Yamaha XVS1100 1999 User Manual [ru]

EB000000

XVS1100 (L)

SERVICE MANUAL

1998 by Yamaha Motor Co.,Ltd.

First edition, October 1998

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Y amaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Y amaha mo­torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.

Y amaha Motor Company , Ltd.is continually striving to improve all its models. Modifications and signifi­cant changes in specifications or procedures will be forwarded to all authorized Y amaha dealers and
will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.

CAUTION:

NOTE: A NOTE provides key information to make procedures easier or clearer.

A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

to

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title
2nd title

1

: This is the title of the chapter with its symbol in the upper right corner of each page.

2

: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper right corner of the page.
3rd title

3

: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

T o help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re­moval and disassembly section.

1. An easy-to-see exploded diagram

4

is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by
a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6

. The meanings of the symbol marks are given on the next page.

7

4. A job instruction chart

accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8

5. For jobs requiring more information, the step-by-step format supplements

are given in addition to

the exploded diagram and the job instruction chart.

1

2

5

4

7

6

3

8

EB003000

1

2

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the
top right of each page and indicate the subject of
each chapter.

General information

3

5

4

6

1

Specifications

2

Periodic inspections and adjustments

3

Engine

4

Cooling system

5

Carburetion

6

Chassis

7

Electrical

8

Troubleshooting

9

7

9

11

13

15 16 17

8

10

12

14

Illustrated symbols 10 to 17 are used to identify
the specifications appearing in the text.

10

Can be serviced with engine mounted

11

Filling fluid

12

Lubricant

13

Special tool

14

Torque

15

Wear limit, clearance

16

Engine speed

17

Ω, V, A

18

21

24

E004000

19 20

22 23

25

Illustrated symbols 18 to 23 in the exploded dia­grams indicate the types of lubricants and lu­brication points.

18

Apply engine oil

19

Apply gear oil

20

Apply molybdenum disulfide oil

21

Apply wheel bearing grease

22

Apply lightweight lithium-soap base grease

23

Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded dia­grams indicate where to apply locking agent

24

and when to install new parts 25.

24

Apply locking agent (LOCTITE)

25

Replace

CHAPTER TITLES

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND
ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

GEN

INFO

SPEC

INSP

ADJ

ENG

CARB

1
2
3
4
5

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CHAS

ELEC

TRBL

SHTG

6
7
8

GEN

INFO

1

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PREPARATION FOR REMOVAL PROCEDURES 1-2. . . . . . . . . . . . . . .

REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

MOTORCYCLE IDENTIFICATION

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number
into the right side of the steering head.

MODEL LABEL

The model label
information will be needed to order spare parts.

1

is affixed to the frame. This

GEN

INFO

1

is stamped

1-1

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCE­DURES

1. Remove all dirt, mud, dust and foreign mate­rial before removal and disassembly.

2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.

3. When disassembling the machine, 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 machine disassembly , clean all 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.

GEN

INFO

EB101010

REPLACEMENT PARTS

1. 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.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.

2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

1-2

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER
PINS

1. Replace all lock washers/plates
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis­ible. When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.

Oil seal

1

GEN

INFO

1

and cot-

CAUTION:

Do not use compressed air to spin the bear­ings dry. This will damage the bearing sur­faces.

Bearing

1

EB101050

CIRCLIPS

1. Check all circlips carefully before reassemb­ly. Always replace piston pin clips after one
use. Replace distorted circlips. When instal­ling a circlip
edged corner
thrust

Shaft

4

3

1

, make sure that the sharp-

2

is positioned opposite the

it receives. See sectional view.

1-3

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture,
etc.

1. Disconnect:

 Connector

2. Check:

 Connector

Moisture  Dry each terminal with an air
blower.
Stains/rust  Connect and disconnect the
terminals several times.

3. Check:

 Connector leads

Looseness  Bend up the pin
nect the terminals.

GEN

INFO

1

and con-

4. Connect:

 Connector terminals

NOTE:

The two terminals “click” together.

5. Check:

 Continuity (using a pocket tester)

NOTE:

 If there is no continuity, clean the terminals.
 When checking the wire harness be sure to

perform steps 1 to 3.

 As a quick remedy, use a contact revitalizer

available at most part stores.

 Check the connector with a pocket tester as

shown.

1-4

GEN

90890 01275

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly . Use only
the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country . In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.

INFO

Tool No.

Weight

90890-01084

Bolt

90890-01085

90890-01135

90890-01229

Final gear

backlash band

90890-01230

Middle gear

backlash band

90890-01231

Tool name/How to use Illustration

Slide hammer bolt/weight

These tools are used to remove the rocker
arm shaft.

Crankcase separating tool

This tool is used to remove the crankshaft.
Coupling gear/Middle shaft tool

This tool is needed when removing or
installing the final pinion shaft nut.

Final gear backlash band

This tool is needed when measuring final gear

/middle gear backlash.

Crankshaft installer pot/bolt/adapter/spacer

Installer pot

90890-01274

Bolt

90890-01275

Adaptor

90890-04130

Spacer

90890-04060

These tools are used to install the crankshaft.
Piston pin puller

90890-01304

This tool is used to remove the piston pin.
Fuel level gauge

90890-01312

This gauge is used to measure the fuel level
in the float chamber.

1-5

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

T-handle

90890-01326

Holder

90890-01460

Puller

90890-01362

Adapter

90890-04131

Weight

90890-01367

Adapter

90890-01381

Ring nut wrench

90890-01403

Exhaust nut

wrench

90890-01268

T-handle/damper rod holder

These tools are needed to loosen and tighten
the damper rod holding bolt.

Flywheel puller/adapter

These tools are needed to remove the rotor.
Fork seal driver weight/adapter

These tools are needed when installing the
slide metal, oil seal and dust seal into the fork.

Ring nut wrench/ehaust and steering nut
wrench

This tool is needed to loosen and tighten the
steering stem ring nut.

90890-01701

90890-03081

90890-03094

90890-031 12

Sheave holder

This tool is needed to hold the rotor when re­moving or installing the rotor bolt.

Compression gauge set

These tools are needed to measure engine
compression.

Vacuum gauge

This gauge is needed for carburetor synchro­nization.

Pocket tester

This instrument is needed for checking the
electrical system.

Engine tachometer

90890-03113

This tool is needed for observing engine r/min.

1-6

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Timing light

90890-03141

This tool is necessary for checking ignition
timing.

Valve guide remover & installer

90890-04014

This tool is needed to remove and install the
valve guide.

Valve spring compressor

90890-04019

This tool is needed to remove and install the
valve assemblies.

INFO

Adapter

90890-01277

Shock puller

90890-01290

Weight

90890-01291

90890-04137

Wrench

90890-04138

Holder

90890-04055

90890-04062

Crankshaft installer bolt adapter/armature
shock puller/weight

These tools are needed when removing the
final pinion shaft.

Bearing retainer wrench

This tool is needed when removing or instal­ling the middle drive shaft assembly.

Middle drive shaft nut wrench/Middle drive
shaft holder

These tools are needed when removing or
installing the middle drive shaft bearing.

Universal joint holder

This tool is needed when removing or instal­ling the driven pinion gear nut.

Bearing retainer wrench

90890-04077

90890-04086

This tool is needed when removing or instal­ling the final drive pinion gear assembly.

Clutch holding tool

This tool is needed to hold the clutch when re­moving or installing the clutch boss nut.

1-7

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Damper spring compressor

90890-04090

This tool is needed when removing or instal­ling the damper spring.

Dynamic spark tester
Ignition checker

90890-06754

This instrument is necessary for checking the
ignition system components.

Yamaha bond No.1215

90890-85505

This sealant (bond) is used on crankcase mat­ing surfaces, etc.

INFO

1-8

SPEC

2

SPEC

CHAPTER 2.

SPECIFICATIONS

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

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

ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TORQUE SPECIFICATIONS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-21. . . . . . . . . . . . . . . .

ENGINE 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

LUBRICATION DIAGRAMS 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SPECIFICATIONS

SPEC

Item

Model code: XVS1100: 5EL1 (For Europe)

5EL2 (For D, A, FIN)
5EL3 (For Australia)

Dimensions:

Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius

Basic weight:

With oil and a full fuel tank

Engine:

Engine type
Cylinder arrangement
Displacement
Bore  stroke
Compression ratio
Compression pressure (STD)
Starting system

2,405 mm
895 mm
1,095 mm
690 mm
1,640 mm
145 mm
3,200 mm

274 kg (5EL2 : 275kg)

Air cooled 4-stroke, SOHC
V-type 2-cylinder

1.063 L
95  75mm

8.3 : 1
1,000 kPa (10 kg/cm
Electric starter

Standard

2

, 10 bar) at 400 r/min

Lubrication system: Wet sump
Oil type or grade:

Engine oil

Final gear oil: SAE80API “GL-4” Hypoid Gear Oil
Oil quantity:

Engine oil

Periodic oil change
With oil filter replacement
Total amount

Final gear case oil

Total amount

Air filter: Dry type element

Temp. C

API standard:

“SE” or higher grade

ACEA standard:

G4 or G5

3.0 L

3.1 L

3.6 L

0.2 L

Fuel:

Type
Fuel tank capacity
Fuel reserve amount

Regular unleaded gasoline
17 L

4.5 L

2-1

GENERAL SPECIFICATIONS

Item Standard

Carburetor:

Type/quantity
Manufacturer

Spark plug:

Type
Manufacturer

Spark plug gap
Clutch type: Wet, multiple-disc
Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Transmission type

Operation

Gear ratio 1st

2nd
3rd
4th
5th

Chassis:

Frame type

Caster angle

Trail
Tire:

Type

Size front

rear

Manufacturer front

rear

Type front

rear

Maximum load-except motorcycle: 201 kg (5EL2 : 200kg)

BSR37/2
MIKUNI

BPR7ES/W22EPR–U
NGK/DENSO

0.7 X 0.8 mm

Spur gear
78/47 (1.660)
Shaft drive
44/47 19/18 32/11 (2.875)
Constant mesh 5-speed
Left foot operation
40/17 (2.353)
40/24 (1.667)
36/28 (1.286)
32/31 (1.032)
29/34 (0.853)

Double cradle
33
136 mm

With tube
110/90-18 61S
170/80-15M/C 77S
BRIDGESTONE/DUNLOP
BRIDGESTONE/DUNLOP
EXEDRA L309/K555F
EXEDRA G546/K555

SPEC

Tire pressure (cold tire):

0 X 90 kg (0 X 198 lb) load *

front
rear

90 kg (198 lb) X Maximum load *

front
rear

Brake:

Front brake type

operation

Rear brake type

operation

200 kPa (2.00 kg/cm2)

2

225 kPa (2.25 kg/cm

225 kPa (2.25 kg/cm
250 kPa (2.50 kg/cm2)
* Load is the total weight of the cargo, rider,
passenger and accessories.

Dual disc brake
Right hand operation
Single disc brake
Right foot operation

2-2

)

2

)

GENERAL SPECIFICATIONS

Item Standard

Suspension:

Front suspension

Rear suspension
Shock absorber:

Front shock absorber

Rear shock absorber
Wheel travel:

Front wheel travel

Rear wheel travel
Electrical:

Ignition system

Generator system

Battery type

Battery capacity
Headlight type: Quartz bulb (halogen)
Bulb wattage  quantity:

Headlight

Auxiliary light

Tail/brake light

Turn signal

Licence light

Meter light

Neutral indicator light

High beam indicator light

Turn indicator light

Oil level caution light

Engine warning light

Telescopic fork
Swingarm (link suspension)

Coil spring/Oil damper
Coil spring/Gas-oil damper

140 mm
113 mm

T.C.I. (digital)
A.C. magneto
GT14B-4
12 V 12 AH

12 V 60 W/55 W  1
12 V 4 W  1
12 V 5 W/21 W  1
12 V 21 W  4
12 V 5 W  1
14 V 1.4 W  2
12 V 1.7 W  1
12 V 1.7 W  1
12 V 1.7 W  1
12 V 1.7 W  1
12 V 1.7 W  1

SPEC

2-3

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

SPEC

Item

Cylinder head:

Warp limit

Cylinder:

Bore size

Measuring point

Camshaft:

Drive method

Cam cap inside diameter

Camshaft outside diameter

Shaft-to-cap clearance

Cam dimensions

Standard Limit

SSS 0.03 mm

95.00 X 95.01 mm
40 mm

Chain drive (left & right)

25.000 X 25.021 mm

24.96 X 24.98 mm

0.020 X 0.061 mm

95.1 mm

SSS

SSS
SSS
SSS
SSS

Intake “A”

“B”

“C”

Exhaust “A”

“B”
“C”

Camshaft runout limit

39.112 X 39.212 mm
#1: 32.093 X 32.193 mm
#2: 32.127 X 32.227 mm

7.162 mm

39.145 X 39.245 mm

32.200 X 32.300 mm

7.195 mm

SSS

2-4

39.012 mm
#1: 31.993 mm
#2: 32.027 mm

7.012 mm

39.045 mm

32.100 mm

7.045 mm

0.03 mm

Item Standard Limit

Timing chain:

Timing chain type/No. of links

Timing chain adjustment method
Rocker arm/rocker arm shaft:

Bearing inside diameter

Shaft outside diameter

Arm-to-shaft clearance
Valve, valve seat, valve guide:

Valve clearance (cold) IN

Valve dimensions:

MAINTENANCE SPECIFICATIONS

SILENT CHAIN/98L
Automatic

14.000 mm X 14.018 mm

13.985 mm X 13.991 mm

0.009 mm X 0.033 mm

0.07 X 0.12 mm

EX

0.12 X 0.17 mm

SPEC

SSS
SSS

14.036 mm

13.95 mm

0.086 mm

SSS
SSS

Head Dia Face width Seat Width

“A” head diameter IN

EX

“B” face width IN

EX

“C” seat width IN

EX

“D” margin thickness IN

EX

Stem outside diameter IN

EX

Guide inside diameter IN

EX

Stem-to-guide clearance IN

EX

47.0 X 47.2 mm

39.0 X 39.2 mm

2.1 mm

2.1 mm

1.2 X 1.4 mm

1.2 X 1.4 mm

1.1 X 1.5 mm

1.1 X 1.5 mm

7.975 X 7.990 mm

7.960 X 7.975 mm

8.000 X 8.012 mm

8.000 X 8.012 mm

0.010 X 0.037 mm

0.025 X 0.052 mm

Margin Thickness

SSS
SSS
SSS
SSS

1.8 mm

1.8 mm

0.8 mm

0.8 mm

SSS
SSS
SSS
SSS

0.08 mm

0.10 mm

2-5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Stem runout limit

Valve seat width IN

Valve spring:

Free length IN

Set length (valve closed) IN

Compressed pressure IN
(installed) EX
Tilt limit IN

EX

EX

EX

EX

SSS

1.2 X 1.4 mm

1.2 X 1.4 mm

44.6 mm

44.6 mm
40 mm
40 mm

160.7 N (16.4 kg)

160.7 N (16.4 kg)

SSS
SSS

0.03 mm

2.0 mm

2.0 mm

43.5 mm

43.5 mm

SSS
SSS
SSS
SSS

2.5_ /1.9mm

2.5_ /1.9mm

Direction of winding
(top view) IN

Piston:

Piston to cylinder clearance

Piston size “D”

Measuring point “H”

Piston off-set

EX

Clockwise
Clockwise

0.025 X 0.050 mm

94.960 X 94.975 mm

5 mm
0 mm

SSS
SSS

0.15 mm

SSS

SSS
SSS

2-6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Piston pin bore inside diameter

Piston pin outside diameter
Piston rings:

Top ring:

Type
Dimensions (B T)
End gap (installed)
Side clearance (installed)

2nd ring:

Type
Dimensions (B T)
End gap (installed)
Side clearance

Oil ring:

22.004 X 22.015 mm

21.991 X 22.000 mm

Plain

1.5 3.8 mm

0.3 X 0.5 mm

0.04 X 0.08 mm

Taper

1.2 3.8 mm

0.30 X 0.45 mm

0.03 X 0.07 mm

SSS
SSS

SSS
SSS

0.8 mm

0.1 mm

SSS
SSS

0.8 mm

0.1 mm

Dimensions (B T)
End gap (installed)

Connecting rod:

Oil clearance
Color code (corresponding size)

Crankshaft:

Crank width “A”

Runout limit “C”

Big end side clearance “D”

2.5 3.4 mm

0.2 X 0.7 mm

0.044 X 0.073 mm
Blue Black Brown Green Yellow

1 2 3 4 5

101.95 X 102.00 mm

SSS

0.320 X 0.474 mm

SSS
SSS

SSS
SSS

SSS

0.02 mm

SSS

2-7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Clutch:

Friction plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch spring free length

Quantity
Clutch housing thrust clearance
Clutch housing radial clearance
Clutch release method
Push rod bending limit

Transmission:

Main axle deflection limit
Drive axle deflection limit

Shifter:

Shifter type

Carburetor:

I. D. mark
Main jet (M.J)
Main air jet (M.A.J)
Jet needle (J.N)
Needle jet (N.J)
Pilot air jet (P.A.J.1)

(P.A.J.2)
Pilot outlet (P.O)
Pilot jet (P.J)
Bypass 1 (B.P.1)
Bypass 2 (B.P.2)
Bypass 3 (B.P.3)
Pilot screw (P.S)
Valve seat size (V.S)
Starter jet (G.S.1)
Starter jet (G.S.2)
Throttle valve size (Th.V)
Fuel level (F.L)

Engine idle speed
Intake vacuum
Engine oil temperature

SPEC

2.9 X 3.1 mm
8

2.5 X 2.7 mm
1

1.9 X 2.1 mm
7

7.2 mm
1

0.05 X 0.40 mm

0.010 X 0.044 mm
Inner push, screw push

SSS

SSS
SSS

Guide bar SSS

5EL1 00
#1: #110, #2: #112.5
#55
#1: 5DL39-53-3/5, #2: 5DL40-53-3/5
P-0M
#63.8
#145

1.0
#17.5

0.8

0.8

0.8
3

1.2
#42.5

0.8
#125
4X5 mm
950 X 1,050 r/min

34.7 X 37.3 kPa (260 X 280 mmHg)
75 X 85_C

2.8 mm

SSS

0.1 mm

SSS

0.1 mm

6.5 mm

SSS
SSS
SSS
SSS

0.5 mm

0.08 mm

0.08 mm

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

Fuel pump:

Type
Model/manufacturer
Consumption amperage <max>
Output pressure

Electrical type
UC-Z6M/MITSUBISHI

0.8 A
12 kPa (0.12 kg/cm

2-8

2

SSS
SSS
SSS

)

SSS

Item Standard Limit

Lubrication system:

Oil filter type
Oil pump type
Tip clearance “A” or “B”
Side clearance
Relief valve operating pressure

Shaft drive:

Middle gear backlash
Final gear backlash

MAINTENANCE SPECIFICATIONS

Paper type
Trochoid type

0.03 X 0.09 mm

0.03 X 0.08 mm
450 X 550 kPa (4.5 X 5.5 kg/cm

0.1 X 0.2 mm

0.1 X 0.2 mm

2

)

SPEC

SSS
SSS

0.15 mm

0.15 mm

SSS

SSS
SSS

2-9

Lubrication chart:

MAINTENANCE SPECIFICATIONS

Item Standard

SPEC

2-10

MAINTENANCE SPECIFICATIONS

Cylinder head tightening sequence:

SPEC

Crankcase tightening sequence:

Left crankcase Right crankcase

2-11

Tightening torques

g

size

y

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Cylinder head
Cylinder head
Plate
Cylinder head cover
Cylinder head (exhaust pipe)
Rocker arm shaft
Camshaft sprocket cover
Tappet cover
Rocker arm shaft (oil passage)
Stopper plate (camshaft)
Spark plug
Cylinder
Lower cylinder head cover
Upper cylinder head cover
Connecting rod
Rotor
Valve adjusting locknut
Camshaft sprocket
Timing chain tensioner
Timing chain tentioner cap
Timing chain guide
Oil pump
Oil strainer cover
Oil filter cover
Oil pump gear
Oil pump cap
Oil deliuery pipe (cylinder head)

(crankcase)
Drain bolt
Carburetor cover
Air filter case stay
Air filter case assembly
Exhaust pipe joint and cylinder head
Exhaust pipe joint and muffler
assembly
Muffler
Crankcase (cylinder)
Crankcase (cylinder)
Crankcase
Crankcase
Bearing retainer (middle drive pinion
gear)
Crankcase cover (left)
Crankcase cover (right)
Clamp
One-way clutch
Primary drive gear

Part name

Nut
Nut

Bolt

Screw

Stud bolt

Union bolt

Bolt
Bolt
Bolt
Bolt

—
Bolt
Bolt

Screw

Nut
Nut

Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt

Union bolt
Union bolt

—
Bolt
Bolt
Bolt

Nut

Bolt
Bolt

Stud bolt
Stud bolt

Bolt
Bolt
Bolt

Bolt
Bolt
Bolt
Bolt

Nut

Thread

M12
M10

M8
M6
M8

M16

M6
M6

M16

M8

M14

M6
M6
M6
M9

M16

M8

M10

M6
M6
M6
M6
M6
M6
M6

M6
M16
M10
M14

M5

M6

M5

M8

M8
M10

M12
M10
M10

M6

M8

M6

M6

M6

M6
M20

Q’ty

8
2
2
4
4
2
4
8
4
4
2
2
6
8
4
1
4
2
4
2
4
3
3
5
1
1
2
1
1
2
2
3
4
2

2
8
2
3

10

3

13
11

1
8
1

Tightening

torque

Nm mSkg

50
35
20

12.5

37.5
10
10
38
20
20
10
10

48

175

27
55
10

10
10
10
10
12
10
20
20
43

10
20

20
25

24
20

38.5
10
25

10
10
10
12

110

5.0

3.5

2.0

4

0.4

1.25

3.75

1.0

1.0

3.8

2.0

2.0

1.0

1.0

5

0.5

4.8

17.5

2.7

5.5

1.0

8

0.8

1.0

1.0

1.0

1.0

1.2

1.0

2.0

2.0

4.3

7

0.7

1.0

2

0.2

2.0

2.0

2.5

2.4

2.0

3.85

1.0

2.5

1.0

1.0

1.0

1.2

11.0

Remarks

Use lock washer

Use lock washer

2-12

MAINTENANCE SPECIFICATIONS

g

size

y

SPEC

Part to be tightened Part name

Clutch spring
Clutch adjuster
Clutch boss
Push lever axle
Middle drive pinion gear
Bearing retainer (middle driven shaft)
Yoke (middle driven shaft)
Bearing housing (middle drive shaft)
Shift lever stopper

Guide bar stopper
Shift dram segment
Shift arm
Shift pedal adjuster

Stator coil
Pickup coil
Starter motor
Neutral switch
Ignition coil
Speed sensor

Bolt

Nut
Nut

Screw

Nut
Nut

Nut
Bolt
Bolt

Screw
Screw

Bolt

Nut

Screw
Screw

Bolt

—

Screw

Bolt

Thread

M6
M8

M20

M8
M44
M88
M14

M8

M8

M6

M5

M6

M6

M6

M5

M6
M10

M5

M6

Q’ty

6
1
1
1
1
1
1
4
1

2
1
1
2

3
2
2
1
4
1

Tightening

torque

Nm mSkg

8

0.8
12
70
12

110
110

—
25
22

10
10

10

10
20

2.5

1.2

7.0

1.2

11.0

11.0
—

2.5

2.2

7

0.7

4

0.4

1.0

1.0

1.0

7

0.7

1.0

2.0

0.25

7

0.7

Remarks

Use lock washer

Stake
Stake
Stake

Use lock washer

1 of 2 has LH
thread

2-13

CHASSIS

MAINTENANCE SPECIFICATIONS

SPEC

Item

Steering system:

Steering bearing type

Front suspension:

Front fork travel
Fork spring free length
Fitting length
Collar length
Spring rate (K1)

Stroke (K1)

Optional spring
Oil capacity
Oil level
Oil grade

Rear suspension:

Shock absorber travel
Spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
Optional spring

(K2)

(K2)

Standard Limit

Angular bearing SSS

140 mm

356.9 mm

319.4 mm
183 mm

8.8 N/mm (0.9 kg/mm)

12.7 N/mm (1.3 kg/mm)
0 X 77.5 mm

77.5 X 140 mm
No

0.464 L
108 mm
Fork oil 10W or equivalent

113 mm

179.5 mm
163 mm

117.7 N/mm (12 kg/mm)
0 X 50 mm
No

SSS

350 mm

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

SSS
SSS
SSS
SSS
SSS
SSS

Swingarm:

Free play limit end

Front wheel:

Type
Rim size
Rim material
Rim runout limit radial

lateral

Rear wheel:

Type
Rim size
Rim material
Rim runout limit radial

lateral

SSS 0 mm

Spoke wheel
18 2.15
Steel

SSS
SSS

Spoke wheel
15M/C MT4.50
Steel

SSS
SSS

SSS
SSS
SSS

1.0 mm

0.5 mm

SSS
SSS
SSS

1.0 mm

0.5 mm

2-14

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Front brake:

Type
Disc outside diameter thickness
Disc deflection limit
Pad thickness inner
Pad thickness outer

Dual disc
298 5 mm

SSS

6.2 mm

6.2 mm

SPEC

SSS

4.5 mm

0.15 mm

0.8 mm

0.8 mm

Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type

Rear brake:

Type
Disc outside diameter thickeness
Disc deflection limit
Pad thickness inner

outer
Master cylinder inside diameter
Caliper cylinder inside dimeter
Brake fluid type

Brake lever & brake pedal:

Brake lever free play (at lever end)
Brake pedal position
Brake pedal free play
Clutch lever free play (at lever end)

Throttle grip free play

14.0 mm

25.4 mm

30.1 mm
DOT 4

Single disc
282 6 mm

SSS

5.55 mm

5.55 mm

12.7 mm

42.9 mm
DOT 4

5 X 8 mm

81.8 mm
0 mm
5 X 10 mm
4 X 6 mm

SSS
SSS
SSS
SSS

SSS

5.5 mm

0.15 mm

0.5 mm

0.5 mm

SSS
SSS

SSS
SSS
SSS
SSS

2-15

Tightening torques

g

Part to be tightened

MAINTENANCE SPECIFICATIONS

Tightening

Thread size

torque

Nm mSkg

SPEC

Remarks

Upper bracket and inner tube
Lower bracket and inner tube
Upper bracket and steering shaft
Ring nut (steering shaft)
Handlebar holder (lower) and upper bracket
Handlebar holder (lower) and handlebar
holder (upper)
Master cylinder (front brake)
Union bolt (brake hose)
Brake hose holder and lower bracket
Brake hose joint and brake pipe
Brake hose joint and brake hose holder
Front fender and outer tube
Headlight stay and lower bracket
Headlight stay and headlight
Front flasher light and lower bracket
Engine mounting:

Frame and stay (front - upper)
Frame and stay (front - lower)
Stay and engine (front - upper)
Stay and engine (front - lower)
Frame and engine (rear - upper)
Frame and engine (rear - lower)

Down tube and frame
lgnition coil and stay
Muffler stay and frame
Rear shock absorber and relay arm
Rear shock absorber and frame
Pivot shaft and swingarm
Relay arm and frame
Connecting arm and relay arm
Connecting arm and swingarm
Final gear case and swingarm
Swingarm end and holder
Fuel tank and fuel cock
Fuel tank bracket and frame
Rider’s seat
Passenger seat
Fuel tank and top cover
Licence bracket and rear fender stay
Rear fender and rear fender stay
Rear fender and tail/brake light
Rear fender stay and rear flasher light
Frame and rear fender
Side cover (left)
Battery cover
Side cover (right)
Starter relay and leads

M8
M10
M22

—

M12

M8

M6
M10

M6
M10

M6

M8

M6

M6

M6
M10

M10
M12
M10
M10
M10
M10

M5

M8
M10
M10
M16
M10
M12
M12
M10

M8

M6

M8

M6

M6

M5

M6

M5

M6
M12

M8

M6

M6

M6

M6

20
30

110

18
32
28

10
30
10
19
10
10

7
8
7

48
48
74
48
48
48
48

4
30
48
40
90
48
48
48
90
23

7
23

7

7

4

7

4

6

7
26

7

7

7

7

2.0

3.0

11.0

1.8

3.2

2.8

1.0

3.0

1.0

1.9

1.0

1.0

0.7

0.8

0.7

4.8

4.8

7.4

4.8

4.8

4.8

4.8

0.4

3.0

4.8

4.0

9.0

4.8

4.8

4.8

9.0

2.3

0.7

2.3

0.7

0.7

0.4

0.7

0.4

0.6

0.7

2.6

0.7

0.7

0.7

0.7

See NOTE

2-16

MAINTENANCE SPECIFICATIONS

g

g

size

SPEC

Part to be ti

Passenger footrest and frame
Sidestand bracket and frame
Sidestand and sidestand bracket
Sidestand switch
Brake pedal/footrest and frame
Rear brake master cylinder and master cylinder
bracket
Master cylinder bracket and down tube
Footrest and frame
Front wheel axle
Front wheel axle pinch bolt
Brake caliper
Brake disc and front wheel
Caliper bleed screw
Rear wheel axle nut
Rear brake caliper and caliper bracket
Caliper bracket and swingarm
Brake hose union bolt
Caliper bleed screw
Clutch hub and damper
Final gear case stud bolt
Final gear case stud bolt
Bearing housing (final gear case)
Bearing housing (final gear case)
Drive pinion
Bearing retainer (final drive pinion gear)
Oil filter bolt (final gear)
Oil drain bolt (final gear)
Housing cover

htened

Thread

M8
M10
M10

M5

M6

M8

M8
M10
M16

M8
M10

M8

M7
M16
M10
M10
M10

M8
M10
M10

M8

M8
M10
M14
M65
M14
M14
M10

Tightening

torque

Nm mSkg

26
64
56

4
7

23
23

64
59
20
40
23

6

107

40
40
30

6
62
18

9
23
40

130
115

23
23
42

2.6

6.4

5.6

0.4

0.7

2.3

2.3

6.4

5.9

2.0

4.0

2.3

0.6

10.7

4.0

4.0

3.0

0.6

6.2

1.8

0.9

2.3

4.0

13.0

11.5

2.3

2.3

4.2

Remarks

LH thread

NOTE:

1. First, tighten the ring nut approximately 52 Nm (5.2 mSkg) by using the torque wrench, then
loosen the ring nut completely.

2. Retighten the ring nut to specification.

2-17

ELECTRICAL

MAINTENANCE SPECIFICATIONS

SPEC

Item
Voltage: 12 V
Ignition system:

Ignition timing (B.T.D.C.)
Advancer type

T.C.I.:

Pickup coil resistance/color
T.C.I. unit model/manufacturer

Ignition coil:

Model/manufacturer
Primary winding resistance
Secondary winding resistance

Spark plug cap:

Type
Resistance

Charging system:

Type
Model/manufacturer
Nominal output
Stator coil resistance/color

10_ at 1,000 r/min
Digital type

189 X 231 Ω at 20_C/Gray – Black
J4T101/MITSUBISHI

F6T507/MITSUBISHI

3.57 X 4.83 Ω at 20_C

10.7 X 14.5 kΩ at 20_C

Resin type
10 kΩ

A.C. magneto
F4T654/MITSUBISHI
14 V 350 W at 5,000 r/min

0.36 X 0.44 Ω at 20_C/White – White

Standard Limit

SSS

SSS
SSS

SSS
SSS

SSS
SSS
SSS

SSS
SSS

SSS
SSS
SSS
SSS

Voltage regulator:

Type
Model/manufacturer
No load regulated voltage

Rectifier:

Model/manufacturer
Capacity
Withstand voltage

Battery:

Specific gravity

Electric starter system:

Type
Starter motor:

Model/manufacturer
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut

Starter relay:

Model/manufacturer
Amperage rating

Semi-conductor, short-circuit type
SH650D-11/SHINDENGEN

14.1 X 14.9 V

SH650D-11/SHINDENGEN
18 A
200 V

1.320 SSS

Constant mesh type

SM-13/MITSUBA

0.6 kW

0.026 X 0.034 Ω at 20_C

12.5 mm

7.65 X 10.01 N (780 X 1021 g)
28 mm

0.7 mm

MS5F-421/JIDECO
180 A

SSS
SSS
SSS

SSS
SSS
SSS

SSS

SSS
SSS
SSS

5 mm

SSS

27 mm

SSS

SSS
SSS

2-18

Item Standard Limit
Horn:

Type
Quantity
Model/manufacturer
Maximum amperage

Flasher relay:

Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage

Oil level gauge:

Model/manufacturer

Starting circuit cut-off relay

Model/manufacturer

Fuel pump relay:

Model/manufacturer

Circuit breaker:

Type
Amperage for individual circuit

MAIN
HEAD LIGHT
SIGNALS
IGNITION
BACK UP
Carburetor heater
Reserve
Reserve
Reserve
Reserve

MAINTENANCE SPECIFICATIONS

Plane type
1
YF-12/NIKKO
3 A

Full transistor type
FE246BH/DENSO
No
75 X 95 cycle/min
21 W 2 + 3.4W

5EL/DENSO SSS

G8R-30Y-B/OMRON SSS

G8R-30Y-B/OMRON SSS

Fuse

30 A 1
15 A 1
10 A 1
10 A 1
5 A 1
15 A 1
30 A 1
15 A 1
10 A 1
5 A 1

SPEC

SSS
SSS
SSS
SSS

SSS
SSS
SSS
SSS
SSS

SSS

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

2-19

GENERAL TORQUE SPECIFICATIONS

/CONVERSION T ABLE

SPEC

EB202001

GENERAL TORQUE
SPECIFICATIONS

This chart specifies torque for standard fasten­ers with standard I.S.O. pitch threads. Torque
specifications for special components or as­semblies are provided for each chapter of this
manual. T o avoid warpage, tighten multi-fasten­er assemblies in a crisscross fashion, in pro­gressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads. Com­ponents should be at room temperature.

A: Distance between flats
B: Outside thread diameter

A

(nut)

B

(Bolt)

10 mm 6 mm 6 0,6
12 mm 8 mm 15 1,5
14 mm 10 mm 30 3,0

17 mm 12 mm 55 5,5

General torque

specifications

Nm

mSkg

EAS00028

CONVERSION TABLE

All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMP

** mm x 0.03937 = ** in

2 mm x 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMP

Known Multiplier Result

Torque

Weight

Distance

Volume/
Capacity

Miscella­neous

mSkg
mSkg
cmSkg
cmSkg

kg
g

km/hr
km
m
m
cm
mm

cc (cm3)
cc (cm
lt (liter)
It (liter)

kg/mm
kg/cm
Centigrade

3

)

2

7.233

86.794

0.0723

0.8679

2.205

0.03527

0.6214

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234
9/5 (_C) + 32

ftSlb
inSlb
ftSlb
inSlb

lb
oz

mph
mi
ft
yd
in
in

oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)

lb/in
psi (lb/in
Fahrenheit (_F)

2

)

19 mm 14 mm 85 8,5
22 mm 16 mm 130 13,0

2-20

LUBRICATION POINTS AND LUBRICANT TYPES

EB203000

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

SPEC

Lubrication point
Oil seal lips
O-ring
Bearing
Connecting rod bolt/nut
Connecting rod small end and big end
Crankshaft pin
Crankshaft journal/big end
Piston surface
Piston pin
Camshaft cam lobe/journal
Rocker arm shaft
Valve stem (IN, EX)

Symbol

Valve stem end (IN, EX)
Timing chain drive gear shafts/sprokets
Oil pump rotor (inner/outer), housing
Idle gear surface
Starter idle gear
Starter idle gear shaft
Starter oneway cam
Middle drive gear
Primary driven gear
Push rod 1, 2
Transmission gear (wheel/pinion)
Shift cam
Shift fork/guide bar
Shift shaft assembly
Push rod ball
Push lever assembly

2-21

EB203010

CHASSIS

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

Lubrication point
Steering head pipe (upper/lower), bearing
Steering head pipe, bearing cover lip
Steering head pipe, oil seal lip
Front wheel oil seal lip (right/left)
Rear wheel oil seal lip
Clutch hub fitting area
Rear brake pedal shaft
Shift pedal shaft
Sidestand bolt, sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever pivot bolt, contact surface
Clutch lever pivot bolt, contact surface

Symbol

Rear shock absorber (lower) oil seal lip
Swingarm pivot bearing inner surface
Swingarm pivot oil seal lip
Relay arm bearing, collar and oil seal
Drive shaft spline
Drive shaft dust cover

2-22

EB205000

LUBRICATION DIAGRAMS

1 Rocker arm shaft (intake)
2 Rocker arm shaft (exhaust)
3 Oil filter

4 Oil pump
5 Drive axle
6 Middle drive shaft

LUBRICATION DIAGRAMS

SPEC

2-23

2 Releaf valve
3 Oil filter

LUBRICATION DIAGRAMS

4 Middle drive shaft1 Oil pump

SPEC

2-24

LUBRICATION DIAGRAMS

SPEC

1 Camshaft
2 Crankshaft
3 Main axle

4 Middle drive shaft
5 Drive axle
6 Connecting rod big end

2-25

EB206000

CABLE ROUTING

1 Clutch cable
2 Starter cable
3 Handlebar switch lead (left)
4 Handlebar switch lead (right)
5 High tension code
6 Starter cable
7 Throttle cable
8 Fuel hose (fuel cock-fuel filter)
9 Fuse box

CABLE ROUTING

10 Alarm connector
11 Fuel pump lead
12 Speed sensor lead
13 Sidestand switch lead
14 Neutral switch lead
15 Pickup coil lead
16 AC magneto lead
17 Ventilation hose
18 Sensing hose (AIS-carburetor

joint)

SPEC

19 Fuel hose (carburetor-fuel pump)
20 Brake hose
21 Heat protector
22 Fuel breather hose (fuel tank-

roll over valve) (for California)

23 Speedometer lead
24 Wireharness
25 Purge hose (carburetor-solenoid

valve) (for California)

2-26

CABLE ROUTING

SPEC

27

26 Purge hose (carburetor-solenoid

valve) (for California)

A Fasten the handlebar switch

leads (left and right) to the
handlebar with plastic locking
tie.

B Position the throttle cable and

starter cable as shown, and
clamp them with holder.

C Clamp the wire harness with

the hook of frame side.

D When installing the pipe of

throttle cables, press it inside.

E Connect the sensing hose

(carburetor joint-AIS side) with
a nozzle.

F Push the wire harness inside

of the tool box plate.

G Route the sidestand lead

inside of engine cover.

H Position the all connectors

inside of the connector cover.

I Route the clutch cable through

the cable guide.

2-27

CABLE ROUTING

SPEC

J Fasten the handlebar switch

leads (left and right) under the
handle crown with a plastic
band.
Set the band at four notches,
and install it no slacking.

K Route the each hoses through

the frame guide and do not
pinch it.

L When installing the fitting plate,

do not pinch the each hoses
and wire harness.

M Fasten the AC magneto lead

and sidestand switch lead with a
plastic locking tie.

N Fasten the alarm lead with a

plastic band on the lid.

2-28

E

1 Battery
2 Battery positive (+) lead
3 Starter motor positive (+) lead
4 Speedometer lead
5 Fuel hose (carburetor-fuel pump)
6 High tension code
7 Main switch lead
8 Throttle cable

9 Brake hose
10 Handlebar switch lead (right)
11 Headlight lead

CABLE ROUTING

12 Ignition coil
13 Master cylinder reservoir hose
14 Breather hose
15 Air filter drain hose
16 Battery negative (–) lead
17 Rear brake switch lead
18 Rear brake hose
19 Carburetor heater connector
20 Rectifier/regulator
21 Main switch lead
22 Flasher relay

SPEC

23 Handlebar switch lead (left)
24 Throttle position sensor lead
25 Carburetor heater lead
26 Thermo switch lead
27 Starting circuit cutoff relay
28 Down tube
29 High tension code
30 Purge hose (carburetor-

solenoid valve) (for California)

31 Carburetor heater lead
32 Oil level switch lead

2-29

E

A Clamp the battery positive (+)

lead to the battery with battery
band.

B Connect the battery negative

(–) lead connector and push it
into the space between battery
box and battery.

C Route the rectifier/regulator

lead, wire harness and starter
motor positive (+) lead through
the outside of frame bracket
and fasten them to the frame
with a plastic locking tie.

CABLE ROUTING

D Connect the purge hose

(carburetor side-solenoid valve
side) with joint. (for California)

E Route the front turn signal light

lead and headlight lead through
the rear of headlight body hole.

F Connect the ignition coil lead at

red tape to the right side.

G Fasten the rear brake switch

lead to the brake switch bracket
with a plastic locking tie.

SPEC

H Fasten the rear brake switch

lead and master cylinder
reservoir hose to the down
tube with a plastic locking tie.

I Fasten the wire harness,

starter motor positive (+) lead
and battery negative (–) lead to
the frame with a plastic locking tie.

J Route the rectifier/regulator

lead and carburetor heater lead
through inside of battery box
hole to outside it and connect
them.

2-30

E

K To rear brake caliper
L Clamp the handlebar switch

lead (right) and main switch
lead to the frame with a holder.

M Arrange the throttle position

sensor connector, carburetor
heater connector and thermo
switch connector between the
starting circuit cutoff relay and
high tension code.

N Fasten the rear brake switch

to the down tube with a plastic
locking tie.

CABLE ROUTING

SPEC

2-31

E

1 Brake hose

2 Throttle cable

3 Master cylinder reservoir hose

4 High tension code

5 Purge hose (carburetor-solenoid

valve) (for California)

6 Rear brake switch lead

7 Brake hose

8 Sensing hose (AIS-carburetor

joint)

9 Fuel hose (carburetor-fuel

pump)

10 Battery negative (–) lead

CABLE ROUTING

11 Battery negative (–) lead

connector

12 Battery
13 Battery positive (+) lead
14 Taillight lead
15 Starter relay
16 Starter motor positive (+) lead
17 Speedometer lead connector
18 Fuel tank breather hose

(fuel tank-roll over valve) (for
California)

19 Ventilation hose

SPEC

20 Starter cable
21 Fuel hose (fuel cock-fuel filter)
22 Carburetor heater lead
23 Thermo switch lead
24 Igniter unit
25 Taillight lead
26 Throttle position sensor lead
27 Fuel filter
28 Igniter unit lead
29 Frame
30 Wire harness

A Clamp the throttle cables with

the holder.

2-32

E

B Route the rear brake switch

lead under the master cylinder
reservoir hose.

C Position the band end of right

side bracket.

D Position the steel band end to

forward.

E Position the steel band end to

right side.

CABLE ROUTING

F Route the battery positive (+)

lead through the slit of the
battery box.

G Clamp the igniter unit lead to

the frame with a holder.

H To the rear fender.

I Route the fuel tank breather

hose under the fuel filter and
connect it (fuel tank side-roll
over valve side) with a joint.
Position the end of clip outside.

SPEC

J Fasten the wire harness with a

band on the tool box plate.

K Fasten the wire harness to the

frame with a plastic locking tie.
Position the locking tie front of
the solder.

2-33

E

L Route wire harness outside of

the guide on the frame.

M Clamp the clutch cable and

starter cable with a holder.
Position the end of holder down
side.

N Route the throttle position

sensor lead and carburetor
heater lead left side of the
tappet cover.

O To the wire harness.

CABLE ROUTING

P Route the igniter lead through

the igniter plate hole to the wire
harness.

Q Clamp the taillight lead with

mud guard clamp.

R Clamp the taillight lead with a

holder on the mud guard.

SPEC

2-34

E

1 Throttle cable

2 Starter cable

3 Clutch cable

4 Handlebar switch lead (left)

5 Headlight lead

6 Brake hose

A Route the handlebar switch

lead (right) rear side of the
throttle cable.

CABLE ROUTING

SPEC

2-35

INSP

ADJ

3

INSP

ADJ

CHAPTER 3

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .

FUEL TANK AND SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOV AL 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INST ALLA TION 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE VALVE CLEARANCE 3-5. . . . . . . . . . . . . . . . . . . . . . .

SYNCHRONIZING THE CARBURETORS 3-8. . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE ENGINE IDLING SPEED 3-10. . . . . . . . . . . . . . . . . . . .

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-11. . . . . . . . . . . . .

CHECKING THE SPARK PLUGS 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE IGNITION TIMING 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

MEASURING THE COMPRESSION PRESSURE 3-14. . . . . . . . . . . . . . .

CHECKING THE ENGINE OIL LEVEL 3-16. . . . . . . . . . . . . . . . . . . . . . . . .

CHANGING THE ENGINE OIL 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-18. . . . . . . . . . . . . . . .

CLEANING THE AIR FILTER ELEMENT 3-19. . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CARBURETOR JOINT AND INTAKE

MANIFOLD 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BREATHER HOSE 3-20. . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE EXHAUST SYSTEM 3-21. . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE FRONT BRAKE 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BRAKE FLUID LEVEL 3-24. . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-25. . . . . . . . . . . . . . .

CHECKING THE BRAKE HOSES 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-26. . . . . . . . . . . . . . . .

ADJUSTING THE SHIFT PEDAL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE FINAL DRIVE OIL LEVEL 3-28. . . . . . . . . . . . . . . . . . . .

CHANGING THE FINAL DRIVE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND ADJUSTING THE STEERING HEAD 3-29. . . . . . . . . .

CHECKING THE FRONT FORK 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-31. . . . . .

CHECKING THE TIRES 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND TIGHTENING THE SPOKES 3-35. . . . . . . . . . . . . . . . .

CHECKING AND LUBRICATING THE CABLES 3-36. . . . . . . . . . . . . . . . .

LUBRICATING THE LEVERS AND PEDALS 3-36. . . . . . . . . . . . . . . . . . .

LUBRICATING THE SIDESTAND 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING THE REAR SUSPENSION 3-36. . . . . . . . . . . . . . . . . . . . .

INSP

ADJ

ELECTRICAL SYSTEM 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHECKING THE FUSES 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING THE HEADLIGHT BULB 3-44. . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE HEADLIGHT BEAM 3-45. . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

EB300000

INSP

ADJ

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust­ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera­tion and a longer service life. The need for costly overhaul work will be greatly reduced. 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.

EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EVERY

NO. ITEM CHECKS AND MAINTENANCE JOBS

1 * Fuel line (manual cock)

2 * Fuel filter

3 Spark plugs

4 * Valves (arm SOHC)

5 Air filter  Clean or replace if necessary. √ √

6 Clutch

7 * Front brake (disc)

8 * Rear brake (disc)

9 * Wheels (spoke)

10 * Tires (EUR)

11 * Wheel bearings

12 * Swingarm (no nipple)

13 * Steering bearings

14 * Chassis fasteners

15 Sidestand

16 * Sidestand switch

 Check fuel hoses for cracks or damage.
 Replace if necessary .

 Check condition.
 Replace if necessary .

 Check condition.
 Clean, regap or replace if necessary .

 Check valve clearance.
 Adjust if necessary .

 Check operation.
 Adjust or replace cable.

 Check operation, fluid level and vehicle for fluid leakage.

(See NOTE.)

 Correct accordingly .
 Repalce brake pads if necessary .

 Check operation, fluid level and vehicle for fluid leakage.

(See NOTE.)

 Correct accordingly .
 Replace brake pads if necessary .

 Check balance, runout, spoke tightness and for damage.
 Tighten spokes and rebalance, replace if necessary.

 Check tread depth and for damage.
 Replace if necessary .
 Check air pressure.
 Correct if necessary .

 Check bearing for looseness or damage.
 Replace if necessary .

 Check swingarm pivoting point for play .
 Correct if necessary .
 Lubricate with molybdenum disulfide grease every

24,000 km or 24 months (whichever comes first).

 Check bearing play and steering for roughness.
 Correct accordingly .
 Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).

 Make sure that all nuts, bolts and screws are properly

tightened.

 Tighten if necessary.
 Check operation.

 Lubricate and repair if necessary .
 Check operation.

 Replace if necessary .

Initial

(1,000 km)

√ √ √

√ √ √

√ √ √

√ √ √

√ √ √

√ √ √

6,000 km

or

6 months

(whichever

comes first)

√ √

√ √

√ √

√ √

√ √

√ √

√ √

√ √

12,000 km

or

12 months

(whichever

comes first)

√

3-1

INSP

PERIODIC MAINTENANCE/LUBRICA TION INTER VALS

NO. ITEM CHECKS AND MAINTENANCE JOBS

17 * Front fork

Rear shock absorber

18 *

assembly

19 * Carburetors (multi)

20 Engine oil

Engine oil filter

21 *

element

22 Final gear oil

 Check operation and for oil leakage.
 Correct accordingly .

 Check operation and shock absorber for oil leakage.
 Replace shock absorber assembly if necessary .

 Check engine idlilng speed, synchronization and start-

er operation.

 Adjust if necessary .
 Check oil level and vehicle for oil leakage.

 Correct if necessary .
 Change. (Warm engine before draining.)

 Replace. √ √

 Check oil level and vehicle for oil leakage.
 Change oil at initial 1,000 km and thereafter every

24,000 km or 24 months (whichever comes first).

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

Initial

(1,000 km)

√ √ √

√ √ √

√ √ √

ADJ

EVERY

6,000 km

or

6 months

(whichever

comes first)

√ √

√ √

12 months

(whichever

comes first)

12,000 km

or

NOTE:

 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
 Hydraulic brake system

–When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check

the brake fluid level regularly and fill as required.
–Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
–Replace the brake hoses every four years or if cracked or damaged.

3-2

FUEL TANK AND SEATS

FUEL TANK AND SEATS

23Nm (2.3mkg)

INSP

ADJ

7 Nm (0.7mkg)

7 Nm (0.7mkg)

Order Job name/Part name Q’ty Remarks

Fuel tank and seats removal

Passenger seat

1

Seat bracket

2

Rider’s seat

3

Fuel hose

4

Ignitor plate

5

Mud guard

6

Meter lead couper

7

Fuel tank assembly

8

3-3

Remove the parts in the order below.
1
1
1

NOTE:

1

Set the fuel cock to “OFF” before dis-

connecting the fuel hose.
1

1
1
1

For installation, reverse the removal

procedure.

FUEL TANK AND SEATS

REMOVAL

1. Remove:
 Ignitor plate

NOTE:

To remove the quick fastener, push its center in
with a screwdriver, then pull the fastener out.

INSP

ADJ

INSTALLATION

1. Install:
 Ignitor plate

NOTE:

T o install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin
in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.

a

3-4

ADJUSTING THE VALVE CLEARANCE

EAS00047

ENGINE

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.

NOTE:

 Valve clearance adjustment should be made

on a cold engine, at room temperature.

 When the valve clearance is to be measured or

adjusted, the piston must be at top dead center
(TDC) on the compression stroke.

1. Remove:

 rider’s seat
 fuel tank

Refer to “FUEL TANK AND SEATS”.

2. Disconnect:
 spark plug caps

3. Remove:
 spark plugs

INSP

ADJ

4. Remove:
 air intake box

5. Remove:

 cylinder head cover (rear cylinder)
 cylinder head cover (front cylinder)

1

1

3-5

ADJUSTING THE VALVE CLEARANCE

6. Remove:
 tappet covers

7. Remove:

 camshaft sprocket cover (rear cylinder)
 camshaft sprocket cover (front cylinder)

1

INSP

ADJ

1

8. Remove:

 timing plug
 straight plug

9. Measure:
 valve clearance

Out of specification  Adjust.

1

2

Valve clearance (cold):
Intake valve:

0.07  0.12 mm

Exhaust valve:

0.12  0.17 mm

3-6

A B

ADJUSTING THE VALVE CLEARANCE

a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-

sion stroke, align either the camshaft sprock­et plate hole
on the cylinder head. When the camshaft
sprocket plate hole or camshaft sprocket
punch mark is aligned with the stationary
pointer, the piston is at top dead center
(TDC).

c. Align the TDC mark

with the stationary pointer
case.

Rear cylinder (“TI” mark)

A

Front cylinder (“I” mark)

B

a

with the stationary pointer

INSP

ADJ

c

on the generator rotor

d

on the crank-

b

d. Measure the valve clearance with a thick-

1

ness gauge

e. Turn the crankshaft crockwise 290_, and

then measure the front cylinder.

10. Adjust
S valve clearance

a. Loosen the locknut
b. Insert a thickness gauge between the end of

the adjusting screw and the valve tip.

c. Turn the adjusting screw

b

until the specified valve clearance is ob-

tained.

Direction

Direction

.

1

.

2

in direction a or

a

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.

3-7

ADJUSTING THE VALVE CLEARANCE/

SYNCHRONIZING THE CARBURETORS

Locknut:

27 Nm (2.7 mkg)

e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust­ment steps until the specified clearance is
obtained.

11. Install:
 all removed parts

NOTE:

Install all removed parts in the reverse order of
their disassembly. Note the following points.

 camshaft sprocket covers
 tappet covers
 spark plugs

EAS00051

SYNCHRONIZING THE CARBURETORS

INSP

ADJ

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

20 Nm (2.0 mkg)

NOTE:

Prior to synchronizing the carburetors, the valve
clearance and the engine idling speed should
be properly adjusted and the ignition timing
should be checked.

1. Stand the motorcycle on a level surface.

NOTE:

Place the motorcycle on a suitable stand.

2. Remove:

 rider’s seat
 fuel tank

Refer to “FUEL TANK AND SEATS”.

3. Remove:
 air duct

4. Remove:
 vacuum plugs

1

1

3-8

SYNCHRONIZING THE CARBURETORS

5. Install:

 vacuum gauge
 engine tachometer

(to the spark plug lead of cyl. #2)

Vacuum gauge:

90890-03094

Engine tachometer:

90890-03113

6. Start the engine and let it warm up for several

minutes.

7. Check:
 engine idling speed

Out of specification  Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.

Engine idling speed:

950  1,050 r/min

1

INSP

ADJ

2

8. Adjust:
 Carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2

by turning the synchronizing screw
ther direction until both gauges read the
same.

b. Rev the engine two or three times, each time

for less than a second, and check the syn­chronization again.

Vacuum pressure at idle speed:

34.7  37.3 kPa (260  280 mmHg)

NOTE:

The difference between the two carburetors
should not exceed 1.33 kPa (10 mmHg).

9. Check:
 engine idling speed

Out of specification  Adjust.

10. Stop the engine and remove the measuring

equipment.

1 1. Adjust:

 throttle cable free play

Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

1

in ei-

3-9

SYNCHRONIZING THE CARBURETORS/

ADJUSTING THE ENGINE IDLING SPEED

Throttle cable free play (at the
flange of the throttle grip)

4  6 mm

12. Install:

 vacuum plugs
 air duct
 fuel tank
 seat

EAS00054

ADJUSTING THE ENGINE IDLING SPEED
NOTE:

Prior to adjusting the engine idling speed, the
carburetor synchronization should be adjusted
properly, the air filter should be clean, and the
engine should have adequate compression.

1. Start the engine and let it warm up for several

minutes.

2. Remove:
 cylinder head cover

3. Install:
 engine tachometer

(to the spark plug lead of cyl. #1)

INSP

ADJ

1

Engine tachometer:

90890-03113

4. Check:
 engine idling speed

Out of specification  Adjust.

Engine idling speed:

950  1,050 r/min

5. Adjust:
 engine idling speed

a. Turn the pilot screw

seated.

b. Turn the pilot screw out the specified number

of turns.

Pilot screw

3 turns out

c. Turn the throttle stop screw

or b until the specified engine idling speed is
obtained.

1

in until it is lightly

2

in direction

a

3-10

Direction

Direction

a

b

Engine idling speed is
increased.

Engine idling speed is
decreased.

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE CABLE FREE PLAY

6. Adjust:
 throttle cable free play

Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

Throttle cable free play (at the
flange of the throttle grip)

4  6 mm

EAS00058

ADJUSTING THE THROTTLE CABLE FREE
PLAY

NOTE:

Prior to adjusting the throttle cable free play , the
engine idling speed should be adjusted.

1. Check:
 throttle cable free play

Out of specification  Adjust.

INSP

ADJ

a

Throttle cable free play (at the
flange of the throttle grip)

4  6 mm

2. Remove:

 rider’s seat
 fuel tank

Refer to “FUEL TANK AND SEATS”.

3. Adjust:
 throttle cable free play

NOTE:

When the motorcycle is accelerating, the accel­erator cable

Carburetor side

a. Loosen the locknut 2 on the accelerator cable.
b. Turn the adjusting nut

until the specified throttle cable free play is
obtained.

Direction

1

is pulled.

a

3

in direction a or

Throttle cable free play
is decreased.

b

Direction

c. 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.

3-11

b

Throttle cable free play
is increased.

ADJUSTING THE THROTTLE CABLE FREE PLAY/

CHECKING THE SPARK PLUGS

Handlebar side

a. Loosen the locknut
b. Turn the adjusting nut

until the specified throttle cable free play is
obtained.

INSP

ADJ

1

.

2

in direction a or

b

Direction

Direction

c. Tighten the locknut.

a

b

Throttle cable free play is
increased.

Throttle cable free play is
decreased.

WARNING

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

EAS00059

CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.

1. Remove:
 cylinder head covers

2. Disconnect:
 spark plug cap

3. Remove:
 spark plug

1

CAUTION:

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 plug type (manufacturer)
BPR7ES (NGK)
W22EPR-U (DENSO)

5. Check:
 electrode

Damage/wear  Replace the spark plug.

 insulator

Abnormal color  Replace the spark plug.
Normal color is a medium-to-light tan color.

6. Clean:
 spark plug

(with a spark plug cleaner or wire brush)

1

2

3-12

CHECKING THE SPARK PLUGS/

CHECKING THE IGNITION TIMING

7. Measure:
 spark plug gap

(with a wire gauge)
Out of specification  Regap.

Spark plug gap

0.7  0.8 mm

8. Install:
 spark plug

NOTE:

Before installing the spark plug, clean the spark
plug and gasket surface.

9. Connect:
 spark plug cap

EAS00064

CHECKING THE IGNITION TIMING

a

20 Nm (2.0 mkg)

INSP

ADJ

NOTE:

Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure that all connections are tight and free
of corrosion.

1. Remove:
 timing plug

1

3-13

2. Install:

 timing light
 engine tachometer

(to the spark plug lead of cyl. #1)

1

2

Timing light:

90890-03141

Engine tachometer:

90890-03113

CHECKING THE IGNITION TIMING/

MEASURING THE COMPRESSION PRESSURE

3. Check:
 ignition timing

a. Start the engine, warm it up for several min-

utes, and then let it run at the specified en­gine idling speed.

Engine idling speed:

950  1,050 r/min

INSP

ADJ

b. Check that the stationary pointer

b

the firing range
Incorrect firing range  Check the ignition
system.

NOTE:

The ignition timing is not adjustable.

4. Install:
 timing plug

EAS00065

MEASURING THE COMPRESSION PRES­SURE

The following procedure applies to all of the cyl­inders.

1

on the generator rotor.

a

is within

NOTE:

Insufficient compression pressure will result in a
loss of performance.

1. Check:
 valve clearance

Out of specification  Adjust.
Refer to “ADJUSTING THE V ALVE CLEAR­ANCE”.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Disconnect:
 spark plug cap

4. Remove:
 spark plug

3-14

MEASURING THE COMPRESSION PRESSURE

CAUTION:

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.

5. Install:
 compression gauge

Compression gauge set:

90890-03081

6. Measure:
 compression pressure

Above the maximum pressure  Inspect the
cylinder head, valve surfaces, and piston
crown for carbon deposits.
Below the minimum pressure  Squirt a few
drops of oil into the affected cylinder and
measure again.

 Refer to the following table.

INSP

ADJ

1

Compression pressure

(with oil applied in the cylinder)
Reading Diagnosis
Higher than

without oil
Same as

without oil

Compression pressure (at sea
level)

a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the engine

until the reading on the compression gauge
stabilized.

Piston wear or damage
 Repair.

Piston ring(-s), valves, cylin­der head gasket or piston
possibly defective  Repair.

Standard:

1,000 kPa (10 kg/cm

Minimum:

900 kPa (9 kg/cm

Maximum:

1,100 kPa (11 kg/cm

2

2

, 9 bar)

2

, 10 bar)

, 11 bar)

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/cm

3-15

2

, 1 bar).

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

7. Install:
 spark plug

8. Connect:
 spark plug cap

EAS00069

CHECKING THE ENGINE OIL LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

INSP

ADJ

20 Nm (2.0 mkg)

3. Check:
 engine oil level

The engine oil level should be between the
minimum level marks

b

marks
Below the minimum level mark  Add the
recommended engine oil to the proper level.

.

Recommended engine oil

Refer to the chart for the
engine oil grade which is best
suited for certain atmospheric
temperatures.
API standard

SE or higher grade

ACEA standard

G4 or G5

a

and maximum level

CAUTION:

 Engine oil also lubricates the clutch and

the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD
not use oils labeled “ENERGY CONSERV­ING II”

 Do not allow foreign materials to enter the

crankcase.

b

or higher.

a

or higher and do

3-16

CHECKING THE ENGINE OIL LEVEL/

CHANGING THE ENGINE OIL

4. Start the engine, warm it up for several min-

utes, and then turn it off.

5. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few
minutes until the oil has settled.

EAS00075

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-

utes, and then turn it off.

2. Place a container under the engine oil drain

bolt.

3. Remove:

 engine oil filler cap
 o-ring
 engine oil drain bolt
 gasket

4. Drain:
 engine oil

(completely from the crankcase)

5. If the oil filter element is also to be replaced,

perform the following procedure.

INSP

ADJ

1

2

WARNING

Oil filter element replacement should be
made cold exhaust pipe and muffler, at room
temperature.

1

a. Remove the muffler

2

tank
(front cylinder)

b. Remove the oil filter element cover plate

element cover

c. Check the O-ring

cracked or damaged.

d. Install the new oil filter element and the ele-

ment cover.

e. Install the exhaust pipe (front cylinder), ele-

ment cover plate, rear brake reservoir tank
and muffler.
Refer to “ENGINE” in chapter 4.

6. Check:
 engine oil drain bolt gasket

Damage  Replace.

7. Install:

 gasket
 engine oil drain bolt

8. Fill:
 crankcase

(with the specified amount of the recom­mended engine oil)

, element cover 3 and exhaust pipe

4

6

Oil filter element cover bolt

10 Nm (1.0 mkg)

, rear brake reservoir

.

and oil filter element 7.

8

and replace it if it is

43 Nm (4.3 mkg)

5

,

3-17

CHANGING THE ENGINE OIL/

ADJUSTING THE CLUTCH CABLE FREE PLAY

Quantity

Total amount

3.6 L
Without oil filter element
replacement

3.0 L
With oil filter element
replacement

3.1 L

9. Install:

 o-ring
 engine oil filter cap

10. Start the engine, warm it up for several min­utes, and then turn it off.

11. Check:

 engine

(for engine oil leaks)

12. Check:

 engine oil level

Refer to “CHECKING THE ENGINE OIL
LEVEL”.

INSP

ADJ

EAS00078

ADJUSTING THE CLUTCH CABLE FREE
PLAY

1. Check:

 clutch cable free play

Out of specification  Adjust.

Clutch cable free play (at the end
of the clutch lever)

5  10 mm

2. Adjust:

 clutch cable free play

Handlebar side

a. Loosen the locknut
b. Turn the adjusting screw

c

until the specified clutch cable free play is

obtained.

Direction

Direction

b

c

Clutch cable free play is
increased.

Clutch cable free play is
decreased.

a

1

.

2

in direction b or

c. Tighten the locknut.

NOTE:

If the specified clutch cable free play cannot be
obtained as described above, perform the mech­anism adjustment procedure described below.

3. Remove:

 left side cover
 clutch adjusting cover

3-18

1

2

ADJUSTING THE CLUTCH CABLE FREE PLAY/

CLEANING THE AIR FILTER ELEMENT

4. Adjust:

 clutch mechanism

Engine side

a. Loosen the locknut
b. Turn in the adjusting screw

seated.
c. Turn the adjusting screw out 1/4 of a turn.
d. Tighten the locknut.
e. Check the clutch cable free play again and

ajust it if necessary.

EAS00086

CLEANING THE AIR FILTER ELEMENT

1. Remove:

 air filter case cover
 air filter element

2

1

1

INSP

.

ADJ

2

until it is lightly

3-19

2. Clean:

 air filter element

Apply compressed air to the outer surface of

the air filter element.

3. Check:

 air filter element

Damage  Replace.

4. Install:

 air filter element
 air filter case cover

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/

CLEANING THE AIR FILTER ELEMENT/

CHECKING THE BREA THER HOSE

CAUTION:

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
turning, leading to poor engine performance
and possible overheating.

NOTE:

When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.

INSP

ADJ

EAS00094

CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD

1. Check:

 carburetor joint

1

Cracks/damage  Replace.

Refer to “CARBURETOR” in chapter 6.

EAS00098

CHECKING THE BREATHER HOSE

1. Remove:

 cylinder head cover

2. Check:

 cylinder head breather hose

1

Cracks/damage  Replace.

Loose connection  Connect properly.

CAUTION:

Make sure that the cylinder head breather
hose is routed correctly.

3-20

CHECKING THE EXHAUST SYSTEM

EAS00100

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex­haust pipes, mufflers and gaskets.

1. Check:

 exhaust pipes
 muffler

Cracks/damage  Replace.

 gaskets

Exhaust gas leaks  Replace.

2. Check:

 tightening torque

2

1

3

INSP

ADJ

Exhaust pipe nut

20 Nm (2.0 mkg)

Exhaust pipe and muffler bolt

20 Nm (2.0 mkg)

Muffler and muffler bracket bolt

25 Nm (2.5 mkg)

4

5

6

3-21

ADJUSTING THE FRONT BRAKE

EAS00108

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Check:

 brake lever free play

Out of specification  Adjust.

Brake lever free play (at the end
of the brake lever)

5  8 mm

2. Adjust:

 brake lever free play

INSP

ADJ

a

a. Loosen the locknut
b. Turn the adjusting bolt

until the specified brake lever free play is ob-

tained.

Direction  Brake lever free play is

Direction  Brake lever free play is

c. Tighten the locknut.

b

c

1

.

2

in direction b or

increased.

decreased.

c

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, inspect and, if nec­essary, bleed the brake system.

CAUTION:

After adjusting the brake lever free play,
make sure that there is no brake drag.

3-22

ADJUSTING THE REAR BRAKE

EAS00110

ADJUSTING THE REAR BRAKE

1. Check:

 brake pedal position

a

(distance

to the top of the brake pedal)

Out of specification  Adjust.

2. Adjust:

 brake pedal position

a. Loosen the locknut
b. Turn the adjusting bolt

until the specified brake pedal position is ob-

tained.

from the top of the rider footrest

Brake pedal position (below the
top of the rider footrest)

81.8 mm

INSP

ADJ

1

.

2

in direction b or

c

Direction  Brake pedal is raised.
Direction  Brake pedal is lowered.

b

c

WARNING

After adjusting the brake pedal position,

2

check that the end of the adjusting bolt

d

visible through the hole

c. Tighten the locknut

Locknut

16 Nm (1.6 mkg)

.

1

to specification.

is

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, inspect and, if nec­essary, bleed the brake system.

CAUTION:

After adjusting the brake pedal position,
make sure that there is no brake drag.

3. Adjust:

 rear brake light switch

Refer to “ADJUSTING THE REAR BRAKE

LIGHT SWITCH”.

3-23

CHECKING THE BRAKE FLUID LEVEL

EAS00115

CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

INSP

ADJ

A

B

2. Check;

 brake fluid level

Below the minimum level mark

recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4

Front brake

A

Rear brake

B

a

 Add the

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 reservoir. Water will signifi­cantly lower the boiling point of the brake
fluid and could cause vapor lock.

CAUTION:

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

NOTE:

In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser­voir is horizontal.

3-24

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE BRAKE HOSES

EAS00128

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

NOTE:

The rear brake light switch is operated by move­ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1. Check:

 rear brake light operation timing

Incorrect  Adjust.

2. Adjust:

 rear brake light operation timing

INSP

ADJ

a. Hold the main body

1

of the rear brake light

switch so that it does not rotate and turn the

2

adjusting nut

in direction a or b until the

rear brake light comes on at the proper time.

Direction  Brake light comes on

a

sooner.

Direction  Brake light comes on

b

later.

EAS00131

CHECKING THE BRAKE HOSES

The following procedure applies to all of the
brake hoses and clamps.

1. Check:

 brake hose

Cracks/damage/wear  Replace.

2. Check:

 brake hose clamp

Loose connection  Tighten.

3. Hold the motorcycle upright and apply the

brake.

4. Check:

 brake hose

Activate the brake several times.

Brake fluid leakage  Replace the damaged

hose.

Refer to “FRONT AND REAR BRAKES” in

chapter 7.

3-25

BLEEDING THE HYDRAULIC BRAKE SYSTEM

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS­TEM

WARNING

Bleed the hydraulic brake system whenever:

 the system was disassembled,
 a brake hose was loosened or removed,
 the brake fluid level is very low,
 brake operation is faulty.

NOTE:

 Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir or brake
fluid reservoir to overflow.

 When bleeding the hydraulic brake system,

make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the 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.

INSP

ADJ

1. Stand the motorcycle on alevel surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

A

B

2. Bleed:

 hydraulic brake system

a. Add the recommended brake fluid to the

proper level.
b. Install the diaphragm (brake master cylinder

reservoir or brake fluid reservoir).

: Rear

1

tightly to the

c. Connect a clear plastic hose

2

bleed screw

: Front

A

d. Place the other end of the hose into a con-

tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.
g. Loosen the bleed screw.

This will release the tension and cause the

brake lever to contact the throttle grip or the

brake pedal to fully extend.

.

B

3-26

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SHIFT PEDAL

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)

k. Fill the reservoir to the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL”.

WARNING

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

INSP

ADJ

EAS00137

ADJUSTING THE SHIFT PEDAL
NOTE:

The shift pedal position is determined by the ad­justing bolt length

1. Measure:

 adjusting the length

Incorrect  Adjust.

Adjusting bolt length

114.7 mm

2. Adjust:

 adjusting bolt length

a. Loosen both locknuts
b. Turn the adjusting bolt 2 in direction b or

to obtain the correct shift pedal position.

Direction  shift pedal is raised.
Direction  shift pedal is lowered.

a

.

a

a

1

c

b

c

3-27

CHECKING THE FINAL DRIVE OIL LEVEL/

CHANGING THE FINAL DRIVE OIL

EAS00144

CHECKING THE FINAL DRIVE OIL LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

2. Remove:

 final drive housing oil filler bolt

3. Check:

 final drive oil level

The final drive oil level should be to the bot-

tom brim

Below the bottom brim  Add the recom-

mended final drive oil to the proper level.

2

of the filler hole.

Recommended final drive oil

SAE 80 hypoid gear oil graded
“GL-4”, “GL-5” or “GL-6”
or
multi-purpose SAE 80W90
hypoid gear oil

INSP

ADJ

1

4. Install:

 final drive housing oil filler bolt

23 Nm (2.3 mkg)

EAS00145

CHANGING THE FINAL DRIVE OIL

1. Place a container under the final drive hous-

ing.

2. Remove:

 final drive housing oil filler bolt
 final drive housing oil drain bolt

1

2

Completely drain the final drive housing of its

oil.

3. Check:

 final drive housing oil drain bolt gasket

Damage  Replace.

4. Install:

 final drive housing oil drain bolt

23 Nm (2.3 mkg)

3-28

5. Fill:

 final drive housing

(with the specified amount of the recom-

mended final drive oil)

CHANGING THE FINAL DRIVE OIL/

CHECKING AND ADJUSTING THE STEERING HEAD

Quantity

0.2 L

Refer to “CHECKING THE FINAL DRIVE OIL
LEVEL”.

EAS00146

CHECKING AND ADJUSTING THE STEER­ING HEAD

1. Stand the motorcycle on a level surface.

W ARNING

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

INSP

ADJ

NOTE:

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

2. Check:

 steering head

Grasp the bottom of the front fork legs and

gently rock the front fork.

Looseness or binding  Adjust the steering

head.

3. Remove:

 upper bracket pinch bolt
 steering stem nut
 upper bracket

2

3

1

4. Adjust:

 steering head

a. Remove the lock washr

2

, and the rubber washer 3.

3-29

1

, the upper ring nut

CHECKING AND ADJUSTING THE STEERING HEAD

b. Loosen the lower ring nut 4 and then tighten

it to specification with a ring nut wrench

NOTE:

Set the torque wrench at a right angle to the ring
nut wrench.

Ring nut wrench

90890-01403

Lower ring nut (initial tightening
torque)

52 Nm (5.2 mkg)

INSP

ADJ

5

.

c. Loosen the lower ring nut

tighten it to specification.

4

completely , then

WARNING

Do not overtighten the lower ring nut.

Lower ring nut (final tightening
torque)

18 Nm (1.8 mkg)

d. Check the steering head for looseness or

binding by turning the front fork all the way in

both directions. If any binding is felt, remove

the lower bracket and inspect the upper and

lower bearings.

Refer to “STEERING HEAD AND HAN-

DLEBAR” in chapter 7.
e. Install the rubber washer
f. Install the upper ring nut
g. Finger tighten the upper ring nut

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

3

.

2

.

2

, then

1

.

NOTE:

Make sure that the lock washer tabs
rectly in the ring nut slots

5. Install:

 upper bracket
 steering stem nut
 upper bracket pinch bolt

3-30

a

sit cor-

b

.

110 Nm (11.0 mkg)

20 Nm (2.0 mkg)

CHECKING THE FRONT FORK/

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

EAS00149

CHECKING THE FRONT FORK

1. Stand the motorcycle on a level surface.

W ARNING

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

2. Check:

 inner tube

Damage/scratches  Replace.

 oil seal

Oil leakage  Replace.

3. Hold the motorcycle upright and apply the

front brake.

4. Check:

 operation

Push down hard on the handlebar several

times and check if the front fork rebounds

smoothly.

Unsmooth operation  Repair.

Refer to “FRONT FORK” in chapter 7.

INSP

ADJ

EAS00159

ADJUSTING THE REAR SHOCK ABSORB­ER ASSEMBLY

W ARNING

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

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

 spring preload

3-31

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/

CHECKING THE TIRES

Ring nut wrench

1HX-28135-00

a. Turn the adjusting knob

b

.

INSP

ADJ

1

in direction a or

Direction  Spring preload is

Direction  Spring preload is

Adjusting position

Standard: 3
Minimum: 1 (soft)
Maximum: 7 (hard)

EB304174

CHECKING THE TIRES

The following procedure applies to both of the
tires.

1. Measure:

 tire pressure

Out of specification  Regulate.

a

increased
(suspension is harder).

b

decreased
(suspension is softer).

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.

3-32

CHECKING THE TIRES

Basic
weight: (with
oil and full
fuel tank)

274 kg

INSP

ADJ

Maximum
load*:

Cold tire
pressure:

Up to 90 kg
load*

90 kg
 maximum
load*

High speed
riding

201 kg

Front Rear
200 kPa

(2.00 kgf/cm
225 kPa

(2.25 kgf/cm
225 kPa

(2.25 kgf/cm

225 kPa

2

)

(2.25 kgf/cm
250 kPa

2

(2.50 kgf/cm

)

250 kPa

2

(2,50 kgf/cm

)

2

2

2

*: total of cargo, rider, passenger and acces-

sories

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

Tire tread depth

1

Side wall

2

Wear indicator

3

WARNING

 Do not use a tubeless tire on a wheel de-

signed 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.

 To avoid pinching the tube, make sure that

the wheel rim band and tube are centered in
the wheel groove.

3-33

CHECKING THE TIRES

 Patching a punctured tube is not recom-

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

INSP

ADJ

Tube wheel
Tube tire only T ube or tubeless tire

 After extensive tests, the tires listed below

have been approved by Yamaha Motor Co.,
Ltd. for this model. Then 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

BRIDGE­STONE

DUNLOP 110/90-18 61S K555F

Rear tire:

110/90-18 61S EXEDRA L309

Tubeless wheel

Type Size

Manufactur­er

BRIDGE­STONE

DUNLOP

Type Size

170/80-15

M/C 77S

170/80-15

M/C 77S

EXEDRA

G546
K555

WARNING

 New tires have a relatilvely low grip on the

road surface until they have been slightly
worn.
Therefor, approximately 100 km should be
traveled at normal speed before any high­speed riding is done.

3-34

CHECKING THE TIRES/

CHECKING AND TIGHTENING THE SPOKES

NOTE:

For tires with a direction of rotation mark
 Install the tire with the mark pointing in the

direction of wheel rotation.

2

 Align the mark

point.

with the valve installation

INSP

ADJ

1

:

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.

2. Tighten:

 spoke

(with a spoke wrench

NOTE:

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

1

3 Nm (0.3 mkg)

)

2

3-35

LUBRICATING THE LEVERS AND PEDALS/LUBRICATING

CHECKING AND LUBRICATING THE CABLES/

THE SIDEST AND/LUBRICATING THE REAR SUSPENSION

EAS00170

CHECKING AND LUBRICATING THE
CABLES

The following procedure applies to all of the
cable sheaths and cables.

W ARNING

Damaged cable sheaths may causes 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

Unsmooth operation  Lubricate.

Recommended lubricant

Engine oil or a suitable cable
lubricant

INSP

ADJ

NOTE:

Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit­able lubing device.

EAS00171

LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.

Recommended lubricant

Engine oil

EAS00172

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.

Recommended lubricant

Engine oil

EAS00174

LUBRICATING THE REAR SUSPENSION

Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.

3-36

Recommended lubricant

Molybdenum disulfide grease

CHECKING AND CHARGING THE BATTERY

EB305020

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BA TTER Y

WARNING

Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi­sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
 Wear protective eye gear when handling or

working near batteries.

 Charge batteries in a well-ventilated area.
 Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,
lighted cigarettes).

 DO NOT SMOKE when charging or han-

dling batteries.

 KEEP BATTERIES AND ELECTROLYTE

OUT OF REACH OF CHILDREN.

 Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eye

injury.
First aid in case of bodily contact:
External

 SKIN – Wash with water.
 EYES – Flush with water for 15 minutes and

get immediate medical attention.
Internal
Drink large quantities of water or milk fol­lowed with milk of magnesia, beaten egg or

WARNING

vegetable oil. Get immediate medical atten­tion.

INSP

ADJ

CAUTION:

 This is a sealed battery. Never remove the

sealing caps because the balance between

cells will not be maintained and battery per-

formance will deteriorate.
 Charging time, charging amperage and

charging voltage for a MF battery are differ-

ent from those of conventional batteries.

The MF battery should be charged as ex-

plained in the charging method illustra-

tions. If the battery is overcharged, the

electrolyte level will drop considerably.

Therefore, take special care when charging

the battery.

3-37

CHECKING AND CHARGING THE BATTERY

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:

S battery cover

1

2. Disconnect:

S battery leads

(from the battery terminals)

CAUTION:

INSP

ADJ

Volt meter

First, disconnect the negative lead
the positive lead

2

.

1

, then

3. Remove:

S battery

4. Check:

S battery charge

a. Connect a pocket tester to the battery termi-

nals.

Tester positive lead  battery positive

terminal

Tester negative lead  battery negative

terminal

NOTE:

S The charge state of a MF battery can be

checked by measuring its open-circuit voltage

(i.e., the voltage when the positive terminal is

disconnected).
S No charging is necessary when the open-cir-

cuit voltage equals or exceeds 12.8 V.

Relationship between open-circuit
voltage and charging time at 20_C

Open-circuit voltage

D This varies depending on the temperature, the state of

charge in battery plates and the electro lyte level.

Charging time (Hours)

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 %

5. Charge:

S battery

(refer to the appropriate charging method il­lustration)

3-38

CHECKING AND CHARGING THE BATTERY

INSP

ADJ

Open-circuit voltage (V)

Condition of charge in battery (%)

Charging

18
17
16
15
14
13
12

11

Open-circuit voltage (V)

10

0102030405060

Ambient
temperature 20_C

Ambient temperature
20_C

Check the Open-circuit
voltage

Time (Minutes)

WARNING

Do not quick charge a battery.

CAUTION:

S Make sure that the battery breather hose

and battery vent are free of obstructions.

S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger.

They force a high-amperage current into

the battery quickly and can cause battery

overheating and battery plate damage.
S If it is impossible to regulate the charging

current on the battery charger, be careful

not to overcharge the battery.
S When charging a battery, be sure to remove

it from the motorcycle. (If charging has to

be done with the battery mounted on the

motorcycle, disconnect the negative lead

from the battery terminal.)
S To reduce the chance of sparks, do not

plug in the battery charger until the battery

charger leads are connected to the battery .
S Before removing the battery charger lead

clips from the battery terminals, be sure to

turn off the battery charger.
S Make sure that the battery charger lead

clips are in full contact with the battery ter-

minal and that they are not shorted. A cor-

roded battery charger lead clip may gener-

ate heat in the contact area and a weak clip

spring may cause sparks.
S If the battery becomes hot to the touch at

any time during the charging process, dis-

connect the battery charger and let the bat-

tery cool before reconnecting it. Hot batter-

ies can explode!
S As shown in the following illustration, the

open-circuit voltage of a MF battery stabi-

lizes about 30 minutes after charging has

been completed. Therefore, wait 30 min-

utes after charging is completed before

measuring the open-circuit voltage.

3-39

CHECKING AND CHARGING THE BATTERY

Charging method using a variable-current (voltage) type charger

INSP

ADJ

Charger

AMP meter

Measure the open-circuit
voltage prior to charging.

Connect a charger and
AMP meter to the battery
and start charging.

Make sure the current is

YES NO

higher than the standard
charging current written on
the battery.

Adjust the voltage so that cur­rent is at standard charging
level.

YES

NOTE:

Voltage should be measured 30 min­utes after the machine is stopped.

NOTE:

Set the charging voltage at 16  17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)

By turning the charging volt­age adjust dial, set the charg­ing voltage at 20  25 V.

Monitor the amperage for 3 
5 minutes to check if the stan­dard charging current is
reached.

Set the timer according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps.”

In case that charging requires more than 5 hours, it is advisable to
check the charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.

Measure the battery open-circuit voltage after having left the battery
unused for more than 30 minutes.

12.8 V or more --- Charging is complete.

12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

NO

If the current does
not exceed stan­dard charging cur­rent after 5 min­utes, replace the
battery.

3-40

CHECKING AND CHARGING THE BATTERY

Charging method using a constant-voltage type charger

INSP

ADJ

Measure the open-circuit
voltage prior to charging.

Connect a charger and
AMP meter to the battery
and start charging.

Make sure the current is

YES NO

higher than the standard
charging current written on
the battery.

Charge the battery until the battery’s
charging voltage is 15 V.

NOTE:

Set the charging time at 20 hours (maxi­mum).

NOTE:

Voltage should be measured 30 min­utes after the machine is stopped.

This type of battery charger cannot
charge the MF battery. A variable volt­age charger is recommended.

Measure the battery open-circuit
voltage after having left the battery
unused for more than 30 minutes.

12.8 V or more --- Charging is com­plete.

12.7 V or less --- Recharging is re-

V olt meter

quired.
Under 12.0 V --- Replace the battery .

Charging method using a constant-current type charger

This type of battery charger cannot charge the MF battery.

Charger

AMP meter

3-41

CHECKING AND CHARGING THE BATTERY

6. Check:

 battery breather hose and battery vent

Obstruction  Clean.
Damage  Replace.

7. Install:

 battery

CAUTION:

 When inspecting the battery, make sure

that the battery breather hose is properly

attached and routed correctly . If the battery

breather hose is positioned so as to allow

electrolyte or hydrogen gas from the bat-

tery to contact the frame, the motorcycle

and its finish may be damaged.
 Make sure that the battery breather hose is

properly routed away from the drive chain

and from below the swingarm.

INSP

ADJ

8. Connect:

 battery leads

(to the battery terminals)

CAUTION:

First, connect the positive lead

2

negative lead

9. Check:

 battery terminals

Dirt  Clean with a wire brush.
Loose connection  Connect properly.

10. Lubricate:

 battery terminals

Recommended lubricant

11. Install:

 battery cover

.

Dielectric grease

1

, then the

3-42

CHECKING THE FUSES

EAS00181

CHECKING THE FUSES

The following procedure applies to all of the
fuses.

CAUTION:

T o avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.

1. Remove:

 rider’s seat
 ignitor plate

Refer to “FUEL TANK AND SEATS”.

 tool box cover

2. Check:

 fuse

a. Connect the pocket tester to the fuse and

check it for continuity.

NOTE:

Set the pocket tester selector to “Ω 1”.

1

INSP

ADJ

Pocket tester

90890-03112

b. If the pocket tester indicates “∞”, replace the

fuse.

3. Replace:

 blown fuse

a. Turn off the ignition.
b. Install a new fuse of the correct amperage

rating.

c. Turn on the switches to verify if the electrical

circuit is operational.

d. If the fuse immediately blows again, check

the electrical circuit.

Fuses

Main 30A 1

Headlight 15A 1

Carburetor

heater

Amperage rating Quantity

15A 1

3-43

Signals 10A 1

Ignition 10A 1

Back up 5A 1

Reserve 30A 1

Reserve 15A 1

Reserve 10A 1

Reserve 5A 1

CHECKING THE FUSES/

REPLACING THE HEADLIGHT BULB

W ARNING

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

4. Install:

 tool box cover
 ignitor plate
 rider’s seat

INSP

ADJ

EAS00182

REPLACING THE HEADLIGHT BULB

1. Disconnect:

 connectors

2. Remove

 headlight bulb cover

3. Remove:

 headlight bulb holder

4. Remove:

 headlight bulb

1

2

1

2

W ARNING

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

5. Install:

 headlight bulb (New)

Secure the new headlight bulb with the head­light bulb holder.

3-44