Yamaha 1100 Service Manual

1-2IMPORTANT INFORMATIONGENINFOEB101000IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCE-DURES1. Remove all dirt, mud, dust and foreign mate-rial bef

CHECKING THE FUSES/REPLACING THE HEADLIGHT BULBINSPADJ3-44WARNINGWARNINGNever use a fuse with an amperage ratingother than that specified. Improvising

3-45REPLACING THE HEADLIGHT BULB/ADJUSTING THE HEADLIGHT BEAMINSPADJCAUTION:ababAvoid touching the glass part of the head-light bulb to keep it free f

ENG 4

ENGCHAPTER 4ENGINEENGINE REMOVAL 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLERS, BRAKE PEDAL AND

ENGCLUCTH 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT CRANKCASE COVER 4-38.

ENGMIDDLE GEAR 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE DRIVE PINION GEAR 4-72. . .

4-1Order Job name/Part name Q’ty Remarks123456Removing the muffler, brake pedaland side coverFuel tankAir filter case assemblyCarburetor assemblyMuffl

4-2ENGINE REMOVALENGOrder Job name/Part name Q’ty Remarks78910111213Rear brake master cylinder/bracketBattery coverBattery leadsRight side coverStarte

4-3Order Job name/Part name Q’ty Remarks1234567891011Removing the leads, shift pedal andclutch cableTool box coverLeft side coverAC magneto lead/picku

4-4Order Job name/Part name Q’ty Remarks123456789Engine mounting bolt removalLeft crankcase coverTool boxHornEngine ground lead connectorEngine stay (

1-3IMPORTANT INFORMATIONGENINFOCAUTION:EB101030LOCK WASHERS/PLATES AND COTTERPINS1. Replace all lock washers/plates 1 and cot-ter pins after removal.

4-5ENGINEENGNOTE:EAS00192INSTALLING THE ENGINE1. Tighten the bolts in the following order.Bolt 1:48 Nm (4.8 mkg)Bolt 2:48 Nm (4.8 mkg)Bolt 3:48 Nm (

4-6Order Job name/Part name Q’ty Remarks1234567Cylinder head removalEngine assemblyLeft crankcase coverTappet cover (exhaust)/O-ringTappet cover (inta

4-7Order Job name/Part name Q’ty Remarks89101112Timing chain tensioner/gasketCamshaft sprocketCylinder headDowel pinsCylinder head gasket1/11121For in

4-8Order Job name/Part name Q’ty Remarks123456Cylinder head removalEngine assemblyOil delivery pipesRight crankcase coverTappet cover (exhaust)/O-ring

4-9Order Job name/Part name Q’ty Remarks789101112Timing chain tensioner/gasketCamshaft sprocket plateCamshaft sprocketCylinder headDowel pinsCylinder

4-10CYLINDER HEADSENGNOTE:EAS00226REMOVING THE CYLINDER HEADSRear cylinder head1. Remove: camshaft sprocket cover tappet covers2. Align: “T” mark a

4-11CYLINDER HEADSENGNOTE:NOTE:NOTE:4. Remove: timing chain tensioner gasket5. Remove: bolt (camshaft sprocket) 1 camshaft sprocket 2To prevent th

4-12CYLINDER HEADSENGNOTE:NOTE:EAS00228CHECKING THE CYLINDER HEADSThe following procedure applies to all of the cyl-inder heads.1. Eliminate: combust

4-13CYLINDER HEADSENGNOTE:NOTE:50 Nm (5.0 mkg)35 Nm (3.5 mkg)20 Nm (2.0 mkg)NOTE:EB401430CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain

4-14CYLINDER HEADSENGWARNINGNOTE:3. Install: camshaft sprocketa. Temporarily install the rotor nut and leftcrankcase cover without the pickup coil an

1-4CHECKING OF CONNECTIONSGENINFONOTE:NOTE:EB801000CHECKING OF CONNECTIONSCheck the connectors for stains, rust, moisture,etc.1. Disconnect: Connecto

4-15CYLINDER HEADSENG55 Nm (5.5 mkg)NOTE:NOTE:d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, andtighten the cap bo

4-16Order Job name/Part name Q’ty Remarks12345678Removing the rocker arm andcamshaftCylinder headsStopper plateCamshaft bushingCamshaft/dowel pinUnion

4-17ROCKER ARMS AND CAMSHAFTENGNOTE:NOTE:EAS00202REMOVING THE ROCKER ARMS AND CAM-SHAFT1. Remove: rocker arm shafts (intake and exhaust) 1 rocker ar

4-18ROCKER ARMS AND CAMSHAFTSENGNOTE:EB401410CHECKING THE ROCKER ARMS ANDROCKER ARM SHAFTSThe following procedure applies to all of therocker arms and

4-19ROCKER ARMS AND CAMSHAFTSENGNOTE:EAS00220INSTALLING THE CAMSHAFT AND ROCK-ER ARMS1. Lubricate: camshaftRecommended lubricantCamshaft/BushingMolyb

4-20ROCKER ARMS AND CAMSHAFTSENGNOTE:5. Install: rocker arms rocker arm shaftsMake sure that the rocker arm shafts is com-pletely pushed into the cy

4-21Order Job name/Part name Q’ty Remarks1234567Removing the valves and valvesprings.Cylinder headsRocker arms and camshaftsValve cottersValve spring

4-22VALVE AND VALVE SPRINGSENGNOTE:NOTE:EAS00237REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.Before r

4-23VALVE AND VALVE SPRINGSENGNOTE:NOTE:Out of specification  Replace the valveguide.Valve-stem-to-valve-guideclearanceIntake 0.010  0.037 mm<Lim

4-24VALVE AND VALVE SPRINGSENGNOTE:5. Measure: valve margin thickness aOut of specification  Replace the valve.Valve margin thickness limit0.8 mm6.

1-5SPECIAL TOOLSGENINFOEB102001SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appr

4-25VALVE AND VALVE SPRINGSENGNOTE:CAUTION:NOTE:4. Lap: valve face valve seatAfter replacing the cylinder head or replacingthe valve and valve guide

4-26VALVE AND VALVE SPRINGSENGEAS00241CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure: valve spring f

4-27VALVE AND VALVE SPRINGSENGNOTE:NOTE:CAUTION:Install the valve spring with the larger pitch afacing up.bSmaller pitch4. Install: valve cottersInst

4-28Remove the parts in the order listed.Refer to “CYLINDER HEADS”.The “5EL” mark should face towards thecylinder head.For installation, reverse the r

4-29CYLINDERS AND PISTONSENGCAUTION:NOTE:NOTE:EAS00254REMOVING THE PISTONSThe following procedure applies to all of the pis-tons.1. Remove: piston pi

4-30CYLINDER AND PISTONSENGNOTE:X + Y2C =2. Measure: piston-to-cylinder clearancea. Measure cylinder bore “C” with the cylinderbore gauge.a40 mm from

4-31CYLINDER AND PISTONSENGNOTE:NOTE:NOTE:EB404410CHECKING THE PISTON RINGS1. Measure: piston ring side clearanceOut of specification  Replace the p

4-32CYLINDERS AND PISTONSENGNOTE:EAS00266CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. CHECK: piston pinBlue

4-33CYLINDERS AND PISTONSENGNOTE:NOTE:2. Install: piston 1 piston pin 2 piston pin clip (New) 3 Apply engine oil onto the piston pin. Make sure t

4-34Order Job name/Part name Q’ty Remarks123456789Removing the timing gearsCylinder headsCylindersClutch assemblyPrimary drive gear nutTiming drive ge

1-6SPECIAL TOOLSGENINFOTool No. Tool name/How to use IllustrationT-handle90890-01326Holder90890-01460T-handle/damper rod holderThese tools are needed

4-35TIMING GEARSENGNOTE:NOTE:NOTE:REMOVING THE TIMING DRIVE GEARFront cylinder1. Straighten the lock washer tab.2. Remove: primary drive gear nut 1Wh

4-36TIMING GEARSENGNOTE:NOTE:10 Nm (1.0 mkg)NOTE:EAS00292CHECKING THE PRIMARY DRIVE1. Check: primary drive gear primary driven gearDamage/wear  Re

4-37NOTE:TIMING GEARSENG110 Nm (11.0 mkg)NOTE:NOTE:Front cylinder1. Install:(Front cylinder) springs 1 dowel pins timing drive gear 2 Insert the

4-38Order Job name/Part name Q’ty Remarks12345Removing the right clutch coverEngine oilMuffler assemblyExhaust pipesBrake pedal/FootrestRear brake mas

4-39Order Job name/Part name Q’ty Remarks67Dowel pinsCrankcase cover gasket21For installation, reverse the removalprocedure.New10 Nm (1.0 mkg)CLUTCHE

4-40Order Job name/Part name Q’ty Remarks1234567891011121314Removing the clutchClutch spring boltsClutch spring plateClutch springClutch spring seatCl

4-41Order Job name/Part name Q’ty Remarks151617Thrust washerClutch housingLong clutch push rod111For installation, reverse the removalprocedure.70 Nm

4-42CLUTCHENGNOTE:NOTE:NOTE:EAS00278REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen: clutch boss nut 1While holding the clutch boss 2

4-43CLUTCHENGNOTE:EAS00286CHECKING THE PRESSURE PLATE1. Check: pressure plateCracks/damage  Replace. bearingDamage/wear  Replace.EAS00285CHECKING

4-44CLUTCHENGNOTE:EAS00281CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check: clutch plateDamage  Replace

1-7SPECIAL TOOLSGENINFOTool No. Tool name/How to use Illustration90890-03141Timing lightThis tool is necessary for checking ignitiontiming.90890-04014

4-45CLUTCHENGNOTE:70 Nm (7.0 mkg)NOTE:EAS00295INSTALLING THE CLUTCH1. Install: clutch housing 1 If the wire circlip 2 has been removed, care-fully

CLUTCHENG4-46NOTE:NOTE:Make sure that the semicircular slot a in thefriction plate is aligned with the mark b on theclutch housing.7. Install: clutch

4-4710 Nm (1.0 mkg)Order Job name/Part name Q’ty Remarks12345Removing the startor coilEngine oilLeft side coverAC magneto lead/pickup lead/sidestand

4-48Order Job name/Part name Q’ty Remarks123456789Removing the generator and starterclutch.RotorDowel pinsSpringsWoodruff keyShaftStarter idler gearCi

4-49GENERATOR AND STARTER CLUTCHENGNOTE:EAS00347REMOVING THE GENERATOR1. Remove: camshaft sprocket cover tappet coversRefer to “REAR CYLINDER HEAD.

4-50GENERATOR AND STARTER CLUTCHENGNOTE: Remove the rotor by pushing back the rotor,the flywheel puller 2 and the adapter 3. Install the flywheel pu

4-51GENERATOR AND STARTER CLUTCHENGNOTE:NOTE:NOTE:175 Nm (17.5 mkg)NOTE:INSTALLING THE GENERATOR1. Install: starter clutch assemblyAlign the hole a

4-52GENERATOR AND STARTER CLUTCHENG4. Check: TDC on the compression strokeIf the marks do not align  Adjust.a. Align the “T” mark a with the station

4-53Order Job name/Part name Q’ty Remarks123456Removing the shift shaft and stopperlever.Engine oilLeft crankcase coverRotor assemblyShift shaftCircli

4-54SHIFT SHAFTENGNOTE:EAS00328CHECKING THE SHIFT SHAFT1. Check: shift shaft 1 shift lever 2Bends/damage/wear  Replace. shift lever spring 3Damage

1-8SPECIAL TOOLSGENINFOTool No. Tool name/How to use Illustration90890-04090Damper spring compressorThis tool is needed when removing or instal-ling t

4-55Order Job name/Part name Q’ty Remarks12345Removing the oil pumpRotor assemblyCrankcase cover (right)Driven gear coverDriven gear (oil pump)/Oil pu

4-56OIL PUMPENGOrder Job name/Part name Q’ty RemarksDisassembling the oil pumpOil pump coverOil pump bodyOil pump rotor (inner)Oil pump rotor (outer)P

4-57OIL PUMPENGEAS00364CHECKING THE OIL PUMP1. Check: oil pump driven gear oil pump body oil pump driven gear cover Cracks/damage/wear  Replace t

4-58OIL PUMPENG10 Nm (1.0 mkg)CAUTION:NOTE:EAS00376ASSEMBLING THE OIL PUMP1. Assemble: oil pumpAfter tightening the bolts, make sure that theoil pum

4-59Order Job name/Part name Q’ty Remarks123456Removing the crankshaft assemblyEngine assemblyCylinder headCylinder and pistonClutch assemblyAC magnet

Order Job name/Part name Q’ty Remarks12345678Removing the crankshaft andconnecting rodCrankshaft assemblyOil pump drive sprocketBearingNuts (connectin

4-61ABCRANKSHAFT AND CONNECTING RODSENGNOTE:NOTE:CAUTION:EAS00386DISASSEMBLING THE CRANKCASE1. Remove: crankcase bolts Loosen each bolt 1/4 of a tur

4-62CRANKSHAFT AND CONNECTING RODSENGNOTE:NOTE:EB412111REMOVING THE CRANKSHAFT1. Remove: crankshaft assembly 1 Remove the crankshaft assembly with t

4-63CRANKSHAFT AND CONNECTING RODSENGCAUTION:NOTE:NOTE:CAUTION:Do not interchange the big end bearings andconnecting rods. To obtain the correctcranks

CRANKSHAFT AND CONNECTING RODSENG4-64NOTE:Refer to “INSTALLING THE CONNECTINGRODS”.Connecting rod nut48 Nm (4.8 mkg)f. Remove the connecting rod and

SPEC 2

4-65CRANKSHAFT AND CONNECTING RODSENGNOTE:NOTE:NOTE:48 Nm (4.8 mkg)NOTE:EB412440CHECKING THE BEARINGS AND OILSEALS1. Check: bearingsClean and lubric

CRANKSHAFT AND CONNECTING RODSENG4-66CAUTION:NOTE:NOTE: When tightening the nuts be sure to use anF-type torque wrench. Without pausing tighten to f

4-67CRANKSHAFT AND CONNECTING RODSENGNOTE:38.5Nm (3.85 mkg)10 Nm (1.0 mkg)NOTE:13101417191516854679,NOTE:2. Tighten: crankcase bolts(follow the pro

4-68Order Job name/Part name Q’ty Remarks12345678Transmission removalCrankcase separationGuide barShift fork 1 “R”Shift fork 2 “C”Shift fork 3 “L”Shif

4-69TRANSMISSIONENGWARNINGEAS00421CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks and related components.1. Check: s

4-70TRANSMISSIONENGEAS00424CHECKING THE TRANSMISSION1. Measure: main axle runout(with a centering device and dial gauge)Out of specification  Replac

4-71TRANSMISSIONENGNOTE:NOTE:WARNINGNOTE:EAS00430INSTALLING THE TRANSMISSION1. Install: shift drum assemblyTurn the shift drum assembly to the neutra

4-72Order Job name/Part name Q’ty Remarks123456789Removing the middle drive piniongearSepalate the crankcaseBearing retainerSpring retainersSpring sea

4-73Order Job name/Part name Q’ty Remarks123456789Removing the middle drivenpinion gear.BoltsCirclipsBearingsDriven yokeNutDrive yokeBearing housing/O

Order Job name/Part name Q’ty Remarks1011121314Collapsible collarMiddle driven shaftOil sealBearingBearing1111For installation, reverse the removalpro

ESPECCHAPTER 2.SPECIFICATIONSGENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATION

4-75MIDDLE GEARENGNOTE:REMOVING THE MIDDLE DRIVE SHAFT AS-SEMBLY1. Remove: bearing retainer middle drive shaft assemblya. Straighten the thread on t

4-76MIDDLE GEARENGNOTE:NOTE:REMOVING THE MIDDLE DRIVEN SHAFTASSEMBLY1. Remove: universal jointa. Remove the circlips 1.b. Place the universal joint i

4-77MIDDLE GEARENG110 Nm (11.0 mkg)NOTE:NOTE:3. Check: O-ring oil sealDamage  Replace the defective part(-s).4. Check: universal joint movementRo

4-78MIDDLE GEARENGNOTE:WARNINGNOTE:NOTE:25 Nm (2.5 mkg)ASSEMBLING THE MIDDLE DRIVEN SHAFTASSEMBLYThe following points are critical when assem-bling t

4-79MIDDLE GEARENG2. Install: shim middle drive shaft assembly3. Install: bearing retainerInstall steps: Attach the bearing retainer wrench 1.Bear

4-80MIDDLE GEARENGCAUTION:CAUTION:CAUTION:NOTE:Do not over tighten the middle driven piniongear nut. If over tighten the middle drivenpinion gear nut,

4-81MIDDLE GEARENGNOTE:NOTE:NOTE:EAS00452ALIGNING THE MIDDLE GEARAligning the middle gear is necessary when anyof the following parts are replaced: C

4-82MIDDLE GEARENGMiddle drive pinion gear shim:Thickness (mm) 0.10, 0.15, 0.20Hundredths Rounded value0, 1, 2 03, 4, 5, 6, 57, 8, 9 10Shims are suppl

CARB 5

CARBCHAPTER 5CARBURETIONCARBURETOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAR

2-1GENERAL SPECIFICATIONSSPECTemp. CSPECIFICATIONSGENERAL SPECIFICATIONSItemStandardModel code: XVS1100: 5EL1 (For Europe)5EL2 (For D, A, FIN)5EL3 (F

5-1Order Job name/Part name Q’ty Remarks1234567891011Removing the carburetorsFuel tankAir filter case assemblyAir ductsCylinder head breather hoseAir

5-2Order Job name/Part name Q’ty RemarksDisassembling the carburetor.Carburetor heater leadsCarburetor heatersFloat chamber/gasketFloatNeedle valve se

5-3Order Job name/Part name Q’ty RemarksDiaphragm setThrottle position sensorPilot screwMain air jetPilot air jet 1Pilot air jet 2Throttle stop screw

5-4CARBURETORSCARBEB600031CHECKING THE CARBURETORSThe following procedure applies to all of the car-buretors.1. Check: carburetor body float chamber

5-5CARBURETORCARB8. Check: vacuum chamber cover 1 piston valve spring 2 plastic cap 3 O-ring 4 spring 5Cracks/damage  Replace.9. Check: jet nee

5-6CARBURETORCARBCAUTION:NOTE:NOTE:EB600042ASSEMBLING THE CARBURETORSThe following procedure applies to both of thecarburetors. Before assembling the

5-7CARBURETORCARBNOTE:EB600063MEASURING AND ADJUSTING THE FUELLEVEL1. Measure: fuel level aOut of specification  Adjust.Fuel level (above the line o

5-8CARBURETORCARBNOTE:EB600071CHECKING AND ADJUSTING THETHROTTLE POSITION SENSOR Before adjusting the throttle position sensor,the engine idling spee

5-9CARBURETORCARBNOTE:Closed-throttle resistance 0.56  0.84 kΩ at 20°C(yellow – black)c. Tighten the throttle position sensor screws.Remove the pocke

5-10VEIW 1VEIW 2AIR INDUCTION SYSTEM (AIS)CARBEB601000AIR INDUCTION SYSTEM (AIS)AIR INDUTIONThis system burns the unburned exhaust gasesby injecting f

EB000000XVS1100 (L)SERVICE MANUAL1998 by Yamaha Motor Co.,Ltd.First edition, October 1998All rights reserved. Any reproduction orunauthorized use wit

2-2GENERAL SPECIFICATIONSSPECItem StandardCarburetor:Type/quantityManufacturerBSR37/2MIKUNISpark plug:TypeManufacturerSpark plug gapBPR7ES/W22EPR–UNGK

5-11Reed valveAir filterOrificeCarburetor joint (near cylinder)To the front cylinder headTo the rear cylinder headTo the orificeTo the carburetor join

CARB

CHAS 6

CHASCHAPTER 6CHASSISFRONT WHEEL AND BRAKE DISCS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 6-3. . . . . . . .

CHASHANDLEBAR 6-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR 6-54. . . .

6-1Order Job name/Part name Q’ty Remarks123456Removing the front wheel and brakediscsBrake calipersFront wheel axle pinch boltFront wheel axleFront wh

FRONT WHEEL AND BRAKE DISCSCHASOrder Job name/Part name Q’ty RemarksDisassembling the front wheelOil sealsBearingsCollar221Disassemble the parts in th

6-3FRONT WHEEL AND BRAKE DISCSCHASWARNINGNOTE:NOTE:NOTE:WARNINGEAS00521REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.Securely sup

FRONT WHEEL AND BRAKE DISCSCHAS6-4NOTE:3 Nm (0.3mkg)NOTE:WARNINGA tight spoke will emit a clear, ringing tone, aloose spoke will sound flat.4. Tighte

6-5FRONT WHEEL AND BRAKE DISCSCHASNOTE:CAUTION:NOTE:a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-headscrewdriver.

2-3GENERAL SPECIFICATIONSSPECItem StandardSuspension:Front suspensionRear suspensionTelescopic forkSwingarm (link suspension)Shock absorber:Front shoc

FRONT WHEEL AND BRAKE DISCSCHAS6-6NOTE:c. Remove the brake caliper.d. Hold the dial gauge at a right angle againstthe brake disc surface.e. Measure th

6-7FRONT WHEEL AND BRAKE DISCSCHASNOTE:59 Nm (5.9 mkg)20 Nm (2.0 mkg)CAUTION:40 Nm (4.0 mkg)WARNINGEAS00544INSTALLING THE FRONT WHEELThe following

6-8FRONT WHEEL AND BRAKE DISCSCHASNOTE:NOTE:NOTE:EAS00549ADJUSTING THE FRONT WHEEL STATICBALANCE After replacing the tire, wheel or both, the frontwh

6-9FRONT WHEEL AND BRAKE DISCSCHAS4. Check: front wheel static balancea. Turn the front wheel and make sure that itstays at each position shown.b. If

6-10Order Job name/Part name Q’ty Remarks1234Removing the muffler and brakecaliperMufflerMuffler stayBrake hose holderBrake caliper1111Remove the part

6-11Order Job name/Part name Q’ty Remarks1234567Removing the rear wheelFinal gear oilFuel tank and seatsRear fender assemblyBrake caliper bracket bolt

6-12REAR WHEEL AND BRAKE DISCCHASOrder Job name/Part name Q’ty RemarksRear wheel disassemblyDisassembling the rear wheelLock washersClutch hubDampersO

6-13REAR WHEEL AND BRAKE DISCCHASWARNINGNOTE:NOTE:EAS00562REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.Securely support the motor

6-14REAR WHEEL AND BRAKE DISCCHASNOTE:EAS00567CHECKING THE REAR WHEEL DRIVE HUB1. Check: rear wheel drive hubCracks/damage  Replace. rear wheel dri

6-15REAR WHEEL AND BRAKE DISCCHASNOTE:f. Tighten the rear axle holder with specifiedtorque.Rear axle end nut23 Nm (2.3 mkg)g. Tighten the rear brake

2-4MAINTENANCE SPECIFICATIONSSPECMAINTENANCE SPECIFICATIONSENGINEItemStandard LimitCylinder head:Warp limitSSS 0.03 mmCylinder:Bore sizeMeasuring poin

6-16Order Job name/Part name Q’ty Remarks1234Removing the front brake padsRetaining boltBrake caliperBrake padsPad spring1121Remove the parts in the o

6-17Order Job name/Part name Q’ty Remarks1234576Removing the rear brake padsMufflerMuffler stayBrake hose holderCaliperCoverClipsPad pinsPad springBra

6-18FRONT AND REAR BRAKESCHASCAUTION:NOTE:EAS00579Disc brake components rarely require dis-assembly.Therefore, always follow these preventivemeasures:

6-19FRONT AND REAR BRAKESCHASNOTE:23 Nm (2.3 mkg)2. Remove: brake pads 1(along with the brake pad shims)3. Measure: brake pad wear limit aOut of sp

6-20FRONT AND REAR BRAKESCHASNOTE:6. Check: brake fluid levelBelow the minimum lever mark a  Add therecommended brake fluid to the proper level.Refe

6-21FRONT AND REAR BRAKESCHASNOTE:NOTE:40 Nm (4.0 mkg)5. Install: brake pad shims(onto the brake pads) brake pads brake pad springAlways install n

6-22Order Job name/Part name Q’ty Remarks12345678Removing the front brake mastercylinder.Brake fluidRear view mirror (right)Brake lever/compression sp

6-23Order Job name/Part name Q’ty RemarksDisassembling the front brakemaster cylinderDust bootCirclipMaster cylinder cupSpring1111Remove the parts in

6-24Order Job name/Part name Q’ty Remarks12345678910Removing the rear brake mastercylinderBrake fluidBrake switch connectorCotter pin/washerPinBoltsBr

6-25Order Job name/Part name Q’ty RemarksDisassembling the rear brake mastercylinderMaster cylinder bootCirclipMaster cylinder cupSpring1111Disassembl

2-5Margin ThicknessHead Dia Face width Seat WidthMAINTENANCE SPECIFICATIONSSPECItem Standard LimitTiming chain:Timing chain type/No. of linksTiming ch

6-26FRONT AND REAR BRAKESCHASNOTE:NOTE:NOTE:NOTE:EAS00588REMOVING THE FRONT BRAKE MASTERCYLINDERBefore removing the front brake master cylin-der, drai

6-27A BA BA BFRONT AND REAR BRAKESCHASEAS00592CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to the both ofthe brake

6-28FRONT AND REAR BRAKESCHASWARNING10 Nm (1.0 mkg)NOTE:30 Nm (3.0 mkg)WARNINGNOTE:EAS00598INSTALLING THE FRONT BRAKE MASTERCYLINDER Before install

6-29FRONT AND REAR BRAKESCHASWARNINGCAUTION: Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing

6-30FRONT AND REAR BRAKESCHASWARNINGCAUTION:WARNINGCAUTION:EAS00610INSTALLING THE REAR BRAKE MASTERCYLINDER1. Install: copper washers (New) brake ho

6-31FRONT AND REAR BRAKESCHAS5. Adjust: brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.Brake pedal position (below thetop of t

6-32Order Job name/Part name Q’ty Remarks123456Removing the front brake calipersBrake fluidBrake hose holderUnion boltCopper washersBrake hoseRetainin

6-33Order Job name/Part name Q’ty RemarksDisassembling the front brakecalipersPad springBrake caliper pistonsDust sealsCaliper piston sealsBleed screw

6-34Order Job name/Part name Q’ty Remarks12345Removing the rear brake caliperMufflerMuffler stayBrake fluidBrake hose holderUnion boltCopper washersBr

6-35Order Job name/Part name Q’ty RemarksDisassembling the rear brake caliperCoverClipsPad pinsPad springBrake padsCaliper pistonsDust sealsPiston sea

2-6MAINTENANCE SPECIFICATIONSSPECItem Standard LimitStem runout limitValve seat width INEXSSS1.2 X 1.4 mm1.2 X 1.4 mm0.03 mm2.0 mm2.0 mmValve spring:F

6-36FRONT AND REAR BRAKESCHASNOTE:NOTE:WARNINGNOTE:EAS00624REMOVING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipe

6-37FRONT AND REAR BRAKESCHASNOTE:WARNING1. Remove: union bolt 1 copper wachers 2 brake hosePut the end of the brake hose into a containerand pump

6-38BAFRONT AND REAR BRAKESCHASWARNINGWARNING1. Check: brake caliper pistons 1Rust/scratches/wear  Replace the brakecaliper piston assembly. brake

6-39FRONT AND REAR BRAKESCHAS30 Nm (3.0 mkg)WARNINGCAUTION:23 Nm (2.3 mkg)WARNING1. Install: brake caliper 1(temporarily) copper washers (New) 2

FRONT AND REAR BRAKESCHAS6-40CAUTION:WARNINGBrake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid

6-41FRONT AND REAR BRAKESCHAS30 Nm (3.0 mkg)WARNINGCAUTION:40 Nm (4.0 mkg)WARNING1. Install: brake caliper 1(temporarily) copper washers New brak

FRONT AND REAR BRAKESCHAS6-42CAUTION:NOTE:Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid im

6-43Order Job name/Part name Q’ty Remarks12345678Removing the front forkFront wheelBrake hose holdersBrake caliper assemblyFront fenderTurn signal lig

Order Job name/Part name Q’ty RemarksDisassembling the front forkCap boltO-ringSpacerSpring seatFork springDust sealOil seal clipDamper rod boltCopper

6-45Order Job name/Part name Q’ty RemarksSeal spacerOuter tube bushingInner tube/inner tube bushingOil lock pieceOuter tube111/111For assembly, revers

2-7MAINTENANCE SPECIFICATIONSSPEC1 2 3 4 5Item Standard LimitPiston pin bore inside diameterPiston pin outside diameter22.004 X 22.015 mm21.991 X 22.0

6-46FRONT FORKCHASWARNINGNOTE:WARNINGCAUTION:EAS00649REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stan

6-47FRONT FORKCHASNOTE:NOTE:WARNING Do not remove the front fork leg protector fromthe outer tube. If the front fork leg protector must be removed,a

6-48FRONT FORKCHASCAUTION:WARNINGNOTE:WARNINGCAUTION:3. Check: damper rod 1Damage/wear  Replace.Obstruction  Blow out all of the oil pas-sages wit

6-49FRONT FORKCHAS30 Nm (3.0 mkg)NOTE:CAUTION:NOTE:NOTE:2. Lubricate: inner tube’s outer surfaceRecommended lubricantYamaha fork and shock oil10 W o

6-50FRONT FORKCHASCAUTION:NOTE:NOTE:7. Install: dust seal 1(with the fork seal driver weight)8. Fill: front fork leg(with the specified amount of th

6-51FRONT FORKCHASNOTE:NOTE:30 Nm (3.0 mkg)7 Nm (0.7 mkg)23 Nm (2.3 mkg)20 Nm (2.0m kg)WARNING Install the fork spring with its smaller pitch up-

6-52Order Job name/Part name Q’ty Remarks1234567891011Removing the handlebarPlastic locking tiesClutch cableClutch switch leadStarter cableHandlebar s

6-5328 Nm (2.8 mkg)10 Nm (1.0 mkg)32 Nm (3.2 mkg)Order Job name/Part name Q’ty Remarks1213141516Throttle grip assemblyHandlebar holders (upper)Hand

6-54HANDLEBARCHASWARNINGNOTE:WARNINGWARNINGEAS00666REMOVING THE HANDLEBAR1. Stand the motorcycle on a level surface.Securely support the motorcycle so

6-55HANDLEBARCHASWARNINGWARNING28 Nm (2.8 mkg)CAUTION:NOTE:a. Apply a light coat of rubber adhesive onto theleft end of the handlebar.b. Slide the ha

2-8MAINTENANCE SPECIFICATIONSSPECItem Standard LimitClutch:Friction plate thicknessQuantityClutch plate thicknessQuantityClutch plate thicknessQuantit

6-56HANDLEBARCHASWARNINGNOTE:NOTE:NOTE: Align the match marks b on the handlebarwith the upper surface of the lower handlebarholders.3. Install: thr

6-57HANDLEBARCHAS9. Adjust: clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.Clutch cable free play (at the endof th

6-58Order Job name/Part name Q’ty Remarks12345678Removing the lower bracketFront fork legsHandlebarHeadlight lens unitLeads (in the headlight body)Fro

6-59Order Job name/Part name Q’ty Remarks9101112131415Rubber washerLower ring nutBearing coverLower bracketBearing (upper)Rubber sealBearing (lower)11

6-60STEERING HEADCHASWARNINGNOTE:WARNINGEAS00677REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.Securely support the motorcycle s

6-61STEERING HEADCHASCAUTION:NOTE:a. Remove the bearing reces from the steeringhead pipe with a long rod 1 and hammer.b. Remove the bearing race from

6-62STEERING HEADCHASNOTE:NOTE:Temporarily tighten the steering stem nut.4. Install: front fork legsRefer to “FRONT FORK”Temporarily tighten the uppe

6-63Order Job name/Part name Q’ty Remarks1234Removing the right side cover andbattery box.SeatsMuffler assemblyBattery coverRight side coverBatteryBat

6-64Order Job name/Part name Q’ty Remarks1234567Removing the left side cover andtool boxTool box coverLeft side coverOwner’s tool kitConnector’sFuel h

6-65Order Job name/Part name Q’ty Remarks1234567Removing the rear shock absorberand swingarmRear wheelConnecting arm boltsConnecting armsRear shock ab

2-9MAINTENANCE SPECIFICATIONSSPECItem Standard LimitLubrication system:Oil filter typeOil pump typeTip clearance “A” or “B”Side clearanceRelief valve

6-66REAR SHOCK ABSORBER AND SWINGARMCHASWARNINGWARNINGEAS00687HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDERThis rear shock absorber and gas cylinde

6-67REAR SHOCK ABSORBER AND SWINGARMCHASWARNINGNOTE:CAUTION:NOTE:EAS00694REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level su

6-68REAR SHOCK ABSORBER AND SWINGARMCHASWARNINGNOTE:EAS00702REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.Securely support the motor

6-69REAR SHOCK ABSORBER AND SWINGARMCHASEAS00696CHECKING THE REAR SHOCK ABSORBERASSEMBLY AND GAS CYLINDER1. Check: rear shock absorber rodBends/damag

6-70REAR SHOCK ABSORBER AND SWINGARMCHASNOTE:CAUTION:EAS00698INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Install: swingarmRefer to “INSTALLING THE

6-71REAR SHOCK ABSORBER AND SWINGARMCHAS2. Install: relay arm left connecting arm right connecting armRear-shock-absorber-assemblylower nut 148 Nm

6-72SHAFT DRIVECHASNOTE:SHAFT DRIVEEAS00715TROUBLESHOOTINGThe following conditions may indicate damaged shaft drive components:ASymptoms B Possible ca

6-73SHAFT DRIVECHASWARNINGWARNINGInspection notes1. Investigate any unusual noises.The following noises may indicate a me-chanical defect:a. A rolling

6-74YESNONOYESYESNOPlace the motorcycle on a suitable stand sothat the front wheel is elevated and then spinthe front wheel. Is the wheel bearing dam-

6-75SHAFT DRIVECHASNOTE:NOTE:EAS00717CHECKING THE FINAL DRIVE OIL FORCONTAMINATION AND INSPECTING THESHAFT DRIVE FOR LEAKS1. Drain: final drive oil(f

2-10MAINTENANCE SPECIFICATIONSSPECItem StandardLubrication chart:

6-761.5 mm11 mm100 mma25 mm14 mmSHAFT DRIVECHASNOTE:EAS00719MEASURING THE RING GEAR BACKLASH1. Secure the final drive assembly in a vise.2. Remove: f

6-77SHAFT DRIVECHASNOTE:g. Rotate the final drive pinion gear 90.h. Reinstall the bolt, special tool, and dialgauge.i. Repeat steps (d) to (h) three

6-78SHAFT DRIVECHASRig gear shimsThickness (mm) 0.25, 0.30, 0.40Thrust washersThickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0b. If it is necessary to increase

6-79Order Job name/Part name Q’ty Remarks1234Removing the final drive assemblyand drive shaft.Rear wheel assemblyCollarDrive shaft assemblyFinal drive

6-80SHAFT DRIVECHASOrder Job name/Part name Q’ty RemarksDisassembling the final gear.Bolts (bearing housing)Nuts (bearing housing)Bearing housing/O-ri

6-81SHAFT DRIVECHASNOTE:CAUTION:WARNINGCAUTION:EAS00724DISASSEMBLING THE FINAL DRIVE AS-SEMBLY1. Remove: ring gear bearing housing nuts ring gear be

6-82SHAFT DRIVECHASNOTE:EAS06725REMOVING AND INSTALLING THE RINGGEAR BEARINGS1. Remove: collar 1 oil seal 2 bearing 3(with an appropriate press too

6-83SHAFT DRIVECHASNOTE:NOTE:5. Install: collar 1 oil seal 2New bearing(with an appropriate press tool 3 and press)The bearing can be reused, but Y

6-84SHAFT DRIVECHASFinal drive pinion gear shimThickness (mm) 0.30, 0.40, 0.50Where:a = a numeral (positive or negative) on the ringgear, to be divide

6-85SHAFT DRIVECHASRing gear shimThickness (mm) 0.30, 0.40, 0.50115Nm (11.5 mkg)CAUTION:f = the ring gear bearing thickness constantRing gear bearing

Left crankcase Right crankcaseMAINTENANCE SPECIFICATIONSSPEC2-11Cylinder head tightening sequence:Crankcase tightening sequence:

SHAFT DRIVECHAS6-86130 Nm (13.0 mkg)CAUTION:NOTE:Bearing retainer wrench90890-040773. Install: gear coupling self-locking nut(with the special tool

6-87SHAFT DRIVECHASThrust washerThickness (mm) 1.2, 1.4, 1.6, 1.8, 2.0g. If the ring-gear-to-thrust-washer clearance isout of specification, select th

6-88SHAFT DRIVECHAS42 Nm (4.3 mkg)4. Tighten: final bearing housing nuts5. Install: rear wheel assemblyRefer to “REAR WHEEL AND BRAKEDISC”.

ELEC 7–+

ELECCHAPTER 7ELECTRICALELECTRICAL COMPONENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCHES 7-2. . . . . . . . . . .

ELECCARBURETOR HEATER SYSTEM 7-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 7-44. . . . . . . . . . . . . . . . . . .

7-1ELECTRICAL COMPONENTSELEC1 Main switch2 Thermo switch3 Flasher relay4 Starting circuit cut off relay5 Ignition coil6 Starter relay7 Fuse8 Igniter u

7-2BBSWITCHESELECCAUTION:NOTE:NOTE:EAS0010SWITCHESCHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity

7-3*1*2CHECKING THE SWITCHESELECEAS00731CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between

7-49 Engine stop switch10 Start switch11 Fuse12 Rear brake switch13 Sidestand switch14 Neutral switch*1: for Europe*2: for AUS1 Clutch switch2 Pass sw

NOTE:CAUTION:EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanics. It i

2-12MAINTENANCE SPECIFICATIONSSPECTightening torquesPart to be tightenedPart nameThreadsizeQ’tyTighteningtorqueRemarksgsizeyNm mSkgCylinder headCylind

7-5CHECKING THE BULBS AND BULB SOCKETSELECEAS00732CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connecti

CHECKING THE BULBS AND BULB SOCKETSELEC7-6WARNINGCAUTION:NOTE:Since the headlight bulb gets extremely hot,keep flammable products and your handsaway f

7-7CHECKING THE BULBS AND BULB SOCKETSELECNOTE:CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. C

7-81456781316171829Pickup coilMain switchAlam system (option)Ignition fuseBatteryMain fuseStarting circuit cut-off relayIgnitor unitIgnition coilSpark

7-9IGNITION SYSTEMELEC2. Battery Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.Min. open-circuit voltag

7-104. Ignition spark gapThe following procedure applies to all of thespark plugs. Disconnect the spark plug cap from thespark plug. Connect the ign

7-11IGNITION SYSTEMELECSecondary coil resistance10.7 X 14.5 kΩ 20 C Is the ignition coil OK?YESReplace the ignitioncoil.NOEAS007487. Pickup coil res

7-12IGNITION SYSTEMELEC12. DiodeS Remove the diode from the wire harness.S Check for continuity as follows:14. WiringS Check the entire ignition syste

7-134567891013202937Main switchAlarm system (option)Ignition fuseBatteryMain fuseStarter relayStarter motorStarting circuit cut off relayNeutral switc

7-14ELECTRIC STARTING SYSTEMELECEB803010STARTING CIRCUIT OPERATIONThe starting circuit on this model consists of thestarter motor, starter relay, and

2-13MAINTENANCE SPECIFICATIONSSPECPart to be tightened Part nameThreadsizeQ’tyTighteningtorqueRemarksgsizeyNm mSkgClutch springClutch adjusterClutch b

7-15ELECTRIC STARTING SYSTEMELEC2. Battery Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.Open-circuit v

7-164. Starting circuit cutoff relay Disconnect the relay unit from the coupler. Connect the pocket tester (Ω  1) and bat-tery (12V) to the relay u

7-17YESReplace the starterrelay.NOBattery positive terminal  red/whiteBattery negative terminal  blue2EAS00750 Check the engine stop switch for con

7-18EAS00766NOThe starting systemcircuit is OK.YESYESReplace the righthandlebar switch.NOProperly connect orrepair the startingsystem’s wiring.12. Sta

121234567891011Order Job name/Part name Q’ty RemarksRemoving the starter motorStarter motor leadStarter motor assemblyDisassembling the starter motorC

7-20ELECTRIC STARTING SYSTEMELECNOTE:EAS00769Checking the starter motor1. Check: commutatorDirt  Clean with 600 grit sandpaper.2. Measure: commutat

7-21ELECTRIC STARTING SYSTEMELECNOTE:NOTE:5. Measure: brush length aOut of specification  Replace the brushesas a set.Min. brush length5 mm6. Measur

7-22ELECTRIC STARTING SYSTEMELECNOTE:3. Install: Starter motor rear cover 1Align the match marks a on the rear cover withthe match marks b on the fro

7-23CHARGING SYSTEMELECAC magneto (stator coil)Rectifier/regulatorBatteryMain fuse2378EB804000CHARGING SYSTEMCIRCUIT DIAGRAM

CHARGING SYSTEMELEC2. Battery Check the condition of the battery.Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.Open-circuit voltage12.8 V

2-14MAINTENANCE SPECIFICATIONSSPECCHASSISItemStandard LimitSteering system:Steering bearing typeAngular bearing SSSFront suspension:Front fork travelF

7-25NOThe charging circuitis OK.YESNOTE:Make sure that the battery is fully charged. Is the charging voltage within specification?EAS007764. Stator c

LIGHTING SYSTEMELEC7-264946478252748445052Auxiliary lightPass switchMain switchBatteryMain fuseMeter lightHigh beam indicatorHeadlightDimmer switchTai

7-27LIGHTING SYSTEMELECOpen-circuit voltage12.8 V or more at 20CYESReplace the fuse(-s).NOYES Clean the batteryterminals. Recharge or re-place the

7-28YG Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK?YESThe dimmer switch isfaulty. Replace thele

7-29 Set the main switch to “ON”. Set the light switch to “ ”. Set the dimmer switch to “ ” or “ ”. Measure the voltage (12 V) of yellow

7-302. Voltage Connect the pocket tester (DC 20 V) to thetail/brake light coupler (wire harness side) asshown.Tester positive probe  blue Tester neg

7-31SIGNAL SYSTEMELECEB806000SIGNAL SYSTEMCIRCUIT DIAGRAM

7-32SIGNAL SYSTEMELEC4Main switch6Ignition fuse7Battery8Main fuse11Oil level gauge12Oil lamp relay20Neutral switch22Oil warning light24Turn signal ind

7-33SIGNALING SYSTEMELECOpen-circuit voltage12.8 V or more at 20CYESReplace the fuse(-s).NOYES Clean the batteryterminals. Recharge or re-place the

7-34SIGNALING SYSTEMELECReplace the left han-dlebar switch.NO1. Horn switch Check the forn switch for continuity.Refer to “CHECKING THE SWITCHES”. I

2-15MAINTENANCE SPECIFICATIONSSPECItem Standard LimitFront brake:TypeDisc outside diameter thicknessDisc deflection limitPad thickness innerPad thic

7-35SIGNALING SYSTEMELECReplace the tail/brake lightbulb, sock-et or both.NO1. Tail/brake light bulb and socket Check the tail/brake light bulb and s

7-36Turn signal lightTurn signal indicator lightReplace the left han-dlebar switch.NO2. Turn signal switch Check the turn signal for continuity.Refer

7-37Tester positive probe  brown Tester negative probe  sky blueReplace the neutralindicator light bulb,socket or both.NOYESThe wiring circuitfrom t

7-38 Set the main switch to “ON”. Measure the voltage (12 V) of brown andblack/red at the meter assembly coupler. Is the voltage within specifi

7-39FUEL PUMP SYSTEMELEC467813141638Main switchIgnition fuseBatteryMain fuseStarting circuit cutoff relayFuel pumpIgnitor unitEngine stop switchEB8080

7-40FUEL PUMP SYSTEMELEC1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pumpEB808010FUEL PUM

7-41FUEL PUMP SYSTEMELEC2. Battery Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.Open-circuit voltage12

7-42Tester (+) lead  Blue/Black terminal Tester (–) lead  Black terminalYESReplace the startingcircuit cutoff relay.NOBattery (+) terminal Red/Bla

7-43FUEL PUMP SYSTEMELECWARNINGEB808030FUEL PUMP TESTGasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosi

7-444782054555657Main switchBatteryMain fuseNeutral switchCarburetor heater fuseThermo switchCarburetor heater relayCarburetor heater 158Carburetor he

2-16MAINTENANCE SPECIFICATIONSSPECTightening torquesPart to be tightenedThread sizeTighteningtorqueRemarksgNm mSkgUpper bracket and inner tubeLower br

7-452. Battery Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.Open-circuit voltage12.8 V or more at 20C

7-46CARBURETOR HEATER SYSTEMELECYESReplace the carbure-tor heater relay.NOBattery (+) terminal  Brown/Yellow terminal Battery (–) terminal  Sky blue

7-47CARBURETOR HEATER SYSTEMELEC7. Carburetor heater Remove the carburetor heater from the car-buretor body. Connect the pocket tester to the carbur

7-48Light onLight off1 Light on (seconds) 0.5 seconds. . . . . 2 Light off (seconds) 0.5 seconds. . . . . 3 Number of blinks Fault code. . . . . .

7-49Repair or replace thewire harness.NO1. Wire harness Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK?YES

7-50YESReplace the speedsensor.NO Set the main switch to “ON”. Turn the rear wheel slowly. Check the tester voltage (0V - 5V - 0V). Is the speed s

TRBLSHTG 8

TRBLSHTGCHAPTER 8.TROUBLESHOOTINGSTARTING FAILURE/HARD STARTING 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-1. . . . . . . .

8-1STARTING FAILURE/HARD STARTINGTRBLSHTGNOTE:Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in a

8-2STARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCETRBLSHTGPiston and piston ring Improperly installe

2-17MAINTENANCE SPECIFICATIONSSPECNOTE:Part to be tightenedThreadsizeTighteningtorqueRemarksgsizeNm mSkgPassenger footrest and frameSidestand bracket

8-3FAULTY GEAR SHIFTING/CLUTCH SLIPPING/DRAGGINGTRBLSHTGTransmission Seized transmission gear Jammed impurities Incorrectly assembled transmissionS

8-4OVERHEATING/FAULTY BRAKE/FRONT FORK OILLEAKAGE AND FRONT FORK MALFUNCTIONTRBLSHTGCompression system Heavy carbon build-upEngine oil Improper oil

8-5UNSTABLE HANDLING/FAULTY LIGHTING AND SIGNAL SYSTEMSTRBLSHTGFront fork Uneven oil levels on both sides Uneven spring tension(uneven damping force

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . . L Blue. . . . . Lg Light green. . . . O Or

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . . L Blue. . . . . Lg Light green. . . . O Or

–13–A Clamp the throttle cables withthe holder. Position the end ofclip downword.B Route the rear brake switch leadunder the master cylinder reser-vor

2-18MAINTENANCE SPECIFICATIONSSPECELECTRICALItemStandard LimitVoltage: 12 VSSSIgnition system:Ignition timing (B.T.D.C.)Advancer type10_ at 1,000 r/mi

2-19MAINTENANCE SPECIFICATIONSSPECItem Standard LimitHorn:TypeQuantityModel/manufacturerMaximum amperagePlane type1YF-12/NIKKO3 ASSSSSSSSSSSSFlasher r

2-20GENERAL TORQUE SPECIFICATIONS/CONVERSION TABLESPECGENERAL TORQUESPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.

2-21LUBRICATION POINTS AND LUBRICANT TYPESSPECEB203000LUBRICATION POINTS AND LUBRICANT TYPESENGINELubrication pointSymbolOil seal lipsO-ringBearingCon

12635478EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbo

2-22LUBRICATION POINTS AND LUBRICANT TYPESSPECEB203010CHASSISLubrication pointSymbolSteering head pipe (upper/lower), bearingSteering head pipe, beari

2-23LUBRICATION DIAGRAMSSPEC4 Oil pump5 Drive axle6 Middle drive shaft1 Rocker arm shaft (intake)2 Rocker arm shaft (exhaust)3 Oil filterEB205000LUBRI

2-244 Middle drive shaft1 Oil pump2 Releaf valve3 Oil filterLUBRICATION DIAGRAMSSPEC

2-254 Middle drive shaft5 Drive axle6 Connecting rod big end1 Camshaft2 Crankshaft3 Main axleLUBRICATION DIAGRAMSSPEC

2-26CABLE ROUTINGSPEC19 Fuel hose (carburetor-fuel pump)20 Brake hose21 Heat protector22 Fuel breather hose (fuel tank-roll over valve) (for Californi

2-27F Push the wire harness insideof the tool box plate.G Route the sidestand leadinside of engine cover.H Position the all connectorsinside of the co

2-28M Fasten the AC magneto leadand sidestand switch lead with aplastic locking tie.N Fasten the alarm lead with aplastic band on the lid.J Fasten the

E2-2923 Handlebar switch lead (left)24 Throttle position sensor lead25 Carburetor heater lead26 Thermo switch lead27 Starting circuit cutoff relay28 D

E2-30H Fasten the rear brake switchlead and master cylinderreservoir hose to the downtube with a plastic locking tie.I Fasten the wire harness,starter

E2-31K To rear brake caliperL Clamp the handlebar switchlead (right) and main switchlead to the frame with a holder.M Arrange the throttle positionsen

24211815 16 17101213111413579248619 2022 2325EB003000ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on thetop right of each page and indica

E2-3220 Starter cable21 Fuel hose (fuel cock-fuel filter)22 Carburetor heater lead23 Thermo switch lead24 Igniter unit25 Taillight lead26 Throttle pos

E2-33J Fasten the wire harness with aband on the tool box plate.K Fasten the wire harness to theframe with a plastic locking tie.Position the locking

E2-34P Route the igniter lead throughthe igniter plate hole to the wireharness.Q Clamp the taillight lead withmud guard clamp.R Clamp the taillight le

E1 Throttle cable2 Starter cable3 Clutch cable4 Handlebar switch lead (left)5 Headlight lead6 Brake hoseA Route the handlebar switchlead (right) rear

INSPADJ 3

INSPADJCHAPTER 3PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPADJELECTRICAL SYSTEM 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-37.

3-1INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJEB300000PERIODIC INSPECTIONS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all inf

3-2PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJNOTE:EVERYNO. ITEM CHECKS AND MAINTENANCE JOBSInitial(1,000 km)6,000 kmor6 months(whichevercomes f

Order Job name/Part name Q’ty Remarks12345678Fuel tank and seats removalPassenger seatSeat bracketRider’s seatFuel hoseIgnitor plateMud guardMeter lea

INSPADJGENERAL INFORMATIONSPECIFICATIONSPERIODIC INSPECTION AND ADJUSTMENTSENGINE OVERHAULCARBURETIONCHASSISELECTRICALTROUBLESHOOTINGGENINFO1SPEC23ENG

3-4FUEL TANK AND SEATSINSPADJNOTE:NOTE:REMOVAL1. Remove: Ignitor plateTo remove the quick fastener, push its center inwith a screwdriver, then pull t

3-5ADJUSTING THE VALVE CLEARANCEINSPADJNOTE:EAS00047ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves. Valve cle

3-6ADJUSTING THE VALVE CLEARANCEINSPADJ6. Remove: tappet covers 17. Remove: camshaft sprocket cover (rear cylinder) 1 camshaft sprocket cover (fron

3-7ADJUSTING THE VALVE CLEARANCEINSPADJA Baba. Turn the crankshaft counterclockwise.b. When the piston is at TDC on the compres-sion stroke, align eit

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE CARBURETORSINSPADJ3-8NOTE:10 Nm (1.0 mkg)10 Nm (1.0 mkg)20 Nm (2.0 mkg)NOTE:NOTE:Locknut:27 Nm (2.7

3-9SYNCHRONIZING THE CARBURETORSINSPADJNOTE:5. Install: vacuum gauge 1 engine tachometer 2(to the spark plug lead of cyl. #2)Vacuum gauge:90890-0309

SYNCHRONIZING THE CARBURETORS/ADJUSTING THE ENGINE IDLING SPEEDINSPADJ3-10NOTE:abThrottle cable free play (at theflange of the throttle grip)4  6 mm1

3-11ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAYINSPADJNOTE:NOTE:abNOTE:6. Adjust: throttle cable free playRefer to “ADJU

3-12ADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGSINSPADJabWARNINGCAUTION:Handlebar sidea. Loosen the locknut 1.b. Turn the adjusting

3-13CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMINGINSPADJ20 Nm (2.0 mkg)NOTE:NOTE:7. Measure: spark plug gap a(with a wire gauge)Out of speci

GENINFO 1

3-14CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSUREINSPADJNOTE:NOTE:3. Check: ignition timinga. Start the engine, warm it up for seve

3-15MEASURING THE COMPRESSION PRESSUREINSPADJCAUTION:WARNINGNOTE:Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lat

3-16MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVELINSPADJ20 Nm (2.0 mkg)NOTE:CAUTION:7. Install: spark plug8. Connect: spark plug

3-17CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OILINSPADJNOTE:WARNING43 Nm (4.3 mkg)4. Start the engine, warm it up for several min-utes, and

3-18CHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAYINSPADJbcNOTE:QuantityTotal amount3.6 LWithout oil filter elementreplacement3.0 LWith

3-19ADJUSTING THE CLUTCH CABLE FREE PLAY/CLEANING THE AIR FILTER ELEMENTINSPADJ4. Adjust: clutch mechanismEngine sidea. Loosen the locknut 1.b. Turn

CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/CHECKING THE BREATHER HOSEINSPADJ3-20CAUTION:NOTE:CAUTION:Never oper

3-21CHECKING THE EXHAUST SYSTEMINSPADJEAS00100CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes, mufflers and ga

3-22ADJUSTING THE FRONT BRAKEINSPADJbcWARNINGCAUTION:EAS00108CHASSISADJUSTING THE FRONT BRAKE1. Check: brake lever free play aOut of specification 

3-23ADJUSTING THE REAR BRAKEINSPADJbcWARNINGWARNINGCAUTION:EAS00110ADJUSTING THE REAR BRAKE1. Check: brake pedal position(distance a from the top of

GENINFOCHAPTER 1.GENERAL INFORMATIONMOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION

3-24ABCHECKING THE BRAKE FLUID LEVELINSPADJNOTE:WARNINGCAUTION:NOTE:EAS00115CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.

3-25ADJUSTING THE REAR BRAKE LIGHT SWITCH/CHECKING THE BRAKE HOSESINSPADJNOTE:abEAS00128ADJUSTING THE REAR BRAKE LIGHTSWITCHThe rear brake light switc

3-26ABBLEEDING THE HYDRAULIC BRAKE SYSTEMINSPADJWARNINGNOTE:NOTE:EAS00134BLEEDING THE HYDRAULIC BRAKE SYS-TEMBleed the hydraulic brake system whenever

3-27BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDALINSPADJWARNINGNOTE:bch. Tighten the bleed screw and then release thebrake lever or br

3-28CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OILINSPADJNOTE:23 Nm (2.3 mkg)23 Nm (2.3 mkg)EAS00144CHECKING THE FINAL DRIVE OIL LE

3-29CHANGING THE FINAL DRIVE OIL/CHECKING AND ADJUSTING THE STEERING HEADINSPADJWARNINGNOTE:Quantity0.2 LRefer to “CHECKING THE FINAL DRIVE OILLEVEL”.

CHECKING AND ADJUSTING THE STEERING HEADINSPADJ3-30NOTE:WARNINGNOTE:110 Nm (11.0 mkg)20 Nm (2.0 mkg)b. Loosen the lower ring nut 4 and then tighteni

3-31CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYINSPADJWARNINGWARNINGCAUTION:EAS00149CHECKING THE FRONT FORK1. Stand the motorcy

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRESINSPADJ3-32abWARNINGRing nut wrench1HX-28135-00a. Turn the adjusting knob 1 in direction

3-33CHECKING THE TIRESINSPADJWARNINGWARNINGBasicweight: (withoil and fullfuel tank)274 kgMaximumload*:201 kgCold tirepressure:Front RearUp to 90 kgloa

1-1MOTORCYCLE IDENTIFICATIONGENINFOEB100000GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010VEHICLE IDENTIFICATION NUMBERThe vehicle identification

3-34CHECKING THE TIRESINSPADJWARNING Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace

3-35CHECKING THE TIRES/CHECKING AND TIGHTENING THE SPOKESINSPADJNOTE:NOTE:3 Nm (0.3 mkg)NOTE:For tires with a direction of rotation mark 1: Install

CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/LUBRICATINGTHE SIDESTAND/LUBRICATING THE REAR SUSPENSIONINSPADJ3-36WARNINGNOTE:E

3-37CHECKING AND CHARGING THE BATTERYINSPADJWARNINGWARNINGCAUTION:EB305020ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYBatteries generate explosi

CHECKING AND CHARGING THE BATTERYINSPADJVolt meterRelationship between open-circuit voltage and charging time at 20_COpen-circuit voltageCharging time

3-39Open-circuit voltage (V)Condition of charge in battery (%)Ambient temperature 20C18Open-circuit voltage (V)17161514131211100102030405060ChargingA

Measure the open-circuitvoltage prior to charging.Connect a charger andAMP meter to the batteryand start charging.Make sure the current ishigher than

3-41Measure the open-circuitvoltage prior to charging.Connect a charger andAMP meter to the batteryand start charging.NOTE:Voltage should be measured

CHECKING AND CHARGING THE BATTERYINSPADJ3-42CAUTION:CAUTION:6. Check: battery breather hose and battery ventObstruction  Clean.Damage  Replace.7. I

3-43CHECKING THE FUSESINSPADJCAUTION:NOTE:EAS00181CHECKING THE FUSESThe following procedure applies to all of thefuses.To avoid a short circuit, alway