Crpton 110

T110SE
SERVICE MANUAL
5TP-F8197-E0
EAS00000
T110SE
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
First edition, January 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
CAUTION: 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.
EASF0001
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1:This is a chapter with its symbol on the upper right of each page.
2nd title 2:This title appears on the upper of each page on the left of the chapter symbol. (For the
chapter “Periodic checks and adjustments” the 3rd title appears.)
3rd title 3:This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. THe infor-
mation has been compiled to provide the mechanic with an easy to read, handy reference that con-
tains comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “Black triangle” with
each procedure preceded by alphabetical letters.
IMPORTANT FEATURES
• Data and a special tool are framed in a box preceded by a relevant symbol 5.
• An encircled numeral 6 indicates a part name, and an encircled alphabetical letter or an align-
ment mark 7, the others being indicated by an alphabetical letter in a box 8.
• A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAMS
Each chapter provide exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly prodedures.
EASF0002
1 2
SYMBOLS
GEN The following symbols are not relevant to
INFO SPEC every vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
CHK ENG
1 General information
2 Specifications
ADJ 3 Periodic checks and adjustments
5 6 4 Engine
5 Carburetor
6 Chassis
CARB CHAS 7 Electrical system
8 Troubleshooting
7 8
– + TRBL
ELEC SHTG
9 0 Symbols 9 to F indicate the following.
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data
C D
T.
R.
E F
G H I Symbols G to L in the exploded diagrams

indicate the types of lubricants and lubrication
points.
E G M G Engine oil
H Gear oil
J K L
I Molybdenum-disulfide oil
J Wheel-bearing grease
B LS M K Lithium-soap-based grease
L Molybdenum-disulfide grease
M N Symbols M to N in the exploded diagrams
indicate the following.
LT
New M Apply locking agent (LOCTITE®)
N Replace the part
EASF0003
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
CARBURETOR CARB 5
CHASSIS CHAS 6
– +
ELECTRICAL SYSTEM ELEC 7

TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
IMPORTANT INFORMATION ......................................................................... 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS ..................................................................................................1-3
CHECKING THE CONNECTIONS ..................................................................1-4
SPECIAL TOOLS ............................................................................................ 1-5

GEN
INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the frame.
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1-1
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
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”.
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
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
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 lubricate the oil seal
lips with grease.
1-2
GEN
IMPORTANT INFORMATION INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat side of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed

air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-3
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with compressed air.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it

up.
4. Connect:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
_
• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
Meter gear bush tool
90890-01052
This tool is used to remove or install the
bushing.
Weight
Weight Slide hammer bolt
90890-01084
Slide hammer bolt
90890-01085 These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight
90890-01184
This tool is used to install the oil seal.

Fork seal driver attachment
90890-01186
This tool is used to install the oil seal.

Ring nut wrench
90890-01268
This tool is used to loosen and tighten
the steering ring nut.
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
1-5
GEN
SPECIAL TOOLS INFO
T-handle
90890-01326
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
Flywheel puller
90890-01362
This tool is used for removing the rotor.

Steering nut wrench
90890-01403
This tool is used to loosen and tighten
the steering ring nut.
Sheave holder
90890-01701
This tool is used for holding the second-
ary pulley.
Thickness gauge
90890-03079
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
This instrument is necessary for check-
ing the electrical system.
Engine tachometer
90890-03113
This tool is needed for detecting engine
rpm.
1-6
GEN
SPECIAL TOOLS INFO
Valve spring compressor
90890-04019
This tool is used when removing or
installing the valve and the valve spring.
Universal clutch holder
90890-04086
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.
Valve lapper
90890-04101
This tool is used for removing and
installing the lifter and for lapping the
valve.
Valve guide remover (4.5 mm)
90890-04116
This tool is needed to remove and
install the valve guide.
Valve guide installer (4.5 mm)
90890-04117
This tool is needed to install the valve
guide.
Valve guide reamer (4.5 mm)
90890-04118
This tool is needed to rebore the new
valve guide.
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
Yamaha bond No. 1215
90890-85505
This sealant (bond) is used for crank-
case mating surfaces, etc.
1-7
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
MAINTENANCE SPECIFICATIONS ............................................................... 2-4

ENGINE..................................................................................................... 2-4
TIGHTENING TORQUES..........................................................................2-8
CHASSIS...................................................................................................2-9
TIGHTENING TORQUES........................................................................2-11
ELECTRICAL .......................................................................................... 2-13
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-15
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-16

ENGINE .................................................................................................. 2-16
CHASSIS ................................................................................................2-18
CABLE ROUTING ......................................................................................... 2-19

SPEC
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model T110SE
Model code 5TP1
Dimensions
Overall length 1,910 mm
Overall width 675 mm
Overall height 1,040 mm
Seat height 760 mm
Wheelbase 1,225 mm
Minimum ground clearance 130 mm
Minimum turning radius 1,900 mm
Weight
Wet (with oil and full fuel tank) 102 kg
Engine
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.1103 L
Bore × stroke 51.0 × 54.0 mm
Compression ratio 9.3 : 1
Compression pressure (STD) 1,300 kPa (13 kgf/cm2) at 500 r/min
Starting system Kick and electric starter
Lubrication system Wet sump
Engine idling speed 1,400 ~ 1,600 r/min
Oil type or grade
Engine oil SAE 20W40 type SE or higher grade motor oil
Periodic oil change amount 0.8 L
Total amount 1.0 L
Air filter Dry type element
Fuel
Recommended fuel Regular gasoline
Fuel tank capacity 4.5 L
2-1
Model T110SE
Carburetor
Type/quantity VM17SH/1
Manufacturer MIKUNI
Spark plug
Type C6HSA
Manufacturer LOCAL MADE
Spark plug gap 0.6 ~ 0.7 mm
Clutch type Wet, multiple-disc and centrifugal automatic
Transmission
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 36/15 (2.400)
Transmission type Constant mesh 4 speed
Operation Left foot operation
Gear ratio 1st 38/12 (3.166)
2nd 33/17 (1.941)
3rd 29/21 (1.380)
4th 23/21 (1.095)
Chassis
Frame type Steel tube underbone
Caster angle 26.2°
Trail 74 mm
Tire
Type With tube
Size front 70/90-17 38P
rear 80/90-17 44P
Model (manufacturer) front LOCAL MADE
rear LOCAL MADE
Min. tire tread depth front 0.8 mm
rear 0.8 mm
Tire pressure (cold tire)
Maximum load*-except motorcycle 110 kg
front 200 kPa (2.00 kg/cm2)
rear 225 kPa (2.25 kg/cm2)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2
Model T110SE
Brake
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation
Suspension
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 95 mm
Rear wheel travel 70 mm
Electrical
Ignition system DC. C.D.I.
Generator system A.C. magneto
Battery type/manufacturer YB5L-B/LOCAL MADE
Battery capacity 12 V 5 AH
Headlight type Incandescence
Bulbs (voltage/wattage × quantity)
Headlight 12 V 25 W/25 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Front turn signal light 12 V 10 W × 2
Rear turn signal light 12 V 10 W × 2
Meter light 14 V 3.0 W × 1
High beam indicator light 12 V 1.7 W × 1
Neutral indicator light 12 V 1.7 W × 1
Turn signal indicator light 12 V 1.7 W × 1
Gear position indicator light 12 V 1.7 W × 4
2-3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head
Max. warpage “*” ---- 0.03 mm
Cylinder
Bore 51.000 ~ 51.015 mm 51.1 mm
Out of round limit ---- 0.03 mm
Camshaft
Drive method Chain drive (left)
Cam dimensions
Intake “A” A 25.775 ~ 25.875 mm 25.745 mm
“B” 21.045 ~ 21.145 mm 21.015 mm
Exhaust “A” 25.775 ~ 25.875 mm 25.749 mm
“B” 20.950 ~ 21.050 mm 20.924 mm
B
Camshaft runout limit ---- 0.03 mm
Timing chain
Timing chain type/No. of links SILENT CHAIN/86 ----
Tensioning system Automatic ----
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10.000 ~ 10.015 mm 10.030 mm
Rocker arm shaft outside diameter 9.981 ~ 9.991 mm 9.950 mm
Rocker-arm-to-rocker-arm-shaft 0.009 ~ 0.034 mm 0.08 mm
clearance
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.05 ~ 0.09 mm ----
EX 0.08 ~ 0.12 mm ----
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 ~ 23.1 mm ----
EX 19.9 ~ 20.1 mm ----
“B” face width IN 1.20 ~ 2.50 mm ----
EX 1.6 ~ 2.9 mm ----
“C” seat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.9 ~ 1.1 mm 1.6 mm
“D” margin thickness IN 0.5 ~ 0.9 mm ----
EX 0.8 ~ 1.2 mm ----
2-4
Item Standard Limit
Valve stem outside diameter IN 4.475 ~ 4.490 mm 4.450 mm
EX 4.460 ~ 4.475 mm 4.435 mm
Guide inside diameter IN 4.500 ~ 4.512 mm 4.542 mm
EX 4.500 ~ 4.512 mm 4.542 mm
Valve-stem-to-guide clearance IN 0.010 ~ 0.037 mm 0.080 mm
EX 0.025 ~ 0.052 mm 0.100 mm
Valve stem runout limit ---- 0.01 mm
Valve seat width IN/EX 0.9 ~ 1.1 mm 1.6 mm
Valve spring
Free length IN/EX 33.75 mm 32.05 mm
Installed length (valve closed) IN/EX 24.2 mm ----
Compressed spring force IN/EX 138 ~ 148 N (13.8 ~ 14.8 kgf) at 24.2 mm ----
Tilt limit “*” IN/EX ---- 1.4 mm
Winding direction IN/EX Clockwise ----

Piston
Piston-to-cylinder clearance 0.008 ~ 0.038 mm 0.150 mm
Piston size “D” 50.977 ~ 50.992 mm ----
Measuring point “H” 5.0 mm ----
Offset 0.5 mm ----
H
Offset direction D Intake side ----
Piston pin bore inside diameter 13.002 ~ 13.013 mm 13.043 mm
Piston pin outside diameter 12.996 ~ 13.000 mm 12.976 mm
Piston rings
Top ring
Ring type Barrel ----
Dimensions (B × T) B 1.00 × 2.00 mm ----
End gap (installed) T 0.15 ~ 0.30 mm 0.40 mm
Ring side clearance (installed) 0.03 ~ 0.07 mm 0.12 mm
2nd ring
Ring type B
Taper ----
Dimensions (B × T) T
1.0 × 2.0 mm ----
End gap (installed) 0.15 ~ 0.30 mm 0.40 mm
Ring side clearance 0.02 ~ 0.06 mm 0.12 mm
Oil ring B
Dimensions (B × T) T 2.0 × 2.2 mm ----
End gap (installed of oil ring rails) 0.30 ~ 0.90 mm ----
2-5
Item Standard Limit
Crankshaft
C C
E
D
A
Crank width “A” 42.95 ~ 43.00 mm ----
Max. runout limit “C” ---- 0.03 mm
Big end side clearance “D” 0.11 ~ 0.41 mm ----
Big end radial clearance “E” 0.004 ~ 0.014 mm ----
Clutch
Friction plates
Thickness 2.7 ~ 2.9 mm 2.6 mm
Plate quantity 5 ----
Clutch plates
Thickness 1.1 ~ 1.3 mm ----
Plate quantity 4 ----
Max. warpage ---- 0.05 mm
Clutch springs
Free length 30.3 mm 28.3 mm
Spring quantity 4 ----
Clutch release method Inner push, cam push ----
Clutch shoe thickness 2.20 mm ----
Clutch shoe groove depth 1.20 mm 0.1 mm
Clutch housing inside diameter 105 mm 106 mm
Weight outside diameter 105.0 mm 103.8 mm
Clutch - in revolution 1,800 ~ 2,200 r/min ----
Clutch - stall revolution 3,100 ~ 3,700 r/min ----
Push rod bending limit ---- 0.5 mm
Transmission
Main axle runout limit ---- 0.03 mm
Drive axle runout limit ---- 0.03 mm
Kickstarter
Kickstarter type Ratchet type ----
Kick clip friction force 9.8 ~ 13.8 N (1.00 ~ 1.41 kgf) ----
2-6
Item Standard Limit
Carburetor
Type VM17SH ----
I.D. mark 5TN1 00 ----
Main jet (M.J) #105 ----
Main air jet (M.A.J) ø1.2 ----
Jet needle (J.N) 4CJT5-2 ----
Needle jet (N.J) E-8M ----
Pilot outlet (P.O) ø0.8 (pitch: 1.70) ----
Pilot jet (P.J) #17.5 ----
Pilot air screw turns out 1-3/8 ----
Valve seat size ø1.5 ----
Starter jet 1 #32.5 ----
Oil pump
Oil pump type Trochoid type ----
Inner-rotor-to-outer-rotor-tip clear- 0.15 mm 0.20 mm
ance
Outer-rotor-to-oil-pump housing 0.06 ~ 0.10 mm 0.15 mm
clearance
Oil-pump-housing-to-inner-rotor-and- 0.06 ~ 0.10 mm 0.15 mm
outer-rotor clearance
Model T110SE
Lubrication chart
OIL RING PISTON CYLINDER HEAD CAMSHAFT
CONNECTING
ROD BIG END
CRANKSHAFT
CLUTCH TRANSMISSION
OIL PUMP
OIL STRAINER
OIL PAN
2-7
TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Cylinder head Nut M8 4 22 2.2
Cylinder head (timing chain side) Bolt M6 2 10 1.0
Spark plug — M10 1 12.5 1.25
Camshaft sprocket cover Screw M6 2 7 0.7
Tappet cover (intake and exhaust side) — M45 2 18 1.8
Stud bolt (cylinder head) Bolt M6 2 7 0.7
Generator rotor Nut M12 1 70 7.0
Timing chain guide (intake side) Bolt M6 2 10 1.0 LT
Valve adjusting screw locknut (intake Nut M5 2 7 0.7

and exhaust side)
Camshaft sprocket Bolt M8 1 20 2.0
Camshaft retainer Bolt M6 1 10 1.0 LT
Timing chain tensioner cap bolt Bolt M6 1 8 0.8

Timing chain tensioner Bolt M6 2 10 1.0
Oil pump assembly Bolt M6 2 7 0.7
Engine oil drain bolt Bolt M12 1 20 2.0
Intake manifold (engine side) Bolt M6 2 10 1.0
Carburetor assembly Bolt M6 2 10 1.0
Exhaust pipe Nut M6 2 7 0.7
Exhaust pipe joint bolt Bolt M8 1 12 1.2
Muffler and muffler bracket Bolt M8 1 16 1.6
Muffler and passenger footrest Bolt M10 1 38 3.8
Air filter case Screw M6 4 2 0.2
Crankcase Bolt M6 9 10 1.0
Crankcase cover (left) Bolt M6 8 10 1.0
Drive sprocket cover Bolt M6 2 7 0.7
Crankcase cover (right) Bolt M6 9 10 1.0
Center plug — M32 1 7 0.7
Timing check plug — M14 1 7 0.7
Stud bolt (crankcase) Bolt M8 4 13 1.3
Kickstarter lever Bolt M6 1 10 1.0
Starter clutch Bolt M6 3 14 1.4 stake
Clutch shoe housing Nut M12 1 50 5.0
Clutch pressure plate Bolt M5 4 6 0.6
Clutch boss Nut M14 1 70 7.0
Clutch release adjusting locknut Nut M6 1 8 0.8
Shift pedal Bolt M6 1 10 1.0
Shift drum segment Bolt M6 1 12 1.2 LT
Shift fork guide bar retainer Bolt M6 2 10 1.0 LT
Pickup coil Bolt M6 2 10 1.0 LT
Stator coil Bolt M6 3 10 1.0 LT
2-8
CHASSIS
Item Standard Limit

Steering system
Steering bearing type Ball and race bearing ----
Lock-to-lock angle (left/right) 45° ----
No./size of steel balls upper 19 pcs/0.187 in ----
lower 16 pcs/0.250 in ----
Front suspension
Front fork travel 95 mm ----
Fork spring free length 257.7 mm 252.5 mm
Installed length 255.7 mm ----
Spring rate (K1) 11 N/mm (1.1 kgf/mm) ----
(K2) 17.2 N/mm (1.72 kgf/mm) ----
Stroke (K1) 0 ~ 64 mm ----
(K2) 64 ~ 95 mm ----
Optional spring available No ----
Oil capacity 0.058 L (58 cm3) ----
Oil level 91 mm ----
Recommended oil Fork oil 10W or equivalent ----
Inner tube outer diameter 26 mm ----
Inner tube bend limit ---- 0.2 mm
Rear suspension
Shock absorber stroke 70 mm ----
Spring free length 229.0 mm 224.0 mm
Installed length 214.0 mm ----
Spring rate (K1) 17.40 N/mm (1.74 kgf/mm) ----
(K2) 30.80 N/mm (3.08 kgf/mm) ----
Stroke (K1) 0 ~ 34 mm ----
(K2) 34 ~ 65 mm ----
Optional spring available No ----
Front wheel
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Max. radial wheel runout ---- 1.0 mm
Max. lateral wheel runout ---- 0.5 mm
Rear wheel
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Max. radial wheel runout ---- 1.0 mm
Max. lateral wheel runout ---- 0.5 mm
2-9
Item Standard Limit
Drive chain
Type/manufacturer 428/DAIDO ----
Link quantity 104 ----
Drive chain slack 25 ~ 35 mm ----
Front brake
Disc brake type Single ----
Disc outside diameter × thickness 220.0 × 3.5 mm 3.0 mm
Pad thickness inner 5.3 mm 0.8 mm
Pad thickness outer 5.3 mm 0.8 mm
Master cylinder inside diameter 11.1 mm ----

Caliper cylinder inside diameter 22.2 mm ----
Brake fluid type DOT 4 ----
Rear brake
Drum brake type Leading, trailing ----
Rear brake pedal free play (pedal 20 ~ 30 mm ----
end)
Drum inside diameter 110 mm 111 mm
Lining thickness 4 mm 2 mm
Shoe spring free length 54 mm 63.5 mm
Throttle cable free play 3 ~ 7 mm ----
2 - 10
TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Handlebar bracket and lower bracket M10 43 4.3
Handlebar and handlebar bracket M8 16 1.6
Brake hose and brake master cylinder M10 26 2.6
Brake hose and brake caliper M10 26 2.6
Brake master cylinder and holder M6 13 1.3
Brake master cylinder and brake lever M6 6 0.6
Rear view mirror (left and right) M10 32 3.2
Front wheel axle nut M10 39 3.9
Lower bracket and front fender M6 10 1.0
Lower bracket and front fork cover M6 7 0.7
Brake hose retainer M6 7 0.7
Front fork and brake caliper M10 35 3.5
Front fork and brake hose holder M6 10 1.0
Brake pad retaining bolt M10 17 1.7
Upper brake caliper retaining bolt M8 22 2.2 LT
Lower brake caliper retaining bolt M8 12 1.2 LT
Bleed screw M8 6 0.6

Front fork cap bolt M20 50 5.0
Lower bracket pinch bolt M10 50 5.0
Damper rod bolt M8 23 2.3 LT
Upper ring nut M25 75 7.5 See NOTE

Lower ring nut M25 30 3.0 See NOTE
Brake disc and wheel hub M8 23 2.3 LT
Brake camshaft and brake camshaft lever M6 7 0.7

Driven sprocket and rear wheel drive hub M8 30 3.0
Rear wheel axle nut M12 60 6.0
Rear shock absorber and frame M10 32 3.2
Rear shock absorber and swingarm M10 32 3.2
Swingarm pivot nut M12 51 5.1
Engine mounting nut M8 34 3.4
Swingarm and drive chain case M6 7 0.7
Drive chain adjuster locknut M6 7 0.7
Swingarm and brake torque rod M8 16 1.6
Brake shoe plate and brake torque rod M8 19 1.9
Rider footrest and crankcase M8 23 2.3
Passenger footrest and frame M8 30 3.0
Sidestand and rider footrest (bolt) M8 26 2.6
Sidestand and rider footrest (nut) M8 16 1.6
Centerstand and centerstand bracket M10 48 4.8
Centerstand bracket and muffler bracket M10 48 4.8
2 - 11
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Basket and basket bracket M6 10 1.0
Brake hose retainer and basket bracket M6 7 0.7
Horn bracket and basket bracket M6 7 0.7
Basket bracket and frame M8 23 2.3
Front cowling bracket and crankcase cover (left M6 7 0.7
and right)
Main switch and frame M6 10 1.0
Ignition coil and frame M6 7 0.7
Seat bracket and frame M6 9 0.9
Fuel tank and frame M8 16 1.6
Fuel cock and frame M6 9 0.9
Seat and seat bracket M6 7 0.7
NOTE:
1. First tighten the lower ring nut 30 Nm (3.0 m • kg) by using a torque wrench, then loosen the ring
nut 1/4 turn.
2. Then, hold the lower ring nut and tighten the upper ring nut 75 Nm (7.5 m • kg) by using a torque
wrench.
2 - 12
ELECTRICAL
Item Standard Limit

System voltage 12 V ----
Ignition system
Ignition timing (B.T.D.C.) 10° at 1,500 r/min ----
Advanced type Digital ----
DC-C.D.I.
Pickup coil resistance/color 248 ~ 372 Ω at 20 °C/R–W ----
C.D.I. unit model/manufacturer 5TF/PT MORIC ----
Ignition coil
Model/manufacturer 4ST/PT MORIC ----
Minimum ignition spark gap 6 mm ----
Primary coil resistance 0.32 ~ 0.48 Ω at 20 °C ----
Secondary coil resistance 5.68 ~ 8.52 kΩ at 20 °C ----
Spark plug cap
Material Resin ----
Resistance 10 kΩ ----
Charging system
Type A.C. magneto ----
Model/manufacturer F5TN/SEPCO ----
Nominal output 14 V 100 W at 5,000 r/min ----
Lighting coil resistance/color 0.24 ~ 0.36 Ω at 20 °C/Y–B ----
Charging coil resistance/color 0.32 ~ 0.48 Ω at 20 °C/W–B ----
Rectifier/regulator
Regulator type Semiconductor short-circuit ----
Model/manufacturer SH656BA/PT. SHINDENGEN ----
No load regulated voltage (DC) 14.1 ~ 14.9 V ----
(AC) 13.0 ~ 14.0 V ----
Rectifier capacity 12 A ----
Withstand voltage 400 V ----
Battery
Specific gravity 1.280 ----
Electric starting system
Type Constant mesh ----
Starter motor
Model/manufacturer 5TN/SEPCO ----
Operation voltage 12 V ----
Power output 0.35 kW ----
Armature coil resistance 0.018 ~ 0.022 Ω at 20 °C ----
Brush overall length 7 mm 3.5 mm
Spring force 3.92 ~ 5.88 N (400 ~ 600 gf) 3.92 N
(400 gf)
Commutator diameter 17.6 mm 16.6 mm
Mica undercut (depth) 1.35 mm ----
2 - 13
Item Standard Limit
Starter relay
Model/manufacturer G4R/OMRON ----
Amperage rating 50 A ----
Coil resistance 54 ~ 66 Ω at 20 °C ----
Horn
Type Plane ----
Quantity 1 ----
Model/manufacturer UBH-F21/MITSUBA ----
Max. amperage 1.5 A ----
Performance 97 ~ 107 db (2 m) ----
Coil resistance 4.30 ~ 4.80 Ω at 20 °C ----
Turn signal relay
Relay type Condenser ----
Model/manufacturer FR22-091/MITSUBA ----
Self-canceling device built-in No ----
Flasher frequency 75 ~ 95 cycle/min ----
Wattage 10 W × 2 + 3.4 W ----
Fuel gauge
Model/manufacturer 5LM/NIPPON SEIKI ----
Sender unit resistance- full 4 ~ 10 Ω at 20 °C ----
- empty 90 ~ 100 Ω at 20 °C ----
Circuit breaker
Circuit breaker type Fuse ----
Main 7A ----
Reserve 7A ----
2 - 14
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EAS00029
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Width across flats
B: Thread diameter
General tightening
A B torques
(nut) (bolt)
Nm m•kg
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 POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant

Oil seal lips LS
Bearings E
O-rings LS
Cylinder head tightening nut and stud bolt thread E
Rocker arm inner surfaces M
Rocker arm shaft E
Camshaft M
Valve stem (IN, EX) E
Valve stem guide (IN, EX) E
Piston pin E
Piston outside and ring groove E
Piston ring E
Cylinder inner surface E
Starter clutch gear inner surface M
Starter idle gear inner surface E
Kickstarter ratchet gear E
Kickstarter gear E
Kickstarter shaft E
Primary driven gear inner surface E
Clutch push rod E
Clutch pressure plate E
Friction plate E
Clutch shoe housing inner surface E
Cage E
Clutch shoe housing boss E
Oil pump assembly E
Shift guide inner surface E
Shift fork guide bar E
Shift shaft thrust surface E
Shift lever inner surface E
Shift shaft stopper lever inner surface E
Timing chain E
Transmission wheel gears inner surface M
2 - 16
Transmission side plate inner surface M
Transmission pinion gears inner surface M
Starter motor guard bolt Yamaha bond No.1215

Generator lead grommet Yamaha bond No.1215
Crankcase cover bolt Yamaha bond No.1215
Crankcase mating surface Yamaha bond No.1215
2 - 17
CHASSIS

Front wheel oil seal lips LS
Speedometer gear unit inner surface LS
Rear wheel oil seal lips LS
Rear brake camshaft LS
Brake torque rod bolt LS
Front wheel axle LS
Rear wheel axle LS
Upper brake caliper retaining bolt LS
Lower brake caliper retaining bolt LS
Throttle grip tube guide inner surface LS
Brake lever pivot bolt LS
Steering head bearing inner race LS
Steering head bearing outer race LS
Steering head upper bearing LS
Steering head lower bearing LS
Sidestand pivot bolt LS
Swingarm pivot shaft LS
Centerstand pivot shaft LS
2 - 18
CABLE ROUTING SPEC
CABLE ROUTING
1 Front brake light switch lead È Put the couplers into the space between the
2 Left handlebar switch lead handlebar and speedometer unit, after connect-
3 Starter cable ing them.
4 Speedometer cable É Fasten the wire harness, speedometer cable,
5 Wire harness throttle cable, and starter cable with the plastic
6 Headlight unit band.
7 Brake hose Ê Hang the wire strap on the wire guide.
8 Throttle cable
9 Right handlebar switch lead
È 2
1
9 3
8 4
Ê 5
7 É
2 - 19
CABLE ROUTING SPEC
1 Wire harness È Align the clamp with the white tape on the wire
2 Cable guide harness.
3 Throttle cable É Clamp the speedometer cable securely to the
4 Starter cable handlebar bracket.
5 Speedometer cable
6 Brake hose
1 6
3 4
A-A
A
2 A
6 B
3 È
3
1 B
1
É5
4 4
B-B
2 - 20
CABLE ROUTING SPEC
1 Air vent hose B Carburetor overflow hose
2 Wire harness C Air filter drain hose
3 A.C. magneto lead D Throttle cable
4 Gear position sensor lead E Starter cable
5 Fuel hose (fuel cock to carburetor) F Main switch lead
6 Fuel cock vacuum hose G Battery breather hose
7 Fuel hose (fuel tank to fuel cock)
8 Fuel cock
9 Starter relay
0 Fuel tank overflow hose
A Starter motor lead
2
E F
D
2
D
E
C-C
A-A
2 D 2 5
E 0
G
6
B-B D-D
E
5 6
A
B È
C
B
A C 1
2
E É Ê 34
D
D
Ë 7
D 8
6 9
0
E
A
C
B
2 - 21
CABLE ROUTING SPEC
È Pass the wire harness, starter cable, and throttle cable through the guide.
É Pass the fuel hose (fuel cock to carburetor) and fuel cock vacuum hose through the guide.
Ê Pass the starter motor lead, gear position sensor lead, and A.C. magneto lead through the guide.
Ë Install the fuel hose clamp facing down.
2
E F
D
2
D
E
C-C
A-A
2 D 2 5
E 0
G
6
B-B D-D
E
5 6
A
B È
C
B
A C 1
2
E É Ê 34
D
D
Ë 7
D 8
6 9
0
E
A
C
B
2 - 22
CABLE ROUTING SPEC
1 Crankcase breather hose B Main switch
2 Wire harness
3 Ignition coil È Insert the end of the air vent hose into the hole in
4 Air vent hose the frame.
5 Main switch lead É Pass the brake hose through the guide.
6 Horn
7 Brake hose
8 Spark plug lead
9 Starter motor lead
0 Starter motor
A Footrest
A-A
9 0
6
A É
A
B
5
È
A
4
3
1 2
2 - 23
CABLE ROUTING SPEC
1 Turn signal relay B Starter relay
2 C.D.I. unit C Starter relay lead
3 Fuel sender D A.C. magneto lead
4 Battery positive lead E Gear position sensor lead
5 Battery breather hose F Starter motor lead
6 Fuel tank overflow hose
7 Rear brake light switch È To the fuse.
8 Fuse
9 Battery
0 Battery negative lead
A Tail/brake light lead
B C D
E
4
0 È
9
A
2 3
1
A
4
A
B
7
0
9
5
8
6
7
6
5
B
2 - 24
CABLE ROUTING SPEC
1 Wire harness È Align the white tape of the wire harness with the
2 C.D.I. unit guide on the fuel tank.
3 Turn signal relay É Pass the tail/brake light lead through the tail/
4 Tail/brake light lead brake light lead guide.
5 Tail/brake light
6 Fuel sender
7 Fuel hose (fuel tank to fuel cock)
8 Fuel cock
9 Rectifier/regulator
7 È
2
6
3
2 - 25
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1
COVERS ..........................................................................................................3-3
REMOVING THE FRONT COWLINGS.....................................................3-3
INSTALLING THE FRONT COWLINGS ................................................... 3-3
REMOVING THE REAR COWLINGS .......................................................3-4
INSTALLING THE REAR COWLINGS......................................................3-4
REMOVING THE HEADLIGHT ASSEMBLY.............................................3-5
INSTALLING THE HEADLIGHT ASSEMBLY ...........................................3-5
ENGINE ...........................................................................................................3-6
ADJUSTING THE VALVE CLEARANCE .................................................. 3-6
ADJUSTING THE ENGINE IDLING SPEED .............................................3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-10
CHECKING THE SPARK PLUG ............................................................. 3-11
MEASURING THE COMPRESSION PRESSURE..................................3-13
CHECKING THE ENGINE OIL LEVEL....................................................3-15
CHANGING THE ENGINE OIL ...............................................................3-16
CHECKING THE EXHAUST SYSTEM....................................................3-17
CLEANING THE AIR FILTER ELEMENT................................................ 3-17
ADJUSTING THE CLUTCH RELEASE SYSTEM ................................... 3-18
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD...... 3-19
CHECKING THE FUEL AND VACUUM HOSES .................................... 3-19
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-20
CHASSIS ....................................................................................................... 3-21

ADJUSTING THE REAR BRAKE............................................................ 3-21
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE SHOES................................................ 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-22
CHECKING THE FRONT BRAKE HOSE................................................ 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-24
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-25
LUBRICATING THE DRIVE CHAIN ........................................................ 3-27
CHECKING THE BRAKE FLUID LEVEL................................................. 3-27
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-28
CHECKING THE FRONT FORK ............................................................. 3-30
CHECKING THE TIRES..........................................................................3-31
CHECKING AND TIGHTENING THE SPOKES...................................... 3-33
CHECKING AND LUBRICATING THE CABLES .................................... 3-34
LUBRICATING THE LEVER AND PEDALS............................................3-34
LUBRICATING THE SIDESTAND........................................................... 3-34
LUBRICATING THE CENTERSTAND ....................................................3-34
CHK
ADJ
ELECTRICAL SYSTEM................................................................................. 3-35
CHECKING AND CHARGING THE BATTERY....................................... 3-35
CHECKING THE FUSE...........................................................................3-39
REPLACING THE HEADLIGHT BULBS ................................................. 3-40
ADJUSTING THE HEADLIGHT BEAM ...................................................3-41
INTRODUCTION/PERIODIC MAINTENANCE AND CHK
LUBRICATION INTERVALS ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information 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 AND LUBRICATION INTERVALS

INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
• Check valve clearance.
1 * Valve(s) √ √
• Adjust if necessary.
• Check condition.
2 * Spark plug √ √ √ √
• Clean or replace if necessary.
• Clean.
3 Air filter √ √
• Replace if necessary.
• Check engine idling speed and starter operation.
4 * Carburetor √ √ √ √
• Adjust if necessary.
• Check fuel hose and vacuum hose for cracks or
5 Fuel line damage. √ √
6 * Engine oil • Replace. (Warm engine before draining.) √ √ Every 2,000 km
7 * Engine oil filter • Check, clean and replace if necessary. √ √ √ √
• Check operation, fluid level and fluid leakage.
8 * Front brake √ √
• Replace brake pads if necessary.
• Check operation and adjust brake pedal free
9 * Rear brake play. √ √
• Replace brake shoes if necessary.
• Check swingarm assembly for looseness.
• Correct if necessary.
10 * Swingarm pivot √
• Lubricate with lithium soap base grease every
16,000 km.
• Check balance, runout, spoke tightness and for
11 * Wheels damage. √ √
• Check bearing assembly for looseness or dam-
12 * Wheels bearings age. √ √ √
• Replace if damaged.
• Check bearing assembly for looseness.
13 * Steering bearing √ √
• Lubricate medium weight wheel bearing grease
every 8,000 km.
• Check operation and for oil leakage.
14 * Front forks √ √
• Repair if necessary.
Rear shock • Check operation and for oil leakage.
15 * √ √
absorber • Repair if necessary.
• Check chain slack and alignment.
16 * Drive chain • Adjust if necessary. Every 500 km
• Clean and lubricate.
• Check all chassis fitting and fasteners.
17 Fittings/Fasteners √ √ √ √
Centerstand and • Check operation.
18 * √ √
sidestand • Repair if necessary.
3-1
PERIODIC MAINTENANCE AND LUBRICATION CHK
INTERVALS ADJ
INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
• Check specific gravity.
19 * Battery • Check that the breather hose is working properly. √ √
* It is recommended that these items be serviced by a Yamaha dealer.

NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
CHK
COVERS ADJ
EASF0004
COVERS
REMOVING THE FRONT COWLINGS
1 1. Remove:
• main switch cover 1
NOTE:
Remove the main switch cover by turning it in
2
the direction of the arrow shown.
2. Remove:
• center panel 2
3. Remove:
• front cowlings (left and right) 1
4. Remove:
• front panel 1
1
INSTALLING THE FRONT COWLINGS

For installation, reverse the removal proce-
dure.
3-3
CHK
COVERS ADJ
REMOVING THE REAR COWLINGS
1. Remove:
• front cowlings (left and right)
1
Refer to “REMOVING THE FRONT COWL-
INGS”.
• side panels (left and right) 1
2. Remove:
• storage compartment 1
3. Remove:
• rear panel 1
1 NOTE:
Remove the rear panel by sliding it in the
direction of the arrow shown.
4. Remove:
1 • rear cowlings (left and right) 1
2
• fuel tank cover 2
INSTALLING THE REAR COWLINGS

2 1. Install:
1
• fuel tank cover 1
• rear cowlings (left and right) 2
NOTE:
Before tightening the rear cowling screws,
make sure that all projections are securely fit-
ted.
3-4
CHK
COVERS ADJ
2. Install:
• rear panel 1
• storage compartment
NOTE:
1 Make sure that all projections are securely fit-
ted.
3. Install:
• side panels (left and right) 1
NOTE:
1 Before tightening each side panel screw, make
sure that all projections are securely fitted.

Refer to “INSTALLING THE FRONT
COWLINGS”.
REMOVING THE HEADLIGHT ASSEMBLY

1. Remove:
• headlight assembly 1
2. Disconnect:
• turn signal light coupler 1
• headlight connectors 2
1
2
INSTALLING THE HEADLIGHT ASSEMBLY

1. Connect:
• headlight connectors
• turn signal light coupler
2. Install:
• headlight assembly 1
NOTE:
Before tightening the headlight assembly
1
screws, make sure that all projections are
securely fitted.
3-5
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
_
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• center panel
INGS”.
2. Remove:
• tappet cover (intake side) 1
• tappet cover (exhaust side) 2
• camshaft sprocket cover 3
(with O-ring)
3. Remove:
• timing check plug 1
(with O-ring)
• center plug 2
(with O-ring)
3-6
CHK
4. Measure:
• valve clearance
Out of specification → Adjust.
a
b Valve clearance (cold)
Intake valve
0.05 ~ 0.09 mm
Exhaust valve
0.08 ~ 0.12 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark a on the
camshaft sprocket with the stationary
pointer b on the cylinder head.
c. Align the TDC mark c on the generator
rotor with the stationary pointer d on the
crankcase cover.
d. Measure the valve clearance with a thick-
ness gauge 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• 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
obtained.
Valve clearance is
Direction a
increased.
Valve clearance is
Direction b
decreased.
Tappet adjusting tool 4

90890-01311
3-7
CHK
• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut
7 Nm (0.7 m·kg)
T.
R.
d. Measure the valve clearance again.
e. 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:
• camshaft sprocket cover
• O-ring New
• timing check plug
(with O-ring) 7 Nm (0.7 m · kg)
T.
R.
• center plug
(with O-ring) 7 Nm (0.7 m · kg)
T.
R.
7. Install:
18 Nm (1.8 m · kg)
T.
R.
• O-ring 2 New
8. Install:
• tappet cover (exhaust side)
• O-ring New
9. Install:
• center panel
COWLINGS”.
3-8
CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
_
Prior to adjusting the engine idling speed, the

air filter element should be clean, and the
engine should have adequate compression.
1. Remove:
• front cowling (right)
INGS”.
2. Start the engine and let it warm up for sev-
eral minutes.
3. Connect:
• engine tachometer
(onto the spark plug lead)
Engine tachometer
90890-03113
4. Check:
• engine idling speed
Engine idling speed

1,400 ~ 1,600 r/min
5. Adjust:
1 • engine idling speed
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pilot air screw 1 in or out until it is
a b lightly seated.
b. Turn the pilot air screw out the specified
number of turns.
Pilot air screw setting

1-3/8 turns out
c. Turn the throttle stop screw 2 in direction

a or b until the specified engine idling
speed is obtained.
Engine idling speed is

Direction a
increased.
Engine idling speed is
Direction b
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-9
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the

flange of the throttle grip)
3 ~ 7 mm
7. Install:
COWLINGS”.
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
_
Prior to adjusting the throttle cable free play,

the engine idling speed should be adjusted.
1. Check:
• throttle cable free play a

a flange of the throttle grip)
3 ~ 7 mm
2. Remove:
• front cowling (left)
INGS”.
3 - 10
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUG ADJ
3. Adjust:
1 • throttle cable free play
2
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull back the adjusting nut cover.
b
b. Loosen the locknut 1.
c. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
Throttle cable free play

Direction a
is increased.
Direction b
is decreased.
d. Tighten the locknut.

e. Slide the adjusting nut cover to its original
position.
WARNING
_
After adjusting the throttle cable free play,

start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
INGS”.
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away

any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
3 - 11
CHK
CHECKING THE SPARK PLUG ADJ
4. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)

C6HSA (LOCAL MADE)
5. Check:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.6 ~ 0.7 mm
8. Install:
• spark plug 12.5 Nm (1.25 m · kg)
T.
R.
NOTE:
_
Before installing the spark plug, clean the

spark plug and gasket surface.
9. Connect:
• spark plug cap
10.Install:
COWLINGS”.
3 - 12
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
_
Insufficient compression pressure will result in

a loss of performance.
1. Measure:
• valve clearance
Out of specification → Adjust
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
CAUTION:
_
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:
• compression gauge 1
1
Compression gauge
90890-03081
6. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea

level)
Minimum
1,130 kPa (11.3 kg/cm2)
Standard
1,300 kPa (13.0 kg/cm2)
Maximum
1,460 kPa (14.6 kg/cm2)
3 - 13
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug

lead before cranking the engine.
c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Piston ring(s) wear
Higher than with-
or damage →
out oil
Repair.
Piston, valves, cyl-
Same as without inder head gasket
oil or piston possibly
defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
T.
R.
8. Connect:
• spark plug cap
9. Install:
COWLINGS”.
3 - 14
CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EAS00070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
_
Make sure the motorcycle is upright.

3. Remove:
• oil filler cap 1
4. Check:
• engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
Recommended oil
SAE 20W40 type SE or higher
grade motor oil
CAUTION:
_
Do not allow foreign materials to enter the

crankcase.
NOTE:
_
Before checking the engine oil level, wait a few

minutes until the oil has settled.

6. Check the engine oil level again.
3 - 15
CHK
CHANGING THE ENGINE OIL ADJ
EAS00075
CHANGING THE ENGINE OIL
2. Place a container under the engine oil drain
bolt.
3. Remove:
1 • oil filler cap 1
• engine oil drain bolt 2
(with gasket)
4. Drain:
• engine oil
(completely from the crankcase)
5. Check:
• engine oil drain bolt gasket
Damage → Replace.
6. Install:
• engine oil drain bolt
(with gasket) 20 Nm (2.0 m · kg)
T.
R.
7. Fill:
• crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
1.0 L
Periodic oil change amount
0.8 L
8. Install:
• oil filler cap
10.Check:
• engine
(for engine oil leaks)
11.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
3 - 16
CHECKING THE EXHAUST SYSTEM/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
CHECKING THE EXHAUST SYSTEM
1. Check:
• exhaust pipe nuts 1
Loose/damage → Tighten/replace.
7 Nm (0.7 m · kg)
T.
R.
• exhaust pipe gasket
Exhaust gas leaks → Tighten/replace.
1
2. Check:
• exhaust pipe joint bolt 1
Loose/damage → Tighten/replace.
12 Nm (1.2 m · kg)
T.
R.
1
EAS00086
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• center panel
INGS”.
2. Remove:
• air filter case cover 1
2 • air filter element 2
3. Clean:
• air filter element
Apply compressed air to the outer surface
of the air filter element.
4. Check:
Damage → Replace.
3 - 17
CLEANING THE AIR FILTER ELEMENT/ CHK
ADJUSTING THE CLUTCH RELEASE SYSTEM ADJ
5. Install:
• air filter case cover
CAUTION:
_
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
engine performance and possible overheat-
ing.
NOTE:
_
When installing the air filter element into the air

filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
6. Install:
• center panel
COWLINGS”.
ADJUSTING THE CLUTCH RELEASE

SYSTEM
1. Adjust:
• clutch release system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting screw 2 in completely,
then turn the adjusting screw out the speci-
fied number of turns.
Adjusting screw:
1/8 turns out
c. Tighten the locknut.

8 Nm (0.8 m · kg)
T.
R.
NOTE:
Hold the adjusting screw and tighten the lock-
nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 18
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHK
CHECKING THE FUEL AND VACUUM HOSES ADJ
EAS00094
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Remove:
INGS”.
2. Check:
• carburetor joint 1
• intake manifold 2
2 Cracks/damage → Replace.
Refer to “CARBURETOR” in chapter 5.
3. Install:
1
COWLINGS”.
EAS00096
CHECKING THE FUEL AND VACUUM
HOSES
fuel and vacuum hoses.
1. Remove:
INGS”.
2. Check:
• fuel cock vacuum hose 1
2 • fuel hose 2
Cracks/damage → Replace.
3. Install:
1 • front cowling (left)
COWLINGS”.
3 - 19
CHK
CHECKING THE CRANKCASE BREATHER HOSE ADJ
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
INGS”.
• side panel (right)
Refer to “REMOVING THE REAR COWL-
INGS”.
2. Check:
• crankcase breather hose 1
CAUTION:
_
Make sure the crankcase breather hose is

1 routed correctly.
3. Install:
Refer to “INSTALLING THE REAR COWL-
INGS”.
COWLINGS”.
3 - 20
CHK
ADJUSTING THE REAR BRAKE ADJ
CHASSIS
EAS00113
ADJUSTING THE REAR BRAKE
1. Check:
• brake pedal free play a
Brake pedal free play (at the end

of the brake pedal)
20 ~ 30 mm
2. Adjust:
• brake pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster 1 in direction a or b
until the specified brake pedal free play is
a
obtained.
b
1 Brake pedal free play is
Direction a
increased.
Brake pedal free play is
Direction b
decreased.
CAUTION:
_
After adjusting the brake pedal free play,

make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
3 - 21
CHECKING THE FRONT BRAKE PADS/
CHECKING THE REAR BRAKE SHOES/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00120
CHECKING THE FRONT BRAKE PADS
brake pads.
1. Operate the brake.
2. Check:
• front brake pad
Wear indicator groove 1 almost disap-
peared → Replace the brake pads as a set.
Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 6.
EAS00126
CHECKING THE REAR BRAKE SHOES
1. Operate the brake.
2. Check:
• wear indicator 1
Reaches the wear limit line 2 → Replace
the brake shoes as a set.
Refer to “REAR WHEEL AND BRAKE” in
chapter 6.
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
_
The rear brake light switch is operated by

movement 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. Remove:
INGS”.
2. Check:
• rear brake light operation timing
Incorrect → Adjust.
3 - 22
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHK
CHECKING THE FRONT BRAKE HOSE ADJ
3. Adjust:
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Hold the main body 1 of the rear brake light
a b 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.
Brake light comes on

Direction a
sooner.
Brake light comes on
Direction b
later.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
INGS”.
EAS00129
CHECKING THE FRONT BRAKE HOSE
1. Check:
• brake hose
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose Connection → Tighten the clamp
bolt.
3. Hold the motorcycle upright and apply the
front brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to “FRONT BRAKE” in chapter 6.
3 - 23
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00133
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system when-

ever:
• the system is disassembled.
• a brake hose is loosened, disconnected
or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
_
• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir to over-
flow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length-
ening the bleeding procedure.
• 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.
1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
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 apply the brake lever several times.
f. Fully pull the brake lever without releasing
it.
g. Loosen the bleed screw.
3 - 24
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
NOTE:
_
Loosening the bleed screw will release the

pressure 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 m·kg)
T.
R.
k. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,

check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
_
The drive chain slack must be checked at the

tightest point on the chain.
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
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
3 - 25
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
WARNING
_
Securely support the motorcycle so that

there is no danger of it falling over.
NOTE:
_
Place the motorcycle on a suitable stand so

that the rear wheel is elevated.
2. Spin the rear wheel several times and find

the tightest position of the drive chain.
3. Check:
• drive chain slack a
Drive chain slack

25 ~ 35 mm
4. Adjust:
• drive chain slack
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Loosen the wheel axle nut 1.
b. Loosen both locknuts 2.
c. Turn both adjusting nuts 3 in direction a or
b until the specified drive chain slack is
b obtained.
23
Direction a Drive chain is tightened.
Direction b Drive chain is loosened.
NOTE:
_
To maintain the proper wheel alignment, adjust

both sides evenly.
d. Tighten both locknuts to specification.
Locknut
7 Nm (0.7 m·kg)
T.
R.
e. Tighten the wheel axle nut to specification.
Wheel axle nut

60 Nm (6.0 m·kg)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 26
LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
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 quickly. Therefore, the
drive chain should be serviced, especially
when the motorcycle is used in dusty areas.
Use only kerosene to clean the drive chain.
Wipe the drive chain dry and thoroughly lubri-
cate it with engine oil or chain lubricant that is
suitable for non-O-ring chains.
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
EAS00115
CHECKING THE BRAKE FLUID LEVEL
NOTE:
_
Make sure the motorcycle is upright.
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid

DOT 4
WARNING
_
• Use only the designated brake fluid.

Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• 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
performance.
3 - 27
CHECKING THE BRAKE FLUID LEVEL/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
_
In order to ensure a correct reading of the

brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
EASF0010
CHECKING AND ADJUSTING THE
STEERING HEAD
WARNING
_

NOTE:
_

that the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• center panel
INGS”.
3 - 28
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
4. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull back the rubber cover 1.
b. Loosen the upper ring nut 2.
c. Loosen the lower ring nut 3 and then
tighten it to specification with a steering nut
wrench 4.
NOTE:
_
Set the torque wrench at a right angle to the

steering nut wrench.
Steering nut wrench

90890-01403
4
3 Lower ring nut

T.
30 Nm (3.0 m·kg)
R.
d. Loosen the lower ring nut counterclockwise

1/4 of a turn.
e. Hold the lower ring nut with a ring nut
wrench 5 and tighten the upper ring nut 2
with a steering nut wrench.
WARNING
_
Do not overtighten the lower ring nut.
Ring nut wrench

90890-01268
Upper ring nut

75 Nm (7.5 m·kg)
T.
R.
f. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 6.
g. Slide the rubber cover to its original posi-
tion.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• center panel
COWLINGS”.
3 - 29
CHK
CHECKING THE FRONT FORK ADJ
EAS00149
CHECKING THE FRONT FORK
WARNING
_

2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 6.
3 - 30
CHK
CHECKING THE TIRES ADJ
EASF0015
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification → Regulate.
WARNING
_
• The tire pressure should only be checked

and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil and
102 kg
a full fuel
tank)
Maximum
110 kg
load*
Front Rear
Cold tire
pressure 200 kPa 225 kPa
(2.00 kgf/cm2) (2.25 kgf/cm2)
* Total weight of rider, passenger, cargo and

accessories
WARNING
_
It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit,
replace the tire immediately.
3 - 31
CHK
CHECKING THE TIRES ADJ
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
ti
Minimum tire tread depth
0.8 mm
1 Tire tread depth

2 Sidewall
3 Wear indicator
WARNING
_
• Do not use a tubeless tire on a wheel

designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• 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
replacement.
Tube wheel Tube tire only

Tube or tubeless
Tubeless wheel
tire
• After extensive tests, the tires listed

below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning han-
dling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
3 - 32
CHECKING THE TIRES/ CHK
CHECKING AND TIGHTENING THE SPOKES ADJ
WARNING
_
• New tires have a relatively low grip on the

road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed
before any high-speed riding is done.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.
NOTE:
_
For tires with a direction of rotation mark 1:

• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 2 with the valve installation
point.
EAS00169
CHECKING AND TIGHTENING THE
SPOKES
spokes.
1. Check:
• spoke 1
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
_
A tight spoke will emit a clear, ringing tone; a

loose spoke will sound flat.
2. Tighten:
• spoke
(with a spoke wrench 2)
3 Nm (0.3 m · kg)
T.
R.
NOTE:
_
Be sure to tighten the spokes before and after

break-in.
3 - 33
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVER AND PEDALS/ CHK
LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
inner and outer cables.
WARNING
_
Damaged outer cable may cause the cable

to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• outer cable
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Engine oil or a suitable cable
lubricant
NOTE:
_
Hold the cable end upright and pour a few

drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS00171
LUBRICATING THE LEVER AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the lever and pedals.
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
moving parts of the sidestand.
EAS00173
LUBRICATING THE CENTERSTAND
moving parts of the centerstand.
3 - 34
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00176
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas

and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
1. Remove:
• rear cowling (right)
INGS”.
• battery band 1
3 - 35
CHK
2. Disconnect:
• battery leads
(from the battery terminals)
CAUTION:
1 _
2 First, disconnect the negative battery lead

1, and then the positive battery lead 2.
3. Remove:
• battery
4. Check:
• electrolyte level
The electrolyte level should be between the
b
minimum level mark a and the maximum
a
level mark b.
Below the minimum level mark → Add dis-
tilled water to the proper level.
CAUTION:
_
Add only distilled water. Tap water con-

tains minerals which are harmful to the bat-
tery.
5. Check:
• specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20 °C
6. Charge:
• battery
Battery charging amperage and time

0.5 amps/10 hrs
WARNING
_
Do not quick charge a battery.
3 - 36
CHK
CAUTION:
_
• Loosen the battery sealing caps.

• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• 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.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charg-
ing has to be done with the battery
mounted on the motorcycle, disconnect
the negative lead from the battery termi-
nal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
NOTE:
_
Replace the battery whenever:

• battery voltage does not rise to specification
or bubbles fail to rise during charging,
• sulfation 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),
• specific gravity readings after a long, slow
charge indicate that the charge of one bat-
tery cell is lower than the rest,
3 - 37
CHK
• warpage or buckling of the battery plates or
insulators is evident.
7. Check:
• battery breather hose and battery vent
Obstruction → Clean.
Damage → Replace.
8. Install:
• battery
9. Connect:
• battery breather hose 1
1 CAUTION:
_
• When checking the battery, make sure the

battery breather hose is properly installed
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.
• Make sure the battery breather hose is
properly routed away from the drive chain
and from below the swingarm.
10.Check:
• battery terminals
Dirt → Clean with a wire brush.
11.Connect:
• battery leads
(to the battery terminals)
CAUTION:
2 _
1 First, connect the positive battery lead 1,

and then the negative battery lead 2.
12.Lubricate:
• battery terminals
Dielectric grease
13.Install:
• battery band
INGS”.
3 - 38
CHK
CHECKING THE FUSE ADJ
EASF0017
CHECKING THE FUSE
CAUTION:
_
To avoid a short circuit, always set the

main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
INGS”.
• fuse holder 1
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
_
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace

the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
WARNING
_
Never use a fuse with an amperage rating

other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
• fuse holder
INGS”.
3 - 39
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183
REPLACING THE HEADLIGHT BULBS
1 The following procedure applies to both of the
headlight bulbs.
1. Remove:
• headlight assembly
Refer to “REMOVING THE HEADLIGHT
ASSEMBLY”.
• headlight bulb cover 1
2. Remove:
1 • headlight bulb holder 1
3. Remove:
1 • headlight bulb 1
WARNING
_
Since the headlight bulb gets extremely

hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
4. Install:
• headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
_
Avoid touching the glass part of the head-

light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
5. Install:
• headlight bulb holder
6. Install:
• headlight bulb cover
Refer to “INSTALLING THE HEADLIGHT
ASSEMBLY”.
3 - 40
CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
EAS00186
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the bolt 1.
b. Slide the bottom of the headlight unit for-
ward a or backward b.
Slide forward Headlight beam is

a raised.
Slide backward Headlight beam is
b lowered.
c. Tighten the bolt 1.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 41
ENG
CHAPTER 4
OVERHAULING THE ENGINE
REMOVING THE ENGINE............................................................................... 4-1

ENGINE OIL .............................................................................................. 4-1
CARBURETOR ......................................................................................... 4-1
MUFFLER AND EXHAUST PIPE.............................................................. 4-1
FOOTREST AND ENGINE GUARD.......................................................... 4-2
BRAKE PEDAL.......................................................................................... 4-2
SHIFT PEDAL ........................................................................................... 4-2
FRONT COWLING BRACKET ..................................................................4-3
WIRE, CABLE AND HOSE........................................................................ 4-3
ENGINE ASSEMBLY ................................................................................ 4-4
INSTALLING THE ENGINE.............................................................................4-5

ENGINE ASSEMBLY ................................................................................ 4-5
WIRE, CABLE AND HOSE........................................................................ 4-5
FRONT COWLING .................................................................................... 4-5
SHIFT PEDAL ........................................................................................... 4-5
BRAKE PEDAL.......................................................................................... 4-6
FOOTREST AND STARTER MOTOR GUARD ........................................ 4-6
MUFFLER..................................................................................................4-6
ENGINE OIL .............................................................................................. 4-6
CARBURETOR ......................................................................................... 4-7
CYLINDER HEAD ........................................................................................... 4-8

REMOVING THE CYLINDER HEAD.........................................................4-9
CHECKING THE CYLINDER HEAD .......................................................4-11
CHECKING TIMING CHAIN GUIDE .......................................................4-12
CHECKING THE TIMING CHAIN TENSIONER...................................... 4-13
INSTALLING THE CYLINDER HEAD .....................................................4-13
CAMSHAFT .................................................................................................. 4-17

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-18
CHECKING THE CAMSHAFT.................................................................4-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-19
CHECKING THE CAMSHAFT SPROCKET............................................4-21
CHECKING THE TAPPET COVERS
AND CAMSHAFT SPROCKET COVER................................................. 4-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-21
VALVES AND VALVE SPRINGS .................................................................4-22

REMOVING THE VALVES...................................................................... 4-23
CHECKING THE VALVES AND VALVE GUIDES ..................................4-24
CHECKING THE VALVE SEATS ............................................................ 4-26
CHECKING THE VALVE SPRINGS........................................................ 4-28
INSTALLING THE VALVES .................................................................... 4-29
ENG
CYLINDER AND PISTON ............................................................................. 4-31
REMOVING THE CYLINDER AND PISTON...........................................4-32
CHECKING THE CYLINDER AND PISTON ...........................................4-33
CHECKING THE PISTON RINGS........................................................... 4-34
CHECKING THE PISTON PIN ................................................................4-35
INSTALLING THE PISTON AND CYLINDER .........................................4-36
GENERATOR AND STARTER CLUTCH .....................................................4-38

REMOVING THE GENERATOR ............................................................. 4-39
REMOVING THE STARTER CLUTCH ...................................................4-40
CHECKING THE STARTER CLUTCH ....................................................4-41
INSTALLING THE STARTER CLUTCH .................................................. 4-42
INSTALLING THE GENERATOR............................................................ 4-42
KICKSTARTER ............................................................................................ 4-44

REMOVING THE KICKSTARTER........................................................... 4-45
CHECKING THE KICKSTARTER ........................................................... 4-46
INSTALLING THE KICKSTARTER ......................................................... 4-47
CLUTCH ....................................................................................................... 4-48

REMOVING THE CLUTCH ..................................................................... 4-49
CHECKING THE FRICTION PLATES.....................................................4-51
CHECKING THE CLUTCH PLATES .......................................................4-51
CHECKING THE CLUTCH SPRINGS.....................................................4-52
CHECKING THE CLUTCH HOUSING ....................................................4-52
CHECKING THE CLUTCH BOSS........................................................... 4-52
CHECKING THE CLUTCH PRESSURE PLATE..................................... 4-53
CHECKING THE CLUTCH PUSH ROD #2............................................. 4-53
CHECKING THE PRIMARY DRIVEN GEAR ..........................................4-53
CHECKING THE CLUTCH SHOE HOUSING.........................................4-54
CHECKING THE CLUTCH SHOE........................................................... 4-54
CHECKING THE CAGE ..........................................................................4-54
CHECKING THE CLUTCH RELEASE SHIFT ARM................................4-55
INSTALLING THE CLUTCH.................................................................... 4-55
OIL PUMP ..................................................................................................... 4-57

REMOVING THE OIL PUMP................................................................... 4-58
DISASSEMBLING THE OIL PUMP......................................................... 4-58
CHECKING THE OIL PUMP ................................................................... 4-59
CHECKING THE OIL STRAINER ........................................................... 4-60
CHECKING THE OIL FILTER .................................................................4-60
ASSEMBLING THE OIL PUMP...............................................................4-60
INSTALLING THE OIL PUMP .................................................................4-61
ENG
SHIFT SHAFT ...............................................................................................4-62
REMOVING THE SHIFT SHAFT............................................................. 4-63
CHECKING THE SHIFT SHAFT ............................................................. 4-65
CHECKING THE STOPPER LEVER ......................................................4-65
CHECKING THE SHIFT GUIDE..............................................................4-65
CHECKING THE OIL SEAL .................................................................... 4-65
INSTALLING THE SHIFT SHAFT ........................................................... 4-66
CRANKCASE AND CRANKSHAFT ............................................................. 4-67

DISASSEMBLING THE CRANKCASE....................................................4-68
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 4-69
CHECKING THE CRANKCASE ..............................................................4-71
CHECKING THE BEARINGS.................................................................. 4-71
CHECKING THE TIMING CHAIN GUIDE ............................................... 4-71
CHECKING THE TIMING CHAIN............................................................ 4-71
INSTALLING THE CRANKSHAFT .......................................................... 4-72
ASSEMBLING THE CRANKCASE.......................................................... 4-72
TRANSMISSION............................................................................................ 4-74
REMOVING THE TRANSMISSION ........................................................ 4-75
DISASSEMBLING THE TRANSMISSION............................................... 4-75
CHECKING THE SHIFT FORKS............................................................. 4-76
CHECKING THE SHIFT DRUM ASSEMBLY..........................................4-77
CHECKING THE TRANSMISSION ......................................................... 4-77
ASSEMBLING THE TRANSMISSION.....................................................4-78
INSTALLING THE TRANSMISSION .......................................................4-78
ENG
REMOVING THE ENGINE ENG
EASF0018
OVERHAULING THE ENGINE

REMOVING THE ENGINE
NOTE:
_
It is not necessary to remove the engine in

order to remove the following components.
• Cylinder head
• Cylinder
• Piston
• Clutch
• Kickstarter
• Shift shaft
• Oil pump
• Generator
• Starter clutch
1. Remove:
INGS” in chapter 3.
• side panels (left and right)
• rear cowlings (left and right)
• drive sprocket
Refer to “DRIVE CHAIN AND SPROCK-
ETS” in chapter 6.
ENGINE OIL
1. Drain:
• engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
CARBURETOR
1. Remove:
• carburetor assembly
MUFFLER AND EXHAUST PIPE
3 1. Remove:
• exhaust pipe joint bolt 1
• lower muffler bolt 2
• washer
• muffler nut
• upper muffler bolt 3
4 1 • washers
2
• muffler 4
4-1
2. Remove:
• exhaust pipe nuts 1
• exhaust pipe 2
2 1
FOOTREST AND ENGINE GUARD

1. Remove:
• footrest bolts 1
• footrest
1
1
2. Remove:
• starter motor guard bolts 1
1 • starter motor guard 2
BRAKE PEDAL
1. Remove:
• rear brake light switch spring
• brake pedal spring
• circlip
• brake pedal 1
SHIFT PEDAL
• shift pedal bolt 1
• shift pedal 2
1 2
4-2
FRONT COWLING BRACKET
• front cowling bracket bolts 1
1 • front cowling bracket 2
WIRE, CABLE AND HOSE

1. Remove:
• negative battery lead 1
2. Remove:
• spark plug cap 1
3. Remove:
• fuel cock vacuum hose 1
4. Remove:
• crankcase breather hose 1
1
4-3
5. Disconnect:
• stator coil coupler 1
3
2 • pickup coil coupler 2
1 • gear position sensor coupler 3
6. Disconnect:
• starter motor lead coupler 1
1
ENGINE ASSEMBLY
2 1. Remove:
1
• rear upper mounting nut
• washer
• front mounting nut
• washer
• rear lower mounting nut
• washer
3 • rear upper mounting bolt 1
• front mounting bolt 2
• rear lower mounting bolt 3
• engine assembly
WARNING
_
Securely support the motorcycle so there

is no danger of it falling over.
4-4
INSTALLING THE ENGINE ENG
EASF0019
INSTALLING THE ENGINE

ENGINE ASSEMBLY
WARNING
_
Securely support the motorcycle so there

is no danger of it falling over when install-
ing engine.
1. Install:
• engine assembly
• rear lower mounting bolt
• front mounting bolt
• rear upper mounting bolt
• washer
• rear lower mounting nut
34 Nm (3.4 m · kg)
T.
R.
• washer
• front mounting nut 34 Nm (3.4 m · kg)
T.
R.
• washer
• rear upper mounting nut
34 Nm (3.4 m · kg)
T.
R.
WIRE, CABLE AND HOSE
1. Connect:
• starter motor lead coupler
• gear position sensor coupler
• pickup coil coupler
• stator coil coupler
• negative battery lead
2. Install:
• crankcase breather hose
• fuel cock vacuum hose
• spark plug cap
FRONT COWLING
• front cowling bracket
• front cowling bracket bolts
7 Nm (0.7 m · kg)
T.
R.
SHIFT PEDAL
• shift pedal 1 10 Nm (1.0 m · kg)
T.
R.
4-5
BRAKE PEDAL
1. Install:
• brake pedal
• circlip New
• brake pedal spring
• rear brake light switch spring
FOOTREST AND STARTER MOTOR

1 GUARD
1. Install:
• starter motor guard
• starter motor guard bolts
23 Nm (2.3 m · kg)
T.
R.
NOTE:
Apply sealant to the thread of starter motor
guard bolt 1.

90890-85505
2. Install:
• footrest
• footrest bolts 23 Nm (2.3 m · kg)
T.
R.
MUFFLER
1. Install:
• exhaust pipe
• exhaust pipe nuts 7 Nm (0.7 m · kg)
T.
R.
2. Install:
• muffler
• washers
• upper muffler bolt 38 Nm (3.8 m · kg)
T.
R.
• washer
• lower muffler bolt 16 Nm (1.6 m · kg)
T.
R.
• muffler nut
• exhaust pipe joint bolt
12 Nm (1.2 m · kg)
T.
R.
ENGINE OIL
1. Fill:
• engine oil
chapter 3.
4-6
CARBURETOR
1. Install:
2. Adjust:
CABLE FREE PLAY” and “ADJUSTING
THE REAR BRAKE LIGHT SWITCH” in
chapter 3.

(at the flange of the throttle grip)
3 ~ 7 mm
4-7
CYLINDER HEAD ENG
EASF0023
CYLINDER HEAD
1 Intake manifold 8 Camshaft sprocket cover

2 Tappet cover (intake side) 9 Dowel pin
3 Cylinder head 0 Gasket
4 Spark plug A Timing chain tensioner
5 Tappet cover (exhaust side)
6 Timing chain guide (exhaust side)
7 Camshaft sprocket
4-8
CYLINDER HEAD ENG
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
• exhaust pipe
Refer to “REMOVING THE ENGINE”.
2. Remove:
• intake manifold bolts
1
• intake manifold 1
(with O-ring)
3. Remove:
• spark plug cap 1
2
• spark plug 2
4. Remove:
1
• tappet cover (exhaust side) 2
• camshaft sprocket cover screws
• camshaft sprocket cover 3
3
(with O-ring)
4-9
CYLINDER HEAD ENG
5. Align:
• “I” mark a on the generator rotor
(with the stationary pointer b on the crank-
case)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark c on the
camshaft sprocket with the stationary
pointer d on the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c
d
6. Loosen:
• camshaft sprocket bolt 1
NOTE:
While holding the generator rotor with a
2
wrench 2, loosen the camshaft sprocket bolt.
7. Remove:
• timing chain tensioner cap bolt
1 • timing chain tensioner bolts
• timing chain tensioner 1
• gasket
8. Remove:
• camshaft sprocket bolt 1
1 • camshaft sprocket 2
• timing chain 3
3 NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
2
4 - 10
CYLINDER HEAD ENG
9. Remove:
• cylinder head bolts
• cylinder head nuts
6 2
4 • cylinder head
NOTE:
_
3 • Loosen the nuts in the proper sequence as

1
5 shown.
• Loosen each nut 1/2 of a turn at a time. After
all of the nuts are fully loosened, remove
them.
1 10.Remove:
• dowel pins 1
2 • gasket 2
• timing chain guide (exhaust side) 3
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
_
Do not use a sharp instrument to avoid damag-

ing or scratching:
• spark plug bore threads
• valve seats
2. Check:
• cylinder head
Damage/scratches → Replace.
4 - 11
CYLINDER HEAD ENG
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylin-
der head.
Maximum cylinder head warpage

0.03 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
_
To ensure an even surface, rotate the cylinder

head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING TIMING CHAIN GUIDE

1. Check:
• timing chain guide (exhaust side)
Damage/wear → Replace.
4 - 12
CYLINDER HEAD ENG
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1 1. Check:
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• cap bolt
• one-way cam
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
EAS00232
INSTALLING THE CYLINDER HEAD
2
1. Install:
• timing chain guide (exhaust side) 1
New 3 • dowel pins 2
• gasket 3 New
2. Install:
• cylinder head
• cylinder head nuts
• cylinder head bolts
NOTE:
_
Pass the timing chain through the timing chain

cavity.
4 - 13
CYLINDER HEAD ENG
3. Tighten:
• cylinder head nuts 22 Nm (2.2 m · kg)
T.
R.
• cylinder head bolts 10 Nm (1.0 m · kg)
5
T.
1
R.
3 NOTE:
_
• Lubricate the cylinder head nuts and bolts

4 with engine oil.
6
2 • Tighten the cylinder head nuts and bolts in
the proper tightening sequence as shown
and torque them in two stages.
4. Install:
1 • camshaft sprocket 1
• timing chain 2
c
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d e a. Turn the crankshaft clockwise.
b. Align the “I” mark a on the generator rotor
2 with the stationary pointer b on the crank-
case.
c. Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
• When installing the camshaft sprocket, be
sure to keep the timing chain as tight as pos-
sible on the exhaust side.
• Align the projection e on the camshaft
sprocket with the slot in the camshaft.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 14
CYLINDER HEAD ENG
5. Install:
• timing chain tensioner
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
1 b. Install the gasket and the timing chain ten-

sioner 2 onto the cylinder.
WARNING
2
Always use a new gasket.
Timing chain tensioner bolt

T.
R. 10 Nm (1.0 m · kg)
c. Turn the timing chain tensioner rod counter-

clockwise with a thin screwdriver 1, make
sure it releases, and then tighten the cap
bolt to specification.
Cap bolt
8 Nm (0.8 m · kg)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Tighten:
• camshaft sprocket bolt
20 Nm (2.0 m · kg)
T.
R.
CAUTION:
Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the
possibility of the bolt coming loose and
damaging the engine.
7. Turn:
• crankshaft
(several turns clockwise)
4 - 15
CYLINDER HEAD ENG
8. Check:
• “I” mark a
Align the “I” mark on the generator rotor
with the stationary pointer b on the crank-
case.
• “I” mark c
Align the “I” mark on the camshaft sprocket
with the stationary pointer d on the cylinder
head.
Out of alignment → Correct.
Refer to the installation steps above.
c
d
9. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
10.Install:
• camshaft sprocket cover screws
7 Nm (0.7 m · kg)
T.
R.
11.Install:
• tappet cover (exhaust side)
• tappet cover (intake side)
18 Nm (1.8 m · kg)
T.
R.
12.Install:
T.
R.
13.Install:
• intake manifold bolts
• intake manifold 10 Nm (1.0 m · kg)
T.
R.
4 - 16
CAMSHAFT ENG
EASf0020
CAMSHAFT
1 Locknut
2 Adjusting screw
3 Rocker arm
4 Rocker arm shaft
5 Camshaft
6 Camshaft retainer
4 - 17
CAMSHAFT ENG
EASF0022
REMOVING THE ROCKER ARMS AND
CAMSHAFT
NOTE:
_
Prior to remove the rocker arms and camshaft,

remove the cylinder head.
1. Loosen:
• locknuts 1
• adjusting screws 2
2. Remove:
• camshaft retainer 1
3. Remove:
• camshaft 1
NOTE:
_
Screw an 8 mm bolt 2 into the threaded end

of the camshaft and then pull out the camshaft.
4. Remove:
• rocker arm shafts
• rocker arms
NOTE:
_
Remove the rocker arm shafts with the slide

hammer bolt 1 and weight 2.
Slide hammer bolt

90890-01085
Weight
90890-01084
4 - 18
CAMSHAFT ENG
EAS00205
CHECKING THE CAMSHAFT
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches
→ Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the
camshaft.
Camshaft lobe dimension limit

Intake
a 25.745 mm
b 21.015 mm
Exhaust
a 25.749 mm
b 20.924 mm
3. Check:
• camshaft oil passage
Obstructions → Blow out with compressed
air.
EAS00206
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• rocker arm
4 - 19
CAMSHAFT ENG
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrica-
tion system.
3. Measure:
• rocker arm inside diameter
Out of specification → Replace.
Rocker arm inside diameter

10.000 ~ 10.015 mm
<Limit>: 10.030 mm
4. Measure:
• rocker arm shaft outside diameter
Rocker arm shaft outside diame-

ter
9.981 ~ 9.991 mm
<Limit>: 9.950 mm
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
_
Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the
rocker arm inside diameter.
Above 0.08 mm → Replace the rocker arm

and rocker arm shaft as a set.
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm
<Limit>: 0.080 mm
4 - 20
CAMSHAFT ENG
EAS00207
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• camshaft sprocket
Worn more than 1/4 tooth a → Replace the
camshaft sprocket and the timing chain as a
set.
a 1/4 tooth
b Correct
1 Timing chain
2 Camshaft sprocket
EAS00212
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
1. Check:
• tappet cover
Damage/wear → Replace the defective
part(s).
EAS00219
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Lubricate:
• camshaft journals
Engine oil
2. Lubricate:
• rocker arm inside surface
• camshaft oil passage
Molybdenum disulfide grease
3. Install:
• camshaft retainer 1
• camshaft retainer bolt
10 Nm (1.0 m · kg)
T.
R.
NOTE:
• Apply locking agent (LOCTITE®) to the
threads of camshaft retainer bolt.
• Install the camshaft retainer with the bent
ends facing inward.
4 - 21
VALVES AND VALVE SPRINGS ENG
EASF0024
VALVES AND VALVE SPRINGS
1 Valve cotter
2 Upper spring seat
3 Valve spring
4 Valve stem seal
5 Lower spring seat
6 Intake valve
7 Exhaust valve
4 - 22
EASF0025
REMOVING THE VALVES
NOTE:
_
Prior to remove the valves, remove the cylin-

der head, camshaft and rocker arms.

valves and related components.
NOTE:
_
Before removing the internal parts of the cylin-

der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Check:
• 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.
NOTE:
_
There should be no leakage at the valve seat

1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 23
2. Remove:
• valve cotters 1
NOTE:
_
Remove the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-04019
3. Remove:
• upper spring seat 1
• valve spring 2
• valve stem seal 3
• lower spring seat 4
• valve 5
NOTE:
_
Identify the position of each part very carefully

so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
valves and valve guides.
1. Measure:
• 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 ~ 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 ~ 0.052 mm
<Limit>: 0.10 mm
4 - 24
2. Replace:
• valve guide
NOTE:
_
To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder
head to 100 °C in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valve-
guide clearance.
NOTE:
_
After replacing the valve guide, reface the

valve seat.
Valve guide remover (4.5 mm)

90890-04116
Valve guide installer (4.5 mm)
90890-04117
Valve guide reamer (4.5 mm)
90890-04118
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness

Intake: 0.5 ~ 0.9 mm
Exhaust: 0.8 ~ 1.2 mm
4 - 25
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
_
• When installing a new valve, always replace

the valve guide.
• If the valve is removed or replaced, always
replace the valve stem seal.
Valve stem runout limit

0.01 mm
EAS00240
CHECKING THE VALVE SEATS
valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width

Intake: 0.9 ~ 1.1 mm
Exhaust: 0.9 ~ 1.1 mm
<Limit>: 1.6 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
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 impres-
sion.
d. Measure the valve seat width.
4 - 26
NOTE:
_
Where the valve seat and valve face contacted

one another, the blueing will have been
removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
_
After replacing the cylinder head or replacing

the valve and valve guide, the valve seat and
valve face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
_
Do not let the lapping compound enter the

gap between the valve stem and the valve
guide.
b. Apply engine 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.
NOTE:
_
For the best lapping results, lightly tap the

valve seat while rotating the valve back and
forth between your hands.
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 Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
4 - 27
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:
• valve spring free length a
spring.
Valve spring free length

Intake and exhaust valve
springs
33.75 mm
<Limit>: 32.05 mm
2. Measure:
• compressed valve spring force a
spring.
b Installed length
Compressed valve spring force

(installed)
springs
138 ~ 148 N
(13.8 ~ 14.8 kgf) at 24.2 mm
3. Measure:
• valve spring tilt a
spring.
Spring tilt limit

springs
1.4 mm
4 - 28
EAS00245
INSTALLING THE VALVES
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
(with the recommended lubricant)
Engine oil
3. Install:
• valve 1
• lower spring seat 2
• valve spring 4
• upper spring seat 5
(into the cylinder head)
NOTE:
_
Install the valve spring with the larger pitch a

facing up.
b Smaller pitch
4 - 29
4. Install:
• valve cotters 1
NOTE:
_
Install the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-04019
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
_
Hitting the valve tip with excessive force

could damage the valve.
4 - 30
CYLINDER AND PISTON ENG
EASF0027
CYLINDER AND PISTON
1 Cylinder 8 Piston pin

2 Cylinder gasket 9 Piston pin clip
3 Dowel pin
4 Top ring
5 2nd ring
6 Oil ring
7 Piston
4 - 31
EASF0028
REMOVING THE CYLINDER AND PISTON
NOTE:
_
1 Prior to removing the cylinder and piston,

remove the cylinder head.
1. Remove:
• cylinder 1
2. Remove:
1 • dowel pins 1
2 • gasket 2
3. Remove:
• piston pin clip 1
• piston pin 2
• piston 3
CAUTION:
_
Do not use a hammer to drive the piston

pin out.
NOTE:
_
• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase.
• Before removing the piston pin, deburr the
piston pin clip groove and the piston pin bore
area of the piston. If both areas are deburred
and the piston pin is still difficult to remove,
remove it with a piston pin puller set.
4. Remove:
• top ring
• 2nd ring
• oil ring
NOTE:
_
When removing a piston ring, open the end

gap with your fingers and lift the other side of
the ring over the piston crown.
4 - 32
EAS00255
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
_
Measure cylinder bore “C” by taking side-to-

side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements.
Cylinder bore “C” 51.000 ~ 51.015 mm

Taper limit “T” 0.05 mm
Out-of-round “R” 0.05 mm
“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1, D3 or D5 – mini-
mum of D2, D4 or D6
b. If out of specification, rebore or replace the
rings as a set.
c. Measure piston skirt diameter “P” with a
micrometer.
a 5 mm from the bottom edge of the piston
Piston size “P”

Standard 50.977 ~ 50.992 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.
4 - 33
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.008 ~ 0.038 mm
<Limit>: 0.15 mm
f. If out of specification, rebore or replace the

rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00263
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
_
Before measuring the piston ring side clear-

ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.03 ~ 0.07 mm
<Limit>: 0.12 mm
2nd ring
0.02 ~ 0.06 mm
<Limit>: 0.12 mm
2. Install:
• piston ring
(into the cylinder)
NOTE:
_
Level the piston ring into the cylinder with the

piston crown.
a 40 mm
4 - 34
3. Measure:
• piston ring end gap
ring.
NOTE:
_
The end gap of the oil ring expander cannot be

measured. If the end gaps of the oil ring rails
are excessive, replace all three piston rings.
Piston ring end gap

Top ring
0.15 ~ 0.30 mm
<Limit>: 0.4 mm
2nd ring
0.15 ~ 0.30 mm
<Limit>: 0.4 mm
Oil ring rails
0.30 ~ 0.90 mm
EAS00265
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
pin.
Piston pin outside diameter

12.996 ~ 13.000 mm
<Limit>: 12.976 mm
3. Measure:
• piston pin bore diameter (of the piston) b
Out of specification → Replace the piston.
Piston pin bore diameter (of the

piston)
13.002 ~ 13.013 mm
<Limit>: 13.043 mm
4 - 35
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b –
Piston pin outside diameter a
Piston-pin-to-piston-pin-bore
clearance
0.002 ~ 0.017 mm
<Limit>: 0.067 mm
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring 1
• 2nd ring 2
• oil ring expander 3
• lower oil ring rail 4
• upper oil ring rail 5
NOTE:
_
Be sure to install the piston rings so that the

manufacturer’s marks or numbers face up.
2. Install:
• piston 1
• piston pin 2
• piston pin clip 3 New
NOTE:
_
• Apply engine oil to the piston pin.

• Make sure the arrow mark a on the piston
points towards the exhaust side of the cylin-
der.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the clip from falling into the crankcase.
4 - 36
3. Install:
2 • gasket 1 New
New 1 • dowel pins 2
4. Lubricate:
• piston
• piston rings
• cylinder
Engine oil
5. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
È forward
6. Install:
• cylinder 1
NOTE:
_
1 • While compressing the piston rings with one

hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
4 - 37
GENERATOR AND STARTER CLUTCH ENG
EASF0034
GENERATOR AND STARTER CLUTCH
1 Starter clutch gear 8 Starter clutch idle gear shaft E Crankcase cover (left)
2 Starter clutch roller 9 Starter clutch idle gear
3 Starter clutch spring cap 0 Stator coil lead holder
4 Starter clutch spring A Pickup coil
5 Starter clutch B Stator coil
6 Woodruff key C Gasket
7 Generator rotor D Dowel pin
4 - 38
EAS00346
REMOVING THE GENERATOR
1. Drain:
• engine oil
chapter 3.
2. Remove:
• shift pedal
• drive sprocket cover
Refer to “REMOVING THE DRIVE CHAIN
AND SPROCKETS” in chapter 6.
3. Disconnect:
• stator coil coupler 1
• pickup coil coupler 2
4. Remove:
• crankcase cover (left) 1
• gasket
• dowel pins
5. Remove:
• generator rotor nut 1
• washer
NOTE:
_
• While holding the generator rotor 2 with the

sheave holder 3, loosen the generator rotor
nut.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
4 - 39
6. Remove:
• generator rotor 1
(with the flywheel puller 2)
• woodruff key
Flywheel puller
90890-01362
EAS00344
REMOVING THE STARTER CLUTCH
1. Remove:
• starter clutch idle gear shaft 1
• starter clutch idle gear 2
• starter clutch gear 3
• washer
2. Remove:
• starter clutch rollers 1
• starter clutch spring caps
• starter clutch springs
3. Remove:
• starter clutch bolt
• starter clutch 1
NOTE:
_

sheave holder, remove the starter clutch bolt.
Sheave holder
90890-01701
4 - 40
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch rollers 1
2. Check:
• starter clutch idle gear 1
• starter clutch gear 2
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• starter clutch gear contacting surfaces a
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto the
starter clutch and hold the starter clutch.
b. When turning the starter clutch gear clock-
wise È, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 41
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
• starter clutch 1 14 Nm (1.4 m · kg)
T.
R.
NOTE:
_

sheave holder, tighten the starter clutch bolt.
• Lock the threads on the starter clutch bolts
by staking them with a center punch.
Sheave holder
90890-01701
EAS00353
INSTALLING THE GENERATOR
1. Install:
• woodruff key
• generator rotor
• generator rotor nut
NOTE:
_
• Clean the tapered portion of the crankshaft

and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly sealed in
the keyway of the crankshaft.
2. Tighten:
• generator rotor nut 1
70 Nm (7.0 m · kg)
T.
R.
NOTE:
_

sheave holder 3, tighten the generator rotor
nut.
Sheave holder
90890-01701
4 - 42
3. Apply:
• sealant
(on to the generator lead grommet)

90890-85505
4. Install:
• gasket New
• crankcase cover 10 Nm (1.0 m · kg)
T.
R.
4 - 43
KICKSTARTER ENG
EASF0033
KICKSTARTER
1 Kickstarter lever 8 Kickstarter ratchet gear clip

2 Crankcase cover (right) 9 Kickstarter ratchet gear
3 Gasket 0 Kickstarter gear
4 Dowel pin A Kickstarter shaft
5 Kickstarter spring cover
6 Kickstarter spring
7 Kickstarter spring guide
4 - 44
KICKSTARTER ENG
REMOVING THE KICKSTARTER
1. Drain:
• engine oil
chapter 3.
2. Remove:
• muffler
• footrest
• brake pedal
3. Remove:
• kickstarter lever bolt 1
• kickstarter lever 2
4. Remove:
• crankcase cover bolts
1
• crankcase cover (right) 1
• gasket
• dowel pins
5. Remove:
• kickstarter shaft assembly 1
4 - 45
KICKSTARTER ENG
6. Remove:
• circlip 1
• kickstarter spring cover 2
• kickstarter spring 3
• kickstarter spring guide 4
• kickstarter ratchet gear clip 5
• circlip 6
• kickstarter ratchet gear 7
• circlip 8
• shim 9
• wave washer 0
• kickstarter gear A
• kickstarter shaft B
EAS00339
CHECKING THE KICKSTARTER
1. Check:
• kickstarter ratchet gear 1
• kickstarter gear 2
2. Check:
• kickstarter spring
3. Measure:
• kickstarter ratchet gear clip force
(with a spring gauge)
Out of specification → Replace the kick-
starter ratchet gear clip.
Kickstarter ratchet gear clip force

1.00 ~ 1.41 kg
4 - 46
KICKSTARTER ENG
EAS00340
INSTALLING THE KICKSTARTER
1. Install:
• kickstarter shaft assembly 1
• kickstarter ratchet gear clip 2
• kickstarter spring 3
NOTE:
_
Turn the kickstarter spring clockwise and

install its end into the hole a in the crankcase.
2. Install:
• crankcase cover (right) 1
1
• crankcase cover bolts
10 Nm (1.0 m · kg)
T.
R.
2 NOTE:
_
Apply sealant to the threads of the crankcase

cover bolts 2.

90890-85505
3. Install:
• kickstarter lever 1
• kickstarter lever bolt
10 Nm (1.0 m · kg)
T.
R.
4 - 47
CLUTCH ENG
EASF0029
CLUTCH
1 Clutch boss nut 8 Clutch plate #1 E Clutch shoe

2 Clutch boss 9 Clutch plate #2 F Clutch release shift arm
3 Clutch housing 0 Clutch push rod #1 G Clutch release adjusting screw
4 Clutch push rod #2 A Clutch shoe housing nut
5 Clutch pressure plate bolt B Clutch shoe housing
6 Clutch pressure plate C Cage
7 Friction plate D Clutch shoe housing boss
4 - 48
CLUTCH ENG
EAS00277
REMOVING THE CLUTCH
1. Drain:
• engine oil
chapter 3.
2. Remove:
• muffler
• footrest
• brake pedal
• kickstarter lever
Refer to “KICKSTARTER”.
• crankcase cover (left)
Refer to “GENERATOR AND STARTER
CLUTCH”.
3. Remove:
• clutch release shift arm 1
4. Remove:
• clutch pressure plate bolts 1
• clutch springs
• clutch pressure plate 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
5. Remove:
• thrust bearing 1
• clutch push rod #1 2
• friction plates 3
• clutch plates #1 4
• clutch plate #2 5
(with springs)
4 - 49
CLUTCH ENG
6. Straighten the lock washer tab.
7. Loosen:
• clutch boss nut 1
NOTE:
_
While holding the clutch boss 2 with the uni-

versal clutch holder 3, loosen the clutch boss
nut.

90890-04086
8. Remove:
• lock washer 2
• clutch boss 3
• washer 4
• clutch housing 5
• collar 6
• spacer 7
9. Remove:
• clutch shoe housing nut 1
• washer
NOTE:
_
• Loosen the clutch shoe housing nut while

holding the generator rotor 2 with the
sheave holder 3.
1
Sheave holder
90890-01701
4 - 50
CLUTCH ENG
10.Remove:
• collar 1
• clutch shoe housing 2
• washer 3
• rollers 4
• cage springs 5
• cage 6
• clutch shoe housing boss 7
• clutch shoe 8
EAS00280
CHECKING THE FRICTION PLATES
friction plates.
1. Check:
• friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
_
Measure the friction plate at four places.
Friction plate thickness

2.7 ~ 2.9 mm
<Limit>: 2.6 mm
EAS00281
CHECKING THE CLUTCH PLATES
clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.
Clutch plate warpage limit

0.05 mm
4 - 51
CLUTCH ENG
EAS00282
CHECKING THE CLUTCH SPRINGS
clutch springs.
1. Check:
• clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
• clutch spring free length a
springs as a set.
Clutch spring free length

30.3 mm
<Limit>: 28.3 mm
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
_
Pitting on the clutch housing dogs will cause

erratic clutch operation.
2. Check:
• bearing
Damage/wear → Replace the bearing and
clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
_
Pitting on the clutch boss splines will cause

erratic clutch operation.
4 - 52
CLUTCH ENG
EAS00286
CHECKING THE CLUTCH PRESSURE
PLATE
1. Check:
• clutch pressure plate
EAS00288
CHECKING THE CLUTCH PUSH ROD #2
1. Check:
• clutch push rod #2
Cracks/damage/wear → Replace the clutch
push rod #2.
2. Measure:
• clutch push rod #2 bending limit
push rod #2.
Clutch push rod #2 bending limit

0.5 mm
EAS00292
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• primary drive gear
(on the clutch shoe housing)
• primary driven gear
(on the clutch housing)
Damage/wear → Replace the clutch shoe
housing and clutch housing as a set.
Excessive noise during operation →
Replace the clutch shoe housing and clutch
housing as a set.
4 - 53
CLUTCH ENG
CHECKING THE CLUTCH SHOE HOUSING
1. Check:
• clutch shoe housing
2. Measure:
• clutch shoe housing inside diameter a
Clutch shoe housing inside diam-

eter
105 mm
<Limit>: 106 mm
CHECKING THE CLUTCH SHOE

1. Check:
• clutch shoe
Scratches → Smooth using coarse sandpa-
per.
2. Measure:
• clutch shoe groove depth a
Groove is worn away → Replace.
Clutch shoe groove depth

1.20 mm
<Limit>: 0.1 mm
CHECKING THE CAGE

1. Check:
• cage 1
Damage/wear/cracks → Replace.
• rollers 2
Wear/bend → Replace.
• cage springs 3
Wear → Replace.
4 - 54
CLUTCH ENG
CHECKING THE CLUTCH RELEASE SHIFT
ARM
1 1. Check:
• clutch release shift arm 1
2 Damage/wear → Replace.
• clutch release adjusting screw 2
EAS00293
INSTALLING THE CLUTCH
1. Install:
• washer
• cage 1
• cage springs 2
• rollers 3
• clutch shoe housing boss 4
2. Tighten:
• clutch shoe housing nut 1
50 Nm (5.0 m · kg)
T.
R.
NOTE:
_
1 • While holding the generator rotor 2 with the

sheave holder 3, tighten the clutch shoe
housing nut.
Sheave holder
90890-01701
3. Install:
• spacer 2
• collar 3
• clutch housing 4
• washer 5
• clutch boss 6
• lock washer 7
4 - 55
CLUTCH ENG
4. Tighten:
• clutch boss nut 1 70 Nm (7.0 m · kg)
T.
R.
NOTE:
_
While holding the clutch boss 2 with the uni-

versal clutch holder 3, tighten the clutch boss
nut.

90890-04086
5. Bend the lock washer tab along a flat side of

the nut.
6. Lubricate:
• friction plates
• clutch plates #1
• clutch plate #2
Engine oil
7. Install:
• friction plates
• clutch plate #2
(with springs)
• clutch plates #1
NOTE:
_
First, install a friction plate and then alternate

between a clutch plate and a friction plate.
8. Install:
• clutch springs
• clutch pressure plate 1
• clutch pressure plate bolts 2
6 Nm (0.6 m · kg)
T.
R.
NOTE:
_
Tighten the clutch pressure plate bolts in

stages and in a crisscross pattern.
9. Adjust:
• clutch release system
Refer to “ADJUSTING THE CLUTCH
RELEASE SYSTEM” in chapter 3.
4 - 56
OIL PUMP ENG
EASF0035
OIL PUMP
1 Oil pump driven gear 8 Engine oil drain bolt

2 Oil pump assembly
3 Gasket
4 Oil filter
5 Oil pump drive gear
6 Oil strainer
7 Gasket
4 - 57
OIL PUMP ENG
REMOVING THE OIL PUMP
1. Drain:
• engine oil
chapter 3.
2. Remove:
• clutch shoe
Refer to “CLUTCH”.
3. Remove:
• oil filter 1
4. Remove:
• oil pump drive gear 1
• oil pump driven gear 2
5. Remove:
• oil pump assembly 1
• gasket 2
• oil strainer 3
DISASSEMBLING THE OIL PUMP

1. Remove:
• screw
• oil pump housing cover 1
• oil pump shaft 2
• pin 3
• inner rotor 4
• outer rotor 5
• oil pump housing 6
4 - 58
OIL PUMP ENG
EAS00364
CHECKING THE OIL PUMP
1. Check:
• oil pump drive gear 1
• oil pump driven gear 2
• oil pump housing 3
• oil pump housing cover 4
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
• 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
clearance
0.15 mm
<Limit>: 0.20 mm
Outer-rotor-to-oil-pump-housing
clearance
0.06 ~ 0.10 mm
<Limit>: 0.15 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06 ~ 0.10 mm
<Limit>: 0.15 mm
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
4 - 59
OIL PUMP ENG
EAS00368
CHECKING THE OIL STRAINER
1. Check:
• oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
CHECKING THE OIL FILTER

1. Check:
• oil filter
Damage → Replace.
Contaminants → Clean with solvent.
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
Engine oil
2. Install:
• oil pump shaft
(to the oil pump housing)
• pin 1
• inner rotor 2
• outer rotor
• oil pump housing cover
• screw
NOTE:
_
When installing the inner rotor, align the pin in

the oil pump shaft with the groove a in the
inner rotor.
3. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
4 - 60
OIL PUMP ENG
EAS00376
INSTALLING THE OIL PUMP
1. Install:
a
• gasket New
• oil pump assembly 1
7 Nm (0.7 m · kg)
T.
R.
NOTE:
Install the gasket with section a in the position
1 as shown in the illustration.
CAUTION:
_
After tightening the bolts, make sure the oil

pump turns smoothly.
2. Install:
• oil filter 1
NOTE:
_
Align the mark a on the oil filter with the oil

hole b in the crankshaft journal.
4 - 61
SHIFT SHAFT ENG
EASF0032
SHIFT SHAFT
1 Shift lever assembly 8 Shift guide spring E Stopper lever spring

2 Shift drum segment 9 Shift fork guide bar F Stopper lever assembly
3 Washer 0 Shift pedal
4 Thrust bearing A Shift shaft
5 Guide B Shift lever
6 Pawl holder C Shift shaft spring stopper
7 Shift guide D Shift shaft spring
4 - 62
SHIFT SHAFT ENG
REMOVING THE SHIFT SHAFT
1. Drain:
• engine oil
chapter 3.
2. Remove:
• clutch
• oil pump driven gear
Refer to “OIL PUMP”.
3. Remove:
• shift fork guide bar 1
• washer 2
• shift guide spring
4. Remove:
• shift guide 1
• pawl holder 2
• guide 3
• dowel pin
5. Remove:
• washers 1
• thrust bearing 2
4 - 63
SHIFT SHAFT ENG
6. Remove:
• shift shaft assembly 1
• shift shaft spring stopper 2
• shift lever assembly 3
7. Remove:
• circlip 1
• washer 2
• shift shaft spring 3
• shift lever 4
• shift shaft 5
8. Remove:
• stopper lever assembly 1
• stopper lever spring 2
9. Remove:
• circlip 1
• washer 2
• stopper lever holder 3
• stopper lever 4
10.Remove:
• shift drum segment 1
• dowel pins
4 - 64
SHIFT SHAFT ENG
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
• shift lever 2
Bends/damage/wear → Replace.
• springs
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Roller turns roughly → Replace.
• stopper lever spring
CHECKING THE SHIFT GUIDE

1. Check:
• shift guide 1
• pawl holder 2
• guide 3
• shift guide spring
CHECKING THE OIL SEAL

1. Check:
• oil seal
4 - 65
SHIFT SHAFT ENG
EAS00331
INSTALLING THE SHIFT SHAFT
1. Install:
• shift drum segment 1
12 Nm (1.2 m · kg)
T.
R.
NOTE:
_
Apply locking agent (LOCTITE®) to the

threads of shift drum segment screw.
2. Install:
• stopper lever 1
• stopper lever spring 2
NOTE:
_
• Hook the ends 3 of the stopper lever spring

onto the stopper lever and the crankcase
boss.
• Mesh the stopper lever with the shift drum
segment assembly.
3. Install:
• shift lever assembly 1
• shift shaft spring stopper 2
• shift shaft assembly 3
NOTE:
_
• Align the punched mark a in the shift lever

assembly with the punched mark b in the
shift shaft assembly.
• Hook the end of the shift shaft spring onto
the shift shaft spring stopper 2.
4 - 66
CRANKCASE AND CRANKSHAFT ENG
EASF0037
CRANKCASE AND CRANKSHAFT

1 Right crankcase 0 Timing chain guide (intake side)
2 Shift fork guide bar retainer
3 Dowel pin
4 Left crankcase
5 Starter motor lead holder
6 Gear position pointer
7 Gear position sensor
8 Crankshaft assembly
9 Timing chain
4 - 67
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
• engine
2. Remove:
• starter motor lead
• starter motor
Refer to “STARTER MOTOR” in chapter 7.
3. Remove:
• cylinder head
Refer to “CYLINDER HEAD”.
• cylinder
• piston
Refer to “CYLINDER AND PISTON”.
• clutch
• shift shaft
Refer to “SHIFT SHAFT”.
• oil pump drive gear
Refer to “OIL PUMP”.
• generator
• starter clutch
Refer to “GENERATOR AND STARTER
CLUTCH”.
4. Remove:
2 • timing chain guide (intake side) bolts 1
• timing chain guide (intake side) 2
1 • timing chain 3
5. Remove:
• shift fork guide bar retainer bolts 1
• shift fork guide bar retainer 2
1 • shift fork guide bar spring
4 - 68
6. Remove:
• crankcase bolts
1 • starter motor lead holders 1
NOTE:
_
Loosen each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
7. Remove:
• right crankcase
• dowel pins
CAUTION:
_
Tap on one side of the crankcase with a

soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
8. Remove:
• crankshaft spacer
• crankshaft assembly
EAS00394
CHECKING THE CRANKSHAFT AND
CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification → Replace the crank-
shaft, bearing or both.
NOTE:
_
Turn the crankshaft slowly.
Maximum crankshaft runout

0.03 mm
4 - 69
2. Measure:
• big end side clearance
shaft.
Big end side clearance

0.11 ~ 0.41 mm
3. Measure:
• crankshaft width
shaft.
Crankshaft width
42.95 ~ 43.00 mm
4. Check:
• crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
• bearing 2
Cracks/damage/wear → Replace the crank-
shaft.
5. Check:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
air.
4 - 70
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• crankcase
• oil delivery passages
air.
EAS00401
CHECKING THE BEARINGS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
CHECKING THE TIMING CHAIN GUIDE

1. Check:
• timing chain guide (intake side)
CHECKING THE TIMING CHAIN

1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
4 - 71
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft assembly
• crankshaft spacer
CAUTION:
_
To avoid scratching the crankshaft and to

ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
EAS00416
ASSEMBLING THE CRANKCASE
1. Apply:
2
• sealant
(onto the crankcase mating surfaces)

90890-85505
1
NOTE:
_
Do not allow any sealant to come into contact

with the oil gallery 1.
2. Install:
• dowel pins 2
3. Install:
• right crankcase
(onto the left crankcase)
NOTE:
_
Tap lightly on the right crankcase with a soft-

face hammer.
4 - 72
4. Install:
• starter motor lead holders
• crankcase bolts 10 Nm (1.0 m · kg)
T.
R.
NOTE:
Apply sealant to the threads of crankcase bolt 1.
1

90890-85505
5. Apply:
• engine oil
(onto the crankshaft bearings and oil deliv-
ery holes)
6. Check:
• crankshaft and transmission operation
7. Install:
• shift fork guide bar spring
• shift fork guide bar retainer
• shift fork guide bar retainer bolts
10 Nm (1.0 m · kg)
T.
R.
NOTE:
_
Apply locking agent (LOCTITE®) to the shift

fork guide bar retainer bolts.
8. Install:
• timing chain
• timing chain guide (intake side)
• timing chain guide (intake side) bolts
10 Nm (1.0 m · kg)
T.
R.
NOTE:
Apply locking agent (LOCTITE®) to the
threads of timing chain guide (intake side)
bolts.
4 - 73
TRANSMISSION ENG
EASF0041
TRANSMISSION
1 Collar 0 4th pinion gear
2 1st wheel gear A 3rd pinion gear
3 4th wheel gear B 2nd pinion gear
4 3rd wheel gear C Shift fork guide bar
5 Side plate D Shift fork “R”
6 Side plate spring E Shift fork “L”
7 Drive axle/2nd wheel gear F Shift drum
8 Drive sprocket
9 Main axle/1st pinion gear
4 - 74
TRANSMISSION ENG
EASF0042
REMOVING THE TRANSMISSION
1 NOTE:
_
Prior to removing the transmission, separate

2 the crankcase.
4
1. Remove:
3
• shift fork guide bar spring
• shift fork “R” 2
• shift fork “L” 3
• shift drum 4
NOTE:
_
Note the position of each part. Pay particular

attention to location and direction of shift forks.
2. Remove:
2 1 • main axle assembly 1
• drive axle assembly 2
DISASSEMBLING THE TRANSMISSION

1. Remove:
• washers 1
• 2nd pinion gear 2
• 3rd pinion gear 3
• circlip 4
• 4th pinion gear 5
• main axle/1st pinion gear 6
4 - 75
TRANSMISSION ENG
2. Remove:
• circlips 1
• washers 2
• collars 3
• 1st wheel gear 4
• 4th wheel gear 5
• 3rd wheel gear 6
• side plate 7
• side plate spring 8
• drive axle/2nd wheel gear 9
EAS00421
CHECKING THE SHIFT FORKS
shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear → Replace
the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent shift

fork guide bar.
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
4 - 76
TRANSMISSION ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves 1
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum bearing
Damage/pitting → Replace the shift drum
assembly.
EAS00424
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the main
axle.
Main axle runout limit

0.03 mm
2. Measure:
• drive axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the drive
axle.
Drive axle runout limit

0.03 mm
3. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
4 - 77
TRANSMISSION ENG
4. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
2 NOTE:
_
1 When reassembling the drive axle, press the

19.3~19.5 mm
2nd wheel gear 1 onto the drive axle 2 as
shown.
5. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
ASSEMBLING THE TRANSMISSION

1 1. Install:
• side plate spring 1
2 • side plate 2
NOTE:
_
Install the side plate spring and side plate as

shown.
EAS00426
INSTALLING THE TRANSMISSION
1. Install:
1 • shift fork “R”
a • shift fork “L”
• shift drum 2
2
NOTE:
_
• Install the side plate with its end a between

the shift fork guide bar and shift drum.
• The embossed marks a on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R”, “L”.
4 - 78
TRANSMISSION ENG
2. Check:
• transmission
• shift drum
• shift forks
NOTE:
_
• Oil each gear, shaft, and bearing thoroughly.

• Before assembling the crankcase, be sure
that the transmission is in neutral and that
the gears turn freely.
4 - 79
CARB
CHAPTER 5
CARBURETOR
CARBURETOR................................................................................................5-1
REMOVING THE CARBURETOR............................................................. 5-2
DISASSEMBLING THE CARBURETOR................................................... 5-3
CHECKING THE CARBURETOR ............................................................. 5-5
ASSEMBLING THE CARBURETOR.........................................................5-7
INSTALLING THE CARBURETOR ........................................................... 5-7
MEASURING AND ADJUSTING THE FUEL LEVEL ................................5-8
CHECKING THE FUEL COCK OPERATION............................................5-9
CARB
CARBURETOR CARB
EASF0043
CARBURETOR
CARBURETOR
1 Starter plunger assem- 6 Jet needle set C Needle jet I Float pivot pin
bly 7 Throttle valve D Main jet J Float chamber
2 Coasting enricher 8 Throttle stop screw set E Pilot jet K Fuel drain screw
spring 9 Pilot air screw set F Needle valve L Carburetor overflow
3 Coasting enricher 0 Air vent hose G Float hose
4 Carburetor top cover A Fuel hose H Float chamber rubber
5 Throttle valve spring B Carburetor joint gasket
5-1
CARBURETOR CARB
REMOVING THE CARBURETOR
WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
1. Remove:
2. Loosen:
• fuel drain screw 1
3. Drain:
• fuel (from float chamber)
1
4. Remove:
• carburetor top cover 1
5. Remove:
• starter plunger assembly 1
1 (from carburetor body)
• gasket
6. Disconnect:
3 • fuel hose 1
• carburetor overflow hose 2
• air vent hose 3
2
1
5-2
CARBURETOR CARB
7. Loosen:
4 • carburetor joint clamp screw 1
8. Remove:
2 • bolts 2
• carburetor assembly 3
• carburetor joint 4
1
3
9. Remove:
• starter plunger assembly 1
(from starter cable)
1
10.Remove:
• throttle valve assembly 1
• throttle valve spring 2
11.Remove:
• throttle valve 1
1 2 • jet needle set 2
NOTE:
Push the jet needle holder 3 with a Phillips
screwdriver, and then turn it to remove the jet
3 needle holder.
DISASSEMBLING THE CARBURETOR

NOTE:
The following parts can be cleaned and
inspected without disassembly.
• Coasting enricher
• Starter plunger
• Throttle stop screw
• Pilot air screw
5-3
CARBURETOR CARB
1. Remove:
• coasting enricher cover
2 • coasting enricher spring 1
1 • coasting enricher 2
2. Remove:
• pilot air screw set 1
3. Remove:
• throttle stop screw set 1
4. Remove:
1 • float chamber 1
• float chamber rubber gasket
5. Remove:
• main jet 1
• needle jet 2
• pilot jet 3
3
2
1
5-4
CARBURETOR CARB
6. Remove:
• float pivot pin 1
• float 2
3 • needle valve 3
2
1
EAS00485
CHECKING THE CARBURETOR
1. Check:
• carburetor body
• float chamber
• jet housing
2. Check:
• fuel passages
Obstructions → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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:
• float chamber body
Dirt → Clean.
4. Check:
• float chamber rubber gasket
5. Check:
• float
Damage → Replace.
5-5
CARBURETOR CARB
6. Check:
• needle valve
7. Check:
• coasting enricher 1
1
• coasting enricher spring 2
2 Cracks/damage → Replace.
8. Check:
1 2 3 4 5 6 • jet needle 1
• needle jet 2
• main jet 3
• pilot jet 4
• pilot air screw 5
• throttle stop screw 6
Obstruction → Clean.
Blow out the jets with compressed air.
9. Check:
• throttle valve
Damage/scratches/wear → Replace.
10.Check:
• starter plunger
• starter plunger spring
Bends/cracks/damage → Replace the
starter plunger assembly.
5-6
CARBURETOR CARB
11.Check:
• hose joints
12.Check:
• air vent hose
• fuel hoses
Obstructions → Clean.
Blow out the hoses with compressed air.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
_
• Before assembling the carburetor, wash

all of the parts in a petroleum-based sol-
vent.
• Always use a new gasket and new O-
rings.
EAS00492
INSTALLING THE CARBURETOR
1. Install:
• jet needle set
NOTE:
Push the jet needle holder 1 with a Phillips
1 screwdriver, and then turn it to secure it in
place.
2. Install:
• throttle valve assembly
a
NOTE:
Align the slit a of the throttle valve with the tab
b b of the carburetor body.
3. Install:
• carburetor joint
• carburetor joint clamp screw
• bolts 10 Nm (1.0 m · kg)
T.
R.
4. Adjust:
• engine idling speed
Engine idling speed

1,400 ~ 1,600 r/min
Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.
5-7
CARBURETOR CARB
5. Adjust:

3 ~ 7 mm

CABLE FREE PLAY” in chapter 3.
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel level a
1 Fuel level (below the float cham-

ber mating surface)
2.5 ~ 3.5 mm
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4
a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to
2
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 onto 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 4.
f. Measure the fuel level a.
3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-8
CARBURETOR CARB
2. Adjust:
• fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor.
1 b. Check the needle valve.
c. If worn, replace the needle valve.
d. If fine, adjust the float level by the needle
valve is slightly 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00506
CHECKING THE FUEL COCK OPERATION
1. Remove:
• rear cowling (left)
1 INGS” in chapter 3.
2. Place a container under the end of the fuel
hose 1.
3. Check:
• fuel cock operation
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suck on the end of the vacuum hose 1.
Fuel flows. Fuel cock is OK.

Replace the fuel
Fuel does not flow.
cock.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• rear cowling (left)
5-9
CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC............................................................... 6-1

REMOVING THE FRONT WHEEL............................................................ 6-2
CHECKING THE FRONT WHEEL ............................................................ 6-3
CHECKING THE BRAKE DISC.................................................................6-5
CHECKING THE SPEEDOMETER GEAR UNIT ...................................... 6-6
INSTALLING THE FRONT WHEEL .......................................................... 6-7
REAR WHEEL AND BRAKE ..........................................................................6-8

REMOVING THE REAR WHEEL .............................................................. 6-9
DISASSEMBLING THE BRAKE SHOE PLATE ...................................... 6-11
CHECKING THE REAR WHEEL............................................................. 6-11
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 6-12
CHECKING THE BRAKE ........................................................................6-13
ASSEMBLING THE BRAKE SHOE PLATE ............................................6-14
INSTALLING THE REAR WHEEL........................................................... 6-14
FRONT BRAKE ............................................................................................. 6-16

FRONT BRAKE CALIPER....................................................................... 6-16
REPLACING THE FRONT BRAKE PADS .............................................. 6-17
DISASSEMBLING THE FRONT BRAKE CALIPER ................................6-20
CHECKING THE FRONT BRAKE CALIPER ..........................................6-21
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ....... 6-22
FRONT BRAKE MASTER CYLINDER....................................................6-25
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 6-26
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 6-27
ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER...........................................6-28
FRONT FORK................................................................................................6-31
REMOVING THE FRONT FORK LEGS.................................................. 6-32
DISASSEMBLING THE FRONT FORK LEGS ........................................ 6-33
CHECKING THE FRONT FORK LEGS .................................................. 6-35
ASSEMBLING THE FRONT FORK LEGS .............................................. 6-36
INSTALLING THE FRONT FORK LEGS ................................................ 6-38
HANDLEBAR ................................................................................................6-40
REMOVING THE HANDLEBAR..............................................................6-41
CHECKING THE HANDLEBAR ..............................................................6-43
INSTALLING THE HANDLEBAR ............................................................ 6-43
STEERING HEAD.......................................................................................... 6-46

REMOVING THE LOWER BRACKET.....................................................6-47
CHECKING THE STEERING HEAD .......................................................6-47
INSTALLING THE STEERING HEAD .....................................................6-49
CHAS
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ......................6-50
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES
AND SWINGARM ...................................................................................6-51
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 6-53
CHECKING THE SWINGARM ................................................................6-54
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES
AND SWINGARM ...................................................................................6-54
DRIVE CHAIN AND SPROCKETS................................................................6-56

REMOVING THE DRIVE CHAIN AND SPROCKETS............................. 6-57
CHECKING THE DRIVE CHAIN ............................................................. 6-58
INSTALLING THE DRIVE CHAIN AND SPROCKETS ........................... 6-59
FRONT WHEEL AND BRAKE DISC CHAS
EASF0044
CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle
2 Brake disc
3 Spacer
4 Oil seal
5 Bearing
6 Spacer
7 Speedometer gear unit
6-1
EAS00519
REMOVING THE FRONT WHEEL
WARNING
_

2. Remove:
• speedometer cable 1
• axle nut 2
• washer 3
1
2 3
3. Elevate:
• front wheel
NOTE:
_

4. Remove:
• front wheel axle 1
• spacer 2
• speedometer gear unit 3
• front wheel
3
1
2
5. Remove:
• brake disc 1
6-2
EAS00526
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent wheel

axle.
2. Check:
• tire
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Check:
• spokes
Loose → Tighten.
Tap the spokes with a screwdriver.
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.
4. Measure:
• front wheel radial runout a
• front wheel lateral runout b
Over the specified limits → Replace.
Front wheel radial runout limit

1.0 mm
Front wheel lateral runout limit
0.5 mm
6-3
5. Check:
• spacers
WARNING
_
• After mounting a new tire, ride conserva-

tively for a while to become accustomed
to the “feel” of the new tire and to allow
the tire to seat itself properly in the rim.
Failure to do so could lead to an accident
with possible injury to the rider or dam-
age to the motorcycle.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 properly.
6. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
7. Replace:
2
• wheel bearings New
• oil seals New
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
New a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
_
To prevent damaging the wheel, place a rag 2

between the screwdriver and the wheel sur-
face.
c. Remove the wheel bearings 3 with a gen-

eral bearing puller.
6-4
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race

4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
_
Use a socket 7 that matches the diameter of

the wheel bearing outer race and oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00527
CHECKING THE BRAKE DISC
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit (maxi-

mum)
0.15 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand so
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 5 ~ 10 mm below
the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-5
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Brake disc thickness limit (mini-

mum)
3.0 mm
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
_
Tighten the brake disc bolts in stages and in a

crisscross pattern.
Brake disc bolt

23 Nm (2.3 m·kg)
T.
LOCTITE®
R.
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00535
CHECKING THE SPEEDOMETER GEAR
UNIT
1. Check:
• speedometer clutch
6-6
EAS00542
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
• speedometer gear unit
2. Install:
• brake disc
• front wheel
Refer to “CHECKING THE BRAKE DISC”.
NOTE:
_
Make sure the projection a on the speedome-

ter gear unit fits between the projections on the
outer tube.
3. Tighten:
• wheel axle nut 39 Nm (3.9 m · kg)
T.
R.
4. Connect:
• speedometer cable 1
NOTE:
Be sure that slit a on the speedometer cable
meshes with the projection b on the speed-
ometer gear unit 2.
WARNING
_
Make sure the brake cable is routed prop-

erly.
CAUTION:
_
Before tightening the wheel axle nut, push

down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
6-7
REAR WHEEL AND BRAKE CHAS
EASF0049
REAR WHEEL AND BRAKE

1 Brake rod adjusting nut 0 Cotter pin
2 Brake camshaft lever A Brake torque rod
3 Pin B Rear wheel drive hub damper
4 Drive chain puller (right) C Rear wheel drive hub
5 Brake shoe wear indicator D Drive chain puller (left)
6 Brake shoe plate E Rear wheel axle
7 Brake camshaft F Brake rod
8 Brake shoe
9 Rear wheel
6-8
EAS00563
REMOVING THE REAR WHEEL
WARNING
_

NOTE:
_

1. Remove:
• brake rod adjusting nut 1
• brake rod 2
• compression spring 3
• washer
• pin 4
NOTE:
1 43 2 Press down on the brake pedal to remove the
pin from the brake rod.
2. Remove:
• cotter pin
• brake torque rod nut 1
• washer
• brake torque rod bolt
• brake torque rod 2
1
2
3. Loosen:
• chain puller locknuts (left and right) 1
• chain puller adjusting nuts (left and right) 2
12
6-9
4. Remove:
1 • rear wheel axle nut 1
• washer
• rear wheel axle 2
• washer
• collar
5. Remove:
1 • rear wheel assembly 1
NOTE:
Push the rear wheel forward and remove the
drive chain from the driven sprocket.
6. Remove:
• brake shoe plate assembly 1
7. Remove:
1 • collar 1
• rear wheel drive hub assembly 2
2
8. Remove:
1 • spacer 1
6 - 10
9. Remove:
• O-ring
1 • rear wheel drive hub dampers 1
DISASSEMBLING THE BRAKE SHOE

1 PLATE
1. Remove:
2 • brake shoes 1
• brake shoe springs 2
2. Remove:
• brake camshaft lever nut
• brake camshaft lever bolt
• brake camshaft lever 1
• brake shoe wear indicator
• brake camshaft
NOTE:
1
When removing the brake camshaft lever,
mark the position on the brake camshaft lever
where it is aligned with the punch mark in the
brake camshaft.
EAS00566
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
Refer to “FRONT WHEEL AND BRAKE
DISC”.
6 - 11
2. Check:
• tire
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Measure:
• radial wheel runout
• lateral wheel runout
DISC”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub
• rear wheel drive hub dampers

6 - 12
EAS00539
CHECKING THE BRAKE
brake shoes.
1. Check:
• brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with course sandpa-
per.
NOTE:
_
After sanding the glazed areas, clean the

brake shoe with a cloth.
2. Measure:
• brake shoe lining thickness a
Brake shoe lining thickness limit

(minimum)
2.0 mm
WARNING
_
Do not allow oil or grease to contact the

brake shoes.
NOTE:
_
Replace the brake shoes as a set, if either is

worn to the wear limit.
3. Measure:
• brake drum inside diameter a
Out of specification → Replace the wheel.
a
Brake drum inside diameter limit
(maximum)
111 mm
4. Check:
• 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:
• brake camshaft
6 - 13
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE
1. Install:
• brake camshaft 1
• brake shoe wear indicator 2
• brake camshaft lever
7 Nm (0.7 m · kg)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Align the punch mark in the brake camshaft
with the mark on the brake camshaft lever.
d. Check that the brake shoes are properly
positioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00571
INSTALLING THE REAR WHEEL
1. Lubricate:
• spacer
• collar
• wheel axle
• wheel bearings
• rear brake camshaft
• brake torque rod bolt
• oil seal lips
2. Install:
• brake torque rod (to brake shoe plate)
19 Nm (1.9 m · kg)
T.
R.
• washer
• cotter pin New
3. Install:
• pin
• washer
• compression spring
• brake rod
• brake rod adjusting nut
NOTE:
Press down on the brake pedal to install the
brake rod.
6 - 14
4. Adjust:
Drive chain slack

25 ~ 35 mm
Refer to “ADJUSTING THE DRIVE CHAIN

SLACK” in chapter 3.
5. Tighten:
• wheel axle nut 60 Nm (6.0 m · kg)
T.
R.
CAUTION:
_
Do not loosen the wheel axle nut after tight-

ening it to the specified torque.
6 - 15
FRONT BRAKE CHAS
FRONT BRAKE
EASF0612
FRONT BRAKE CALIPER
1 Brake caliper bolt 5 Brake caliper seal
2 Retaining bolt 6 Brake caliper piston
3 Brake caliper 7 Brake pad spring
4 Bleed screw kit 8 Brake pad
35 Nm (3.5 m • kg)
T.
R.
27 Nm (2.7 m • kg)
1
T.
R.
LS 4
3
LS
8 5
6 - 16
FRONT BRAKE CHAS
EAS00579
CAUTION:
_
Disc brake components rarely require dis-

assembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS
NOTE:
_
When replacing the brake pads, it is not neces-

1 sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Loosen:
• retaining bolts 1
2. Remove:
• brake caliper bolts
• washer
• brake caliper 1
1
6 - 17
FRONT BRAKE CHAS
3. Remove:
• retaining bolts
• brake pads 1
4. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit

0.8 mm
5. Install:
• brake pads
• brake pad spring
NOTE:
_
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 m·kg)
T.
R.
d. Install new brake pads and a new brake pad

spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 18
FRONT BRAKE CHAS
6. Lubricate:
• retaining bolts
CAUTION:
_
• Do not allow grease to contact the brake

pads.
• Remove any excess grease.
7. Install:
• brake caliper
• brake caliper bolt 35 Nm (3.5 m · kg)
T.
R.
• retaining bolts 27 Nm (2.7 m · kg)
T.
R.
8. Check:
LOWER • brake fluid level
a Below the minimum level mark a → Add
level.
LEVEL” in chapter 3.
9. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6 - 19
FRONT BRAKE CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
_
Before disassembling the brake caliper, drain

the brake fluid from the entire brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
_
Put the end of the brake hose into a container

1 and pump out the brake fluid carefully.
2
2. Remove:
• retaining bolts 1
• brake caliper 2
1
3. Remove:
• brake caliper pistons 1
• brake caliper seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the pistons from
the brake caliper.
WARNING
_
• Cover the brake caliper pistons with a

rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
• Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 20
FRONT BRAKE CHAS
EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component

replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Every two years
and whenever the
Brake fluid
brake is disassem-
bled
1. Check:
Rust/scratches/wear → Replace the brake
caliper pistons.
• brake caliper cylinders 2
Scratches/wear → Replace the brake cali-
per assembly.
• brake caliper body 3
Cracks/damage → Replace the brake cali-
per assembly.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
_
Whenever a brake caliper is disassembled,

replace the piston seals.
6 - 21
FRONT BRAKE CHAS
EAS00634
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
_
• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

DOT 4
1. Install:
• brake caliper seals 1 New
2. Install:
• brake caliper 1
3 (temporarily)
• copper washers 2 New
• brake hose 3
• union bolt 4 26 Nm (2.6 m · kg)
T.
R.
4 WARNING
2
1
_
Proper brake hose routing is essential to

New
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
_
b When installing the brake hose onto the

a
brake caliper 1, make sure the brake pipe
a touches the projection b on the brake
caliper.
1
6 - 22
FRONT BRAKE CHAS
3. Remove:
• brake caliper
4. Install:
• brake pad springs
• brake pads
• brake caliper
• brake caliper bolts (with washer)
35 Nm (3.5 m · kg)
T.
R.
• retaining bolts 27 Nm (2.7 m · kg)
T.
R.
5. Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
_

performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_

6. Bleed:
• brake system
6 - 23
FRONT BRAKE CHAS
7. Check:
LOWER • brake fluid level
a Below the minimum level mark a → Add
level.
8. Check:
system.
6 - 24
FRONT BRAKE CHAS
EASF0050
FRONT BRAKE MASTER CYLINDER
1 Brake master cylinder kit
2 Brake master cylinder reservoir cap
3 Brake master cylinder reservoir diaphragm
4 Brake master cylinder
5 Brake master cylinder holder
6 Brake hose
7 Brake lever
6 - 25
FRONT BRAKE CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
_
Before disassembling the front brake master

cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
Refer to “REMOVING THE HEADLIGHT
ASSEMBLY” in chapter 3.
• speedometer assembly
Refer to “HANDLEBAR”.
2. Remove:
• union bolt 1
• copper washers 2
1 • brake hose
NOTE:
_
To collect any remaining brake fluid, place a

container under the master cylinder and the
end of the brake hose.
2
3. Remove:
1 • brake master cylinder assembly 1
4. Remove:
• brake light switch 1
2 • brake lever 2
6 - 26
FRONT BRAKE CHAS
5. Remove:
• brake master cylinder kit 1
6. Remove:
• brake master cylinder reservoir cap 1
• brake master cylinder reservoir diaphragm
holder 2
3
• brake master cylinder reservoir diaphragm 3
2
1
7. Remove:
2 • brake hose 1
• brake hose retainers 2
2 • brake hose holder 3
EAS00590
CHECKING THE FRONT BRAKE MASTER
1 CYLINDER
1. Check:
• brake master cylinder 1
• brake fluid delivery passages 2
2 (brake master cylinder body)
air.
2. Check:
• brake master cylinder kit
6 - 27
FRONT BRAKE CHAS
3. Check:
1 • brake master cylinder reservoir 1
• brake master cylinder reservoir diaphragm 2
2
4. Check:
• brake hose 1
1
EAS00598
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
_
• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.
components.
1 Recommended brake fluid

DOT 4
1. Install:
• brake master cylinder 1
13 Nm (1.3 m · kg)
T.
R.
NOTE:
_
• Install the brake master cylinder holder with

the “UP” mark facing up.
• Adjust the brake master cylinder to the
proper angle.
• First, tighten the upper bolt, then the lower
bolt.
6 - 28
FRONT BRAKE CHAS
2. Install:
1 New • copper washers 1 New
• brake hose 2
• union bolt 26 Nm (2.6 m · kg)
T.
R.
WARNING
2 _
Proper brake hose routing is essential to

insure safe motorcycle operation. Refer to
a “CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
NOTE:
_
Turn the handlebar to the left and right to make

sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
3. Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
_

performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
6 - 29
FRONT BRAKE CHAS
CAUTION:
_

4. Bleed:
• brake system
5. Check:
• brake fluid level
Below the minimum level mark a → Add
level.
6. Check:
system.
6 - 30
FRONT FORK CHAS
EASF0054
FRONT FORK
1 Front fork cover (right) 0 Damper rod bolt
2 Front fork cap bolt A Front fork cover (left)
3 Dust seal B Front fender
4 Oil seal clip
5 Oil seal
6 Fork spring
7 Damper rod
8 Inner tube
9 Outer tube
6 - 31
FRONT FORK CHAS
EAS00649
REMOVING THE FRONT FORK LEGS
front fork legs.
WARNING
_

NOTE:
_

2. Remove:
3. Remove:
• brake caliper assembly
• brake hose retainers
Refer to “FRONT BRAKE”.
• front wheel
DISC”.
4. Remove:
• front fork cover bolts (left and right)
• collars (left and right)
• front fork covers (left and right) 1
1
5. Remove:
• front fender bolts
• collars
• front fender 1
6 - 32
FRONT FORK CHAS
6. Remove:
• front fork cap bolt 1
(with a 10-mm hexagonal wrench)
1
7. Loosen:
• lower bracket pinch bolt 2
WARNING
_
Before loosening the lower bracket pinch

2
bolt, support the front fork leg.
8. Remove:
• front fork leg
EAS00655
DISASSEMBLING THE FRONT FORK LEGS
front fork legs.
1. Remove:
• fork spring
2. Drain:
1 • fork oil
NOTE:
_
Stroke the inner tube 1 several times while

draining the fork oil.
3. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
Do not scratch the inner tube.
6 - 33
FRONT FORK CHAS
4. Remove:
• damper rod assembly bolt
• copper washer
NOTE:
_
While holding the damper rod assembly with a

10 mm hexagon nut/socket wrench 1 and the
T-handle 2, loosen the damper rod assembly
bolt 3.
T-handle
90890-01326
5. Remove:
• inner tube
• rebound spring
• damper rod
NOTE:
Pull out the inner tube and damper rod
together.
6. Remove:
• oil seal 1
2 Rag
6 - 34
FRONT FORK CHAS
EAS00657
CHECKING THE FRONT FORK LEGS
1
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
2
WARNING
_
Do not attempt to straighten a bent inner

tube as this may dangerously weaken it.
2. Measure:
• spring free length a
Out of specifications → Replace.
Spring free length

257.7 mm
<Limit>: 252.5 mm
3. Check:
• damper rod 1
1 Obstructions → Blow out all of the oil pas-
sages with compressed air.
CAUTION:
_
• The front fork leg has a built-in damper

adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
6 - 35
FRONT FORK CHAS
EAS00659
ASSEMBLING THE FRONT FORK LEGS
front fork legs.
WARNING
_
• Make sure the oil levels in both front fork

legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
_
• When assembling the front fork leg, be sure

to replace the oil seal.
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• damper rod 1
• rebound spring
• inner tube 2
CAUTION:
_
Allow the damper rod to slide slowly down

the inner tube 2 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Lubricate:
• inner tube outer surface
Fork oil 10W or equivalent
3. Tighten:
• damper rod assembly bolt 1
23 Nm (2.3 m·kg)
LOCTITE®
T.
R.
6 - 36
FRONT FORK CHAS
NOTE:
_
Tighten the damper rod assembly bolt 1 while

holding the damper rod with the T-handle 2
and a 10 mm hexagon nut/socket wrench 3.
T-handle
90890-01326
4. Install:
• oil seal 1 New
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
Fork seal driver weight

90890-01184
Fork seal driver attachment
90890-01186
CAUTION:
_
Make sure the numbered side of the oil seal

faces up.
NOTE:
_
• Before installing the oil seal, lubricate its lips

with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to pro-
tect the oil seal during installation.
5. Install:
• oil seal clip 1 New
NOTE:
_
Adjust the oil seal clip so that it fits into the

outer tube’s groove.
6 - 37
FRONT FORK CHAS
6. Fill:
• front fork leg
mended fork oil)
Quantity (each front fork leg)

0.58 L
Recommended oil
Fork 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)
91 mm
NOTE:
_
• While filling the front fork leg, keep it upright.

• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
7. Install:
• fork spring 1
NOTE:
_
Install the fork spring with the smaller pitch fac-

ing up.
EAS00662
INSTALLING THE FRONT FORK LEGS
front fork legs.
1. Install:
• front fork leg 1
Temporarily tighten the lower bracket pinch
bolt.
NOTE:
_
Pull up the inner tube until it is stopped, then

install the front fork cap bolt 2.
2. Tighten:
• lower bracket pinch bolt 1
50 Nm (5.0 m · kg)
T.
R.

50 Nm (5.0 m · kg)
T.
R.
6 - 38
FRONT FORK CHAS
3. Install:
• front fender 10 Nm (1.0 m · kg)
T.
R.
• front fork cover 7 Nm (0.7 m · kg)
T.
R.
4. Install:
• front wheel
DISC”.
• brake hose retainers
• brake caliper assembly
6 - 39
HANDLEBAR CHAS
EASF0055
HANDLEBAR
1 Rear view mirror (left and right)
2 Throttle grip
3 Right handlebar switch
4 Handlebar
5 Left handlebar switch
6 Handlebar grip
7 Starter cable
8 Throttle cable
9 Handlebar bracket
6 - 40
HANDLEBAR CHAS
EAS00666
REMOVING THE HANDLEBAR
WARNING
_

2. Remove:
Refer to “REPLACING THE HEADLIGHT
BULBS” in chapter 3.
3. Disconnect:
1 • meter assembly couplers 1
• right handlebar switch coupler 2
• left handlebar switch coupler 3
• front brake light switch connectors 4
4
2 3
4. Disconnect:
2 3 • speedometer cable 1
5. Remove:
• plastic locking ties 2
• speedometer assembly 3
2
1
2
6. Remove:
1 • rear view mirrors (left and right) 1
1
2 • brake master cylinder 2
6 - 41
HANDLEBAR CHAS
7. Remove:
• right handlebar switch 1
1
8. Remove:
• throttle cable 1
• throttle grip 2
2
9. Remove:
• washer
• starter lever 1
• starter cable 2
• spring washer
2
1
10.Remove:
• left handlebar switch 1
1
11.Remove:
• handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
6 - 42
HANDLEBAR CHAS
12.Remove:
• wire harness strap 1
13.Remove:
• handlebar 1
• washers
1 • bushings
• handlebar bracket 2
2
EAS00668
CHECKING THE HANDLEBAR
1 1. Check:
• handlebar 1
Bends/cracks/damage → Replace.
WARNING
_
Do not attempt to straighten a bent handle-

bar as this may dangerously weaken it.
EAS00670
INSTALLING THE HANDLEBAR
WARNING
_

2. Install:
a b • handlebar bracket 1
43 Nm (4.3 m · kg)
T.
R.
NOTE:
Align the projection a in the handlebar bracket
1 with the slit b in the steering shaft.
6 - 43
HANDLEBAR CHAS
3. Install:
• bushings
• washers
• handlebar 16 Nm (1.6 m · kg)
T.
R.
• wire harness strap
Refer to “CABLE ROUTING” in chapter 2.
4. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
1 • left handlebar switch 1
NOTE:
_
a Align the projection a on the left handlebar

switch with the hole in the handlebar.
6. Install:
• throttle grip 1
• throttle cable 2
NOTE:
1 Lubricate the inside of the throttle grip with a
2 thin coat of lithium-soap-based grease and
install it onto the handlebar.
7. Install:
• right handlebar switch 1
NOTE:
_
Align the projection a on the right handlebar

1 a switch with the hole in the handlebar.
WARNING
Make sure the throttle grip operates
smoothly.
6 - 44
HANDLEBAR CHAS
8. Install:
• brake master cylinder
13 Nm (1.3 m · kg)
T.
R.
9. Install:
• plastic locking ties
Refer to “CABLE ROUTING” in chapter 2.
10.Adjust:
CABLE FREE PLAY” in chapter 3.

3 ~ 7 mm
6 - 45
STEERING HEAD CHAS
EASF0057
STEERING HEAD
1 Rubber cover
2 Upper ring nut
3 Lower ring nut
4 Ball race cover
5 Bearing inner race
6 Upper bearing
7 Bearing outer race
8 Lower bearing
9 Lower bracket
6 - 46
STEERING HEAD CHAS
EAS00679
REMOVING THE LOWER BRACKET
WARNING
_

2. Remove:
• front panel
• front fork
Refer to “FRONT FORK”.
• handlebar
Refer to “HANDLEBAR”.
3. Remove:
• rubber cover
• upper ring nut 1
• lower ring nut 2
NOTE:
_
Hold the lower ring nut with the steering nut

wrench, and then remove the upper ring nut
2 1 with the ring nut wrench.
Steering nut wrench

90890-01403
Ring nut wrench
90890-01268
WARNING
_
Securely support the lower bracket so that

there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent

Kerosene
6 - 47
STEERING HEAD CHAS
2. Check:
2 • bearings 1
1
• bearing races 2
Damage/pitting → Replace.
3. Replace:
• bearings
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
_
If the bearing race is not installed properly,

the steering head pipe could be damaged.
NOTE:
_
• Always replace the bearings and bearing

races as a set.
• Whenever the steering head is disassem-
bled, replace the rubber seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• lower bracket 1
(along with the steering stem)
1 Bends/cracks/damage → Replace.
6 - 48
STEERING HEAD CHAS
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
2. Install:
• lower ring nut
• upper ring nut
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
3. Install:
• front fork legs
Refer to “FRONT FORK”.
6 - 49
REAR SHOCK ABSORBER ASSEMBLY AND
SWINGARM CHAS
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
1 Rear shock absorber
2 Brake torque rod
3 Swingarm
4 Bushing
5 Swingarm pivot shaft
6 Drive chain case
6 - 50
SWINGARM CHAS
EAS00691/EAS00702
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLIES AND SWINGARM
WARNING
_

NOTE:
_

2. Remove:
• muffler
Refer to “REMOVING THE ENGINE” in
chapter 4.
• rear wheel
Refer to “REAR WHEEL AND BRAKE”.
3. Remove:
• drive chain case screws
• drive chain case 1
4. Remove:
• cotter pin
• bolt
• washer
• brake torque rod 1
6 - 51
SWINGARM CHAS
5. Remove:
• rear shock absorber bolt (left and right) 1
• washer
2 • rear shock absorber nut (left and right) 2
• washers
3
• rear shock absorber assembly (left and
right) 3
6. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the swing-
É arm pivot shaft nut.
È Pivot shaft nut

T.
R.
51 Nm (5.1 m·kg)
b. Measure the swingarm side play È by mov-

ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers and bearings.
Swingarm side play (at the end of

the swingarm)
T.
R.
1 mm
d. Check the swingarm vertical movement É

by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
washer and bushings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 52
SWINGARM CHAS
7. Remove:
• swingarm pivot shaft nut 1
3 • washer 2
• swingarm pivot shaft 3
1 • swingarm 4
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both rear
shock absorber assemblies.
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bushings
• bolts
6 - 53
SWINGARM CHAS
EAS00707
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.
2. Check:
• swingarm pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent pivot

shaft.
3. Wash:
• washer
• bushings
Recommended cleaning solvent

Kerosene
4. Check:
• washer
• bushings
EAS00711/EAS00699
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES AND
SWINGARM
1. Lubricate:
6 - 54
SWINGARM CHAS
2. Install:
• swingarm
• washer
• swingarm pivot shaft nut
51 Nm (5.1 m · kg)
T.
R.
3. Install:
• rear shock absorber assemblies
• rear shock absorber nuts
• rear shock absorber bolts
32 Nm (3.2 m · kg)
T.
R.
4. Install:
• brake torque rod (to swingarm)
16 Nm (1.6 m · kg)
T.
R.
5. Install:
• drive chain case 7 Nm (0.7 m · kg)
T.
R.
6. Install:
• rear wheel
• muffler
chapter 4.
6 - 55
DRIVE CHAIN AND SPROCKETS CHAS
DRIVE CHAIN AND SPROCKETS
1 Rear wheel drive hub A Drive sprocket cover
2 Driven sprocket
3 Lock washer
4 Collar
5 Oil seal
6 Bearing
7 Master link
8 Drive chain
9 Drive sprocket
0 Circlip
6 - 56
EAS00706
REMOVING THE DRIVE CHAIN AND
SPROCKETS
WARNING
_

NOTE:
_

2. Remove:
• rear wheel
• rear wheel drive hub assembly
3. Remove:
1 • drive sprocket cover bolts
• drive sprocket cover 1
4. Remove:
• master link clip 1
• master link plate 2
• master link body 3
5. Remove:
• drive chain
6. Remove:
• circlip 1
1 • drive sprocket 2
6 - 57
7. Straighten the lock washer tabs.
8. Remove:
1
• driven sprocket nuts
2 • driven sprocket bolts
• lock washers 1
• driven sprocket 2
EAS00710
CHECKING THE DRIVE CHAIN
1. Measure:
• ten-link section a of the drive chain
Out of specification → Replace the drive
chain.
Ten-link drive chain section limit

(maximum)
121.4 mm
NOTE:
_
• While measuring the ten-link section, push

down on the drive chain to increase its ten-
sion.
• Measure the length between the inside edge
of the drive chain roller 1 and A as shown.
• Perform this measurement at two or three
different places.
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
3. Clean:
• drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 58
4. Check:
• drive chain rollers 1
Damage/wear → Replace the drive chain.
• drive chain side plates 2
Cracks/damage/wear → Replace the drive
chain.
5. Lubricate:
• drive chain
6. Check:
• drive sprocket
• driven sprocket
Worn more than 1/4 tooth a → Replace the
drive chain and sprockets as a set.
Bent teeth → Replace the drive chain and
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
EAS00714
INSTALLING THE DRIVE CHAIN AND
1 New SPROCKETS
1. Install:
2 • driven sprocket 2 30 Nm (3.0 m · kg)
T.
R.
• lock washers 1 New

• driven sprocket bolts
1 • driven sprocket nuts
NOTE:
Tighten the bolts in a crisscross pattern.
2. Bend:
• lock washer tab 1
NOTE:
Bend the lock washer tabs along a flat side of
each bolt.
6 - 59
3. Install:
• drive sprocket 1
a • circlip 2
1
NOTE:
Install the drive sprocket with the flat side a
towards the engine.
4. Lubricate:
• drive chain
• master link New
5. Install:
• master link body
• master link plate
6. Install:
• master link clip 1
CAUTION:
_
• The closed end of the master link clip

must face in the direction of drive chain
rotation.
• Never install a new drive chain onto worn
drive chain sprockets; this will dramati-
cally shorten the drive chain’s life.
7. Adjust:
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack

25 ~ 35 mm
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
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
6 - 60
– +
ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................ 7-1
CHECKING SWITCH CONTINUITY................................................................7-3
CHECKING THE SWITCHES..........................................................................7-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-7

TYPES OF BULBS .................................................................................... 7-7
CHECKING THE CONDITION OF THE BULBS ....................................... 7-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................7-9
IGNITION SYSTEM ....................................................................................... 7-10

CIRCUIT DIAGRAM ................................................................................ 7-10
TROUBLESHOOTING ............................................................................7-11
ELECTRIC STARTING SYSTEM .................................................................. 7-15

CIRCUIT DIAGRAM ................................................................................ 7-15
STARTER MOTOR........................................................................................ 7-18

REMOVING THE STARTER MOTOR.....................................................7-19
DISASSEMBLING THE STARTER MOTOR...........................................7-19
CHECKING THE STARTER MOTOR .....................................................7-19
ASSEMBLING THE STARTER MOTOR................................................. 7-21
INSTALLING THE STARTER MOTOR ...................................................7-21
CHARGING SYSTEM....................................................................................7-22
CIRCUIT DIAGRAM ................................................................................ 7-22
LIGHTING SYSTEM ......................................................................................7-25

CIRCUIT DIAGRAM ................................................................................ 7-25
CHECKING THE LIGHTING SYSTEM....................................................7-27
SIGNALING SYSTEM ...................................................................................7-29

CIRCUIT DIAGRAM ................................................................................ 7-29
CHECKING THE SIGNALING SYSTEM ................................................. 7-32
– +
ELEC
– +
ELECTRICAL COMPONENTS ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch 7 Ignition coil
2 Positive battery lead 8 Wire harness
3 Negative battery lead
4 Battery
5 Fuse
6 Rear brake light switch
7-1
– +
ELECTRICAL COMPONENTS ELEC
1 Horn
2 Turn signal relay
3 Fuel gauge
4 Starter relay
5 C.D.I. unit
7-2
– +
CHECKING SWITCH CONTINUITY ELEC
EAS00730
“∞” “0” CHECKING SWITCH CONTINUITY

Check each switch for continuity with the
pocket tester. If the continuity reading is incor-
rect, check the wiring connections and if nec-
essary, replace the switch.
“Ω×1”
CAUTION:
_
Never insert the tester probes into the cou-

pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
1 pler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
NOTE:
_
• Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
b and forth between the switch positions a few
times.
Br R
OFF
a The terminal connections for switches (e.g.,
ON
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
Br R 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.
NOTE:
_
“ ” 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 red and brown
when the switch is set to “ON”.
7-3
– +
CHECKING SWITCH CONTINUITY ELEC
7-4
– +
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1 2 3 4
P B Y Y/R G Ch Br/W Dg
OFF HI L Br/W Ch
PUSH LO N P B
R Dg Y/R
Y G
(RED)
P W
Y/W Sb
L/W
7 8
5 6
L/R B Y/R L
Br R OFF OFF
START ON
G/Y R Y/R L/R

L B
0
Br R
OFF R
ON Br
7-5
– +
CHECKING THE SWITCHES ELEC
1 Horn switch
2 Dimmer switch
3 Turn signal switch
5 Rear brake light switch
6 Fuse
7 Start switch
8 Light switch
9 Front brake light switch
0 Main switch
7-6
– +
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 con-
tinuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket
by pushing and turning the bulb counter-
clockwise.
• Bulbs D and E are used for meter and indi-
cator lights and can be removed from their
respective sockets by carefully pulling them
out.
7-7
– +
CHECKING THE CONDITION OF THE
BULBS
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely

hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• Be sure to hold the socket firmly when

removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise 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.
2. Check:
• bulb (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check for continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check for continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
– +
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Check:
• bulb socket (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
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
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
1
OFF R R Br B O EAS00734
ON Br Br R W
Br R W W R R
0 A O O
R 9 Y Y/R W W B
W B W W B
R R Y Y/R Y
B B C
Br B
B
W R R W
CIRCUIT DIAGRAM
2 B
R
IGNITION SYSTEM
R/W R Br
R L/W Br L/W Br Br
R R
4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7
R R 8
L/W
R
Br
3 OFF OFF
L/W
START ON Y/R L/R L/W Y/R
L B B L/B
5 Br
B L/B
Br
7 - 10
G Br/W
Br Br Br
F
Y
R Br L Ch Dg
Br/W
P
Br
Y/W Sb Sb Y/W E
H P L/B Br/W
W W
L/W P P L/W TUV WXYZ[ B Br D
(BLACK) (BLACK)
I J K B G/Y
OFF HI L Br/W Ch Ch Br/W (BLACK) (BLACK)
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
Dg Ch Ch Dg (RED) (RED)
B G G B G/Y G/Y
B
Ch Dg
IGNITION SYSTEM
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
1 Main switch Ch Dg L G/Y
G
2 Fuse N N
3 Battery Q MM L
G G O O
B B
ELEC
0 A.C. magneto B B
P W W P B L
Ch Ch
P Y/W Sb Sb Y/W Y
A C.D.I. unit B Dg Dg
L/W L/W Ch Dg
–
B Ignition coil B B L B
B
G/Y
C Spark plug Dg Ch
+
– +
IGNITION SYSTEM ELEC
EAS00736 EAS00739
TROUBLESHOOTING
2. Battery
The ignition system fails to operate (no • Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. fuse Minimum open-circuit voltage
2. battery 12.8 V or more at 20°C
3. spark plug
• Is the battery OK?
4. ignition spark gap
5. spark plug cap resistance YES NO
6. ignition coil resistance
7. pickup coil resistance
8. main switch • Clean the battery
9. wiring connections (of the entire ignition terminals.
system) • Recharge or
replace the battery.
NOTE:
_
• Before troubleshooting, remove the following EAS00740
part(s): 3. Spark plug

1. front cowling (right)
• Check the condition of the spark plug.
2. rear cowling
• Check the spark plug type.
• Troubleshoot with the following special
• Measure the spark plug gap.
tool(s).
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Ignition checker Standard spark plug
90890-06754 C6HSA (LOCAL MADE)
Pocket tester Spark plug gap
90890-03112 0.6 ~ 0.7 mm
EAS00738 • Is the spark plug in good condition, is it of
1. Fuse the correct type, and is its gap within spec-
ification?
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chap- YES NO
ter 3.
• Is the fuse OK?
Re-gap or replace
YES NO the spark plug.
Replace the fuse.
7 - 11
– +
EAS00742 EAS00744
4. Ignition spark gap 5. Spark plug cap resistance

• Disconnect the spark plug cap from the • Remove the spark plug cap from the spark
spark plug. plug lead.
• Connect the ignition checker 1 as shown. • Connect the pocket tester (“Ω × 1k” range)
2 Spark plug cap to the spark plug cap as shown.
• Set the main switch to “ON”. • Measure the spark plug cap resistance.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
• Measure the ignition spark gap a. Ω×1k
Spark plug cap resistance

7.5 ~ 12.5 kΩ at 20°C
• Is the spark plug cap OK?

Minimum ignition spark gap YES NO
6 mm
• Is there a spark and is the spark gap within

Replace the spark
specification?
plug cap.
NO YES
The ignition system

is OK.
7 - 12
– +
EAS00746 EAS00748
6. Ignition coil resistance 7. Pickup coil resistance

• Disconnect the ignition coil connector from • Disconnect the pickup coil coupler from
the ignition coil terminal. the wire harness.
• Connect the pocket tester (Ω × 1) to the • Connect the pocket tester (Ω × 100) to the
ignition coil as shown. pickup coil terminal as shown.
Positive tester probe → terminal 1 Positive tester probe → white 1
Negative tester probe → Negative tester probe → red 2
ignition coil base 2
2
B Y W R W
1 2 1
• Measure the pickup coil resistance.

• Measure the primary coil resistance.
Pickup coil resistance
Primary coil resistance 248 ~ 372 Ω at 20°C
0.32 ~ 0.48 Ω at 20°C (between white and red)
• Connect the pocket tester (Ω × 1k) to the • Is the pickup coil OK?
ignition coil as shown.
YES NO
Negative tester probe → terminal 1
Positive tester probe → spark plug lead 2
Replace the stator
coil/pickup coil
assembly.
EAS00749
8. Main switch
1 • Check the main switch for continuity.

2 Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
• Measure the secondary coil resistance. YES NO

Secondary coil resistance
5.68 ~ 8.52 kΩ at 20°C Replace the main
• Is the ignition coil OK? switch.
YES NO
Replace the ignition

coil.
7 - 13
– +
EAS00754
9. Wiring
• Check the entire ignition system wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system wiring properly con-
nected and without defects?
YES NO
Replace the C.D.I. Properly connect or

unit. repair the ignition
system wiring.
7 - 14
1
ON Br Br R W
Br R W W R R
0 A O O
R 9 Y Y/R W W B
W B W W B
R R Y Y/R Y
B B C
Br B
B
W R R W
CIRCUIT DIAGRAM
2 B
R
R/W R Br
R L/W Br L/W Br Br
R R
4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7
R R 8
L/W
R
Br
3 OFF OFF
L/W
ELECTRIC STARTING SYSTEM
L B B L/B
5 Br
B L/B
Br
7 - 15
G Br/W
Br Br Br
F
Y
R Br L Ch Dg
Br/W
P
Br
Y/W Sb Sb Y/W E
H P L/B Br/W
W W
(BLACK) (BLACK)
I J K B G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B G/Y G/Y
B
Ch Dg
ELECTRIC STARTING SYSTEM
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
G
1 Main switch N N
2 Fuse G G Q O O MM L
B B
ELEC
B B
3 Battery P W W P B L
Ch Ch
P Y/W Sb Sb Y/W Y
B Dg Dg
L/W L/W Ch Dg
–
4 Starter relay
5 Starter motor B B L B
B
G/Y
Dg Ch
+
7 Start switch
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check:
1. fuse
2. battery Minimum open-circuit voltage
3. starter motor 12.8 V or more at 20°C
4. starter relay
5. main switch
6. start switch YES NO
7. wiring connections
(of the entire starting system)
• Clean the battery
NOTE:
_
terminals.
• Before troubleshooting, remove the following
• Recharge or
part(s):
2. rear cowling EAS00758
3. headlight cover 3. Starter motor

4. engine guard
• Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
tool(s).
lead 3.
Pocket tester
90890-03112
EAS00738
1. Fuse
Refer to “CHECKING THE FUSE” in chap-
ter 3.
• Is the fuse OK? WARNING
_
YES NO • A wire that is used as a jumper lead

must have at least the same capacity or
more as that of the battery lead, other-
Replace the fuse. wise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
7 - 16
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00761 EAS00764
4. Starter relay 6. Start switch

• Remove the starter relay from the starter • Check the start switch for continuity.
relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”.
• Connect the pocket tester (Ω × 1) and bat- • Is the start switch OK?
tery (DC 12 V) to the starter relay coupler
as shown. YES NO
Positive battery terminal → brown 1

Negative battery terminal → blue/white 2 Replace the right
Positive tester probe → red 3 handlebar switch.
Negative tester probe → red/white 4 EAS00766
3 7. Wiring
• Check the entire starting system wiring.
R
R/W R
• Is the starting system wiring properly con-
L/W Br
R/W YES NO
1 2
4
The starting system Properly connect or
• Does the starter relay have continuity
circuit is OK. repair the starting
between red and red/white?
system wiring.
YES NO
Replace the starter

relay.
EAS00749
5. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
YES NO
Replace the main

switch.
7 - 17
– +
STARTER MOTOR ELEC
EASF0061
STARTER MOTOR
1 Starter motor yoke
2 Armature
3 Brush set
4 Starter motor lead
5 Starter motor front cover
7 - 18
– +
STARTER MOTOR ELEC
REMOVING THE STARTER MOTOR
1. Remove:
• footrest assembly
• starter motor guard
chapter 4.
2. Remove:
• starter motor 1
3. Remove:
1 • starter motor lead 1
DISASSEMBLING THE STARTER MOTOR

1. Remove:
1 • starter motor front cover bolts
(with washers)
• starter motor front cover 1
• gasket 2
4
• washer 3
23 • armature 4
EAS00769
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600-grit sandpaper.
7 - 19
– +
STARTER MOTOR ELEC
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit

16.6 mm
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.35 mm
NOTE:
_
The mica of the commutator must be undercut

to ensure proper operation of the commutator.
4. Measure:
• 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 coil
Commutator resistance 1
0.018 ~ 0.022 Ω at 20°C
Insulation resistance 2
Above 1 MΩ at 20°C
b. If any resistance is out of specification,

replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 20
– +
STARTER MOTOR ELEC
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit

3.5 mm
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

3.92 ~ 5.88 N (400 ~ 600 gf)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
• washer
(to armature)
• armature
(in start motor front cover 1)
• gasket New
• starter motor yoke
• starter motor front cover bolts
(with washers)
• O-ring New
NOTE:
Align the mark a on the starter motor yoke
with the mark b on the starter motor front
cover.
INSTALLING THE STARTER MOTOR

For installation, reverse the removal proce-
dure.
7 - 21
1
ON Br Br R W
Br R W W R R
0 A O O
R 9 Y Y/R W W B
W B W W B
R R Y Y/R Y
B B C
Br B
B
W R R W
CIRCUIT DIAGRAM
2 B
R
R/W R Br
CHARGING SYSTEM
R L/W Br L/W Br Br
R R
4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7
R R 8
L/W
R
Br
3 OFF OFF
L/W
L B B L/B
5 Br
B L/B
Br
7 - 22
G Br/W
Br Br Br
F
Y
R Br L Ch Dg
Br/W
P
Br
Y/W Sb Sb Y/W E
H P L/B Br/W
W W
(BLACK) (BLACK)
I J K B G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B G/Y G/Y
B
Ch Dg
CHARGING SYSTEM
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
G
N N
G G Q O O MM L
B B
ELEC
2 Fuse B B
P W W P B L
Ch Ch
P Y/W Sb Sb Y/W Y
3 Battery B Dg Dg
L/W L/W Ch Dg
–
9 Rectifier/regulator B B L B
B
G/Y
0 A.C. magneto Dg Ch
+
– +
CHARGING SYSTEM ELEC
EAS00774 EAS00739
TROUBLESHOOTING
2. Battery
The battery cannot be charged. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check:
1. fuse
2. battery Minimum open-circuit voltage
3. charging voltage 12.8 V or more at 20°C
4. charging coil resistance
(of the entire charging system) YES NO
NOTE:
_

part(s):
terminals.
1. rear cowlings
• Recharge or
tool(s).
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
1. Fuse
ter 3.
• Is the fuse OK?
YES NO
Replace the fuse.
7 - 23
– +
CHARGING SYSTEM ELEC
EAS00775 EAS00776
3. Charging voltage 4. Charging coil resistance

• Connect the engine tachometer to the • Disconnect the stator coil coupler from the
spark plug lead. wire harness.
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (Ω × 1) to the
battery as shown. charging coil terminals as shown.
Positive tester probe → Positive tester probe → white 1
positive battery terminal 1 Negative tester probe → black 2
Negative tester probe →
negative battery terminal 2
B Y W R W
2 1
• Measure the charging coil resistances.
Charging coil resistance
• Start the engine and let it run at approxi- 0.32 ~ 0.48 Ω at 20°C (W – B)
mately 5,000 r/min.
• Measure the charging voltage. • Is the charging coil OK?
Charging voltage YES NO
14 V at 5,000 r/min
NOTE:
_
Replace the stator
Make sure the battery is fully charged. coil/pickup coil
assembly.
EAS00779
• Is the charging voltage within specifica-
tion? 5. Wiring
• Check the wiring connections of the entire
NO YES
charging system.
The charging circuit • Is the charging system wiring properly
is OK. connected and without defects?
YES NO
Replace the rectifier/ Properly connect or

regulator. repair the charging
system wiring.
7 - 24
1 8 Light switch
OFF R R Br B O 9 Rectifier/regulator EAS00780
ON Br Br R W
0 A.C. magneto
Br R W W R R
J Dimmer switch
0 A O O
R 9 Y Y/R W W
L Tail/brakeBlight
W B W W B
R R Y Y/R Y O Headlight C
B B
Br B
B
T Meter light
W R R W
CIRCUIT DIAGRAM
U High beam indicator light

2 B
R
LIGHTING SYSTEM
R/W R Br
R L/W Br L/W Br Br
R R
4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7
R R 8
L/W
R
Br
3 OFF OFF
L/W
L B B L/B
5 Br
B L/B
Br
7 - 25
G Br/W
Br Br Br
F
Y
R Br L Ch Dg
Br/W
P
Br
Y/W Sb Sb Y/W E
H P L/B Br/W
W W
(BLACK) (BLACK)
I J K B G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B G/Y G/Y
B
Ch Dg
LIGHTING SYSTEM
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
G
N N
G G Q O O MM L
B B
ELEC
B B
P W W P B L
Ch Ch
P Y/W Sb Sb Y/W Y
B Dg Dg
L/W L/W Ch Dg
–
B B L B
B
G/Y
Dg Ch
+
– +
LIGHTING SYSTEM ELEC
EAS00781 EAS00776
TROUBLESHOOTING
2. Lighting coil resistance
Any of the following fail to light: head- • Disconnect the stator coil coupler from the
light, high beam indicator light, taillight, wire harness.
or meter light. • Connect the pocket tester (Ω × 1) to the
lighting coil terminals as shown.
Check:
1. light switch Positive tester probe → yellow 1
2. lighting coil resistance Negative tester probe → black 2
(of the entire lighting system)
NOTE:
_

part(s):
1. rear cowlings
2. headlight assembly B Y W R W
tool(s). 2 1
• Measure the lighting coil resistances.
Pocket tester Lighting coil resistance

90890-03112 0.24 ~ 0.36 Ω at 20°C (Y – B)
EAS00783 • Is the lighting coil OK?

1. Light switch YES NO
• Check the light switch for continuity.
Replace the stator
• Is the light switch OK?
coil/pickup coil
YES NO assembly.
EAS00787
The light switch is 3. Wiring

faulty. Replace the • Check the entire lighting system wiring.
right handlebar Refer to “CIRCUIT DIAGRAM”.
switch. • Is the lighting system wiring properly con-
YES NO
Check the condition Properly connect or

of each of the lighting repair the lighting
system circuits. system wiring.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.
7 - 26
– +
EAS00788
CHECKING THE LIGHTING SYSTEM 3. Voltage
1. The headlight and the high beam indicator • Connect the pocket tester (AC 20 V) to the
light fail to come on. headlight and high beam indicator light
EAS00784
connectors as shown.
1. Dimmer switch
È When the dimmer switch is set to “ ”.
• Check the dimmer switch for continuity. É When the dimmer switch is set to “ ”.
• Is the dimmer switch OK?
YES NO
The dimmer switch is

faulty. Replace the
left handlebar switch.
2. Headlight bulb and socket Headlight

• Check the headlight bulb and socket for Positive tester probe →
continuity. green 1 or yellow 2
Refer to “CHECKING THE BULBS AND Negative tester probe → black 3
BULB SOCKETS”.
• Are the headlight bulb and socket OK?
YES NO
Replace the head-

light bulb, socket or
both.
High beam indicator light

Positive tester probe → yellow 4
Negative tester probe → black 5
• Set the main switch to “ON”.
• Start the engine.
• Set the dimmer switch to “ ” or “ ”.
• Measure the voltage (AC 12 V) of green 1
(yellow 2) on the headlight connector
(wire harness side) and yellow 4 on the
meter assembly connector (wire harness
side).
• Is the voltage within specification?
YES NO
This circuit is OK. Replace the rectifier/

regulator.
7 - 27
– +
EAS00789 EAS00790
2. The meter light fails to come on. 3. The tail/brake light fails to come on.
1. Meter light bulb and socket 1. Tail/brake light bulb and socket
• Check the meter light bulb and socket for • Check the tail/brake light bulb and socket
continuity. for continuity.
Refer to “CHECKING THE BULBS AND Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. BULB SOCKETS”.
• Are the meter light bulb and socket OK? • Are the tail/brake light bulb and socket
OK?
YES NO
YES NO
Replace the meter

light bulb, socket or Replace the tail/
both. brake light bulb,
socket or both.
2. Voltage
• Connect the pocket tester (AC 20 V) to the 2. Voltage
meter light coupler (wire harness side) as • Connect the pocket tester (AC 20 V) to the
shown. tail/brake light coupler (wire harness side)
Positive tester probe → blue 1 as shown.
Negative tester probe → black 2 Positive tester probe → blue 1
1
Br L L Br
1 2
Ch Dg Dg Ch
B L L B
G B B G Y G/Y
Ch Dg Dg Ch
2

• Start the engine. • Set the main switch to “ON”.
• Measure the voltage (AC 12 V) of brown • Start the engine.
lead terminal 1 on the meter light coupler • Measure the voltage (AC 12 V) of blue
(wire harness side). lead terminal 1 on the tail/brake light cou-
• Is the voltage within specification? pler (wire harness side).
YES NO
YES NO
This circuit is OK. Replace the rectifier/

regulator. This circuit is OK. Replace the rectifier/
regulator.
7 - 28
1
ON Br Br R W
Br R W W R R
0 A O O
R 9 Y Y/R W W B
W B W W B
R R Y Y/R Y
B B C
Br B
B
W R R W
CIRCUIT DIAGRAM
2 B
R
R/W R Br
SIGNALING SYSTEM
R L/W Br L/W Br Br
R R
4
Y/R
R/W R/W
R R/W R/W L/W L/W
6
L/W 7
R R 8
L/W
R
Br
3 OFF OFF
L/W
L B B L/B
5 Br
B L/B
Br
7 - 29
G Br/W
Br Br Br
F
Y
R Br L Ch Dg
Br/W
P
Br
Y/W Sb Sb Y/W E
H P L/B Br/W
W W
(BLACK) (BLACK)
I J K B G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B G/Y G/Y
B
Ch Dg
SIGNALING SYSTEM
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
G
N N
G G Q O O MM L
B B
ELEC
B B
P W W P B L
Ch Ch
P Y/W Sb Sb Y/W Y
B Dg Dg
L/W L/W Ch Dg
–
B B L B
B
G/Y
Dg Ch
+
– +
SIGNALING SYSTEM ELEC
1 Main switch
2 Fuse
3 Battery
D Rear brake light switch
E Front brake light switch
F Turn signal relay
G Horn
I Horn switch
K Turn signal switch
L Tail/brake light
M Rear turn signal light
N Front turn signal light
P Gear position sensor
Q Fuel sender
S Fuel gauge
V Turn signal indicator light
W Neutral indicator light
X 1st gear position indicator light
Y 2nd gear position indicator light
Z 3rd gear position indicator light
[ 4th gear position indicator light
7 - 30
– +
EAS00794 EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to light: turn • Check the condition of the battery.
signal light, brake light or an indicator Refer to “CHECKING AND CHARGING
light. THE BATTERY” in chapter 3.
• The horn fails to sound.
Minimum open-circuit voltage
Check: 12.8 V or more at 20°C
1. fuse
2. battery
3. main switch YES NO
(of the entire signaling system)
NOTE:
_
terminals.
• Recharge or
part(s):
2. front panel EAS00783
3. rear cowlings 3. Main switch

4. headlight assembly
• Check the main switch for continuity.
tool(s).
YES NO
Pocket tester
90890-03112
Replace the main
EAS00738
switch.
1. Fuse EAS00795
• Check the fuse for continuity. 4. Wiring

ter 3. • Check the entire signaling system wiring.
• Is the fuse OK? Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system wiring properly
YES NO connected and without defects?
YES NO
Replace the fuse.
Check the condition Properly connect or

of each of the signal- repair the signaling
ing system circuits. system wiring.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.
7 - 31
– +
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn
1. The horn fails to sound. • Disconnect the pink connector at the horn
1. Horn switch terminal.
• Connect a jumper lead 1 to the horn ter-
• Check the horn switch for continuity.
minal and ground the jumper lead.
• Is the horn switch OK?
• Does the horn sound?
YES NO
Br
Replace the left han-

dlebar switch. 1
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
NO YES
Positive tester probe → brown 1
Negative tester probe → ground
The horn is OK.
Br P
4. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the pink terminal as
1
shown.
Positive tester probe → pink 1

Br P
• Measure the voltage (DC 12 V) of brown
lead terminal at the horn terminal.
1
YES NO
The wiring circuit

from the main switch • Set the main switch to “ON”.
to the horn connector • Measure the voltage (DC 12 V) of pink
is faulty and must be lead terminal 1 at the horn terminal.
repaired. • Is the voltage within specification?
YES NO
Repair or replace the Replace the horn.

horn.
7 - 32
– +
EAS00797
2. The tail/brake light fails to come on. 3. Voltage
1. Tail/brake light bulb and socket • Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
• Check the tail/brake light bulb and socket
as shown.
for continuity.
Refer to “CHECKING THE BULBS AND Positive tester probe → green/yellow 1
BULB SOCKETS”. Negative tester probe → black 2
• Are the tail/brake light bulb and socket
OK?
1 2
YES NO
B L L B
Y G/Y
Ch Dg Dg Ch
Replace the tail/
brake light bulb,
socket or both.
2. Brake light switches • Set the main switch to “ON”.

• Check the brake light switches for continu- • Pull in the brake lever or push down on the
ity. brake pedal.
Refer to “CHECKING THE SWITCHES”. • Measure the voltage (DC 12 V) of green/
• Is the brake light switch OK? yellow lead terminal 1 on the tail/brake
light coupler (wire harness side).
YES NO • Is the voltage within specification?
YES NO
Replace the brake
light switch.
This circuit is OK. The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
7 - 33
– +
EAS00799
3. The turn signal light, turn signal indicator 3. Voltage
light or both fail to blink. • Connect the pocket tester (DC 20 V) to the
1. Turn signal indicator light bulb and socket turn signal relay coupler as shown.
• Check the turn signal light bulb and socket Positive tester probe → brown 1
for continuity. Negative tester probe → ground
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
OK? Br/W
1 Br
YES NO
Replace the turn sig-

nal light bulb, socket
or both. • Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown
2. Turn signal switch lead terminal 1 at the turn signal relay
• Check the turn signal switch for continuity. coupler.
Refer to “CHECKING THE SWITCHES”. • Is the voltage within specification?
• Is the turn signal switch OK? NO
YES
YES NO
The wiring circuit
Replace the left han- from the main switch
dlebar switch. to the turn signal
relay coupler is faulty
and must be
repaired.
7 - 34
– +
4. Voltage 5. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler as shown. turn signal light coupler (wire harness
Positive tester probe → brown/white 1 side) as shown.
Negative tester probe → ground Turn signal light
È Rear
É Front
Left turn signal light
1 Br/W Positive tester probe → chocolate 1
Br Negative tester probe → ground
Right turn signal light
Positive tester probe → dark green 2
Ê Turn signal indicator light
• Set the main switch to “ON”. Positive tester probe → chocolate 3
• Measure the voltage (DC 12 V) on brown/ Negative tester probe → ground
white lead terminal 1 at the turn signal Positive tester probe → dark green 4
relay coupler. Negative tester probe → ground
• Is the voltage within specification? È
YES NO
B L L B
The turn signal relay Y G/Y
Ch Dg Dg Ch
is faulty and must be
replaced. 2 1
B B
Ch Ch
Dg Dg
1
2
Ê
4 3
Br L L Br
Ch Dg Dg Ch
G B B G
Sb Y/W Y/W Sb
W W
P L/W L/W P
7 - 35
– +
EAS00801
• Set the main switch to “ON”. 4. The gear position indicator lights fail to
• Set the turn signal switch to “ ” or “ ”. come on.
• Measure the voltage (DC 12 V) of the
chocolate 1 or dark green lead terminal 1. Gear position indicator light bulb and
2 at the turn signal light coupler (wire har- socket
ness side) and chocolate 3 or dark green • Check the gear position indicator light bulb
4 at the turn signal indicator light coupler and socket for continuity.
(wire harness side). Refer to “CHECKING THE BULBS AND
• Is the voltage within specification? BULB SOCKETS”.
• Are the gear position indicator light bulb
YES NO
and socket OK?
This circuit is OK. The wiring circuit YES NO

from the turn signal
switch to the turn sig- Replace the gear
nal light coupler is position indicator
faulty and must be light bulb, socket or
repaired. both.
2. Gear position sensor

• Check the gear position sensor for conti-
nuity.
• Is the gear position sensor OK?
YES NO
Replace the gear

position sensor.
7 - 36
– +
EAS00804
3. Voltage 5. The fuel level gauge fails to operate.
• Connect the pocket tester (DC 20 V) to the 1. Fuel sender
meter assembly coupler (wire harness
• Remove the fuel sender from the fuel tank.
side) as shown.
• Connect the pocket tester to the fuel
Neutral indicator light sender coupler (fuel sender side) as
Positive tester probe → sky blue 1 shown.
Positive tester probe → green 1
1st gear position indicator light
Positive tester probe → white 2
Negative tester probe → ground 2 1
2nd gear position indicator light
Positive tester probe → pink 3 B G

3rd gear position indicator light
Positive tester probe → yellow/white 4 È
4th gear position indicator light
É
Positive tester probe → blue/white 5
Negative tester probe → ground • Measure the fuel sender resistances.
Fuel sender resistance
(up position È)
Br L L Br
(Ω × 1)
Ch Dg Dg Ch 4 ~ 10 Ω at 20°C
G B B G Fuel sender resistance
1 (down position É)
Sb Y/W Y/W Sb (Ω × 10)
W W 90 ~ 100 Ω at 20°C
P L/W L/W P
2
45 3 • Is the fuel sender OK?
• Set the main switch to “ON”. YES NO
• Shift the transmission into each gear.
• Measure the voltage (DC 12 V) of the sky
blue 1, white 2, pink 3, yellow/white 4, Replace the fuel
or blue/yellow 5 lead terminal at the sender.
meter assembly coupler (wire harness
side).
YES NO
This circuit is OK. The wiring circuit

from the main switch
to the meter assem-
bly coupler is faulty
and must be
repaired.
7 - 37
– +
2. Voltage 3. Fuel level gauge
• Connect the pocket tester (DC 20 V) to the • Set the main switch to “ON”.
meter assembly coupler (wire harness • Move the float up 1 or down 2.
side) as shown. • Check that the fuel level gauge needle
Positive tester probe → brown 1 moves to “F” or “E”.
Negative tester probe → ground NOTE:
_
Before reading the fuel level gauge, leave the

float in one position (either up or down) for at
least three minutes.
Br L L Br
Ch Dg Dg Ch
G B B G
1
• Measure the voltage (DC 12 V) of brown
lead terminal 1 on the meter assembly
2
coupler (wire harness side).
• Is the voltage within specification? • Does the fuel level gauge needle move
YES NO appropriately?
YES NO
Check the wiring
connections of the
Replace the fuel level
entire signaling sys-
gauge.
tem
4. Wiring
Check the entire signaling system’s wiring.
7 - 38
TRBL
SHTG
CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
ELECTRICAL SYSTEM.............................................................................8-1
COMPRESSION SYSTEM........................................................................ 8-2
INTAKE AND EXHAUST SYSTEM ........................................................... 8-3
TRBL
SHTG
TRBL
TROUBLESHOOTING SHTG
EASF0062
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM
8-1
TRBL
COMPRESSION SYSTEM
8-2
TRBL
INTAKE AND EXHAUST SYSTEM
8-3
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
T110SE WIRING DIAGRAM
1 Main switch
2 Fuse
3 Battery
4 Starter relay
5 Starter motor
1 6 Right handlebar switch
7 Start switch
OFF R R Br B O
ON Br Br R W
8 Light switch
0 A.C. magneto
W W R R
Br R
R 9 Y Y/R
0 W W
A O O
B
W B W W B A C.D.I. unit
R R Y Y/R Y
C B Ignition coil
C Spark plug
B B
Br B
B
W R R W D Rear brake light switch
2 E Front brake light switch
F Turn signal relay
B
R
G Horn
R/W R Br
H Left handlebar switch
R L/W Br L/W Br Br I Horn switch
R R
J Dimmer switch
4 K Turn signal switch
Y/R
R R/W R/W
R/W R/W
6 L Tail/brake light
M Rear turn signal light
L/W L/W
R R
L/W 7 8 N Front turn signal light
L/W
R
3 Br
L/W
OFF OFF O Headlight
START ON Y/R L/R
L B
L/W Y/R
B L/B P Gear position sensor
5 Br
Q Fuel sender
B L/B R Meter assembly
S Fuel gauge
T Meter light
Br
U High beam indicator light
V Turn signal indicator light
G Br/W W Neutral indicator light
Br
F Br Br X 1st gear position indicator light
R
Y Y 2nd gear position indicator light
Br L Ch Dg
Z 3rd gear position indicator light
P
Br
Br/W
E [ 4th gear position indicator light
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[ D
L/W P
(BLACK)
P L/W
(BLACK)
I J K B
B
Br
G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B G/Y G/Y
B
Ch Dg
Y G
G B Sb W P Y/W L/W
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
G
N N
G G Q O O MM L
B B
B B
P W W P B L
Ch Ch
B
P Y/W Sb Sb Y/W Dg Dg
Y
Ch Dg
L/W L/W
B B L B
B
G/Y
Dg Ch
COLOR CODE
B............ Black Sb.......... Sky blue L/B......... Blue/Black
Br........... Brown P............ Pink L/R ........ Blue/Red
Ch.......... Chocolate R ........... Red L/W........ Blue/White
Dg.......... Dark green W........... White R/W ....... Red/White
G ........... Green Y............ Yellow Y/R ........ Yellow/Red
L ............ Blue Br/W ...... Brown/White Y/W ....... Yellow/White
O ........... Orange G/Y........ Green/Yellow

Crpton 110

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T110SE

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

HOW TO USE THIS MANUAL

G H I Symbols G to L in the exploded diagrams

ELECTRICAL SYSTEM ELEC 7

IMPORTANT INFORMATION ......................................................................... 1-2

CHECKING THE CONNECTIONS ..................................................................1-4

SPECIAL TOOLS ............................................................................................ 1-5

ENGINE SERIAL NUMBER

Do not spin the bearing with compressed

CHECKING THE CONNECTIONS

If the pin 1 on the terminal is flattened, bend it

Make sure all connections are tight.

• If there is no continuity, clean the terminals.

This tool is used to install the oil seal.

This tool is used to install the oil seal.

This tool is used for removing the rotor.

GENERAL SPECIFICATIONS ........................................................................ 2-1

MAINTENANCE SPECIFICATIONS ............................................................... 2-4

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-15

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-16

CABLE ROUTING ......................................................................................... 2-19

Winding direction IN/EX Clockwise ----

OIL RING PISTON CYLINDER HEAD CAMSHAFT

Valve adjusting screw locknut (intake Nut M5 2 7 0.7

Timing chain tensioner cap bolt Bolt M6 1 8 0.8

Shift fork guide bar retainer Bolt M6 2 10 1.0 LT

Pickup coil Bolt M6 2 10 1.0 LT

Stator coil Bolt M6 3 10 1.0 LT

Item Standard Limit

Master cylinder inside diameter 11.1 mm ----

Lower brake caliper retaining bolt M8 12 1.2 LT

Bleed screw M8 6 0.6

Upper ring nut M25 75 7.5 See NOTE

Brake camshaft and brake camshaft lever M6 7 0.7

Item Standard Limit

GENERAL TIGHTENING TORQUE

Lubrication point Lubricant

Cylinder head tightening nut and stud bolt thread E

Rocker arm inner surfaces M

Rocker arm shaft E

Valve stem (IN, EX) E

Valve stem guide (IN, EX) E

Piston outside and ring groove E

Cylinder inner surface E

Starter clutch gear inner surface M

Starter idle gear inner surface E

Kickstarter ratchet gear E

Primary driven gear inner surface E

Clutch push rod E

Clutch pressure plate E

Clutch shoe housing inner surface E

Clutch shoe housing boss E

Oil pump assembly E

Shift guide inner surface E

Shift fork guide bar E

Shift shaft thrust surface E

Shift lever inner surface E