Yamaha XV1600 A RoadStar 98 03 Service Manual ENG XV16

User Manual: XV16

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XV16AL/XV16ALC
XV16ATL/XV16ATLC
SERVICE MANUAL
LIT-11616-12-56

4WM-28197-E0

EAS00001

XV16AL/XV16ALC
XV16ATL/XV16ATLC
SERVICE MANUAL
 1998 by Yamaha Motor Corporation, U.S.A.
First Edition, October 1998
All rights reserved. Any reproduction or unauthorized use without the written permission of
Yamaha Motor Corporation, U.S.A. is expressly
prohibited.
Printed in U.S.A.
P/N LIT-11616-12-56

EAS00003

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and
repairs on Yamaha vehicles should have a basic understanding of mechanics and the 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.
This model has been designed and manufactured to perform within certain specifications in
regard to performance and emissions. Proper service with the correct tools is necessary to
ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes
that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives.
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 dealers and will appear in future editions of this manual where applicable.
This Service Manual contains information regarding periodic maintenance to the emission
control system. Please read this material carefully.
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

CAUTION:
NOTE:

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.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner
of each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each
page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub section title(s) appears.
3 Sub section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start
of each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described
sequentially.

********

GEN
INFO

SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 8 indicate the subject of
each chapter.

SPEC

CHK
ADJ

1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Carburetor
7 Electrical system
8 Troubleshooting

CHAS

ENG

CARB

ELEC

–

TRBL
SHTG

Symbols 9 to F indicate the following.

9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data

Symbols G to L in the exploded diagrams
indicate the types of lubricants and lubrication points.

E
J

K
B

L
M

Symbols M to N in the exploded diagrams
indicate the following.

G Engine oil
H Gear oil
I Molybdenum disulfide oil
J Wheel bearing grease
K Lithium soap base grease
L Molybdenum disulfide grease

New

M Apply locking agent (LOCTITE).
N Replace the part.

********

TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
CARBURETION

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

CARB

–

ELECTRICAL SYSTEM
TROUBLESHOOTING

ELEC

TRBL
SHTG

GEN
INFO
CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .................................................. 1-1
MODEL CODE ....................................................................................... 1-1
FEATURES .................................................................................................... 1-2
IMPORTANT INFORMATION ...................................................................... 1-6
PREPARATION FOR REMOVAL AND DISASSEMBLY ....................... 1-6
REPLACEMENT PARTS ........................................................................ 1-6
GASKETS, OIL SEALS AND O-RINGS ................................................ 1-6
LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-7
BEARINGS AND OIL SEALS ................................................................ 1-7
CIRCLIPS ............................................................................................... 1-7
CHECKING THE CONNECTIONS ................................................................. 1-8
SPECIAL TOOLS ........................................................................................... 1-9

MOTORCYCLE IDENTIFICATION

GEN
INFO

EAS00014

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017

VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering
head pipe.

EAS00018

MODEL CODE
The model code label 1 is affixed to the
frame. This information will be needed to
order spare parts.

1-1

FEATURES

GEN
INFO

EAS00019

FEATURES
Twin spark plugs
For this model, two spark plugs are incorporated in each cylinder.
By using two spark plugs, the combustion
time in the combustion chamber is shortened in an attempt to improve torque.

Speed sensor
The speed sensor is installed to the crankcase and it detects the number of passing
gears while the vehicle is running in 5th
gear and sends the information out as an
electrical signal to the ignitor unit.

Self-diagnosis device
This model is equipped with a self-diagnosis device that has four functions.
The engine trouble indicator light will come
on or flash if trouble occurs in an engine
monitoring circuit.
Circuit

Indicator lights

Number of
flashes

Throttle
position
sensor

Engine trouble indicator light 1

Speed
sensor

Engine trouble indicator light 1

Solenoid Engine trouble indicator light 1

Fuel level Fuel level indicator light 8
meter
2
1-2

Refer to “SELF-DIAGNOSIS” in chapter 7.

FEATURES

GEN
INFO

Auto decompression mechanism
The auto decompression mechanism occurs when the engine is started. When the engine is
started, the decompression cam and pin raise the exhaust valve lifters, push the push rods,
move the rocker arms, and lower the exhaust valves which compress the cylinder. When the
cylinder is compressed, pressure is released immediately, resulting in smoother engine starting capabilities and smoother crankshaft revolutions.

1 Decompression solenoid
2 Decompression solenoid rod
3 Decompression connector
4 Decompression lever
5 Decompression push rod
6 Decompression cam
7 Pin
8 Spring
9 Camshaft

1-3

FEATURES

GEN
INFO

Operation
1. When the starter switch is pushed, electricity is run to the decompression solenoid 1 causing it to push out the
decompression solenoid rod 2.
2. When the decompression solenoid rod is
pushed out, the decompression connector 3 moves the decompression levers
4 in the direction indicated by the
arrows, and then the levers push the
decompression rods 5 toward the camshaft side.

3. The decompression cam 6 is pushed in
the direction indicated by the arrow, and
then the pin 7 raises the projection of
the decompression cam.

4. When the camshaft is rotated by the selftiming motor, the exhaust valve lifters 8
are lifted by the pin just before top dead
center (TDC) and the exhaust valve push
rod 9 and valve rocker arms are operated. Thus, opening the exhaust valve
becomes easy.
5. When the engine starts and reaches a
specific engine speed the decompression solenoid is turned off and the
decompression system stops operating.

1-4

FEATURES

GEN
INFO

Hydraulic valve lifters
Since the hydraulic valve-lifting mechanism maintains a valve clearance of zero, periodic
valve clearance adjustments are unnecessary.
The advantages of this system as compared to conventional techniques include the following: mechanical noise is reduced, the camshaft action on the valves remains unaffected by
engine speed or temperature, and the valve timing is kept stable.

1 Plunger
2 Oil reservoir
3 Check valve spring
4 Check valve
5 Spring retainer
6 High-pressure chamber
7 Plunger spring
8 Valve lifter body
9 Oil supply inlet
0 Push rod cup
A Plunger retaining clip
B Valve push rod

The hydraulic valve-lifting system functions as follows:
1. As the camshaft rotates, the valve lifter is pushed up by the passing cam lobe.
2. Since the check valve 4 prevents the engine oil contained inside the high-pressure chamber from escaping, the plunger 1 moves up along with the valve lifter body 8 and pushes
up the push rod, causing the valve to be lifted.
3. As the camshaft continues to rotate, the valve lifter moves back down to its original position, where it remains while the cam heel passes.
When a positive valve clearance is caused by either heat expansion of the cylinder head or
engine oil leaking from the valve lifter during stage 2, the plunger, which no longer receives
pressure from the push rod, is pushed up by the plunger spring 7. As a result, the valve
clearance is zeroed and engine oil is allowed to return to the high-pressure chamber from the
reservoir 2 through the check valve 4.
When, on the contrary, a negative valve clearance occurs (this is the case when the cam heel
is passing the valve lifter, but the rocker arm, pushed by the push rod, is lifting the valve), the
plunger 1 continues to receive pressure from the valve push rod. As engine oil contained
inside the high-pressure chamber leaks from the gaps between the valve lifter body 8 and
the plunger 1 as well as between the valve lifter body 8 and the check valve 4, the
plunger 1 moves down and the valve clearance is zeroed.

1-5

IMPORTANT INFORMATION

GEN
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 “SPECIAL TOOLS”.
3. When disassembling, always keep
mated parts together. This includes
gears, cylinders, 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
disassembly. 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 recommended 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
surfaces, 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.
1-6

IMPORTANT INFORMATION

GEN
INFO

EAS00023

LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates 1 and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock washer tabs and the cotter
pin ends along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, lubricate the oil seal lips with a light coat of
lithium soap base grease. Oil bearings
liberally when installing, if appropriate.
1 Oil seal

CAUTION:
ACHTUNG:
Do not spin bearings 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

1-7

CHECKING THE CONNECTIONS

GEN
INFO

EAS00026

CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors
for stains, rust, moisture, etc.
1.
•
•
•

Disconnect:
lead
coupler
connector

2.
•
•
•

Check:
lead
coupler
connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several 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
YU-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.
1-8

SPECIAL TOOLS

GEN
INFO

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques. Special tools, part numbers, or both may differ
depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
YM-01080-A

Tool name/Function
Flywheel puller

This tool is used to remove the generator
rotor.
T-handle
YM-01326
Damper rod
holder
YM-1300-1

T-handle
Damper rod holder
These tools are used to hold the cartridge
cylinder when loosening or tightening the
cartridge cylinder bolt.
Fuel level gauge

YM-01312-A
This tool is used to measure the fuel level
in the float chamber.
Timing light
YM-33277-A
This tool is used to check the ignition timing.
Belt tension gauge
YM-03170
This tool is used to measure the drive belt
slack.
Fork seal
driver weight
YM-33963
Adapter
YM-8020

Fork seal driver weight
Adapter
These tools are used to install the front
fork’s oil seal and dust seal.
Dynamic spark tester

YM-34487
This tool is used to check the ignition system components.
Valve spring compressor
YM-04019
This tool is used to remove or install the
valve assemblies.
1-9

Illustration

SPECIAL TOOLS
Tool No.

Tool name/Function

GEN
INFO

Illustration

Valve guide remover (6 mm)
YM-4064-A
This tool is used to remove or install the
valve guides.
Valve guide installer
YM-4065-A
This tool is used to install the valve
guides.
Valve guide reamer
YM-4066
This tool is used to rebore the new valve
guides.
Universal clutch holder
YM-91042

YS-01880

This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
Sheave holder
This tool is used to hold the generator
rotor when removing or installing the generator rotor bolt, generator shaft bolt or
pickup coil rotor bolt.
Piston pin puller

YU-01304
This tool is used to remove the piston
pins.
Micrometer (75 ~ 100 mm)
YU-03009
This tool is used to measure the piston
skirt diameter.
Cylinder bore gauge (50 ~ 100 mm)
YU-03017
This tool is used to measure the cylinder
bore.
Pocket tester
YU-03112
This tool is used to check the electrical
system.

1 - 10

SPECIAL TOOLS
Tool No.

Compression
gauge
YU-33223
Compression
gauge adapter
YU-33223-3

Tool name/Function
Compression gauge

These tools are used to measure engine
compression.
Steering nut wrench

YU-33975
This tool is used to loosen or tighten the
steering stem ring nuts.
Oil filter wrench
YU-38411
This tool is needed to loosen or tighten
the oil filter cartridge.
Inductive tachometer
YU-8036-A
This tool is used to check engine speed.
Quick Gasket
ACC-11001-05This sealant is used to seal two mating
01
surfaces (e. g., crankcase mating surfaces).
Oil pressure gauge
90890-03153
This tool is used to measure the engine oil
pressure.

1 - 11

GEN
INFO

Illustration

SPEC
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
ENGINE SPECIFICATIONS ........................................................................... 2-2
CHASSIS SPECIFICATIONS ....................................................................... 2-11
ELECTRICAL SPECIFICATIONS ................................................................. 2-15
TIGHTENING TORQUES ............................................................................ 2-18
GENERAL TIGHTENING TORQUES .................................................. 2-18
ENGINE TIGHTENING TORQUES ..................................................... 2-19
CHASSIS TIGHTENING TORQUES ................................................... 2-21
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ............ 2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .......... 2-24
ENGINE OIL LUBRICATION CHART .......................................................... 2-25
ENGINE OIL FLOW DIAGRAMS ................................................................ 2-26
TRANSFER GEAR OIL FLOW DIAGRAMS ................................................ 2-30
CABLE ROUTING ....................................................................................... 2-32

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Dimensions
Overall length
Overall width
Overall height

Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)

Standard

Limit

2,500 mm (98.4 in)
980 mm (38.6 in)
1,140 mm (44.9 in): XV16A
1,500 mm (59.1 in): XV16AT
710 mm (28.0 in)
1,685 mm (66.3 in)
145 mm (5.71 in)
3,200 mm (126 in)

-------------------------

332 kg (732 lb): XV16A
347 kg (765 lb): XV16AT
307 kg (678 lb): XV16A
322 kg (710 lb): XV16AT
196 kg (432 lb): XV16A
181 kg (399 lb): XV16AT

-------------------

2-1

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS
Item

Standard

Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
30

60˚F

15˚C

Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Transfer gear oil
Recommended oil
Quantity
Oil ﬁlter
Oil ﬁlter type
Bypass valve opening pressure

Limit

Air-cooled, 4-stroke, OHV
1,602 cm3
V-type 2-cylinder
95 × 113 mm (3.74 × 4.45 in)
8.3:1
850 ~ 950 r/min
52 kPa (390 mm Hg, 15.4 in Hg)

----------------------

1,200 kPa
(12.0 kgf/cm2, 171 psi) at 200 r/min

----

Unleaded fuel (for USA)
Regular unleaded gasoline (for CDN)

-------

20 L (17.6 Imp qt, 21.1 US qt)
3.5 L (3.08 Imp qt, 3.70 US qt)

-------

Dry sump

-------

Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40˚F/5˚C or above)
(Non-Friction modiﬁed)

5.0 L (4.4 Imp qt, 5.3 US qt)
3.7 L (3.3 Imp qt, 3.9 US qt)

-------

4.1 L (3.6 Imp qt, 4.3 US qt)

----

60 kPa (0.6 kgf/cm2, 8.5 psi) at 900 r/min
0.60 MPa (6.0 kgf/cm2, 85 psi)

-------

SAE80API “GL-4” hypoid gear oil
0.4 L (0.35 Imp qt, 0.42 US qt)

-------

Cartridge (paper)
80 ~ 120 kPa
(0.8 ~ 1.2 kgf/cm2, 11.3 ~ 17.1 psi)

-------

2-2

ENGINE SPECIFICATIONS
Item

SPEC

Standard

Engine oil pump
Oil pump type
Inner rotor to outer rotor tip clearance
Inner rotor outer rotor 2 to oil pump
housing clearance (feed pump)
Inner rotor outer rotor 1 to oil
pump housing clearance
(scavenging pump)
Transfer oil pump
Oil pump type
Inner rotor to outer rotor tip clearance
Inner rotor outer rotor to oil pump
housing clearance
Starting system type
Spark plugs
Model
Manufacturer
Quantity
Spark plug gap
Cylinder heads
Max. warpage

Trochoidal
0.00 ~ 0.12 mm (0.000 ~ 0.005 in)
0.03 ~ 0.08 mm (0.001 ~ 0.003 in)
0.06 ~ 0.11 mm (0.002 ~ 0.004 in)

Trochoidal
0.07 ~ 0.12 mm (0.003 ~ 0.005 in)
0.03 ~ 0.08 mm (0.001 ~ 0.003 in)

Limit
---0.17 mm
(0.007 in)
0.13 mm
(0.005 in)
0.16 mm
(0.006 in)

0.17 mm
(0.007 in)
0.16 mm
(0.006 in)

Electric starter
DPR7EA-9/X22EPR-U9
NGK/DENSO
4
0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
----

------------0.10 mm
(0.004 in)

Camshafts
Drive system
Crankcase hole inside diameter

Gear drive
25.000 ~ 25.021 mm
(0.9843 ~ 0.9851 in)
Camshaft cover hole inside diam- 28.000 ~ 28.021 mm
eter
(1.1024 ~ 1.1032 in)
Camshaft journal diameter
24.937 ~ 24.950 mm
(crankcase side)
(0.9818 ~ 0.9823 in)
Camshaft journal diameter
27.967 ~ 27.980 mm
(camshaft cover side)
(1.1011 ~ 1.1016 in)
Camshaft to crankcase clearance
0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in)
Camshaft to camshaft cover clear- 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)
ance
Camshaft intake cam dimensions

2-3

----------------------

SPEC

ENGINE SPECIFICATIONS
Item

Standard

Measurement A

Limit

36.594 ~ 36.649 mm
(1.4407 ~ 1.4429 in)
31.950 ~ 32.050 mm
(1.2579 ~ 1.2618 in)

Measurement B

36.494 mm
(1.4368 in)
31.850 mm
(1.2539 in)

Camshaft exhaust cam dimensions

Measurement A

36.554 ~ 36.654 mm
(1.4391~ 1.4431 in)
31.950 ~ 32.050 mm
(1.2579 ~ 1.2618 in)

Measurement B

36.454 mm
(1.4352 in)
31.850 mm
(1.2539 in)

Rocker arms, Rocker arm shafts
Rocker arm inside diameter

15.000 ~ 15.018 mm
(0.5906 ~ 0.5913 in)
Rocker arm shaft outside diameter 14.981 ~ 14.991 mm
(0.5898 ~ 0.5902 in)
Rocker arm to rocker arm shaft
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
clearance
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
0 ~ 0.04 mm (0 ~ 0.0016 in)
Exhaust
0 ~ 0.04 mm (0 ~ 0.0016 in)
Valve dimensions

15.036 mm
(0.5920 in)
14.97 mm
(0.5894 in)
0.08 mm
(0.003 in)

-------

C
D

A
Head Diameter

Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust

Seat Width

Face Width

Margin Thickness

33.9 ~ 34.1 mm (1.3346 ~ 1.3425 in)
27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)

-------

1.3 ~ 2.3 mm (0.0512 ~ 0.0906 in)
1.2 ~ 2.4 mm (0.0472 ~ 0.0945 in)

-------

0.9 ~ 1.1 mm (0.035 ~ 0.043 in)
0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

2-4

2.0 mm
(0.079 in)
2.0 mm
(0.079 in)

ENGINE SPECIFICATIONS
Item
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust

Valve guide inside diameter
Intake
Exhaust

SPEC

Standard
0.7 ~ 1.3 mm (0.028 ~ 0.051 in)
0.7 ~ 1.3 mm (0.028 ~ 0.051 in)

5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)

6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)

Valve stem-to-valve guide clearance
Intake
0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
Exhaust
Valve stem runout

Valve seat width
Intake
Exhaust
Valve springs
Inner springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
----

0.9 ~ 1.1 mm (0.035 ~ 0.043 in)
0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

38.26 mm (1.51 in)
38.26 mm (1.51 in)

Limit
0.4 mm
(0.016 in)
0.4 mm
(0.016 in)
5.945 mm
(0.2341 in)
5.920 mm
(0.2331 in)
6.05 mm
(0.2382 in)
6.05 mm
(0.2382 in)

0.08 mm
(0.0031 in)
0.1 mm
(0.004 in)
0.01 mm
(0.0004 in)

-------

36.26 mm
(1.43 in)
36.26 mm
(1.43 in)

29.0 mm (1.14 in)
29.0 mm (1.14 in)

-------

63 ~ 73 N (6.3 ~ 7.3 kgf, 13.9~ 16.1 lb)
63 ~ 73 N (6.3 ~ 7.3 kgf, 13.9~ 16.1 lb)

-------

2-5

ENGINE SPECIFICATIONS
Item

Standard

SPEC
Limit

Spring tilt

Intake

----

Exhaust

----

Winding direction (top view)
Intake
Exhaust

Outer springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust

2.5˚ /2.4 mm
(2.5˚/0.094 in)
2.5˚ /2.4 mm
(2.5˚/0.094 in)

Counterclockwise
Counterclockwise

43.25 mm (1.70 in)
43.25 mm (1.70 in)

-------

41.26 mm
(1.62 in)
41.26 mm
(1.62 in)

31.0 mm (1.22 in)
31.0 mm (1.22 in)

-------

139 ~ 161 N
(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)
139 ~ 161 N
(13.9 ~ 16.1 kgf, 30.6 ~ 35.5 lb)

-------

Spring tilt

Intake

----

Exhaust

----

2.5˚ /2.4 mm
(2.5˚/0.094 in)
2.5˚ /2.4 mm
(2.5˚/0.094 in)

2-6

ENGINE SPECIFICATIONS
Item

Standard

Winding direction (top view)
Intake
Exhaust

Limit

Clockwise
Clockwise

-------

22.9680 ~ 22.9744 mm
(0.9043 ~ 0.9045 in)
22.990 ~ 23.010 mm
(0.9051 ~ 0.9059 in)
0.0156 ~ 0.0420 mm
(0.0006 ~ 0.0017 in)

----

293.45 ~ 293.95 mm
(11.553 ~ 11.573 in)
0.3 mm (0.012 in)

----

Max. taper

95.000 ~ 95.010 mm
(3.7402 ~ 3.7406 in)
----

Max. out of round

----

Valve lifters
Valve lifter outside diameter

SPEC

Valve lifter case inside diameter
Valve lifter-to-valve lifter case
clearance
Valve push rods
Valve push rod length
Valve push rod runout
Cylinders
Bore

Pistons
Piston-to-cylinder clearance

0.025 ~ 0.050 mm (0.001 ~ 0.002 in)

Diameter D

94.960 ~ 94.975 mm
(3.7386 ~ 3.7392 in)

-------

----

0.05 mm
(0.0016 in)
0.05 mm
(0.0016 in)
0.15 mm
(0.006 in)
----

H
D

Height H
Piston pin bore (in the piston)
Diameter
Offset
Piston pins
Outside diameter
Piston pin-to-piston pin bore
clearance

5 mm (0.20 in)

----

22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
1.0 mm (0.04 in)

22.045 mm
(0.8679 in)
----

21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)
0.004 ~ 0.024 mm
(0.00016 ~ 0.00094 in)

21.971 mm
(0.8650 in)
0.074 mm
(0.0029 in)

2-7

ENGINE SPECIFICATIONS
Item

SPEC

Standard

Limit

Piston rings
Top ring
B
T

Ring type
Dimensions (B × T)
End gap (installed)

Barrel
1.2 × 3.8 mm (0.047 × 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)

Ring side clearance

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

------0.65 mm
(0.026 in)
0.12 mm
(0.0047 in)

2nd ring
B
T

Ring type
Dimensions (B × T)
End gap (installed)

Taper
1.2 × 3.8 mm (0.047 × 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)

Ring side clearance

0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

------0.8 mm
(0.031 in)
0.12 mm
(0.0047 in)

Oil ring
B
T

Dimensions (B × T)
End gap (installed)
Connecting rods
Crankshaft pin-to-big end bearing
clearance
Bearing color code
Connecting rod length
Crankshaft
C

2.5 × 3.4 mm (0.098 × 0.134 in)
0.2 ~ 0.7 mm (0.008 ~ 0.028 in)

-------

0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)

----

1 = Blue, 2 = Black, 3 = Brown,
4 = Green, 5 = Yellow.
191.95 ~ 192.05 mm (7.557 ~ 7.561 in)

----

E
D
A

Width A
Max. runout C

132.8 ~ 133.2 mm (5.228 ~ 5.244 in)

Big end side clearance D

0.320 ~ 0.474 mm (0.013 ~ 0.019 in)
2-8

---0.04 mm
(0.0016 in)
----

ENGINE SPECIFICATIONS
Item
Big end radial clearance E

Crankshaft journal-to-crankshaftjournal bearing clearance
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Min. length
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Max. main axle runout
Max. drive axle runout

SPEC

Standard
0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in)
0.030 ~ 0.062 mm (0.0012 ~ 0.0024 in)

Wet, multiple disc
Rack and pinion (pull rod type)
Cable operation
Left-hand operation
10 ~ 15 mm (0.39 ~ 0.59 in)

2.9 ~ 3.1 mm (0.114 ~ 0.122 in)
9

Limit
0.09 mm
(0.0035 in)
0.1 mm
(0.0040 in)
----------------

2.8 mm
(0.110 in)
----

2.2 ~ 2.4 mm (0.087 ~ 0.094 in)
8
----

------0.2 mm
(0.008 in)

7 mm (0.276 in)
1

------6.5 mm
(0.256 in)

Constant mesh, 5-speed
Spur gear
72/47 (1.532)
Belt drive
35/32 × 70/33 (2.320)
Left-foot operation
39/16 (2.437)
30/19 (1.578)
29/25 (1.160)
29/32 (0.906)
21/28 (0.750)
-------

2-9

---------------------------------0.08 mm
(0.003 in)
0.08 mm
(0.003 in)

ENGINE SPECIFICATIONS
Item
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift fork thickness
Air ﬁlter type
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Carburetor
Model (manufacturer) × quantity
Throttle cable free play (at the
ﬂange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Starter jet 1
Starter jet 2
Butterﬂy valve size
Fuel level (below the ﬂoat chamber mating surface)

Standard
Guide bar
---6.26 ~ 6.39 mm (0.246 ~ 0.252 in)
Dry element

SPEC
Limit
---0.025 mm
(0.001 in)
-------

Electrical
4WM (MITSUBISHI)
15 ~ 20 kPa
(0.15 ~0.20 kgf/cm2, 2.1 ~ 2.8 psi)

----------

BSR40 (MIKUNI) × 1
3 ~ 5 mm (0.12 ~ 0.20 in)

-------

4WM1 00
4WM2 10 (for California)
#165
#60
6HDC26
X-2
#100
1.0 (XV16A), 1.1 (XV16AT)
#35
0.9
1.0
0.9
2-1/2
2.0
#57.5
1.0
#110
2.0 ~ 3.0 mm (0.079 ~ 0.12 in)

-------------------------------------------------------

2 - 10

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS
Item

Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)

Standard

Limit

Double cradle
32˚
142 mm (5.59 in)

----------

Spoke wheel

----

16 × MT3.00
Steel
140 mm (5.51 in)

----------

----

1 mm
(0.04 in)
0.5 mm
(0.02 in)

----

Spoke wheel

----

16 × MT3.50
Steel
110 mm (4.33 in)

----------

----

1 mm
(0.04 in)
0.5 mm
(0.02 in)

----

With tube
130/90 - 16 67H
D404FL (DUNLOP)/
G703F (BRIDGESTONE)

Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
250 kPa (2.5 kg/cm2, 36 psi)
90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kg/cm2, 36 psi)
High-speed riding
250 kPa (2.5 kg/cm2, 36 psi)
* Load is the total weight of the cargo,
rider, passenger and accessories.
Min. tire tread depth
----

2 - 11

----------

1.6 mm
(0.06 in)

CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)

SPEC

Standard
With tube
150/80 B16 71H
D404 (DUNLOP)/
G702 (BRIDGESTONE)

Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
250 kPa (2.5 kg/cm2, 36 psi)
90 kg (198 lb) ~ Maximum load* 280 kPa (2.8 kg/cm2, 40 psi)
High-speed riding
280 kPa (2.8 kg/cm2, 40 psi)
* Load is the total weight of the cargo,
rider, passenger and accessories.
Min. tire tread depth
---Front brakes
Brake type
Operation
Brake lever free play (lever end)
Recommended ﬂuid
Brake discs
Diameter × thickness
Min. thickness

Dual-disc brake
Right-hand operation
2 ~ 5 mm (0.08 ~ 0.20 in)
DOT 4
298 × 5 mm (11.7 × 0.20 in)
----

Max. deflection

----

Brake pad lining thickness

6.0 mm (0.24 in)

Limit
----------

----------

1.6 mm
(0.06 in)
---------------4.5 mm
(0.18 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)

Master cylinder inside diameter
15.8 mm (0.62 in)
---Caliper cylinder inside diameter
30.1 mm (1.19 in) and 33.3 mm (1.31 in)
---Rear brake
Brake type
Single-disc brake
---Operation
Right-foot operation
---Brake pedal position (from the top 100 mm (3.9 in)
---of the brake pedal to the bottom of
the rider footrest board)
Recommended ﬂuid
DOT 4
---Brake discs
Diameter × thickness
320 × 7 mm (12.6 × 0.28 in)
---Min. thickness
---6.5 mm
(0.26 in)
Max. deﬂection
---0.1 mm
(0.004 in)
Brake pad lining thickness
7.5 mm (0.30 in)
0.5 mm
(0.02 in)

2 - 12

CHASSIS SPECIFICATIONS

SPEC

Item

Standard

Limit

Master cylinder inside diameter
Caliper cylinder inside diameter
Steering
Steering bearing type
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length

12.7 mm (0.5 in)
33.9 mm (1.33 in) and 30.2 mm (1.19 in)

-------

Taper roller bearings

----

Telescopic fork
Coil spring/oil damper
140 mm (5.51 in)

----------

Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Inner tube outer diameter
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Swingarm
Free play (at the end of the swingarm)
Radial
Axial

571 mm (22.5 in)

566 mm
(22.3 in)

6.8 N/mm (0.7 kgf/mm, 39.2 lb/in)
0 ~ 140 mm (0 ~ 5.51 in)
No

-------

Yamaha fork oil 5WT
554 cm3 (19.5 Imp oz, 18.7 US oz)
110 mm (4.33 in)

----------

43 mm (1.69 in)

----

Swingarm (link suspension)
Coil spring/gas-oil damper

-------

50 mm (1.97 in)

----

187 mm (7.36 in)
172 mm (6.77 in): XV16A
169 mm (6.65 in): XV16AT
127 N/mm (13 kgf/mm, 728 lb/in)
0 ~ 50 mm (0 ~ 1.97 in)
No
1,000 kPa (10 kgf/cm2, 142 psi)

----

182 mm
(7.17 in)
----------------

1 mm
(0.04 in)
1 mm
(0.04 in)

----

2 - 13

CHASSIS SPECIFICATIONS
Item
Drive belt
Model (manufacturer)
Drive belt slack (on a sidestand)
Drive belt slack
(on a suitable stand)

Standard
UBD-0568
7.5 ~ 13 mm (0.30 ~ 0.51 in)
14 ~ 21 mm (0.55 ~ 0.83 in)

SPEC
Limit
----------

2 - 14

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS
Item

System voltage
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit
model (manufacturer)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug caps
Material
Resistance
Throttle position sensor standard
resistance
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance
Voltage regulator
Regulator type
Model
No-load regulated voltage
Rectiﬁer
Model
Rectiﬁer capacity
Withstand voltage
Battery
Battery type
Battery voltage/capacity
Headlight type
Indicator light type × quantity
Bulbs (voltage/wattage × quantity)
Headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
Meter light

Standard

Limit

12 V

----

Transistorized coil ignition (TCI)
10˚ BTDC at 1,000 r/min
40˚ BTDC at 4,000 r/min
Throttle position sensor and electrical
248 ~ 372 Ω / Gy–B
J4T098 (MITSUBISHI)

----------------------

J0383 (DENSO)
6 mm (0.24 in)
1.53 ~ 2.07 Ω
12 ~ 18 kΩ

-------------

Resin
10 kΩ
4.0 ~ 6.0 kΩ

----------

AC magneto
F4T363 (MITSUBISHI)
14 V / 21 A at 5,000 r/min
0.45 ~ 0.55 Ω at 20˚C (68˚F)

-------------

Semiconductor, short circuit
SH650D-11
14.1 ~ 14.9 V

----------

SH650D-11
18 A
200 V

----------

YTX20L-BS
12V / 18AH
Halogen bulb
Bulb × 3 and LED × 2

-------

12 V 60 W / 55 W × 1
12 V 8 W / 27 W × 1
12 V 27 W / 8 W × 2
12 V 27 W × 2
14 V 1.7 W × 3

----------------

2 - 15

ELECTRICAL SPECIFICATIONS
Item
Neutral indicator light
Turn signal indicator light
High beam indicator light
Fuel level indicator light
Engine trouble indicator light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Horn
Horn type
Model (manufacturer) × quantity
Max. amperage
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Fuel sender
Model (manufacturer)
Resistance
Sidestand relay
Model (manufacturer)
Coil resistance
Diode
Fuel pump maximum amperage
Fuel pump relay model (manufacturer)
Thermo switch model (manufacturer)

SPEC

Standard

Limit

12 V 1.7 W × 1
12 V 1.7 W × 1
12 V 1.7 W × 1
LED
LED
Constant mesh

----

SM-13 (MITSUBA)
0.8 kW

-------

10 mm (0.40 in)
7.65 ~ 10.01 N
(765 ~ 1,001 gf, 27.0 ~ 35.3 oz)
25 ~ 35 mΩ
28 mm (1.10 in)
0.7 mm (0.03 in)

5 mm
(0.20 in)
------27 mm
(1.06 in)
----

MS5F-411 (JIDECO)
100 A
4.18 ~ 4.62 Ω

----------

Eddy
YP-12 (NIKKO) × 2
2A

----------

Semi-transistor
FB257H (DENSO)
Yes
75 ~ 95 cycles/min.
27 W × 2 + 3.4 W, 21 (23) W × 2 + 3.4 W

----------------

4WM (NIPPON SEIKI)
13 ~ 140 Ω at 20 ˚C (68 ˚F)

-------

G8R-30Y-B (OMRON)
202 ~ 248 Ω
Yes
1A
G8R-30Y-B (OMRON)

----------------

4TR (NIPPON TEXISAS INSTALLMENTS)

----

2 - 16

ELECTRICAL SPECIFICATIONS
Item
Fuses (amperage × quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Carburetor heater fuse
Backup fuse (odometer)
Reserve fuse

Standard
30 A × 1
15 A × 1
10 A × 1
15 A × 1
10 A × 1
5A×1
30 A, 15 A, 10 A, 5 A × 1

2 - 17

SPEC
Limit
-------------------

TIGHTENING TORQUES

SPEC

TIGHTENING TORQUES
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications for special 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. Components
should be at room temperature.

A: Width across flats
B: Thread diameter

A
(nut)

B
(bolt)

10 mm

General tightening
torques
Nm

m•kg

ft•lb

6 mm

0.6

4.3

12 mm

8 mm

1.5

14 mm

10 mm

3.0

17 mm

12 mm

5.5

19 mm

14 mm

8.5

22 mm

16 mm

130

13.0

2 - 18

TIGHTENING TORQUES

SPEC

ENGINE TIGHTENING TORQUES
Tightening torque
Item

Fastener Thread size Q’ty

Remarks
Nm m·kgf ft·lb

Spark plug

–

M12

1.8

Cylinder head

Nut

M12

5.0

Cylinder head

Nut

M10

3.9

Stud bolt

1.5

Camshaft driven gear

Nut

M14

5.2

Camshaft drive gear

Bolt

M10

3.0

Connecting rod

Bolt

38.5

3.85

Rocker arm adjusting screw

Nut

2.0

Front cylinder camshaft end
cover

Bolt

1.0

7.2

Engine oil drain bolt (crankcase)

–

M14

4.3

Engine oil drain bolt (oil tank)

–

M14

4.3

Oil filter cartridge

–

M20

1.7

Oil filter bolt

–

M20

7.0

Oil filter bracket

Bolt

1.0

7.2

Oil delivery pipe (generator
cover-to-crankcase)

Nut

M20

4.0

–

M16

4.0

Oil delivery pipe (cylinder headto-crankcase)

Union
bolt

M10

2.1

Oil delivery pipe (cylinder headto-crankcase)

Union
bolt

1.8

Bolt

1.2

8.7

Screw

0.3

2.2

Bolt

0.7

5.1

Screw

0.3

2.2

Exhaust pipe

Nut

2.0

Muffler

Bolt

M10

2.5

Muffler clamp

Bolt

M10

3.0

Crankcase (cylinder head)

Stud bolt

M12

–

Crankcase (cylinder head)

Stud bolt

M10

–

Crankcase (transfer gear case)

Stud bolt

1.3

9.4

Pickup coil

Screw

0.7

5.1

Pickup coil lead holder

Screw

0.7

5.1

Stator coil assembly

Screw

0.7

5.1

Stator coil assembly lead holder

Bolt

0.7

5.1

Starter clutch

Bolt

2.4

Cylinder head (exhaust pipe)

Joint bolt

Carburetor joint
Carburetor joint clamp
Air filter case
Air filter case clamp

2 - 19

TIGHTENING TORQUES

SPEC

Tightening torque
Item

Fastener Thread size Q’ty

Remarks
Nm m·kgf ft·lb

Generator rotor

Bolt

M12

160

16.0

115

Generator shaft

Bolt

2.8

Pickup coil rotor

Bolt

M12

115

11.5

Baffle plate

Bolt

1.0

7.2

Clutch boss

Nut

M20

7.0

Clutch spring plate

Bolt

0.8

5.8

Pull lever

Bolt

1.0

7.2

–

1.8

Middle drive gear

Nut

M22

8.5

Transfer gear case

Bolt

3.0

Transfer gear case

Nut

3.0

–

0.8

5.8

Screw

0.7

5.1

Transfer gear oil pump

Bolt

1.0

7.2

Drive pulley case

Bolt

3.0

Drive pulley

Nut

M22

8.5

Drive pulley cover bracket

Bolt

3.0

Shift arm

Bolt

1.0

7.2

–

1.2

8.7

Shift shaft spring stopper

Bolt

2.2

Stopper lever

Bolt

1.0

7.2

Neutral switch

Screw

0.7

5.1

Transfer gear oil drain bolt

Transfer gear oil checking bolt
Transfer gear oil pump cover

Shift rod locknut

Use a lock
washer.

2
Use a lock
washer.

Use a lock
washer.

HINWEIS:
NOTE:
*1: When installing the crankcase stud bolts (cylinder head), make sure that their installed
length is 140.5 ~ 142.5 mm (5.53 ~ 5.61 in).
*2: When installing the crankcase stud bolts (transfer gear case), make sure that their
installed length is 68.3 ~ 70.3 mm (2.69 ~ 2.77 in).

2 - 20

TIGHTENING TORQUES

SPEC

CHASSIS TIGHTENING TORQUES

Item

Thread size

Upper bracket and inner tube
Upper bracket and steering shaft
Handlebar holder (lower) and handlebar
holder (upper)
Ring nut (steering shaft)
Brake hose joint and lower bracket
Front brake master cylinder cap
Handlebar holder (lower)
Front brake master cylinder
Union bolt (brake hose)
Engine mounting:
Mounting bolt
(cylinder head and engine stay)
Mounting bolt
(crankcase and engine stay)
Mounting bolt (crankcase and frame)
Engine stay and frame
Transfer gear case stay and frame
Muffler stay and frame
Muffler stay and muffler
Ignition coil
Swingarm pivot shaft
Relay arm and swingarm
Relay arm and connecting rod
Relay arm and rear shock absorber
Rear shock absorber, connecting rod
and frame
Drive belt case (upper) and swingarm
Drive belt case (lower) and swingarm
Mud guard and swingarm
Fuel petcock and fuel tank
Fuel sender and fuel tank
Fuel tank (rear) and frame
Meter cover and fuel tank
Side cover and frame
Starter relay and battery positive lead
Starter relay and starter motor lead
Rear fender side mold and rear fender
stay
Sidestand bolt and nut
Footrest bracket and frame
Rear footrest and frame

Tightening torque
Nm

m·kgf

ft·lb

M6
M22

10
130

1.0
13.0

7.2
94

2.3

M25
M6
M4
M12
M6
M10

3
7
2
40
10
30

0.3
0.7
0.2
4.0
1.0
3.0

2.2
5.1
1.4
29
7.2
22

M10

4.8

M12

8.8

M12
M10
M8
M8
M10
M6
M18
M12
M12
M10

88
48
30
26
30
7
125
59
59
40

8.8
4.8
3.0
2.6
3.0
0.7
12.5
5.9
5.9
4.0

64
35
22
19
22
5.1
90
43
43
29

M12

5.9

M6
M6
M6
M6
M6
M6
M6
M6
M6
M6

10
7
7
7
7
7
7
7
7
7

1.0
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

7.2
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1
5.1

3.0

M10
M10
M8

48
48
23

4.8
4.8
2.3

35
35
17

2 - 21

Remarks

See NOTE.

TIGHTENING TORQUES
Item
Rear master cylinder and rear brake
bracket
Rear brake reservoir tank
Union bolt (rear brake hose)
Footrest bracket and rear brake bracket
Footrest bracket and shift rod bracket
Front wheel axle
Front wheel axle pinch bolt
Rear wheel axle nut
Front brake caliper
Rear brake caliper
Brake disc and wheel
Caliper bleed screw
Driven pulley and rear wheel clutch hub
Rear brake caliper bracket and swingarm

Thread size

SPEC

Tightening torque
Nm

m·kgf

ft·lb

2.3

M6
M10
M8
M8
M18
M8
M18
M10
M10
M8
M8

4
30
16
16
78
19
150
40
40
23
6

0.4
3.0
1.6
1.6
7.8
1.9
15.0
4.0
4.0
2.3
0.6

2.9
22
11
11
56
13
110
29
29
17
4.3

M12

9.5

M10

4.8

Remarks

2
LT

HINWEIS:
NOTE:
1.First, tighten the ring nut to approximately 52 Nm (5.2 m • kg, 37 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.

2 - 22

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point

Lubricant

Oil seal lips

O-rings

Bearings

Connecting rod bolts and nuts

Connecting rod small end and big end

Crankshaft pins

Crankshaft journals

Piston surfaces

Piston pins

Camshaft cam lobes and camshaft journals

Valve push rods

Valve push rod end balls

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Valve lifters

Oil pump rotors (inner and outer) and oil pump housing

Oil strainer

Starter clutch idle gear inner surface

Starter clutch idle gear shaft

Starter clutch roller and starter clutch gear outer surface

Clutch pull rod

Pressure plate bearing

Transmission gears (wheel and pinion)

Shift drum

Shift forks and shift fork guide bars

Shift shaft

Shift pedal

Shift lever joint

Crankcase mating surface

Sealant
(Quick Gasket)

Stator coil lead grommet

Sealant
(Quick Gasket)

Pickup coil lead grommet

Sealant
(Quick Gasket)

2 - 23

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point

Lubricant

Steering bearings and bearing races (upper and lower)

Steering bearing cover

Steering head pipe lower oil seal

Front wheel oil seal (right and left)

Rear wheel oil seal

Rear wheel drive hub mating surface

Rear brake pedal shaft

Shift pedal

Front footrest pivot

Sidestand sliding surface

Tube guide (throttle grip) inner surface

Brake lever pivot bolt, contact surface

Clutch lever pivot bolt, contact surface

Swingarm pivot shaft

Swingarm pivot bearing

Swingarm pivot oil seal

Relay arm bearing (inner)

Rear shock absorber bearing (inner)

Connecting rod bearing (inner)

2 - 24

ENGINE OIL LUBRICATION CHART
ENGINE OIL LUBRICATION CHART

2 - 25

SPEC

ENGINE OIL FLOW DIAGRAMS

SPEC

ENGINE OIL FLOW DIAGRAMS
1 Oil tank
2 Oil strainer
3 Dipstick
4 Oil delivery pipe
5 Push rod
6 Oil filter cartridge
7 Engine oil drain bolt (oil tank)

2 - 26

ENGINE OIL FLOW DIAGRAMS
1 Valve lifter
2 Push rod
3 Rocker arm shaft
4 Crankshaft

2 - 27

SPEC

ENGINE OIL FLOW DIAGRAMS

SPEC

1 Engine oil pump
2 Oil strainer
3 Engine oil drain bolt (engine)

2 - 28

ENGINE OIL FLOW DIAGRAMS
1 Main axle
2 Drive axle
3 Engine oil pump
4 Oil strainer
Å To oil tank
ı From oil tank
Ç To oil filter cartridge

2 - 29

SPEC

TRANSFER GEAR OIL FLOW DIAGRAMS

SPEC

TRANSFER GEAR OIL FLOW DIAGRAMS
1 Middle driven shaft
2 Transfer gear oil pump

2 - 30

TRANSFER GEAR OIL FLOW DIAGRAMS
1 Transfer gear oil pump
2 Middle driven shaft

2 - 31

SPEC

CABLE ROUTING

SPEC

EB206000

CABLE ROUTING
1 Throttle cables
2 Brake hose
3 Clutch cable
4 Left handlebar switch lead
5 Vacuum hose (air induction system)
6 Rear brake light switch lead
7 Rectifier/regulator

Å Route the rear brake light switch lead in front of the
rectifier/regulator bracket on the frame.

2 - 32

CABLE ROUTING
1 Spark plug cap #3
2 Ignition coil (rear cylinder)
3 Spark plug cap #1
4 Fuse box
5 Starter relay
6 Thermo switch
7 Fuel tank breather hose
8 Horns
9 Fuel pump
0 Starter motor lead
A Fuel pump lead

SPEC

B Carburetor heater lead
C Throttle position sensor lead
D Horn lead
E Sidestand switch lead
F Sidestand switch
Å Fasten the wire harness, fuel sender lead (wire harness side) and
seat lock cable with a plastic locking tie.
ı To the speed sensor, neutral switch, stator coil and decompression solenoid.
Ç Fasten the throttle position sensor lead, carburetor heater lead and
fuel pump lead with a plastic locking tie to the engine bracket.

2 - 33

CABLE ROUTING
1 Battery
2 Turn signal relay
3 Relay unit
4 Oil tank breather hose
5 Ignition coil (front cylinder)
6 Main switch coupler
7 Meter assembly couplers
8 Right handlebar switch lead
9 Fuel tank breather hose
0 Spark plug cap #4

SPEC

A Spark plug cap #2
B Sidestand switch coupler
C Pickup coil lead
D Horn leads
E Starter motor lead
F Sidestand switch lead
G Decompression solenoid lead
H Stator coil lead
I Rollover valve

2 - 34

CABLE ROUTING
Å Fasten the fuel tank breather and oil tank
breather hose with a plastic clamp and then
insert the clamp into the frame.
ı To the stator coil.
Ç To the decompression solenoid.
Î To the fuel tank.
‰ To the wire harness.

SPEC

Ï Fasten the starter motor lead, stator coil lead,
decompression solenoid lead, pickup coil
lead speed sensor lead and neutral switch
lead with a plastic clamp and then insert the
clamp into the frame.
Ì To the starter relay.
Ó To the decompression solenoid.
È To the speed sensor.

2 - 35

CABLE ROUTING
1 Fuel tank breather hose
2 Oil tank breather hose
3 Relay unit
4 Turn signal relay
5 Tail/brake light and rear turn signal light subwire harness coupler
6 Thermo switch
7 Fuse box
8 Fuel sender lead
9 Vacuum hose (air induction system)
0 Solenoid valve lead (California only)
A Spark plug lead #4

SPEC

B Spark plug lead #2
C Spark plug lead #1
D Spark plug lead #3
Å Fasten the wire harness with a plastic clamp
and then insert the clamp into the relay
bracket.
ı Position the white tape on the wire harness
with the hole on battery box, as shown.
Ç To the main switch.
Î To the meter assembly.

2 - 36

CABLE ROUTING

SPEC

Evaporative emission control system (California only)
1 Main switch
2 Fuel tank breather hose
3 Charcoal canister to carburetor hose
4 Charcoal canister
5 Charcoal canister to rollover valve hose

6 Rollover valve
7 Solenoid valve coupler
8 Solenoid valve
9 Solenoid valve to air filter case hose
0 Solenoid valve to carburetor hose

2 - 37

CHK
ADJ
CONTENTS
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................... 3-1
SEATS AND SIDE COVERS ......................................................................... 3-3
XV16AT ACCESSORY PARTS ..................................................................... 3-4

FUEL TANK ................................................................................................... 3-6
AIR FILTER CASE ......................................................................................... 3-7
ENGINE ......................................................................................................... 3-8
ADJUSTING THE VALVE CLEARANCE ............................................... 3-8
ADJUSTING THE ENGINE IDLING SPEED ....................................... 3-12
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................ 3-13
CHECKING THE SPARK PLUGS ........................................................ 3-14
CHECKING THE IGNITION TIMING ................................................... 3-16
MEASURING THE COMPRESSION PRESSURE ............................... 3-18
CHECKING THE ENGINE OIL LEVEL ................................................. 3-20
CHANGING THE ENGINE OIL ............................................................ 3-22
MEASURING THE ENGINE OIL PRESSURE ..................................... 3-25
CHECKING THE TRANSFER GEAR OIL LEVEL ................................. 3-26
CHANGING THE TRANSFER GEAR OIL ........................................... 3-27
ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-28
CLEANING THE AIR FILTER ELEMENT ............................................. 3-29
CHECKING THE CARBURETOR JOINT ............................................. 3-30
CHECKING THE FUEL HOSES AND FUEL FILTER ........................... 3-30
CHECKING THE CYLINDER HEAD BREATHER HOSE AND
TRANSFER GEAR CASE BREATHER HOSE ................................. 3-31
CHECKING THE EXHAUST SYSTEM ................................................ 3-31
CHASSIS ..................................................................................................... 3-32
ADJUSTING THE FRONT BRAKE ...................................................... 3-32
ADJUSTING THE REAR BRAKE ........................................................ 3-33
CHECKING THE BRAKE FLUID LEVEL .............................................. 3-34

CHK
ADJ
CHECKING THE FRONT BRAKE PADS ............................................. 3-35
CHECKING THE REAR BRAKE PADS ................................................ 3-35
ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-35
CHECKING THE BRAKE HOSE .......................................................... 3-36
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................ 3-37
ADJUSTING THE SHIFT PEDAL ........................................................ 3-39
ADJUSTING THE DRIVE BELT SLACK .............................................. 3-39
CHECKING AND ADJUSTING THE STEERING HEAD ..................... 3-41
CHECKING THE FRONT FORK ........................................................... 3-43
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .............. 3-44
CHECKING THE TIRES ....................................................................... 3-45
CHECKING AND TIGHTENING THE SPOKES ................................... 3-48
CHECKING AND LUBRICATING THE CABLES ................................. 3-49
LUBRICATING THE LEVERS AND PEDALS ...................................... 3-50
LUBRICATING THE SIDESTAND ....................................................... 3-50
LUBRICATING THE REAR SUSPENSION ......................................... 3-50
ELECTRICAL SYSTEM ............................................................................... 3-51
CHECKING AND CHARGING THE BATTERY .................................... 3-51
CHECKING THE FUSES ...................................................................... 3-56
REPLACING THE HEADLIGHT BULB ................................................ 3-58
ADJUSTING THE HEADLIGHT BEAM ............................................... 3-59
INSTRUMENT FUNCTIONS ...................................................................... 3-61
INDICATOR LIGHTS ........................................................................... 3-61
COMBINATION METER ..................................................................... 3-61

CHK
ADJ

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS/
GENERAL MAINTENANCE AND LUBRICATION CHART
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/LUBRICATION INTERVALS
INITIAL
No.

ITEM

ODOMETER READINGS

600 mi
4,000 mi
8,000 mi
12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month
6 months 12 months 18 months 24 months 30 months

ROUTINE

1 *

Valve clearance
(See page 3-8.)

• Check valve clearance when
engine is cold.
• Adjust if necessary.

Spark plug
(See page 3-14.)

• Check condition.
• Adjust gap and clean.
• Replace at 8,000 mi (13,000 km) or
12 months and thereafter every
8,000 mi (13,000 km) or 12 months.

√

Replace

√

Replace

√

Crankcase ventilation
3 * system
(See page 3-31.)

• Check breather hose for cracks or
damage.
• Replace if necessary.

√

4 *

Fuel line
(See page 3-30.)

• Check fuel hose for cracks or damage.
• Replace if necessary.

√

5 *

Fuel filter
(See page 3-30.)

• Replace initial 20,000 mi (31,000
km) and thereafter every 20,000 mi
(31,000 km).

6 *

Exhaust system
(See page 3-31.)

• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.

7 *

Idle speed
(See page 3-12.)

• Check and adjust engine idle
speed.
• Adjust cable free play.

Evaporative Emission
8 * control system (For
California only)

Every 15,000 mi (24,000 km)

Replace

√

• Check control system for damage.
• Replace if necessary.

√

* Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.

GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
No.

ITEM

Engine oil
(See page 322.)

ROUTINE

• Replace

TYPE

√

See page 3-21.

2 * Oil filter

• Replace

—

Air filter
3 * (See page 329.)

• Clean with compressed
air.
• Replace if necessary.

—

Front brake
4 * (See page 332.)

• Check operation and
fluid leakage. (See page
3-34)
• Correct if necessary.

—

Rear brake
5 * (See page 333.)

• Check operation and
fluid leakage. (See page
3-34)
• Correct if necessary.

—

ODOMETER READINGS

600 mi
4,000 mi
8,000 mi
12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month
6 months 12 months 18 months 24 months 30 months
√

√

3-1

√

Replace
brake fluid

√

Replace
brake fluid

√

CHK
ADJ

GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
No.

ITEM

ROUTINE

Clutch
6 * (See page 328.)

• Check operation and
free play.
• Correct if necessary.

Transfer
case oil
7 *
(See page 326.)
Control
cable
(See page 349.)

8 *

Rear arm
pivot bear9 * ing
(See page 484.)

TYPE

ODOMETER READINGS

600 mi
4,000 mi
8,000 mi
12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month
6 months 12 months 18 months 24 months 30 months

—

√

• Check vehicle for leakage.
• Replace every 16,000
mi (25,000 km) or
24 months.

SAE 80 API “GL-4”
hypoid gear oil

Replace

• Apply chain lube thoroughly.

Yamaha chain and
cable lube or SAE
10W30 motor oil

√

• Check bearing assembly for looseness.
• Moderately repack
every 16,000 mi (25,000
km).

Medium weight
wheel bearing
grease

√

Check

√

Replace

√

Repack

Brake/
Clutch lever
pivot shaft
(See page 350.)

• Apply chain lube
lightly.

Yamaha chain and
cable lube or SAE
10W30 motor oil

√

Brake pedal
and shift
pedal shaft
(See page 350.)

• Lubricate
• Apply chain lube
lightly.

Yamaha chain and
cable lube or SAE
10W30 motor oil

√

12 *

Sidestand
pivot
(See page 350.)

• Check operation and
lubricate.
• Apply chain lube
lightly.

Yamaha chain and
cable lube or SAE
10W30 motor oil

√

13 *

Sidestand
switch
(See page 350.)

• Check and clean or
replace if necessary.

—

√

Front fork
14 * (See page 343.)

• Check operation and for
leakage.

—

√

Steering
bearings
15 *
(See page 341.)

• Check bearing assembly for looseness.
• Moderately repack
every 16,000 mi (25,000
km).

Lithium soap base
grease

√

Repack

√

—

√

16 *

Wheel bearings
(See page 45.)

• Check bearings for
smooth rotation.

Rear suspension link
17 * pivots
(See page 484.)

• Apply grease lightly.

Drive belt
18 * (See page 339.)

• Check the belt tension.
• Adjust if necessary.

√

Molybdenum disulfide grease

√

—

Every 2,500 mi (4,000 km)

* Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.

NOTE:
The air filter element needs more frequent service if you are riding in unusually wet or dry
areas.
1.Hydraulic brake system
• Replace the brake fluid after disassembling the master cylinder or caliper cylinder.
• Check the brake fluid level and add fluid as required.
• Replace the master cylinder and caliper cylinder oil seals every two years.
• Replace the brake hoses every four years or if cracked or damaged.
3-2

SEATS AND SIDE COVERS

CHK
ADJ

SEATS AND SIDE COVERS

Order
1
2
3
4

Job/Part
Removing the seats and side covers
Rider seat
Passenger seat
Left side cover
Right side cover

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
For installation, reverse the removal
procedure.

3-3

XV16AT ACCESSORY PARTS

CHK
ADJ

XV16AT ACCESSORY PARTS

Order
1
2
3

Job/Part
Accessory parts removal (front)
Front windshield
Chrome flasher bracket cover
Windshield stay

Q’ty

Remarks
Remove the parts in the order listed.

1
1
2
For installation, reverse the removal
procedure.

3-4

XV16AT ACCESSORY PARTS

CHK
ADJ

Order
1
2
3
4
5
6
7
8

Job/Part
Accessory parts removal (rear)
Emblem
Backrest holder
Backrest
Backrest stay
Saddlebag
Passenger footrest
Saddlebag stay
Grip

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
2
2
2
2
For installation, reverse the removal
procedure.

3-5

FUEL TANK

CHK
ADJ

EAS00040

FUEL TANK

6
1

3
3
5

Order

1
2
3
4

Job/Part
Removing the fuel tank
Rider seat
Meter assembly
Meter assembly coupler
Fuel tank breather hose
Fuel hose

5
6

Fuel sender coupler
Fuel tank

Q’ty

2
1

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”.
Disconnect.
Disconnect.
NOTE:
Before disconnecting the fuel hose,
set the fuel cock to “OFF”.

1
1

Disconnect.
For installation, reverse the removal
procedure.

3-6

AIR FILTER CASE

CHK
ADJ

AIR FILTER CASE

Order
1

2
3

Job/Part
Removing the air filter case
Vacuum chamber breather hose
(air filter case to solenoid valve
hose)
Cylinder head breather hose
Air filter case

Q’ty
1

1
1

Remarks
Remove the parts in the order listed.
Disconnect.

Disconnect.
For installation, reverse the removal
procedure.

3-7

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

EAS00047

ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of
the valves.
NOTE:
• The valve clearance is automatically
adjusted by the hydraulic valve lifter.
However, there are times that the valve
clearance is needed to be adjusted manually. If this is the case, adjust the clearance
of the two maladjusted or worn valves, of
a rocker arm, with the adjusting screw.

Å If clearance is on the slip side 1, loosen the
adjusting screw and bring the valve clearance
a within specification. Check if the valve
clearance b on the adjusting screw 2 side is
within specification.
ı If clearance is on the adjusting screw 2 side,
tighten the adjusting screw and bring the
valve clearance b within specification.

• 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:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
• fuel tank
Refer to “FUEL TANK”.

2.
•
•
•
3.
•
•
•
•
3-8

Disconnect:
spark plug caps 1
cylinder head breather hose 2
oil tank breather hose 3
Remove:
spark plugs
cylinder head covers (upper)
gaskets
dowel pins

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

4. Remove:
• shift rod 1

5. Remove:
• rider footrest (left) bolts 1

3
6. Remove:
• engine left side cover 1

7. Remove:
• timing mark accessing screw 1
• crankshaft end cover 2

8. Remove:
• decompression solenoid cover 1
• camshaft sprocket cover 2

3-9

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

9. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0 ~ 0.04 mm (0 ~ 0.0016 in)
Exhaust valve
0 ~ 0.04 mm (0 ~ 0.0016 in)

CAUTION:
ACHTUNG:
Be sure to check the intake and exhaust
valves.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Piston #1 TDC (rear cylinder)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a
on the pickup coil rotor with the pointer
b on the clutch/pickup coil rotor cover.
c. Check the camshaft drive gear mark c
position and camshaft driven gear mark
d position as shown.
If the marks are not aligned, turn the
crankshaft counterclockwise 360 degrees
and recheck step b.
d. Measure the valve clearance with a thickness gauge.
Piston #2 TDC (front cylinder)
a. Turn the crankshaft counterclockwise
from the piston #1 TDC by 405 degrees.
b. When piston #2 is at TDC on the compression stoke, align the TDC mark e on
the pickup coil rotor with the pointer b
on the clutch/pickup coil rotor cover.
c. Check the camshaft drive gear mark c
position and camshaft driven gear mark
d position as shown.
d. Measure the valve clearance with a thickness gauge.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 10

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

10.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.

Adjusting
screw side

Slip side

Direction a

Valve clearance is
increased.

Valve clearance is
decreased.

Direction b

Valve clearance is
decreased.

Valve clearance is
increased.

d. Hold the adjusting screw to prevent it
from moving and tighten the locknut to
specification.

Locknut
20 Nm (2.0 m • kg, 14 ft • lb)

e. Measure the valve clearance again.
f. If the valve clearance is still out of specification, repeat all of the valve clearance
adjustment steps until the specified
clearance is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

11.Install:
• all removed parts
NOTE:
For installation, reverse the removal procedure. Note the following points.
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS” in chapter 5.
12.Adjust:
• installed shift rod length
Refer to “ADJUSTING THE SHIFT
PEDAL”.

3 - 11

ADJUSTING THE ENGINE IDLING SPEED

CHK
ADJ

EAS00054

ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed,
the carburetor synchronization should be
adjusted properly, the air filter element
should be clean, and the engine should
have adequate compression.
1. Start the engine and let it warm up for
several minutes.
2. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
3. Remove:
• fuel tank bolt 1
4. Lift up the fuel tank end.

5. Install:
• inductive tachometer 1
(onto the spark plug lead of cylinder #1)
Inductive tachometer
YU8036-A
6. Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
850 ~ 950 r/min

7. Adjust:
• engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the throttle stop screw 1 in direction a or b until the specified engine
idling speed is obtained.
Direction a

Engine idling speed is
increased.

Direction b

Engine idling speed is
decreased.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 12

ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK
ADJ

8. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 8 mm (0.16 ~ 0.31 in)

EAS00058

ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed should be
adjusted.

1. Measure:
• throttle cable free play a
Out of specification → Adjust.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 8 mm (0.16 ~ 0.31 in)

2. Adjust:
• throttle cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
Carburetor side
a. Remove the rider seat and fuel tank.
Refer to “SEATS AND SIDE COVERS”
and “FUEL TANK”.
b. Loosen the locknut 2 on the decelerator
cable.
c. Turn the adjusting nut 3 in direction a
or b to take up any slack on the decelerator cable.
d. Loosen the locknut 4 on the accelerator
cable.
3 - 13

ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS

CHK
ADJ

e. Turn the adjusting nut 5 in direction a
or b until the specified throttle cable free
play is obtained.
Direction a

Throttle cable free play is
increased.

Direction b

Throttle cable free play is
decreased.

f. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot be obtained on the carburetor side of
the cable, use the adjusting nut on the handlebar side.
g. Install the fuel tank and rider seat. Refer
to “FUEL TANK” and “SEATS AND SIDE
COVERS”.
Handlebar side
a. Loosen the locknut 6.
b. Turn the adjusting nut 7 in direction c
or d until the specified throttle cable free
play is obtained.
Direction c

Throttle cable free play is
increased.

Direction d

Throttle cable free play is
decreased.

c. Tighten the locknut.

WARNING
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00059

CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND SIDE COVERS”
and “FUEL TANK”.
3 - 14

CHECKING THE SPARK PLUGS
2.
•
3.
•

CHK
ADJ

Disconnect:
spark plug cap
Remove:
spark plug

CAUTION:
ACHTUNG:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to prevent
it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect → Change.
Spark plugs
Model (manufacturer)
DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)

5. Check:
• electrodes 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 gauge)
Out of specification → Regap.
Spark plug gap
0.8 ~ 0.9 mm (0.031 ~ 0.35 in)

T.
R.

8. Install:
• spark plug

18 Nm (1.8 m · kg, 13 ft · lb)

NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
9. Connect:
• spark plug cap
10.Install:
• fuel tank
• rider seat
Refer to “FUEL TANK” and “SEATS AND
SIDE COVERS”.
3 - 15

CHECKING THE IGNITION TIMING

CHK
ADJ

EAS00061

CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check
the wiring connections of the entire ignition
system. Make sure all connections are tight
and free of corrosion.
1. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
2. Remove:
• fuel tank bolt 1
3. Lift up the fuel tank end.

3
4. Remove:
• shift rod 1

5. Remove:
• rider footrest (left) bolts 1

6. Remove:
• engine left side cover 1

3 - 16

CHECKING THE IGNITION TIMING

CHK
ADJ

7. Remove:
• timing mark accessing screw 1

8. Install:
• timing light 1
• inductive tachometer 2
(onto the spark plug lead of cylinder #1)
Timing light
YU-33277-A
Inductive tachometer
YU-8036-A

9. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Start the engine, warm it up for several
minutes, and then let it run at the specified engine idling speed.
Engine idling speed
850 ~ 950 r/min
b. Check that the pointer a is within the
required firing range b on the pickup
coil rotor.
Incorrect firing range → Check the ignition system.
NOTE:
The ignition timing is not adjustable.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

10.Install:
• all removed parts
NOTE:
For installation, reverse the removal procedure. Note the following point.
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS” in chapter 5.

3 - 17

CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE

CHK
ADJ

11.Adjust:
• installed shift rod length
Refer to “ADJUSTING
PEDAL”.

THE

SHIFT

EAS00065

MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of
the cylinders.
NOTE:
Insufficient compression pressure
result in a loss of performance.

will

1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND SIDE COVERS”
and “FUEL TANK”.
4. Remove:
• camshaft sprocket cover
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
• decompression solenoid
Refer to “CAMSHAFTS”.
5. Install:
• camshaft sprocket cover
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
6. Disconnect:
• spark plug cap
7. Remove:
• spark plug

CAUTION:
ACHTUNG:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
3 - 18

MEASURING THE COMPRESSION PRESSURE

CHK
ADJ

8. Install:
• compression gauge 1
• compression gauge adapter 2
Compression gauge
YU-33223
Compression gauge adapter
YU-33223-3

9. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
1,000 kPa (10 kg/cm2, 142 psi)
Standard
1,200 kPa (12 kg/cm2, 171 psi)
Maximum
1,400 kPa (14 kg/cm2, 199 psi)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure
between cylinders should not exceed
100 kPa (1 kg/cm2, 14 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder head, valve surfaces, and piston
crown for carbon deposits.
d. Carbon deposits → Eliminate.
e. If the compression pressure is below the
minimum specification, squirt a few
drops of oil into the cylinder and measure again.

3 - 19

MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL

CHK
ADJ

Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading

Diagnosis

Higher than without oil

Piston wear or damage → Repair.

Piston rings,
valves, cylinder
Same as without oil head gasket, or piston possibly defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

10.Install:
• spark plug
T.
R.

18 Nm (1.8 m · kg, 13 ft · lb)

11.Connect:
• spark plug cap
12.Remove:
• camshaft sprocket cover
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
13.Install:
• decompression solenoid
Refer to “CAMSHAFTS”.
• camshaft sprocket cover
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
14.Install:
• fuel tank
• rider seat
Refer to “FUEL TANK” and “SEATS AND
SIDE COVERS”.

EAS00071

CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.
2. Start the engine and warm it up by running the engine or letting the engine run
at idle for 15 minutes until the engine oil
inside of the oil tank has reached a temperature of 60 ˚C (140 ˚F) and then turn it
off.
3 - 20

CHECKING THE ENGINE OIL LEVEL

CHK
ADJ

3. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
4. Remove:
• dipstick 1
5. Check:
• engine oil level
The engine oil level should be between
the minimum level mark a and maximum level mark b.
Below the minimum level mark → Add
the recommended engine oil to the
proper level.
NOTE:
• Before checking the engine oil level, wait
a few minutes until the oil has settled.
• Do not screw the dipstick in when insecting the oil level.

Recommended oil
Yamalube 4 (20W 40) or
SAE 20W40 type SE motor oil

CAUTION:
ACHTUNG:
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.
• Do not allow foreign materials to enter
the crankcase.
NOTE:
API Service “SE”, “SF” and “SG” type or
equivalent (e.g., “SF-SE”, “SF-SE-CC”, “SFSE-SD”).
6. Install:
• dipstick

3 - 21

CHANGING THE ENGINE OIL

CHK
ADJ

EAS00073

CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several
minutes, and then turn it off.
2. Place a container under the engine oil
drain bolt.
3. Remove:
• dipstick 1
• engine oil drain bolt (oil tank) 2
• engine oil drain bolt (engine) 3
4. Drain:
• engine oil
(completely from the oil tank and crankcase)

5. If the oil filter cartridge is also to be
replaced, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the oil filter cartridge 1 with an
oil filter wrench 2.
Oil filter wrench
YU-38411

b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine
oil.

CAUTION:
ACHTUNG:
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.

3 - 22

CHANGING THE ENGINE OIL

CHK
ADJ

c. Tighten the new oil filter cartridge to
specification with an oil filter wrench.

Oil filter cartridge
17 Nm (1.7 m • kg, 12 ft • lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Check:
• engine oil drain bolt gasket
Damage → Replace.
7. Install:
• engine oil drain bolt
T.
R.

43 Nm (4.3 m · kg, 31 ft · lb)

8. Fill:
• oil tank
(with the specified amount of the recommended engine oil)

Quantity
Total amount
5.0 L (4.4 lmp qt, 5.3 US qt)
Periodic oil replacement
3.7 L (3.3 lmp qt, 3.9 US qt)
With oil filter cartridge replacement
4.1 L (3.6 lmp qt, 4.3 US qt)
NOTE:
• Pour the engine oil in several stages.
• First, pour in 2.5 L (2.2 Imp qt, 2.6 US qt)
of oil, and then start the engine and rev it
3 to 5 times. Stop the engine, and then
pour in the remainder of the specified
amount.

CAUTION:
ACHTUNG:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
9. Fill: (when the engine is disassembled)
• crankcase and oil tank
Quantity
Total amount
5.0 L (4.4 lmp qt, 5.3 US qt)
Oil tank
2.0 L (1.8 lmp qt, 2.1 US qt)
Crankcase
3.0 L (2.6 lmp qt, 3.2 US qt)

3 - 23

CHANGING THE ENGINE OIL

CHK
ADJ

NOTE:
After the engine has been disassembled,
pour the specified amount of engine oil into
the crankcase and the oil tank. When pouring engine oil into the crankcase, pour it
into the hole of the removed bolt 1.
10.Install:
• dipstick
11.Start the engine, warm it up for several
minutes, and then turn it off.
12.Check:
• engine
(for engine oil leaks)
13.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

14.Check:
• engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Slightly loosen the oil gallery bolt 1.

b. Start the engine and keep it idling until
engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after
one minute, turn the engine off so that it
will not seize.
c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “ENGINE OIL
PUMP” in chapter 5.
d. Start the engine after solving the problem(s) and check the engine oil pressure
again.
e. Tighten the oil gallery bolt to specification.

Oil gallery bolt
21 Nm (2.1 m • kg, 15 ft • lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 24

MEASURING THE ENGINE OIL PRESSURE

CHK
ADJ

EAS00077

MEASURING THE ENGINE OIL PRESSURE
1. Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
2. Start the engine, warm it up for several
minutes, and then turn it off.

CAUTION:
ACHTUNG:
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.

3
3. Remove:
• oil gallery bolt 1

WARNING
WARNING
The engine, muffler and engine oil are
extremely hot.

4. Install:
• oil pressure gauge 1
Oil pressure gauge
90890-03153
5. Measure:
• engine oil pressure
(at the following conditions)
Engine oil pressure
0.4 ~ 0.8 kPa (0.004 ~
0.008 kg/cm2, 0.057 ~ 0.114 psi)
Engine speed
Approx. 900 r/min
Engine oil temperature
60 ˚C (140 ˚F)

3 - 25

MEASURING THE ENGINE OIL PRESSURE/
CHECKING THE TRANSFER GEAR OIL LEVEL

CHK
ADJ

Out of specification → Adjust.
Engine oil pressure

Possible causes

Below specification

• Faulty oil pump
• Clogged oil filter
• Leaking oil passage

• Leaking oil passage
Broken or damaged
• Faulty oil filter
oil seal
Above specification • Oil viscosity too
high
6. Install:
• oil gallery bolt
T.
R.

20 Nm (2.0 m · kg, 14 ft · lb)

CHECKING THE TRANSFER GEAR OIL
LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.

2. Remove:
• checking bolt 1

3. Check:
• transfer gear oil level
The transfer gear oil level should be up
to the brim 1 of the hole.
Below the brim → Add the recommended transfer gear oil to the proper
level.
Recommended oil
SAE80API “GL-4” Hypoid gear oil
3 - 26

CHECKING THE TRANSFER GEAR OIL LEVEL/
CHANGING THE TRANSFER GEAR OIL

CHK
ADJ

CAUTION:
ACHTUNG:
Do not allow foreign materials to enter the
transfer case.
4. Install:
• checking bolt
T.
R.

8 Nm (0.8 m · kg, 5.8 ft · lb)

CHANGING THE TRANSFER GEAR OIL
1. Place a container under the transfer gear
oil drain bolt.
2. Remove:
• straight plug 1
• transfer gear oil drain bolt 2
3. Drain:
• transfer gear oil
(completely from the transfer gear case)
4. Check:
• transfer gear oil drain bolt gasket
Damage → Replace.
5. Install:
• transfer gear oil drain bolt

T.
R.

18 Nm (1.8 m · kg, 13 ft · lb)

6. Fill:
• transfer gear case
(with the specified amount of the recommended transfer gear oil)
Quantity
Total amount
0.4 L (0.35 Imp qt, 0.42 US qt)

7.
•
8.
•

3 - 27

Install:
straight plug
Check:
transfer gear oil level
Refer to “CHECKING THE TRANSFER
GEAR OIL LEVEL”.

ADJUSTING THE CLUTCH CABLE FREE PLAY

CHK
ADJ

EAS00078

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

Handlebar side
a. Pull the boot 1 off.
b. Loosen the locknut 2.
c. Turn the adjusting bolt 3 in direction a
or b until the specified clutch cable free
play is obtained.
Direction a

Clutch cable free play is
increased.

Direction b

Clutch cable free play is
decreased.

d. Tighten the locknut.
NOTE:
If the specified clutch cable free play cannot
be obtained on the handlebar side of the
cable, use the adjusting nut on the engine
side.
e. Pull the boot 1 in.
Engine side
a. Loosen the locknut 4.
b. Turn the adjusting bolt 5 in direction c
or d until the specified clutch cable free
play is obtained.
Direction c

Clutch cable free play is
increased.

Direction d

Clutch cable free play is
decreased.

c. Tighten the locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 28

CLEANING THE AIR FILTER ELEMENT

CHK
ADJ

EAS00086

CLEANING THE AIR FILTER ELEMENT
1. Remove:
• air filter case
Refer to “AIR FILTER CASE”.
2. Remove:
• air filter case cover 1
• air filter element 2

3
3. Clean:
• air filter element
Apply compressed air to the outer surface of the air filter element.
4. Check:
• air filter element
Damage → Replace.
• O-ring
Damage → Replace.
5. Install:
• air filter element
• air filter case cover

CAUTION:
ACHTUNG:
Never operate the engine without the air
filter 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
overheating.
NOTE:
When installing the air filter element into
the air filter case cover, make sure their
sealing surfaces are aligned to prevent any
air leaks.
6. Install:
• air filter case
Refer to “AIR FILTER CASE”.
3 - 29

CHECKING THE CARBURETOR JOINT/
CHECKING THE FUEL HOSES AND FUEL FILTER

CHK
ADJ

EAS00094

CHECKING THE CARBURETOR JOINT
1. Remove:
• carburetor assembly
Refer to “CARBURETOR” in chapter 6.
2. Check:
• carburetor joint 1
Cracks/damage → Replace.
Refer to “CARBURETOR” in chapter 6.
3. Install:
• carburetor assembly
Refer to “CARBURETOR” in chapter 6.

3
EAS00097

CHECKING THE FUEL HOSES AND FUEL
FILTER
The following procedure applies to all of
the fuel hoses.
1. Remove:
• fuel pump cover 1

2. Check:
• fuel hose 1
Cracks/damage → Replace.
• fuel filter 2
Contaminants/damage → Replace.
NOTE:
• Drain and flush the fuel tank if abrasive
damage to any components of the fuel
line is evident.
• The arrow mark on the fuel filter must
point towards the fuel pump 3 as shown.
3. Install:
• fuel pump cover

3 - 30

CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER
GEAR CASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM

CHK
ADJ

EAS00098

CHECKING THE CYLINDER HEAD
BREATHER HOSE AND TRANSFER GEAR
CASE BREATHER HOSE
1. Remove:
• rider seat
• fuel tank
Refer to “SEATS AND SIDE COVERS”
and “FUEL TANK”.
2. Check:
• oil pump breather hose 1
• cylinder head breather hose 2
Cracks/damage → Replace.
Loose connection → Connect properly.

CAUTION:
ACHTUNG:

Make sure the crankcase breather hose is
routed correctly.
3. Install:
• fuel tank
• rider seat
Refer to “FUEL TANK” and “SEATS AND
SIDE COVERS”.

EAS00100

CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of
the exhaust pipes, mufflers and gaskets.
1. Check:
• exhaust pipe 1
• muffler 2
Cracks/damage → Replace.
• gasket 3
Exhaust gas leaks → Replace.
2. Measure:
• tightening torque

T.
R.

3 - 31

Exhaust pipe nut 4
20 Nm (2.0 m • kg, 14 ft • lb)
Exhaust pipe and muffler bolt 5
25 Nm (2.5 m • kg, 18 ft • lb)
Muffler and muffler bracket bolt 6
30 Nm (3.0 m • kg, 22 ft • lb)

ADJUSTING THE FRONT BRAKE

CHK
ADJ

EAS00108

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

a. Loosen the locknut 1.

b. Turn the adjusting screw 2 in direction
a or b until the specified brake lever
free play is obtained.
Direction a

Brake lever free play is
increased.

Direction b

Brake lever free play is
decreased.

c. Tighten the locknut.

WARNING
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.

CAUTION:
ACHTUNG:
After adjusting the brake lever free play,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 32

ADJUSTING THE REAR BRAKE

CHK
ADJ

EAS00110

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

a. Loosen the locknut 1.

b. Turn the adjusting bolt 2 in direction a
or b until the specified brake pedal position is obtained.
Direction a

Brake pedal is raised.

Direction b

Brake pedal is lowered.

WARNING
WARNING
After adjusting the brake pedal position,
check that the end c of the adjusting bolt
is visible through the hole d.
c. Tighten the locknut 1 to specification.

Locknut
18 Nm (1.8 m • kg, 13 ft • lb)

WARNING
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.

CAUTION:
ACHTUNG:
After adjusting the brake pedal position,
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
3 - 33
LIGHT SWITCH”.

CHECKING THE BRAKE FLUID LEVEL

CHK
ADJ

EAS00115

CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.

2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.

Recommended brake fluid
DOT 4
Å Front brake
ı Rear brake
ı

WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• 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:
ACHTUNG:
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.

3 - 34

CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE
PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHK
ADJ

EAS00120

CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• brake pad
Wear indicator groove 1 almost disappeared → Replace the brake pads as a
set.
Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 4.
Brake pad wear limit a
0.5 mm (0.02 in)

3
EAS00118

CHECKING THE REAR BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• brake pad
Wear indicators 1 almost touch the
brake disc → Replace the brake pads as a
set.
Refer to “REPLACING THE REAR BRAKE
PADS” in chapter 4.
Brake pad wear limit a
0.5 mm (0.02 in)

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.
3 - 35

ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE BRAKE HOSE

CHK
ADJ

1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Hold the main body 1 of the rear brake
light switch so that it does not rotate and
turn the adjusting nut 2 in direction a
or b until the rear brake light comes on
at the proper time.
Direction a

Brake light comes on
sooner.

Direction b

Brake light comes on
later.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00129

CHECKING THE BRAKE HOSE
1. Check:
• brake hose
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the front or rear brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.

3 - 36

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK
ADJ

EAS00134

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING
WARNING
Bleed the hydraulic brake system whenever:
• the brake system was disassembled,
• a brake hose was loosened, disconnected, or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
1. Remove:
• muffler
• muffler bracket 1

3
2. Remove:
• plastic clamps 1
NOTE:
• Be careful not to spill any brake fluid or
allow the brake master cylinder reservoir
or brake fluid reservoir to overflow.
• 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 lengthening 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.

3. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).

3 - 37

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK
ADJ

c. Connect a clear plastic hose 1 tightly to
the bleed screw 2.
Å Front

ı Rear

d. Place the other end of the hose into a
container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact the throttle grip or the brake pedal to
fully extend.
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the
brake fluid in the plastic hose.
j. Tighten the bleed screw to specification.

Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)

k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

WARNING
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Install:
• plastic clamps
• muffler bracket
T.
R.

26 Nm (2.6 m · kg, 19 ft · lb)

• muffler
5. Tighten:
• muffler bolts
T.
R.

30 Nm (3.0 m · kg, 22 ft · lb)

• muffler clamp bolts
T.
R.

3 - 38

25 Nm (2.5 m · kg, 18 ft · lb)

ADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE BELT SLACK

CHK
ADJ

EAS00137

ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined by
the installed shift rod length a.
1. Measure:
• installed shift rod length a
Incorrect → Adjust.
Installed shift rod length
374.4 ~ 378.4 mm
(14.74 ~ 14.90 in)
2. Adjust:
• installed shift rod length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Loosen both locknuts 1.

b. Turn the shift rod 2 in direction b or c
to obtain the correct shift pedal position.
Direction b

Installed shift rod length
increases.

Direction c

Installed shift rod length
decreases.

c. Tighten both locknuts.
d. Make sure the installed shift rod length is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ADJUSTING THE DRIVE BELT SLACK

CAUTION:
ACHTUNG:
A drive belt 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 belt slack within the specified limits.
NOTE:
Measure the drive belt slack when the
engine is cold, and when the drive belt is
dry.

3 - 39

ADJUSTING THE DRIVE BELT SLACK

CHK
ADJ

1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on the sidestand and
or on a suitable stand so that the rear wheel
is elevated.
2. Rotate the rear wheel several times and
check the drive belt to locate its tightest
point.

3
3. Measure:
• drive belt slack a
Out of specification → Adjust.
Drive belt slack
On the sidestand
7.5 ~ 13 mm at 4.5 kg
(0.30 ~ 0.51 in at 10 lbs)
On a suitable stand
14 ~ 21 mm at 4.5 kg
(0.55 ~ 0.83 in at 10 lbs)
Belt tension gauge
YM-03170
NOTE:
• The level marks of the level window on
the lower drive belt cover are in units of 5
mm (0.20 in). Use them as a standard for
measuring the drive belt slack.
• Measure the drive belt slack when the
drive belt has been pushed with 4.5 kg (10
lbs) of pressure using a belt tension
gauge 1.
4. Adjust:
• drive belt slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

NOTE:
Place the motorcycle on the suitable stand
so that the rear wheel is elevated.
3 - 40

ADJUSTING THE DRIVE BELT SLACK/
CHECKING AND ADJUSTING THE STEERING HEAD

CHK
ADJ

a. Loosen the brake caliper bracket bolt 1.
b. Loosen the wheel axle nut 2.
c. Loosen both locknuts 3.
Å Right

ı Left

d. Turn both adjusting bolts 4 in direction
a or b until the specified drive chain
slack is obtained.
Direction a

Drive belt slack is
reduced.

Direction b

Drive belt slack is
increased.

NOTE:
To maintain the proper wheel alignment,
adjust both sides evenly.

e. Tighten both locknuts to specification.

Locknut
32 Nm (3.2 m • kg, 23 ft • lb)

f. Tighten the
specification.

wheel

axle

nut

Wheel axle nut
150 Nm (15.0 m • kg, 110 ft • lb)

g. Tighten the brake caliper bracket bolt to
specification.

Brake caliper bracket bolt
40 Nm (4.0 m • kg, 29 ft • lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00146

CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.

3 - 41

CHECKING AND ADJUSTING THE STEERING HEAD

CHK
ADJ

2. Check:
• steering head
Grasp the bottom of the front fork legs
and gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• meter assembly
Refer to “FUEL TANK”.
4.
•
5.
•
•
•

Loosen:
upper bracket pinch bolts 1
Remove:
steering stem nut 2
washer
upper bracket 3

3
6. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.

b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring nut
wrench 5.
NOTE:
Set the torque wrench at a right angle to the
ring nut wrench.
Ring nut wrench
YU-33975

T.
R.

Lower ring nut (initial tightening
torque)
52 Nm (5.2 m • kg, 37 ft • lb)

c. Loosen the lower ring nut completely,
then tighten it to specification.

WARNING
WARNING
Do not overtighten the lower ring nut.

T.
R.

3 - 42

Lower ring nut (final tightening
torque)
3 Nm (0.3 m • kg, 2.2 ft • lb)

CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK

CHK
ADJ

d. Check the steering head for looseness or
binding by turning the front fork all the
way in both directions. If any binding is
felt, remove the lower bracket and check
the upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2, then
align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten
the upper ring nut until their slots are
aligned.
h. Install the lock washer 1.
NOTE:
Make sure the lock washer tabs sit correctly
in the ring nut slots.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7.
•
•
•

Install:
upper bracket
washer
steering stem nut
T.
R.

130 Nm (13.0 m · kg, 94 ft · lb)

8. Tighten:
• upper bracket pinch bolt
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

9. Install:
• meter assembly
Refer to “FUEL TANK”.

EAS00149

CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

3 - 43

CHECKING THE FRONT FORK/
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

CHK
ADJ

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 4.

3
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload

CAUTION:
ACHTUNG:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
• spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Loosen the locknut 1

b. Turn the adjusting ring 2 in direction a
or b.

3 - 44

Direction a

Spring preload is
increased (suspension is
harder).

Direction b

Spring preload is
decreased (suspension is
softer).

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/
CHECKING THE TIRES

CHK
ADJ

Adjusting length a
Minimum 42.5 mm (1.67 in)
Standard 42.5 mm (1.67 in)
Maximum 51.5 mm (2.03 in)

CAUTION:
ACHTUNG:
Never turn the adjusting ring beyond the
maximum or minimum setting.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3
EAS00166

CHECKING THE TIRES
The following procedure applies to both of
the tires.
1. Measure:
• tire pressure
Out of specification → Regulate.

WARNING
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.

3 - 45

CHECKING THE TIRES

CHK
ADJ

Basic weight
332 kg (732 lb): XV16A
(with oil and a
347 kg (765 lb): XV16AT
full fuel tank)
Maximum
load*

196 kg (432 lb): XV16A
181 kg (399 lb): XV16AT

Cold tire pressure
Up to 90 kg
load*

Front tire

Rear tire

250 kPa
250 kPa
2
(2.5 kgf/cm , (2.5 kgf/cm2,
36 psi)
36 psi)

250 kPa
280 kPa
90 kg ~ maxi(2.5 kgf/cm2, (2.8 kgf/cm2,
mum load*
36 psi)
40 psi)
High-speed
riding

250 kPa
280 kPa
(2.5 kgf/cm2, (2.8 kgf/cm2,
36 psi)
40 psi)

* total of cargo, rider, passenger and accessories

WARNING
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1 Tire tread depth
2 Side wall
3 Wear indicator

WARNING
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 a tube tire, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
3 - 46

CHECKING THE TIRES

CHK
ADJ

• 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 recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality
replacement.
Å Tire
Å

ı Wheel

Tube wheel

Tube tire only

Tubeless wheel

Tube or tubeless
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 handling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.

Front tire
Manufacturer

Size

Model

BRIDGESTONE

130/90-16
67H

G703F

DUNLOP

130/90-16
67H

D404FL

Manufacturer

Size

Model

BRIDGESTONE

150/80 B16
71H

G702

DUNLOP

150/80 B16
71H

D404

Rear tire

3 - 47

CHECKING THE TIRES/
CHECKING AND TIGHTENING THE SPOKES

CHK
ADJ

WARNING
WARNING
• After mounting a new tire, ride conservatively 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 damage to the motorcycle.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 4 to specification.
NOTE:
For tires with a direction of rotation mark
5:
• Install the tire with the mark pointing in
the direction of wheel rotation.
• Align the mark 6 with the valve installation point.

Tire air valve stem locknut
1.5 Nm (0.5 m • kg, 1.1 ft • Ib)

EAS00169

CHECKING AND TIGHTENING THE SPOKES
The following procedure applies to all of
the spokes.
1. Check:
• spoke
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.

3 - 48

CHECKING AND TIGHTENING THE SPOKES/
CHECKING AND LUBRICATING THE CABLES

CHK
ADJ

2. Tighten:
• spokes
(with a spoke wrench 1)
T.
R.

3 Nm (0.3 m · kg, 2.2 ft · lb)

NOTE:
Be sure to tighten the spokes before and
after break-in.

EAS00170

CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of
the cable sheaths and cables.

WARNING
WARNING

Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement.
Replace
damaged
cable
sheaths and cables as soon as possible.
1. Check:
• cable sheath
Damage → Replace.

2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
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 lubing device.

3 - 49

LUBRICATING THE LEVERS AND PEDALS/LUBRICATING
THE SIDESTAND/LUBRICATING THE REAR SUSPENSION

CHK
ADJ

EAS00171

LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-tometal moving parts of the levers and pedals.
Recommended lubricant
Lithium soap base grease

EAS00172

LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-tometal moving parts of the sidestand.
Recommended lubricant
Lithium soap base grease

EAS00174

LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-tometal moving parts of the rear suspension.
Recommended lubricant
Molybdenum disulfide grease

3 - 50

CHECKING AND CHARGING THE BATTERY

CHK
ADJ

EAS00178

ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY

WARNING
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• 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 handling 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 followed with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.

CAUTION:
ACHTUNG:
Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.

3 - 51

CHECKING AND CHARGING THE BATTERY

CHK
ADJ

NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery
by measuring the specific gravity of the
electrolyte. Therefore, the charge of the battery has to be checked by measuring the
voltage at the battery terminals.
1. Remove:
• rider seat
Refer to “SEATS AND SIDE COVERS”.
2. Disconnect:
• battery leads
(from the battery terminals)

CAUTION:
ACHTUNG:
First, disconnect the negative battery lead
1, then the positive battery lead 2.
3.
•
•
4.
•

Remove:
battery band
battery
Measure:
battery charge

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit
voltage (i.e., the voltage when the positive
battery terminal is disconnected).
• No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as
shown in the charts and the following
example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30 %
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 52

CHECKING AND CHARGING THE BATTERY

CHK
ADJ

5. Charge:
• battery
(refer to the appropriate
method illustration)

charging

WARNING
WARNING
Do not quick charge a battery.

CAUTION:
ACHTUNG:
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
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 charging has to be done with the battery
mounted on the motorcycle, disconnect
the negative battery lead from the battery
terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery 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 terminals and that they are not shorted. A corroded 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!
• As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit voltage.

3 - 53

CHECKING AND CHARGING THE BATTERY

CHK
ADJ

Charging method using a variable voltage charger

3 - 54

CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger

3 - 55

CHK
ADJ

CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
6.
•
•
7.
•

CHK
ADJ

Install:
battery
battery band
Connect:
battery leads
(to the battery terminals)

CAUTION:
ACHTUNG:
First, connect the positive battery lead 1,
then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• rider seat
Refer to “SEATS AND SIDE COVERS”.

EAS00181

CHECKING THE FUSES
The following procedure applies to all of
the fuses.

CAUTION:
ACHTUNG:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• left side cover
Refer to “SEATS AND SIDE COVERS”.
2. Check:
• continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the pocket tester to the fuse and
check the continuity.

3 - 56

CHECKING THE FUSES

CHK
ADJ

NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
YU-03112
b. If the pocket tester indicates “∞”, replace
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.

c. Set the main switch to “ON” and verify if
the electrical circuit is operational.
d. If the fuse immediately blows again,
check the electrical circuit.
Item

Amperage

Q’ty

Main fuse

30A

Headlight fuse

15A

Ignition fuse

15A

Signaling system fuse

10A

Carburetor
heater fuse

10A

Backup fuse

Reserve fuse

30A

Reserve fuse

15A

Reserve fuse

10A

Reserve fuse

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

WARNING
WARNING
Never use a fuse with an amperage other
than that specified. Improvising or using a
fuse with the wrong amperage may cause
extensive damage to the electrical system,
cause the lighting and ignition systems to
malfunction and could possibly cause a fire.
3 - 57

CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULB

CHK
ADJ

4. Install:
• left side cover
Refer to “SEATS AND SIDE COVERS”.

EAS00182

REPLACING THE HEADLIGHT BULB
1. Remove:
• screws 1
• headlight lens unit 2

3
2.
•
3.
•

Disconnect:
headlight coupler 1
Remove:
headlight bulb holder cover 2

4.
•
5.
•

Detach:
headlight bulb holder 1
Remove:
headlight bulb 2

WARNING
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

3 - 58

REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM

CHK
ADJ

6. Install:
New
• headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.

CAUTION:
ACHTUNG:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
7. Attach:
• headlight bulb holder
8. Install:
• headlight bulb holder cover
9. Connect:
• headlight coupler
10.Install:
• headlight lens unit
• screws

EAS00184

ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the adjusting screw 1 in direction
a or b.
Direction a

Headlight beam is raised.

Direction b

Headlight beam is lowered.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 59

ADJUSTING THE HEADLIGHT BEAM

CHK
ADJ

2. Adjust:
• headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the adjusting knob 2 in direction a
or b.
Direction a

Headlight beam moves to
the right.

Direction b

Headlight beam moves to
the left.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3 - 60

INSTRUMENT FUNCTIONS

CHK
ADJ

INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
1 Fuel indicator light “
”
2 High beam indicator light “
”
3 Turn indicator light “
”
4 Neutral indicator light “
”
5 Engine trouble indicator light “

”

Neutral indicator light “
”
This indicator comes on when the transmission is in neutral.
High beam indicator light “
”
This indicator comes on when the headlight high beam is used.
Turn indicator light “
”
This indicator flashes when the turn
switch is moved to the left or right.
Fuel level indicator light “
”
When the fuel level drops below approximately 3.5 L (0.8 Imp gal, 0.9 US gal), this
light will come on. When this light comes
on, turn the fuel cock to “RES”. Then, fill
the tank at the first opportunity.
Engine trouble indicator light “
”
This indicator light will come on or flash
if trouble occurs in a monitoring circuit.
In such a case, take the motorcycle to a
Yamaha dealer to have the self-diagnostic systems checked.

COMBINATION METER
1 Combination meter
2 Clock
3 Odometer/trip meter
4 Mode button
5 Set button

This combination meter is equipped with an
odometer and a twin trip meter. Pushing
the mode button will change the display
from one to the other as follows.
“ODO” → “TRIP A” → “TRIP B” → “ODO”
When set to “ODO”, it indicates the motorcycle’s total mileage. When set to “TRIP A”
or “TRIP B”, it indicates the motorcycle’s
mileage since the trip meter was last reset.
Use the trip meter to estimate how far you
can ride on a tank of fuel. This information
will enable you to plan fuel stops in the
future.
3 - 61

INSTRUMENT FUNCTIONS

CHK
ADJ

To reset the trip meter to “0”, push the set
button until it displays “TRIP A” or “TRIP
B”, then push mode button and hold it
down for at least one second.
NOTE:
This motorcycle does not have a tachometer. However, it is equipped with an engine
revolution limiter, which prevents the
engine revolution from exceeding approximately 4,400 r/min.

3
Setting the clock
This clock always shows the time regardless of the main switch position.
1. Turn the main switch to “ON”.
2. Press both left and right buttons simultaneously until both hours and minutes
flash. 1
3. Push the left button and the hour display
will flash. 2
4. Push the right button to change the
hours. 3
5. Push the left button and the minute display will flash. 4
6. Push the right button to change the minutes. 5
7. Push the left button and both hours and
minutes will flash. 6
8. Push the right button for two seconds to
set the clock. 7

3 - 62

CHAS
CONTENTS
CHASSIS

FRONT WHEEL AND BRAKE DISCS ........................................................... 4-1
REMOVING THE FRONT WHEEL ........................................................ 4-3
DISASSEMBLING THE FRONT WHEEL .............................................. 4-3
CHECKING THE FRONT WHEEL .......................................................... 4-4
CHECKING THE BRAKE DISCS ............................................................ 4-6
ASSEMBLING THE FRONT WHEEL .................................................... 4-7
INSTALLING THE FRONT WHEEL ....................................................... 4-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE ....................... 4-9
REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY ...................... 4-11
REMOVING THE REAR WHEEL ......................................................... 4-16
CHECKING THE REAR WHEEL .......................................................... 4-16
CHECKING THE REAR WHEEL DRIVE HUB ...................................... 4-17
CHECKING AND REPLACING THE REAR WHEEL PULLEY ............. 4-17
ASSEMBLING THE REAR WHEEL ..................................................... 4-18
INSTALLING THE REAR WHEEL ....................................................... 4-18
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................ 4-21

CHAS
FRONT AND REAR BRAKES ...................................................................... 4-22
REPLACING THE FRONT BRAKE PADS ............................................ 4-24
REPLACING THE REAR BRAKE PADS .............................................. 4-27
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER .......... 4-35
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER ............ 4-35
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ..................................................................................... 4-36
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ....................................................................... 4-37
ASSEMBLING AND INSTALLING THE REAR BRAKE
MASTER CYLINDER ....................................................................... 4-40
DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-47
DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-47
CHECKING THE FRONT AND REAR BRAKE CALIPERS .................. 4-48
ASSEMBLING AND INSTALLING THE FRONT
BRAKE CALIPERS ........................................................................... 4-49
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER ............................................................................. 4-52

FRONT FORK .............................................................................................. 4-55
REMOVING THE FRONT FORK LEGS ............................................... 4-59
DISASSEMBLING THE FRONT FORK LEGS ..................................... 4-59
CHECKING THE FRONT FORK LEGS ................................................ 4-60
ASSEMBLING THE FRONT FORK LEGS ........................................... 4-61
INSTALLING THE FRONT FORK LEGS ............................................. 4-64
HANDLEBAR ............................................................................................... 4-67
REMOVING THE HANDLEBAR .......................................................... 4-69
CHECKING THE HANDLEBAR ........................................................... 4-69
INSTALLING THE HANDLEBAR ........................................................ 4-69
STEERING HEAD ........................................................................................ 4-73
REMOVING THE LOWER BRACKET .................................................. 4-75
CHECKING THE STEERING HEAD .................................................... 4-75
INSTALLING THE STEERING HEAD ................................................. 4-76
REAR SHOCK ABSORBER AND SWINGARM .......................................... 4-79
HANDLING THE REAR SHOCK ABSORBER ..................................... 4-83
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER .............................................................................. 4-83
REMOVING THE REAR SHOCK ABSORBER AND
SWINGARM .................................................................................... 4-83
CHECKING THE REAR SHOCK ABSORBER ...................................... 4-84
CHECKING THE REPLAY ARM AND CONNECTING ARM ............... 4-85
CHECKING THE SWINGARM ............................................................ 4-85
INSTALLING THE REAR SHOCK ABSORBER AND
SWINGARM .................................................................................... 4-86

CHAS
DRIVE BELT AND DRIVE PULLEY ............................................................. 4-90
REMOVING THE DRIVE BELT AND DRIVE PULLEY ......................... 4-91
CHECKING THE DRIVE BELT ............................................................. 4-91
INSTALLING THE DRIVE BELT AND DRIVE PULLEY ....................... 4-92

FRONT WHEEL AND BRAKE DISCS

CHAS

EAS00514

CHASSIS
FRONT WHEEL AND BRAKE DISCS

Order

Job/Part
Q’ty
Remarks
Removing the front wheel and brake
Remove the parts in the order listed.
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.

1
2
3
4
5
6
7
8
9

Reflector (left and right)
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collar (left and right)
Brake disc cover (left)
Brake disc cover (right-with weight)
Brake disc (left and right)

2
2
1
1
1
2
1
1
2

Loosen.

For installation, reverse the removal
procedure.
4-1

FRONT WHEEL AND BRAKE DISCS

CHAS

Order
1
2
3

Job/Part
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer

Q’ty

Remarks
Remove the parts in the order listed.

2
2
1
For assembly, reverse the disassembly
procedure.

4-2

FRONT WHEEL AND BRAKE DISCS

CHAS

EAS00521

REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
2. Remove:
• left brake caliper
• right brake caliper
NOTE:
Do not squeeze the brake lever when
removing the brake calipers.

3. Elevate:
• front wheel

NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.

EAS00523

DISASSEMBLING THE FRONT WHEEL
1. Remove:
• oil seals
• wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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
surface.
c. Remove the wheel bearings with a general bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-3

FRONT WHEEL AND BRAKE DISCS

CHAS

EAS00526

CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.

WARNING
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
• tire
• front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

3. Check:
• spokes
Bends/damage → Replace.
Loose → Tighten.
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.

4. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Maximum radial wheel runout
1.0 mm (0.04 in)
Maximum lateral wheel runout
0.5 mm (0.02 in)

5. Check:
• collars
Damage/wear → Replace.

4-4

FRONT WHEEL AND BRAKE DISCS

CHAS

6. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage/wear → Replace.

7. Replace:
• wheel bearings
• oil seals New

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
surface.

c. Remove the wheel bearings 3 with a
general bearing puller.
d. Install the new wheel bearings and oil
seals in the reverse order of disassembly.

CAUTION:
ACHTUNG:
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-5

FRONT WHEEL AND BRAKE DISCS

CHAS

EAS00531

CHECKING THE BRAKE DISCS
The following procedure applies to all of
the brake discs.
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Maximum brake disc deflection
Front: 0.15 mm (0.006 in)
Rear: 0.15 mm (0.006 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Place the motorcycle on a suitable stand
so that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left
or right to ensure that the front wheel is
stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 1.5 mm (0.05 in)
below the edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specification → Replace.
Minimum brake disc thickness
Front: 4.5 mm (0.18 in)
Rear: 6.5 mm (0.26 in)

4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the brake disc cover and brake
disc.
b. Rotate the brake disc cover and brake
disc by one bolt hole.
c. Install the brake disc cover and brake
disc.
4-6

FRONT WHEEL AND BRAKE DISCS

CHAS

NOTE:
Tighten the brake disc bolts in stages and in
a crisscross pattern.

T.
R.

Brake disc bolt
23 Nm (2.3 m • kg, 17 ft • lb)
LOCTITE

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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00539

ASSEMBLING THE FRONT WHEEL
1. Install:
• wheel bearings
• oil seals New
Install the new wheel bearings and oil
seals in the reverse order of disassembly.

CAUTION:
ACHTUNG:
Do not contact the wheel bearing inner
race 1 or balls 2. Contact should be made
only with the outer race 3.
NOTE:
Use a socket 4 that matches the diameter
of the wheel bearing outer race and oil seal.

EAS00544

INSTALLING THE FRONT WHEEL
The following procedure applies to both
brake discs.
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium soap base grease
4-7

FRONT WHEEL AND BRAKE DISCS

CHAS

2. Install:
• brake discs
• brake disc covers
T.
R.

23 Nm (2.3 m · kg, 17 ft · lb)

NOTE:
• Apply locking agent (LOCTITE 648) to the
threads of the brake disc bolts.
• Tighten the brake disc bolts in stages and
in a crisscross pattern.
3.
•
•
•
4.
•

Install:
collars
front wheel
front wheel axle
Tighten:
front wheel axle 1
T.
R.

78 Nm (7.8 m · kg, 56 ft · lb)

• wheel axle pinch bolt 2
T.
R.

20 Nm (2.0 m · kg, 14 ft · lb)

CAUTION:
ACHTUNG:
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.

5. Install:
• brake calipers
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

WARNING
WARNING
Make sure the brake hose is routed properly.
6. Install:
• reflectors

4-8

FRONT WHEEL AND BRAKE DISCS

CHAS

EAS00549

ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel, or both, the
front wheel static balance should be
adjusted.
• Adjust the front wheel static balance with
the brake discs installed.
1.
•
2.
•

Remove:
balancing weight(s)
Find:
front wheel’s heavy spot

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Place the front wheel on a suitable balancing stand.
b. Spin the front wheel.
c. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.

d. Turn the front wheel 90˚ so that the “X1”
mark is positioned as shown.
e. Release the front wheel.
f. When the wheel stops, put an “X2” mark
at the bottom of the wheel.
g. Repeat steps (b) through (f) several times
until all the marks come to rest at the
same spot.
h. The spot where all the marks come to
rest is the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.

b. Turn the front wheel 90˚ so that the
heavy spot is positioned as shown.
4-9

FRONT WHEEL AND BRAKE DISCS

CHAS

c. If the heavy spot does not stay in that
position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the front wheel and make sure it
stays at each position shown.
b. If the front wheel does not remain stationary at all of the positions, rebalance
it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4 - 10

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

EAS00550

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

Order

1
2
3

Job/Part
Removing the rear fender and muffler
Rider seat

Q’ty

Muffler
Tail/brake light and turn signal light
sub-wire harness
Rear fender assembly

1
1

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”
in chapter 3.
Disconnect.

1
For installation, reverse the removal
procedure.

4 - 11

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

EAS00550

Order

Job/Part
Removing the rear wheel

Q’ty

Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable
stand so that the rear wheel is elevated.

1
2
3
4
5
6
7
8
9

Upper drive belt cover
Brake caliper
Brake caliper bracket bolt
Locknut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Right adjusting plate
Left adjusting plate
Rear wheel axle

1
1
1
2
2
1
1
1
1

4 - 12

Loosen.
Loosen.

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

Order
Job/Part
10
Rear wheel
11
Collar (left and right)
12
Brake caliper bracket

Q’ty
1
2
1

Remarks

For installation, reverse the removal
procedure.

4 - 13

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

EAS00556

Order

1
2
3
4
5
6
7
8
9
10
11

Job/Part
Removing the brake disc and rear
wheel pulley
Brake disc
Rear wheel pulley
Oil seal
Collar
Circlip
Bearing
Collar
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Rear wheel

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
1
1
1
1
1
6
1
For installation, reverse the removal
procedure.

4 - 14

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

EAS00560

Order
1
2
3
4

Job/Part
Disassembling the rear wheel
Oil seal
Bearing
Spacer
Bearing

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
4
For assembly, reverse the disassembly
procedure.

4 - 15

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

EAS00561

REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
2. Remove:
• brake caliper
NOTE:
Do not depress the brake pedal when
removing the brake caliper.

3. Remove:
• rear wheel
NOTE:
Push the rear wheel forward and remove
the drive belt from the rear wheel pulley.

EAS00566

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

4 - 16

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

3. Check:
• spokes
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
Cracks/damage → Replace.
• rear wheel drive hub dampers 2
Damage/wear → Replace.

EAS00568

CHECKING AND REPLACING THE REAR
WHEEL PULLEY
1. Check:
• rear wheel pulley
Surface plating has come off → Replace
the rear wheel pulley.
Bent teeth → Replace the rear wheel pulley.
2. Replace:
• rear wheel pulley
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the self-locking nuts and the
rear wheel pulley.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces that
contact the pulley.
c. Install the new rear wheel pulley.
4 - 17

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

Rear wheel pulley self-locking nut
95 Nm (9.5 m • kg, 68 ft • lb)

NOTE:
Tighten the self-locking nuts in stages and
in a crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ASSEMBLING THE REAR WHEEL
1. Install:
• bearings
• spacer
• bearing
• oil seal New
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

EAS00572

INSTALLING THE REAR WHEEL
1. Lubricate:
• oil seal lips
Recommended lubricant
Lithium soap base grease

2. Install:
• rear wheel drive hub dampers 1

3. Install:
• rear wheel drive hub assembly 1

4 - 18

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

4. Install:
• rear wheel pulley 1
T.
R.

95 Nm (9.5 m · kg, 68 ft · lb)

NOTE:
Tighten the self-locking nuts in stages and
in a crisscross pattern.

5. Install:
• brake disc
NOTE:
• Apply locking agent (LOCTITE 648) to the
threads of the brake disc bolts.
• Tighten the brake disc bolts in stages and
in a crisscross pattern.

6.
•
•
•

Install:
brake caliper bracket 1
washer
brake caliper bracket bolt 2

NOTE:
Temporarily
bracket bolt.

7.
•
•
•
•
•
•

tighten

the

brake

caliper

Install:
collars
rear wheel
adjusting plates
rear wheel axle
washer
wheel axle nut

NOTE:
Temporarily tighten the wheel axle nut.
8. Adjust:
• drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” in chapter 3.

4 - 19

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

9. Tighten:
• wheel axle nut
T.

150 Nm (15.0 m · kg, 110 ft · lb)

• brake caliper bracket bolt
T.
R.

48 Nm (4.8 m · kg, 35 ft · lb)

10.Install:
• brake caliper 1
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

11.Install:
• upper drive belt cover 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

12.Install:
• muffler
13.Tighten:
• muffler mounting bolt 1
T.
R.

30 Nm (3.0 m · kg, 22 ft · lb)

• Clamp bolt 2
T.
R.

25 Nm (2.5 m · kg, 18 ft · lb)

14.Install:
• rear fender assembly
15.Tighten:
88 Nm (8.8 m · kg, 64 ft · lb)
• nut 1
48 Nm (4.8 m · kg, 35 ft · lb)
• bolts 2
16.Connect:
• tail/brake light and turn signal light subwire harness coupler 3
R.

4 - 20

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY

CHAS

17.Install:
• rider seat
Refer to “SEATS AND SIDE COVERS” in
chapter 3.

EAS00575

ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel, or both, the
rear wheel static balance should be
adjusted.
• Adjust the rear wheel static balance with
the brake disc and rear wheel drive hub
installed.
1. Adjust:
• rear wheel static balance
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4 - 21

FRONT AND REAR BRAKES

CHAS

EAS00577

FRONT AND REAR BRAKES
FRONT BRAKE PADS

Order

1
2
3
4
5
6
7

Job/Part
Removing the front brake pads

Q’ty

Brake hose holder bolt
Retaining bolt
Brake caliper
Brake pad
Brake pad shim
Brake pad spring
Brake pad spring

Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.

1
2
1
2
1
2
1
For installation, reverse the removal
procedure.

4 - 22

FRONT AND REAR BRAKES

CHAS

EAS00578

REAR BRAKE PADS

Order

1
2
3
4
5
6

Job/Part
Removing the rear brake pads
Muffler

Q’ty

Brake caliper bolt
Brake pad cover
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad

Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC
AND REAR WHEEL PULLEY”.

2
1
2
2
1
2
For installation, reverse the removal
procedure.

4 - 23

FRONT AND REAR BRAKES

CHAS

EAS00579

CAUTION:
ACHTUNG:
Disc brake components rarely require disassembly.
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
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• 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.

EAS00580

REPLACING THE FRONT BRAKE PADS
The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose or
disassemble the brake caliper.
1.
•
•
•

4 - 24

Remove:
brake hose holder bolt 1
brake caliper retaining bolts 2
brake caliper 3

FRONT AND REAR BRAKES

CHAS

2. Remove:
• brake pads 1
(along with the brake pad shim)
• brake pad springs

3. Measure:
• brake pad thickness a
Out of specification → Replace the brake
pads as a set.
Minimum brake pad thickness
0.5 mm (0.02 in)

4. Install:
• brake pads
• brake pad springs

NOTE:
Always install new brake pads, brake pad
shim and a new brake pad springs 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, 4.3 ft • lb)

d. Install a new brake pad shim onto the
new brake pad that is on the caliper piston side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4 - 25

FRONT AND REAR BRAKES

CHAS

5. Lubricate:
• brake caliper retaining bolt
Recommended lubricant
Lithium soap base grease

CAUTION:
ACHTUNG:
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
6. Install:
• brake caliper
• brake caliper retaining bolts
T.
R.

27 Nm (2.7 m · kg, 19 ft · lb)

• brake hose holder bolt

7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

8. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4 - 26

FRONT AND REAR BRAKES

CHAS

EAS00583

REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose or
disassemble the brake caliper.
1. Remove:
• brake caliper 1
• brake pad cover 2
2.
•
•
•

Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3

3. Remove:
• brake pads 1

4. Measure:
• brake pad thickness a
Out of specification → Replace the brake
pads as a set.
Minimum brake pad thickness
0.5 mm (0.02 in)

5. Install:
• brake pads
• brake pad spring
NOTE:
Always install new brake pads and a 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.
4 - 27

FRONT AND REAR BRAKES

CHAS

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, 4.3 ft • lb)

d. Install new brake pads and a new brake
pad spring.
NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6.
•
•
•
•

Install:
brake pad pins
brake pad clips
brake pad cover
brake caliper

T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

7. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4 - 28

FRONT AND REAR BRAKES

CHAS

EAS00584

FRONT BRAKE MASTER CYLINDER

Order

1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the front brake master
cylinder
Brake fluid
Rear view mirror
Brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm holder
Brake master cylinder reservoir diaphragm
Brake lever
Brake lever spring
Front brake light switch connector
Union bolt
Brake hose
Copper washer

Q’ty

4 - 29

Remarks
Remove the parts in the order listed.
Drain.

1
1
1
1
2
1
2
1
1
2

Disconnect.
Disconnect.

FRONT AND REAR BRAKES

CHAS

Order
Job/Part
11
Brake master cylinder holder
12
Brake master cylinder
13
Front brake light switch

Q’ty
1
1
1

Remarks

For installation, reverse the removal
procedure.

4 - 30

FRONT AND REAR BRAKES

CHAS

EAS00585

Order

1
2
3
4

Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
For assembly, reverse the disassembly
procedure.

4 - 31

FRONT AND REAR BRAKES

CHAS

EAS00586

REAR BRAKE MASTER CYLINDER

Order

1
2
3
4
5
6
7
8
9
10

Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Brake fluid
Drain.
Brake fluid reservoir cover
1
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm
1
holder
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Union bolt
1
Copper washer
2
Brake hose
1
Disconnect.
Rear brake light switch
1
Disconnect.

4 - 32

FRONT AND REAR BRAKES

CHAS

Order
11
12
13
14

Job/Part
Left footrest assembly
Cotter pin
Pin
Brake master cylinder

Q’ty
1
1
1
1

Remarks

For installation, reverse the removal
procedure.

4 - 33

FRONT AND REAR BRAKES

CHAS

EAS00587

Order

1
2
3
4

Job/Part
Disassembling the rear brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
For assembly, reverse the disassembly
procedure.

4 - 34

FRONT AND REAR BRAKES

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:
union bolt 1
copper washers 2
brake hose 3

NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.

EAS00589

DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt 1
• copper washers 2
• brake hose 3

NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.

4 - 35

FRONT AND REAR BRAKES

CHAS

EAS00592

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

Å Front
ı Rear

2. Check:
• brake master cylinder kit 1
Damage/scratches/wear → Replace.

Å Front
ı Rear

3. Check:
• rear brake fluid reservoir 1
Cracks/damage → Replace.
• rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.

4. Check:
• front brake master cylinder reservoir 1
Cracks/damage → Replace.
• front brake master cylinder reservoir diaphragm 2
Damage/wear → Replace.

4 - 36

FRONT AND REAR BRAKES

CHAS

5. Check:
• brake hoses
• brake fluid reservoir hose
Cracks/damage/wear → Replace.

EAS00598

ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER

4
1.
•
•
•

Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3

2. Install:
• front brake light switch 1

3. Install:
• brake master cylinder
• brake master cylinder holder 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a in the handlebar.
• First, tighten the upper bolt, then the
lower bolt.
4 - 37

FRONT AND REAR BRAKES

Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.

4.
•
•
•

CHAS

WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and to the
right to make sure the brake hose does
not touch other parts (e.g., wire harness,
cables, leads). Correct if necessary.

5. Install:
• brake lever spring 1
• brake lever 2

6. Connect:
• front brake light switch connectors 1

7. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4

4 - 38

FRONT AND REAR BRAKES

CHAS

WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.

CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

8. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. Install:
• brake master cylinder diaphragm
• brake master cylinder diaphragm holder
• brake master cylinder cap
• rear view mirror
10.Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

11.Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4 - 39

FRONT AND REAR BRAKES

CHAS

EAS00608

ASSEMBLING AND INSTALLING THE REAR
BRAKE MASTER CYLINDER
1. Install:
• brake master cylinder kit 1
• circlip 2 New
• dust boot 3

2. Install:
• brake master cylinder 1
T.
R.

23 Nm (2.3 m · kg, 17 ft · lb)

3. Install:
• left footrest assembly 1
T.
R.

48 Nm (4.8 m · kg, 35 ft · lb)

4. Install:
• rear brake light switch 1

Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.

5.
•
•
•

WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
4 - 40

FRONT AND REAR BRAKES

CHAS

CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.

6. Install:
• brake fluid reservoir hose 1
• brake fluid reservoir 2

7. Fill:
• brake fluid reservoir
(to the maximum level mark)

Recommended brake fluid
DOT 4

CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4 - 41

FRONT AND REAR BRAKES

CHAS

8. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. Install:
• brake fluid reservoir diaphragm
• brake fluid reservoir diaphragm holder
• brake fluid reservoir cap
• brake fluid reservoir cover
10.Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

11.Adjust:
• brake pedal position a
Refer to “ADJUSTING
BRAKE” in chapter 3.

THE

REAR

Brake pedal position (below the
top of the rider footrest)
100 mm (3.9 in)

12.Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.

4 - 42

FRONT AND REAR BRAKES

CHAS

EAS00613

FRONT BRAKE CALIPERS

Order

1
2
3
4
5
6
7
8

Job/Part
Removing the front brake calipers

Q’ty

Brake fluid
Reflector
Brake hose holder bolt
Union bolt
Copper washer
Brake hose
Retaining bolt
Brake caliper bolt
Brake caliper

1
1
1
2
1
2
2
1

Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
Drain.

Loosen.

For installation, reverse the removal
procedure.

4 - 43

FRONT AND REAR BRAKES

CHAS

EAS00615

Order

Job/Part
Disassembling the front brake calipers

Q’ty

Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.

1
2
3
4
5
6
7
8
9

Retaining bolt
Brake caliper
Brake caliper bracket
Brake pad
Brake pad spring
Brake pad spring
Brake caliper piston
Brake caliper piston seal
Bleed screw

2
1
2
2
2
1
2
4
1
For assembly, reverse the disassembly
procedure.

4 - 44

FRONT AND REAR BRAKES

CHAS

EAS00616

REAR BRAKE CALIPER

Order

1
2
3
4
5

Job/Part
Removing the rear brake caliper
Muffler

Q’ty

Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bolt
Brake caliper

Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC
AND REAR WHEEL PULLEY”.
Drain.

1
2
1
2
1
For installation, reverse the removal
procedure.

4 - 45

FRONT AND REAR BRAKES

CHAS

EAS00617

Order
1
2
3
4
5
6
7
8

Job/Part
Q’ty
Remarks
Disassembling the rear brake caliper
Remove the parts in the order listed.
Brake pad cover
1
Brake pad clip
2
Brake pad pin
2
Brake pad spring
1
Brake pad
2
Brake caliper piston
4
Brake caliper piston seal
8
Bleed screw
1
For assembly, reverse the disassembly
procedure.

4 - 46

FRONT AND REAR BRAKES

CHAS

EAS00624

DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of
the brake calipers.
NOTE:
Before disassembling either brake caliper,
drain the brake fluid from the entire brake
system.
1.
•
•
•

Remove:
union bolt 1
copper washers 2
brake hose 3

NOTE:
Put the end of the brake hose into a container and pump out the brake fluid carefully.

2. Remove:
• brake caliper pistons
• brake caliper piston seals

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Blow compressed air into the brake hose
joint opening a to force out the pistons
from the brake caliper.

WARNING
WARNING
• Cover the brake caliper pistons with a
rag. Be careful not to get injured when
the pistons are expelled from the brake
caliper.
• Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00627

DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire brake
system.

4 - 47

FRONT AND REAR BRAKES
1.
•
•
•

CHAS

Remove:
union bolt 1
copper washers 2
brake hose 3

NOTE:
Put the end of the brake hose into a container and pump out the brake fluid carefully.

2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Secure the right side brake caliper piston
with a peace of wood 3.
b. Blow compressed air into the brake hose
joint opening a to force out the left side
pistons from the brake caliper.

WARNING
WARNING
• Never try to pry out the brake caliper pistons.
• Do not loosen the bolts 4.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side piston from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00633

CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component replacement schedule

4 - 48

Brake pads

If necessary

Piston seals

Every two years

Brake hoses

Every two years

Brake fluid

Every two years
and whenever the
brake is disassembled

FRONT AND REAR BRAKES

CHAS

1. Check:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper.
• brake caliper cylinders 2
Scratches/wear → Replace the brake caliper.
• brake calipers
Cracks/damage → Replace.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.

WARNING
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Å Front
ı Rear

2. Check:
• brake caliper brackets 1
Cracks/damage → Replace.

Å Front
ı Rear

EAS00638

ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of
the brake calipers.

WARNING
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
4 - 49

FRONT AND REAR BRAKES

CHAS

• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1.
•
•
•

Install:
bleed screw
brake caliper piston seals 1
brake caliper pistons 2

2.
•
•
•

Install:
brake pad spring 1
brake pad springs 2
brake pads 3

New

NOTE:
Install the brake pad with the attached
brake pad shim on the brake caliper piston
side.

3. Install:
• brake caliper bracket 1
• retaining bolts 2
NOTE:
Temporarily tighten the retaining bolts.

4. Install:
• brake caliper 1
• brake caliper bolts 2
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

5. Tighten:
• retaining bolts 3
T.
R.

4 - 50

27 Nm (2.7 m · kg, 19 ft · lb)

FRONT AND REAR BRAKES

Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.

6.
•
•
•

CHAS

WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.

CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection a on the brake caliper.

7. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)

Recommended brake fluid
DOT 4

WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• 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.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.

CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4 - 51

FRONT AND REAR BRAKES

CHAS

8. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

9. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

10.Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

EAS00642

ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER

WARNING
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4

4 - 52

FRONT AND REAR BRAKES

CHAS

1.
•
•
•

Install:
bleed screw
brake caliper piston seals 1
brake caliper pistons 2

2.
•
•
•
•

Install:
brake pads
brake pad spring 1
brake pad pins 2
brake pad clips 3

New

NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
3.
•
4.
•
•

Install:
brake pad cover
Install:
brake caliper 1
brake caliper bolts 2
T.
R.

Install:
copper washers New
brake hose
30 Nm (3.0 m · kg, 22 ft · lb)
union bolt
T.

5.
•
•
•

40 Nm (4.0 m · kg, 29 ft · lb)

WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.

CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection a on the brake caliper.

4 - 53

FRONT AND REAR BRAKES

CHAS

6. Fill:
• brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4

CAUTION:
ACHTUNG:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
7. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
8. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
9. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4 - 54

FRONT FORK

CHAS

EAS00647

FRONT FORK

Order

Job/Part
Removing the front fork legs

Q’ty

Front wheel

1
2
3
4
5
6
7
8
9

Meter assembly
Front fender
Brake hose holder
Upper bracket pinch bolt
Cap bolt
Steering stem nut
Upper bracket
Upper fork cover
Upper fork cover spacer
Upper fork cover washer

1
1
4
1
1
1
1
1
1

4 - 55

Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FUEL TANK” in chapter 3.

Loosen.

FRONT FORK

CHAS

Order
10
11
12
13
14

Job/Part
Lower bracket pinch bolt
Front fork leg
Bolt
Brake hose guide
Lower fork cover

Q’ty
Remarks
2
Loosen.
1
3
1
1
For installation, reverse the removal
procedure.

4 - 56

FRONT FORK

CHAS

EAS00648

Order

1
2
3
4
5
6
7
8
9
0

Job/Part
Disassembling the front fork leg

Q’ty

Cap bolt
O-ring
Fork spring
Dust seal
Oil seal clip
Cartridge cylinder bolt
Copper washer
Cartridge cylinder
Rebound spring
Inner tube

1
1
1
1
1
1
1
1
1
1

4 - 57

Remarks
Remove the parts in the order listed.
The following procedure applies to
both of the front fork legs.

FRONT FORK

CHAS

Order
A
B
C
D
E
F

Job/Part
Oil seal
Seal spacer
Outer tube bushing
Inner tube bushing
Oil flow stopper
Outer tube

Q’ty
1
1
1
1
1
1

Remarks

For assembly, reverse the disassembly
procedure.

4 - 58

FRONT FORK

CHAS

EAS00649

REMOVING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
3. Remove:
• front fork leg

EAS00652

DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)

CAUTION:
ACHTUNG:
Do not scratch the inner tube.
2. Drain:
• fork oil
NOTE:
Stroke the outer tube several times while
draining the fork oil.

4 - 59

FRONT FORK

CHAS

3. Remove:
• cartridge cylinder bolt
NOTE:
While holding the cartridge cylinder with
the damper rod holder 1 and T-handle 2,
loosen the cartridge cylinder bolt.
Damper rod holder
YM-1300-1
T-Handle
YM-01326

4. Remove:
• inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket
in a vise with soft jaws.
c. Separate the inner tube from the outer
tube by pulling the inner tube forcefully
but carefully.

CAUTION:
ACHTUNG:
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bushing must be replaced.
• Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00656

CHECKING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.

WARNING
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
4 - 60

FRONT FORK

CHAS

2. Measure:
• spring free length a
Out of specification → Replace.
Spring free length limit
566 mm (22.3 in)

3. Check:
• cartridge cylinder 1
Damage/wear → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• oil flow stopper 2
Damage → Replace.

4. Check:
• cap bolt O-ring
Damage/wear → Replace.

EAS00658

ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.

WARNING
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg,
make sure all of the components are
clean.
4 - 61

FRONT FORK

CHAS

1. Install:
• cartridge cylinder 1

CAUTION:
ACHTUNG:
Allow the cartridge cylinder 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.
•
3.
•

Install:
oil flow stopper 3
Lubricate:
inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil 5WT
or equivalent

4. Install:
• outer tube
(onto the inner tube)
• copper washer New
• cartridge cylinder bolt

5. Tighten:
• cartridge cylinder bolt 1
T.
R.

20 Nm (2.0 m · kg, 14 ft · lb)

NOTE:
• Apply the locking agent (LOCTITE 204) to
the threads of the cartridge cylinder bolt.
• While holding the cartridge cylinder with
the damper rod holder 2 and T-handle 3,
tighten the cartridge cylinder bolt.
Damper rod holder
YM-1300-1
T-handle
YM-01326

4 - 62

FRONT FORK

CHAS

6. Install:
• outer tube bushing 1 New
• seal spacer 2
(with the fork seal driver weight 3 and
adapter 4)
Fork seal driver weight
YM-33963
Adapter
YM-8020
7. Install:
• oil seal 1 New
(with the fork seal driver weight 2 and
adapter 3)

CAUTION:
ACHTUNG:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its
lips with lithium soap base 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
protect the oil seal during installation.

8. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.

9. Install:
• dust seal 1 New
(with the fork seal driver weight 2)

4 - 63

FRONT FORK

CHAS

10.Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
554 L (488 lmp qt, 589 US qt)
Front fork leg oil level a
(from the top of the inner tube,
with the inner tube fully compressed, and without the fork
spring)
110 mm (4.33 in)
Recommended oil
Yamaha fork and shock oil 5WT
or equivalent
NOTE:
• While filling the front fork leg, keep it
upright.
• After filling, slowly pump the front fork
leg up and down to distribute the fork oil.

11.Install:
• fork spring
• cap bolt
NOTE:
• Before installing the cap bolt, lubricate its
O-ring with grease.
• Temporarily tighten the cap bolt.

EAS00662

INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Install:
• lower fork cover 1
• brake hose guide 2
10 Nm (1.0 m · kg, 7.2 ft · lb)
• bolts 3
R.

2. Install:
• front fork leg
NOTE:
• When aligning the fork tube do not install
the upper fork cover.
• Temporarily tighten the lower bracket
pinch bolts.

4 - 64

FRONT FORK

CHAS

3. Install:
• Upper bracket
• Steering stem nut
T.

130 Nm (13.0 m · kg, 94 ft · lb)

NOTE:
Make sure the inner fork tube is flush with
the top of the upper bracket.

4. Tighten:
• lower bracket pinch bolt 1
T.
R.

• cap bolt

20 Nm (2.0 m · kg, 14 ft · lb)

23 Nm (2.3 m · kg, 17 ft · lb)

WARNING
WARNING
Make sure the brake hoses are routed properly.
5. Remove:
• steering stem nut
• upper bracket

6.
•
•
•

Install:
upper fork washer 1
upper fork spacer 2
upper fork cover 3

7. Install:
• upper bracket 1
• steering stem nut 2
T.
R.

4 - 65

130 Nm (13.0 m · kg, 94 ft · lb)

FRONT FORK

CHAS

8. Tighten:
• upper bracket pinch bolts 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

9. Install:
• brake hose holder
• front fender
T.
R.

23 Nm (2.3 m · kg, 17 ft · lb)

10.Install:
• front wheel
Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4 - 66

HANDLEBAR

CHAS

EAS00664

HANDLEBAR

Order
1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the handlebar
Rear view mirror (left and right)
Plastic clamp
Front brake light switch connector
Brake master cylinder holder
Brake master cylinder
Right handlebar switch
Throttle cable holder
Throttle cable
Throttle grip
Clutch switch connector

Q’ty
2
4
2
1
1
1
1
2
1
1

4 - 67

Remarks
Remove the parts in the order listed.

Disconnect.

Disconnect.
Disconnect.

HANDLEBAR

CHAS

Order
11
12
13
14
15
16
17
18

Job/Part
Left handlebar switch
Handlebar grip
Clutch cable
Clutch lever holder
Cable guide
Upper handlebar holder
Handlebar
Lower handlebar holder

Q’ty
Remarks
1
1
1
Disconnect.
1
1
2
1
2
For installation, reverse the removal
procedure.

4 - 68

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Remove:
• handlebar grip 1
NOTE:
Blow compressed air between the handlebar and the handlebar grip, and gradually
push the grip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR
1. Check:
• handlebar
Bends/cracks/damage → Replace.

WARNING
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

EAS00670

INSTALLING THE HANDLEBAR
1. Install:
• washers
• lower handlebar holders 1
• cable guide 2
NOTE:
Temporarily tighten the nuts 3.
2. Install:
• handlebar
• upper handlebar holders
T.
R.

23 Nm (2.3 m · kg, 17 ft · lb)

CAUTION:
ACHTUNG:
• First, tighten the bolts on the front side of
the handlebar holder, then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
4 - 69

HANDLEBAR

CHAS

NOTE:
• The upper handlebar holders should be
installed with the arrows a facing forward Å.
• Align the match marks b on the handlebar with the upper surface of the lower
handlebar holders.
3. Tighten:
• lower handlebar holder nuts
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

4. Install:
• clutch lever
NOTE:
Align the slit of clutch lever holder with the
punch mark a on the handlebar.

5. Install:
• clutch cable
NOTE:
Lubricate the end of the clutch cable with a
thin coat of lithium soap base grease.

6. Install:
• left handlebar switch
NOTE:
Align the end a of the left handlebar switch
with the punch mark b on the handlebar.
7. Connect:
• clutch switch connector

4 - 70

HANDLEBAR

CHAS

8. 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
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

9. Install:
• throttle grip
10.Connect:
• throttle cable

11.Install:
• right handlebar switch
NOTE:
Align the projection a on the right handlebar switch with the hole b in the handlebar.

12.Install:
• brake master cylinder
• brake master cylinder holder
T.
R.

4 - 71

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the brake master cylinder
holder with the punch mark a in the handlebar.

HANDLEBAR

CHAS

• First, tighten the upper bolt, then the
lower bolt.
13.Connect:
• front brake light switch connector

14.Install:
• plastic clamp
• rear view mirrors

15.Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play (at the end
of the clutch lever)
10 ~ 15 mm (0.39 ~ 0.59 in)

16.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 8 mm (0.16 ~ 0.31 in)

4 - 72

STEERING HEAD

CHAS

EAS00676

STEERING HEAD

Order

1
2
3
4
5
6
7
8

Job/Part
Removing the lower bracket
Meter assembly
Front fork legs/fork covers
Front wheel

Q’ty

Handlebar/handlebar holders
Steering stem nut
Upper bracket
Headlight lens unit
Lead (in the headlight body)
Headlight body
Headlight bracket
Chrome turn signal light bracket
cover
Turn signal light bracket assembly

1
1
1
1
1
1
1
1

4 - 73

Remarks
Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “FRONT FORK”.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “HANDLEBAR”.

STEERING HEAD

CHAS

Order
9
10
11
12
13
14
15
16
17
18

Job/Part
Brake hose joint
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Bearing cover
Upper bearing
Lower bearing
Bearing outer race

Q’ty
1
1
1
1
1
1
1
1
1
2

Remarks

For installation, reverse the removal
procedure.

4 - 74

STEERING HEAD

CHAS

EAS00677

REMOVING THE LOWER BRACKET
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• lower ring nut 1
(with the special tool 2)
Ring nut wrench
YU-33975

WARNING
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

2. Check:
• bearings
• bearing races
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.
4 - 75

STEERING HEAD

CHAS

c. Install a new rubber seal and new bearing races.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CAUTION:
ACHTUNG:
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 disassembled, replace the rubber seal.

4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.

EAS00683

INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium soap base grease

2.
•
•
•
•
•

4 - 76

Install:
upper bearing
lower bearing
bearing races
bearing cover
lower bracket

STEERING HEAD
3.
•
•
•
•

CHAS

Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.

4. Install:
• brake hose joint 1
T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

5. Install:
• turn signal light bracket assembly 1
• chrome turn signal light bracket cover 2

6. Install:
• headlight bracket 1

7.
•
8.
•

Install:
headlight body 1
Connect:
leads
(in the headlight body)
9. Install:
• headlight lens unit

4 - 77

STEERING HEAD

CHAS

10.Install:
• upper bracket
• steering stem nut
• front fork legs
Refer to “FRONT FORK”.

11.Install:
• handlebar
Refer to “HANDLEBAR”.
• front fork legs
Refer to “FRONT FORK”.
• meter assembly
Refer to “FUEL TANK” in chapter 3.

4 - 78

REAR SHOCK ABSORBER AND SWINGARM

CHAS

********

REAR SHOCK ABSORBER AND SWINGARM

Order

1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the rear shock absorber
and swingarm
Rear wheel
Adjusting bolt
Locknut
Mud guard
Lower drive belt cover
Horn coupler
Horn
Self-locking nut
Bolt (shock absorber-connecting
arm-frame)
Cover (left and right)
Pivot shaft nut/washer

Q’ty

Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC
AND REAR WHEEL PULLEY”.

1
1
1
1
1
1
1
1
2
1/1

4 - 79

Disconnect.

R= 158 mm (6.22 in)

REAR SHOCK ABSORBER AND SWINGARM

CHAS

Order
Job/Part
11
Pivot shaft
12
Rear shock absorber and swingarm
assembly

Q’ty
1
1

Remarks

For installation, reverse the removal
procedure.

4 - 80

REAR SHOCK ABSORBER AND SWINGARM

CHAS

Order

1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the rear shock absorber
and swingarm
Self-locking nut/washer/bolt
Self-locking nut/washer/bolt
Connecting arm
O-ring
Rear shock absorber
Spacer/O-ring
Self-locking nut/washer/bolt
Relay arm
Spacer/oil seal/bearing
Spacer/bearing

Q’ty

Remarks
Remove the parts in the order listed.

1/1/1 Bolt R= 53 mm (2.19 in)
1/1/1 Bolt R= 124 mm (4.88 in)
2
4
1
1/2
1/1/1 Bolt R= 77 mm (3.03 in)
1
1/2/1
1/2

4 - 81

REAR SHOCK ABSORBER AND SWINGARM

CHAS

Order
11
12
13
14
15
16

Job/Part
Spacer/bearing
Swingarm
Dust cover
Washer
Spacer
Bearing

Q’ty
1/1
1
2
2
1
2

Remarks

For installation, reverse the removal
procedure.

4 - 82

REAR SHOCK ABSORBER AND SWINGARM

CHAS

EAS00686

HANDLING THE REAR SHOCK ABSORBER

WARNING
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure you understand the following information. The manufacturer cannot be held
responsible for property damage or personal injury that may result from improper
handling of the rear shock absorber.
• Do not tamper or attempt to open the
rear shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping performance.

EAS00689

DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER
Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. To release the gas pressure, drill a 2 ~
3-mm (0.08 ~ 0.12 in) hole through the gas
cylinder at a point 15 mm (0.6 in) from its
end as shown.

WARNING
WARNING
Wear eye protection to prevent eye damage from released gas or metal chips.

EAS00703

REMOVING THE REAR SHOCK ABSORBER
AND SWINGARM
1. Stand the motorcycle on a level surface.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
4 - 83

REAR SHOCK ABSORBER AND SWINGARM

CHAS

2. Remove:
• bolt (shock absorber - connecting arm frame) 1
NOTE:
When removing the bolt (shock absorber connecting arm - frame) 1, hold the swingarm so that it does not drop down.

3. Measure:
• swingarm free play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Measure the tightening torque of the
pivot shaft nut.

Pivot shaft nut
125 Nm (12.5 m • kg, 90 ft • lb)

b. Measure the swingarm free play Å by
moving the swingarm from side to side.
c. If the swingarm free play is out of specification, check the spacers, bearings,
washers, and dust covers.
Swingarm free play (at the end of
the swingarm)
Zero mm (Zero in)
d. Check the swingarm vertical movement
ı by moving the swingarm up and
down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust
covers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00696

CHECKING THE REAR SHOCK ABSORBER
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Gas leaks/oil leaks → Replace the rear
shock absorber assembly.
4 - 84

REAR SHOCK ABSORBER AND SWINGARM

CHAS

• spring
Damage/wear → Replace the rear shock
absorber assembly.
• gas cylinder
Damage/gas leaks → Replace.
• bushings
Damage/wear → Replace.
• O-ring
Damage/wear → Replace.
• bolts
Bends/damage/wear → Replace.

CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arms 2
Damage/wear → Replace.
• bearings
• oil seals
Damage/pitting → Replace.
• spacers
• Damage/scratches → Replace.
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends/cracks/damage → Replace.

2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.

WARNING
WARNING
Do not attempt to straighten a bent pivot
shaft.

4 - 85

REAR SHOCK ABSORBER AND SWINGARM
3.
•
•
•
•

CHAS

Wash:
pivot shaft
dust covers
spacer
bearings
Recommended cleaning solvent
Kerosine

4.
•
•
•

Check:
dust covers
spacer
oil seals
Damage/wear → Replace.
• bearings
Damage/pitting → Replace.

EAS00711

INSTALLING THE REAR SHOCK ABSORBER
AND SWINGARM
1. Lubricate:
• bearings
• spacers
• dust covers
• O-rings
• pivot shaft
Recommended lubricant
Molybdenum disulfide grease

2.
•
•
•
•

4 - 86

Install:
bearings
spacer 1
washers 2
dust covers 3

REAR SHOCK ABSORBER AND SWINGARM
3.
•
•
•

CHAS

Install:
bearings
oil seals 1
spacers 2

4. Install:
• relay arm 1
(onto the swingarm)
T.
R.

59 Nm (5.9 m · kg, 43 ft · lb)

5. Install:
• o-rings 1
• spacer 2

6. Install:
• connecting arms 1
(onto the rear shock absorber)

7. Install:
• connecting arms 1
(onto the relay arm)
T.
R.

4 - 87

59 Nm (5.9 m · kg, 43 ft · lb)

REAR SHOCK ABSORBER AND SWINGARM

CHAS

8. Install:
• rear shock absorber 1
(onto the relay arm)
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

9. Install:
• rear shock absorber and swingarm
assembly
• pivot shaft
• washer
• pivot shaft nut
T.
R.

125 Nm (12.5 m · kg, 90 ft · lb)

• covers

10.Install:
• bolt (shock absorber - connecting arm frame) 1
NOTE:
When installing the bolt (shock absorber connecting arm - frame), hold the swingarm
so that it does not drop down.

11.Install:
• horn 1
12.Connect:
• horn coupler 2

13.Install:
• lower drive belt cover 1

4 - 88

REAR SHOCK ABSORBER AND SWINGARM

CHAS

14.Install:
• mud guard 1

15.Install:
• locknut 1
• adjusting bolt 2

16.Install:
• rear wheel
Refer to “REAR WHEEL, BRAKE DISC
AND REAR WHEEL PULLEY”.
17.Adjust:
• drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” in chapter 3.

4 - 89

DRIVE BELT AND DRIVE PULLEY

CHAS

DRIVE BELT AND DRIVE PULLEY

Order

1
2
3
4
5
6
7
8

Job/Part
Removing the drive belt and drive
pulley
Rear wheel

Q’ty

Rear shock absorber and swingarm
assembly
Drive pulley cover bracket
Drive pulley cover
Slider
Dowel pin
Drive belt
Drive pulley nut
Lock washer
Drive pulley

Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, BRAKE DISC
AND REAR WHEEL PULLEY”.
Refer to “REAR SHOCK ABSORBER
AND SWINGARM”.

1
1
2
2
1
1
1
1
For installation, reverse the removal
procedure.

4 - 90

DRIVE BELT AND DRIVE PULLEY

CHAS

REMOVING THE DRIVE BELT AND DRIVE
PULLEY
NOTE:
Loosen the drive pulley nut before remove
the rear wheel.
1.
•
•
2.
3.
•

Remove:
drive pulley cover bracket 1
drive pulley cover 2
Straighten the lock washer tab.
Loosen:
drive pulley nut 1

NOTE:
When loosening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.

CHECKING THE DRIVE BELT
1. Clean:
• drive belt

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Wipe the drive belt with a clean cloth.
b. Put the drive belt in a mixture of mild
detergent and water. Then, remove any
dirt from the drive belt.
c. Remove the drive belt from the mixture
and rinse it off with clean water. Then, let
the drive belt thoroughly dry.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:
• drive belt

CAUTION:
ACHTUNG:
• To protect the drive belt from damage,
handle it with care.
• The drive belt can not be bent smaller
than 127 mm (5 in) a.
• The removed drive belt can not be
twisted inside out.
4 - 91

DRIVE BELT AND DRIVE PULLEY

CHAS

3. Check:
• drive pulley
• rear wheel pulley
Bent teeth → Replace the drive belt and
pulleys as a set.

INSTALLING THE DRIVE BELT AND DRIVE
PULLEY
1. Install:
• drive pulley 1
• lock washer 2 New
• drive pulley nut 3

2. Install:
• drive belt

CAUTION:
ACHTUNG:
Install the drive belt facing the same way it
was removed.

3. Install:
• rear shock absorber and swingarm
assembly
Refer to “REAR SHOCK ABSORBER AND
SWINGARM”.
• rear wheel
Refer to “REAR WHEEL, BRAKE DISC
AND SWINGARM”.

4. Tighten:
• drive pulley nut
T.
R.

85 Nm (8.5 m · kg, 61 ft · lb)

NOTE:
When tightening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.
5. Bend the lock washer tab along a flat
side of the nut.
4 - 92

DRIVE BELT AND DRIVE PULLEY

CHAS

6. Install:
• dowel pins 1
• sliders 2

7. Install:
• drive pulley cover 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

• drive pulley cover bracket 2

4 - 93

• bolts (M8)

• bolts (M10)

53 Nm (5.3 m · kg, 38 ft · lb)
30 Nm (3.0 m · kg, 22 ft · lb)

ENG
CONTENTS
ENGINE

ENGINE ......................................................................................................... 5-1
INSTALLING THE ENGINE ................................................................... 5-8

ENG
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS .............................. 5-12
REMOVING THE ROCKER ARMS, PUSH RODS AND
VALVE LIFTERS .............................................................................. 5-18
CHECKING THE ROCKER ARMS AND ROCKER
ARM SHAFTS ................................................................................. 5-18
CHECKING THE ROCKER ARM BASES ............................................ 5-20
CHECKING THE PUSH RODS ............................................................ 5-20
CHECKING THE VALVE LIFTERS AND VALVE
LIFTER CASES ................................................................................ 5-20
BLEEDING THE VALVE LIFTER .......................................................... 5-21
CHECKING THE PUSH ROD COVERS ............................................... 5-23
INSTALLING THE VALVE LIFTERS AND PUSH ROD COVERS ....... 5-23
INSTALLING THE ROCKER ARMS AND PUSH RODS ..................... 5-24
INSTALLING THE CYLINDER HEAD COVERS .................................. 5-26
INSTALLING THE CAMSHAFT SPROCKET COVER AND
ENGINE LEFT SIDE COVER ........................................................... 5-27
CAMSHAFTS .............................................................................................. 5-29
REMOVING THE CAMSHAFTS .......................................................... 5-31
CHECKING THE CAMSHAFTS ........................................................... 5-32
CHECKING THE DECOMPRESSION SYSTEM .................................. 5-34
CHECKING THE OIL DELIVERY PIPE ................................................. 5-35
INSTALLING THE CAMSHAFTS ........................................................ 5-35
CYLINDER HEADS ...................................................................................... 5-39
REMOVING THE CYLINDER HEADS ................................................. 5-41
CHECKING THE CYLINDER HEADS .................................................. 5-41
CHECKING THE OIL DELIVERY PIPE ................................................. 5-42
INSTALLING THE CYLINDER HEADS ............................................... 5-42
VALVES AND VALVE SPRINGS ............................................................... 5-44
REMOVING THE VALVES .................................................................. 5-45
CHECKING THE VALVES AND VALVE GUIDES ............................... 5-46
CHECKING THE VALVE SEATS ......................................................... 5-48
CHECKING THE VALVE SPRINGS ..................................................... 5-50
INSTALLING THE VALVES ................................................................ 5-51
CYLINDERS AND PISTONS ....................................................................... 5-53
REMOVING THE CYLINDERS AND PISTONS .................................. 5-54
CHECKING THE CYLINDERS AND PISTONS ................................... 5-54
CHECKING THE PISTON RINGS ........................................................ 5-56
CHECKING THE PISTON PINS ........................................................... 5-57
INSTALLING THE PISTONS AND CYLINDERS ................................ 5-58

ENG
CLUTCH ...................................................................................................... 5-60
REMOVING THE CLUTCH .................................................................. 5-65
REMOVING THE PRIMARY DRIVE GEAR ......................................... 5-65
CHECKING THE FRICTION PLATES .................................................. 5-66
CHECKING THE CLUTCH PLATES .................................................... 5-66
CHECKING THE CLUTCH SPRING PLATE ........................................ 5-67
CHECKING THE CLUTCH HOUSING ................................................. 5-67
CHECKING THE CLUTCH BOSS ........................................................ 5-67
CHECKING THE PRESSURE PLATE .................................................. 5-67
CHECKING THE PULL LEVER SHAFT AND PULL ROD .................... 5-68
CHECKING THE PRIMARY DRIVE ..................................................... 5-68
INSTALLING THE PICKUP COIL AND PULL LEVER SHAFT ............ 5-68
INSTALLING THE PRIMARY DRIVE GEAR ....................................... 5-69
INSTALLING THE CLUTCH ................................................................ 5-70
SHIFT SHAFT .............................................................................................. 5-74
CHECKING THE SHIFT SHAFT .......................................................... 5-75
CHECKING THE STOPPER LEVER ..................................................... 5-75
INSTALLING THE STOPPER LEVER AND SHIFT SHAFT ................. 5-75
GENERATOR AND STARTER CLUTCH ..................................................... 5-77
REMOVING THE GENERATOR .......................................................... 5-80
CHECKING THE STARTER CLUTCH .................................................. 5-80
INSTALLING THE GENERATOR ........................................................ 5-81

TRANSFER GEAR CASE ............................................................................ 5-85
REMOVING THE BATTERY ................................................................ 5-91
REMOVING THE MIDDLE DRIVEN SHAFT ....................................... 5-91
CHECKING THE MIDDLE DRIVE ........................................................ 5-91
CHECKING THE OIL STRAINER ......................................................... 5-92
CHECKING THE OIL PUMP ................................................................ 5-92
CHECKING THE OIL PIPE ................................................................... 5-93
ASSEMBLING THE OIL PUMP ........................................................... 5-93
INSTALLING THE TRANSFER GEAR CASE ...................................... 5-94
INSTALLING THE OIL TANK COVER ................................................ 5-97
INSTALLING THE BATTERY .............................................................. 5-98
CRANKCASE ............................................................................................. 5-100
DISASSEMBLING THE CRANKCASE .............................................. 5-103
CHECKING THE CRANKCASE ......................................................... 5-104
CHECKING THE BEARINGS AND OIL SEAL ................................... 5-104
CHECKING THE OIL DELIVERY PIPE ............................................... 5-105
CHECKING THE ENGINE OIL PUMP DRIVE .................................... 5-105
ASSEMBLING THE CRANKCASE .................................................... 5-105

ENG
ENGINE OIL PUMP ................................................................................... 5-108
CHECKING THE OIL PUMP .............................................................. 5-111
CHECKING THE RELIEF VALVE ....................................................... 5-111
CHECKING THE OIL STRAINER ....................................................... 5-112
ASSEMBLING THE OIL PUMP ......................................................... 5-112
INSTALLING THE OIL PUMP ........................................................... 5-113
INSTALLING THE OIL STRAINER .................................................... 5-113
CRANKSHAFT AND CONNECTING RODS ............................................. 5-114
REMOVING THE CRANKSHAFT ...................................................... 5-115
REMOVING THE CONNECTING RODS ........................................... 5-115
CHECKING THE CRANKSHAFT AND CONNECTING RODS .......... 5-115
INSTALLING THE CONNECTING RODS ......................................... 5-119
INSTALLING THE CRANKSHAFT .................................................... 5-121
TRANSMISSION ....................................................................................... 5-122
CHECKING THE SHIFT FORKS ........................................................ 5-125
CHECKING THE SHIFT DRUM ASSEMBLY .................................... 5-125
CHECKING THE TRANSMISSION ................................................... 5-126
INSTALLING THE TRANSMISSION, SHIFT DRUM
ASSEMBLY AND SHIFT FORKS .................................................. 5-126

ENGINE

ENG

EAS00188

ENGINE
ENGINE

5
Order

1
2
3
4

Job/Part
Removing the muffler and exhaust
pipes
Muffler
Front exhaust pipe
Rear exhaust pipe
Gasket

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
2
For installation, reverse the removal
procedure.

5-1

ENGINE

ENG

5
Order

Job/Part
Removing the oil filter bracket and
horns
Rider seat/side covers

Q’ty

Remarks

Refer to “SEATS AND SIDE COVERS”
in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “CARBURETOR” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 6.
Refer to “STARTER MOTOR” in chapter 7.

Fuel tank
Air filter case
Carburetor/carburetor joint
Air induction system parts
Starter motor

5-2

ENGINE

ENG

5
Order

Job/Part
Engine oil/oil filter cartridge
Transfer gear oil
Transfer gear case
Rider footrest (left)

Q’ty

Drain.
Drain.
Refer to “TRANSFER GEAR CASE”.
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
Refer to “GENERATOR AND STARTER
CLUTCH”.

Rider footrest (right)
1
2
3
4
5

Remarks

Oil filter bolt
Oil filter bracket
Horn
Oil delivery pipe
Brake hose holder

1
1
2
1
1
For installation, reverse the removal
procedure.

5-3

ENGINE

ENG

5
Order
1
2
3
4
5
6
7
8
9

Job/Part
Disconnecting the leads and hoses
Spark plug caps
Cylinder head breather hose
Oil tank breather hose
Clutch cable
Charcoal canister hose (carburetor
to charcoal canister)
Plastic clamp
Stator coil coupler
Decompression solenoid coupler
Pickup coil coupler

Q’ty
4
1
1
1
1
1
1
2
1

5-4

Remarks
Disconnect the parts in the order listed.

ENGINE

ENG

5
Order
Job/Part
10
Neutral switch cover
11
Neutral switch
12
Speed sensor

Q’ty
1
1
1

Remarks

For connecting, reverse the disconnection procedure.

5-5

ENGINE

ENG

EAS00191

ENGINE

5
Order

Job/Part
Removing the engine

Q’ty

Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.

1
2
3
4
5
6
7
8

Self-locking nut
Upper front mounting bolt
Front engine bracket bolt
Horn bracket
Front engine bracket
Self-locking nut
Upper rear mounting bolt
Rear engine bracket bolt

4
1
4
1
2
2
1
2

5-6

ENGINE

ENG

5
Order
9
10
11
12

Job/Part
Rear engine bracket
Lower front mounting bolt
Lower rear mounting bolt
Engine

Q’ty
Remarks
2
1
1
1
Refer to “INSTALLING THE ENGINE”.
For installation, reverse the removal
procedure.

5-7

ENGINE

ENG

INSTALLING THE ENGINE
1. Install:
• lower rear mounting bolt 1
• lower front mounting bolt 2
• rear engine brackets 3
• rear engine bracket bolts 4
• upper rear mounting bolt 5
• self-locking nuts 6
• front engine brackets 7
• horn bracket 8
• front engine bracket bolts 9
• upper front mounting bolt 0
• self-locking nuts A
NOTE:
Do not fully tighten the bolts and nuts.
2. Tighten:
• front engine bracket bolts 9
T.
R.

48 Nm (4.8 m · kg, 35 ft · lb)

• self-locking nut 6
T.
R.

48 Nm (4.8 m · kg, 35 ft · lb)

• self-locking nuts A
T.
R.

88 Nm (8.8 m · kg, 64 ft · lb)

5
3. Install:
• speed sensor 1

4. Install:
• neutral switch 1
• neutral switch cover 2

5-8

ENGINE
5.
•
•
•
•
•
6.
•

ENG

Connect:
speed sensor coupler
neutral switch connector
pickup coil coupler
decompression solenoid coupler
stator coil coupler
Install:
plastic clamp 1

7. Connect:
• charcoal canister hose (carburetor to
charcoal canister) 1

8. Connect:
• clutch cable 1

5
9.
•
•
•

Connect:
oil tank breather hose 1
cylinder head breather hose 2
spark plug caps 3

NOTE:
Refer to “CABLE ROUTING” in chapter 2.

10.Install:
• brake hose holder 1
40 Nm (4.0 m · kg, 29 ft · lb)
• joint bolt 2
• oil delivery pipe 3
R.

T.
R.
R.

5-9

• bolts 4

40 Nm (4.0 m · kg, 29 ft · lb)
10 Nm (1.0 m · kg, 7.2 ft · lb)

ENGINE

ENG

11.Install:
• horns 1
12.Connect:
• horn couplers

13.Install:
• oil filter bracket 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

• oil filter bolt 2
T.
R.

70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:
Apply locking agent (LOCTITE) to the
threads of the oil filter bracket bolts.
14.Install:
• rider footrest (right)
Refer to “GENERATOR AND STARTER
CLUTCH”.
• rider footrest (left)
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
• transfer gear case
Refer to “TRANSFER GEAR CASE”.
15.Fill:
• transfer gear case
(with the specified amount of the recommended transfer gear oil)
Refer to “CHANGING THE TRANSFER
GEAR OIL” in chapter 3.
16.Install:
• oil filter cartridge
17.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.

5 - 10

ENGINE

ENG

18.Install:
• starter motor
Refer to “STARTER MOTOR” in chapter
7.
• air induction system parts
Refer to “AIR INDUCTION SYSTEM” in
chapter 6.
• carburetor joint
• carburetor
Refer to “CARBURETOR” in chapter 6.
• air filter case
Refer to “AIR FILTER CASE” in chapter 3.
• fuel tank
Refer to “FUEL TANK” in chapter 3.
• side covers
• rider seat
Refer to “SEATS AND SIDE COVERS” in
chapter 3.

19.Install:
• gaskets
• exhaust pipes
NOTE:
Finger tighten the exhaust pipe nuts.

5
T.
R.

20.Install:
• muffler
• bolts 1

30 Nm (3.0 m · kg, 22 ft · lb)

21.Tighten:
• exhaust pipe nuts
T.
R.

20 Nm (2.0 m · kg, 14 ft · lb)

• clamp bolts 1
T.
R.

5 - 11

25 Nm (2.5 m · kg, 18 ft · lb)

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

5
Order

1
2
3
4
5
6
7
8

Job/Part
Removing the engine left side cover
and camshaft sprocket cover
Rider seat/fuel tank/air filter case

Q’ty

Engine oil
Spark plug cap
Spark plug
Shift rod
Charcoal canister hose
Rider footrest (left)
Engine left side cover
Timing mark accessing screw
Crankshaft end cover

4
4
1
2
1
1
1
1

5 - 12

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVER”,
“FUEL TANK” and “AIR FILTER CASE”
in chapter 3.
Drain.
Disconnect.

Disconnect.

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

5
Order
9
10
11
12

Job/Part
Decompression solenoid cover
Camshaft sprocket cover
Camshaft sprocket cover gasket
Dowel pin

Q’ty
1
1
1
2

Remarks

For installation, reverse the removal
procedure.

5 - 13

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

5
Order
1
2
3
4
5
6
7
8
9
10

Job/Part
Removing cylinder head covers
Cylinder head breather hose
Oil tank breather hose
Bolt
Bolt
Bolt
Bolt
Rear cylinder head cover
Front cylinder head cover
Cylinder head cover gasket
Dowel pin

Q’ty
1
1
4
4
4
12
1
1
2
4

5 - 14

Remarks
Remove the parts in the order listed.

R = 65 mm (2.56 in)
R = 35 mm (1.38 in)
R = 50 mm (1.97 in)
R = 25 mm (0.98 in)

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

5
Order
11
12
13
14

Job/Part
Rear cylinder head cover spacer
Front cylinder head cover spacer
Cylinder head cover spacer gasket
Dowel pin

Q’ty
1
1
2
4

Remarks

For installation, reverse the removal
procedure.

5 - 15

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

5
Order

1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the push rods and rocker
arms
Push rod
Rear rocker arm base
Front rocker arm base
Rocker arm base gasket
Dowel pin
Rocker arm shaft
Rocker arm 1
Rocker arm 2
Locknut
Adjusting screw

Q’ty

Remarks
Remove the parts in the order listed.

4
1
1
2
4
4
2
2
2
2
For installation, reverse the removal
procedure.

5 - 16

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

5
Order
1
2
3
4
5
6
7
8
9
10

Job/Part
Removing the valve lifters
Push rod cover
Oil seal
O-ring
Throttle stop screw
Throttle stop screw holder
Rear valve lifter case cover
Front valve lifter case cover
Rear valve lifter case
Front valve lifter case
Valve lifter

Q’ty
2
4
4
1
1
1
1
1
1
4

Remarks
Remove the parts in the order listed.

Unhook.

For installation, reverse the removal
procedure.

5 - 17

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

REMOVING THE ROCKER ARMS, PUSH
RODS AND VALVE LIFTERS
1. Align:
• TDC mark a on the pickup coil rotor
(with the pointer b on the clutch/pickup
coil rotor cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a
on the pickup coil rotor with the pointer
b on the clutch/pickup coil rotor cover.
c. Check the camshaft drive gear mark c
position and camshaft driven gear mark
d position as shown.
If the marks are not aligned, turn the
crankshaft counterclockwise 360 degrees
and recheck step b.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Remove:
• rocker arm bases
(with the rocker arms)
3. Remove:
• valve lifters
NOTE:
Make a note of the position of each valve
lifter so that they can be installed in the correct place.

CAUTION:
ACHTUNG:
Do not lay the removed valve lifter on its side.

CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all of
the rocker arms and rocker arm shafts.
1. Check:
• rocker arm
Damage/wear → Replace.

5 - 18

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/scratches → Replace or check the
lubrication system.

3. Measure:
• rocker arm inside diameter a
Out of specification → Replace.
Rocker arm inside diameter
15.000 ~ 15.018 mm
(0.5906 ~ 0.5913 in)

4. Measure:
• rocker arm shaft outside diameter
Out of specification → Replace.
Rocker arm shaft outside diameter
14.981 ~ 14.991 mm
(0.5898 ~ 0.5902 in)

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 (0.003 in) → Replace the
defective part(s).
Rocker arm to rocker arm shaft
clearance
0.009 ~ 0.037 mm
(0.0003 ~ 0.0015 in)

5 - 19

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

CHECKING THE ROCKER ARM BASES
1. Check:
• rocker arm base
Cracks/damage → Replace.

CHECKING THE PUSH RODS
1. Check:
• push rod
• push rod end
Bends/damage → Replace.

2. Measure:
• push rod runout
Out of specification → Replace.
Push rod runout
0.3 mm (0.012 in)

5
CHECKING THE VALVE LIFTERS AND
VALVE LIFTER CASES
1. Check:
• valve lifter
Blue discoloration/excessive wear/pitting/scratches → Replace or check the
lubrication system.

2. Check:
• valve lifter case 1
Damage/wear → Replace the valve lifter
case.
• O-ring 2
Damage/wear → Replace the O-ring.

5 - 20

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

3. Measure:
• valve lifter outside diameter a
Out of specification → Replace.
Valve lifter case outside diameter
22.9680 ~ 22.9744 mm
(0.9043 ~ 0.9045 in)

4. Measure:
• valve lifter case inside diameter a
Out of specification → Replace.
Valve lifter case inside diameter
22.990 ~ 23.010 mm
(0.9051 ~ 0.9059 in)

5. Calculate:
• valve lifter-to-valve lifter case clearance
NOTE:
Calculate the clearance by subtracting the
valve lifter case outside diameter.

Above 0.072 mm (0.0028 in) → Replace
the defective part(s)
Valve lifter-to-valve lifter case
clearance
0.0156 ~ 0.042 mm
(0.0006 ~ 0.0017 in)

BLEEDING A VALVE LIFTER
A valve lifter must be bled in the following
cases.
• When installing a new valve lifter
• When the valve lifter leaks oil

5 - 21

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

1. Bleed:
• valve lifter
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fill a container with kerosene and place
the valve lifter into the container as
shown.
Pump the plunger side of the valve lifter
with a press a number of times to let in
kerosene.

CAUTION:
ACHTUNG:
• Do not pump the valve lifter excessively.
• Kerosene is highly flammable.
1 Kerosene
2 Valve lifter

b. Install the valve lifter into the engine.

CAUTION:
ACHTUNG:
Be sure to install the valve lifter in its
appropriate position.
c. Start the engine and warm it up.
d. Stop the engine.
e. Remove the camshaft sprocket cover.
f. Rotate the camshaft until the punch mark
1 on the camshaft driven gear aligns
with the punch mark on the camshaft
drive gear as shown. This is the condition in which piston #1 is at top dead
center (TDC).
NOTE:
The crankshaft can be rotated smoothly
when the spark plugs are removed.

WARNING
WARNING
Be careful since the engine is hot.
g. With piston #1 at TDC, count the indicated number of gear teeth and place
marks 2 through 5 on the camshaft
driven gear as shown. When these marks
align between the centers of the camshaft drive and driven gears, the corresponding valve lifter is at its highest
point.
1
2
3
4
5
5 - 22

Piston #1 TDC punch mark
Cylinder #2 intake valve at its highest point
Cylinder #1 exhaust valve at its highest point
Cylinder #1 intake valve at its highest point
Cylinder #2 exhaust valve at its highest point

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

h. Rotate the crankshaft until the mark (on
the camshaft driven gear) for the valve
lifter to be bled aligns with the camshaft
drive gear as shown.
Example: For bleeding the cylinder #2
intake valve lifter, align mark 1 as
shown.
1 Cylinder #2 intake valve at its highest point
2 Piston #1 TDC punch mark

i. Leave the camshaft drive and driven
gears aligned for five minutes to allow
the valve lifter to bleed.
j. If necessary, repeat steps “h” and “i” to
bleed other valve lifters.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5
CHECKING THE PUSH ROD COVERS
1. Check:
• push rod cover 1
Cracks/damage → Replace.
• oil seal 2
• O-ring 3
Damage/wear → Replace the oil seal and
O-ring as a set.

INSTALLING THE VALVE LIFTERS AND
PUSH ROD COVERS
1. Install:
• valve lifter cases (front and rear)
• valve lifters
NOTE:
• Install the valve lifter in the correct place.
• After installing the valve lifters, fill the
tops of them with engine oil.
5 - 23

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

2.
•
•
•

Install:
oil seals 1
O-rings 2
push rod covers 3

3.
•
•
4.
•

Install:
valve lifter case covers 1
throttle stop screw holder 2
Hook:
throttle stop screw 3

5. Install:
• O-rings 1
• oil seals 2

5
INSTALLING THE ROCKER ARMS AND
PUSH RODS
The following procedure applies to both
cylinders.
1. Install:
• rocker arms 1
• rocker arm shafts 2
(onto rocker arm base)
NOTE:
The thread hole a of the rocker arm shaft
must face to the outside.

5 - 24

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

2. Install:
• dowel pins 1
• rocker arm gasket 2 New

3. Install:
• rocker arm base
(with rocker arms)
• push rods

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Put the rocker arm base on the cylinder
head.
b. Install the push rods.
NOTE:
• Be sure to correctly install the push rods
between the rocker arms and valve lifters
as shown. The illustration is viewed from
the right side of the motorcycle.

Å Rear cylinder
ı Front cylinder
1 Intake side rocker arm
2 Exhaust side rocker arm
3 Intake valve lifter
4 Exhaust valve lifter

• Lubricate the push rod end balls with
engine oil.
c. Install the rocker arm base bolts.
NOTE:
Tighten the rocker arm base bolts in stages
and in a crisscross pattern.

Rocker arm base bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5 - 25

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

INSTALLING THE CYLINDER HEAD
COVERS
The following procedure applies to both
cylinders.
1. Install:
• dowel pins 1
• cylinder head cover spacer gasket 2
New

2. Install:
• cylinder head cover spacer 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Install:
• dowel pins 1
• cylinder head cover gasket 2

New

5
4. Install:
• cylinder head cover 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

Bolts 2: R = 25 mm (0.98 in)
Bolts 3: R = 35 mm (1.38 in)
Bolts 4: R = 50 mm (1.97 in)
Bolts 5: R = 65 mm (2.56 in)

5. Connect:
• oil tank breather hose 1
• cylinder head breather hose 2

5 - 26

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

INSTALLING THE CAMSHAFT SPROCKET
COVER AND ENGINE LEFT SIDE COVER
1. Install:
• dowel pins 1
• camshaft sprocket cover gasket 2
New

2. Install:
• camshaft sprocket cover 1
• decompression solenoid cover 2

3. Install:
• crankshaft end cover 1
• timing mark accessing screw 2

5
4. Install:
• engine left side cover 1

5.
•
6.
•

5 - 27

Install:
rider footrest (left) 1
Connect:
charcoal canister hoses

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

ENG

7. Install:
• shift rod 1

8.
•
9.
•

Install:
spark plugs
Connect:
spark plug caps

NOTE:
Refer to “CABLE ROUTING” in chapter 2.
Å Forward

10.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.

11.Install:
• air filter case
• fuel tank
• rider seat
Refer to “AIR FILTER CASE”, “FUEL
TANK” and “SEATS AND SIDE COVERS”
in chapter 3.

12.Adjust:
• installed shift rod length
Refer to “ADJUSTING
PEDAL” in chapter 3.

5 - 28

THE

SHIFT

CAMSHAFTS

ENG

CAMSHAFTS

5
Order

1
2
3
4
5
6
7
8

Job/Part
Removing the camshafts
Valve lifters

Q’ty

Remarks
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
Refer to “ENGINE”.

Muffler/exhaust pipes
Decompression solenoid
Long decompression push rod
Short decompression push rod
Camshaft drive gear
Straight key
Camshaft driven gear
Straight key
Oil delivery pipe

1
1
1
1
1
1
1
1

5 - 29

92 mm (3.6 in)
78 mm (3.1 in)

CAMSHAFTS

ENG

5
Order
9
10
11
12
13
14

Job/Part
Camshaft cover
Camshaft cover gasket
Dowel pin
Front cylinder camshaft end cover
Front cylinder camshaft
Rear cylinder camshaft

Q’ty
1
1
1
1
1
1

Remarks

For installation, reverse the removal
procedure.

5 - 30

CAMSHAFTS

ENG

REMOVING THE CAMSHAFTS
1. Loosen:
• front cylinder camshaft end cover bolts
1
• camshaft drive gear bolt 2
NOTE:
• Place a folded copper washer 3 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock
them.
• Do not damage the teeth of the camshaft
drive and camshaft driven gears.

2. Loosen:
• camshaft driven gear nut 1
NOTE:
• Place a folded copper washer 2 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock
them.
• Do not damage the teeth of the camshaft
drive and camshaft driven gears.

3.
•
•
•
•

Remove:
front cylinder camshaft end cover
camshaft drive gear 1
camshaft driven gear 2
straight keys

NOTE:
Cover the crankcase hole with a clean rag 3
to prevent the straight keys from falling into
the crankcase.
4. Remove:
• oil delivery pipe 1
• camshaft cover 2
(along with the camshafts)
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 - 31

CAMSHAFTS

ENG

EAS00204

CHECKING THE CAMSHAFTS
1. Check:
• cams
Blue discoloration/pitting/scratches →
Replace the camshaft.

2. Measure:
• cam dimensions a and b
Out of specification → Replace the camshaft.
Minimum cam lobe dimensions
Intake cam
a 36.494 mm (1.4368 in)
b 31.850 mm (1.2539 in)
Exhaust cam
a 36.454 mm (1.4352 in)
b 31.850 mm (1.2539 in)

5
3. Measure:
• camshaft journal diameter (crankcase
side) a
Out of specification → Replace the camshaft.
Camshaft journal diameter
(crankcase side)
24.937 ~ 24.950 mm
(0.9818 ~ 0.9823 in)
4. Measure:
• camshaft journal diameter (camshaft
cover side) b
Out of specification → Replace the camshaft.
Camshaft journal diameter
(camshaft cover side)
27.967 ~ 27.980 mm
(1.1011 ~ 1.1016 in)
5 - 32

CAMSHAFTS

ENG

5. Measure:
• crankcase hole inside diameter c
Out of specification → Replace the crankcase.
Crankcase hole inside diameter
25.000 ~ 25.021 mm
(0.9843 ~ 0.9851 in)

6. Measure:
• camshaft cover hole inside diameter d
Out of specification → Replace the camshaft cover.
Camshaft cover hole inside diameter
28.000 ~ 28.021 mm
(1.1024 ~ 1.1032 in)

7. Calculate:
• camshaft-to-crankcase clearance
Out of specification → Replace the defective part(s).
NOTE:
Calculate the clearance by subtracting the
crankcase side camshaft journal diameter
(crankcase side) from the crankcase hole
inside diameter.

Camshaft to crankcase clearance
0.050 ~ 0.084 mm
(0.0020 ~ 0.0033 in)
8. Calculate:
• camshaft-to-camshaft cover clearance
Out of specification → Replace the defective part(s).
NOTE:
Calculate the clearance by subtracting the
camshaft journal diameter (camshaft cover
side) from the camshaft cover hole inside
diameter.
Camshaft to camshaft cover
clearance
0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)

5 - 33

CAMSHAFTS

ENG

9. Check:
• camshaft drive gears
• camshaft driven gears
Chips/pitting/roughness/wear → Replace
the defective part(s).

CHECKING THE DECOMPRESSION
SYSTEM
1. Check:
• decompression system
NOTE:
• Check the decompression system while
the decompression push rod is installed in
the camshaft.
• Check that the decompression pin 1
projects from the camshaft.
• Check that the decompression push rod 2
moves smoothly.

5
2. Check:
• decompression push rods
Bends/damage → Replace.

5 - 34

CAMSHAFTS

ENG

CHECKING THE OIL DELIVERY PIPE
1. Check:
• oil delivery pipe 1
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
• O-rings 2
Damage/wear → Replace.

INSTALLING THE CAMSHAFTS
1. Install:
• camshafts
(to the camshaft cover)
• front cylinder camshaft end cover
NOTE:
• Apply molybdenum disulfide oil onto the
camshaft journals and cam lobes.
• Align the punch mark a on the rear cylinder camshaft with the punch mark b on
the front cylinder camshaft.

5
2. Install:
• front cylinder camshaft end cover 1
NOTE:
Finger tighten the end cover bolts.

3. Install:
• dowel pins 1
• camshaft cover gasket 2

5 - 35

New

CAMSHAFTS

ENG

4. Install:
• camshaft cover 1
(along with the camshafts)
• oil delivery pipe 2
NOTE:
Tighten the camshaft cover bolts in stages
and in a crisscross pattern.

5.
•
•
•

Install:
straight keys
camshaft drive gear 1
camshaft driven gear 2

NOTE:
• Cover the crankcase hole with a clean rag
3 to prevent the straight keys from falling
into the crankcase.
• Align the punch mark a on the camshaft
drive gear 1 with the punch mark b on
the camshaft driven gear 2.
• Insert a cross-headed screwdriver into
one of the holes in the outer camshaft
driven gear and rotate the gear until the
teeth of both driven gears are aligned.
The teeth of both camshaft driven gears
must be aligned for installation.

6.
•
•
•

Install:
washers
camshaft drive gear bolt
camshaft driven gear nut

7. Tighten:
• camshaft driven gear nut 1
T.
R.

52 Nm (5.2 m · kg, 37 ft · lb)

NOTE:
• Place a folded copper washer 2 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.
• Do not damage the teeth of the camshaft
drive and camshaft driven gear.
5 - 36

CAMSHAFTS

ENG

8. Tighten:
• camshaft drive gear bolt 1
T.
R.

30 Nm (3.0 m · kg, 22 ft · lb)

• front cylinder camshaft end cover bolts
2
NOTE:
• Place a folded copper washer 3 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock
them.
• Do not damage the teeth of the camshaft
drive and camshaft driven gear.

9. Install:
• short decompression push rod 1
• long decompression push rod 2

5
10.Install:
• decompression solenoid 1

11.Install:
• valve lifters
• push rods
• rocker arms
• cylinder head covers
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
• exhaust pipes
• muffler
Refer to “ENGINE”.
5 - 37

CAMSHAFTS

ENG

12.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
13.Install:
• air filter case
• fuel tank
• rider seat
Refer to “AIR FILTER CASE”, “FUEL
TANK” and “SEATS AND SIDE COVERS”
in chapter 3.

5 - 38

CYLINDER HEADS

ENG

CYLINDER HEADS

5
Order

Job/Part
Removing the cylinder head
Rider seat/fuel tank/air filter case

Q’ty

Carburetor/carburetor joint
Muffler/exhaust pipes
Rocker arms/push rod cover
1
2
3
4
5

Reed valve case to rear cylinder pipe
Reed valve case to front cylinder
pipe
Gasket
Oil delivery pipe
Copper washer

5 - 39

1
1
2
1
4

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”,
“FUEL TANK” and “AIR FILTER CASE”
in chapter 3.
Refer to “CARBURETOR” in chapter 6.
Refer to “ENGINE”.
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
Disconnect.
Disconnect.

CYLINDER HEADS

ENG

5
Order
6
7
8
9
10

Job/Part
Copper washer
Rear cylinder head
Front cylinder head
Cylinder head gasket
Dowel pin

Q’ty
2
1
1
2
4

Remarks

For installation, reverse the removal
procedure.

5 - 40

CYLINDER HEADS

ENG

REMOVING THE CYLINDER HEADS
1. Remove:
• cylinder head
NOTE:
• Loosen the nuts in the proper sequence.
• Follow the numerical order shown in the
illustration. Loosen each bolt 1/4 of a turn
at a time until all of the nuts are loose.

EAS00228

CHECKING THE CYLINDER HEADS
The following procedure applies to each
cylinder head.
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
• spark plug bore threads
• valve seats

5
2. Check:
• cylinder head
Damage/scratches → Replace.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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 cylinder head as follows.

5 - 41

CYLINDER HEADS

ENG

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 THE OIL DELIVERY PIPE
1. Check:
• oil delivery pipe 1
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.

EAS00232

INSTALLING THE CYLINDER HEADS
1. Install:
• dowel pins 1
• gasket 2 New

5
2.
•
•
•

Install:
cylinder heads
washers
cylinder head nuts (M12: 1 ~ 4)
T.
R.

50 Nm (5.0 m · kg, 36 ft · lb)

• cylinder head nuts (M10: 5, 6)
T.
R.

39 Nm (3.9 m · kg, 28 ft · lb)

NOTE:
• Lubricate the cylinder head nuts with
engine oil.
• Tighten the cylinder head nuts in the
proper tightening sequence as shown and
torque them in two stages.

5 - 42

CYLINDER HEADS
3.
•
•
•

ENG

Install:
copper washers New
oil delivery pipe 1
oil delivery pipe bolts (M10)
T.
R.

21 Nm (2.1 m · kg, 15 ft · lb)

• oil delivery pipe bolt (M8)
T.
R.

4.
•
•
•

18 Nm (1.8 m · kg, 13 ft · lb)

Install:
gaskets
reed valve case to front cylinder pipe 1
reed valve case to rear cylinder pipe 2

5. Install:
• rocker arms
• cylinder head covers
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
• muffler
• exhaust pipes
Refer to “ENGINE”.
• carburetor
Refer to “CARBURETOR” in chapter 6.
• air filter case
• fuel tank
• rider seat
Refer to “AIR FILTER CASE”, “FUEL
TANK” and “SEATS AND SIDE COVERS”
in chapter 3.

5 - 43

VALVES AND VALVE SPRINGS

ENG

VALVES AND VALVE SPRINGS

5
Order

1
2
3
4
5
6
7
8

Job/Part
Removing the valves and valve
springs

Q’ty

Remarks
Remove the parts in the order listed.
The following procedure applies to
both cylinders.
Refer to “CYLINDER HEADS”.

Cylinder head
Valve cotter
Upper spring seat
Outer valve spring
Inner valve spring
Intake valve
Exhaust valve
Valve oil seal
Lower spring seat

4
4
4
4
2
2
4
4
For installation, reverse the removal
procedure.

5 - 44

VALVES AND VALVE SPRINGS

ENG

EAS00238

REMOVING THE VALVES
The following procedure applies to all of
the valves and related components.
NOTE:
Before removing the internal parts of the
cylinder head (e.g., valves, valve springs,
valve seats), make sure the valves properly
seal.
1. Check:
• valve
(for leakage)
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Remove:
• valve cotters
NOTE:
Remove the valve cotters by compressing
the valve springs with the valve spring
compressor 1.
Valve spring compressor
YM-04019
3.
•
•
•
•
•
•

5 - 45

Remove:
upper spring seat 1
outer valve spring 2
inner valve spring 3
valve 4
oil seal 5
lower spring seat 6

VALVES AND VALVE SPRINGS

ENG

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
The following procedure applies to all of
the 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 clearance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
: 0.08 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0006 ~ 0.0020 in)
: 0.1 mm (0.004 in)

2. Replace:
• valve guide
NOTE:
To ease valve guide removal and installation, and to maintain the correct fit, heat the
cylinder head to 100 ˚C (212 ˚F) in an oven.

5 - 46

VALVES AND VALVE SPRINGS

ENG

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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-tovalve-guide clearance.
NOTE:
After replacing the valve guide, reface the
valve seat.
Valve guide remover (6 mm)
YM-4064-A
Valve guide installer (6 mm)
YM-04065-A
Valve guide reamer (6 mm)
YM-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5
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
0.7 ~ 1.3 mm (0.028 ~ 0.051 in)
: 0.4 mm (0.016 in)

5 - 47

VALVES AND VALVE SPRINGS

ENG

6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always
replace the valve guide.
• If the valve is removed or replaced,
always replace the oil seal.
Valve stem runout
0.01 mm (0.0004 in)

EAS00240

CHECKING THE VALVE SEATS
The following procedure applies to all of
the 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
(0.035 ~ 0.043 in)
: 2.0 mm (0.079 in)
Exhaust: 0.9 ~ 1.1 mm
(0.035 ~ 0.043 in)
: 2.0 mm (0.079 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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
impression.
5 - 48

VALVES AND VALVE SPRINGS

ENG

d. Measure the valve seat width.
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:
ACHTUNG:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then
clean off all of the lapping compound.
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.

5 - 49

VALVES AND VALVE SPRINGS

ENG

g. Apply Mechanic’s blueing dye (Dykem)
b onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
j. Measure the valve seat width again. If
the valve seat width is out of specification, reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00241

CHECKING THE VALVE SPRINGS
The following procedure applies to all of
the valve springs.
1. Measure:
• valve spring free length a
Out of specification → Replace the valve
spring.
Valve spring free length (intake
and exhaust)
Inner valve spring
38.26 mm (1.51 in)
: 36.26 mm (1.43 in)
Outer valve spring
43.25 mm (1.70 in)
: 41.26 mm (1.62 in)

5 - 50

VALVES AND VALVE SPRINGS

ENG

2. Measure:
• compressed valve spring force a
Out of specification → Replace the valve
spring.
b Installed length

Compressed valve spring force
(installed)
Intake and exhaust inner valve
spring
6.3 ~ 7.3 kg at 29.0 mm
(13.9 ~ 16.1 lb at 1.14 in)
Intake and exhaust outer valve
spring
13.9 ~ 16.1 kg at 31.0 mm
(30.6 ~ 35.5 lb at 1.22 in)

3. Measure:
• valve spring tilt a
Out of specification → Replace the valve
spring.
Maximum valve spring tilt
Intake and exhaust inner valve
spring
2.4 mm (0.094 in)
Intake and exhaust outer valve
spring
2.4 mm (0.094 in)

EAS00246

INSTALLING THE VALVES
The following procedure applies to all of
the valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)

5 - 51

VALVES AND VALVE SPRINGS

ENG

2. Lubricate:
• valve stem 1
• oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil

3.
•
•
•
•
•
•

Install:
lower spring seat 1
oil seal 2 New
valve 3
inner valve spring 4
outer valve spring 5
upper spring seat 6
(into the cylinder head)

NOTE:
Install the valve springs with the larger
pitch a facing up.
b Smaller pitch

5
4. Install:
• valve cotters
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor 1.
Valve spring compressor
YM-04019
5. To secure the valve cotters onto the
valve stem, lightly tap the valve tip with
a soft-face hammer.

CAUTION:
ACHTUNG:
Hitting the valve tip with excessive force
could damage the valve.

5 - 52

6. Install:
• cylinder head
Refer to “CYLINDER HEADS”.

CYLINDERS AND PISTONS

ENG

EAS00251

CYLINDERS AND PISTONS

5
Order

1
2
3
4
5
6
7
8
9

Job/Part
Removing the cylinders and pistons
Cylinder heads
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
2nd ring
Oil ring

Q’ty

Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.

2
2
4
4
2
2
2
2
2
For installation, reverse the removal
procedure.

5 - 53

CYLINDERS AND PISTONS

ENG

EAS00254

REMOVING THE CYLINDERS AND
PISTONS
The following procedure applies to all of
the cylinders and pistons.
1. Remove:
• piston pin clip 1
• piston pin 2
• piston 3

CAUTION:
ACHTUNG:
Do not use a hammer to drive the piston
pin out.
NOTE:
• Before removing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the piston pin clip from falling
into the crankcase.
• For reference during installation, put an
identification mark on each piston crown.
• Before removing the piston pin, deburr
the piston pin clip groove and the piston
pin bore area. If both areas are deburred
and the piston pin is still difficult to
remove, remove it with the piston pin
puller 4.
Piston pin puller
YU-01304

2.
•
•
•

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.

EAS00258

CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of
the cylinders and pistons.
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the cylinder, and the piston and piston rings as a
set.
5 - 54

CYLINDERS AND PISTONS

ENG

2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Measure cylinder bore “C” with the cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking sideto-side and front-to-back measurements of
the cylinder. Then, find the average of the
measurements.
Cylinder bore gauge
YU-03017
Cylinder bore “C”

95.000 ~ 95.010 mm
(3.7402 ~ 3.7406 in)

Maximum taper “T” 0.05 mm (0.0016 in)
Out of round “R”

0.05 mm (0.0016 in)

“C” = maximum of D1 ~ D6
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1, D3 or D5
– minimum of D2, D4 or D6

b. If out of specification, replace the cylinder, and the piston and piston rings as a
set.
c. Measure piston skirt diameter “P” with
the micrometer.
Micrometer
YU-03009
a 5 mm (0.20 in) from the bottom edge of the
piston

Piston size “P”
Standard

94.960 ~ 94.975 mm
(3.7386 ~ 3.7392 in)

d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”

5 - 55

CYLINDERS AND PISTONS

ENG

Piston-to-cylinder clearance
0.025 ~ 0.050 mm
(0.001 ~ 0.002 in)
: 0.15 mm (0.006 in)
f. If out of specification, replace the cylinder, and the piston and piston 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 clearance, eliminate any carbon deposits from
the piston ring grooves and piston rings.
Piston ring side clearance
Top ring
0.03 ~ 0.08 mm
(0.0012 ~ 0.0031 in)
: 0.12 mm (0.0047 in)
2nd ring
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
: 0.12 mm (0.0047 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown.
a 10 mm (0.39 in)

3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is
excessive, replace all three piston rings.

5 - 56

CYLINDERS AND PISTONS

ENG

Piston ring end gap
Top ring
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
: 0.65 mm (0.026 in)
2nd ring
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
: 0.80 mm (0.031 in)
Oil ring
0.2 ~ 0.7 mm (0.008 ~ 0.028 in)

EAS00266

CHECKING THE PISTON PINS
The following procedure applies to all of
the piston pins.
1. Check:
• piston pin
Blue discoloration/grooves → Replace
the piston pin and then check the lubrication system.
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
Piston pin outside diameter
21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)
: 21.971 mm (0.8650 in)

3. Measure:
• piston pin bore diameter (in the piston)
b
Out of specification → Replace the piston
pin.
Piston pin bore diameter (in the
piston)
22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
: 22.045 mm (0.8679 in)

5 - 57

CYLINDERS AND PISTONS

ENG

4. Calculate:
• piston pin-to-piston pin bore clearance
Out of specification → Replace the piston
pin.
Piston pin-to-piston pin bore clearance =
Piston pin bore diameter (in the piston) b –
Piston pin outside diameter a
Piston pin-to-piston pin bore
clearance
0.004 ~ 0.024 mm
(0.00016 ~ 0.00094 in)
: 0.074 mm (0.0029 in)

EAS00268

INSTALLING THE PISTONS AND
CYLINDERS
The following procedure applies to all of
the pistons and cylinders.
1. Install:
• top ring
• 2nd ring
• lower oil ring rail
• upper oil ring rail
• oil ring expander
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 onto the piston pin.
• Make sure the “arrow” mark a on the piston faces towards the front of the motorcycle.
• Before installing the piston pin clip, cover
the crankcase opening with a clean rag to
prevent the clip from falling into the
crankcase.

5 - 58

CYLINDERS AND PISTONS

ENG

3. Install:
• dowel pins 1
• gasket 2 New

4.
•
•
•

Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil

5. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
Å Front of the motorcycle

6. Install:
• cylinder 1
NOTE:
While compressing the piston rings with
one hand, install the cylinder with the other
hand.

5 - 59

CLUTCH

ENG

EAS00273

CLUTCH

5
Order

Job/Part
Removing the clutch cover
Left side cover

Q’ty

Engine left side cover

1
2
3
4
5
6
7

Engine oil
Clutch cable
Pull lever
Pull lever spring
Pickup coil coupler
Shift arm
Clutch cable holder
Clutch cover

1
1
1
1
1
1
1

5 - 60

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”
in chapter 3.
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
Drain.
Disconnect.

Disconnect.

CLUTCH

ENG

5
Order
Job/Part
8
Clutch cover gasket
9
Dowel pin

Q’ty
1
1

Remarks

For installation, reverse the removal
procedure.

5 - 61

CLUTCH

ENG

5
Order

1
2
3
4
5
6

Job/Part
Removing the pull lever shaft and
pickup coil
Pull lever
Pull lever spring
Circlip
Pull lever shaft
Oil seal
Bearing
Pickup coil lead holder
Pickup coil

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
2
3
3
1
For installation, reverse the removal
procedure.

5 - 62

CLUTCH

ENG

EAS00274

5
Order

1
2
3
4
5
6
7
8
9
10
11
12

Job/Part
Removing the clutch
Generator rotor cover
Clutch spring plate retainer
Clutch spring plate
Clutch spring plate seat
Pressure plate
Pull rod
Friction plate
Clutch plate
Lock washer
Wire circlip
Clutch plate
Friction plate
Clutch damper spring

Q’ty

1
1
1
1
1
7
6
1
1
1
1
1

5 - 63

Remarks
Remove the parts in the order listed.
Refer to “GENERATOR”.

CLUTCH

ENG

5
Order
13
14
15
16
17
18
19
20
21
22
23

Job/Part
Clutch damper spring seat
Clutch boss
Thrust washer
Clutch housing
Circlip
Oil pump drive gear
Dowel pin
Spacer
Pickup coil rotor
Primary drive gear
Straight key

Q’ty
1
1
1
1
1
1
1
1
1
1
1

Remarks

For installation, reverse the removal
procedure.

5 - 64

CLUTCH

ENG

EAS00277

REMOVING THE CLUTCH
1. Remove:
• clutch cable holder 1
• clutch cover 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the
universal clutch holder 3, loosen the clutch
boss nut.
Universal clutch holder
YM-91042
4.
•
•
•

Remove:
clutch boss nut 1
lock washer 2
clutch boss assembly 3

NOTE:
There is a built-in damper between the
clutch boss and the clutch plate. It is not
necessary to remove the wire circlip 4 and
disassemble the built-in damper unless
there is serious clutch chattering.

EAS00279

REMOVING THE PRIMARY DRIVE GEAR
1. Remove:
• pickup coil rotor bolt 1

5 - 65

CLUTCH

ENG

NOTE:
While holding the generator rotor 2 with
the sheave holder 3, loosen the pickup coil
rotor bolt.
Sheave holder
YS-01880

EAS00280

CHECKING THE FRICTION PLATES
The following procedure applies to all of
the friction plates.
1. Check:
• friction plate
Damage/wear → 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
2.9 ~ 3.1 mm (0.114 ~ 0.122 in)
: 2.8 mm (0.110 in)

EAS00281

CHECKING THE CLUTCH PLATES
The following procedure applies to all of
the clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification → Replace the clutch
plates as a set.
Maximum clutch plate warpage
0.2 mm (0.008 in)

5 - 66

CLUTCH

ENG

EAS00283

CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate 1
Damage → Replace.
2. Check:
• clutch spring plate seat 2
Damage → Replace.

EAS00284

CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr 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.

5
EAS00285

CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace
clutch boss.

the

NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
EAS00286

CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.

5 - 67

CLUTCH

ENG

EAS00287

CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
• pull lever shaft pinion gear teeth a
• pull rod teeth b
Damage/wear → Replace the pull lever
shaft and pull rod as a set.
2. Check:
• pull rod bearing
Damage/wear → Replace.

EAS00292

CHECKING THE PRIMARY DRIVE
1. Check:
• primary drive gear 1
• primary driven gear 2
Damage/wear → Replace the primary
drive gear and clutch housing as a set.
Excessive noise during operation →
Replace the primary drive gear and
clutch housing as a set.
INSTALLING THE PICKUP COIL AND PULL
LEVER SHAFT
1. Apply:
• sealant
(onto the pickup coil lead grommet)
Quick Gasket
ACC-11001-05-01

2. Install:
7 Nm (0.7 m · kg, 5.1 ft · lb)
• pickup coil
• pickup coil lead holder
R.

T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:
Apply locking agent (LOCTITE) to the
threads of the pickup coil bolts and pickup
coil lead holder bolts.

5 - 68

CLUTCH

ENG

3. Install:
• bearings
• oil seals 1
NOTE:
Lubricate the oil seal lips with lithium soap
base grease.

4.
•
•
•

Install:
pull lever shaft 1
washer
circlip

EAS00303

INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
• straight key 1
• primary drive gear 2
• pickup coil rotor 3
• spacer 4
• pickup coil rotor bolt 5

T.
R.

115 Nm (11.5 m · kg, 85 ft · lb)

CAUTION:
ACHTUNG:
The timing marks on the pickup coil rotor
must face outside.
NOTE:
• Apply locking agent (LOCTITE) to the
threads of the pickup coil rotor bolt.
• While holding the generator rotor 6 with
the sheave holder 7, tighten the pickup
coil rotor bolt.
Sheave holder
YS-01880
2. Bend the lock washer tab along a flat
side of the nut.

5 - 69

CLUTCH

ENG

EAS00296

INSTALLING THE CLUTCH
1. Install:
• dowel pin 1
• oil pump drive gear 2
• plate 3
• circlip 4

2. Install:
• clutch housing 1
• thrust washer 2
NOTE:
• Lubricate the clutch housing bearings
with engine oil.
• Make sure that the primary driven gear
teeth and primary drive gear teeth mesh
correctly.
• Make sure that the oil pump drive gear
teeth and oil pump driven gear teeth
mesh correctly.

5
3. Install:
• clutch boss assembly 1
NOTE:
• If the wire circlip 2 has been removed,
carefully install a new one.
• Install the clutch damper spring 3 with
the “OUTSIDE” mark facing out.

4.
•
•
•

Install:
clutch boss 1
lock washer New
clutch boss nut 2
T.
R.

70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:
While holding the clutch boss with the universal clutch holder 3, tighten the clutch
boss nut.
5 - 70

CLUTCH

ENG

Universal clutch holder
YM-91042
5. Bend the lock washer tab along a flat
side of the nut.
6. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil

7. Install:
• friction plates
• clutch plates
NOTE:
• First, install a friction plate and then alternate between a clutch plate and a friction
plate.
• Align the two embossed mark a on the
clutch housing with the two semicircular
slots b in the friction plates.

8. Install:
• pressure plate 1
NOTE:
Align the punch mark a on the pressure
plate with the punch mark b on the clutch
boss.

5 - 71

CLUTCH
9.
•
•
•

ENG

Install:
clutch spring plate seat 1
clutch spring plate 2
clutch spring plate retainer 3
T.
R.

8 Nm (0.8 m · kg, 5.8 ft · lb)

NOTE:
Tighten the clutch spring plate retainer
bolts in stages and in a crisscross pattern.

10.Install:
• dowel pins 1
• clutch cover gasket 2 New

11.Install:
• clutch cover 1
• clutch cable holder 2
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
Tighten the clutch cover bolts in stages and
in a crisscross pattern.

12.Connect:
• pickup coil coupler
NOTE:
Refer to “CABLE ROUTING” in chapter 2.

T.
R.

13.Install:
• shift arm 1

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
Align the mark a in the shift shaft with the
slot in the shift arm.

5 - 72

CLUTCH

ENG

14.Install:
• pull lever spring
• pull lever
NOTE:
If there is no free play in the clutch, install
the pull lever to the pull lever shaft in order
to get the distance a between the pull lever
and clutch cable holder to 31.8 mm (1.25 in).

15.Connect:
• clutch cable 1

16.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.

17.Install:
• engine left side cover
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
• left side cover
Refer to “SEATS AND SIDE COVERS” in
chapter 3.
18.Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.

5 - 73

SHIFT SHAFT

ENG

EAS00327

SHIFT SHAFT

5
Order

1
2
3
4
5
6
7

Job/Part
Removing the shift shaft and stopper lever
Engine oil
Clutch housing
Circlip
Shift shaft spring
Shift shaft
Shift shaft spring stopper
Lock washer
Stopper lever
Stopper lever spring

Q’ty

Remarks
Remove the parts in the order listed.
Drain.
Refer to “CLUTCH”.

2
1
1
1
1
1
1
For installation, reverse the removal
procedure.

5 - 74

SHIFT SHAFT

ENG

EAS00328

CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
Bends/damage/wear → Replace.
• shift lever spring 2
Damage/wear → Replace.

EAS00330

CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the stopper lever.

EAS00331

INSTALLING THE STOPPER LEVER AND
SHIFT SHAFT
1. Install:
• stopper lever 1
• stopper lever spring 2

NOTE:
• Apply locking agent (LOCTITE) to the
threads of stopper lever bolt.
• Install the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss 3.
• Mesh the stopper lever with the shift
drum segment assembly.

2. Install:
• lock washer 1 New
• shift shaft spring stopper 2
T.
R.

22 Nm (2.2 m · kg, 16 ft · lb)

NOTE:
Apply locking agent (LOCTITE) to the
threads of shift shaft spring stopper.
3. Bend the lock washer tab along a flat
side of the shift shaft spring stopper.
5 - 75

SHIFT SHAFT
4.
•
•
•

ENG

Install:
shift shaft spring
circlips
shift shaft 1

NOTE:
Install the end of the shift shaft spring onto
the shift shaft spring stopper 2.

5. Install:
• clutch housing
Refer to “CLUTCH”.
6. Fill:
• oil tank
Refer to “CHANGING THE ENGINE OIL”.

5 - 76

GENERATOR AND STARTER CLUTCH

ENG

EAS00341

GENERATOR AND STARTER CLUTCH

5
Order

1
2
3
4
5
6
7
8
9

Job/Part
Removing the stator coil assembly
Rider seat/left side cover/fuel tank

Q’ty

Muffler/exhaust pipes
Engine oil
Plastic locking tie
Rear brake light switch coupler
Rider footrest (right)
Stator coil assembly coupler
Decompression solenoid coupler
Oil delivery pipe
Generator cover
Generator cover gasket
Dowel pin

1
1
1
1
2
1
1
1
2

5 - 77

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”
and “FUEL TANK” in chapter 3.
Refer to “ENGINE”.
Drain.
Disconnect.
Disconnect.
Disconnect.

GENERATOR AND STARTER CLUTCH

ENG

5
Order
Job/Part
10
Stator coil assembly lead holder
11
Stator coil assembly

Q’ty
1
1

Remarks

For installation, reverse the removal
procedure.

5 - 78

GENERATOR AND STARTER CLUTCH

ENG

EAS00343

5
Order
1
2
3
4
5
6

Job/Part
Removing the generator rotor
Starter clutch idle gear shaft #2
Starter clutch idle gear shaft #1
Starter clutch idle gear #2
Starter clutch idle gear #1
Generator rotor
Starter clutch gear

Q’ty

Remarks
Remove the parts in the order listed.

1
1
1
1
1
1
For installation, reverse the removal
procedure.

5 - 79

GENERATOR AND STARTER CLUTCH

ENG

EAS00347

REMOVING THE GENERATOR
1. Remove:
• generator cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all
of the bolts are fully loosened, remove
them.
2. Remove:
• generator rotor bolt 1
• washer
NOTE:
While holding the generator rotor 2 with
the sheave holder 3, loosen the generator
rotor bolt.
Sheave holder
YS-01880
3. Remove:
• generator rotor 1
(with the rotor puller 2)
Rotor puller
YM-01080-A

5
EAS00348

CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch idle gears 1
• starter clutch gear 2
Chips/pitting/roughness/wear → Replace
the defective part(s).

2. 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
clockwise Å, the starter clutch and the
starter clutch gear should engage, otherwise the starter clutch is faulty and must
be replaced.
5 - 80

GENERATOR AND STARTER CLUTCH

ENG

c. When turning the starter clutch gear
counterclockwise ı, it should turn
freely, otherwise the starter clutch is
faulty and must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00354

INSTALLING THE GENERATOR
1. Install:
• starter clutch gear 1
• generator rotor 2
• washer
• generator rotor bolt 3
NOTE:
Clean the tapered portion of the crankshaft
and the generator rotor hub.
2. Tighten:
• generator rotor bolt 1
T.
R.

160 Nm (16.0 m · kg, 115 ft · lb)

NOTE:
While holding the generator rotor 2 with
the sheave holder 3, tighten the generator
rotor bolt.

Sheave holder
YS-01880

3.
•
•
•
•

5 - 81

Install:
starter clutch idle gear #1 1
starter clutch idle gear #2 2
starter clutch idle gear shaft #1 3
starter clutch idle gear shaft #2 4

GENERATOR AND STARTER CLUTCH

ENG

4. Apply:
• sealant
(onto the stator coil assembly lead grommet)
Quick Gasket
ACC-11001-05-01

5. Install:
• stator coil assembly 1
T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

• stator coil assembly lead holder
T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:
Apply locking agent (LOCTITE) to the
threads of the stator coil assembly bolts.
6. Install:
• dowel pins 1
• generator cover gasket 2

New

5
7. Install:
• generator cover 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

8. Install:
• oil delivery pipe joint 1
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

• bolts 2
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

• oil delivery pipe 3
T.
R.

5 - 82

40 Nm (4.0 m · kg, 29 ft · lb)

GENERATOR AND STARTER CLUTCH

ENG

9. Connect:
• decompression solenoid couplers
• stator coil assembly coupler
NOTE:
Refer to “CABLE ROUTING” in chapter 2.

10.Install:
• rider footrest (right) 1
T.
R.

48 Nm (4.8 m · kg, 35 ft · lb)

11.Connect:
• rear brake light switch coupler 1
NOTE:
Refer to “CABLE ROUTING” in chapter 2.

5
12.Install:
• plastic locking tie 1
NOTE:
Fasten the rear brake light switch lead and
wire harness.

13.Fill:
• oil tank
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.

5 - 83

GENERATOR AND STARTER CLUTCH

ENG

14.Install:
• exhaust pipes
• muffler
Refer to “ENGINE”.

15.Install:
• fuel tank
• left side cover
• rider seat
Refer to “FUEL TANK” and “SEATS AND
SIDE COVERS” in chapter 3.

5 - 84

TRANSFER GEAR CASE

ENG

TRANSFER GEAR CASE

5
Order

1
2
3
4
5
6
7
8
9

Job/Part
Removing the battery box
Rider seat/side covers

Q’ty

Negative battery lead
Positive battery lead
Tool kit holder
Tool kit
Battery holder
Battery
Plastic bracket
Ignitor unit coupler
Ignitor unit holder

1
1
1
1
1
1
1
3
1

5 - 85

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”
in chapter 3.
Disconnect.

Disconnect.

TRANSFER GEAR CASE

ENG

5
Order
10
11
12
13
14
15

Job/Part
Ignitor unit
Battery box
Relay unit coupler
Turn signal relay coupler
Plastic clamp
Relay bracket

Q’ty
Remarks
1
1
1
Disconnect.
1
Disconnect.
1
1
For installation, reverse the removal
procedure.

5 - 86

TRANSFER GEAR CASE

ENG

5
Order

1
2
3
4
5
6
7
8
9

Job/Part
Removing the oil tank cover
Muffler/exhaust pipes
Engine oil
Oil tank breather hose
Dipstick
Dipstick joint
Oil pipe #1
Oil pipe #2
Oil tank cover
Oil tank cover gasket
Dowel pin
Oil strainer

Q’ty

1
1
1
1
1
1
1
2
1

Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Drain.
Disconnect.

For installation, reverse the removal
procedure.

5 - 87

TRANSFER GEAR CASE

ENG

5
Order

Job/Part
Removing the transfer gear case
Transfer gear oil
Drive pulley

Q’ty

1
2
3
4
5
6
7
8
9
10

Drive pulley case
Dowel pin
Cover
Dowel pin
Transfer gear oil pump
Transfer gear oil pump gasket
Transfer gear case cover
Transfer gear case cover gasket
Dowel pin
Oil strainer

1
2
1
2
1
1
1
1
2
1

5 - 88

Remarks
Remove the parts in the order listed.
Drain.
Refer to “DRIVE BELT AND DRIVE PULLEY” in chapter4.

TRANSFER GEAR CASE

ENG

5
Order
11
12
13
14
15
16
17
18
19

Job/Part
Lock washer
Primary chain
Middle drive gear
Middle driven shaft
Transfer gear case
Spacer
Dowel pin
Oil seal
Bearing

Q’ty
1
1
1
1
1
1
2
1
2

Remarks

For installation, reverse the removal
procedure.

5 - 89

TRANSFER GEAR CASE

ENG

5
Order

1
2
3
4
5
6
7

Job/Part
Disassembling the transfer gear
case oil pump
Oil pump cover
Pin
Pin
Oil pump shaft
Oil pump inner rotor
Oil pump outer rotor
Oil pump housing

Q’ty

Remarks
Remove the parts in the order listed.

1
2
1
1
1
1
1
For assembly, reverse the disassembly
procedure.

5 - 90

TRANSFER GEAR CASE

ENG

REMOVING THE BATTERY
1. Disconnect:
• battery leads
(from the battery terminals)

WARNING
WARNING
First, disconnect the negative battery lead,
then the positive battery lead.

REMOVING THE MIDDLE DRIVEN SHAFT
NOTE:
Loosen the middle drive gear nut before
removing the drive pulley.
1. Straighten the lock washer tab.
2. Loosen:
• middle drive gear nut 1
NOTE:
When loosening the middle drive gear nut,
press down on the brake pedal so the middle drive gear does not move.

5
3.
•
•
•

Remove:
primary chain 1
middle drive gear 2
middle driven shaft 3

NOTE:
Remove the primary chain, middle drive
gear and middle driven shaft at the same
time.

CHECKING THE MIDDLE DRIVE
1. Check:
• middle drive gear 1
• middle driven gear 2
Damage/wear → Replace the middle
drive gear, middle driven shaft and primary chain as a set.

5 - 91

TRANSFER GEAR CASE

ENG

2. Check:
• primary chain 1
Damage/stiffness → Replace the primary
chain, middle drive gear and middle
driven shaft as a set.

CHECKING THE OIL STRAINER
1. Check:
• oil strainer
Damage → Replace.
Contaminants → Clean with engine oil.

CHECKING THE OIL PUMP
1. Check:
• oil pump housing 1
• oil pump cover 2
Cracks/damage/wear →
defective part(s).

Replace

the

2. Measure:
• inner rotor-to-outer rotor tip clearance a
• outer rotor-to-oil pump housing clearance b
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing

Inner rotor-to-outer rotor tip
clearance
0.07 ~ 0.12 mm (0.003 ~ 0.005 in)
Outer rotor-to-oil pump housing
clearance
0.03 ~ 0.08 mm (0.001 ~ 0.003 in)

5 - 92

TRANSFER GEAR CASE

ENG

3. Check:
• oil pump operation
Unsmooth → Repair or replace the defective part(s).

CHECKING THE OIL PIPE
1. Check:
• oil pipe
Damage → Replace.

EAS00375

ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)

Recommended lubricant
Engine oil
2.
•
•
•
•
•

Install:
oil pump housing 1
oil pump outer rotor 2
oil pump inner rotor 3
oil pump shaft 4
pin 5

NOTE:
• When installing the oil pump shaft, align
the pin in the oil pump shaft with the
groove in the oil pump inner rotor.
• Align the arrow a on the oil pump outer
rotor with the arrow b on the oil pump
inner rotor.

5 - 93

TRANSFER GEAR CASE

ENG

3. Install:
• pins 1
• oil pump cover 2
T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:
Apply locking agent (LOCTITE) to the
threads of the oil pump cover screws.

4. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.

INSTALLING THE TRANSFER GEAR CASE
1. Install:
• bearings
• oil seal
2. Install:
• middle driven shaft 1
• middle drive gear 2
• primary chain 3
(into the transfer gear case)
• O-ring
• spacer
• drive pulley nut 4
NOTE:
• Install the middle driven shaft, middle
drive gear and primary chain at the same
time.
• Temporarily install the drive pulley nut
onto the middle driven shaft.

3.
•
•
•

5 - 94

Install:
oil strainer 1
dowel pins 2
transfer gear case cover gasket 3

New

TRANSFER GEAR CASE

ENG

4. Install:
• transfer gear case cover 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

5. Install:
• dowel pins 1

6. Install:
• transfer gear case assembly 1
NOTE:
• While installing the middle drive gear 2
onto the drive axle, install the transfer
gear case assembly onto the engine.
• Align the splines on the middle gear with
the splines on the drive axle.

7. Install:
• transfer gear case bolts 1
T.
R.

T.
R.

• nut 2

30 Nm (3.0 m · kg, 22 ft · lb)
30 Nm (3.0 m · kg, 22 ft · lb)

8. Install:
• lock washer New
• middle drive gear nut 1
T.
R.

85 Nm (8.5 m · kg, 61 ft · lb)

9. Bend the lock washer tab along a flat
side of the nut.

5 - 95

TRANSFER GEAR CASE

ENG

10.Remove:
• drive pulley nut

11.Install:
• transfer gear oil pump gasket
• transfer gear oil pump 1

New

T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
Apply locking agent (LOCTITE) only to the
threads of the transfer gear oil pump bolts
2 (M6 × 25 mm bolts).
12.Install:
• dowel pins 1

5
13.Install:
• cover 1
• cover bolts (M8) 2
T.
R.

24 Nm (2.4 m · kg, 17 ft · lb)

• cover bolts (M6) 3
T.
R.

14.Install:
• dowel pins 1

5 - 96

10 Nm (1.0 m · kg, 7.2 ft · lb)

TRANSFER GEAR CASE

ENG

15.Install:
• drive pulley case 1
T.
R.

30 Nm (3.0 m · kg, 22 ft · lb)

16.Install:
• drive pulley
Refer to “DRIVE BELT AND DRIVE PULLEY” in chapter 4.

17.Fill:
• transfer gear case
(with the specified amount of the recommended transfer gear oil)
Refer to “CHANGING THE TRANSFER
GEAR OIL” in chapter 3.

INSTALLING THE OIL TANK COVER
1. Install:
• dowel pins 1
• oil tank cover gasket 2 New
• oil strainer 3

2. Install:
• oil tank cover 1
T.
R.

5 - 97

10 Nm (1.0 m · kg, 7.2 ft · lb)

TRANSFER GEAR CASE

ENG

3. Install:
• dipstick joint 1
• dipstick 2
NOTE:
Finger tighten the dipstick joint bolt.
4. Connect:
• oil tank breather hose 3

T.
R.

5. Install:
• oil pipes 1

10 Nm (1.0 m · kg, 7.2 ft · lb)

INSTALLING THE BATTERY
1. Install:
• relay bracket 1
• plastic clamp 2
2. Connect:
• turn signal relay coupler
• relay unit coupler

3. Install:
• battery box

4.
•
•
5.
•

5 - 98

Install:
ignitor unit 1
ignitor unit holder 2
Connect:
ignitor unit couplers

TRANSFER GEAR CASE

ENG

6. Install:
• plastic bracket

7. Install:
• negative battery lead 1
(to the dipstick joint)

8.
•
•
•
•
9.
•

Install:
battery 1
battery holder 2
tool kit 3
tool kit holder 4
Connect:
battery leads
(to the battery terminals)

CAUTION:
ACHTUNG:
First, connect the positive battery lead 5,
then the negative battery lead 6.
10.Check:
• battery terminals

5 - 99

CRANKCASE

ENG

CRANKCASE

5
Order

1
2
3

Job/Part
Separating the crankcase
Engine
Camshaft
Piston
Shift shaft
Generator rotor

Q’ty

Generator shaft end cover
Oil delivery pipe
Engine oil pump driven gear stopper

1
1
1

5 - 100

Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
Refer to “CYLINDERS AND PISTONS”.
Refer to “SHIFT SHAFT”.
Refer to “GENERATOR AND STARTER
CLUTCH”.

CRANKCASE

ENG

5
Order
4
5
6
7
8

Job/Part
Engine oil pump driven gear
Left crankcase
Dowel
Joint pipe
Right crankcase

Q’ty
1
1
2
1
1

Remarks

For installation, reverse the removal
procedure.

5 - 101

CRANKCASE

ENG

5
Order

1
2
3

Job/Part
Removing the baffle plate and bearings
Crankshaft
Transmission
Baffle plate
Oil seal
Bearing

Q’ty

Remarks
Remove the parts in the order listed.
Refer to “CRANKSHAFT”.
Refer to “TRANSMISSION”.

1
1
4
Installation, reverse the removal procedure.

5 - 102

CRANKCASE

ENG

EAS00386

DISASSEMBLING THE CRANKCASE
NOTE:
Loosen the generator shaft bolt before
removing the generator rotor.
1. Remove:
• generator shaft bolt 1
NOTE:
While the holding the generator rotor 2
with the sheave holder 3, loosen the generator shaft bolt.
Sheave holder
YS-01880

2. Remove:
• crankcase bolts

NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all
of the bolts are fully loosened, remove
them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).

5
ı

Å Right crankcase
ı Left crankcase

M8 × 100 mm bolts: 1, 2
M8 × 80 mm bolt: 3
M6 × 105 mm bolt: K
M6 × 85 mm bolts: 9, C
M6 × 75 mm bolts: D, E
M6 × 60 mm bolts: 4 ~ 7
M6 × 40 mm bolts: 8, 0 ~ B, F ~ J
3. Turn:
• shift drum segment
NOTE:
Turn the shift drum segment 1 to the position shown in the illustration. In this position, the shift drum segment’s teeth will not
contact the crankcase during crankcase separation.

5 - 103

CRANKCASE

ENG

4. Remove:
• right crankcase

CAUTION:
ACHTUNG:
• First check that the shift drum segment’s
teeth then remove the right crankcase.
• Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase halves separate evenly.

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
Cracks/damage → Replace.
• oil delivery passages
Obstruction → Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OIL SEAL
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seal
Damage/wear → Replace.
5 - 104

CRANKCASE

ENG

CHECKING THE OIL DELIVERY PIPE
1. Check:
• oil delivery pipe 1
Damage → Replace.
Obstruction → Wash and blow out with
compressed air.
• O-rings 2
Damage/wear → Replace.

CHECKING THE ENGINE OIL PUMP DRIVE
1. Check:
• oil pump drive gear 1
• oil pump driven gear 2
Chips/pitting/roughness/wear → Replace
the defective part(s).

EAS00416

ASSEMBLING THE CRANKCASE
1. Apply:
• sealant
(onto the crankcase mating surfaces)
Quick Gasket
ACC-11001-05-01

NOTE:
Do not allow any sealant to come into contact with the oil gallery.
2. Install:
• dowel pins 1
• joint pipe 2

3. Install:
• left crankcase
(onto the right crankcase)
NOTE:
• Turn the shift drum segment 1 to the
position shown in the illustration. In this
position, the shift drum segment’s teeth
will not contact the crankcase during
crankcase installation.
• Tap lightly on the left crankcase with a
soft-face hammer.
5 - 105

CRANKCASE

ENG

4. Install:
• crankcase bolts

NOTE:
• Lubricate the bolt threads with engine oil.
• Tighten each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
• Tighten the bolts in numerical order (refer
to the numbers in the illustration).
Å Left crankcase
ı Right crankcase

M8 × 100 mm bolts: 1, 2
M8 × 80 mm bolt: 3
M6 × 105 mm bolt: K
M6 × 85 mm bolts: 9, C
M6 × 75 mm bolts: D, E
M6 × 60 mm bolts: 4 ~ 7
M6 × 40 mm bolts: 8, 0 ~ B, F ~ J

T.
R.

Bolt 1 ~ 3
24 Nm (2.4 m • kg, 17 ft • lb)
Bolt 4 ~ K
10 Nm (1.0 m • kg, 7.2 ft • lb)

5. Check:
• crankshaft and transmission operation
Rough movement → Repair.

5
Install:
engine oil pump driven gear 1
engine oil pump driven gear stopper 2
oil delivery pipe 3
bolts 4
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.

6.
•
•
•
•

7. Install:
• generator rotor
Refer to “GENERATOR AND STARTER
CLUTCH”.

5 - 106

CRANKCASE

ENG

8. Install:
• washer
• generator shaft bolt 1
T.
R.

28 Nm (2.8 m · kg, 20 ft · lb)

NOTE:
• Apply locking agent (LOCTITE) to the
threads of the generator shaft bolt.
• While holding the generator rotor 2 with
the sheave holder 3, tighten the generator shaft bolt.
Sheave holder
YS-01880

9. Install:
• generator shaft end cover 1

5
10.Install:
• shift shaft
• clutch
Refer to “SHIFT SHAFT” and “CLUTCH”.
• pistons
• cylinders
Refer to “CYLINDERS AND PISTONS”.
• camshaft
Refer to “CAMSHAFTS”.
• cylinder head
Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”.
11.Install:
• engine
Refer to “ENGINE”.

5 - 107

ENGINE OIL PUMP

ENG

ENGINE OIL PUMP

5
Order

1
2

Job/Part
Removing the engine oil pump
Crankcase
Oil strainer
Engine oil pump assembly

Q’ty

Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.

1
1
Installation, reverse the removal procedure.

5 - 108

ENGINE OIL PUMP

ENG

5
Order
1
2
3
4
5
6
7
8
9
0

Job/Part
Disassembling the engine oil pump
Spring retainer
Spring
Relief valve
Oil pump housing cover 1
Pin
Spring
Ball
Oil pump outer rotor 1
Oil pump inner rotor 1
Pin

Q’ty
1
1
1
1
2
1
1
1
1
1

5 - 109

Remarks
Remove the parts in the order listed.

ENGINE OIL PUMP

ENG

5
Order
A
B
C
D
E
F
G
H

Job/Part
Oil pump housing cover 2
Pin
Oil pump shaft
Pin
Oil pump inner rotor 2
Oil pump outer rotor 2
Oil seal
Oil pump housing

Q’ty
1
2
1
1
1
1
2
1

Remarks

For assembly, reverse the disassembly
procedure.

5 - 110

ENGINE OIL PUMP

ENG

EAS00363

CHECKING THE OIL PUMP
1. Check:
• oil pump housing 1
• oil pump housing covers 2
Cracks/damage/wear → Replace
defective part(s).

the

Inner rotor-to-outer rotor tip
clearance
0 ~ 0.12 mm (0 ~ 0.005 in)
Outer rotor-to-oil pump housing
clearance (feed pump)
0.03 ~ 0.08 mm (0.001 ~ 0.003 in)
Outer rotor-to-oil pump housing
clearance (scavenging pump)
0.06 ~ 0.11 mm (0.001 ~ 0.004 in)

3. Check:
• oil pump operation
Rough movement → Repeat steps (1)
and (2) or replace the defective part(s).

EAS00365

CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
Damage/wear → Replace the defective
part(s).

5 - 111

ENGINE OIL PUMP
2.
•
•
•

ENG

Check:
ball 1
spring 2
oil seal 3
Damage/wear → Replace the defective
part(s).

EAS00368

CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.

EAS00374

ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2.
•
•
•
•
•
•
•
•

Install:
oil pump housing 1
oil seals 2
oil pump outer rotor 2 3
oil pump inner rotor 2 4
pin 5
oil pump shaft 6
pins 7
oil pump housing cover 2 8
T.
R.

•
•
•
•
•
•
•

pin 9
oil pump inner rotor 1 0
oil pump outer rotor 1 A
ball B
spring C
pins D
oil pump housing cover 1 E
T.
R.

• relief valve F
5 - 112

2 Nm (0.2 m · kg, 1.4 ft · lb)

ENGINE OIL PUMP

ENG

• spring G
• spring retainer H
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
When installing the inner rotor, align the
pin in the oil pump shaft with the groove in
the inner rotor.

3. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.

5
EAS00378

INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
T.
R.

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
The arrow a on the oil strainer cover must
point towards the rear of the engine.

5 - 113

CRANKSHAFT AND CONNECTING RODS

ENG

CRANKSHAFT AND CONNECTING RODS

5
Order

1
2
3
4
5
6

Job/Part
Removing the crankshaft and connecting rods
Crankcase
Crankshaft
Generator shaft
Connecting rod cap
Big end lower bearing
Connecting rod
Big end upper bearing

Q’ty

Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.

1
1
2
2
2
2
For installation, reverse the removal
procedure.

5 - 114

CRANKSHAFT AND CONNECTING RODS

ENG

REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft journal bearing 1
NOTE:
Remove the crankshaft journal bearing with
the bearing remover and installer 2 and
bearing driver 3.
Bearing remover and installer
YM-28898
Bearing driver
YM-04058

EAS00391

REMOVING THE CONNECTING RODS
1. Remove:
• connecting rod caps 1
• connecting rods
• big end bearings

NOTE:
Identify the position of each big end bearing so that it can be reinstalled in its original place.
EAS00398

CHECKING THE CRANKSHAFT AND
CONNECTING RODS
1. Measure:
• crankshaft runout
Out of specification → Replace the crankshaft.
Maximum crankshaft runout
0.04 mm (0.0016 in)
2.
•
•
•

Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear → Replace the crankshaft
and bearings.
• generator shaft drive gear 1
Damage/wear → Replace the crankshaft.

5 - 115

CRANKSHAFT AND CONNECTING RODS

ENG

3. Measure:
• crankshaft pin-to-big end bearing clearance
Out of specification → Replace the big
end bearings.
Crankshaft pin-to-big end bearing
clearance
0.037 ~ 0.074 mm
(0.0015 ~ 0.0029 in)
: 0.09 mm (0.0035 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

The following procedure applies to all of
the connecting rods.

CAUTION:
ACHTUNG:
Do not interchange the big end bearings
and connecting rods. To obtain the correct
crankshaft pin-to-big end bearing clearance
and prevent engine damage, the big end
bearings must be installed in their original
positions.
a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting
rod halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a on the big end
bearings with the notches b in the connecting rod and connecting rod cap.
c. Put a piece of Plastigauge 1 on the
crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or crankshaft until the clearance measurement
has been completed.
• Lubricate the bolt threads and seats with
molybdenum disulfide grease.
• Make sure the projection c on the connecting rod faces towards the left side of
the crankshaft.
• Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned.
5 - 116

CRANKSHAFT AND CONNECTING RODS

ENG

e. Tighten the connecting rod bolts.

CAUTION:
ACHTUNG:
• When tightening the connecting rod
bolts, be sure to use an F-type torque
wrench.
• Without pausing, tighten the connecting
rod bolts to the specified torque. Apply
continuous torque between 3.3 and 4.0 m
• kg (24 and 29 ft • lb). Once you reach 3.3
m • kg (24 ft • lb), DO NOT STOP TIGHTENING until the specified torque is
reached. If the tightening is interrupted
between 3.3 and 4.0 m • kg (24 and 29 ft •
lb), loosen the connecting rod bolts to
less than 3.3 m • kg (24 ft • lb) and start
again.
Refer to “INSTALLING THE CONNECTING RODS”.

Connecting rod bolt
38.5 Nm (3.85 m • kg, 28 ft • lb)

f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS”.

g. Measure the compressed Plastigauge
width e on each crankshaft pin.
If the crankshaft pin-to-big end bearing
clearance is out of specification, select
replacement big end bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5 - 117

CRANKSHAFT AND CONNECTING RODS

ENG

4. Select:
• big end bearings (P1 ~ P2)
NOTE:
• The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the
replacement big end bearing sizes.
• “P1” ~ “P2” refer to the bearings shown in
the crankshaft illustration.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are “6”
and “2” respectively, then the bearing size
for “P 1” is:
“P1” (connecting rod) – “P1” (crankshaft web) =
6 – 2 = 4 (green)
BIG END BEARING COLOR CODE
1

blue

black

brown

green

yellow

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Measure:
• crankshaft journal diameter a
Out of specification → Replace the crankshaft.
Crankshaft journal diameter
49.968 ~ 49.980 mm
(1.967 ~ 1.968 in)
NOTE:
Measure the diameter of each crankshaft
journal at two places.

5 - 118

CRANKSHAFT AND CONNECTING RODS

ENG

6. Measure:
• crankshaft journal bearing inside diameter a
Out of specification → Replace the
crankcase assembly.
Crankshaft journal bearing inside
diameter
50.01 ~ 50.03 mm
(1.969 ~ 1.970 in)
NOTE:
Measure the inside diameter of each crankshaft journal bearing at two places.

7. Calculate:
• crankshaft journal-to-crankshaft journal
bearing clearance
Out of specification → Replace the crankshaft and crankshaft journal bearings as
a set.
NOTE:
Calculate the clearance by subtracting the
crankshaft journal diameter from the crankshaft journal bearing inside diameter.
Crankshaft journal-to-crankshaft
journal bearing clearance
0.030 ~ 0.062 mm
(0.0012 ~ 0.0024 in)

INSTALLING THE CONNECTING RODS
1. Lubricate:
• bolt threads and seats
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide grease

5 - 119

CRANKSHAFT AND CONNECTING RODS
2.
•
•
•

ENG

Lubricate:
crankshaft pins
big end bearings
connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil

3.
•
•
•

Install:
big end bearings
connecting rods
connecting rod caps
(onto the crankshaft pins)

NOTE:
• Align the projections a on the big end
bearings with the notches b in the connecting rods and connecting rod caps.
• Be sure to reinstall each big end bearing
in its original place.
• Make sure the projection c on the connecting rods face towards the left side of
the crankshaft.
• Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned.

4. Tighten:
• connecting rod bolt 1
T.
R.

40 Nm (4.0 m · kg, 29 ft · lb)

CRANKSHAFT AND CONNECTING RODS

ENG

INSTALLING THE CRANKSHAFT
1. Install:
• generator shaft 1

2. Install:
• crankshaft
NOTE:
• Make sure that the generator shaft drive
gear teeth and generator shaft driven gear
teeth mesh correctly.
• Align the right connecting rod with the
front cylinder sleeve hole.

5 - 121

TRANSMISSION

ENG

TRANSMISSION

5
Order

1
2
3
4
5
6
7
8

Job/Part
Removing the shift forks, shift drum
assembly and transmission
Crankcase
Shift fork guide bar
Shift fork “L”
Shift fork “R”
Shift fork “C”
Shift drum assembly
Drive axle assembly
Main axle assembly
Spacer

Q’ty

Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.

2
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.

5 - 122

TRANSMISSION

ENG

5
Order

1
2
3
4
5
6
7
8

Job/Part
Q’ty
Remarks
Disassembling the main axle assemRemove the parts in the order listed.
bly
Circrip
1
Washer
1
5th pinion gear
1
2nd/3rd pinion gear
1
Circlip
1
Washer
1
4th pinion gear
1
Main axle/1st pinion gear
1
For assembly, reverse the disassembly
procedure.

5 - 123

TRANSMISSION

ENG

5
Order

1
2
3
4
5
6
7
8
9
0
A
B

Job/Part
Q’ty
Remarks
Disassembling the drive axle assemRemove the parts in the order listed.
bly
5th wheel gear
1
Circlip
1
Washer
1
2nd wheel gear
1
Circlip
1
Washer
1
1st wheel gear
1
4th wheel gear
1
Circlip
1
Washer
1
3rd wheel gear
1
Drive axle
1
For assembly, reverse the disassembly
procedure.
5 - 124

TRANSMISSION

ENG

EAS00421

CHECKING THE SHIFT FORKS
The following procedure applies to all of
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear → Replace
the shift fork.

2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.

WARNING
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
fork(s) and shift fork guide bar(s) as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift drum
assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift drum
5 - 125
assembly.

TRANSMISSION

ENG

EAS00425

CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge
1)
Out of specification → Replace the main
axle.
Maximum main axle runout
0.08 mm (0.003 in)
2. Measure:
• drive axle runout
(with a centering device and dial gauge
1)
Out of specification → Replace the drive
axle.
Maximum drive axle runout
0.08 mm (0.003 in)
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. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the defective part(s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
INSTALLING THE TRANSMISSION, SHIFT
DRUM ASSEMBLY AND SHIFT FORKS
1. Install:
• main axle assembly 1
• drive axle assembly 2
• O-ring
• spacer

5 - 126

TRANSMISSION
2.
•
•
•
•
•

ENG

Install:
shift drum assembly 1
shift fork “R”
shift fork “C”
shift fork “L”
shift fork guide bars

NOTE:
The embossed marks on the shift forks
should face towards the right side of the
engine and be in the following sequence:
“R”, “C”, “L”.

3. Check:
• transmission
Rough movement → Repair.

NOTE:
Oil each gear, shaft, and bearing thoroughly.

5 - 127

CARB
CONTENTS
CARBURETOR

CARBURETOR .............................................................................................. 6-1
CHECKING THE CARBURETOR ........................................................... 6-6
CHECKING THE CARBURETOR JOINT ............................................... 6-8
ASSEMBLING THE CARBURETOR ..................................................... 6-8
INSTALLING THE CARBURETOR JOINT .......................................... 6-12
INSTALLING THE CARBURETOR ...................................................... 6-12
MEASURING AND ADJUSTING THE FUEL LEVEL .......................... 6-14
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR .......................................................................................... 6-15
CHECKING THE FUEL PUMP ............................................................. 6-19
CHECKING THE FUEL COCK ............................................................. 6-19
CHECKING THE FUEL COCK OPERATION ....................................... 6-20
AIR INDUCTION SYSTEM ......................................................................... 6-21
AIR INJECTION ................................................................................... 6-21
AIR CUTOFF VALVE ........................................................................... 6-21

CARB
CHECKING THE AIR INDUCTION SYSTEM ...................................... 6-26
INSTALLING THE AIR INDUCTION SYSTEM ................................... 6-26

CARBURETOR

CARB

EAS00480

CARBURETOR
CARBURETOR

Order

1
2
3
4
5
6
7
8

Job/Part
Removing the carburetor
Rider seat

Q’ty

Fuel tank
Air filter case
Fuel (from the carburetor)
Carburetor joint clamp screw
Throttle stop screw
Vacuum chamber breather hose
(carburetor to solenoid valve hose)
Throttle cable
Fuel hose
Throttle position sensor
Starter cable
Starter plunger

1
1
1
2
1
1
1
1

6-1

Remarks
Remove the parts in the order listed.
Refer to “SEATS AND SIDE COVERS”
in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Loosen.
Unhook.
Disconnect.
Disconnect.

Disconnect.

CARBURETOR

Order
Job/Part
9
Charcoal canister hose
(carburetor to charcoal canister)
10
Carburetor heater connector
11
Carburetor
12
Fuel pump bracket assembly
(with fuel pump)
13
Vacuum hose
14
Carburetor joint

Q’ty
1
Disconnect.
2
1
1

Disconnect.

1
1

Disconnect.

CARB

Remarks

For installation, reverse the removal
procedure.

6-2

CARBURETOR

CARB

EAS00483

Order
1
2
3
4
5
6
7
8
9

Job/Part
Disassembling the carburetor
Throttle stop screw
Vacuum chamber air vent hose
Fuel strainer
Throttle cable holder
Throttle position sensor bracket
Carburetor heater
Coasting enricher cover
Coasting enricher spring
Coasting enricher

Q’ty
1
1
1
1
1
1
1
1
1

6-3

Remarks
Remove the parts in the order listed.

CARBURETOR

Order
0
A
B
C
D
E
F
G
H
I

Job/Part
Vacuum chamber cover
Piston valve spring
Jet needle holder
Jet needle kit
Piston valve
Float chamber
Float chamber rubber gasket
Drain bolt
Accelerator plunger
Float pivot pin

Q’ty
1
1
1
1
1
1
1
1
1
1

6-4

CARB

Remarks

CARBURETOR

Order
J
K
L
M
N
O
P
Q
R

Job/Part
Float
Needle valve
Needle valve seat
Main jet
Spacer
Needle jet
Pilot jet
Starter jet
Pilot air jet

Q’ty
1
1
1
1
1
1
1
1
1

CARB

Remarks

For assembly, reverse the disassembly
procedure.

6-5

CARBURETOR

CARB

EAS00485

CHECKING THE CARBURETOR
1. Check:
• carburetor body
• float chamber
• jet housing
Cracks/damage → Replace.

2. Check:
• fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Wash the carburetor in a petroleumbased 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 1
Cracks/damage/wear → Replace.

5. Check:
• float
Damage → Replace.

6. Check:
• needle valve 1
• needle valve seat 2
Damage/obstruction/wear → Replace
the needle valve, needle valve seat and
O-ring as a set.
7. Check:
• O-ring 3
Damage/wear → Replace the needle valve,
needle valve seat and O-ring as a set.
6-6

CARBURETOR

CARB

8. Check:
• piston valve 1
Damage/scratches/wear → Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.

9.
•
•
•
•

Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
jet needle spring 4
Cracks/damage → Replace.

10.Check:
• jet needle kit 1
• main jet 2
• needle jet 3
• pilot jet 4
• starter jet 5
• pilot air jet 6
Bends/damage/wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
11.Check:
• piston valve movement
Insert the piston valve into the carburetor body and move it up and down.
Tightness → Replace the piston valve.

12.Check:
• starter plunger 1
• starter plunger spring 2
Bends/cracks/damage → Replace.
• O-ring 3
Damage/wear → Replace.

6-7

CARBURETOR

CARB

13.Check:
• coasting enricher cover 1
• coasting enricher spring 2
Cracks/damage → Replace.
• coasting enricher 3
Cracks/tears/damage → Replace.

14.Check:
• accelerator plunger 1
• accelerator plunger spring 2
Bends/cracks/damage → Replace.
• O-ring 3
Damage/wear → Replace.

15.Check:
• fuel hose
Cracks/damage/wear → Replace.
Obstruction → Clean.
Blow out the hoses with compressed air.

CHECKING THE CARBURETOR JOINT
1. Check:
• carburetor joint 1
Cracks/damage → Replace.
• O-rings 2
Damage/wear → Replace the O-ring.

EAS00487

ASSEMBLING THE CARBURETOR

CAUTION:
ACHTUNG:
• Before assembling the carburetor, wash
all the parts in a petroleum-based solvent.
• Always use a new gasket.

6-8

CARBURETOR

CARB

1. Install:
• pilot air jet 1

2. Install:
• starter jet 1
• pilot jet 2

3. Install:
• needle jet 1
NOTE:
Align the slot a on the needle jet with the
projection b on the carburetor body.

4. Install:
• spacer 1
• main jet 2

5. Install:
• needle valve seat 1

6-9

CARBURETOR

CARB

6.
•
•
•

Install:
needle valve
float 1
float pin 2

7.
•
•
•

Install:
accelerator plunger 1
drain bolt 2
float chamber rubber gasket 3

8. Install:
• float chamber 1

9.
•
•
•
•
•

Install:
piston valve 1
jet needle kit
jet needle holder
piston valve spring
vacuum chamber cover 2

NOTE:
• Install the end of the piston valve spring
onto the spring guide on the vacuum
chamber cover.
• Align the tab a on the piston valve diaphragm with the recess in the carburetor
body.

6 - 10

CARBURETOR

CARB

10.Install:
• coasting enricher 1
• coasting enricher spring
• coasting enricher cover 2
NOTE:
Align the tab a on the coasting enricher
with the recess b in the carburetor body.

11.Install:
• terminal 1
• washer
• carburetor heater 2
T.
R.

2.5 Nm (0.25 m · kg, 2.0 ft · lb)

NOTE:
Use “Heat Sinker” when installing the carburetor heater.

Heat Sinker

12.Install:
• throttle position sensor bracket 1
• throttle cable holder 2
• fuel strainer 3
• vacuum chamber air vent hose 4

6 - 11

CARBURETOR

CARB

13.Install:
• throttle stop screw
• drain hose

INSTALLING THE CARBURETOR JOINT
1. Install:
• carburetor joint 1
T.
R.

12 Nm (1.2 m · kg, 8.7 ft · lb)

2. Connect:
• vacuum hose 2

EAS00492

INSTALLING THE CARBURETOR
1. Connect:
• carburetor heater connectors 1
• charcoal canister hose (carburetor to
charcoal canister) 2

2.
•
3.
•

Install:
starter plunger
Connect:
starter cable 1

4. Install:
• throttle position sensor
NOTE:
• Align the slot a of the throttle position
sensor with the projection b of the throttle lever shaft.
• For the correct installation, refer to
“CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR”.
6 - 12

CARBURETOR

CARB

5. Connect:
• fuel hose 1

6. Connect:
• throttle cables 1

7. Connect:
• float chamber breather hose
(carburetor to solenoid valve) 1

8. Hook:
• throttle stop screw 1

9. Install:
• carburetor
NOTE:
Align the projection a of the carburetor
with slot of the carburetor joint.
10.Tighten:
• carburetor joint clamp screw 1

6 - 13

CARBURETOR

CARB

11.Adjust:
• engine idling speed
Engine idling speed
850 ~ 950 r/min
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.

12.Adjust:
• throttle cable free play
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 8 mm (0.16 ~ 0.31 in)
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

EAS00498

MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel level a
Out of specification → Adjust.
Fuel level (below the float chamber mating surface)
2.0 ~ 3.0 mm (0.079 ~ 0.12 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand
to ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 onto the
fuel drain pipe 2.
Fuel level gauge
YM-01312-A
d. Loosen the fuel drain bolt 3.
e. Measure the fuel level a.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6 - 14

CARBURETOR

CARB

2. Adjust:
• fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the carburetor.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00502

CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor, the engine idling speed should be
properly adjusted.
1. Check:
• throttle position sensor
(installed on the carburetor)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

6 - 15

CARBURETOR

CARB

d. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Positive tester probe → yellow terminal 3
Negative tester probe → black terminal 2
e. While slowly opening the throttle, check
that the throttle position sensor resistance is within the specified range.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since
the readings (from closed to wide-open
throttle) may differ slightly from those specified.
Out of specification or the resistance
changes abruptly → Go to step 2 below.
Throttle position sensor resistance
(520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ) at
20 ˚C (68 ˚F)
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:
• throttle position sensor
(removed from the carburetor)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Disconnect the throttle position sensor
coupler from the wire harness.
b. Remove the throttle position sensor from
the carburetor.
c. Connect the pocket tester (Ω × 1k) to the
throttle position sensor.
Positive tester probe → blue terminal 1
Negative tester probe → black terminal 2

6 - 16

CARBURETOR

CARB

d. Measure the maximum throttle position
sensor resistance.
Out of specification → Replace the throttle position sensor.
Maximum throttle position sensor resistance
4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F)
(blue — black/blue)
e. Connect the pocket tester (Ω × 1k) to the
throttle position sensor coupler.
Positive tester probe → yellow terminal 3
Negative tester probe → black terminal 2
f. While slowly opening the throttle, check
that the throttle position sensor resistance is within the specified range.
The resistance does not change or it
changes abruptly → Replace the throttle
position sensor.
The slot is worn or broken → Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since
the readings (from closed to wide-open
throttle) may differ slightly from those specified.
Throttle position sensor resistance
0 ~ 5 ± 1.0 kΩ at 20 ˚C (68 ˚F)
(yellow — black/blue)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6 - 17

CARBURETOR

CARB

3. Adjust:
• throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Disconnect the throttle position sensor
coupler from the wire harness.
b. Connect the pocket tester (Ω × 1k) to the
throttle position sensor coupler.
Positive tester probe → blue terminal 1
Negative tester probe → black terminal 2
c. Measure the throttle position sensor
maximum resistance.
d. Calculate the throttle position sensor
maximum resistance when the throttle is
fully closed.
Throttle position sensor maximum
resistance (throttle is fully closed) =
Maximum resistance × (0.13 ~ 0.15)
Example:
If the maximum resistance = 5 kΩ, then the
throttle position sensor’s maximum resistance when the throttle is fully closed
should be:
5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω
Lift the carburetor assembly slightly out of
the intake manifolds.
Loosen the throttle position sensor screws 4.
Connect the pocket tester (Ω × 100) to the
throttle position sensor.
Positive tester probe → yellow terminal 3
Negative tester probe → black terminal 1
e. Adjust the throttle position sensor angle
so that the measured resistance is within
the specified range.
Throttle position sensor resistance
650 ~ 750 Ω
(yellow — black terminal)
After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6 - 18

CARBURETOR

CARB

EAS00504

CHECKING THE FUEL PUMP
1. Check:
• fuel pump 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Disconnect the fuel hose (fuel pump to
carburetor) 2 from the carburetor.
b. Place a container under the end of the
fuel hose.
c. Set the fuel cock to “ON” or “RES”.
d. Start the engine and check if fuel flows
from the fuel hose 2.
Fuel flows.

Fuel pump is OK.

Fuel does not flow.

Replace the fuel
pump.

e. Stop the engine and check if the fuel
stops flowing from the fuel hose 2.
Fuel stops flowing.

Fuel pump is OK.

Fuel flows.

Replace the fuel
pump.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS00505

CHECKING THE FUEL COCK
1. Drain:
• fuel
(from the fuel tank)
2. Disconnect:
• fuel hose
(from the fuel cock)
3. Remove:
• fuel cock 1
4. Check:
• fuel cock
Cracks/damage/wear → Replace.
5. Check:
• fuel cock strainer 1
(with compressed air)
Dirt/obstruction → Clean.
Damage → Replace the fuel cock as a set.
• rubber gasket 2
Cracks/damage/wear → Replace.
6 - 19

CARBURETOR
6.
•
7.
•

CARB

Install:
fuel cock
Connect:
fuel hose

EAS00506

CHECKING THE FUEL COCK OPERATION
NOTE:
After installing the fuel cock, check its operation.
1. Set the fuel cock to “OFF”.
2. Disconnect:
• fuel hose
(from the fuel cock)
3. Check:
• fuel cock operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Place a container under the end of the
fuel cock.
b. Check that the fuel cock lever is turned to
“ON” or “RES”.
Fuel flows.

Fuel cock is OK.

Fuel does not flow.

Replace the fuel
cock.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Connect:
• fuel hose

6 - 20

AIR INDUCTION SYSTEM

CARB

EAS00507

AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned
exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing
the emission of hydrocarbons.
When there is negative pressure at the
exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust
port. The required temperature for burning
the unburned exhaust gases is approximately 600 to 700 ˚C (1,112 to 1,292 ˚F).

EAS00508

AIR CUTOFF VALVE
The air cutoff valve is operated by the
intake gas pressure through the piston
valve diaphragm. Normally, the air cutoff
valve is open to allow fresh air to flow into
the exhaust port. During sudden deceleration (the butterfly valve suddenly closes),
negative pressure is generated and the air
cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and
when the pressure decreases, the air cutoff
valve automatically closes to guard against
a loss of performance due to self-EGR
(Exhaust Gas Recirculation).
1 During normal operation, the air cutoff
valve is open.
2 During sudden deceleration (the butterfly
valve suddenly closes), the air cutoff valve
closes.
3 At high engine speeds and when the
pressure decreases, the air cutoff valve is
closed.

Å From the air cleaner
ı To the reed valve
Ç To the carburetor joint

6 - 21

AIR INDUCTION SYSTEM

CARB

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve
2 Air cut valve
3 Air cleaner
4 Carburetor joint

Å To the carburetor joint
ı To the front cylinder head
Ç To the rear cylinder head
Î To the air cut valve

6 - 22

AIR INDUCTION SYSTEM

Order

1
2
3
4
5
6
7
8

Job/Part
Removing the air induction system
fuel tank
Reed valve case to rear cylinder
head hose
Reed valve case to rear cylinder
head pipe
Reed valve case to front cylinder
head hose
Reed valve case to front cylinder
head hose
Gasket
Rectifier/regulator coupler
Rectifier/regulator
Air filter bracket

Q’ty

6 - 23

Remarks
Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.

1
1
1
1
2
1
1
1

CARB

Disconnect.

AIR INDUCTION SYSTEM

Order
9
10
11
12
13
14
15
16
17
18
19
20

Job/Part
Air filter
Air filter cover
Air filter hose
Air cut valve to air filter hose
Plastic locking tie
Vacuum hose
Bracket
Air cut valve holder
Air cut valve
Air cut valve to reed valve cover
hose
Reed valve cover
Reed valve case

Q’ty
1
1
1
1
1
1
1
1
1
1
1
1

6 - 24

CARB

Remarks

AIR INDUCTION SYSTEM

Order
Job/Part
21
Reed valve base
22
Reed valve stopper
23
Reed valve

Q’ty
1
2
2

CARB

Remarks

For installation, reverse the removal
procedure.

6 - 25

AIR INDUCTION SYSTEM

CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM
1. Check:
• hoses
Loose connection → Connect properly.
Cracks/damage → Replace.
• pipes
Cracks/damage → Replace.

2.
•
•
•

Check:
fibre reed 1
fibre reed stopper
reed valve seat
Cracks/damage → Replace the reed
valve.

3. Measure:
• fibre reed bending a
Out of specification → Replace the reed
valve.
Maximum fibre reed bending
0.4 mm (0.016 in)
1 Surface plate

4. Check:
• air cutoff valve
Cracks/damage → Replace.

INSTALLING THE AIR INDUCTION SYSTEM
1. Install:
• reed valves 1
• reed valve stoppers 2
• reed valve base 3

6 - 26

AIR INDUCTION SYSTEM

CARB

2.
•
•
•

Install:
reed valve case 1
reed valve cover
bracket 2

3.
•
•
•

Install:
air cut valve to reed valve cover hose 1
air cut valve 2
air cut valve holder 3

4. Install:
• bracket
(with the air cut valve and reed valve)

5. Install:
• vacuum hose 1
• plastic locking tie 2

6. Install:
• air cut valve to air filter hose 1

6 - 27

AIR INDUCTION SYSTEM
7.
•
•
•

CARB

Install:
air filter 1
air filter hose 2
air filter cover 3

8. Install:
• air filter bracket 1

9. Install:
• air filter case assembly 1

10.Install:
• rectifier/regulator 1
11.Connect:
• rectifier/regulator coupler 2

12.Install:
• gaskets
• reed valve case to front cylinder head
pipe 1
• reed valve case to front cylinder head
hose
• reed valve case to rear cylinder head
pipe 2
• reed valve case to rear cylinder head
hose
6 - 28

AIR INDUCTION SYSTEM

CARB

13.Install:
• fuel tank
Refer to “FUEL TANK” in chapter 3.

6 - 29

ELEC
CONTENTS
ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS ...................................................................... 7-1

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS ................................................................................................ 7-2
SWITCHES .................................................................................................... 7-6
CHECKING SWITCH CONTINUITY ...................................................... 7-6
CHECKING THE SWITCHES ........................................................................ 7-7
CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-9
TYPES OF BULBS ................................................................................. 7-9
CHECKING THE CONDITION OF THE BULBS .................................... 7-9
CHECKING THE CONDITION OF THE BULB SOCKETS ................... 7-11
CHECKING THE LEDs ......................................................................... 7-11

–

ELEC

–

IGNITION SYSTEM .................................................................................... 7-12
CIRCUIT DIAGRAM ............................................................................ 7-12
TROUBLESHOOTING ......................................................................... 7-13
ELECTRIC STARTING SYSTEM ................................................................. 7-17
CIRCUIT DIAGRAM ............................................................................ 7-17
STARTING CIRCUIT CUTOFF SYSTEM OPERATION ...................... 7-18
TROUBLESHOOTING ......................................................................... 7-19
STARTER MOTOR ...................................................................................... 7-23
CHECKING THE STARTER MOTOR .................................................. 7-25
ASSEMBLING THE STARTER MOTOR ............................................. 7-26
INSTALLING THE STARTER MOTOR ............................................... 7-27
CHARGING SYSTEM ................................................................................. 7-28
CIRCUIT DIAGRAM ............................................................................ 7-28
TROUBLESHOOTING ......................................................................... 7-29
LIGHTING SYSTEM .................................................................................... 7-31
CIRCUIT DIAGRAM ............................................................................ 7-31
TROUBLESHOOTING ......................................................................... 7-32
CHECKING THE LIGHTING SYSTEM ................................................ 7-33
SIGNALING SYSTEM ................................................................................. 7-37
CIRCUIT DIAGRAM ............................................................................ 7-37
TROUBLESHOOTING ......................................................................... 7-39
CHECKING THE SIGNALING SYSTEM ............................................. 7-40
FUEL PUMP SYSTEM ................................................................................ 7-46
CIRCUIT DIAGRAM ............................................................................ 7-46
FUEL PUMP CIRCUIT OPERATION ................................................... 7-47
TROUBLESHOOTING ......................................................................... 7-48
CHECKING THE FUEL PUMP ............................................................. 7-50
CARBURETOR HEATING SYSTEM ........................................................... 7-51
CIRCUIT DIAGRAM ............................................................................ 7-51
TROUBLESHOOTING ......................................................................... 7-52
SELF-DIAGNOSIS ....................................................................................... 7-55
TROUBLESHOOTING ......................................................................... 7-57

ELECTRICAL COMPONENTS

ELEC

ESA00729

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Wire harness
2 Main switch
3 Front brake light switch
4 Ignition coils
5 Throttle position sensor
6 Clutch switch
7 Decompression solenoid
8 Relay unit
9 Turn signal relay
0 Ignitor unit

A Battery
B Starter relay
C Main fuse
D Thermo switch
E Fuse box
F Speed sensor
G Horns
H Neutral switch
I Sidestand switch
J Pickup coil

7-1

K Stator coil assembly
L Rear brake light switch
M Rectifier/regulator

–

ARRANGEMENT OF THE ELECTRICAL COMPONENTS
AND COUPLERS

ELEC

–

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS
1 Right handlebar switch coupler, left handlebar switch couplers and front turn signal connectors
2 Headlight coupler

1 Tail/brake light connectors and rear turn signal connectors

7-2

ARRANGEMENT OF THE ELECTRICAL COMPONENTS
AND COUPLERS
1 Spark plug cap #3
2 Rear brake light switch coupler
3 Ignition coil (front cylinder)
4 Meter assembly couplers

1 Rear brake light switch lead
2 Rectifier/regulator
3 Rectifier/regulator coupler
4 Starter motor
5 Starter motor lead

5 Carburetor heater sub-wire
harness coupler
6 Throttle position sensor
coupler
7 Fuel sender coupler

6 Horn coupler
7 Horn
8 Pickup coil
9 Sidestand switch

7-3

ELEC

8 Spark plug cap #2
9 Spark plug cap #1
0 Fuel pump
A Fuel pump coupler

–

ARRANGEMENT OF THE ELECTRICAL COMPONENTS
AND COUPLERS

ELEC

–

1 Fuse box
2 Stator coil coupler, decompression solenoid couplers, pickup coil coupler, speed sensor coupler,
neutral switch connector and sidestand switch coupler
3 Battery negative lead
4 Battery positive lead
5 Battery
6 Ignitor unit
7 Tail/brake light and rear turn signal light sub-wire harness coupler
8 Starter relay
9 Main fuse
0 Starter relay coupler
A Thermo switch
B Thermo switch coupler
C Horn
D Horn coupler

7-4

ARRANGEMENT OF THE ELECTRICAL COMPONENTS
AND COUPLERS

ELEC

–

1 Carburetor heater
2 Throttle position sensor
3 Ignition coil (rear cylinder)
4 Main switch coupler

5 Main switch
6 Solenoid valve coupler
7 Solenoid valve
8 Spark plug cap #4

9 Rear brake light switch

1 Diode
2 Turn signal relay
3 Relay unit
4 Stator coil

5 Decompression solenoid
6 Neutral switch
7 Speed sensor
8 Relay unit coupler

9 Turn signal relay coupler

7-5

SWITCHES

ELEC

–

EAS00730

SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is
incorrect, check the wiring connections and
if necessary, replace the switch.

CAUTION:
ACHTUNG:
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
YU-03112
NOTE:
• Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1”
range.
• When checking for continuity, switch back
and forth between the switch positions a
few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown
in an illustration similar to the one on the
left.
The switch positions a are shown in the far
left column and the switch lead colors b
are shown in the top row in the switch illustration.
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/
blue, and between blue/yellow and blue/
black when the switch is set to “ON”.

7-6

CHECKING THE SWITCHES

ELEC

–

EAS00731

CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between
the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace the switch.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.

7-7

CHECKING THE SWITCHES
1 Dimmer switch
2 Horn switch
3 Turn signal switch
4 Clutch switch
5 Engine stop switch
6 Start switch
7 Front brake light switch
8 Main switch

ELEC

–

9 Fuse
0 Rear brake light switch
A Sidestand switch
B Neutral switch

7-8

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 continuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
Incorrect continuity reading → 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
which must be detached before removing the bulb. The majority of these 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 counterclockwise.
• Bulbs D and E are used for meter and
indicator lights and can be removed
from their respective socket by carefully
pulling them out.

CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of
the bulbs.
1. Remove:
• bulb

7-9

CHECKING THE BULBS AND BULB SOCKETS

ELEC

–

WARNING
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

CAUTION:
ACHTUNG:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
YU-03112
NOTE:
Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1”
range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the tester positive probe to terminal 1 and the tester negative probe to
terminal 2, and check the continuity.
b. Connect the tester positive probe to terminal 1 and the tester negative probe to
terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7 - 10

CHECKING THE BULBS AND BULB SOCKETS

ELEC

–

CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of
the bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
YU-03112
NOTE:
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CHECKING THE LEDs
The following procedure applies to all of
the LEDs.
1. Check:
LED (for proper operation)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Disconnect the meter assembly coupler
(meter assembly side).

b. Connect two jumper leads 1 from the
battery terminals to the respective coupler terminals as shown.

WARNING
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
c. When the jumper leads are connected to
the terminals the respective LED should
illuminate.
Does not light → Replace the meter
assembly.
7 - 11 ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

3 Main switch
4 Battery
5 Main fuse
9 Relay unit
B Ignitor unit
C Ignition coil
D Spark plug
F Pickup coil
G Neutral switch
a Engine stop switch
i Ignition fuse
k Sidestand switch
l Diode

IGNITION SYSTEM

7 - 12

ELEC
–
+

EB802001

IGNITION SYSTEM

CIRCUIT DIAGRAM

IGNITION SYSTEM

–

EB802401

EB802011

TROUBLESHOOTING

2.Battery

The ignition system fails to operate (no
spark or intermittent spark).

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. engine stop switch
10.neutral switch
11.sidestand switch
12.diode
13.relay unit (diode)
14.wiring
(of the entire ignition system)

Minimum open-circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)
• Is the battery OK?
YES

NO
• Clean the battery
terminals.
• Recharge or
replace the battery.

EB802403

3.Spark plugs

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) side covers
4) ignition coils
5) headlight lens unit
• Troubleshoot with the following special
tool(s).

ELEC

The following procedure applies to all of
the spark plugs.
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK
PLUGS” in chapter 3.
Standard spark plug
DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)
Spark plug gap
0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

Dynamic spark tester
YM-34487
Pocket tester
YU-03112

• Is the spark plug in good condition, is it
of the correct type, and its gap within
specification?

EB802400

1.Main and ignition fuses
YES

• Check the main and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES

NO
Re-gap or replace
the spark plug.

NO
Replace the fuse(s).

7 - 13

IGNITION SYSTEM

ELEC

–

EB802405

4.Ignition spark gap
The following procedure applies to all of
the spark plugs.
• Disconnect the spark plug cap from the
spark plug.
• Connect the dynamic spark tester 1 as
shown.
2 Spark plug cap
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.

Spark plug cap resistance
10 kΩ at 20 ˚C (68 ˚F)
• Is the spark plug cap OK?
NO

YES

Replace the spark
plug cap.
EB802409

6.Ignition coil resistance
The following procedure applies to all of
the ignition coils.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.

Minimum ignition spark gap
6 mm (0.24 in)
• Is there a spark and is the spark gap
within specification?
NO

Tester positive probe → red/black
Tester negative probe → orange (gray)

YES
The ignition system
is OK.

EB802407

5.Spark plug cap resistance
The following procedure applies to all of
the spark plug caps.
• Disconnect the spark plug cap from the
spark plug.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.

• Measure the primary coil resistance.
Primary coil resistance
1.53 ~ 2.07 Ω at 20 ˚C (68 ˚F)
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
• Measure the secondary coil resistance.
Tester positive probe →
spark plug lead 1
Tester negative probe →
spark plug lead 2
7 - 14

IGNITION SYSTEM

–

ELEC

EB802411

8.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES

NO
Replace the main
switch.

Secondary coil resistance
12 ~ 18 kΩ at 20 ˚C (68 ˚F)
• Is the ignition coil OK?

EB802412

9.Engine stop switch
NO

YES

• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?

Replace the ignition
coil.

YES

EB802410

7.Pickup coil resistance
• Disconnect the pickup coil coupler from
the wire harness.
• Connect the pocket tester (Ω × 100) to
the pickup coil coupler.

Replace the right
handlebar switch.
EB802413

10.Neutral switch

Tester positive probe → gray 1
Tester negative probe → black 2

• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
NO

YES

Replace the neutral
switch.

EB802414

• Measure the pickup coil resistance.

11.Sidestand switch

Pickup coil resistance
248 ~ 372 Ω at 20 ˚C (68 ˚F)
(between gray and black)

• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?

• Is the pickup coil OK?
YES

YES

Replace the
stand switch.

Replace the pickup
coil.
7 - 15

side-

IGNITION SYSTEM

ELEC

–

EB802415

12.Diode

13.Relay unit (diode)

• Remove the diode from the coupler.
• Connect the pocket tester (Ω × 1) to the
diode terminals as shown.
• Check the diode for continuity as follows.

• Remove the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Check the diode for continuity as follows.

Tester positive probe →
blue/white 1 ContinuTester negative probe →
ity
blue/yellow 2

Tester positive probe →
sky blue 1 ContinuTester negative probe →
ity
blue/yellow 2

Tester positive probe →
blue/yellow 2 No contiTester negative probe →
nuity
blue/white 1

Tester positive probe →
blue/yellow 2 No continuity
Tester negative probe →
sky blue 1

NOTE:
When you switch the tester’s positive
and negative probes, the readings in the
above chart will be reversed.

• Are the tester readings correct?

YES

Replace the diode.

Replace
unit.

the

relay

EAS00754

14.Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES
Replace the ignitor
unit.
7 - 16

NO
Properly connect or
repair the ignition
system’s wiring.

3 Main switch
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
9 Relay unit
B Ignitor unit
E Decompression solenoid

7
G Neutral switch
Y Clutch switch
a Engine stop switch
b Start switch
i Ignition fuse
k Sidestand switch
l Diode

ELECTRIC STARTING SYSTEM

7 - 17

ELEC
–
+

EB803000

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM

ELEC

–

EB803010

STARTING CIRCUIT CUTOFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and
the main switch is set to “ON” (both
switches are closed), the starter motor can
only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and the
sidestand is up (the sidestand switch is
closed).
The starting circuit cutoff relay prevents the
starter motor from operating when neither
of these conditions has been met. In this
instance, the starting circuit cutoff relay is
open so current cannot reach the starter
motor. When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the engine can be
started by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE SIDESTAND IS UP
AND THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cutoff relay (relay unit)
7 Diode (relay unit)
8 Clutch switch
9 Sidestand switch
0 Diode
A Neutral switch
B Start switch
C Ignitor unit
D Starter relay
E Starter motor
F Decompression solenoid thermistor

7 - 18

ELECTRIC STARTING SYSTEM

ELEC

–

EB802401

EB803020

TROUBLESHOOTING

2.Battery

The starter motor fails to turn.

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Check:
1. main and ignition fuses
2. battery
3. starter motor
4. relay unit (starting circuit cutoff relay)
5. relay unit (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.diode
12.clutch switch
13.start switch
14.wiring
(of the entire starting system)
15.decompression solenoid

Open-circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)
• Is the battery OK?
NO

YES

• Clean the battery
terminals.
• Recharge or
replace the battery.

EB803400

3.Starter motor

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) side covers
4) headlight lens unit
• Troubleshoot with the following special
tool(s).

• Connect the battery positive terminal 1
and starter motor lead 2 with a jumper
lead 3.

Pocket tester
YU-03112

EB802400

WARNING
WARNING

1.Main and ignition fuses

• A wire that is used as a jumper lead
must have at least the same capacity of
the battery lead, otherwise the jumper
lead may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.

• Check the main and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES

• Does the starter motor turn?
Replace the fuse(s).

YES

NO
Repair or replace
the starter motor.

7 - 19

ELECTRIC STARTING SYSTEM

ELEC

–

EB803403

EB803402

4.Relay unit (starting circuit cutoff relay)

5.Relay unit (diode)

• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the relay unit terminals
as shown.

• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) to the
relay unit terminals as shown.
• Check the diode for continuity as follows.

Battery positive terminal → red/black 1
Battery negative terminal →
black/yellow 2

Tester positive probe →
sky blue 1
Tester negative probe →
black/yellow 2 Continuity
Tester positive probe →
sky blue 1
Tester negative probe →
blue/yellow 3

Tester positive probe → blue 3
Tester negative probe → blue/white 4

Tester positive probe →
black/yellow 2
Tester negative probe →
sky blue 1 No continuity
Tester positive probe →
blue/yellow 3
Tester negative probe →
sky blue 1

• Does the starting circuit cutoff relay
have continuity between blue and blue/
white?
NO

YES
Replace
unit.

the

relay

NOTE:
When you switch the tester’s positive
and negative probes, the readings in the
above chart will be reversed.
• Are the tester readings correct?
NO

YES
Replace
unit.

7 - 20

the

relay

ELECTRIC STARTING SYSTEM

–

ELEC

EB802412

EB803404

6.Starter relay

8.Engine stop switch

• Disconnect the starter relay from the
coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the starter relay terminals as shown.

• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES

Battery positive terminal → red/white 1
Battery negative terminal → blue 2

NO
Replace the right
handlebar switch.

Tester positive probe → red 3
Tester negative probe → black 4
EB802413

9.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
NO

YES

Replace the neutral
switch.

• Does the starter relay have continuity
between red and black?
YES

NO
EB802414

10.Sidestand switch
Replace the starter
relay.

• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?

EB802411

7.Main switch

YES

• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?

Replace the
stand switch.

NO
Replace the main
switch.

7 - 21

side-

ELECTRIC STARTING SYSTEM

ELEC

–

EB803406

11.Diode

13.Start switch

• Remove the diode from the coupler.
• Connect the pocket tester (Ω × 1) to the
diode terminals as shown.
• Check the diode for continuity as follows.

• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES

Tester positive probe →
blue/white 1 ContinuTester negative probe →
ity
blue/yellow 2

Replace the right
handlebar switch.

Tester positive probe →
blue/yellow 2 No contiTester negative probe →
nuity
blue/white 1

FAS00754

14.Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
YES

NO
Properly
connect
or repair the starting system’s wiring.

NOTE:
When you switch the tester’s positive
and negative probes, the readings in the
above chart will be reversed.

15.Decompression solenoid (thermistor)

• Are the tester readings correct?
YES

• Check the decompression solenoid for
continuity.
Refer to “SELF-DIAGNOSIS”.
• Is the decompression solenoid OK?

NO
Replace the diode.

YES

EB803405

12.Clutch switch
Replace the ignitor
unit.

• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
YES

NO
Replace the clutch
switch.

7 - 22

Replace the decompression solenoid.

STARTER MOTOR

ELEC

–

EB803500

STARTER MOTOR

Order

1
2

Job/Part
Removing the starter motor
Starter motor lead
Starter motor assembly

Q’ty

Remarks
Remove the parts in the order listed.

1
1
For installation, reverse the removal
procedure.

7 - 23

STARTER MOTOR

ELEC

–

EB803501

Order
1
2
3
4
5
6
7
8
9
0
A
B
C
D

Job/Part
Q’ty
Remarks
Disassembling the starter motor
Remove the parts in the order listed.
Circlip
1
Starter motor
1
Starter motor rear cover
1
Lock washer
1
Oil seal
1
Bearing
1
Washer set
1
Starter motor front cover
1
Washer set
1
O-ring
2
Armature assembly
1
Brush seat (along with the brushes)
1
Brush holder (along with the brushes)
1
Starter motor yoke
1
For assembly, reverse the disassembly
procedure
7 - 24

STARTER MOTOR

ELEC

–

EB803511

CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Minimum commutator diameter
27 mm (1.06 in)
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade which has been grounded to fit the
commutator.
Mica undercut
0.7 mm (0.03 in)
NOTE:
The mica must be undercut to ensure
proper operation of the commutator.

4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
YU-03112
Armature assembly
Commutator resistance 1
0.025 ~ 0.035 Ω at 20 ˚C (68 ˚F)
Insulation resistance 2
Above 1 MΩ at 20 ˚C (68 ˚F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7 - 25

STARTER MOTOR

ELEC

–

5. Measure:
• brush length a
Out of specification → Replace the
brushes as a set.
Minimum brush length
5 mm (0.20 in)

6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
7.65 ~ 10.01 N
(765 ~ 1,001 gf, 27.0 ~ 35.3 oz)

7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).

EB803701

ASSEMBLING THE STARTER MOTOR
1. Install:
• starter motor yoke 1
• bush holder 2

7
2. Install:
• brush seat 1
NOTE:
Align the tab a on the brush seat with the
slot b in the starter motor rear cover.

7 - 26

STARTER MOTOR

ELEC

–

3. Install:
• armature assembly

Install:
bearing
oil seal
lock washer 1

5.
•
•
•
•

Install:
O-rings 1 New
starter motor rear cover 2
starter motor front cover 3
bolts
7 Nm (0.7 m · kg, 5.1 ft · lb)
T.

4.
•
•
•

NOTE:
Align the match marks a on the starter
motor yoke with the match marks b on the
front and rear covers.
6. Install:
• starter motor gear 1
• circlip 2

7
INSTALLING THE STARTER MOTOR
1. Install:
• starter motor 1
T.
R.

7 Nm (0.7 m · kg, 5.1 ft · lb)

2. Connect:
• starter lead 2
T.
R.

7 - 27

5 Nm (0.5 m · kg, 3.6 ft · lb)

ELEC

CHARGING SYSTEM

–

EB804000

CHARGING SYSTEM
CIRCUIT DIAGRAM

W W W

W
W
W

(BLACK)

R/G

B
W W

W W

5
R

R
R

R Br/L
L/Y L/B

ON
OFF

(BLACK)
Br/L
L/Y

L/B

Br/L R
L/B L/Y

(BLACK)

R/W

L
L

R/W
B
B
B

B
B

1 Generator
2 Rectifier/regulator
4 Battery
5 Main fuse
7 - 28

CHARGING SYSTEM

ELEC

–

EB802401

EB804010

TROUBLESHOOTING

2.Battery

The battery is not being charged.

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil assembly resistance
5. wiring
(of the entire charging system)

Open-circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)
• Is the battery OK?
NO

YES

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) left side cover
• Troubleshoot with the following special
tool(s).

• Clean the battery
terminals.
• Recharge or
replace the battery.

Inductive tachometer
YU-8036-A
Pocket tester
YU-03112

EB804400

3.Charging voltage
• Connect the inductive tachometer to the
spark plug lead of cylinder #1.
• Connect the pocket tester (DC 20V) to
the battery as shown.
Tester positive probe →
battery positive terminal
Tester negative probe →
battery negative terminal

EB802400

1.Main fuse

• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
YES

NO
Replace the fuse.

• Start the engine and let it run at approximately 5,000 r/min.
• Measure the charging voltage.
Charging voltage
14 V at 5,000 r/min

7 - 29

CHARGING SYSTEM

ELEC

–

EB804404

NOTE:
Make sure that the battery is fully
charged.

5.Wiring
• Check the wiring connections of the
entire charging system.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?

• Is the charging voltage within specification?
NO

YES
YES
The charging circuit
is OK.

Replace the rectifier/regulator.

EB804401

4.Stator coil assembly resistances

NO
Properly
connect
or repair the charging system’s wiring.

• Disconnect the generator coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
stator coil assembly coupler as shown.
Tester positive probe → white 1
Tester negative probe → white 2
Tester positive probe → white 1
Tester negative probe → white 3

• Measure the stator coil assembly resistances.

Stator coil resistance
0.45 ~ 0.55 Ω at 20 ˚C (68 ˚F)
• Is the stator coil assembly OK?
YES

NO
Replace the stator
coil assembly.

7 - 30

3 Main switch
4 Battery
5 Main fuse
O High beam indicator light
P Meter light
V Dimmer switch
Z Front turn signal/position light
\ Headlight
c Tail/brake light
h Headlight fuse

LIGHTING SYSTEM

EB805000

LIGHTING SYSTEM

CIRCUIT DIAGRAM

7 - 31

ELEC
–
+

LIGHTING SYSTEM

ELEC

–

EB802401

EB805010

TROUBLESHOOTING

2.Battery

Any of the following fail to light: headlight, high beam indicator light, taillight,
position light or meter light.

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Open-circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)

Check:
1. main, and headlight fuses
2. battery
3. main switch
4. dimmer switch
5. wiring
(of the entire charging system)

• Is the battery OK?
YES

NO
• Clean the battery
terminals.
• Recharge or
replace the battery.

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) left side cover
4) headlight lens unit
• Troubleshoot with the following special
tool(s).

EB802411

3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?

Pocket tester
YU-03112

YES

EB802400

Replace the main
switch.

1.Main and headlight fuses
• Check the main and headlight fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and headlight fuses OK?
YES

EB805401

4.Dimmer switch
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?

YES

Replace the fuse(s).

NO
Replace the left handlebar switch.

7 - 32

LIGHTING SYSTEM
EB805404

ELEC

–

EB805410

CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator light fail to come on.

5.Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
YES
Check the condition
of each of the lighting system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.

1.Headlight bulb and socket
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the headlight bulb and socket OK?

NO
Properly
connect
or repair the lighting system’s wiring.

YES

Replace the headlight bulb, socket or
both.

2.High beam indicator light bulb and socket
• Check the high beam indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the high beam indicator light bulb and
socket OK?
NO

YES

Replace the high
beam indicator
light bulb, socket or
both.

3.Voltage
• Connect the pocket tester (DC 20 V) to
the headlight coupler and the meter
assembly couplers as shown.
Å When the dimmer switch is set to “
ı When the dimmer switch is set to “

Headlight coupler

7 - 33

”
”

LIGHTING SYSTEM

ELEC

–

EB805411

Headlight
Tester positive probe →
yellow 1 or green 2
Tester negative probe → black 3
High beam indicator light
Tester positive probe → yellow 4
Tester negative probe → black 5

2. A meter light fails to come on.
1.Meter light bulb and socket
• Check the meter light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the meter light bulb and socket OK?

Meter assembly coupler (wire harness
side)

YES

Replace the meter
light bulb, socket or
both.

• Set the main switch to “ON”.
• Set the dimmer switch to “
” or
“
”.
• Measure the voltage (12 V) of yellow
(green) 2 on the headlight coupler and
yellow 4 on the meter assembly coupler.
• Is the voltage within specification?
YES

2.Voltage
• Connect the pocket tester (20 V) to the
meter assembly coupler (wire harness
side) as shown.
Tester positive probe → blue 1
Tester negative probe → black 2

NO
The wiring circuit
from
the
main
switch to the headlight coupler and
meter
assembly
couplers are faulty
and
must
be
repaired.

• Set the main switch to “ON”.
• Measure the voltage (12 V) of blue 1 on
the meter assembly coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.

7 - 34

NO
The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.

LIGHTING SYSTEM

–

4. The front turn signal/position light fails
to come on.

EB805412

3. A tail/brake light fails to come on.
1.Tail/brake light bulb and socket

1.Front turn signal/position light bulb and
socket

• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?

• Check the front turn signal/position light
bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the front turn signal/position light
bulb and socket OK?

YES

ELEC

YES
Replace the tail/
brake light bulb,
socket or both.

Replace the front turn
signal/position light
bulb, socket or both.

2.Voltage
2.Voltage

• Connect the pocket tester (DC 20 V) to
the tail/brake light connectors (wire harness side) as shown.

• Connect the pocket tester (DC 20 V) to
the front turn signal/position light connectors (wire harness side) as shown.

Tester positive probe → blue 1
Tester negative probe → black 2

• Set the main switch to “ON”.
• Measure the voltage (12 V) of blue 1 on
the tail/brake light coupler (wire harness
side).
• Is the voltage within specification?
YES

• Set the main switch to “ON”.
• Measure the voltage (12 V) of blue 1 on
the front turn signal/position light connectors (wire harness side).
• Is the voltage within specification?

YES
This circuit is OK.

The wiring circuit
from
the
main
switch to the tail/
brake light coupler
is faulty and must
be repaired.

This circuit is OK.

7 - 35

NO
The wiring circuit
from
the
main
switch to the front
turn
signal/position light connectors is faulty and
must be repaired.

SIGNALING SYSTEM
EB806000

SIGNALING SYSTEM
CIRCUIT DIAGRAM

7 - 37

ELEC

–

SIGNALING SYSTEM

ELEC

–

3 Main switch
4 Battery
5 Main fuse
8 Backup fuse
B Ignitor unit
G Neutral switch
J Engine trouble indicator light
K Turn signal indicator light
L Neutral indicator light
M Speedometer assembly (speedometer, combination meter and fuel level meter)
N Fuel level indicator light
Q Fuel sender
R Turn signal relay
S Horn
W Horn switch
X Turn signal switch
Z Front turn signal/position light
[ Rear turn signal light
_ Front brake light switch
c Tail/brake light
d Rear brake light switch
j Signaling system fuse

7 - 38

SIGNALING SYSTEM

–

EB802401

EB806010

TROUBLESHOOTING

2.Battery

• Any of the following fail to light: turn
signal light, brake light or an indicator
light.
• The horn fails to sound.

• Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
chapter 3.
Open-circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)

Check:
1. main, signaling system and backup fuses
2. battery
3. main switch
4. wiring
(of the entire signaling system)

• Is the battery OK?
YES

EB802411

3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?

Pocket tester
YU-03112

YES

NO
Replace the main
switch.

EB802400

1.Main, signaling system and backup
fuses

EB806400

4.Wiring

• Check the main, signaling system and
backup fuses for continuity.
Refer to “CHECKING AND CHARGING
THE FUSES” in chapter 3.
• Are the main, signaling system and
backup fuses OK?
YES

NO
• Clean the battery
terminals.
• Recharge or
replace the battery.

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) side covers
4) headlight lens unit
• Troubleshoot with the following special
tool(s).

ELEC

• Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?

YES

Replace the fuse(s).
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.

7 - 39

Properly
connect
or repair the signaling system’s wiring.

SIGNALING SYSTEM

ELEC

–

EB806410

3.Horn

CHECKING THE SIGNALING SYSTEM
1.The horn fails to sound.

• Disconnect the horn coupler at the horn.
• Connect a jumper lead 1 to the brown
terminal in the horn coupler and the
horn terminal.
• Connect a jumper lead 2 to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?

1.Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
YES

NO
Replace the left handlebar switch.

2.Voltage
• Connect the pocket tester (DC 20 V) to
the horn coupler as shown.
Tester positive probe → brown 1
Tester negative probe → ground
NO

YES
The horn is OK.

4.Voltage
• Connect the pocket tester (DC 20 V) to
the horn coupler as shown.
Tester positive probe → pink 1
Tester negative probe → ground

• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (12 V) of brown on
the horn coupler.
• Is the voltage within specification?
YES

NO
The wiring circuit
from
the
main
switch to the horn
connector is faulty
and
must
be
repaired.

• Set the main switch to “ON”.
• Measure the voltage (12 V) of pink 1 on
the horn coupler.
• Is the voltage within specification?
YES

7 - 40

Repair or replace
the horn.

NO
Replace the horn.

SIGNALING SYSTEM

ELEC

–

EB806411

• Set the main switch to “ON”.
• Pull in the brake lever or push down on
the brake pedal.
• Measure the voltage (12 V) of yellow at
the tail/brake light coupler (wire harness
side).
• Is the voltage within specification?

2. A tail/brake light fails to come on.
1.Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
YES

This circuit is OK.

Replace the tail/
brake light bulb,
socket or both.

3. A turn signal light, turn signal indicator
light or both fail to blink.

• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?

1.Turn signal light bulb and socket
• Check the turn signal light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
OK?

NO
Replace the brake
light switch.

YES

3.Voltage
• Connect the pocket tester (DC 20 V) to
the tail/brake light coupler (wire harness
side) as shown.

The wiring circuit
from
the
main
switch to the tail/
brake light coupler
is faulty and must
be repaired.

EB806413

2.Brake light switches

YES

NO
Replace the turn
signal light bulb,
socket or both.

Tester positive probe → yellow 1
Tester negative probe → black 2
2.Turn signal indicator light bulb and socket
• Check the turn signal indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the turn signal indicator light bulb and
socket OK?
YES

7 - 41

NO
Replace the turn signal indicator light
bulb, socket or both.

SIGNALING SYSTEM

ELEC

–

3.Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
YES

NO
Replace the left handlebar switch.

• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (12 V) of brown/
white at the turn signal relay coupler.
• Is the voltage within specification?

4.Voltage
• Connect the pocket tester (DC 20 V) to
the turn signal relay coupler as shown.

YES

Tester positive probe → brown 1
Tester negative probe → ground

The
turn
signal
relay is faulty and
must be replaced.
6.Voltage
• Connect the pocket tester (DC 20 V) to
the turn signal light connectors (wire
harness side) or the meter assembly
coupler as shown.

• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
at the turn signal relay coupler.
• Is the voltage within specification?
YES

Å Turn signal light
ı Turn signal indicator light

Left turn signal light
Tester positive probe → chocolate 1
Tester negative probe → ground
Right turn signal light
Tester positive probe → dark green 2
Tester negative probe → ground

NO
The wiring circuit
from
the
main
switch to the turn
signal relay coupler
is faulty and must
be repaired.

5.Voltage
• Connect the pocket tester (DC 20 V) to
the turn signal relay coupler as shown.
Tester positive probe → brown/white 1
Tester negative probe → ground

7 - 42

SIGNALING SYSTEM
ı

ELEC

–

2.Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES

Replace the neutral
switch.

• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or
“ ”.
• Measure the voltage (12 V) of chocolate 1
or dark green 2 at the turn signal light connectors (wire harness side) or the meter
assembly coupler.
• Is the voltage within specification?
YES
This circuit is OK.

3.Voltage
• Connect the pocket tester (DC 20 V) to
the meter assembly coupler as shown.
Tester positive probe → brown 1
Tester negative probe → sky blue 2

NO
The wiring circuit
from the turn signal
switch to the turn
signal light connector or the meter
assembly coupler
are faulty and must
be repaired.

• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and sky blue 2 at the meter assembly
coupler.
• Is the voltage within specification?

EB806414

4. The neutral indicator light fails to come
on.

YES

1.Neutral indicator light bulb and socket

This circuit is OK.

• Check the neutral indicator light bulb
and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the neutral indicator light bulb and
socket OK?
YES

NO
Replace the neutral
indicator light bulb,
socket or both.

7 - 43

The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.

SIGNALING SYSTEM

–

ELEC

EB806417

3.Voltage

5. The fuel level indicator light, fuel level
meter or both fail to come on.

• Connect the pocket tester (DC 20 V) to
the meter assembly coupler (wire harness side) as shown.

1.Fuel level indicator light LED
• Check the LED of the fuel level indicator
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Is the fuel level indicator light LED OK?

Tester positive probe → brown 1
Tester negative probe → black 2

YES

Replace the meter
assembly.
• Set the main switch to “ON”.
• Measure the voltage (12 V).
• Is the voltage within specification?

2.Fuel sender
• Disconnect the fuel sender coupler from
the wire harness.
• Drain the fuel from the fuel tank and
remove the fuel sender from the fuel
tank.
• Connect the pocket tester (Ω × 10) to the
fuel sender coupler.

YES
Replace the meter
assembly.

Tester positive probe → green 1
Tester negative probe → black/blue 2

The wiring circuit
from
the
main
switch to the meter
assembly coupler is
faulty and must be
repaired.

6. An engine trouble indicator light fails to
come on.
1.Engine trouble indicator LED
• Check the LED of the engine indicator
light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Measure the fuel sender resistance.
Fuel sender resistance
Full position of the float Å
11 ~ 13 Ω at 20 ˚C (68 ˚F)
Empty position of the float ı
140 ~ 143 Ω at 20 ˚C (68 ˚F)

YES

Replace the meter
assembly.

• Is the fuel sender OK?
NO

YES
Replace
sender.

the

fuel
7 - 44

SIGNALING SYSTEM
EAS00843

2.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES
Replace the ignitor
unit.

NO
Repair or replace
the wire harness.

7 - 45

ELEC

–

3 Main switch
4 Battery
5 Main fuse
9 Relay unit
0 Fuel pump
B Ignitor unit
a Engine stop switch
i Ignition fuse

FUEL PUMP SYSTEM

7 - 46

ELEC
–
+

EB808000

FUEL PUMP SYSTEM

CIRCUIT DIAGRAM

FUEL PUMP SYSTEM
EB808010

FUEL PUMP CIRCUIT OPERATION
The ignitor unit includes the control unit for the fuel pump.
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Ignitor unit
7 Fuel pump relay
8 Fuel pump

7 - 47

ELEC

–

FUEL PUMP SYSTEM

ELEC

–

EAS00739

EB808020

TROUBLESHOOTING

2.Battery

The fuel pump fails to operate.

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Check:
1. main and ignition fuses
2. battery
3. main switch
4. engine stop switch
5. relay unit (fuel pump relay)
6. fuel pump
7. wiring
(the entire fuel pump system)

Minimum open circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)
• Is the battery OK?
YES

• Clean the battery
terminals.
• Recharge or
replace the battery.

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) side covers
4) headlight lens unit
• Troubleshoot with the following special
tool(s).

EAS00749

3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?

Pocket tester
YU-03112

YES

NO
Replace the main
switch.

EAS00738

1.Main and ignition fuses
• Check the main and ignition fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES

EAS00750

4.Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?

YES

Replace the fuse(s).

NO
Replace the right
handlebar switch.

7 - 48

FUEL PUMP SYSTEM

ELEC

–

• Measure the fuel pump resistance.

5.Relay unit (fuel pump relay)
• Disconnect the relay unit from the coupler.
• Connect the pocket tester (Ω × 1) and
battery (12 V) to the relay unit terminals
as shown.

Fuel pump resistance
1.6 ~ 2.2 Ω at 20 ˚C (68 ˚F)
• Is the fuel pump OK?
YES

Battery positive terminal → red/black 1
Battery negative terminal → blue/red 2

NO
Replace the fuel
pump.

Tester positive probe → red/black 1
Tester negative probe → blue/black 3
EAS00754

7.Wiring
• Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the fuel pump system’s wiring properly connected and without defects?
YES

• Does the fuel pump relay have continuity between red/black and blue/black?
Replace the ignitor
unit.

YES
Replace
unit.

the

relay

EB808400

6.Fuel pump resistance

• Disconnect the fuel pump coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
fuel pump coupler (fuel pump side) as
shown.
Tester positive probe → black/blue 1
Tester negative probe → black 2

7 - 49

Properly
connect
or repair the fuel
pump system’s wiring.

FUEL PUMP SYSTEM

ELEC

–

EB808410

CHECKING THE FUEL PUMP

WARNING
WARNING
Gasoline is extremely flammable and under
certain circumstances there can be a danger of an explosion or fire. Be extremely
careful and note the following points:
• Stop the engine before refuelling.
• Do not smoke and keep away from open
flames, sparks or any other source of fire.
• If you do accidentally spill gasoline, wipe
it up immediately with dry rags.
• If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make
sure that the engine is completely cool
before performing the following test.

1.Check:
• fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fill the fuel tank.
b. Put the end of the fuel hose into an open
container.
c. Turn the fuel cock to “ON” or “RES”.
d. Connect the battery (12 V) to the fuel
pump coupler as shown.
Battery positive lead → black/blue 1
Battery negative lead → black 2
e. If fuel flows out of the fuel hose, the fuel
pump is OK. If fuel does not flow, replace
the fuel pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7 - 50

3 Main switch
4 Battery
5 Main fuse
e Carburetor heater
f Thermo switch
g Carburetor heater fuse

CARBURETOR HEATING SYSTEM

7 - 51

ELEC
–
+

EAS00820

CARBURETOR HEATING SYSTEM

CIRCUIT DIAGRAM

CARBURETOR HEATING SYSTEM

ELEC

–

EAS00739

EAS00821

TROUBLESHOOTING

2.Battery

The carburetor heating system fails to
operate.

• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Check:
1. Main and carburetor heater fuses
2. Battery
3. Main switch
4. Thermo switch
5. Carburetor heater
6. Wiring
(of the entire carburetor heating system)

Minimum open circuit voltage
12.8 V or more at 20 ˚C (68 ˚F)
• Is the battery OK?

• Clean the battery
terminals.
• Recharge or
replace the battery.

NOTE:
• Before troubleshooting, remove the following part(s).
1) rider seat
2) fuel tank
3) carburetor
4) left side cover
• Troubleshoot with the following special
tool(s).

EAS00749

3.Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?

Pocket tester
YU-03112

YES

Replace the main
switch.

EAS00738

1.Main and carburetor heater fuses
• Check the main and carburetor heater
fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and carburetor heater
fuses OK?
YES

YES

EAS00823

4.Thermo switch
• Remove the thermo switch from the
plastic bracket.
• Connect the pocket tester to the thermo
switch coupler as shown.
Tester positive lead → black 1
Tester negative lead → black 2

• Immerse the thermo switch in a container filled with water 3.
• Place a thermometer 4 in the water.
• Slowly heat the water, than let it cool to
the specified temperature as indicated in
the table.
• Check the thermo switch for continuity
at the temperatures indicated in the
table.

Replace the fuse(s).

7 - 52

CARBURETOR HEATING SYSTEM

ELEC

–

WARNING
WARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
• Does the thermo switch operate properly?
NO

YES

Replace the thermo
switch.

5.Carburetor heater
• Remove the carburetor heater from the
carburetor.
• Connect the pocket tester to the carburetor heater as shown.
Tester positive probe →
carburetor heater terminal 1
Tester negative probe →
carburetor heater body 2

Å The thermo switch circuit is open.
ı The thermo switch circuit is closed.

Test step Water temperature

Continuity

Less than 23 ± 3 ˚C
(73.4 ± 5.4 ˚F)

YES

More than 23 ± 3 ˚C
(73.4 ± 5.4 ˚F)

More than 12 ± 4 ˚C
(53.6 ± 7.2 ˚F)

Less than 12 ± 4 ˚C
(53.6 ± 7.2 ˚F)

YES

• Measure carburetor heater resistance.
Carburetor heater resistance
12 V 30 W: 6 ~ 10 Ω at 20˚C (68˚F)
• Is the carburetor heater OK?
YES

Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase

NO
Replace the carburetor heater.

7 - 53

CARBURETOR HEATING SYSTEM

ELEC

–

EAS00754

6.Wiring
• Check the entire carburetor heating system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the carburetor heating system’s wiring properly connected and without
defects?
YES
This circuit is OK.

NO
Properly
connect
or repair the carburetor heating system’s wiring.

7 - 54

SELF-DIAGNOSIS

ELEC

–

EB812000

SELF-DIAGNOSIS
The XV16AL/XV16ALC/XV16ATL/XV16ATLC features a self-diagnosing system for the following circuit(s):
• throttle position sensor
• speed sensor
• decompression solenoid
• fuel level meter
If any of these circuits is defective, the respective condition code will be displayed by the
engine trouble indicator light or fuel level indicator light when the main switch is set to “ON”
(irrespective of whether the engine is running or not).
Indicator light

Circuit
Throttle position sensor

Defect(s)
• Disconnected
• Short-circuit
• Locked

•

•
Speed sensor

Decompression solenoid

Fuel level
meter

• Abnormal pulse
• Disconnected
• Short-circuit

•

• Disconnected
• Short-circuit
• Over heated
solenoid
• Disconnected
thermistor in
solenoid
• Short-circuited
thermistor in
solenoid
• Disconnected
• Short-circuit

•

•
•

Condition code
When
When
System response
engine is engine is
stopped
running
Lights up
The ignitor unit stays set to the Blinks in
wide-open throttle ignition tim- patterns
ing. The motorcycle can be rid- of 3
den.
The engine trouble indicator
light displays the condition code.
The engine speed limiter sets in Blinks in
Lights up
patterns
approximately 4,400 rpm.
The engine trouble indicator of 4
light displays the condition code.
The decompression solenoid Blinks in
Lights up
patterns
does not move.
The starter motor does not oper- of 6
ate.
The engine trouble indicator
light displays the condition code.

• The fuel level meter displays the Blinks in
patterns
empty position.
• The fuel level indicator light dis- of 8
plays the condition code.

Blinks in
patterns
of 8

NOTE:
When the main switch is turned on, the engine trouble indicator light and fuel level indicator
light in the meter assembly normally come on for 1.4 seconds and then go off. However, if
there is a malfunction, the corresponding indicator light then begins flashing when the
engine is stopped or comes on when the engine is running.

7 - 55

SELF-DIAGNOSIS

ELEC

–

Display order on the engine trouble indicator light and fuel level indicator light
1 Engine trouble indicator light
2 Fuel level indicator light

1 Indicator lights check...............................1.4 seconds
2 Light off ....................................................3 seconds
3 Condition code.........................................First fault code (3 = throttle position sensor)
4 Condition code.........................................Next fault code (4 = speed sensor)
5 Light on ....................................................0.5 second
6 Light off ....................................................0.5 second
Å Light on
ı Light off
Ç Main switch is turned on
Î Repetition

7 - 56

SELF-DIAGNOSIS
EB812010

ELEC

–

EAS00843

TROUBLESHOOTING

1.Wire harness

The engine trouble indicator light or the
fuel level indicator light starts to blink,
display the self-diagnosis sequence.

• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?

Check:
1. throttle position sensor
2. speed sensor
3. decompression solenoid
4. fuel level meter

YES

Repair or replace
the wire harness.

NOTE:
• Before troubleshooting, remove the following part(s):
1) rider seat
2) fuel tank
3) left side cover
• Troubleshoot with the following special
tool(s).

EB812401

2.Throttle position sensor
• Check the throttle position sensor for
continuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
chapter 6.
• Is the throttle position sensor OK?

Pocket tester
YU-03112

YES

EB812020

Replace the ignitor
unit.

1. Throttle position sensor
CIRCUIT DIAGRAM

A Throttle position sensor
B Ignitor unit

7 - 57

NO
Replace the throttle position sensor.

SELF-DIAGNOSIS

ELEC

–

2. Speed sensor
CIRCUIT DIAGRAM

B Ignitor unit
H Speed sensor
EAS00843

1.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES

Replace the speed
sensor.
BAD
Replace the ignitor
unit.

Repair or replace
the wire harness.

7 - 58

SELF-DIAGNOSIS

ELEC

–

3. Decompression solenoid
CIRCUIT DIAGRAM

B Ignitor unit
E Decompression solenoid
EAS00843

1.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES

NO
• Measure the decompression solenoid
resistance.

Repair or replace
the wire harness.

Decompression solenoid resistance (thermistor)
68.75 ~ 78.75 Ω at 25 ˚C (77 ˚F)

2.Decompression solenoid (thermistor)

NOTE:
The resistance value for the thermistor
changes when the temperature changes;
therefore, measure the decompression
solenoid resistance at the specified temperature.

• Disconnect the decompression solenoid
couplers from the wire harness.
• Connect the pocket tester (Ω × 10) to the
decompression solenoid coupler as shown.
Tester positive probe → green 1
Tester negative probe → green 2

• Connect the pocket tester (Ω × 1) to the
decompression solenoid coupler as
shown.
Tester positive probe → black 3
Tester negative probe → black 4
Decompression solenoid resistance
1.2 Ω at 20 ˚C (68 ˚F)
7 - 59

SELF-DIAGNOSIS

ELEC

–

EB812403

• Check the decompression solenoid for
continuity.
• Is the decompression solenoid OK?
YES
Replace the ignitor
unit.

1.Fuel level indicator light LED
• Check the LED of the fuel level indicator
light.
Refer to “CHECKING THE LEDs”.
• Is the fuel level indicator light LED OK?

NO
Replace the decompression solenoid.

YES
Repair the
assembly.

EB812040

meter

4. Fuel level meter
CIRCUIT DIAGRAM
2.Fuel sender
• Disconnect the fuel sender coupler from
the wire harness.
• Drain the fuel from the fuel tank and
remove the fuel sender from the fuel
tank.
• Connect the pocket tester (Ω × 10) to the
fuel sender coupler.
Tester positive probe → green 1
Tester negative probe → black/blue 2

M Speedometer assembly (fuel level meter)
N Fuel level indicator light
Q Fuel sender

• Measure the fuel sender resistance.
Fuel sender resistance
Full position of the float Å
11 ~ 13 Ω at 20 ˚C (68 ˚F)
Empty position of the float ı
140 ~ 143 Ω at 20 ˚C (68 ˚F)
• Is the fuel sender OK?
NO

YES
Replace
sender.

7 - 60

the

fuel

SELF-DIAGNOSIS
EAS00843

3.Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES
Replace the meter
assembly.

NO
Replace or replace
the wire harness.

7 - 61

ELEC

–

TRBL
SHTG
CONTENTS
TROUBLESHOOTING
STARTING PROBLEMS ................................................................................ 8-1
ENGINE ................................................................................................. 8-1
FUEL SYSTEM ...................................................................................... 8-1
ELECTRICAL SYSTEMS ....................................................................... 8-2
INCORRECT ENGINE IDLING SPEED .......................................................... 8-2
ENGINE ................................................................................................. 8-2
FUEL SYSTEM ...................................................................................... 8-2
ELECTRICAL SYSTEMS ....................................................................... 8-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................ 8-3
ENGINE ................................................................................................. 8-3
FUEL SYSTEM ...................................................................................... 8-3
FAULTY GEAR SHIFTING ............................................................................ 8-3
SHIFTING IS DIFFICULT ....................................................................... 8-3
SHIFT PEDAL DOES NOT MOVE ......................................................... 8-3
JUMPS OUT OF GEAR ......................................................................... 8-3
FAULTY CLUTCH ......................................................................................... 8-3
CLUTCH SLIPS ...................................................................................... 8-3
CLUTCH DRAGS ................................................................................... 8-3
OVERHEATING ............................................................................................. 8-4
ENGINE ................................................................................................. 8-4
FUEL SYSTEM ...................................................................................... 8-4
CHASSIS ............................................................................................... 8-4
ELECTRICAL SYSTEMS ....................................................................... 8-4
POOR BRAKING PERFORMANCE................................................................ 8-4

FAULTY FRONT FORK LEGS........................................................................ 8-4
LEAKING OIL ........................................................................................ 8-4
MALFUNCTION .................................................................................... 8-4
UNSTABLE HANDLING ............................................................................... 8-5

TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................... 8-5
HEADLIGHT DOES NOT LIGHT ........................................................... 8-5
HEADLIGHT BULB BURNT OUT ......................................................... 8-5
TAIL/BRAKE LIGHT DOES NOT LIGHT ............................................... 8-5
TAIL/BRAKE LIGHT BULB BURNT OUT .............................................. 8-5
TURN SIGNAL DOES NOT LIGHT ....................................................... 8-5
TURN SIGNAL BLINKS SLOWLY ........................................................ 8-5
TURN SIGNAL REMAINS LIT .............................................................. 8-5
TURN SIGNAL BLINKS QUICKLY ....................................................... 8-5
HORN DOES NOT SOUND .................................................................. 8-5

STARTING PROBLEMS

TRBL
SHTG

EAS00844

TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

STARTING PROBLEMS
FUEL SYSTEM
Fuel tank (See page 3-6)
• Empty fuel tank
• Clogged fuel filter
• Clogged fuel strainer
• Clogged fuel tank breather hose
• Clogged rollover valve
• Clogged rollover valve hose
• Deteriorated or contaminated fuel
Fuel pump (See page 7-46 to 7-50)
• Faulty fuel pump
• Faulty fuel pump relay
Fuel cock (See page 6-19 to 6-20)
• Clogged or damaged fuel hose
Carburetor (See page 6-1 to 6-20)
• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Damaged float
• Worn needle valve
• Incorrectly installed needle valve seat
• Incorrect fuel level
• Incorrectly installed pilot jet
• Clogged starter jet
• Faulty starter plunger
• Incorrectly adjusted starter cable

ENGINE
Cylinders and cylinder heads (See page
5-39 to 5-43 and 5-53 to 5-59)
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Incorrectly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
Pistons and piston rings (See page 5-53 to
5-59)
• Incorrectly installed piston ring
• Damaged, worn, or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter (See page 3-7 and 3-29)
• Incorrectly installed air filter
• Clogged air filter element
Crankcase and crankshaft (See page 5-100
to 5-107 and 5-114 to 5-121)
• Incorrectly assembled crankcase
• Seized crankshaft

8-1

STARTING PROBLEMS/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery (See page 3-51 to 3-56)
• Faulty battery
• Discharged battery
Fuses (See page 3-56 to 3-58)
• Blown, damaged, or incorrect fuse
• Incorrectly installed fuse
Spark plugs (See page 3-14 to 3-15)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coils (See page 7-14 to 7-15)
• Damaged ignition coil
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead

TRBL
SHTG

Ignition system (See page 7-12 to 7-16)
• Faulty ignitor unit
• Faulty pickup coil
Switches and wiring (See page 7-7 to 7-8)
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty sidestand switch
• Faulty clutch switch
• Incorrectly grounded circuit
• Loose connections
Starting system (See page 7-17 to 7-27)
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cutoff relay
• Faulty starter clutch

EAS00846

INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery (See page 3-51 to 3-56)
• Incorrectly charged battery
• Faulty battery
Spark plugs (See page 3-14 to 3-15)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coils (See page 7-14 to 7-15)
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Damaged ignition coil
Ignition system (See page 7-12 to 7-16)
• Faulty ignitor unit
• Faulty pickup coil

ENGINE
Cylinders and cylinder heads (See page
5-39 to 5-43 and 5-53 to 5-59)
• Incorrect valve clearance
• Damaged valve train components
Air filter (See page 3-7 and 3-29)
• Clogged air filter element
FUEL SYSTEM
Carburetor (See page 6-1 to 6-20)
• Faulty starter plunger
• Loose or clogged pilot jet
• Loose or clogged pilot air jet
• Damaged or loose carburetor joint
• Incorrectly adjusted engine idling speed
(throttle stop screw)
• Incorrect throttle cable free play
• Flooded carburetor
• Faulty air induction system

8-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY GEAR SHIFTING/FAULTY CLUTCH

TRBL
SHTG

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING PROBLEMS”.
ENGINE
Air filter (See page 3-7 and 3-29)
• Clogged air filter element

FUEL SYSTEM
Carburetor (See page 6-1 to 6-20)
• Faulty diaphragm
• Incorrect fuel level
• Loose or clogged main jet
Fuel pump (See page 7-46 to 7-50)
• Faulty fuel pump

EAS00850

FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shift shaft (See page 5-74 to 5-76)
• Incorrect shift pedal position
• Incorrectly returned stopper lever
Shift forks (See page 5-122 to 5-127)
• Worn shift fork
Shift drum (See page 5-122 to 5-127)
• Incorrect axial play
• Worn shift drum groove
Transmission (See page 5-122 to 5-127)
• Worn gear dog

SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft (See page 5-74 to 5-76)
• Incorrectly adjusted shift rod
• Bent shift shaft
Shift drum and shift forks (See page 5-122
to 5-127)
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission (See page 5-122 to 5-127)
• Seized transmission gear
• Foreign object between transmission
gears
• Incorrectly assembled transmission

EAS00851

FAULTY CLUTCH

CLUTCH DRAGS
Clutch (See page 5-60 to 5-73)
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
Engine oil (See page 3-20 to 3-21)
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil

CLUTCH SLIPS
Clutch (See page 5-60 to 5-73)
• Incorrectly assembled clutch
• Incorrectly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
Engine oil (See page 3-20 to 3-21)
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil

8-3

OVERHEATING/POOR BRAKING PERFORMANCE/
FAULTY FRONT FORK LEGS

TRBL
SHTG

EAS00855

OVERHEATING
ENGINE
Cylinder heads and pistons (See page 5-53
to 5-59)
• Heavy carbon buildup
Engine oil (See page 3-20 to 3-21)
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
FUEL SYSTEM
Carburetor (See page 6-1 to 6-20)
• Incorrect main jet setting
• Incorrect fuel level
• Damaged or loose carburetor joint
Air filter (See page 3-7 and 3-29)
• Clogged air filter element

CHASSIS
Brakes (See page 3-34 to 3-38 and 4-22 to
4-54)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plugs (See page 3-14 to 3-15)
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system (See page 7-12 to 7-16)
• Faulty ignitor unit

EAS00857

POOR BRAKING PERFORMANCE (See page 3-34 to 3-38 and 4-22 to 4-54)
•
•
•
•
•
•
•
•
•
•

Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level

EAS00860

FAULTY FRONT FORK LEGS (See page 3-43 to 3-44 and 4-55 to 4-66)
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged cartridge
• Incorrect oil viscosity
• Incorrect oil level

LEAKING OIL
• Bent, damaged, or rusty inner tube
• Damaged outer tube
• Incorrectly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged cartridge cylinder bolt copper
washer
• Damaged cap bolt O-ring

8-4

UNSTABLE HANDLING/FAULTY LIGHTING OR
SIGNALING SYSTEM

TRBL
SHTG

EAS00864

UNSTABLE HANDLING
Handlebar (See page 4-67 to 4-72)
• Bent or incorrectly installed handlebar
Steering head components (See page 3-41
to 3-43 and 4-73 to 4-78)
• Incorrectly installed upper bracket
• Incorrectly installed lower bracket
(incorrectly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork legs (See page 3-43 to 3-44 and
4-55 to 4-66)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both
front fork legs)
• Damaged fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Swingarm (See page 4-79 to 4-89)
• Worn bearing or bushing
• Bent or damaged swingarm

Rear shock absorber assembly
(See page 4-79 to 4-89)
• Faulty rear shock absorber spring
• Leaking oil or gas
Tires (See page 3-45 to 3-48)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheels (See page 3-48 to 3-49 and
4-1 to 4-21)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Incorrectly installed bearing race

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEM (See page 7-31 to 7-45)

HEADLIGHT DOES NOT LIGHT
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Incorrectly grounded circuit
• Poor contacts (main or dimmer switch)
• Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Incorrectly grounded circuit
• Faulty main switch
• Faulty dimmer switch
• Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT LIGHT
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light
switch
8-5
• Tail/brake light bulb life expired

TURN SIGNAL DOES NOT LIGHT
• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Incorrectly grounded circuit
• Faulty battery
• Blown, damaged, or incorrect fuse
TURN SIGNAL BLINKS SLOWLY
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
• Faulty turn signal relay
• Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY
• Incorrect turn signal bulb
• Faulty turn signal relay
• Burnt-out turn signal bulb
HORN DOES NOT SOUND
• Incorrectly adjusted horn
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged, or incorrect fuse
• Faulty wire harness

COLOR CODE
B ........... black
Br .......... brown
Ch ......... chocolate
Dg ......... dark green
G ........... green
Gy ......... gray
L............ blue
Lg.......... light green
O ........... orange

P............ pink
R............ red
Sb ......... sky blue
W .......... white
Y............ yellow
B/L......... black/blue
B/R ........ black/red
B/W ....... black/white
B/Y ........ black/yellow

Br/B ....... brown/black
Br/L ....... brown/blue
Br/W ...... brown/white
Br/Y ....... brown/yellow
G/B ........ green/black
G/R ........ green/red
G/Y ........ green/yellow
L/B ......... blue/black
L/R ......... blue/red

L/W........ blue/white
L/Y ......... blue/yellow
R/B......... red/black
R/G ........ red/green
R/W ....... red/white
R/Y......... red/yellow
Y/B......... yellow/black
Y/R......... yellow/red

XV16AL/XV16ALC/XV16ATL/XV16ATLC WIRING DIAGRAM (For USA and CDN)

N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
^
a
b
c
d
e
f
g
h
i
j
k
l

1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
Generator
Rectifier/regulator
Main switch
Battery
Main fuse
Starter relay
Starter motor
Backup fuse
Relay unit
Fuel pump
Throttle position sensor
Ignitor unit
Ignition coil
Spark plug
Decompression solenoid
Pickup coil
Neutral switch
Speed sensor
Meter assembly
Engine trouble indicator light
Turn signal indicator light
Neutral indicator light
Speedometer assembly
(speedometer, combination
meter and fuel level meter)
Fuel level indicator light
High beam indicator light
Meter light
Fuel sender
Turn signal relay
Horn
Solenoid
Left handlebar switch
Dimmer switch
Horn switch
Turn signal switch
Clutch switch
Front turn signal/position light
Rear turn signal light
Headlight
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Tail/brake light
Rear brake light switch
Carburetor heater
Thermo switch
Carburetor heater fuse
Headlight fuse
Ignition fuse
Signaling system fuse
Sidestand switch
Diode

YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

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User Access                     : Print, Extract, Print high-res
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Producer                        : Acrobat Distiller 5.0 (Windows)
Create Date                     : 2001:08:20 10:25:32-07:00
Modify Date                     : 2006:10:31 21:25:43+01:00
Metadata Date                   : 2006:10:31 21:25:43+01:00
Format                          : application/pdf
Creator                         : Mosue
Title                           : Yamaha XV1600 A RoadStar 98-03 Service Manual ENG
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Page Count                      : 449
Author                          : Mosue

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Yamaha XV1600 A RoadStar 98 03 Service Manual ENG XV16

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