutch push rod/ O-ring
Push plate
1
1
1
1
1/1
1/1
1
Refer to INSTALLING THE CLUTCH.
Refer to INSTALLING THE CLUTCH.
cedure.
8 Nm (0.8 mSkg)
70 Nm (7.0 mSkg)
6 Nm (0.6 mSkg)
12 Nm (1.2 mSkg)
CLUTCH
ENG
4-33
CLUTCH
ENG
NOTE:
NOTE:
EAS00277
REMOVING THE CLUTCH
1. Straighten the lock washer tab 1 .
2. Loosen:
S clutch boss nut 2
While holding the clutch boss 3 with the univer-
sal clutch holder 4 , loosen the clutch boss nut.
Universal clutch holder
90890-04086
3. Remove:
S clutch boss nut 1
S lock washer 2
S clutch boss 3
S thrust washer 4
S clutch housing 5
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
S friction plate
Damage/ wear ! Replace the friction plates
as a set.
2. Measure:
S friction plate thickness
Out of specification ! Replace the friction
plates as a set.
Measure the friction plate at four places.
Friction plate thickness
2.9 X 3.1 mm
<Limit>: 2.7 mm
EAS00281
CHECKING THE CLUTCH PLATES
clutch plates.
1. Check:
S clutch plate
Damage ! Replace the clutch plates as a
set.
4-34
CLUTCH
ENG
NOTE:
NOTE:
2. Measure:
S clutch plate warpage
(with a surface plate and thickness gauge
1 )
Out of specification ! Replace the clutch
plates as a set.
Clutch plate warpage limit
Less than 0.05 mm
EAS00282
CHECKING THE CLUTCH SPRINGS
clutch springs.
1. Check:
S clutch spring
Damage ! Replace the clutch springs as a
set.
2. Measure:
S clutch spring free length
Out of specification ! Replace the clutch
springs as a set.
Clutch spring free length
34.9 mm
<Limit>: 33.9 mm
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
S clutch housing dogs
Damage/ pitting/ wear ! Deburr the clutch
housing dogs or replace the clutch housing.
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
S clutch boss splines
Damage/ pitting/ wear ! Replace the clutch
boss.
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
4-35
CLUTCH
ENG
NOTE:
70 Nm (7.0 mSkg)
NOTE:
EAS00288
CHECKING THE CLUTCH PUSH RODS
1. Check:
S O-ring 1
S short clutch push rod 2
S long clutch push rod 3
S ball 4
Cracks/ damage/ wear ! Replace the de-
fective part(-s).
2. Measure:
S long clutch push rod bending limit
Out of specification ! Replace the long
clutch push rod.
Long clutch push rod bending limit
0.2 mm
EAS00298
INSTALLING THE CLUTCH
1. Install:
S clutch housing 1
S thrust washer 2
S clutch boss 3
S lock washer
S clutch boss nut
Make sure that the teeth on the lock washer are
correctly aligned with the grooves on the clutch
boss.
2. Tighten:
S clutch boss nut 1
While holding the clutch boss with the universal
clutch holder 2 , tighten the clutch boss nut.
Universal clutch holder
90890-04086
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
S friction plates 1
S clutch plates 2
Engine oil
4-36
CLUTCH
ENG
NOTE:
New
6 Nm (0.6 mSkg)
NOTE:
NOTE:
5. Install:
S friction plates
S clutch plates
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
6. Install:
S long clutch push rod
S ball
7. Install:
S short clutch push rod 1
S O-ring 2
S push plate
3
S washer 4
S nut 5
8. Install:
S pressure plate 1
S clutch springs 2
S clutch spring bolts 3
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
9. Check:
S push lever position
Push lever mark
a
and crankcase mark b
not aligned ! Correct.
Push the push lever in direction
c
and make
sure that the marks are aligned.
10. Adjust:
S push lever position
b. Turn the adjusting screw 2 in or out until the
marks are aligned.
c. Hold the adjusting screw to prevent it from
moving and then tighten the locknut to speci-
fication.
4-37
CLUTCH
ENG
CAUTION:
7 Nm (0.7 mSkg)
NOTE:
Do not overtighten the locknut since this
will remove the free play between both push
rods.
Push lever lock nut
8Nm (0.8mSkg)
11. Install:
S clutch cover 1
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
4-38
SHIFT SHAFT AND STOPPER LEVER
ENG
1
2
3
4
5
6
7
8
9
Removing the shift shaft and stop-
per lever
Clutch
Shift pedal
Shift shaft
Plate washer
Torsion spring
Stopper lever
Plate washer
Circlip
Torsion spring
Collar
Tension spring
1
1
1
1
1
1
1
1
1
Refer to CLUTCH.
Refer to ENGINE.
Refer to INSTALLING THE SHIFT
SHAFT
12 Nm (1.2 mSkg)
EAS00327
4-39
ENG
10
11
12
13
Screw
Segment
Dowel pins (short length)
Dowel pins (long length)
1
1
4
1
cedure.
Refer to INSTALLING THE SEGMENT.
12 Nm (1.2 mSkg)
4-40
ENG
NOTE:
NOTE:
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
S shift shaft 1
S shift lever 2
Bends/ damage/ wear ! Replace.
S shift lever spring
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
S stopper lever
Roller turns roughly ! Replace the stopper
lever.
INSTALLING THE SEGMENT
1. Install:
S segment 1
S dowel pin 2 (long length)
S dowel pins 3 (short length)
Install the dowel pin 2 (long length) into the
hole beside the match mark
a
position.
2. Install:
S segment 1
Fit the dowel pin 2 (long length) on the seg-
ment to the locating hole
a
on the sift cam and
install the segment.
4-41
ENG
INSTALLING THE SHIFT SHAFT
1. Install:
S shift shaft assembly
a. Set the stopper lever and return spring to the
shift shaft.
b. Mesh the stopper lever 1 with the shift cam
segment.
c. Install the shift lever 2 to the shift cam seg-
ment.
d. After installing the shift shaft, check the shift
cam for smooth operation by turning the shift
shaft with your hand.
2. Check:
S shift lever 1 position
Gaps
a
and b are not equal ! Replace the
defective parts.
4-42
OIL PUMP
ENG
1
2
3
4
5
6
7
Removing the oil pump
Clutch
Nut
Lock washer
Primary drive gear
Oil pump drive gear
Oil pump cover
Oil pump assembly
Gasket (oil pump cover)
1
1
1
1
1
1
1
Remove the parts in the order listed
Refer to CLUTCH.
PRIMARY DRIVE GEAR.
Refer to INSTALLING/ THE OIL PUMP.
procedure.
50 Nm (5.0 mSkg)
7 Nm (0.7 mSkg)
EAS00357
OIL PUMP
4-43
1
2
3
4
5
6
7
Disassembling the oil pump
Oil pump housing
Dowel pin
Oil pump driven gear
Dowel pins
Inner rotor
Outer rotor
Housing
1
1
1
2
1
1
1
Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
Refer to ASSEMBLING THE OIL
PUMP.
7 Nm (0.7 mSkg)
OIL PUMP
ENG
EAS00360
4-44
OIL PUMP
ENG
NOTE:
REMOVING THE PRIMARY DRIVE GEAR
1. Straighten the lock washer tab.
2. Remove:
S nut (primary drive gear) 1
S lock washer 2
S primary drive gear 3
Place a folded aluminium plate or copper wash-
er
a
between the teeth of the balancer drive
gear 4 and balancer driven gear 5 .
EAS00364
CHECKING THE OIL PUMP
1. Check:
S oil pump driven gear 2
S oil pump housing 3
S oil pump housing cover 4
Cracks/ damage/ wear ! Replace the de-
fective part(-s).
2. Measure:
S inner-rotor-to-outer-rotor-tip clearance A
S outer-rotor-to-oil-pump-housing clearance
B
S oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance C
Out of specification ! Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip cle-
arance
0.03 X 0.09 mm
<Limit 0.14 mm>
Outer-rotor-to-oil-pump-housing
clearance
0.10 X 0.15 mm
<Limit 0.35 mm>
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.03 X 0.09 mm
<Limit 0.14 mm>
3. Check:
S oil pump operation
Unsmooth ! Repeat steps (1) and (2) or re-
place the defective part(-s).
4-45
OIL PUMP
ENG
7 Nm (0.7 mSkg)
NOTE:
7 Nm (0.7 mSkg)
CAUTION:
EAS411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
S inner rotor
S outer rotor
S oil pump shaft
Engine oil
2. Install:
S oil pump shaft 1
(to the oil pump cover 2 )
S pin 3
S inner rotor 4
S outer rotor 5
S pin 6
S oil pump housing 7
S screw 8
When installing the inner rotor, align the pin 3
in the oil pump shaft with the groove
a
on the
inner rotor 4 .
3. Check:
S oil pump operation
Refer to CHECKING THE OIL PUMP.
EAS00376
INSTALLING THE OIL PUMP
1. Install:
S oil pump 1
S oil pump drive gear 2
After tightening the bolts, make sure that
the oil pump turns smoothly.
4-46
OIL PUMP
ENG
New
50 Nm (5.0 mSkg)
NOTE:
EAS00302
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
S lock washer 2
S primary drive gear nut 3
S Place a folded aluminum plate
a
or copper
washer between the teeth of the balancer
drive gear 4 and the balancer driven gear 5
in order to lock them.
S Do not damage the balancer drive and balanc-
er driven gears teeth.
2. Bend the lock washer tab along a flat side of
the nut.
4-47
BALANCER GEAR
ENG
1
2
3
4
5
6
7
8
9
10
Removing the balancer gear
Clutch
Primary drive gear
Nut / Lock washer
Balancer driven gear
Woodruff key
Claw washer
Balancer drive gear
Buffer boss
Compression spring
Dowel pins
Woodruff key
Plate washer
1/ 1
1
1
1
1
1
6
3
1
1
Refer to CLUTCH.
Refer to OIL PUMP.
Refer to REMOVING/ INSTALLING
THE BALANCER DRIVEN GEAR.
cedure.
Refer to ASSEMBLING THE BALANC-
ER DRIVE GEAR ASSEMBLY.
50 Nm (5.0 mSkg)
BALANCER GEAR
4-48
BALANCER GEAR
ENG
NOTE:
NOTE:
NOTE:
SR******
REMOVING THE BALANCER DRIVEN GEAR
1. Straighten the lock washer tab.
2. Remove:
S nut (balancer driven gear) 1
S lock washer 2
S balancer driven gear 3
Place a folded aluminium plate or copper wash-
er
a
between the teeth of the balancer drive
gear 4 and balancer driven gear 3 .
SR******
CHECKING THE BALANCER DRIVE GEAR
1. Inspect:
S balancer drive gear 1
S buffer boss 2
S compression spring 3
S dowel pins 4
Wear/ Pitting/ Scratches ! Replace.
SR******
ASSEMBLING THE BALANCER DRIVE
GEAR
1. Assembly:
S dowel pins 1
S compression springs 2
Install the dowel pins and compression springs
alternately as shown as.
2. Install:
S buffer boss 1
Align the punched mark
a
on the buffer boss
with the one on the balancer drive gear.
4-49
BALANCER GEAR
ENG
NOTE:
New
50 Nm (5.0 mSkg)
NOTE:
SR******
INSTALLING THE BALANCER DRIVEN
GEAR
1. Install:
S balancer driven gear 1
Install the balancer driven gear, then mesh the
balancer driven gear match mark
a
and ba-
lancer drive gear assembly match mark b .
2. Install:
S lock washer 1
S nut (balancer drive gear) 2
S Place a folded aluminium plate or copper
washer
a
between the teeth of the balancer
drive gear 3 and balancer driven gear 4 .
3. Bend the lock washer tab, after tighten the
nut flats.
4-50
STARTER CLUTCH AND GENERATOR
ENG
1
2
3
4
Removing the generator cover
Side cover
Generator lead couplers
Generator cover
Gasket
Dowel pins
1
1
1
2
Remove the parts in the orser listed.
Refer to CHANGING THE ENGINE OIL
in CHAPTER 3.
Refer to SEAT FUEL TANK AND SIDE
COVER in CHAPTER 3.
cedure.
7 Nm (0.7 mSkg)
GENERATOR COVER
4-51
ENG
1
2
3
4
Removing the stator coil
Clamp (stator coil)
Clamp (pickup coil)
Pickup coil
Stator coil
1
1
1
1
cedure.
3 Nm (0.3 mSkg)
7 Nm (0.7 mSkg)
EAS00341
STATOR COIL
4-52
ENG
1
2
3
4
5
6
7
8
9
10
11
Removing the starter clutch and
generator rotor
Generator rotor
Idle shaft / collar
Starter idle gear
Woodruff key
Starter wheel gear
Shim
Dowel pins (Inner)
Spring caps
Compression springs
Dowel pins (outer)
Starter clutch
1
1
1
1
1
1
3
3
3
3
1
THE GENERATOR ROTOR.
Refer to INSTALLING THE STARTER
CLUTCH.
cedure.
30 Nm (3.0 mSkg)
50 Nm (5.0 mSkg)
EAS00343
STARTER CLUTCH AND GENERATOR ROTOR
4-53
ENG
NOTE:
NOTE:
REMOVING THE GENERATOR ROTOR
1. Remove:
S bolt 1 (magneto)
S plain washer 2
S Loosen the bolt (generator rotor) 1 while
holding the rotor with a sheave holder 3 .
S Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder:
90890-01701
2. Remove:
S generator rotor 1
S woodruff key
Remove the rotor using sheave holder 2 , rotor
puller 3 and rotor puller attachment 4 .
Rotor puller:
90890-01080
Rotor puller attachment:
90890-04052
EAS00348
CHECKING THE STARTER CLUTCH
1. Check:
S starter clutch idle gear 1
S starter clutch drive gear 2
S starter clutch gear 3
Burrs/ chips/ roughness/ wear ! Replace
the defective part(-s).
2. Check:
S starter clutch operation
a. Hold the starter clutch.
4-54
ENG
30 Nm (3.0 mSkg)
b. When turning the starter clutch gear clock-
wise
a
, the starter clutch and the starter
clutch gear should engage.
If the starter clutch gear and starter clutch do
not engage, the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch gear counter-
clockwise b , it should turn freely.
If the starter clutch gear does not turn freely,
the starter clutch is faulty and must be re-
placed.
3. Inspect:
S dowel pins 1
S spring caps 3
Wear/ Damage ! Replace.
4. Inspect:
S starter wheel gear
(contacting surface)
Pitting/ Wear/ Damage ! Replace.
INSTALLING THE STARTER CLUTCH
1. Install:
S starter clutch assembly 1
2. Unloosen the starter clutch assembly by us-
ing the center punch.
3. Install:
S spring caps 2
S dowel pins 3
4-55
ENG
NOTE:
50 Nm (5.0 mSkg)
NOTE:
INSTALLING THE GENERATOR ROTOR
1. Install:
S shim 1
S starter wheel gear 2
S woodruff key 3
2. Install:
S generator rotor 1
S Clean the tapered portion of the crankshaft
and the rotor hub.
S When installing the rotor, make sure the wood-
ruff key is properly seated in the key way of the
crankshaft and turning the starter wheel gear
2 clockwise.
3. Tighten:
S generator rotor 1
Tighten the bolt while holding the generator ro-
tor with the sheave holder 2 .
Sheave holder:
90890-01701
4-56
1
Separation the crankcase
Engine
Cylinder head
Cylinder and piston
Clutch
Primary drive gear/ oil pump
Balancer weight drive gear
Shift shaft and segment
Generator / starter clutch
Timing chain guide (intake) 1
Refer to ENGINE.
Refer to CYLINDER AND PISTON.
Refer to CLUTCH.
Refer to OIL PUMP.
Refer to BALANCER DRIVE GEAR.
Refer to SHIFT SHAFT.
Refer to STARTER CLUTCH AND
GENERATOR.
7 Nm (0.7 mSkg)
8 Nm (0.8 mSkg)
CRANKSHAFT
ENG
CRANKSHAFT
CRANKCASE
4-57
2
3
4
Timing chain
Crankcase
Dowel pins
1
1
2
Refer to DISASSEMBLING/ ASSEM-
BLING THE CRANKCASE.
cedure.
8 Nm (0.8 mSkg)
7 Nm (0.7 mSkg)
CRANKSHAFT
ENG
4-58
CRANKSHAFT
ENG
1
2
3
4
5
6
7
Removing the crankshaft and ba-
lancer weight
Balancer weight
Crankshaft assembly
Dowel pin
Plunger seal
Compression spring
Bearings (balancer weight)
Bearing (crankshaft right)
1
1
1
1
1
2

1
Refer to INSTALLING THE CRANK
SHAFT.
THE PLUNGER SEAL.
cedure.
CRANKSHAFT AND BALANCER WEIGHT
4-59
CRANKSHAFT
ENG
NOTE:
NOTE:
CAUTION:
NOTE:
EAS00386
DISASSEMBLING THE CRANKCASE
1. Remove:
S crankcase bolts
S Loosen each bolt 1/ 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
S Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).
S The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
2. Remove:
S right crankcase
Set the left crankcase half under then put in the
flat head screw driver to the separating slit
a
.
S First check that the shift drum segments
teeth and the drive axle circlip are properly
positioned, then remove the right crank-
case.
S Do not damage the crankcase mating sur-
faces.
REMOVING THE PLUNGER SEAL
1. Remove:
S Dowel pin 1
S Plunger seal 2
S Compression spring 3
Remove the plunger seal and compression
spring, push the plunger seal lightly and remove
the dowel pin.
4-60
CRANKSHAFT
ENG
NOTE:
EAS00394
CHECKING THE CRANKSHAFT AND CON-
NECTING ROD
1. Measure:
S crankshaft runout
Out of specification ! Replace the crank-
shaft, bearing or both.
Turn the crankshaft slowly.
Crankshaft runout
Less than 0.03 mm
2. Measure:
S big end axial clearance
Out of specification ! Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end axial clearance
0.35 X 0.65 mm
Limit 1.0 mm
3. Measure:
S crankshaft width
Out of specification ! Replace the crank-
shaft.
Crankshaft width
55.95 X 56.00 mm
4. Check:
S crankshaft sprocket 1
Damage/ wear ! Replace the crankshaft.
S bearing 2
Cracks/ damage/ wear ! Replace the
crankshaft.
5. Check:
S crankshaft journal
Scratches/ wear ! Replace the crankshaft.
S crankshaft journal oil passage
4-61
CRANKSHAFT
ENG
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
S bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement ! Replace.
2. Check:
S oil seals
EAS00207
CHECKING THE TIMING CHAIN, CAM-
SHAFT SPROCKET, AND TIMING CHAIN
GUIDES
1. Check:
S timing chain
Damage/ stiffness ! Replace the timing
chain and camshaft sprocket as a set.
2. Check:
S camshaft sprocket
More than 1/ 4 tooth
a
wear ! Replace the
camshaft sprocket and the timing chain as a
set.
a 1/ 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
S timing chain guide (exhaust side)
S timing chain guide (intake side)
S timing chain guide (top side)
part(-s).
SR******
INSTALLING THE PLUNGER SEAL
1. Install:
S Compression spring 1
S Plunger seal 2
S Dowel pin 3
2. Check the plunger seal smooth operation
pushing the plunger seal by your finger.
4-62
CRANKSHAFT
ENG
CAUTION:
NOTE:
7 Nm (0.7 mSkg)
NOTE:
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
S crankshaft assembly 1
S balancer weight assembly 2
To avoid scratching the crankshaft and to
ease the installation procedure, apply
grease onto the oil seal lips and apply en-
gine oil onto each bearing.
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
S sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
Do not allow any sealant to come into contact
with the oil gallery
a
.
3. Install:
S dowel pins
S right crankcase
4. Tighten:
S crankcase right half
Tighten the screws in decreasing numerical or-
der (see numbers on the illustration).
4-63
TRANSMISSION
ENG
1
2
3
4
5
6
7
8
9
10
Removing the transmission, shift
drum assembly and shift forks
Crankcase separating
Shift fork guide bar 2 (short length)
Shift fork guide bar 1 (long length)
Shift cam
Shift fork 1 C (center)
Shift fork 2 R (right)
Shift fork 3 L (left)
Main axle assembly
Plate washer
Drive axle assembly
Plate washer
1
1
1
1
1
1
1
1
1
1
Refer to CRANKCASE AND
CRANKSHAFT.
Refer to INSTALLING THE
TRANSMISSION, SHIFT FORK AND
SHIFT DRUM ASSEMBLY.
cedure.
Refer to REMOVING THE TRANSMIS-
SION.
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
4-64
TRANSMISSION
ENG
Disassembling the drive axle and
main axle
Second wheel gear
First wheel gear
Fifth wheel gear
Circlip/ washer
Third wheel gear
Forth wheel gear
Drive axle
Second pinion gear
Forth pinion gear
Third pinion gear
Circlip/ washer
Fifth pinion gear gear
Main axle
1
1
1
1/ 1
1
1
1
1
1
1
1/ 1
1
1
For assembly, reverse the removal pro-
cedure.
8
1
2
3
4
5
6
7
9
10
11
12
13
DRIVE AXLE AND MAIN AXLE
4-65
TRANSMISSION
ENG
WARNING
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
S Drive axle assembly 1
S Main axle assembly 2
Remove them at same the time.
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks and related components.
1. Check:
S shift fork cam follower 1
S shift fork pawl 2
Bends/ damage/ scoring/ wear ! Replace
the shift fork.
2. Check:
S shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends ! Replace.
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
S shift fork movement
(on the shift fork guide bar)
Rough movement ! Replace the shift forks
and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
S shift drum grooves
Damage/ scratches/ wear ! Replace the
shift drum.
S shift drum segment
S shift drum bearing
Damage/ pitting ! Replace.
4-66
TRANSMISSION
ENG
90.9 X 91.1 mm
NOTE:
EAS00424
CHECKING THE TRANSMISSION
1. Measure:
S main axle runout
(with a centering device and dial gauge 1 )
Out of specification ! Replace the main
axle.
Main axle runout limit
0.08 mm
2. Measure:
S drive axle runout
(with a centering device and dial gauge 1 )
Out of specification ! Replace the drive
axle.
Drive axle runout limit
0.08 mm
3. Check:
S transmission gears
Blue discoloration/ pitting/ wear ! Replace
the defective gear(-s).
S transmission gear dogs
Cracks/ damage/ rounded edges ! Replace
the defective gear(-s).
4. Check:
S transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect ! Reassemble the transmission
axle assemblies.
When reassembling the main axle, press the
2nd pinion gear 1 onto it 2 as shown.
5. Check:
S transmission gear movement
Rough movement ! Replace the defective
part(-s).
6. Check:
S circlips
Damage/ bends/ looseness ! Replace.
4-67
TRANSMISSION
ENG
NOTE:
NOTE:
EAS00426
INSTALLING THE TRANSMISSION, SHIFT
FORKS AND SHIFT DRUM ASSEMBLY
1. Install:
S shift fork 3 L (left) 1
(face the L side for the clutch side.)
S shift fork 2 R (right) 2
(face the R side for the clutch side.)
S shift fork 1 C (center) 3
(face the C side for the magneto side.)
S shift fork guide bar 1 4 (long)
S shift fork guide bar 2 5 (short)
Install the shift forks with the embossed mark to
the right and in sequence (R, C, L) beginning
from the right.
2. Check:
S shift cam operation
Unsmoothy operation ! Repair.
Check the transmission and shift forks for
smooth operation by turning the shift cam with
your hand.
ENG
CARB

5
CHAPTER 5.
CARBURETOR
CARBURETOR 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETOR 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CARBURETOR 5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL 5-7 . . . . . . . . . . . . .
CHECKING THE FUEL COCK 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL COCK OPERATION 5-8 . . . . . . . . . . . . . . . . . . .
5-1
CARBURETOR
CARB
1
2
3
4
Removing the carburetor
Side cover
Seat
Fuel tank
Heater unit lead
Carburetor joint clamp screw
Air filter joint clamp screw
Carburetor assembly
Carburetor top
1
1
1
1
Remove the parts in order listed.
NOTE:
COVER in CHAPTER 3.
Disconnect the cable from wireharness.
Loosen.
procedure.
NOTE:
EAS00480
CARBURETOR
CARBURETOR
5-2
CARBURETOR
CARB
Disassembly the carburetor
Throttle cable
Throttle valve assembly
Throttle valve spring
Mixing chamber top/ O-ring
Drain screw assembly
Float chamber
Gasket (float chamber)
Float pin/ float
Needle valve assembly
Main jet
Main nozzle/ O-ring
1
1
1
1/ 1
1
1
1
1/ 1
1
1
1/ 1
Refer to ASSEMBLYING THE
CARBURETOR.
1
10
2
3
4
5
6
7
8
9
11
EAS00483
5-3
CARBURETOR
CARB
Pilot screw assembly
Pilot jet
Throttle stop screw assembly
Starter plunger assembly
Screw/ gasket
Heater unit / washer
1
1
1
1
1/ 1
1/ 1
procedure.
Refer to ASSEMBLING THE
CARBURETOR.
12
13
14
15
16
17
5-4
CARBURETOR
CARB
EAS00485
CHECKING THE CARBURETOR
1. Check:
S carburetor body
S float chamber
S jet housing
2. Check:
S fuel passages
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
S float chamber body
Dirt ! Clean.
4. Check:
S float chamber rubber gasket
5. Check:
S float
Damage ! Replace.
6. Check:
S needle valve 1
S needle valve seat 2
Damage/ obstruction/ wear ! Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:
S gasket 3
Damage/ wear ! Replace the needle valve,
needle valve seat and O-ring as a set.
5-5
CARBURETOR
CARB
CAUTION:
8. Check:
S piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness ! Replace the piston valve.
9. Check:
S starter plunger 1
S starter plunger spring 2
Bends/ cracks/ damage ! Replace.
10. Check:
S hose joints
11. Check:
S fuel hoses 1
Blow out the hoses with compressed air.
EAS00487
ASSEMBLING THE CARBURETOR
S Before assembling the carburetor, wash all
of the parts in a petroleum-based solvent.
S Always use a new gasket.
1. Install:
S main nozzle 1
S main jet 2
S pilot jet 3
5-6
CARBURETOR
CARB
NOTE:
2. Install:
S needle valve seat 1
3. Install:
S float 1
S needle valve
S float pin 2
Install the float pin from the side opposite the ar-
row.
4. Install:
S float chamber 1
S pilot screw 2
5. Install:
S starter plunger kit 1
5-7
CARBURETOR
CARB
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
Engine idling speed
1,300 X 1,500 r/ min
Refer to ADJUSTING THE ENGINE ID-
LING SPEED in chapter 3.
2. Adjust:
3 X 5 mm
CABLE FREE PLAY in chapter 3.
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
S fuel level
a
Fuel level (below the float cham-
ber mating surface)
0 X 2.0 mm
a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 to the fuel drain
pipe 2 .
Fuel level gauge
90890-01312
d. Loosen the fuel drain screw 3 .
e. Hold the fuel level gauge vertically next to the
float chamber.
f. Measure the fuel level
a
.
5-8
CARBURETOR
CARB
NOTE:
2. Adjust:
S fuel level
a. Remove the carburetor.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slight-
ly bending the float tang 1 .
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
EAS00505
CHECKING THE FUEL COCK
1. Check:
S fuel cock
2. Check:
S fuel cock strainer
(with compressed air)
Dirt / obstruction ! Clean.
Damage ! Replace.
EAS00506
CHECKING THE FUEL COCK OPERATION
After installing the fuel cock, check its opera-
tion.
1. Check that the fuel cock lever is positioned to
ON or RESERVE.
2. Place a container under the end of the fuel
hose.
3. Check:
S fuel cock operation 1
Fuel flows. Fuel cock is OK.
Fuel does not flow. Replace the fuel
cock.
CHAS

6
CHAPTER 6.
CHASSIS
FRONT WHEEL AND BRAKE DISC 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISC 6-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 6-8 . . . . . . . . . .
REAR WHEEL AND REAR BRAKE 6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE AND REAR WHEEL SPROCKET 6-12 . . . . . . . . . . . . . . . .
REMOVING THE REAR WHEEL 6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 6-16 .
CHECKING THE BRAKE 6-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE BRAKE SHOE PLATE 6-17 . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 6-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 6-18 . . . . . . . . . . . .
FRONT BRAKE 6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS 6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS 6-20 . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER 6-23 . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6-25 . . . .
CHECKING THE FRONT BRAKE MASTER CYLINDER 6-25 . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER 6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPER 6-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPER 6-30 . . . . . . . . . . . . . .
CHECKING THE FRONT BRAKE CALIPER 6-30 . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPER 6-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK 6-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS 6-36 . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS 6-36 . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS 6-37 . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS 6-38 . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS 6-41 . . . . . . . . . . . . . . . . . . . . . . .
HANDLEBAR 6-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBAR 6-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBAR 6-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBAR 6-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD 6-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET 6-49 . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD 6-49 . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD 6-50 . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER AND SWINGARM 6-51 . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER 6-52 . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER 6-52 . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 6-53 . . . . . . .
REMOVING THE DRIVE CHAIN 6-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM 6-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 6-55 . . . . . . .
CHECKING THE SWINGARM 6-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN 6-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 6-57 . . . . . .
INSTALLING THE SWINGARM 6-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE DRIVE CHAIN 6-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
1
2
3
4
5
6
Removing the front wheel and brake
disc
Speedometer cable
Wheel axle
Front wheel assembly
Collar
Meter gear unit assembly
Brake disc
1
1
1
1
1
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
Refer to REMOVING/INSTALLING THE
FRONT WHEEL
procedure.
NOTE:
13 Nm (1.3 mSkg)
90 Nm (9.0 mSkg)
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00512
CHASSIS
6-2
CHAS
Disassembling the front wheel
Oil seal
Bearing
Spacer
Spacer flange
Bearing
1
1
1
1
1
Refer to ASSEMBLYNG/
DISASSEMBLING THE FRONT
WHEEL.
procedure.
1
2
3
4
5
6-3
CHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00519
REMOVING THE FRONT WHEEL
2. Remove:
S speedometer cable 1
S brake caliper 2
S wheel axle 3
Do not squeeze the brake lever when removing
the brake caliper.
3. Elevate:
S front wheel
EAS00526
CHECKING THE FRONT WHEEL
1. Check:
S wheel axle
Roll the wheel axle on a flat surface.
Bends ! Replace.
Do not attempt to straighten a bent wheel
axle.
2. Check:
S tire
S front wheel
Refer to CHECKING THE TIRES and
CHECKING THE WHEELS in chapter 3.
6-4
CHAS
NOTE:
2 Nm (0.2 mSkg)
NOTE:
1.5 Nm (0.15 mSkg)
WARNING
3. Check:
S spokes
Loose ! Tighten.
Tap the spokes with a screwdriver.
A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.
4. Tighten:
S spokes
After tightening the spokes, measure the front
wheel runout.
5. Measure:
S front wheel radial runout
a
S front wheel lateral runout b
Over the specified limits ! Replace.
Front wheel radial runout limit
2 mm
Front wheel lateral runout limit
2 mm
6. Check:
S collars
S Tire valve stem locknut
S 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 pos-
sible injury to the rider or damage to the
motorcycle.
S After a tire has been repaired or replaced,
be sure to tighten the tire valve stem lock-
nut 1 to specification.
6-5
CHAS
NOTE:
CAUTION:
NOTE:
7. Check:
S wheel bearings
Front wheel turns roughly or is loose ! Re-
place the wheel bearings.
S oil seals
8. Replace:
S wheel bearings (New)
S oil seals (New)
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 1 with a gener-
al bearing puller 2 .
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing center
race 1 or balls 2 . Contact should be made
only with the outer race 3 .
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
6-6
CHAS
NOTE:
EAS00527
CHECKING THE BRAKE DISC
1. Check:
S brake disc
Damage/ galling ! Replace.
2. Measure:
S brake disc deflection 1
Out of specification ! Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit (maxi-
mum)
0.15 mm
a. Place the motorcycle on a suitable stand so
that the front wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is station-
ary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 X 3 mm below the
edge of the brake disc.
3. Measure:
S brake disc thickness
Measure the brake disc thickness at a few
different locations.
Brake disc thickness limit (mini-
mum)
3 mm
4. Adjust:
S brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Brake disc bolt
13 Nm (1.3 mSkg)
LOCTITE
6-7
CHAS
NOTE:
NOTE:
90 Nm (9.0 mSkg)
30 Nm (3.0 mSkg)
WARNING
CAUTION:
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips
S speedometer drive gear
S speedometer driven gear
Lithium soap base grease
2. Install:
S speedometer gear unit 1
Make sure that the speedometer gear unit and
the wheel hub are installed with the three pro-
jections
a
meshed into the three slots b re-
spectively.
3. Install:
S front wheel
Make sure that the slot
a
in the speedometer
gear unit fits over the stopper b on the outer
tube.
4. Tighten:
S wheel axle
S brake caliper bolts
Make sure that the brake hose is routed
properly.
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
6-8
CHAS
NOTE:
NOTE:
NOTE:
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
S After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
S Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
S balancing weight(-s) 1
Place the front wheel on a suitable balancing
stand.
2. Find:
S front wheels heavy spot
a. Spin the front wheel.
b. When the front wheel stops, put an
1
mark at the bottom of the wheel.

c. Turn the front wheel 90_ so that the X
1
mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an X
2
mark at
the bottom of the wheel.
f. Repeat steps (b) through (d) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheels heavy spot X.
3. Adjust:
S front wheel static balance
a. Install a balancing weight 1 onto the rim ex-
actly opposite the heavy spot X.
Start with the lightest weight.
6-9
CHAS
b. Turn the front wheel 90_ so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:
S front wheel static balance
a. Turn the front wheel and make sure that it
stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
6-10
REAR WHEEL AND REAR BRAKE
CHAS
1
2
3
4
5
6
7
8
Removing the rear wheel
Adjuster
Brake rod
Pin
Compression spring
Chain case
Axle nut/washer
Chain pullers
Wheel axle
1
1
1
1
1
1/1
2
1
Refer toREMOVING/INSTALLING THE
REAR WHEEL.
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
NOTE:
90 Nm (9.0 mSkg)
REAR WHEEL
6-11
CHAS
9
10
Rear wheel assembly
Collar/O-ring
1
1/1
Refer to REMOVING/INSTALLING THE
REAR WHEEL.
procedure.
90 Nm (9.0 mSkg)
6-12
1
2
3
4
Removing the rear brake and rear
wheel sprocket
Shoe plate
Nuts/washers (driven sprocket)
Bolts
Driven sprocket
1
6/6
6
1
procedure.
Refer to ASSEMBLYNG THE REAR
WHEEL.
35 Nm (3.5 mSkg)
CHAS
REAR BRAKE AND REAR WHEEL SPROCKET
6-13
CHAS
Disassembling the rear wheel
Bearing
Collar
Spacer
Oil seal
Bearing
1
1
1
1
1
procedure.
1
2
3
4
5
6-14
CHAS
Disassembling the brake shoe plate
Brake shoe kit
Tension springs
Camshaft lever
Indicator plate
Camshaft
2
2
1
1
1
Refer to REMOVING THE REAR
WHEEL/ASSEMBLYING THE BRAKE
SHOE PLATE.
procedure.
1
2
3
4
5
9 Nm (0.9 mSkg)
6-15
CHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00563
REMOVING THE REAR WHEEL
2. Remove:
Swheel axle 1
Srear wheel
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
3. Remove:
S brake shoe plate
4. Remove:
S brake shoes 1
S brake camshaft lever 2
Mark the position on the brake camshaft lever
where it is aligned with the punch mark on the
brake camshaft.
EB701401
CHECKING THE REAR WHEEL
1. Check:
S wheel axle
S rear wheel
S wheel bearings
S oil seals
Refer to FRONT WHEEL.
2. Check:
S tire
S rear wheel
Refer to CHECKING THE TIRES and
CHECKING THE WHEELS in chapter 3.
3. Check:
S spokes
4. Measure:
S rear wheel radial runout
S rear wheel lateral runout
6-16
CHAS
NOTE:
NOTE:
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
S rear wheel sprocket
a
wear ! Replace the
rear wheel sprocket.
Bent teeth ! Replace the rear wheel sprock-
et.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
35 Nm (3.5 mSkg)
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00569
CHECKING THE BRAKE
brake shoes.
1. Check:
S brake shoe lining
Glazed areas ! Repair.
Sand the glazed areas with course sandpa-
per.
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure:
S brake shoe lining thickness
a
Brake shoe lining thickness limit
(minimum)
2 mm
6-17
CHAS
WARNING
NOTE:
Do not allow oil or grease to contact the
brake shoes.
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
S brake drum inside diameter
a
Out of specification ! Replace the wheel.
Brake drum inside diameter limit
(maximum)
111 mm
4. Check:
S brake drum inner surface
Oil deposits ! Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches ! Repair.
Lightly and evenly polish the scratches with
an emery cloth.
5. Check:
S brake camshaft
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE
1. Install:
S brake camshaft 1
S brake shoe wear indicator 2
a. Align the projection
a
on the brake shoe
wear indicator with the notch b in the brake
shoe camshaft.
b. Check that the brake shoes are properly
positioned.
6-18
CHAS
90 Nm (9.0 mSkg)
WARNING
NOTE:
EAS00571
INSTALLING THE REAR WHEEL
1. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips
2. Adjust:
S drive chain slack
Drive chain slack
35 X 60 mm
Refer to ADJUSTING THE DRIVE CHAIN
SLACK in chapter 3.
3. Tighten:
S wheel axle nut
Make sure that the brake hose is routed
properly.
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE
S After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
S Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
S rear wheel static balance
6-19
FRONT BRAKE
CHAS
1
2
3
Removing the front brake pads
Bolt (caliper support bolt)
Brake pads
Pad springs
1
2
1
Refer to REPLACING THE FRONT
BRAKE PADS.
procedure.
27 Nm (2.7 mSkg)
FRONT BRAKE
FRONT BRAKE PADS
6-20
FRONT BRAKE
CHAS
CAUTION:
NOTE:
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
S Never disassemble brake components un-
less absolutely necessary.
S If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
S Never use solvents on internal brake com-
ponents.
S Use only clean or new brake fluid for clean-
ing brake components.
S Brake fluid may damage painted surfaces
up any spilt fluid immediately.
S Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
S Flush with water for 15 minutes and get im-
mediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
S caliper support bolts 1
2. Remove:
S brake caliper 2
3. Remove:
S brake pads 1
S brake pad spring 2
6-21
FRONT BRAKE
CHAS
NOTE:
NOTE:
CAUTION:
4. Measure:
S brake pad wear limit
a
Out of specification ! Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm
5. Install:
S brake pads 1
S brake pad spring 2
Always install new brake pads and a new brake
pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mSkg)
d. Install new brake pads and brake pad spring.
S Make sure that the brake pad spring is
installed correctly as shown.
6. Lubricate:
S brake caliper guide bar 1
S brake pad bolts 2
S Do not allow grease to contact the brake
pads.
S Remove any excess grease.
6-22
FRONT BRAKE
CHAS
27 Nm (2.7 mSkg)
7. Install:
S brake caliper
S brake pad bolt
8. Check:
S brake fluid level
a
! Add the
LEVEL in chapter 3.
9. Check:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
6-23
FRONT BRAKE
CHAS
1
2
3
4
5
6
7
8
Removing the front brake master
cylinder
Drain the brake fluid
Rear view mirror (right)
Brake lever/ compression spring
Brake switch
Union bolt
Copper washers
Brake hose
Bracket (master cylinder)
Master cylinder
1
1/ 1
1
1
2
1
1
1
Refer to DISASSEMBLING/ASSEM-
BLING AND INSTALLING THE FRONT
BRAKE MASTER CYLINDER.
For installation, reverse the removal proce-
dure.
26 Nm ( 2.6 mSkg)
2 Nm (0.2 mSkg)
7 Nm (0.7 mSkg)
FRONT BRAKE MASTER CYLINDER
6-24
FRONT BRAKE
CHAS
Disassembling the front brake mas-
ter cylinder
Rubber boots
Circlip
Master cylinder kit
Spring
1
1
1
1
For assembly, reverse the removal proce-
dure.
1
2
3
4
6-25
FRONT BRAKE
CHAS
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:
S brake switch 1
2. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00590
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
S brake master cylinder 1
Damage/ scratches/ wear ! Replace.
S brake fluid delivery passages 2
(brake master cylinder body)
2. Check:
S brake master cylinder kit 1
Damage/ scratches/ wear ! Replace.
3. Check:
S brake master cylinder reservoir diaphragm
6-26
FRONT BRAKE
CHAS
WARNING
7 Nm (0.7 mSkg)
NOTE:
New
26 Nm (2.6 mSkg)
WARNING
CAUTION:
4. Check:
S brake hose 1
EAS00598
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
S Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents.
DOT 4
1. Install:
S brake master cylinder 1
S Install the brake master cylinder holder with
the UP mark 2 facing up.
S First, tighten the upper bolt, then the lower
bolt.
2. Install:
S copper washers 1
S brake hose 2
S union bolt 3
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
CABLE ROUTING.
When installing the brake hose onto the
master cylinder,make sure that the brake
pipe
a
touches the projection b on the
master cylinder.
6-27
FRONT BRAKE
CHAS
NOTE:
WARNING
CAUTION:
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
S brake master cylinder reservoir
mended brake fluid)
DOT 4
brake performance.
mance.
4. Bleed:
S brake system
5. Check:
S brake fluid level
a
! Add the
LEVEL in chapter 3.
6. Check:
system.
6-28
FRONT BRAKE
CHAS
1
2
3
4
5
6
Removing the front brake caliper
Drain teh brake fluid
Brake hose holder
Union bolt
Plain washer
Brake hose
Caliper support bolt
Caliper assembly
1
1
1
1
1
1
Refer to DISASSEMBLING/
FRONT BRAKE CALIPER .
procedure.
30 Nm (3.0 mSkg)
27 Nm (2.7 mSkg)
26 Nm (2.6 mSkg)
FRONT BRAKE CALIPER
6-29
FRONT BRAKE
CHAS
Disassembling the front brake cali-
per
Brake pad
Caliper pistons
Dust seals
Piston seals
Bleed screw/ Cap
2
2
2
1
Refer to BRAKE PAD section.
Refer to DISASSEMBLING THE FRONT
BRAKE CALIPER.
procedure.
1
2
3
4
6 Nm (0.6 mSkg)
6-30
FRONT BRAKE
CHAS
NOTE:
NOTE:
WARNING
EAS00619
DISASSEMBLING THE FRONT BRAKE CAL-
IPER
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
S union bolt 1
S copper washers 2
S brake hose
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
S brake caliper pistons 1
S brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening
a
to force out the pistons from
the brake caliper.
S Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
S Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper piston seals.
EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every two years
Brake fluid Every two years and
whenever the brake is
disassembled.
6-31
FRONT BRAKE
CHAS
WARNING
WARNING
New
26 Nm (2.6 mSkg)
1. Check:
S brake caliper pistons 1
Rust / scratches/ wear ! Replace the brake
caliper.
S brake caliper cylinders 2
Scratches/ wear ! Replace the brake cali-
per.
S brake caliper body 3
Cracks/ damage ! Replace the brake cali-
per.
S brake fluid delivery passages
(brake caliper body)
Whenever a brake caliper is disassembled,
replace the piston seals.
2. Check:
S brake caliper bracket 1
EAS00634
FRONT BRAKE CALIPER
S Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents as they will cause the piston seals
to swell and distort.
S Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
DOT 4
1. Install:
S brake caliper 1
(temporarily)
S copper washers 2
S brake hose 3
S union bolt 4
6-32
FRONT BRAKE
CHAS
WARNING
CAUTION:
27 Nm (2.7 mSkg)
30 Nm (3.0 mSkg)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
CABLE ROUTING.
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe
a
touches the projection b on the
brake caliper.
2. Remove:
S brake caliper
3. Install:
S brake pads
S brake pad springs
S brake caliper retaining bolt
S brake caliper bracket
S brake hose holder
Refer to REPLACING THE BRAKE PADS.
4. Fill:
S brake master cylinder reservoir
mended brake fluid)
DOT 4
brake performance.
mance.
6-33
FRONT BRAKE
CHAS
CAUTION:
5. Bleed:
S brake system
6. Check:
S brake fluid level
a
! Add the
LEVEL in chapter 3.
7. Check:
system.
6-34
FRONT FORK
CHAS
1
2
3
4
5
6
7
8
Removing the front fork
Front wheel
Brake hose holder
Caliper
Front fender
Cap bolt / O-ring
Bolt (upper bracket)
Bolts (under bracket)
Front fork assembly (left)
Front fork assembly (right)
1
1
1
1/ 1
1
2
1
1
Refer to FRONT WHEEL AND BRAKE
DISC.
Loosen the bolt.
NOTE:
FRONT FORK.
procedure.
23 Nm (2.3 mSkg)
30 Nm (3.0 mSkg)
23 Nm (2.3 mSkg)
5 23 Nm (2.3 mSkg)
FRONT FORK
6-35
FRONT FORK
CHAS
procedure.
10
Disassembling the front fork
Cap bolt / O-ring
Collar/ washer
Fork spring
Boot
Retaining clip
Oil seal
Damper rod bolt
Inner tube assembly
Oil seal
Outer tube bushing
Damper rod
Rebound spring
Outer tube
1/ 1
1/ 1
1
1
1
1
1
1
1
1
1
1
1
Drain the fork oil.
NOTE:
Refer to DISASSEMBLING/
ASSEMBLING THE FRONT FORK.
Refer to ASSEMBLING THE FRONT
FORK
1
2
3
4
5
6
7
8
9
11
12
13
27 Nm (2.7 mSkg)
23 Nm (2.3 mSkg)
6-36
FRONT FORK
CHAS
WARNING
NOTE:
WARNING
NOTE:
CAUTION:
EAS00649
REMOVING THE FRONT FORK LEGS
front fork legs.
2. Loosen:
S upper bracket pinch bolt 1
S cap bolt 2
S lower bracket pinch bolt 3
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
3. Remove:
S front fork leg
EAS00655
DISASSEMBLING THE FRONT FORK LEGS
front fork legs.
1. Drain:
S fork oil
While stroking the inner tube several times,
drain the fork oil.
2. Remove:
S boot 1
S oil seal clip 2
(with a flat-head screwdriver)
Do not scratch the inner tube.
6-37
FRONT FORK
CHAS
NOTE:
WARNING
3. Remove:
S damper rod bolt
S copper washer
While holding the damper rod with the damper
rod holder 1 and T-handle 2 , loosen the
damper rod bolt.
Damper rod holder
90890-01294
T-handle
90890-01326
4. Remove:
S inner tube
EAS00657
CHECKING THE FRONT FORK LEGS
front fork legs.
1. Check:
S inner tube 1
S outer tube 2
Bends/ damage/ scratches ! Replace.
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
S spring free length
a
Over the specified limit ! Replace.
Spring free length limit
338 mm
3. Check:
S damper rod 1
Obstruction ! Blow out all of the oil pas-
sages with compressed air.
6-38
FRONT FORK
CHAS
CAUTION:
WARNING
NOTE:
CAUTION:
S The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
S When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
S cap bolt O-ring
EAS00659
ASSEMBLING THE FRONT FORK LEGS
front fork legs.
S Make sure that the oil levels in both front
fork legs are equal.
S Uneven oil levels can result in poor han-
dling and a loss of stability.
S When assembling the front fork leg, be sure to
replace the following parts:
-outer tube bushing
-oil seal
S Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
S damper rod 1
S inner tube 2
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
6-39
FRONT FORK
CHAS
27 Nm (2.7 mSkg)
NOTE:
CAUTION:
NOTE:
2. Lubricate:
S inner tubes outer surface
Fork oil 10W or equivalent
3. Tighten:
S damper rod bolt
While holding the damper rod with the damper
rod holder 1 and T-handle 2 , tighten the
damper rod bolt.
Damper rod holder
90890-01294
T-handle
90890-01326
4. Install:
S outer tube bushing 1
(with the fork seal driver weight and adapter)
Fork seal driver weight
90890-01367
Adapter
90890-01368
5. Install:
S oil seal 1
(with the fork seal driver weight and adapter)
Make sure that the numbered side of the oil
seal faces up.
S Before installing the oil seal, apply lithium soap
base grease onto its lips.
S Apply fork oil onto the outer surface of the in-
ner tube.
S Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 2 to protect
the oil seal during installation.
6-40
FRONT FORK
CHAS
1
3
NOTE:
NOTE:
NOTE:
6. Install:
S oil seal clip 1
Adjust the oil seal clip so that it fits into the outer
tubes groove.
7. Install:
S boot 1
8. Fill:
S front fork leg
mended fork oil)
Quantity (each front fork leg)
0.243 L
Yamaha fork and shock oil
10W or equivalent.
Front fork leg oil level
a
(from
the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
135 mm
S While filling the front fork leg, keep it upright.
S After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
9. Install:
S spring 1
S spring seat 2
S spacer 3
S cap bolt 4
S Before installing the cap bolt, apply grease
onto O-ring.
S Temporarily tighten the cap bolt.
6-41
FRONT FORK
CHAS
NOTE:
30 Nm (3.0 mSkg)
23 Nm (2.3 mSkg)
23 Nm (2.3 mSkg)
WARNING
EAS00662
INSTALLING THE FRONT FORK LEGS
front fork legs.
1. Install:
S front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
Make sure that the inner fork tube is flush with
the top of the handlebar holder.
2. Tighten:
S lower bracket pinch bolt 1
S cap bolt 2
S upper bracket pinch bolt 3
Make sure that the brake hoses are routed
properly.
6-42
HANDLEBAR
CHAS
1
2
3
4
5
6
7
Removing the handlebar
Master cylinder bracket
Master cylinder
Housing (throttle grip)
Throttle grip assembly
Handlebar switch (right)
Clutch switch
Clutch cable
1
1
1
1
1
1
1
Refer to INSTALLING THE HANDLE-
BAR.
20 Nm (2.0 mSkg)
HANDLEBAR
6-43
HANDLEBAR
CHAS
8
9
10
11
12
13
Handlebar switch (left)
Grip (left)
Clutch lever
Starter cable holder
Upper holders
Handlebar
1
1
1
1
2
1
Refer to REMOVING THE HANDLEBAR
section.
procedure.
Refer to INSTALLING THE
HANDLEBAR section.
20 Nm (2.0 mSkg)
6-44
HANDLEBAR
CHAS
]
WARNING
NOTE:
WARNING
WARNING
EAS00666
REMOVING THE HANDLEBAR
2. Remove:
S throttle cable housing 1
S throttle grip 2
3. Remove:
S handlebar grip (left) 1
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR
2. Check:
S handlebar 1
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
3. Install:
S handlebar grip
a. Apply a light coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
6-45
HANDLEBAR
CHAS
WARNING
WARNING
20 Nm (2.0 mSkg)
CAUTION:
NOTE:
NOTE:
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
EB704700
INSTALLING THE HANDLEBAR
2. Install:
S handlebar 1
S upper handlebar holders 2
S First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
S Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
S The upper handlebar holders should be
installed with the arrows
a
facing forward.
a
large
b short
S Align the match marks
c
on the handlebar
with the upper surface of the lower handlebar
holders.
3. Install:
S throttle grip
S throttle cable housing
S throttle cable
4. Install:
S right handlebar switch 1
Align the pin
a
on the handlebar switch with the
hole b in the handlebar.
6-46
HANDLEBAR
CHAS
NOTE:
NOTE:
5. Install:
S left handkbar switch
Align the tab
a
on the plate with the slot b on
the handkbar switch/
6. Install:
S clutch cable
7. Connect:
S clutch switch coupler
Apply a thin coat of litium soap base grease
onto the end of the clutch cable.
8. Adjust:
Refer to ADJUSTING THE CLUTCH
Clutch cable free play (at the end
of the clutch lever)
10 X 15 mm
9. Adjust:
3 X 5 mm
6-47
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Removing the lower bracket
Front fork
Handlebar
Headlight cover
Headlight unit
Flasher light assembly (left)
Flasher light assembly (right)
Meter cable/ Meter lead
Meter assembly
Headlight stay
Steering stem nut
Handlebar crown
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Ball race cover
Lower bracket
1
1
1
1
1/ 1
1
2
1
1
1
1
1
1
1
1
Refer to FRONT FORK.
Refer to HANDLEBAR
Disconnect the connector.
Refer to INSTALLING THE STEERING
HEAD.
NOTE:
90 Nm (9.0 mSkg)
1st 38 Nm (3.8mSkg)
2nd 18 Nm (1.8 mSkg)
5
STEERING HEAD
CHAS
STEERING HEAD
6-48
STEERING HEAD
CHAS
16
17
18
19
20
Ball race (upper)
Ball
Ball
Ball race (center)
Ball race (lower)
1
22
19
1
1
cedure.
Refer to INSTALLING THE STEERING.
90 Nm (9.0 mSkg)
1st 38 Nm (3.8mSkg)
2nd 18 Nm (1.8 mSkg)
5
6-49
STEERING HEAD
CHAS
WARNING
NOTE:
WARNING
EAS00679
REMOVING THE LOWER BRACKET
2. Remove:
S upper ring nut
S rubber washer
S lower ring nut 1
Hold the lower ring nut with the exhaust and
steering nut wrench, then remove the upper ring
nut with the ring nut wrench.
Exhaust and steering nut
wrench 2
90897-01268
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
S bearing balls
S bearing races
Recommended cleaning solvent
Kerosine
2. Check:
S bearing balls 1
S bearing races 2
3. Replace:
S bearing balls
S bearing races
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
6-50
STEERING HEAD
CHAS
CAUTION:
NOTE:
NOTE:
NOTE:
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new dust seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.
S Always replace the bearing balls and bearing
races as a set.
S Whenever the steering head is disassembled,
replace the dust seal.
4. Check:
S upper bracket
S lower bracket
(along with the steering stem)
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
S upper bearing
S lower bearing
S bearing races
2. Install:
S lower ring nut 1
S rubber washer
S upper ring nut 2
S lock washer 3
Refer to INSPECTING THE STEERING
HEAD in chapter 3.
3. Install:
S upper bracket
S steering stem nut
Temporarily tighten the steering stem nut.
4. Install:
S front fork legs
Refer to FRONT FORK.
Temporarily tighten the upper and lower bracket
pinch bolts.
6-51
REAR SHOCK ABSORBER AND SWINGARM
CHAS
1
2
3
4
5
6
7
Rear shock absorber and swingarm
removal
Rear wheel
Chain case
Rear shock absorber
Drive chain
Nut
Pivot shaft
Swingarm
Cover (swingarm)
Bush
1
1
1
1
1
2
2
Remove the parts in order.
REAR SHOCK ABSORBER
DRIVE CHAIN
procedure.
Refer to REAR WHEEL AND REAR
BRAKE.
SWINGARM.
80 Nm (8.0 mSkg)
56 Nm (5.6 mSkg)
6-52
CHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBER
This rear shock absorber contain highly com-
pressed nitrogen gas. Before handling the
rear shock absorber, read and make sure you
understand the following information. The
manufacturer cannot be held responsible for
property damage or personal injury that may
result from improper handling of the rear
shock absorber.
S Do not tamper or attempt to open the rear
shock absorber.
S Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
S Do not deform or damage the rear shock
absorber in any way. If the rear shock ab-
sorber or both are damaged, damping per-
formance will suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORB-
ER
a. Gas pressure must be released before dis-
posing of a rear shock absorber. To release
the gas pressure, drill 2 X 3mm hole through
the gas cylinder at a point 15 X 20 mm from
its end as shown.
Wear eye protection to prevent eye damage
from released gas or metal chips.
6-53
CHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
NOTE:
EAS00694
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
2. Remove:
S rear shock absorber assembly lower pin 1
While removing the rear shock absorber as-
sembly lower pin, hold the swingarm so that it
does not drop down.
3. Remove:
S rear shock absorber assembly upper bolt 1
S rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
EAS00706
REMOVING THE DRIVE CHAIN
2. Remove:
S chain cover
3. Remove:
S master link clip
(with interlocking slip-joint pliers )
4. Remove:
S master link plate 1
S master link 2
5. Remove:
S drive chain
6-54
CHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
2. Remove:
S rear shock absorber assembly lower pin 1
When removing the rear shock absorber as-
sembly lower pin, hold the swingarm so that it
does not drop down.
3. Check:
S swingarm side play A
S swingarm vertical movement B
a. Check the tightening torque of the pivot shaft
nut.
Pivot shaft nut
80 Nm (8.0 mSkg)
b. Check the swingarm side play A by moving
the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end
of the swingarm)
1.0 mm
d. Check the swingarm vertical movement B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
6-55
CHAS
WARNING
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
S rear shock absorber rod
Bends/ damage ! Replace the rear shock
absorber assembly.
S rear shock absorber
Gas leaks/ oil leaks ! Replace the rear
shock absorber assembly.
S spring
Damage/ wear ! Replace the rear shock
absorber assembly.
S bushings
S dust seals
S bolts
Bends/ damage/ wear ! Replace.
EAS00707
CHECKING THE SWINGARM
1. Check:
S swingarm
2. Check:
S pivot shaft
Roll the pivot shaft on a flat surface.
Bends ! Replace.
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
S pivot shaft
S dust covers
S spacer
S washers
S bearings
Recommended cleaning solvent
Kerosine
6-56
CHAS
NOTE:
4. Check:
S dust covers 1
S spacer 2
S oil seals 3
S bearings
EAS00710
CHECKING THE DRIVE CHAIN
1. Measure:
S 10-link section
a
of the drive chain
Out of specification ! Replace the drive
chain.
10-link drive chain section
limit (maximum)
121.4 mm
S While measuring the 10-link section, push
down on the drive chain to increase its tension.
S Measure the length between drive chain roller
1 and
11
as shown.
S Perform this measurement at two or three dif-
ferent places.
2. Check:
S drive chain
Stiffness ! Clean and lubricate or replace.
3. Clean:
S drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosine and remove
any remaining dirt.
c. Remove the drive chain from the kerosine
and completely dry it.
6-57
CHAS
56 Nm (5.6 mSkg)
NOTE:
4. Check:
S drive chain rollers 1
Damage/ wear ! Replace the drive chain.
S drive chain side plates 2
Damage/ wear ! Replace the drive chain.
Cracks ! Replace the drive chain and make
sure that the battery breather hose is proper-
ly routed away from the drive chain and be-
low the swingarm.
5. Lubricate:
S drive chain
Engine oil or chain lubricant
suitable for non-O-ring chains
6. Check:
S drive sprocket
a
wear ! Replace the
drive chain sprockets as a set.
Bent teeth ! Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
EAS00697
INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:
S spacers
S bearings
Molybdenum disulfide grease
2. Install:
When installing the rear shock absorber assem-
bly, lift up the swingarm.
6-58
CHAS
80 Nm (8.0 mSkg)
CAUTION:
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:
S bearings
S spacers
S dust covers
S pivot shaft
Molybdenum disulfide grease
2. Install:
S Swingarm
3. Install
S rear wheel
Refer to INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY and REAR
WHEEL.
4. Adjust:
S drive chain slack
SLACK in chapter 3.
Drive chain slack
35 X 60 mm
EAS00714
INSTALLING THE DRIVE CHAIN
1. Lubricate:
S drive chain
S master link (New)
Engine oil or chain lubricant
suitable for non-O-ring chains
2. Install:
S master link 1
S master link plate 2
3. Install:
S master link clip 1
S The closed end of the master link clip must
face in the direction of drive chain rotation.
S Never install a new drive chain onto worn
drive chain sprockets; this will dramatical-
ly shorten the drive chains life.
4. Adjust:
S drive chain slack
SLACK in chapter 3.
Drive chain slack
35 X 60 mm
6-59
CHAS
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
CHAS
ELEC

7
+
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCHES 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCH CONTINUITY 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH CONTINUITY INSPECTION 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BULBS AND BULB SOKETS 7-4 . . . . . . . . . . . . . . . . . . . .
TYPES OF BULBS 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS 7-4 . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS 7-6 . . . . . . . .
IGNITION SYSTEM 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUTOFF SYSTEM OPERATION 7-13 . . . . . . . . . . .
STARTER MOTOR 7-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM 7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 7-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 7-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 7-25 . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 7-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 7-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM 7-30 . . . . . . . . . . . . . . . . . . . . . . .
7-1
ELECTRICAL COMPONENTS
ELEC
1 Horn
2 Flasher relay
3 Main switch
4 Fuse holder assembly
5 Starter relay
7 Battery
15 C.D.I. unit 8 Neutral relay
9 Thermo switch
10 Sidestand switch
11 Rear brake switch
12 Neutral switch
13 Spark plug cap
14 Ignition coil
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
7-2
SWITCHES
ELEC
CAUTION:
NOTE:
NOTE:
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.
Never insert the tester probes into the cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
S Before checking for continuity, set the pocket
tester to 0 and to the 1 range.
S When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions
a
are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between blue/ red and red
when the switch is set to .
There is continuity between blue/ red and blue,
between brown/ blue and red, and between
blue/ yellow and blue/ black when the switch is
set to ON.
7-3
1 Turn signal switch
2 Lights switch
3 Dimmer switch
4 Horn switch
5 Clutch switch
6 Front brake switch
7 Engine stop switch
8 Start switch
9 Main switch
10 Neutral switch
11 Sidestand switch
13 Fuse
14 Thermo switch
SWITCH INSPECTION
ELEC
EAS00731
SWITCH CONTINUITY INSPECTION
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to CHECKING SWITCH CONTINUITY.
Damage/ wear Repair or replace the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
7-4
CHECKING THE BULBS AND BULB SOCKETS
ELEC
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage/ wear ! Repair or replace the bulb,
bulb socket or both.
Improperly connected ! Properly connect.
Incorrect continuity reading ! Repair or re-
place the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
S Bulbs A and B are used for headlights and
usually use a bulb holder which must be de-
tached before removing the bulb. The majority
of these bulbs can be removed from their re-
spective socket by turning them counterclock-
wise.
S Bulb C is used for turn signal and tail / brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.
S Bulbs D and E are used for meter and indica-
tor lights and can be removed from their re-
spective socket by carefully pulling them out.
CHECKING THE CONDITION OF THE
BULBS
bulbs.
1. Remove:
S bulb
7-5
ELEC
WARNING
CAUTION:
NOTE:
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
S Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
S 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 adverse-
ly affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
2. Check:
S bult (for continuity)
(with the pocket tester)
No continuity ! Replace.
Pocket tester
90890-03112
Before checking for continuity, set the pocket
tester to 0 and to the 1 range.
a. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
2 , and check the continuity.
b. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
7-6
ELEC
NOTE:
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Check:
S bulb socket (for continuity)
(with the pocket tester)
No continuity ! Replace.
Pocket tester
90890-03112
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,
replace the bulb socket.
7-7
1 C.D.I. magneto
2 Neutral switch
4 Battery
6 Fuse
11 Main switch
13 Diode
14 C.D.I. unit
15 Ignition coil
16 Spark plug
21 Sidestand switch
22 Neutral relay
IGNITION SYSTEM
ELEC
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
7-8
IGNITION SYSTEM
ELEC
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to CHECKING THE SPARK PLUG in
CHAPTER 3.
1. Spark plug
Standard spark plug
DR8EA (NGK)
Spark plug gap
0.6 X 0.7 mm
S Is the spark plug in good condition, is it of the
correct type, and its gap within specifica-
tion?
YES
Re-gap or replace the
spark plug.
NO
2. Ignition spark gap
S Disconnect the spark plug cap from the spark
plug.
S Connect the ignition checker as shown.
Spark plug cap
S Turn the main switch to ON.
S Measure the ignition spark gap .
S Check the spark by pushing the starter
switch, and gradually increase the spark gap
until a misfire occurs.
Min. ignition spark gap
6 mm
S Is there a spark and is the spark gap within
specification?
NO
The ignition system is
OK.
YES
3. Spark plug cap resistance
S Remove the spark plug cap.
S Connect the pocket tester ( 1k) to the
spark plug cap as shown.
S Measure the spark plug cap resistance.
1
2
a
NOTE:
EAS00736
TROUBLESHOOTING
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. spark plug
2. ignition spark gap
3. spark plug cap resistance
4. ignition coil
5. pickup coil resistance
6. source coil resistance
7. main switch
8. engine stop switch
9. sidestand switch
10. neutral relay
11. neutral switch
12. diode
13. wiring connection
(entire ignition system)
S Before troubleshooting, remove the following
part(-s):
1) side covers (left and right)
2) seat
3) fuel tank
S Troubleshoot with the following special
tool(-s).
Ignition checker
90890-06754
Pocket tester
90890-03112
EAS06740
EAS00742
EAS00744
7-9
Spark plug cap resistance
10 k at 20_C
S Is the spark plug cap OK?
YES
Replace the ignition
coil.
NO
S Disconnect the ignition coil lead from the
wireharness.
S Connect the pocket tester ( 1) to the igni-
tion coil as shown.
4. Ignition coil resistance
YES
Replace the spark
plug cap.
NO
S Measure the primary coil resistance.
Primary coil resistance
0.18 X 0.28 at 20_C
S Connect the pocket tester ( 1k) to the
ignition coil as shown.
S Measure the secondary coil resistance.
Tester positive probe ! spark plug lead
Tester negative probe ! orange
Secondary coil resistance
6.32 X 9.48 k at 20_C
S Is the ignition coil OK?
S Disconnect the pickup coil coupler from the
wire harness.
S Connect the pocket tester ( 100) to the
pickup coil terminal as shown.
5. Pickup coil resistance
S Measure the pickup coil resistance.
Pickup coil resistance
656 X 984 at 20_C
(between red and white)
Tester positive probe ! orange
Tester negative probe ! ground
YES
Replace the pickup
coil.
NO
Tester positive probe ! red
Tester negative probe ! white
S Is the pickup coil OK?
1
2
1
2
1
2
IGNITION SYSTEM
ELEC
EAS00746 EAS00748
7-10
S Disconnect the source coil coupler from the
wireharness.
charging coil terminal as shown.
6. Source coil resistance
S Measure the source coil resistance.
Source coil resistance:
624 X 936 (20_C)
(between brown and green)
S Is the source coil OK?
Tester positive probe ! brown
Tester negative probe ! green
1
2
YES
Replace the source
coil.
NO
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
7. Main switch
YES
Replace the main
switch.
NO
S Check the engine stop switch for continuity.
S Is the engine stop switch OK?
8. Engine stop switch
YES
Replace the right
handlebar switch.
NO
S Check the sidestand switch for continuity.
S Is the sidestand switch OK?
9. Sidestand switch
YES
Replace the side-
stand switch.
NO
S Check the neutral relay for continuity.
Refer to ELECTRIC STARTING SYSTEM.
S Is the neutral relay OK?
10. Neutral relay
YES
Replace the neutral
relay.
NO
S Check the neutral switch for continuity.
S Is the neutral switch OK?
11. Neutral switch
YES
Replace the neutral
switch.
NO
IGNITION SYSTEM
ELEC
EAS00749
EAS00750
EAS00752
EAS00751
7-11
S Disconnect the diode from the coupler.
diode terminals as shown.
S Measure the diode for continuity as follows.
12. Diode
Tester positive probe !
blue/ white
Tester negative probe !
blue/ black
1
2
blue/ black
blue/ white
1
2
Continuity
No continu-
ity
S Check the entire ignition systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the ignition systems wiring properly con-
nected and without defects?
13. Wiring
NO
Replace the CDI unit.
YES
Properly connect or
repair the ignition
systems wiring.
YES
Replace the relay
unit.
NO
NOTE:
When you switch the and + leads of the
digital pocket tester the readings in the above
chart will be reversed.
S Are the tester readings correct?
IGNITION SYSTEM
ELEC
EAS00766
7-12
2 Neutral switch
4 Battery
5 Starter relay
6 Fuse
7 Starter motor
9 Start switch
11 Main switch
12 Clutch switch
21 Sidestand switch
22 Neutral relay
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
CIRCUIT DIAGRAM
7-13
ELEC
EAS00756
STARTING CIRCUIT CUTOFF SYSTEM OP-
ERATION
If the engine stop switch is set to and the
main switch is set to ON (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
S The transmission is in neutral (the neutral
switch is closed).
S The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
The neutral relay prevents the starter motor
from operating when neither of these conditions
has been met. In this instance, the neutral relay
is open so current cannot reach the starter mo-
tor. When at least one of the above conditions
has been met the neutral relay is closed and the
engine can be started by pressing the start
switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
5 Neutral relay
6 Clutch switch
7 Sidestand switch
8 Neutral switch
9 Start switch
10 Starter relay
11 Starter motor
7-14
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING THE
BATTERY in chapter 3.
Specific gravity:
1.280 at 20_C
S Is the battery OK?
YES
S Refill the battery fluid.
S Clean the battery te-
rminals.
S Recharge or replace
the battery.
NO
3. Starter motor
S Connect the battery positive terminal and
starter motor lead with a jumper lead .
YES
Repair or replace the
starter motor.
NO
EAS00758
1
3 2
WARNING
S A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
S This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
S Does the starter motor turn?
ELEC
NOTE:
YES NO
Replace the fuse(-s).
1. Fuse
S Check the fuse for continuity.
Refer to CHECKING THE FUSES in chap-
ter 3.
S Is the fuse OK?
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1. fuse
2. battery
3. starter motor
4. neutral relay
5. starter relay
6. main switch
7. engine stop switch
8. neutral switch
9. sidestand switch
10. clutch switch
11. start switch
12. wiring
(of the entire starting system)
S Before, troubleshooting, remove the following
part(-s):
2) seat
3) fuel tank
tool(-s).
Pocket tester
90890-03112
EAS00738
7-15
YES
Replace the relay unit.
NO
Battery positive terminal ! brown
Battery negative terminal ! sky blue
1
2
Tester positive probe ! blue/ white
Tester negative probe ! black/ white
3
4
4. Neutral relay
S Disconnect the relay unit from the coupler.
S Connect the pocket tester ( 1) and bat-
tery (12 V) to the relay unit terminals as
shown.
S Does the starting circuit cutoff relay have
continuity between black/ white and bl-
ue/ white?
Battery positive terminal ! red/ white
Battery negative terminal ! brown
1
2
Tester positive probe ! red
Tester negative probe ! black
3
4
5. Starter relay
S Disconnect the starter relay from the coupler.
S Connect the pocket tester ( 1) and bat-
tery (12 V) to the starter relay coupler as
shown.
S Does the starter relay have continuity be-
tween red and check?
YES
Replace the starter
relay.
NO
6. Main switch
YES
Replace the main
switch.
NO
7. Engine stop switch
S Check the engine stop switch for continuity.
S Is the engine stop switch OK?
YES
Replace the right
handlebar switch.
NO
R
Br R/ W
ELEC
EAS00761
EAS00749
EAS00750
7-16
8. Neutral switch
YES
Replace the neutral
switch.
NO
9. Sidestand switch
S Check the sidestand switch for continuity.
S Is the sidestand switch OK?
YES
Replace the side-
stand switch.
NO
10. Clutch switch
S Check the clutch switch for continuity.
S Is the clutch switch OK?
YES
Replace the clutch
switch.
NO
11. Start switch
S Check the start switch for continuity.
S Is the start switch OK?
YES
Replace the right
handlebar switch.
NO
12. Wiring
S Check the entire starting systems wiring.
S Is the starting systems wiring properly con-
NO
The starting system
circuit is OK.
YES
Properly connect or
repair the starting
systems wiring.
ELEC
EAS00751
EAS00752
EAS00763
EAS00764
EAS00766
7-17
Order Job name/ Part name Qty Remarks
1
2
3
Starter motor removal
Starter motor lead
Starter motor
O-ring
1
1
1
Remove the parts in order.
Refer to ENGINE OIL REPLACEMENT
in CHAPTER 3.
Reverse the removal procedure for
installation.
Refer to Assembly section.
Starter motor disassembly
Front cover
Washer set
Rear cover
Armature coil
Brush
1
1
1
1
1
Disassemble the parts in order.
Reverse the disassembly procedure for
assembly.
1
2
3
4
5
ELEC
STARTER MOTOR
7-18
ELEC
NOTE:
EAS00769
Checking the starter motor
1. Check:
S commutator
Dirt ! Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter
a
Out of specification ! Replace the starter
motor.
Min. commutator diameter
21 mm
3. Measure:
S mica undercut
a
Out of specification ! Scrape the mica to the
proper measurement with a hacksaw blade
which has been grounded to fit the commuta-
tor.
Mica undercut
1.5 mm
The mica must be undercut to ensure proper
operation of the commutator.
4. Measure:
S armature assembly resistances (commuta-
tor and insulation)
Out of specification ! Replace the starter
motor.
a. Measure the armature assembly resis-
tances with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Commutator resistance 1
0.0171 X 0.0209 at 20_C
Insulation resistance 2
Above 1 M at 20_C
b. If any resistance is out of specification, re-
place the starter motor.
7-19
ELEC
NOTE:
New
5 Nm (0.5 mSkg)
NOTE:
5. Measure:
S brush length
a
Out of specification ! Replace the brushes
as a set.
Min. brush length
3.5 mm
6. Measure:
S brush spring free length (Compressed
spring)
a
Out of specification ! Replace the brush
springs as a set.
Brush spring
14.5 mm
7. Check:
S gear teeth
Damage/ wear ! Replace the gear.
8. Check:
S bearing
S oil seal
part(-s).
EAS00772
Assembling the starter motor
1. Install:
S washer set
Align the tabs
a
on the washer with the slots b
in the starter motor front cover.
2. Install:
S starter motor yoke 1
S O-rings 2
S starter motor front cover 3
S starter motor rear cover 4
S bolts
Align the match marks
a
on the starter motor
yoke with the match marks b on the front and
rear covers.
7-20
1 C.D.I. magneto
4 Battery
6 Fuse
CHARGING SYSTEM
ELEC
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
7-21
NOTE:
S Connect the engine tachometer to the spark
plug lead.
S Connect the pocket tester (DC 20 V) to the
battery as shown.
NO YES
Make sure that the battery is fully charged.
S Is the charging voltage within specification?
3. Charging voltage
The charging circuit
is OK.
battery positive terminal
battery negative terminal
S Start the engine and let it run at approximate-
ly 5,000 r/ min.
S Measure the charging voltage.
Charging voltage
14.5 V at 5,000 r/ min
CHARGING SYSTEM
ELEC
NOTA:
YES NO
Replace the fuse.
1. Fuse
S Check the main fuses for continuity.
ter 3.
S Is the main fuses OK?
YES NO
2. Battery
Specific gravity
1.280 at 20_C
S Refill the battery fl-
uid.
S Clean the battery
terminals.
S Recharge or repla-
ce the battery.
EAS00774
TROUBLESHOOTING
The battery is not being charged.
Check:
1. fuse
2. battery
3. charging voltage
4. stator coil assembly resistance
5. wiring
(of the entire charging system)
part(-s):
2) seat
tool(-s).
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
EAS00775
7-22
CHARGING SYSTEM
ELEC
S Check the wiring connections of the entire
charging system.
S Is the charging systems wiring properly con-
NO
Replace the rectifi-
er/ regulator.
YES
5. Wiring
Properly connect or
repair the charging
systems wiring.
4. Stator coil assembly resistance
S Disconnect the starter coil coupler from the
wire harness.
S Connect the pocket tester ( 1) to the sta-
tor coil assembly coupler as shown.
Stator coil resistance
0.48 X 0.72 at 20_C
S Is the stator coil assembly OK?
YES
Replace the stator
coil assembly.
NO
Tester positive probe ! white
1
2
S Measure the stator coil assembly resis-
tances.
Tester positive probe ! white
1
3
EB804401
EB804404
7-23
4 Battery
6 Fuse
11 Main switch
25 Meter light
28 High beam indicator light
32 Lights switch
33 Dimmer switch
40 Headlight
41 Auxiliary light
42 Tail / Brake light
LIGHTING SYSTEM
ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
7-24
LIGHTING SYSTEM
ELEC
NOTE:
YES NO
1. Fuse
ter 3.
S Is the fuse OK?
2. Battery
Specific gravity
1.280 at 20 _C
YES
S Refill the battery
fluid.
S Clean the battery
terminals.
S Recharge or
replace the battery.
NO
EAS00749
YES
Replace the main
switch.
NO
3. Main switch
EAS00783
S Check the lights switch for continuity.
S Is the lights switch OK?
YES
The lights switch is
faulty. Replace the
right handlebar
switch.
NO
4. Lights switch
EAS00781
TROUBLESHOOTING
Any of the following fail to light: head
light, high beam indicator light, taillight,
auxiliary light or meter light.
Check:
1. fuse
2. battery
3. main switch
4. lights switch
5. dimmer switch
6. wiring
(of the entire charging system)
part(-s):
2) seat
3) fuel tank
tool(-s).
Pocket tester
90890-03112
EAS00738
7-25
S Check the dimmer switch for continuity.
S Is the dimmer switch OK?
YES
The dimmer switch is
faulty. Replace the
left handlebar switch.
NO
5. Dimmer switch
S Check the entire lighting systems wiring.
S Is the lighting systems wiring properly con-
YES
Properly connect or
repair the lighting
systems wiring.
NO
7. Wiring
Check the condition
of each of the lighting
systems circuits.
Refer to CHECKING
THE LIGHTING
SYSTEM.
S Check the headlight bulb and socket for con-
tinuity.
Refer to CHECKING THE BULBS AND
BULB SOCKETS.
S Are the headlight bulb and socket OK?
YES
Replace the head-
light bulb, socket or
both.
NO
1. Headlight bulb and socket
2. Voltage
headlight and high beam indicator light cou-
plers as shown.
When the dimmer switch is set to .
When the dimmer switch is set to .
A
B
LIGHTING SYSTEM
ELEC
EAS00784
EAS00787
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
7-26
LIGHTING SYSTEM
ELEC
Headlight
yellow or green
High beam indicator light
Tester positive probe ! yellow
S Set the main switch to ON.
S Set the light switch to .
S Set the dimmer switch to or .
S Measure the voltage (12 V) of yellow (green)
on the headlight coupler (headlight side).
S Is the voltage within specification?
1 2
3
4
5
2
YES
Replace the meter
both.
NO
YES
The wiring circuit
from the main switch
to the meter assem-
bly coupler is faulty
and must be re-
paired.
NO
S Set the light switch to or .
S Measure the voltage (12 V) of blue on the
meter assembly coupler (wire harness side).
This circuit is OK.
EAS00789
2. A meter light fails to come on.
1. Meter light bulb and socket
S Check the meter light bulb and socket for
continuity.
BULB SOCKETS.
S Are the meter light bulb and socket OK?
The wiring circuit
to the headlight cou-
pler is faulty and must
be repaired.
NO
YES
2. Voltage
S Connect the pocket tester (20 V) to the meter
assembly coupler (wire harness side) as
shown.
Tester positive probe ! blue
1
2
This circuit is OK.
1
7-27
Replace the tail/brake
both.
NO
EAS00790
3. A tail / brake light fails to come on.
1. Tail / brake light bulb and socket
S Check the tail / brake light bulb and socket for
continuity.
BULB SOCKETS.
S Are the tail / brake light bulb and socket OK?
YES
2. Voltage
tail / brake light coupler (wire harness side) as
shown.
Tester positive probe ! blue
Tester negative probe ! black 2
YES
The wiring circuit fr-
om the main switch to
the tail / brake light co-
upler is faulty and mu-
st be repaired.
NO
This circuit is OK.
S Measure the voltage (12 V) of blue on the
tail / brake light coupler (wire harness side).
1
Replace the auxiliary
both.
NO
EAS00791
4. The auxiliary light fails to come on.
1. Auxiliary light bulb and socket
S Check the auxiliary light bulb and socket for
continuity.
BULB SOCKETS.
S Are the auxiliary light bulb and socket OK?
YES
1
2. Voltage
auxiliary light couplers (wire harness side) as
shown.
Tester positive probe ! blue/ red
1
2
YES
the auxiliary light con-
nectors is faulty and
must be repaired.
NO
This circuit is OK.
S Measure the voltage (12 V) of blue/ red on
the auxiliary light couplers (wire harness
side).
1
LIGHTING SYSTEM
ELEC
7-28
2 Neutral switch
4 Battery
6 Fuse
11 Main switch
17 Thermo switch
18 Carburetor heater
19 Horn
20 Flasher relay
26 Neutral indicator light
27 Turn signal indicator light
30 Horn switch
31 Turn signal switch
36 Rear turn signal light (right)
38 Front turn signal light (left)
39 Rear turn signal light (left)
SIGNAL SYSTEM
ELEC
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
7-29
Specific gravity
1.280 at 20_C
YES
NO
YES
S Refill the battery fluid.
S Clean the battery ter-
minals.
S Recharge or replace
the battery.
NO
Replace the main sw-
itch.
NO
EAS00749
3. Main switch
YES
1. Fuse
FUSES in chapter 3.
S Is the fuse OK?
2. Battery
Refer to CHECKING THE BATTERY in
chapter 3.
NO
EAS00795
4. Wiring
S Check the entire signaling systems wiring.
S Is the signaling systems wiring properly con-
YES
Properly connect or
repair the signaling
systems wiring.
Check the condition
of each of the signal-
ing systems circuits.
Refer to CHECKING
THE SIGNALING SY-
STEM.
SIGNAL SYSTEM
ELEC
NOTE:
EAS00794
TROUBLESHOOTING
S Any of the following fail to light: turn sig-
nal light, brake light or an indicator light.
S The horn fails to sound.
Check:
1. fuse
2. battery
3. main switch
4. wiring
(of the entire signaling system)
part(-s):
2) seat
3) fuel tank
tool(-s).
Pocket tester
90890-03112
EAS00738
7-30
Replace the left han-
dlebar switch.
NO
1. Horn switch
S Check the horn switch for continuity.
S Is the horn switch OK?
YES
2. Voltage
horn connector at the horn terminal as
shown.
1
The horn is OK.
YES
3. Horn
S Disconnect the pink connector at the horn
terminal.
S Connect a jumper lead to the horn terminal
and ground the jumper lead.
S Push the horn switch.
S Does the horn sound?
NO
4. Voltage
horn connector at the black terminal as
shown.
Tester positive probe ! pink
1
S Push the horn switch.
S Measure the voltage (12 V) of brown at the
horn terminal.
The wiring circuit
to the horn connector
is faulty and must be
repaired.
NO YES
S Measure the voltage (12 V) of pink at the
horn terminal.
1
NO YES
Replace the horn. Repair or replace the
horn.
1
SIGNAL SYSTEM
ELEC
EAS00796
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
7-31
Replace the tail/brake
both.
NO
1. Tail / brake light bulb and socket
S Check the tail / brake light bulb and socket for
continuity.
BULB SOCKETS.
S Are the tail / brake light bulb and socket OK?
YES
3. Voltage
tail / brake light coupler (wire harness side) as
shown.
Tester positive probe ! yellow
1
Replace the brake lig-
ht switch.
NO
2. Brake light switches
S Check the brake light switches for continuity.
S Is the brake light switch OK?
YES
2
YES
the tail / brake light co-
upler is faulty and
must be repaired.
NO
This circuit is OK.
S Pull in the brake lever or push down on the
brake pedal.
S Measure the voltage (12 V) of yellow at the
tail / brake light coupler (wire harness side).
Replace the turn sig-
nal light bulb, socket
or both.
NO
EAS00799
3. A turn signal light, turn signal indicator light
or both fail to blink.
1. Turn signal light bulb and socket
S Check the turn signal light bulb and socket for
continuity.
BULB SOCKETS.
S Are the turn signal light bulb and socket OK?
YES
Replace the left han-
dlebar switch.
NO
3. Turn signal switch
S Check the turn signal switch for continuity.
S Is the turn signal switch OK?
YES
SIGNAL SYSTEM
ELEC
EAS00797
2. A tail / brake light fails to come on.
7-32
A B
The wiring circuit from
the main switch to the
flasher relay coupler
(flasher relay side) is
faulty and must be re-
paired.
NO
4. Voltage
S Connect the pocket tester (DC V 20) to the
flasher relay coupler (wire harness side) as
shown.
YES
Tester positive proble ! brown
Tester negative proble ! ground
1
S Measure the voltage (12 V) of brown at the
flasher relay coupler (wire harness side).
1
5. Voltage
flasher relay coupler (wire harness side) as
shown.
The flasher relay is
placed.
NO YES
S Measure the voltage (12 V) on brown/ white
at the flasher relay coupler (wire harness
side).
6. Voltage
turn signal light connectors or the meter as-
sembly coupler (wire harness side) as
shown.
Turn signal light
Turn signal indicator light
A
B
Left turn signal light
chocolate (orange)
Right turn signal light
Tester positive probe ! dark green
Turn signal indicator light
brown/ white
1
2
1 Tester positive probe ! brown/ white
3
4
SIGNAL SYSTEM
ELEC
7-33
SIGNAL SYSTEM
ELEC
Replace the neutral
indicator bulb, socket
or both.
NO
YES
The wiring circuit
from the turn signal
switch to the turn sig-
nal light connector is
paired.
NO
This circuit is OK.
EAS00800
4. The neutral indicator light fails to come on.
1. Neutral indicator light bulb and socket
S Check the neutral indicator light bulb and
socket for continuity.
S Are the neutral indicator light bulb and socket
OK?
YES
S Set the turn switch to or .
S Measure the voltage (12 V) of chocolate
(orange) or dark green at the turn signal
light connector (wire harness side).
3. Voltage
meter assembly coupler (wire harness side)
as shown.
Tester negative probe ! sky blue
1
2
1 2
Replace the neutral
switch.
NO
2. Neutral switch
YES
S Measure the voltage (12 V) of brown and
sky blue at the meter assembly coupler.
1
2
YES
The wiring circuit
to the meter light bulb
coupler is faulty and
must be repaired.
NO
This circuit is OK.
5. The carburetor heater fails to come on.
1. Thermo switch
S Disconnect the thermo switch from the wire-
harness..
S Connect the pocket tester ( 1) to the ther-
mo switch lead.
Tester positive proble ! black
Tester negative proble ! black
1
2
7-34
Replace the thermo
switch.
NO YES
S Check the thermo switch for continuity at the
temperatures indicated below.
COOL DOWN
HEAT UP
A
B
S Does the thermo switch operated properly?
2. Carburetor heater
S Remove the carburetor heating element from
the carburetor.
S Connect the pocket tester ( 1) to the car-
buretor heating element.
heating element
heating element body
1
2
Carburetor heating element resis-
tance:
6 X 12 (20_C)
YES
Replace the carbure-
tor heater element.
NO
S Measure the carburetor heater resistance.
S Is the carburetor heating element OK?
This circuit is OK.
8_C " 4_C 19_C " 3_C
SIGNAL SYSTEM
ELEC
!
TRBL
SHTG

8
CHAPTER 8.
TROUBLESHOOTING
STARTING PROBLEMS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT ENGINE IDLING SPEED 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 8-2 . . . . . . . . . . . . .
FAULTY GEAR SHIFTING 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY CLUTCH 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR BRAKING PERFORMANCE 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY FRONT LEGS 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING AND SIGNALING SYSTEMS 8-5 . . . . . . . . . . . . . . . . . .
8-1
STARTING PROBLEMS
TRBL
SHTG
NOTE:
EAS00844
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE
Cylinders and cylinder head(-s)
S Loose spark plug
S Loose cylinder head
S Damaged cylinder head gasket
S Worn or damaged cylinder
S Incorrect valve clearance
S Incorrectly sealed valve
S Incorrect valve-to-valve-seat contact
S Incorrect valve timing
S Faulty valve spring
S Seized valve
Pistons and piston rings
S Incorrectly installed piston ring
S Damaged, worn or fatigued piston ring
S Seized piston ring
S Seized or damaged piston
Air filter
S Incorrectly installed air filter
S Clogged air filter element
Crankcase and crankshaft
S Incorrectly assembled crankcase
S Seized crankshaft
FUEL SYSTEM
Fuel tank
S Empty fuel tank
S Clogged fuel filter
S Clogged fuel tank breather hole
S Deteriorated or contaminated fuel
Fuel cock
S Clogged or damaged fuel hose
Carburetors
S Deteriorated or contaminated fuel
S Clogged pilot jet
S Clogged pilot air passage
S Sucked-in air
S Damaged float
S Worn needle valve
S Incorrectly installed needle valve seat
S Incorrect fuel level
S Incorrectly installed pilot jet
S Clogged starter jet
S Faulty starter plunger
S Incorrectly adjusted starter cable
ELECTRICAL SYSTEMS
Battery
S Faulty battery
S Discharged battery
Fuse
S Blown, damaged or incorrect fuse
S Incorrectly installed fuse
Spark plug
S Incorrect spark plug gap
S Incorrect spark plug heat range
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
S Faulty spark plug cap
Ignition coil
S Damaged ignition coil
S Broken or shorted primary or secondary coils
S Faulty spark plug lead
Ignition system
S Faulty CDI unit
S Faulty pickup coil
Switches and wiring
S Faulty main switch
S Faulty engine stop switch
S Broken or shorted wiring
S Faulty neutral switch
S Faulty start switch
S Faulty sidestand switch
S Faulty clutch switch
S Incorrectly grounded circuit
S Loose connections
Starting system
S Faulty starter motor
S Faulty starter relay
S Faulty neutral relay
S Faulty starter clutch
8-2
INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM AND-
HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING
TRBL
SHTG
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinders and cylinder head
S Incorrect valve clearance
S Damaged valve train components
Air filter
FUEL SYSTEM
Carburetor
S Faulty starter plunger
S Loose or clogged pilot jet
S Loose or clogged pilot air jet
S Damaged or loose carburetor joint
S Incorrectly adjusted engine idling speed
(throttle stop screw)
S Incorrect throttle cable free play
S Flooded carburetor
ELECTRICAL SYSTEMS
Battery
S Faulty battery
S Discharged battery
Spark plug
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
S Faulty spark plug cap
Ignition coil
S Broken or shorted primary or secondary coils
S Faulty spark plug lead
S Damaged ignition coil
Ignition system
S Faulty CDI unit
S Faulty pickup coil
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to STARTING PROBLEMS.
ENGINE
Air filter
FUEL SYSTEM
Carburetors
S Faulty diaphragm
S Loose or clogged main jet
EAS00850
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT
Refer to CLUTCH DRAGS.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
S Incorrectly adjusted shift rod
S Bent shift shaft
Shift drum and shift forks
S Foreign object in a shift drum groove
S Seized shift fork
S Bent shift fork guide bar
Transmission
S Seized transmission gear
S Foreign object between transmission gears
S Incorrectly assembled transmission
JUMPS OUT OF GEAR
Shift shaft
S Incorrect shift pedal position
S Incorrectly returned stopper lever
Shift forks
S Worn shift fork
Shift drum
S Incorrect axial play
S Worn shift drum groove
Transmission
S Worn gear dog
8-3
FAULTY CLUTCH/ OVERHEATING
TRBL
SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS
Clutch
S Incorrectly assembled clutch
S Incorrectly adjusted clutch cable
S Loose or fatigued clutch spring
S Worn friction plate
S Worn clutch plate
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (low)
S Deteriorated oil
CLUTCH DRAGS
Clutch
S Unevenly tensioned clutch spring
S Warped pressure plate
S Bent clutch plate
S Swollen friction plate
S Bent clutch push rod
S Damaged clutch boss
S Burnt primary driven gear bushing
S Match marks not aligned
Engine oil
S Incorrect oil viscosity (high)
S Deteriorated oil
EAS00854
OVERHEATING
ENGINE
Cylinder head(-s) and piston(-s)
S Heavy carbon buildup
Engine oil
S Incorrect oil viscosity
S Inferior oil quality
FUEL SYSTEM
Carburetors
S Incorrect main jet setting
S Damaged or loose carburetor joint
Air filter
CHASSIS
Brakes
S Dragging brake
ELECTRICAL SYSTEMS
Spark plugs
Ignition system
S Faulty CDI unit
8-4
POOR BRAKING PERFORMANCE/ FAULTY FRONT FORK
LEGS/ UNSTABLE HANDLING
TRBL
SHTG
EAS00859
POOR BRAKING PERFORMANCE
Front brake
S Worn brake pad
S Worn brake disc
S Air in hydraulic brake system
S Leaking brake fluid
S Faulty brake caliper piston seal
S Loose union bolt
S Damaged brake hose
S Oil or grease on the brake disc
S Oil or grease on the brake pad
S Incorrect brake fluid level
Rear brake
S Improper brake pedal adjustment
S Worn brake shoe
S Improper brake shoe contact
S Worn camshaft
S Worn brake drum
S Mud or water into brake drum inside
S Oily or greasy brake lining
S Faulty brake cable
S Broken or fatigued tension spring
S Faulty camshaft, cam lever
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL
S Bent, damaged or rusty inner tube
S Damaged outer tube
S Incorrectly installed oil seal
S Damaged oil seal lip
S Incorrect oil level (high)
S Loose damper rod assembly bolt
S Damaged damper rod assembly, bolt, or
copper washer
S Damaged cap bolt O-ring
MALFUNCTION
S Bent or damaged inner tube
S Bent or damaged outer tube
S Damaged fork spring
S Worn or damaged outer tube busing
S Bent or damaged damper rod
S Incorrect oil viscosity
EAS00864
UNSTABLE HANDLING
Handlebar
S Bent or incorrectly installed handlebar
Steering head components
S Incorrectly installed upper bracket
S Incorrectly installed lower bracket
(incorrectly tightened ring nut)
S Bent steering stem
S Damaged ball bearing or bearing race
Front fork legs
S Unevenoil levels (both front fork legs)
S Unevenly tensioned fork spring (both front
fork legs)
S Damaged fork spring
S Bent or damaged inner tube
S Bent or damaged outer tube
Swingarm
S Worn bearing or bushing
S Bent or damaged swingarm
Rear shock absorber assembly
S Faulty rear shock absorber spring
S Leaking oil or gas
Tires
S Uneven tire pressures (front and rear)
S Incorrect tire pressure
S Uneven tire wear
Wheels
S Incorrect wheel balance
S Loose sporks
S Deformed wheel rim
S Damaged wheel bearing
S Bent or loose wheel axle
S Excessive wheel runout
Frame
S Bent frame
S Damaged steering head pipe
S Incorrectly installed bearing race
8-5
FAULTY LIGHTING AND SIGNALING SYSTEMS
TRBL
SHTG
EAS00866
FAULTY LIGHTING AND
SIGNALING SYSTEMS
HEADLIGHT DOES NOT LIGHT
S Wrong headlight bulb
S Too many electrical accessories
S Hard charging
S Incorrect connection
S Poor contacts (main or light switch)
S Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
S Wrong headlight bulb
S Faulty battery
S Faulty rectifier/ regulator
S Faulty light switch
S Headlight bulb life expired
TAIL/ BRAKE LIGHT DOES NOT LIGHT
S Wrong tail / brake light bulb
S Too may electrical accessories
S Burnt-out tail / brake light bulb
TAIL/ BRAKE LIGHT BULB BURNT OUT
S Wrong tail / brake light bulb
S Faulty battery
S Incorrectly adjusted rear brake light switch
S Tail / brake light bulb life expired
TURN SIGNAL DOES NOT LIGHT
S Faulty turn signal switch
S Faulty flasher relay
S Burnt-out turn signal bulb
S Damaged or faulty wire harness
S Faulty battery
TURN SIGNAL BLINKS SLOWLY
S Faulty turn signal switch
S Wrong turn signal bulb
TURN SIGNAL REMAINS LIT
S Burnt-out-turn signal bulb
TURN SIGNAL BLINKS QUICKLY
S Incorrect turn signal bulb
S Burnt-out turn signal bulb
HORN DOES NOT SOUND
S Incorrectly adjusted horn
S Damaged or faulty horn
S Faulty horn switch
S Faulty battery
S Faulty wire harness
TRBL
SHTG
COLOR CODE
B Black . . . . .
Br Brown . . . .
Ch Chocolate . . .
Dg Dark green . . .
G Green . . . .
L Blue . . . . .
O Orange . . . .
Sb Sky blue . . . .
P Pink . . . . .
R Red . . . . .
Y Yellow . . . . .
W White . . . .
B/ R Black/ Red . . .
B/ W Black/ White . .
Br / L Brown/ Blue . .
Br / W Brown/ White .
G/ R Green/ Red . .
G/ W Green/ White . .
G/ Y Green/ Yellow . .
L/ B Blue/ Black . . .
L/ R Blue/ Red . . .
L/ W Blue/ White . .
L/ Y Blue/ Yellow . . .
R/ L Red/ Blue . . .
R/ W Red/ White . .
W/ B White/ Black . .
W/ L White/ Blue . .
W/ R White/ Red . .
1 C.D.I. magneto
2 Neutral switch
3 Rectifier / Regulator
4 Battery
5 Starter relay
6 Fuse
7 Starting motor
8 Handlebar switches (right)
9 Start switch
11 Main switch
12 Clutch switch
13 Diode
14 C.D.I. unit
15 Ignition coil
16 Spark plug
17 Thermo switch
18 Carbuletor heater
19 Horn
20 Flasher relay
21 Sidestand switch
22 Neutral relay
23 Speedometer
24 Reed switch (for D[5EK2])
25 Meter light
26 Neutral indicator light
27 Turn signal indicator light
28 Hi-beam indicator light
29 Handlebar switches (left)
30 Horn switch
31 Turn switch
32 Lights switch
33 Dimmer switch
36 Rear turn signal light (right)
38 Front turn signal light (left)
39 Rear turn signal light (left)
40 Headlight
41 Auxiliary light
TW125 99 WIRING DIAGRAM

TW125 RepairManual

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TW125 RepairManual

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EAS00000

mark at the bottom of the wheel.

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