Yamaha FZS 1000 N 2001 Service Manual
Yamaha FZS 1000 N 2001 Service Manual
Yamaha FZS 1000 N 2001 Service Manual
FZS1000 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, December 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve-
hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed-
eral environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
3
4
5
8
7
EAS00008
1 2 SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ADJ CHAS 3 Periodic checks and adjustments
4 Chassis
5 Engine
5 6
6 Cooling system
7 Carburetor(-s)
ENG COOL 8 Electrical system
9 Troubleshooting
7 8
CARB ELEC
Symbols 10 to 17 indicate the following.
9 10 10 Serviceable with engine mounted
11 Filling fluid
TRBL 12 Lubricant
SHTG 13 Special tool
14 Tightening torque
11 12 15 Wear limit, clearance
16 Engine speed
17 Electrical data
13 14
15 16 17
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS
4
ENGINE ENG
5
COOLING SYSTEM COOL
6
CARBURETORS CARB
7
ELECTRICAL SYSTEM ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
EAS00018
MODEL CODE
The model code label 1 is affixed to the frame.
This information will be needed to order spare
parts.
1-1
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
”mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
EAS00023
1-2
GEN
IMPORTANT INFORMATION INFO
EAS00024
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1 Bearing
EAS00025
CIRCLIPS
1. Before reassembly, check all circlips careful-
ly and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positioned op-
posite the thrust 3 that the circlip receives.
4 Shaft
1-3
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
4. Connect:
lead
coupler
connector
NOTE:
Make sure that all connections are tight.
5. Check:
continuity
(with a pocket tester)
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps 1 to 3.
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
90890-01080
This tool is used to remove the generator
rotor.
Rotor holding tool
90890-01304
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Radiator cap Radiator cap tester
tester Adapter
90890-01325
Adapter These tools are used to check the cooling
90890-01352 system.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Damper rod holder
1-5
GEN
SPECIAL TOOLS INFO
90890-01426
This tool is needed to loosen or tighten the
oil filter cartridge.
Rod holder
90890-01434
This tool is used to support the damper ad-
justing rod.
Rod puller Rod puller
90890-01437 Rod puller attachment
Rod puller
attachment These tools are used to pull up the front
90890-01436 fork damper rod.
Fork seal driver Fork seal driver weight
weight Fork seal driver attachment (ø43)
90890-01367
Fork seal driver
attachment (ø43) This tool is used to install the front fork’s oil
90890-01374 seal and dust seal.
Micrometer (50 75 mm)
90890-03008
This tool is used to measure the piston skirt
diameter.
Vacuum gauge
Vacuum gauge
90890-03094
This guide is used to synchronize the car-
buretors.
Compression Compression gauge
gauge Compression gauge adapter
90890-03081
Compression
gauge adapter These tools are used to measure engine
90890-04136 compression.
Pocket tester
90890-03112
This tool is used to check the electrical sys-
tem.
Engine tachometer
90890-03113
1-6
GEN
SPECIAL TOOLS INFO
90890-03141
This tool is used to check the ignition tim-
ing.
Carburetor angle driver 2
90890-03173
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring com- Valve spring compressor
pressor Valve spring compressor attachment
90890-04019
Attachmenht
90890-04108 These tools are used to remove or install
90890-04114 the valve assemblies.
Middle driven shaft Middle driven shaft bearing driver
bearing driver Mechanical seal installer
90890-04058
Mechanical seal
installer These tools are used to install the water
90890-04078 pump seal.
Universal clutch holder
90890-06754
This tool is used to check the ignition sys-
tem components.
1-7
GEN
SPECIAL TOOLS INFO
90890-85505
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
1-8
SPEC
CHAPTER 2.
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I)
(N) (NL) (S) (SF) (CH) (P)
5LV2 (F)
5LV3 (D)
5LV4 (AUS)
Dimensions
Overall length 2,125 mm
Overall width 765 mm
Overall height 1,190 mm
Seat height 820 mm
Wheelbase 1,450 mm
Minimum ground clearance 140 mm
Minimum turning radius 2,900 mm
Weight
Wet (with oil and a full fuel tank) 231 kg
Dry (without oil and fuel) 208 kg
Maximum load (total of cargo, rider, 189 kg
passenger, and accessories)
2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC
Displacement 998 cm3
Cylinder arrangement Forward-inclined parallel 4-cylinder
Bore stroke 74 58 mm
Compression ratio 11.4 : 1
Engine idling speed 1,050 1,150 r/min
Vacuum pressure at engine idling 30 kPa (225 mm Hg)
speed
Standard compression pressure 1,450 kPa (14.5 kg/cm2) at 400 r/min
(at sea level)
Fuel
Recommended fuel Regular unleaded gasoline
Fuel tank capacity
Total (including reserve) 21 L
Reserve only 4.0 L
Engine oil
Lubrication system Wet sump
Recommended oil
SAE20W40SE or SAE10W30SE
Quantity
Total amount 3.7 L
Without oil filter cartridge 2.8 L
replacement
With oil filter cartridge replacement 3.0 L
Oil pressure (hot) 45 kPa at 1,100 r/min
(0.45 kg/cm2 at 1,100 r/min)
Relief valve opening pressure 490 570 kPa (4.9 5.7 kg/cm2)
2-2
ENGINE SPECIFICATIONS SPEC
2-3
ENGINE SPECIFICATIONS SPEC
2-4
ENGINE SPECIFICATIONS SPEC
2-5
ENGINE SPECIFICATIONS SPEC
Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder SSS
Bore stroke 74 58 mm SSS
Compression ratio 11.4 : 1 SSS
Bore 74.00 74.01 mm SSS
Max. taper SSS 0.05 mm
Max. out-of-round SSS 0.05 mm
2-6
ENGINE SPECIFICATIONS SPEC
Height H 5 mm
Piston pin bore (in the piston)
Diameter 17.002 17.013 mm 17.043
Offset
Offset direction Intake side
Piston pins
Outside diameter 16.991 17.000 mm 16.971
Piston-pin-to-piston-pin-bore 0.002 0.022 mm 0.072 mm
clearance
Piston rings
Top ring
2-7
ENGINE SPECIFICATIONS SPEC
2-8
ENGINE SPECIFICATIONS SPEC
2-9
ENGINE SPECIFICATIONS SPEC
2-10
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Double cradle SSS
Caster angle 26_ SSS
Trail 104 mm SSS
Front wheel
Wheel type Cast wheel SSS
Rim
Size 17 MT3.50 SSS
Material Aluminum SSS
Wheel travel 140 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Rear wheel
Wheel type Cast wheel SSS
Rim
Size 17 MT5.50 SSS
Material Aluminum SSS
Wheel travel 135 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Front tire
Tire type Tubeless SSS
Size 120/70 ZR17 (58W) SSS
Model (manufacturer) MEZ4Y FRONT (METZELER) SSS
BT020F U (BRIDGESTONE)
Tire pressure (cold)
0 90 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
90 201 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
High-speed riding 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
Min. tire tread depth SSS 1.6 mm
2-11
CHASSIS SPECIFICATIONS SPEC
2-12
CHASSIS SPECIFICATIONS SPEC
2-13
CHASSIS SPECIFICATIONS SPEC
2-14
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type Transistorized coil ignition SSS
Ignition timing 5_ BTDC at 1,100 r/min SSS
Advanced timing 55_ BTDC at 5,000 r/min SSS
Advancer type Throttle position sensor and electrical SSS
Pickup coil resistance/color 248 372 Ω/Gy-B SSS
Transistorized coil ignition unit TNDF66 (DENSO) SSS
model (manufacturer)
Ignition coils
Model (manufacturer) J0313 (DENSO) SSS
Minimum ignition spark gap 6 mm SSS
Primary coil resistance 1.87 2.53 Ω SSS
Secondary coil resistance 12 18 kΩ SSS
Spark plug caps
Material Rubber SSS
Resistance 10 kΩ SSS
Throttle position sensor standard
resistance 4 6 kΩ SSS
Charging system
System type AC magneto SSS
Model (manufacturer) F4T361 (MITSUBISHI) SSS
Normal output 14 V/365 W at 5,000 r/min SSS
Stator coil resistance/color 0.27 0.33 Ω at 20_C/W-W SSS
Rectifier/regulator
Regulator type Semiconductor short circuit SSS
Model ((manufacture)) SH650C-11 ((SHINDENGEN)) SSS
No-load regulated voltage 14.1 14.9 V SSS
Rectifier capacity 18 A SSS
Withstand voltage 200 V SSS
Battery
Battery type GT14B-4 SSS
Battery voltage/capacity 12 V/12AH SSS
Headlight type Halogen bulb
Bulbs (voltage/wattage quantity)
Headlight 12 V 60 W/55 W 2 SSS
Auxiliary light 12 V 5 W 2 SSS
Tail/brake light 12 V 5 W/21 W 2 SSS
Turn signal light 12 V 21 W 4 SSS
Meter light 12 V 2 W 3 SSS
2-15
ELECTRICAL SPECIFICATIONS SPEC
2-16
ELECTRICAL SPECIFICATIONS SPEC
2-17
TIGHTENING TORQUES SPEC
EAS00029
TIGHTENING TORQUE
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special
components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Compo-
nents should be at room temperature.
2-18
TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mSkgf
Spark plugs – M10 4 13 1.3
Cylinder head Nut M10 8 50 5.0
Cylinder head Cap nut M10 2 50 5.0
Cylinder head Bolt M6 2 12 1.2
Camshaft caps Bolt M6 28 10 1.0
Cylinder head cover Bolt M6 6 12 1.2
Cylinder head (exhaust pipe) Stud bolt M8 8 15 1.5
Connecting rod caps Nut M8 8 36 3.6
Generator rotor Bolt M10 1 65 + 60_ 6.5 + 60_
Crankshaft sprocket Bolt M10 1 60 6.0
Cap bolt (timing chain tensioner) Bolt M6 1 6.4 0.64
Camshaft sprocket Bolt M7 4 24 2.4
Water pump inlet pipe Bolt M6 1 10 1.0
Water pump outlet pipe Bolt M6 1 10 1.0
Oil/water pump assembly driven
Bolt M6 1 15 1.5
sprocket
Oil pump Bolt M6 1 12 1.2
Oil cooler Bolt M20 1 35 3.5
Engine oil drain bolt – M14 1 43 4.3
Oil strainer housing Bolt M6 2 10 1.0
Oil/water pump assembly driven
Bolt M6 1 12 1.2
sprocket cover
Oil delivery pipe Bolt M6 1 10 1.0
Oil filter bolt Bolt M20 1 70 7.0
Oil filter cartridge – M20 1 17 1.7
Oil pipe Bolt M6 2 10 1.0
Air cleaner cap and air cleaner Screw M6 4 6 0.6
Frame and air cleaner Bolt M6 3 7 0.7
Air cleaner cover and air cleaner Screw M6 6 2 0.2
Ring nut and cylinder head Nut M8 8 20 2.0
Exhaust pipe and muffler Bolt M8 3 20 2.0
Emission check bolt Bolt M8 4 10 1.0
EXUP pulley cover Bolt M6 3 10 1.0
EXUP cable bracket Bolt M6 3 10 1.0
EXUP pulley and shaft arm Bolt M5 1 10 1.0
Exhaust joint Bolt M4 2 3 0.3
Exhaust pipe assembly Bolt M8 1 20 2.0
Air induction system pipe Band – 4 3.5 0.35
Crankcase (cylinder head) Stud bolt M10 10 10 1.0
Crankcase Bolt M9 10 See note
Crankcase Bolt M6 2 14 1.4
Crankcase Bolt M6 14 12 1.2
Crankcase Bolt M8 2 24 2.4
2-19
TIGHTENING TORQUES SPEC
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mSkgf
AC magneto cover Bolt M6 9 12 1.2
Drive sprocker cover Bolt M6 4 10 1.0
Plate Bolt M6 2 10 1.0
Clutch cover Bolt M6 8 12 1.2
Timing chain cap bolt Bolt M6 8 12 1.2
Shift shaft cover Bolt M6 5 12 1.2
Breather plate Bolt M6 5 10 1.0
Timing mark accessing screw Bolt M8 1 15 1.5
Starter clutch idle gear shaft Bolt M6 1 10 1.0
Starter one-way clutch Bolt M6 3 12 1.2
Use a lock
Clutch boss Nut M20 1 90 9.0
washer.
Clutch spring Bolt M6 6 8 0.8
Use a lock
Drive sprocket Nut M22 1 85 8.5
washer.
Main axle bearing housing Screw M6 3 12 1.2
Shift lever stopper Bolt M6 2 10 1.0
Stopper screw Screw M8 1 22 2.2
Shift rod Nut M6 1 6.5 0.65 Left thread
Shift rod Nut M6 2 6.5 0.65
Shift rod joint Bolt M6 1 10 1.0
Shift arm Bolt M6 1 10 1.0
AC magneto stator coil Screw M6 3 14 1.4
Ignitor unit Screw M5 2 7 0.7
Neutral switch – M10 1 20 2.0
Pick up coil Bolt M6 2 10 1.0
Thermo unit – – 1 15 1.5
NOTE:
1. First, tighten the bolt to approximately 14.7 Nm (1.5 mSkg) with a torque wrench.
2. Retighten the bolt to 14.7 Nm (1.5 mSkg), and tighten another 45 50_.
2-20
TIGHTENING TORQUES SPEC
2-21
TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
Tightening
Item Thread size Remarks
Nm mkgf
Upper bracket pinch bolt M8 30 3.0
Upper bracket cap nut M22 110 11
Upper bracket and handlebar holder M10 32 3.2
Handlebar holder M8 23 2.3
Lower bracket pinch bolt – 23 2.3
Lower bracket ring nut M25 18 1.8 See note
Front brake master cylinder M6 10 10
Front brake hose union bolt M10 30 3.0
Engine mounting
Engine mounting bolt/nut M10 55 5.5
Engine mounting bolt/nut M8 33 3.3
Frame and down tube M10 89 8.9
Clutch cable lock nut M8 7 0.7
Ignition coil and stay M6 7 0.7
Pivot shaft M18 125 12.5
Rear shock absorber (upper) M10 40 4.0
Rear shock absorber and relay arm M10 40 4.0
Relay arm and frame M10 40 4.0
Relay arm and connecting arm M12 48 4.8
Connecting arm and swing arm M12 48 4.8
Drive chain guard M6 7 0.7
Drive chain case M6 7 0.7
Fuel cock M6 7 0.7
Fuel sender M5 4 0.4
Side cover M6 4 0.4
Coolant reservoir tank M6 4 0.4
Front wheel axle M16 72 7.2
Front wheel axle pinch bolt M8 23 2.3
Front brake caliper M10 40 4.0
Front brake disk M6 18 1.8
Front brake bleed screw M8 6 0.6
Rear brake torque rod M8 23 2.3
Rear wheel sprocket M10 69 6.9
Drive chain adjusting nut M8 16 1.6
Rear brake caliper M10 40 4.0
Rear wheel axle M24 150 15
Rear brake hose union bolt M10 30 3.0
Rear brake bleed screw M8 6 0.6
Rear brake disk M8 23 2.3
Rider footrest bracket and frame M8 30 3.0
Rear brake reservoir tank M6 4 0.4
Rear brake master cylinder M8 23 2.3
Rider footrest and bracket M10 55 5.5
Passenger footrest bracket and frame M8 28 2.8
Passenger footrest bracket and muffler M10 48 4.8
NOTE:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
2-22
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00031
2-23
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00032
CHASSIS
Lubrication point Lubricant
Steering bearings, steering seal lips and ball race cover lips
Pivot shaft
Swing arm pivoting points and connecting arm bearings
Connecting arm oil seal lips
Swing arm oil seal lips
Relay arm bearings
Relay arm oil seal lips
Rear shock absorber upper bolt
Front wheel oil seal lips
Rear wheel oil seal lips
Clutch hub oil seal lips
Throttle cable end
Starter cable end and starter lever
Rear brake pedal moving point
Shift pedal moving point
Side stand moving point
Passenger footrest ball joint and moving point
Engine mounting bracket collar and oil seal lips
Mainstand moving point
2-24
COOLING SYSTEM DIAGRAMS SPEC
EAS00033
2-25
COOLING SYSTEM DIAGRAMS SPEC
1 Radiator cap
2 Thermostat housing
3 Radiator
4 Oil cooler
5 Water jacket joint
2-26
COOLING SYSTEM DIAGRAMS SPEC
1 Radiator cap
2 Thermostat
3 Thermo unit
2-27
COOLING SYSTEM DIAGRAMS SPEC
1 Radiator
2-28
ENGINE OIL LUBRICATION CHART SPEC
Exhaust
camshaft
Intake
camshaft
Main gallery
Oil filter
Main axle
Oil
cooler
Relief
Strainer
valve Drive axle
2-29
LUBRICATION DIAGRAMS SPEC
EAS00034
LUBRICATION DIAGRAMS
1 Oil cooler
2 Oil filter cartridge
3 Drain bolt
4 Oil level switch
5 Oil strainer
6 Oil pump
2-30
LUBRICATION DIAGRAMS SPEC
1 Intake camshaft
2 Exhaust camshaft
3 Oil cooler
4 Oil strainer
5 Oil pump
2-31
LUBRICATION DIAGRAMS SPEC
1 Intake camshaft
2 Exhaust camsahft
3 Oil filter cartridge
4 Oil level switch
2-32
LUBRICATION DIAGRAMS SPEC
1 Cylinder head
2 Crankshaft
2-33
LUBRICATION DIAGRAMS SPEC
1 Main axle
2 Oil delivery pipe
3 Drive axle
2-34
CABLE ROUTING SPEC
EAS00035
CABLE ROUTING
A Fasten the handlebar switch lead (right) and han- F Route the horn lead outside the motorcycle body,
dlebar with a plastic band. and fasten with the under bracket. Do not loose be-
B Route the handlebar switch lead (right) backward tween the horn and under bracket.
the throttle cable and right side the brake hose G Route the brake hose through the brake hose
guide. guide.
C Fasten the handlebar switch lead (left) and handle- H Route the throttle cable 1 and 2 backward the brake
bar with a plastic band. hose, and left side the brake hose guide.
D Fasten the handlebar switch lead (left), main switch
lead, clutch cable and starter cable with a plastic
band. Clamp beneath the horn lead branching posi-
tion. Do not fasten the horn lead.
E Route the main switch lead front and left side the
another leads.
2-35
CABLE ROUTING SPEC
1 Fuel pump lead 17 Handle crown
2 Fuel pump 18 Handlebar switch lead
3 EXUP cable 19 Brake hose guide
4 Handlebar switch lead (right)
5 Throttle cable 1 A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed
6 Throttle cable 2 sensor lead, rear brake light switch lead and fuel pump with a plastic
7 Water-carburetor hose clamp.
8 Fan motor lead B Fasten the fuel hose, pickup coil lead, neutral switch lead and speed
9 Coolant reservoir tank over flow sensor lead with a plastic clamp under the fuel hose.
hose C Put the EXUP cable into the air box cover.
10 Fuel tank drain hose D Route the T.P.S. lead inward the EXUP cable.
11 Fuel tank breather hose E Fasten the water-carburetor hose with a plastic band.
12 White paint mark F Route the coolant hose over the frame.
13 Rear brake light switch lead G Fasten the handlebar switch lead and frame with a plastic guide.
14 Neutral switch lead H Align the white tape mark of the handlebar switch lead (right) with the
15 Speedo sensor lead tank rail welding bead and clamp down throttle cables 1 and 2.
16 Pickup coil lead
2-36
CABLE ROUTING SPEC
I Route the water-carburetor hose between the Q Insert the all couplers into the rubber cover.
frame cross pipe and fan motor lead. R Route the rear brake light switch lead inside the
J To the carburetor another leads.
K Fasten the T.P.S. lead with a steel clamp. S Route the neutral switch lead and speed sensor
L Fasten the coolant hose with a plastic band. lead left side the coolant reservoir hose.
M Fasten the pickup coil lead with a steel clamp. T Route the coolant reservoir hose left side the en-
N Pass the coolant reservoir tank overflow hose, fuel gine mounting bracket.
tank drain hose and fuel tank breather hose through U Route the coolant reservoir hose forward the neu-
the frame hose holder from the inside of the vehicle tral switch lead and speed sensor lead.
to the outside. At this time, pull the fuel tank drain V Route the coolant reservoir hose backward the
hose and fuel tank breather hose so that the white another hoses.
paint marks are within a 20 mm range. W Route the EXUP cable forward the another hoses.
O Route the EXUP cable forward the another hoses, X Route the EXUP cable forward the frame cross
and upward the engine mounting bracket. pipe.
P Fasten the rear brake light switch lead with a plastic Y Route the fuel tank drain hose and fuel tank breath-
guide. er hose forward the neutral switch lead and speed
sensor lead.
2-37
CABLE ROUTING SPEC
1 Starter cable A Fasten the main switch lead and handlebar switch lead with a plastic
2 Clutch cable guide.
3 Handlebar switch lead (left) B Fasten the water-head hose and water-carburetor hose with a plastic
4 Main switch lead band.
5 EXUP servo motor C Fasten the clutch cable with a plastic band.
6 Starting circuit cutoff relay D Fasten the clutch cable with a steel clamp.
7 Starter motor lead E Fasten the wire harness with a plastic band.
8 Fan motor relay F To the fuel sender.
9 Air cleaner case drain hose G Route the fuel sender lead inside the seat rail.
10 Sidestand switch lead H Route the battery negative lead forward the frame stay.
11 oil level switch lead I Route the main harness inside the rear fender groove.
12 ACgenerator lead J Fasten the wire harness, sidestand switch lead, oil level switch and
13 Water-head pipe flame with a plastic band. Do not fasten the Acgenerator lead (white).
14 Water-carburetor hose K Route the starter motor lead and battery negative lead inside the plastic
15 Throttle cable 2 band.
16 Throttle cable 1 L Route the all hoses outside the fuel hose.
17 EXUP cable M Route the fuel hose through the steel guide.
2-38
CABLE ROUTING SPEC
N Fasten the sidestand switch lead, oil level switch lead, and rectifier regulator lead.
ACgenerator lead, starter motor lead, battery negative U Route the water carburetor hose outside the coolant
lead and air cleaner case drain hose with a plastic clamp. hose.
O Fasten the sidestand switch lead, oil level switch lead, V Route the starter cable outside the coolant hose, and up-
ACgenerator lead and air filter case drain hose with a per the water-carburetor hose.
plastic clamp. W Route the high tension cable (#2, 3) forward the EXUP
P Fasten the sidestand switch lead and frame with a plastic cable and high tension cable (#4).
clamp. X Route the throttle cable between the water-head hose,
Q Route the air cleaner box drain hose inside the sidestand and upper the EXUP cable.
switch lead, and put the end of the hose backward. Y Route the high tension cable (#4) between the water-
R Fasten the sidestand switch lead and frame with a plastic head hose.
clamp. Z Taillight lead and flasher light lead (right) should not be
S Fasten the sidestand switch lead, oil level switch lead and stick out from the gap between the rear fender and tail-
air filter case drain hose with a plastic clamp. Do not crush light.
the air filter case drain hose. AA Route the flasher light lead through the hole on the rear
T Route the high tension cable (#1) outside the starter cable fender.
and water-carburetor hose, and under the clutch cable AB Route the wire harness in the groove.
2-39
CABLE ROUTING SPEC
1 Clutch cable 17 Ignition coil lead
2 Handlebar switch lead 18 Battery
3 Main switch lead 19 Emergency engine stop switch
4 Starter cable 20 Flasher relay
5 Thermo unit lead 21 Fuse box
6 Throttle cable 1 22 Igniter unit
7 Throttle cable 2 23 Flasher light lead
8 Handlebar switch lead (right) 24 Taillight lead
9 Coolant reservoir hose 25 Alarm coupler (free)
10 Ignition coil 26 Starter relay
11 Fuel hose 27 Battery positive lead
12 Fan motor lead 28 Fan motor lead
13 EXUP servo motor lead 29 Battery negative lead
14 Rectifier/ regulator lead 30 Starting circuit cutoff relay
15 White paint mark
16 Main harness
2-40
CABLE ROUTING SPEC
A Fasten the flasher light lead and headlight lead with K Fasten the fuel hose and air induction system hose
a plastic clamp. with a plastic clamp.
B Route the rectifier / regulator lead upper the fan mo- L Route the coolant reservoir hose under the frame
tor lead and EXUP servomotor lead. cross pipe.
C Route the throttle cable right side the fan motor M Fasten the fuel hose and frame with a plastic band.
lead, EXUP servo motor lead and thermo unit lead. N Put the fuel tank drain hose into the frontward nipple
D Fasten the flasher light lead with a plastic clamp. on the fuel tank.
E Route the all leads between the frame cross pipe O Put the fuel tank breather hose into the backward
and bracket. nipple on the fuel tank.
F Do not excessively bend the throttle cable. P Route the coolant reservoir hose under the air vent
G Route the coolant reservoir hose under the frame hose and air induction system hose.
cross pipe. Q Route the air vent hose upper the main harness.
H Fasten the ignition coil and ignition coil lead with a R All coupler into the rubber cover.
plastic clamp. S Fasten the Rectifier / regulator lead with a plastic
I Route the T.P.S. lead under the air vent hose. band in the main harness.
J Fasten the EXUP cable with a plastic band.
2-41
CABLE ROUTING SPEC
T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear
with a plastic clamp. Do not fasten the red / black fender.
lead and orange lead. AB Fasten the battery positive lead with a plastic band.
U Fasten the handlebar switch lead (left / right), main
switch lead, EXUP servo motor lead, fan motor lead
and thermo unit lead with a plastic clamp.
V Fasten the rectifier / regulator stay and rectifier / reg-
ulator lead with a plastic clamp.
W Route the wire harness under the rectifier / regula-
tor.
X Fasten the battery negative lead with a battery
band.
Y Insert the ground lead coupler in the battery band.
Z Fasten the taillight lead and flasher light lead, and
put in the groove on the taillight bracket.
2-42
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-5
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . 3-10
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-12
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-13
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-17
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-22
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-23
CHECKING THE CARBURETOR JOINTS AND
INTAKE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . 3-24
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . 3-25
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ADJUSTING THE EXUP CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . 3-36
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-37
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . 3-39
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-41
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 3-43
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 3-45
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
CHK
ADJ
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-50
Fuel line
1 * Check fuel hoses for cracks or damage. √ √ √ √ √
(See page 3-24)
Fuel filter
2 * Check condition. √ √
(See page 3-24)
Check condition.
Spark plugs Clean and regap.
√ √
3
(See page 3
3-15)
15)
Replace. √ √
Valves Check valve clearance.
4 * Every 40,000 km
(See page 3-5) Adjust.
3-1
CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
ODOMETER READING ( 1,000 km) ANNUAL
NO
NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
Chassis fasteners Make sure that all nuts, bolts and
16 * √ √ √ √ √
(See page 2-22) screws and properly tightened.
Sidestand /
Check operation.
17 centerstand
Lubricate.
√ √ √ √ √
(Seep age 3-50)
Sidestand switch
18 * Check operaiton. √ √ √ √ √ √
(See page 8-21)
Front fork
19 * Check operation and for oil leakage. √ √ √ √
(See page 3-43)
Rear shock
absorber Check operation and shock absorber for
20 *
assembly oil leakage.
√ √ √ √
(See page 4-64)
Rear suspension
relay arm and Check operation. √ √ √ √
21 * connecting arm
pivoting points
(See page 4-69)
Lubricate with lithium-soap-based grease. √ √
3-2
CHK
FRONT COWLING ADJ
EAS00038
3-3
CHK
SEAT, SIDE COVER AND FUEL TANK ADJ
EAS00040
19 Nm (1.9 mkg)
10 Nm (1.0 mkg)
4 Nm (0.4 mkg)
10 Nm (1.0 mkg)
8 Grab bar 1
9 Rear cowling 1
For installation, reverse the removal
procedure.
3-4
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00045
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:
cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.
2. Measure:
valve clearance
Out of specification Adjust.
#2 Cylinder 180_
#4 Cylinder 360_
#3 Cylilnder 540_
3. Remove:
S intake camshaft
S exhaust camshaft
NOTE:
S Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chap-
ter 5.
S When removing the timing chain and cam-
shafts, fasten a wire to the timing chain to re-
trieve it if it falls into the crankcase.
4. Adjust:
S valve clearance
Valve lapper
90890–04101
3-6
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
NOTE:
Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
NOTE:
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.
3-7
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
VALVE PAD SELECTION TABLE
INTAKE
Measured INSTALLED PAD NUMBER
clearance
# 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08 X 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11 X 0.20 Specification
exa 0.21 X 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
! 0.23 X 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28 X 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 X 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 185 190 195 200 205 210 215 220 225 230 235 240
0.83 X 0.87 190 195 200 205 210 215 220 225 230 235 240
0.88 X 0.92 195 200 205 210 215 220 225 230 235 240
0.93 X 0.97 200 205 210 215 220 225 230 235 240 EXAMPLE:
0.98 X 1.02 205 210 215 220 225 230 235 240 VALVE CLEARANCE: 0.11 X 0.20 mm
1.03 X 1.07 210 215 220 225 230 235 240 Installed is 150
1.08 X 1.12 215 220 225 230 235 240 Measured clearance is 0.25 mm
1.13 X 1.17 220 225 230 235 240 Replace 150 pad with 160 pad
1.18 X 1.22 225 230 235 240
1.23 X 1.27 230 235 240
1.28 X 1.32 235 240
1.33 X 1.37 240
EXHAUST
Measured INSTALLED PAD NUMBER
clearance
# 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08 X 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 X 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18 X 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21 X 0.30 Specification
exa 0.31 X 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
! 0.33 X 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 X 0.87 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88 X 0.92 185 190 195 200 205 210 215 220 225 230 235 240
0.93 X 0.97 190 195 200 205 210 215 220 225 230 235 240
0.98 X 1.02 195 200 205 210 215 220 225 230 235 240
1.30 X 1.07 200 205 210 215 220 225 230 235 240 EXAMPLE:
1.08 X 1.12 205 210 215 220 225 230 235 240 VALVE CLEARANCE: 0.21 X 0.30 mm
1.13 X 1.17 210 215 220 225 230 235 240 Installed is 175
1.18 X 1.22 215 220 225 230 235 240 Measured clearance is 0.35 mm
1.23 X 1.27 220 225 230 235 240 Replace 175 pad with 185 pad
1.28 X 1.32 225 230 235 240
1.33 X 1.37 230 235 240
1.38 X 1.42 235 240
1.43 X 1.47 240
3-8
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
e. Install the new valve pad 1 and the valve lift-
er 2 .
NOTE:
Apply molybdenum disulfide to the valve pad.
Lubricate the valve lifter with molybdenum dis-
ulfide oil.
The valve lifter must turn smoothly when ro-
tated by hand.
Install the valve lifter and the valve pad in the
correct place.
NOTE:
Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 4.
Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft
cap marks.
Rotate the crankshaft clockwise several turns
to seat the parts.
5. Install:
cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.
6. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.
3-9
CHK
SYNCHRONIZING THE CARBURETORS ADJ
EAS00050
2. Remove:
vacuum cap
3. Install:
vacuum gauge 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Vacuum gauge
90890-03094
Engine tachometer
90890-03113
3-10
CHK
SYNCHRONIZING THE CARBURETORS ADJ
6. Adjust:
carburetor synchronization
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa (10
mm Hg).
7. Measure:
engine idling speed
Out of specification Adjust.
8. Stop the engine and remove the measuring
equipment.
9. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
10. Install:
vacuum cap
3-11
CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00052
Engine tachometer
90890-03113
3. Measure:
engine idling speed
Out of specification Adjust.
4. Adjust:
engine idling speed
Pilot screw
2 turns out
3-12
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
c. Turn the throttle stop screw 2 in direction a
or b until the specified engine idling speed is
obtained.
EAS00055
1. Check:
throttle cable free play a
Out of specification Adjust.
2. Remove:
seat
fuel tank
3-13
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Adjust:
throttle cable free play
NOTE:
When the motorcycle is accelerating, the accel-
erator cable 1 is pulled.
Carburetor side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 4 on the accelerator
cable.
d. Turn the adjusting nut 5 in direction a or b
until the specified throttle cable free play is
obtained.
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.
3-14
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUGS ADJ
4. Install:
fuel tank
seat
EAS00059
3. Check:
spark plug type
Incorrect Change.
Spark plug type (manufacturer)
CR9E (NGK)
U27ESR-N (DENSO)
4. Check:
electrode 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is a medium-to-light tan color.
5. Clean:
spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
spark plug gap a
(with a wire gauge)
Out of specification Regap.
3-15
CHECKING THE SPARK PLUGS/ CHK
CHECKING THE IGNITION TIMING ADJ
7. Install:
spark plug 13 Nm (1.3 mkg)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Connect:
spark plug cap
EAS00063
1. Remove:
timing plug 1
2. Install:
timing light 1
engine tachometer 2
(to the spark plug lead of cyl. #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3. Check:
ignition timing
3-16
CHECKING THE IGNITION TIMING/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
b. Check that the mark a is within the required
firing range b on the pickup coil rotor.
Incorrect firing range Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
4. Remove:
timing light
engine tachometer
5. Install:
timing plug
EAS00065
1. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
spark plug cap
4. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
compression gauge 1
Compression gauge
90890-03081
Compression gauge adapter
90890-04136
3-17
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
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.
Compression pressure
(with oil applied into cylinder)
Reading Diagnosis
Higher than Piston ring(-s) wear or
without oil damage Repair.
Piston valves, cylinder
head gasket or piston
Same as possibly defective
without oil Repair.
Compression pressure
(at sea level)
NOTE:
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1
kg/cm2).
7. Install:
spark plug 13 Nm (1.3 mkg)
8. Connect:
spark plug cap
3-18
CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EAS00069
3. Check:
engine oil level
The engine oil level should be between the
minimum level marks a and maximum level
marks b .
Below the minimum level mark Add the
recommended engine oil to the proper level.
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 a or higher and do
not use oils labeled “ENERGY CONSERV-
ING II” b or higher.
Do not allow foreign materials to enter the
crankcase.
3-19
CHK
CHANGING THE ENGINE OIL ADJ
EAS00073
3. Remove:
engine oil filler cap 1
engine oil drain bolt 2
(along with the gasket)
4. Drain:
engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.
CAUTION:
Make sure that the O-ring 1 is positioned
correctly in the groove of the oil filter car-
tridge.
3-20
CHK
CHANGING THE ENGINE OIL ADJ
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
6. Check:
engine oil drain bolt gasket
Damage Replace.
7. Install:
engine oil drain bolt 43 Nm (4.3 mkg)
8. Fill:
crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
3.7 L
Without oil filter cartridge
replacement
2.8 L
With oil filter cartridge replace-
ment
3.0 L
9. Install:
engine oil filler cap
10. Start the engine, warm it up for several min-
utes, and then turn it off.
11. Check:
engine
(for engine oil leaks)
12. Check:
engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
13. Check:
engine oil pressure
3-21
CHANGING THE ENGINE OIL/ CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
Oil gallery bolt
10 Nm (1.0 mkg)
EAS00078
2. Adjust:
clutch cable free play
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Engine side
a. Loosen the locknuts 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is ob-
tained.
3-22
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
EAS00086
2. Remove:
air filter case cover 1
air filter element
3. Clean:
air filter element
Apply compressed air to the outer surface of
the air filter element.
4. Check:
air filter element
Damage Replace.
5. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor en-
gine performance and possible overheat-
ing.
3-23
CLEANING THE AIR FILTER ELEMENT / CHK
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS /
CHECKING THE FUEL HOSES AND FUEL FILTER ADJ
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.
6. Install:
cover
side cover
fuel tank
seat
EAS00095
2. Check:
carburetor joint 1
intake manifold 2
Cracks/damage Replace.
Refer to “CARBURETOR” in chapter 6.
3. Install:
air chamber cover
fuel tank
seat
EAS00097
2. Check:
fuel hose 1
Cracks/damage Replace.
fuel filter 2
Damage/dirt Replace.
3-24
CHECKING THE FUEL HOSES AND FUEL FILTER/ CHK
CHECKING THE CRANKCASE BREATHER HOSE /
CHECKING THE EXHAUST SYSTEM ADJ
NOTE:
Drain and flush the fuel tank if abrasive dam-
age to any components of the fuel line is evi-
dent.
The arrow mark a on the fuel filter should face
to the side of the fuel pump 1 .
3. Install:
side cover
fuel tank
seat
EAS00098
3. Install:
fuel tank
seat
EAS00099
3-25
CHK
ADJUSTING THE EXUP CABLES ADJ
EAS00101
2. Remove:
EXUP valve pulley cover 1
3. Check:
EXUP operation
CAUTION:
To avoid damaging the servomotor, do not
leave the battery connected to it for more
than a few seconds.
3-26
ADJUSTING THE EXUP CABLES/ CHK
CHECKING THE COOLANT LEVEL ADJ
4. Check:
EXUP cable free play a
5. Adjust:
EXUP cable free play
6. Install:
EXUP valve pulley cover
10 Nm (1.0 mkg)
7. Install:
fuel tank
seat
EAS00102
2. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
Below the minimum level mark Add the
recommended coolant to the proper level.
3-27
CHK
CHECKING THE COOLANT LEVEL ADJ
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
3-28
CHK
CHECKING THE COOLING SYSTEM ADJ
EAS00104
3-29
CHK
CHANGING THE COOLANT ADJ
EAS00105
4. Remove:
radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap, while still pressing down turn it
counterclockwise, and then remove it.
5. Remove:
coolant drain bolt 1
(along with the copper washer)
6. Drain:
coolant
(from the engine and radiator)
3-30
CHK
CHANGING THE COOLANT ADJ
7. Check:
copper washer 1
coolant drain bolt 2
Damage Replace.
8. Install:
coolant drain bolt
7 Nm (0.7 mkg)
9. Connect:
coolant reservoir hose
10. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol anti
freeze containing corrosion inhibi
tors for aluminum engines
Mix ratio
50% antifreeze/50% water
Quantity
Total amount
2.4 L
Coolant reservoir capacity
0.3 L
From minimum to maximum
level mark
0.2 L
3-31
CHK
CHANGING THE COOLANT ADJ
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
Do not mix different types of antifreeze.
11. Install:
radiator cap
12. Fill:
coolant reservoir
(with the recommended coolant to the maxi-
mum level mark a )
13. Install:
coolant reservoir cap
14. Start the engine, warm it up for several min-
utes, and then turn it off.
15. Check:
coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
16. Install:
rear suspension
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” in chapter 4.
fuel tank
seat
3-32
CHK
ADJUSTING THE FRONT BRAKE ADJ
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
brake lever position
(distance a from the throttle grip to the brake
lever)
WARNING
After adjusting the brake lever position,
make sure that the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.
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 con-
siderably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if nec-
essary, bleed the brake system.
CAUTION:
After adjusting the brake lever position,
make sure that there is no brake drag.
3-33
CHK
ADJUSTING THE REAR BRAKE ADJ
EAS00110
2. Adjust:
brake pedal position
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt 2 is
visible through the hole c .
Locknut
18 Nm (1.8 mkg)
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 consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
3-34
ADJUSTING THE REAR BRAKE/ CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
3. Adjust:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115
A Front brake
B Rear brake
B 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 perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
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 reser-
voir is horizontal.
3-35
CHECKING THE BRAKE PADS/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00122
A
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
front brake pad
rear brake pad
Wear indicator groove 1 almost disap-
peared Replace the brake pads as a set.
Refer to “REPLACING THE FRONT BRAKE
B PADS” and “REPLACING THE REAR
BRAKE PADS” in chapter 4.
A Front brake
B Rear brake
EAS00128
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
rear brake light operation timing
3-36
CHECKING THE BRAKE HOSES/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00131
EAS00134
1. Remove:
reservoir cap 1
diaphragm 2
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 hydrau-
lic brake system, considerably lengthening the
bleeding procedure.
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM / CHK
ADJUSTING THE SHIFT PEDAL ADJ
2. Bleed:
hydraulic brake system
Bleed screw
6 Nm (0.6 mkg)
EAS00110
EAS00140
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
3. Check:
drive chain slack a
Out of specification Adjust.
3-39
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
4. Adjust:
drive chain slack
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
Locknut
16 Nm (1.6 mkg)
3-40
LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EAS00142
Recommended lubricant
Engine oil or chain lubricant
suitable forO-ring chains
EAS00146
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:
front cowling assembly
Refer to “FRONT COWLING”.
upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:
steering head
3-41
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
NOTE:
Set the torque wrench at a right angle to the ring
nut wrench.
NOTE:
Make sure that the lock washer tabs a sit cor-
rectly in the ring nut slots b .
5. Install:
upper bracket
front cowling assembly
3-42
CHECKING AND ADJUSTING THE STEERING HEAD / CHK
CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS
ADJ
Steering stem nut
110 Nm (11 mkg)
Upper bracket pinch bolt
30 Nm (3.0 mkg)
Handlebar holder bolt
23 Nm (2.3 mkg)
EAS00149
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 4.
EAS00155
Spring preload
CAUTION:
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
3-43
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
1. Adjust:
spring preload
Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).
Adjusting positions
Standard: 2
Minimum: 5*
Maximum: 1
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
Rebound damping
p g is
Direction a increased (suspension is
harder).
Rebound damping
p g is
Direction b decreased (suspension is
softer).
Adjusting positions
Standard: 7 clicks out*
Minimum: 17 clicks out*
Maximum: 1 clicks out*
3-44
ADJUSTING THE FRONT FORK LEGS/ CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
Compression damping is
Direction increased (suspension is
harder).
Compression damping is
Direction decreased (suspension is
softer).
Adjusting positions
Standard: 6 clicks out*
Minimum: 21 clicks out*
Maximum: 1 clicks out*
EAS00158
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the own-
er’s tool kit.
3-45
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
a. Turn the adjusting ring 1 in direction a or
b.
b. Align the desired position on the adjusting
ring with the stopper 2 .
Spring preload is
Direction a (s spension is
increased (suspension
harder).
Spring preload is de-
Direction b (s spension is
creased (suspension
softer).
Adjusting positions
Standard: 6
Minimum: 1
Maximum: 11
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
Rebound damping is
Direction a (s spension is
increased (suspension
harder).
Rebound damping is
Direction b (s spension is
decreased (suspension
softer).
Adjusting positions
Standard: 20 clicks out*
Minimum: 10 clicks out*
Maximum: 3 clicks out*
3-46
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHK
CHECKING THE TIRES ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
Compression damping is
Direction a increased (suspension is
harder).
Compression damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Standard: 7 clicks in
Minimum: 1 clicks in
Maximum: 12 clicks in
EAS00162
3-47
CHK
CHECKING THE TIRES ADJ
Basic weight
(with oil and a 231 kg
full fuel tank)
Maximum
189 kg
load*
Cold tire
Front tire Rear tire
pressure
Up to 90 kg 250 kPa 270 kPa
load* (2.5 kgf/cm2) (2.7 kgf/cm2)
90 kg 250 kPa 290 kPa
maximum load* (2.5 kgf/cm2) (2.9 kgf/cm2)
High 250 kPa 290 kPa
speed riding (2.5 kgf/cm2) (2.9 kgf/cm2)
*: total of cargo, rider, passenger and accesso-
ries
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.
WARNING
Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.
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.
Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
A Tire B Wheel
3-48
CHK
CHECKING THE TIRES ADJ
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufactur-
er and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.
Front tire
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any highspeed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
3-49
CHECKING AND LUBRICATING THE CABLES / CHK
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION ADJ
EAS00170
1. Check:
cable sheath
Damage Replace.
2. Check:
cable operation
Unsmooth operation Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.
EAS00171
Recommended lubricant
lithium soap base grease
EAS00172
Recommended lubricant
lithium soap base grease
EAS00174
Recommended lubricant
lithium soap base grease
3-50
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
SKIN – Wash with water.
EYES – Flush with water for 15 minutes and
get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
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.
3-51
CHK
CHECKING AND CHARGING THE BATTERY ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring 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 seat
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
S battery
4. Check:
S battery charge
NOTE:
13.0 Relationship between the open-circuit voltage
S The charge state of a MF battery can be
Open-circuit voltage (V)
3-52
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging 5. Charge:
Ambient temperature 20_C
S battery
Open-circuit voltage (V)
temperature
20_C
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
Charging condition of the battery (%) 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.
3-53
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a variable voltage charger
NO
3-54
CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a constant voltage charger
Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 V. Charge the charge the MF battery. A variable
battery until the battery’s charging voltage charger is recommended.
voltage is 15 V.
NOTE:
Set the charging time at 20 hours
(maximum).
3-55
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Check:
battery vent
Obstruction Clean.
Damage Replace.
7. Install:
battery
8. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
9. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
10. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
11. Install:
seat
EAS00181
1. Remove:
seat
2. Check:
fuse
3-56
CHK
CHECKING THE FUSES ADJ
Pocket tester
90890-03112
3. Replace:
blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
seat
3-57
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183
2. Remove:
headlight bulb holder 1
3. Remove:
headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:
headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install:
headlight bulb holder
6. Install:
bulb cover
7. Connect:
headlight coupler
3-58
ADJUSTING THE HEADLIGHT BEAMS/ CHK
ADJUSTING THE DIGITAL CLOCK ADJ
EAS00185
EAS00187
1. Adjust:
digital clock 1
3-59
CHAS
CHAPTER 4
CHASSIS
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CHASSIS
FRONT WHEEL AND BRAKE DISCS
72 Nm (7.2 mkg)
40 Nm (4.0 mkg)
18 Nm (1.8 mkg)
4-1
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00518
FRONT WHEEL
4-2
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00521
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
left brake caliper
right brake caliper
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.
3. Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
EAS00523
4-3
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00525
2. Check:
tire
front wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits Replace.
4. Check:
wheel bearings
Front wheel turns roughly or is loose Re-
place the wheel bearings.
oil seals
Damage/wear Replace.
5. Replace:
wheel bearings New
oil seals New
CAUTION:
Do not contact the wheel bearing center race
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
EAS00531
4-5
FRONT WHEEL AND BRAKE DISCS CHAS
3. Measure:
S brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
4. Adjust:
S brake disc deflection
EAS00539
NOTE:
Use a shocket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
4-6
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00544
Recommended lubricant
Lithium soap base grease
2. Tighten:
wheel axle 1 72 Nm (7.2 mkg)
wheel axle pinch bolt 2
23 Nm (2.3 mkg)
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebar several times and
check if the front fork rebounds smoothly.
3. Install:
brake caliper 40 Nm (4.0 mkg)
WARNING
Make sure that the brake hose is routed
properly.
EAS00549
1. Remove:
balancing weight(-s)
NOTE:
Place the front wheel on a suitable balancing
stand.
4-7
FRONT WHEEL AND BRAKE DISCS CHAS
2. Find:
S front wheel’s heavy spot
3. Adjust:
S front wheel static balance
4. Check:
S front wheel static balance
4-8
REAR WHEEL AND BRAKE DISC CHAS
EAS00551
40 Nm (4.0 mkg)
1 Brake caliper 1
2 Brake torque rod 1 Loosen.
3 Nut 1
4 Washer 1
5 Wheel axle 1
6 Rear wheel assembly 1
For installation, reverse the removal
procedure.
4-9
REAR WHEEL AND BRAKE DISC CHAS
EAS00560
4-10
REAR WHEEL AND BRAKE DISC CHAS
18 Nm (1.8 mkg)
69 Nm (6.9 mkg)
4-11
REAR WHEEL AND BRAKE DISC CHAS
EAS00561
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
brake caliper 1
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:
locknut 1
adjusting nut 2
4. Remove:
wheel axle nut 3
wheel axle
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
left collar 1
rear wheel drive hub 2
rear wheel drive hub damper
right collar
4-12
REAR WHEEL AND BRAKE DISC CHAS
EAS00565
EAS00567
EAS00568
4-13
REAR WHEEL AND BRAKE DISC CHAS
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00531
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
4-14
REAR WHEEL AND BRAKE DISC CHAS
4. Adjust:
S brake disc deflection
EAS00572
Recommended lubricant
Lithium soap base grease
2. Tighten:
S wheel axle nut 150 Nm (15 mSkg)
S brake caliper bolts 40 Nm (4.0 mSkg)
EAS00575
1. Adjust:
S rear wheel static balance
Refer to “FRONT WHEEL”.
4-15
FRONT AND REAR BRAKES CHAS
EAS00577
4-16
FRONT AND REAR BRAKES CHAS
40 Nm (4.0 mkg)
6 Nm (0.6 mkg)
4-17
FRONT AND REAR BRAKES CHAS
EAS00579
CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get im-
mediate medical attention.
EAS00582
1. Remove:
brake hose holder 1
brake caliper 2
4-18
FRONT AND REAR BRAKES CHAS
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
3. Remove:
brake pads 1
(along with the brake pad shims)
4. Measure:
brake pad wear limit
Out of specification Replace the brake
pads as a set.
5. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
Bleed screw
6 Nm (0.6 mkg)
4-19
FRONT AND REAR BRAKES CHAS
d. Install new brake pad shims onto the new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must point
in the direction of disc rotation.
6. Install:
brake pad cover
brake pad pins
brake pad clips
brake caliper 40 Nm (4.0 mkg)
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
1. Remove:
brake caliper 1
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
brake pads
(along with the brake pad shims)
4-20
FRONT AND REAR BRAKES CHAS
3. Measure:
brake pad wear limit
Out of specification Replace the brake
pads as a set.
4. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, brake pad pins, brake pad clips, and a
brake pad spring as a set.
Bleed screw
6 Nm (0.6 mkg)
4-21
FRONT AND REAR BRAKES CHAS
5. Install:
brake pad cover
brake pad pins
brake pad clips
brake caliper 40 Nm (4.0 mkg)
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-22
FRONT AND REAR BRAKES CHAS
EAS00584
10 Nm (1.0 mkg)
30 Nm (3.0 mkg)
4-23
FRONT AND REAR BRAKES CHAS
EAS00585
4-24
FRONT AND REAR BRAKES CHAS
EAS00586
30 Nm (3.0 mkg)
4 Nm (0.4 mkg)
23 Nm (2.3 mkg)
4-25
FRONT AND REAR BRAKES CHAS
EAS00587
4-26
FRONT AND REAR BRAKES CHAS
EAS00588
1. Disconnect:
brake switch coupler
(from the brake switch)
2. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
2. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4-27
FRONT AND REAR BRAKES CHAS
EAS00592
A B
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
brake master cylinder
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
C D A Front
B Rear
2. Check:
brake master cylinder kit 1
Damage/scratches/wear Replace.
C Front
D Rear
3. Check:
rear brake fluid reservoir 1
Cracks/damage Replace.
rear brake fluid reservoir diaphragm 2
Cracks/damage Replace.
4. Check:
front brake master cylinder reservoir 1
Cracks/damage Replace.
front brake master cylinder reservoir dia-
phragm 2
Damage/wear Replace.
5. Check:
brake hoses
Cracks/damage/wear Replace.
4-28
FRONT AND REAR BRAKES CHAS
EAS00598
1. Install:
brake master cylinder 1
10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up.
Align the end of the brake master cylinder hold-
er with the punch mark a on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
copper washers 1 New
brake hose 2
union bolt 3 30 Nm (3.0 mkg)
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
a brake pipe touches the projection a on the
brake master cylinder.
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
4-29
FRONT AND REAR BRAKES CHAS
3. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
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 perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-30
FRONT AND REAR BRAKES CHAS
EAS00608
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a as
shown.
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2. Fill:
brake fluid reservoir
(to the maximum level mark a )
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 perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4-31
FRONT AND REAR BRAKES CHAS
3. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Adjust:
brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
6. Adjust:
rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
4-32
FRONT AND REAR BRAKES CHAS
EAS00613
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
30 Nm (3.0 mkg)
4-33
FRONT AND REAR BRAKES CHAS
EAS00615
6 Nm (0.6 mkg)
4-34
FRONT AND REAR BRAKES CHAS
EAS00616
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
4-35
FRONT AND REAR BRAKES CHAS
EAS00617
6 Nm (0.6 mkg)
4-36
FRONT AND REAR BRAKES CHAS
EAS00625
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
WARNING
Never try to pry out the brake caliper pis-
tons.
Do not loosen the bolts 3 .
4-37
FRONT AND REAR BRAKES CHAS
EAS00628
1. Remove:
union bolt 1
copper washers 2
brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
WARNING
Never try to pry out the brake caliper pis-
tons.
Do not loosen the bolts 3 .
4-38
FRONT AND REAR BRAKES CHAS
EAS00633
A 1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake cali-
per.
brake calipers
Cracks/damage Replace.
brake fluid delivery passages
(brake caliper body)
B Obstruction Blow out with compressed Air.
WARNING
Whenever a brake caliper Is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
brake caliper brackets 1
Cracks/damage Replace.
4-39
FRONT AND REAR BRAKES CHAS
EAS00638
1. Install:
brake caliper
(temporarily)
copper washers 1 New
brake hose 2
union bolt 3 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper, make sure that the brake pipe
a touches the projection b on the brake
caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad pins
brake pad clips
brake hose holder 6 Nm (0.6 mkg)
brake caliper 40 Nm (4.0 mkg)
Refer to “REPLACING THE BRAKE PADS”.
4-40
FRONT AND REAR BRAKES CHAS
4. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
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 perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-41
FRONT AND REAR BRAKES CHAS
EAS00644
1. Install:
brake caliper 1
(temporarily)
copper washers New
brake hose 2
union bolt 3 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper, make sure that the brake pipe
a touches the projection b on the brake
caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad pin
brake pad clips
brake caliper 40 Nm (4.0 mkg)
Refer to “REPLACING THE BRAKE PADS”.
4. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
4-42
FRONT AND REAR BRAKES CHAS
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 perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
7. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-43
FRONT FORK CHAS
EAS00647
FRONT FORK
30 Nm (3.0 mkg)
25 Nm (2.5 mkg)
23 Nm (2.3 mkg)
4-44
FRONT FORK CHAS
EAS00648
25 Nm (2.5 mkg)
35 Nm (3.5 mkg)
4-45
FRONT FORK CHAS
EAS00649
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Loosen:
upper bracket pinch bolt 1
cap bolt 2
lower bracket pinch bolt 3
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
3. Remove:
front fork leg
EAS00653
4-46
FRONT FORK CHAS
2. Remove:
spacer 1
spring seat 2
spring 3
damper adjusting rod 4
3. Drain:
fork oil
4. Remove:
oil seal clip 1
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
5. Remove:
damper rod bolt
damper rod 1
NOTE:
While holding the damper rod with the damper
rod holder 2 , loosen the damper rod bolt.
6. Remove:
inner tube
4-47
FRONT FORK CHAS
CAUTION:
Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.
EAS00657
2. Measure:
spring free length a
Over the specified limit Replace.
3. Check:
damper rod
Damage/wear Replace.
Obstruction Blow out all of the oil pas-
sages with compressed air.
oil flow stopper
Damage Replace.
CAUTION:
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
cap bolt O-ring
Damage/wear Replace.
4-48
FRONT FORK CHAS
EAS00660
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
-inner tube bushing
-outer tube bushing
-oil seal
-dust seal
Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
damper rod 1
CAUTION:
Allow the damper rod to slide slowly down
the inner tube 2 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
NOTE:
Install the oil flow stopper with a flat surface part
a downward.
2. Lubricate:
inner tube’s outer surface
Recommended lubricant
Fork oil 5W or equivalent
3. Tighten:
damper rod bolt 1 35 Nm (3.5 mkg)
LOCTITE
NOTE:
While holding the damper rod with the damper
rod holder 2 , tighten the damper rod bolt.
4-49
FRONT FORK CHAS
4. Install:
oil seal 1
(with the fork seal driver weight 2 and fork
seal driver attachemt 3 )
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, apply lithium soap
base grease onto its lips.
Apply fork oil onto the outer surface of the inner
tube.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
5. Install:
oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
6. Fill:
front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
NOTE:
Be sure to bleed the front fork.
4-50
FRONT FORK CHAS
7. Install:
rod puller 1
rod puller attachment 2
(onto the damper rod 3 )
Rod puller
90890-01437
Rod puller attachment
90890-01436
11. Measure:
front fork leg oil level a
Out of specification Correct.
4-51
FRONT FORK CHAS
12. Install:
spring 1
spring seats 2
spacer 3
nut 4
damper adjusting rod 5
cap bolt 6
b smaller pitch
b. Install the rod puller and the rod puller attach-
ment onto the damper rod.
c. Pull up the rod puller and install the rod hold-
er 1 between the rod puller attachment 2
and the spacer.
NOTE:
Use the side of the rod holder that is marked “B”.
4-52
FRONT FORK CHAS
EAS00662
2. Tighten:
lower bracket pinch bolt 1
23 Nm (2.3 mkg)
cap bolt 2 25 Nm (2.5 mkg)
upper bracket pinch bolt 3
30 Nm (3.0 mkg)
WARNING
Make sure that the brake hoses are routed
properly.
3. Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK”
in chapter 3.
4-53
HANDLEBAR CHAS
EAS00664
HANDLEBAR
23 Nm (2.3 mkg)
26 Nm (2.6 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
4-54
HANDLEBAR CHAS
EAS00666
2. Remove:
throttle cable housing 1
throttle grip 2
3. Remove:
handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
2. Check:
handlebar
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
4-55
HANDLEBAR CHAS
3.Install:
handlebar grip
EAS00672
2. Install:
handlebar 1
upper handlebar holders 2
23 Nm (2.3 mkg)
CAUTION:
First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
Align the match marks a in the handlebar with
the upper surface of the lower handlebar hold-
ers.
3. Install:
throttle grip 1
throttle cables
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.
4-56
HANDLEBAR CHAS
5. Install:
left handlebar switch
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.
6. Install:
clutch lever holder
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the left handlebar.
7. Install:
brake master cylinder
Refer to “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYL-
INDER”.
8. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
4-57
STEERING HEAD CHAS
EAS00676
STEERING HEAD
4-58
STEERING HEAD CHAS
EAS00677
2. Remove:
lower ring nut 1
(with the special tool 2 )
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
2. Check:
bearings 1
bearing races 2
Damage/pitting Replace.
3. Replace:
bearings
bearing races
4-59
STEERING HEAD CHAS
b. Remove the bearing race 3 from the lower
bracket with a floor chisel 4 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00683
Recommended lubricant
Lithium soap base grease
2. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “INSPECTING THE STEERING
HEAD” in chapter 3.
3. Install:
upper bracket
steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
4-60
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00685
40 Nm (4.0 mkg)
40 Nm (4.0 mkg)
48 Nm (4.8 mkg)
48 Nm (4.8 mkg)
40 Nm (4.0 mkg)
4-61
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00687
EAS00689
4-62
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00694
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
connecting arm bolt 1
relay arm bolt 2
rear shock absorber assembly lower bolt 3
NOTE:
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
rear shock absorber assembly upper bolt 1
rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
4-63
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00696
EAS00698
Recommended lubricant
Molybdenum disulfide grease
2. Install:
rear shock absorber assembly
NOTE:
When installing the rear shock absorber as-
sembly, lift up the swingarm.
Install the connecting arm front bolt from the
right.
4-64
SWINGARM AND DRIVE CHAIN CHAS
EAS00700
85 Nm (8.5 mkg)
23 Nm (2.3 mkg)
4 Pivot shaft 1
5 Swing arm 1
6 Drive chain case 1
7 Drive chain guard 1
8 Dust cover 2
9 Oil seal 2
4-65
SWINGARM AND DRIVE CHAIN CHAS
85 Nm (8.5 mkg)
23 Nm (2.3 mkg)
4-66
SWINGARM AND DRIVE CHAIN CHAS
EAS00703
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
connecting arm bolt 1
relay arm bolt 2
rear shock absorber assembly lower bolt 3
NOTE:
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Check:
swingarm side play A
swingarm vertical movement B
4-67
SWINGARM AND DRIVE CHAIN CHAS
EAS00704
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
foot rest (left)
drive sprocket cover
drive chain guide 1
drive sprocket 2
EAS00707
2. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
pivot shaft
dust covers
spacer
washers
bearings
4-68
SWINGARM AND DRIVE CHAIN CHAS
4. Check:
dust covers 1
spacer 2
oil seals 3
Damage/wear Replace.
bearings 4
Damage/pitting Replace.
5. Check:
connecting arms 1
relay arm 2
Damage/wear Replace.
bearings 3
oil seals 4
Damage/pitting Replace.
spacers 5
Damage/scratches Replace.
EAS00709
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
4-69
SWINGARM AND DRIVE CHAIN CHAS
3. Clean:
drive chain
4. Check:
O-rings 1
Damage Replace the drive chain.
drive chain rollers 2
Damage/wear Replace the drive chain.
drive chain side plates 3
Damage/wear Replace the drive chain.
Cracks Replace the drive chain and make
sure that the battery breather hose is proper-
ly routed away from the drive chain and be-
low the swingarm.
5. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
drive sprocket
rear wheel sprocket
More than 1/4 tooth a wear Replace the
drive chain sprockets as a set.
Bent teeth Replace the drive chain sprock-
ets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
4-70
SWINGARM AND DRIVE CHAIN CHAS
EAS00713
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
2. Install:
drive chain 1
drive sprocket 2
washer 3 New
drive sprocket nut 4 85 Nm (8.5 mkg)
drive chain guide 5
NOTE:
While applying the rear brake, tighten the drive
sprocket nut.
Recommended lubricant
Molybdenum disulfide grease
2. Install:
relay arm 48 Nm (4.8 mkg)
left connecting arm
right connecting arm 48 Nm (4.8 mkg)
4-71
SWINGARM AND DRIVE CHAIN CHAS
NOTE:
Install the connecting arm front bolt 1 from the
right.
3. Install:
rear shock absorber assembly
rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and ”REAR
WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
CAUTION:
A drive chain that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swingarm
or cause an accident. Therefore, keep the
drive chain slack within the specified limits.
4-72
ENG
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
DRIVE SPROCKET AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . 5-1
LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 5-11
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
INSTATLLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . . 5-62
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . 5-63
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . 5-64
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . . 5-67
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . 5-72
CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . . 5-73
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . . . 5-74
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
ENG
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 5-84
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
ENG
ENGINE ENG
EAS00188
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
85 Nm (8.5 mkg)
20 Nm (2.0 mkg)
5-2
ENGINE ENG
EAS00191
ENGINE
55 Nm (5.5 mkg)
55 Nm (5.5 mkg)
24 Nm (2.4 mkg)
24 Nm (2.4 mkg)
33 Nm (3.3 mkg)
5-3
ENGINE ENG
EAS00192
3. Install:
shift arm 1 10 Nm (10 mkg)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.
5-4
CAMSHAFT ENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVERS
13 Nm (1.3 mkg)
12 Nm (1.2 mkg)
5-5
CAMSHAFT ENG
EAS00196
CAMSHAFTS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
10 Nm (1.0 mkg)
5-6
CAMSHAFT ENG
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
10 Nm (1.0 mkg)
5-7
CAMSHAFT ENG
EAS00198
3. Loosen:
camshaft sprocket bolts 1
4. Loosen:
cap bolt 1
5. Remove:
timing chain tensioner 2
gasket
6. Remove:
camshaft sprocket 1
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 2 .
5-8
CAMSHAFT ENG
7. Remove
timing chain guide (exhaust side) 1
camshaft caps
dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
8. Remove:
intake camshaft 1
exhaust camshaft 2
EAS00204
2. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
5-9
CAMSHAFT ENG
3. Measure:
S camshaft runout
Out of specification Replace.
Camshaft runout
Less than 0.03 mm
4. Measure:
S camshaft-journal-to-camshaft-cap clear-
ance
Out of specification ³ Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028 X 0.062 mm
5. Measure:
S camshaft journal diameter a
Out of specification Replace the cam-
shaft.
Within specification Replace the cylinder
head and the camshaft caps as a set.
5-10
CAMSHAFT ENG
EAS00208
2. Check:
camshaft sprocket
More than 1/4 tooth a wear Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
timing chain guide (exhaust side) 1
timing chain guide (intake side) 2
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
EAS00210
5-11
CAMSHAFT ENG
2. Check:
one-way cam operation
Rough movement Replace the timing
chain tensioner housing.
3. Check:
cap bolt
copper washer
spring
gasket
timing chain tensioner rod
Damage/wear Replace the defective
part(-s).
EAS00217
2. Install:
dowel pins
intake camshaft caps
exhaust camshaft caps
NOTE:
Make sure that the punch marks a on the cam-
shafts are aligned with the arrow marks b on
the camshaft caps.
Out of alignment Reinstall.
5-12
CAMSHAFT ENG
3. Install:
camshaft cap bolts 10 Nm (1.0 mkg)
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, cam-
shaft caps, and camshafts will result.
4. Install:
intake camshaft sprocket
exhaust camshaft sprocket
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
5-13
CAMSHAFT ENG
d. Turn both camshafts opposite each other so
that the punch marks c in the camshaft are
aligned with the arrow marks d in the cam-
shaft caps as shown.
e. While holding the camshafts, temporarily
tighten the camshaft sprocket bolts.
5. Install:
timing chain tensioner
6. Turn:
crankshaft
(several turns clockwise)
5-14
CAMSHAFT ENG
7. Check:
“T” mark a
Make sure that the “T” mark a on the pickup
coil rotor is aligned with the crankcase mat-
ing surface b .
8. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
9. Install:
timing mark accessing screw
15 Nm (15 mkg)
crankshaft end cover
5-15
CYLINDER HEAD ENG
EAS00221
CYLINDER HEAD
12 Nm (1.2 mkg)
5-16
CYLINDER HEAD ENG
EAS00223
EAS00230
2. Check:
cylinder head
Damage/scratches Replace.
cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
5-17
CYLINDER HEAD ENG
EAS00233
3. Tighten:
cylinder head nuts 1 X 10
1st 20 Nm (2.0 mkg)
2nd 50 Nm (5.0 mkg)
cylinder head bolt 11 12
NOTE:
First, tighten the nuts 1 X 10 to approximate-
ly 20 Nm (2.0 mkg) with a torque wrench.
Retighten the nuts to 50 Nm (5.0 mkg).
NOTE:
Apply engine oil onto the threads of the cylin-
der head nuts.
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
exhaust camshaft
intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
5-18
VALVES AND VALVE SPRINGS ENG
EAS00236
5-19
VALVES AND VALVE SPRINGS ENG
5-20
VALVES AND VALVE SPRINGS ENG
EAS00237
1. Remove:
valve lifter 1
valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
valve sealing
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
3. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
5-21
VALVES AND VALVE SPRINGS ENG
4. Remove:
upper spring seat 1
valve spring 2
oil seal 3
lower spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter A –
Valve stem diameter B
Valve-stem-to-valve-guide
clearance
Intake
0.010 X 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.020 X 0.047 mm
<Limit>: 0.1 mm
5-22
VALVES AND VALVE SPRINGS ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C in an oven.
5-23
VALVES AND VALVE SPRINGS ENG
3. Eliminate:
carbon deposits
(from the valve face and valve seat)
4. Check:
valve face
Pitting/wear Grind the valve face.
valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always re-
place the oil seal.
EAS00240
5-24
VALVES AND VALVE SPRINGS ENG
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
5-26
VALVES AND VALVE SPRINGS ENG
EAS00242
EAS00245
2. Lubricate:
valve stem 1
oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
valve 1
lower spring seat 2
oil seal 3
valve spring 4
upper spring seat 5
(into the cylinder head)
NOTE:
Install the valve spring with the larger pitch a
facing up.
b Smaller pitch
NOTE:
Make sure that each valve is installed in its origi-
nal place. Refer to the following embossed
marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “5LV”
5-27
VALVES AND VALVE SPRINGS ENG
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
6. Install:
valve pad 1
valve lifter 2
NOTE:
Apply molybdenum disulfide oil onto the valve
lifter and valve pad.
The valve lifter must move smoothly when ro-
tated with a finger.
Each valve lifter and valve pad must be rein-
stalled in its original position.
5-28
GENERATOR ENG
EB410000
GENERATOR
14 Nm (1.4 mSkg)
12 Nm (1.2 mSkg)
5-29
GENERATOR ENG
REMOVING THE GENERATOR
1. Remove:
generator rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
generator rotor bolt 1
washer
NOTE:
While holding the generator rotor 2 with the rotor
holding tool 3 , loosen the generator rotor bolt.
3. Remove:
generator rotor 1
(with the flywheel puller 2 and rotor holding
tool 3 )
Flywheel puller
90890-01080
2. Install:
generator rotor
washer
generator rotor bolt
WARNING
Always use a new generator rotor bolt.
CAUTION:
Clean the tapered portion of the crankshaft
and the generator rotor hub with lacquer
thinner.
Lubricate the generator rotor bolt threads
with engine oil.
5-30
GENERATOR ENG
3. Tighten:
S generator rotor bolt 1 New
65 Nm (6.5 mSkg) + 60_
NOTE:
S While holding the generator rotor 2 with the
rotor holding tool 3 , tighten the generator ro-
tor bolt.
S After tightening to 65 Nm (6.5 mSkg), tighten
another 60_.
4. Install:
S generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
5-31
PICKUP COIL ENG
PICKUP COIL
60 Nm (6.0 mkg)
12 Nm (1.2 mkg)
15 Nm (1.5 mkg)
10 Nm (1.0 mkg)
5-32
PICKUP COIL ENG
60 Nm (6.0 mkg)
12 Nm (1.2 mkg)
15 Nm (1.5 mkg)
10 Nm (1.0 mkg)
5-33
PICKUP COIL ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:
pickup coil lead holder 1
pickup coil rotor cover 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
pickup coil rotor bolt 1
washer
pickup coil rotor 2
NOTE:
While holding the generator rotor 3 with the ro-
tor holding tool 4 , loosen the pickup coil rotor
bolt.
5-34
PICKUP COIL ENG
2. Tighten:
pickup coil rotor bolt 1
60 Nm (6.0 mkg)
NOTE:
While holding the generator rotor 2 with the ro-
tor holding tool 3 , tighten the pickup coil rotor
bolt.
3. Apply:
sealant
(onto the pickup coil lead grommet)
4. Install:
pickup coil rotor cover
pickup coil lead holder
NOTE:
When installing the pickup coil rotor cover,
align the timing chain guide (intake side) pin 1
with the hole 2 in the pickup coil rotor cover.
Tighten the pickup coil rotor cover bolts in
stages and in a crisscross pattern.
5-35
CLUTCH ENG
EAS00273
CLUTCH
CLUTCH COVER
12 Nm (1.2 mkg)
12 Nm (1.2 mkg)
5-36
CLUTCH ENG
EB405010
5-37
CLUTCH ENG
EAS00274
CLUTCH
12 Nm (1.2 mkg)
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
5-38
CLUTCH ENG
12 Nm (1.2 mkg)
70 Nm (7.0 mkg)
8 Nm (0.8 mkg)
5-39
CLUTCH ENG
EAS00277
3. Remove:
clutch boss nut 1
lock washer 2
clutch boss 3
EAS00280
5-40
CLUTCH ENG
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
3. Measure:
assembly width a
Out of specification Adjust.
Assembly width
43.1 43.9 mm
NOTE:
When adjusting the clutch assembly width [by
replacing the clutch plate(s)], be sure to replace
the clutch plate 1 first. After replacing the
clutch plate 1 , if specifications cannot be met,
replace the clutch plate 2 .
5-41
CLUTCH ENG
EAS00281
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge 1 )
Out of specification Replace the clutch
plates as a set.
EAS00282
2. Measure:
clutch spring free length
Out of specification Replace the clutch
springs as a set.
5-42
CLUTCH ENG
EAS00284
2. Check:
bearing
Damage/wear Replace the clutch hous-
ing.
EAS00285
EAS00286
EAS00287
5-43
CLUTCH ENG
2. Check:
pull rod bearing
Damage/wear Replace.
EAS00351
2. Check:
starter clutch idle gear
starter clutch drive gear
starter clutch gear
Burrs/chips/roughness/wear Replace
the defective part(-s).
3. Check:
starter clutch gear’s contacting surfaces
Damage/pitting/wear Replace the starter
clutch gear.
5-44
CLUTCH ENG
4. Check:
starter clutch operation
EAS00299
2. Install:
lock washer New
clutch boss nut 1 90 Nm (9.0 mkg)
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3 , tighten the clutch boss nut.
5-45
CLUTCH ENG
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
friction plates
clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
friction plates
clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
6. Measure:
assembly width a
Out of specification Adjust.
Refer to “CHECKING THE FRICTION
PLATE”.
Assembly width
43.1 43.9 mm
5-46
CLUTCH ENG
7. Install:
pressure plate 1
NOTE:
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.
8. Install:
clutch springs
clutch spring bolts 8 Nm (0.8 mkg)
NOTE:
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
9. Install:
pull lever
NOTE:
Align the punch mark a in the pull lever shaft
with the mark b on the clutch cover.
10. Install:
dowel pins
gasket New
clutch cover 12 Nm (1.2 mkg)
NOTE:
When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod groove c
and pull lever shaft groove d are engaged.
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
5-47
SHIFT SHAFT ENG
EAS00326
SHIFT SHAFT
GENERATOR ROTOR COVER
12 Nm (1.2 mkg)
5-48
SHIFT SHAFT ENG
EAS00328
EAS00330
EAS00331
2. Install:
shift shaft 1
spacer
NOTE:
Lubricate the oil seal lips with lithium soap
base grease.
Install the end of the shift shaft spring onto the
shift shaft spring stopper 2 .
5-49
OIL PAN AND OIL PUMP ENG
EAS00356
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
43 Nm (4.3 mkg)
10 Nm (1.0 mkg)
5-50
OIL PAN AND OIL PUMP ENG
EB411001
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
43 Nm (4.3 mkg)
10 Nm (1.0 mkg)
5-51
OIL PAN AND OIL PUMP ENG
EAS00360
10 Nm (1.0 mkg)
15 Nm (1.5 mkg)
5-52
OIL PAN AND OIL PUMP ENG
EAS00362
EAS00364
Inner-rotor-to-outer-rotor-tip
clearance
0.09 0.15 mm
<Limit>: 0.23 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03 0.08 mm
<Limit>: 0.15 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06 0.11 mm
<Limit>: 0.18 mm
3. Check:
oil pump operation
Unsmooth Repeat steps (1) and (2) or re-
place the defective part(-s).
5-53
OIL PAN AND OIL PUMP ENG
EAS00365
EAS00366
EAS00368
EAS00374
Recommended lubricant
Engine oil
5-54
OIL PAN AND OIL PUMP ENG
2. Install:
pin 1
inner rotor 2
outer rotor 3
oil pump housing 4
NOTE:
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove a on the in-
ner rotor 2 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
EAS00378
NOTE:
The arrow a on the oil strainer housing must
point towards the front of the engine.
5-55
OIL PAN AND OIL PUMP ENG
EAS00380
WARNING
Always use new copper washers.
NOTE:
Tighten the oil pan bolts in stages and in a
crisscross pattern.
Lubricate the oil level switch’s O-ring with en-
gine oil.
5-56
CRANKCASE ENG
EAS00381
CRANKCASE
CRANKCASE
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
5-57
CRANKCASE ENG
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
5-58
CRANKCASE ENG
EAS00382
36 Nm (3.6 mkg)
5-59
CRANKCASE ENG
CRANKSHAFT
5-60
CRANKCASE ENG
EAS00384
3. Remove:
lower crankcase
CAUTION:
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
M9 125 mm bolts: 1 X 10
M8 125 mm bolts: 21 X 22
M6 100 mm bolts: 11 X 20 , 23 X 28
4. Remove:
dowel pins
O-ring
5. Remove:
crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
5-61
CRANKCASE ENG
EAS00393
2. Remove:
piston pin clips 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
For reference during installation, put identifica-
tion marks on the piston crown.
Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 1 .
5-62
CRANKCASE ENG
3. Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
EAS00387
5-63
CRANKCASE ENG
EAS00256
“C” = maximum of D1 D6
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1 D3 or D5 – minimum of
D2 D4 or D6
5-64
CRANKCASE ENG
c. Measure piston skirt diameter “P” with the
micrometer.
a 0.5 mm from the bottom edge of the piston.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.030 0.055 mm
<Limit>: 0.12 mm
EAS00263
5-65
CRANKCASE ENG
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the pis-
ton crown as shown.
a 5 mm
3. Measure:
piston ring end gap
Out of specification Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
EAS00266
2. Measure:
piston pin outside diameter
Out of specification Replace the piston
pin.
5-66
CRANKCASE ENG
3. Measure:
piston pin bore inside diameter
Out of specification → Replace the piston.
4. Calculate:
piston-pin-to-piston clearance
Out of specification Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 0.022 mm
<Limit>: 0.072 mm
EAS00395
Crankshaft runout
Less than 0.03 mm
2. Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear Replace the crankshaft.
3. Measure:
crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification Replace the crank-
shaft journal bearings.
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.029 0.053 mm
5-67
CRANKCASE ENG
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
5-68
CRANKCASE ENG
f. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase.
Crankcase bolt
Bolt 1 10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45 50_
Bolt 11 15 , 17 20 , 23 ,
25 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 22
24 Nm (24 mSkg)
NOTE:
Lubricate the crankcase bolt threads with en-
gine oil.
4. Select:
S crankshaft journal bearings (J1 J5)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 stamped into the low-
er crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
S “J1 J5” refer to the bearings shown in the
crankshaft illustration.
S If “J1 J5” are the same, use the same size
for all of the bearings.
5-69
CRANKCASE ENG
Crankshaft-pin-to-big-end-bearing
clearance
0.031 0.055 mm
NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.
5-70
CRANKCASE ENG
c. Put a piece of Plastigauge 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.
NOTE:
Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
Apply molybdenum disulfide grease onto the
bolts, threads, and nut seats.
5-71
CRANKCASE ENG
6. Select:
big end bearings (P1 P4)
NOTE:
The numbers A stamped into the crankshaft
web and the numbers 1 on the connecting
rods are used to determine the replacement
big end bearing sizes.
“P1” “P5” refer to the bearings shown in the
crankshaft illustration.
EAS00399
2. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and crankshaft sprocket as a set.
oil/water pump assembly drive chain 2
Damage/stiffness Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
EAS00407
2. Install:
crankshaft
5-73
CRANKCASE ENG
EAS00268
2. Install:
piston 1
(onto the respective connecting rod 2 )
piston pin 3
piston pin clip New 4
NOTE:
Apply engine oil onto the piston pin.
Make sure that the “Y” mark a on the connect-
ing rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustra-
tion.
Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
e Oil ring expander
5-74
CRANKCASE ENG
5. Lubricate:
crankshaft pins
big end bearings
connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:
big end bearings
connecting rod assembly
(into the cylinder and onto the crankshaft
pin).
connecting rod cap
(onto the connecting rod)
NOTE:
Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
Be sure to reinstall each big end bearing in its
original place.
While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
Make sure that the “Y” marks a on the con-
necting rods face towards the left side of the
crankshaft.
Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
7. Align:
bolt heads
(with the connecting rod caps)
8. Tighten:
connecting rod nuts
36 Nm (3.6 mkg)
CAUTION:
When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
Without pausing, tighten the connecting
rod nuts to the specified torque. Apply con-
tinuous torque between 2.0 and 3.6 mkg.
Once you reach 2.0 mkg DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted be-
tween 2.0 and 3.6 mkg, loosen the con-
necting rod nut to less than 2.0 mkg and
start again.
5-75
CRANKCASE ENG
EAS00414
Recommended lubricant
Engine oil
2. Apply:
sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2 3 mm of
the crankshaft journal bearings.
3. Install:
dowel pin
4. Install:
crankshaft journal lower bearings 1
(into the lower crankcase)
NOTE:
Align the projections a on the crankshaft jour-
nal lower bearings with the notches b in the
crankcase.
Install each crankshaft journal lower bearing in
its original place.
5-76
CRANKCASE ENG
6. Install:
S upper crankcase 1
(onto the lower crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
7. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Tighten the bolts in increasing numerical order.
S Install washers on bolts 1 X 10 .
M9 125 mm bolts: 1 X 10
M8 125 mm bolts: 21 X 22
M6 100 mm bolts: 11 X 20 , 23 X 28
Crankcase bolt
Bolt 1 X 10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45 X 50_
Bolt 11 X 15 , 17 X 20 , 23 ,
25 X 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 X 22
24 Nm (24 mSkg)
5-77
TRANSMISSION ENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
12 Nm (1.2 mkg)
10 Nm (1.0 mkg)
5-78
TRANSMISSION ENG
5-79
TRANSMISSION ENG
5-80
TRANSMISSION ENG
5-81
TRANSMISSION ENG
5-82
TRANSMISSION ENG
EAS00420
EAS00421
2. Check:
shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
shift fork movement
(on the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
5-83
TRANSMISSION ENG
EAS00422
EAS00425
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
3. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(-s).
transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(-s).
4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Damage/bends/looseness Replace.
5-84
TRANSMISSION ENG
EAS00428
2. Check:
transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
5-85
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
COOLING SYSTEM
RADIATOR
6-1
RADIATOR COOL
EAS00455
2. Check:
radiator hoses
radiator pipes
Cracks/damage Replace.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
4. Check:
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-2
RADIATOR COOL
EAS00456
2. Check:
cooling system
Leaks Repair or replace any faulty part.
6-3
THERMOSTAT COOL
EAS00460
THERMOSTAT
6-4
THERMOSTAT COOL
EAS00461
15 Nm (1.5 mkg)
6-5
THERMOSTAT COOL
EAS00462
1 Thermometer
2 Water
3 Thermostat
4 Container
A Closes
B Opens
NOTE:
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover 1
S thermostat housing 2
Cracks/damage Replace.
EAS00464
6-6
THERMOSTAT COOL
2. Install:
thermo unit 1 15 Nm (1.5 mkg)
CAUTION:
Use extreme care when handling the thermo
unit. Replace any part that was dropped or
subjected to a strong impact.
EAS00466
6-7
WATER PUMP COOL
EAS00469
WATER PUMP
10 Nm (1.0 mkg)
Oil/water pump assembly and oil Refer to “OIL PAN AND OIL PUMP” in
pump rotor chapter 5.
1 Water pump cover 1
2 O-ring 1
3 Pin 2
4 Impeller shaft (along with the impeller) 1
6-8
WATER PUMP COOL
10 Nm (1.0 mkg)
6-9
WATER PUMP COOL
EAS00470
2. Remove:
oil sesal 1
bearing 2
NOTE:
Tap out the bearing and oil seal from the outside
of the water pump housing.
3. Remove:
rubber damper holder 1
rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
EAS00473
6-10
WATER PUMP COOL
EAS00475
2. Install:
water pump seal New 1
CAUTION:
Never apply oil or grease onto the water
pump seal surface.
NOTE:
Install the water pump seal with the water
pump seal installers.
Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .
A Push down
6-11
WATER PUMP COOL
3. Install:
rubber damper New 1
rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
4. Measure:
tilt
Out of specification Repeat steps (3) and
(4).
CAUTION:
Make sure that the rubber damper and rub-
ber damper holder are flush with the impel-
ler.
Tilt limit
0.15 mm
1 Straightedge
2 Impeller
6-12
CARB
CHAPTER 7
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 7-10
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
CARBURETORS
CARBURETORS
AIR FILTER CASE
7-1
CARBURETORS CARB
EAS00481
7-2
CARBURETORS CARB
EAS00482
1 Starter plunger 1
2 Pilot air jet 1
3 Vacuum chamber cover 1
4 Piston valve spring 1
5 Piston valve 1
6 Jet needle holder 1
7 Jet needle kit 1
8 Pilot screw 1
9 Fuel drain bolt 1
10 Float pin 1
7-4
CARBURETORS CARB
7-5
CARBURETORS CARB
EAS00486
2. Check:
fuel passages
Obstruction Clean.
3. Check:
float chamber body 1
Dirt Clean.
4. Check:
float chamber rubber gasket 2
Cracks/damage/wear Replace.
5. Check:
float 1
Damage Replace.
6. Check:
needle valve 1
needle valve seat 2
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:
O-ring 3
Damage/wear Replace the needle valve,
needle valve seat and O-ring as a set.
7-6
CARBURETORS CARB
8. Check:
piston valve 1
Damage/scratches/wear Replace.
rubber diaphragm 2
Cracks/tears Replace.
9. Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
Cracks/damage Replace.
10. Check:
jet needle kit 1
needle jet 2
main jet 3
main jet holder 4
pilot jet 5
pilot screw 6
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
11. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
12. Check:
fuel feed pipes
hose joint
Cracks/damage Replace.
Obstruction Clean.
Blow out the pipes with compressed air.
13. Check:
fuel feed hoses
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
7-7
CARBURETORS CARB
EAS00489
1. Install:
jet needle kit
2. Install:
needle jet 1
pilot jet 2
main jet 3
3. Measure:
float height a
Out of specification Adjust.
Float height
12.5 13.5 mm
7-8
CARBURETORS CARB
d. If either the needle valve seat or needle valve
is worn, replace them both.
e. If both the needle valve seat and needle
valve are fine, adjust the float height by bend-
ing the float tang 1 .
f. Check the float height again.
4. Install:
piston valve
piston valve spring
vacuum chamber cover
NOTE:
Align the tab a on the piston valve diaphragm
with the recess b in the carburetor body.
5. Install:
connecting bracket
NOTE:
After installing the connecting bracket, check
that the throttle cable lever and starter plunger
link operate smoothly.
EAS00493
3. Adjust:
throttle cable free play
7-9
CARBURETORS CARB
EAS00495
2. Adjust:
fuel level
7-10
CARBURETORS CARB
EAS00500
1. Check:
S throttle position sensor
7-11
CARBURETORS CARB
2. Adjust:
throttle position sensor angle
Throttle position
Tachometer reading
sensor angle
0 r/min 1 Too small
5,000 r/min 2 Correct
10,000 r/min 3 Too large
7-12
CARBURETORS CARB
EAS00504
7-13
AIR INDUCTION SYSTEM CARB
EAS00507
EAS00508
VIEW 2. (FLOW)
7-14
AIR INDUCTION SYSTEM CARB
EAS00509
1 Reed valve
2 Air cleaner
3 Air cutoff valve
4 Carburetor joint (cylinder #4)
A To the air cutoff valve
B To cylinder #1
C To cylinder #2
D To cylinder #3
E To cylinder #4
7-15
AIR INDUCTION SYSTEM CARB
EAS00510
2. Check:
fibre reed 1
fibre reed stopper
reed valve seat
Cracks/damage Replace the reed valve.
3. Measure:
fibre reed bending limit a
Out of specification Replace the reed
valve.
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
7-16
ELEC
CHAPTER 8
ELECTRICAL
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
ELECTRICAL COMPONENTS ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch 7 Starting circuit cutoff relay 12 Oil level gauge
2 Fuel sender 8 Flasher relay 13 Ignition coil
3 Rear brake switch 9 Speed sensor 14 Rectifier/ Regulator
4 Battery 10 Sidestand switch 15 Thermo unit
5 Ignitor unit 11 Neutral switch 16 Horn
6 Starter relay 17 Emargency stop switch
18 Fan motor relay
8-1
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
8-2
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Ignitor unit
2 Fuse box
3 Battery
4 Fuel pump
5 Fuel pump coupler
6 Brake light switch coupler
7 Newtral switch coupler
8 Pickup coil coupler
9 Speed sensor coupler
8-3
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Ignition coil #2.3
2 Ignition coil #1.4
3 Rectifier/ regulator
4 Stator coil
8-4
ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Emargency stop switch
2 Flasher relay
3 Starter relay
4 Fan motor relay
5 Starting circuit cutoff relay
6 Stator coil coupler
7 Sidestand switch coupler
8 Fuel sender coupler
9 Oil level switch coupler
8-5
INSTRUMENT FUNCTIONS ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Turn indicator light “ ” “ ”
This indicator flashes when the turn switch is
moved to the left or right, and the hazard
switch is on.
Neutral indicator light “ ”
This indicator comes on when the transmis-
sion is in neutral.
High beam indicator light “ ”
This indicator comes on when the headlight
high beam is used.
1 Turn indicator light (left) “ ”
2 Turn indicator light (right) “ ”
3 Neutral indicator light “ ”
4 High beam indicator light “ ”
WARNING LIGHT
Oil evel warning light “ ”
This warning light comes on when the engine
oil level is low. If this symbol flashes, stop the
engine immediately and fill it with oil to the
specified level.
Coolant temperature warning light “ ”
This warning light comes on when the cool-
ant temperature is too high.
Fuel level warning light “ ”
When the fuel level drops below approxi-
1 Oil level warning light “ ”
mately 5.5 L, this light will come on.When this
light comes on, fill the fuel tank at the first op-
2 Coolant temperature warning light “ ”
portunity.
3 Fuel level warning light “ ”
CAUTION:
Do not run the motorcycle until you know it
has sufficient engine oil.
Do not run the motorcycle if the engine is
overheated.
NOTE:
Even if the oil is filled to the specified level, the
warning light may flicker when riding on a slope
or during sudden acceleration or deceleration,
but this is normal.
8-6
INSTRUMENT FUNCTIONS ELEC
DIGITAL CLOCK
Clock
To set the clock:
1. Push both the “SELECT” 1 and “RESET” 2
buttons for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button 2 to set the hours.
3. Push the “SELECT” button 1 to change the
minutes.
4. When the minute digits start flashing, push
the “RESET” button 2 to set the minutes.
1 “SELECT” button
5. Push the “SELECT” button 1 to start the
clock.
2 “RESET” button
NOTE:
After setting the clock, be sure to push the “SE-
LECT” button 1 before turning the main switch
to “OFF”, otherwise the clock will not be set.
8-7
CHECKING SWITCH CONTINUITY ELEC
EAS00730
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
8-8
CHECKING THE SWITCHES ELEC
EAS00731
8-9
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
Bulbs A are used for headlights and usually
use a bulb holder which must be detached be-
fore removing the bulb. The majority of these
bulbs can be removed from their respective
socket by turning them counterclockwise.
Bulb B is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.
Bulbs C are used for meter and indicator lights
and can be removed from their respective
socket by carefully pulling them out.
8-10
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
bulb
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bult (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
8-11
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
bulb socket (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
8-12
IGNITION SYSTEM ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 Main switch
5 Battery
7 Fuse (main)
15 Ignitor
16 Ignition coil
17 Spark plug
18 Pickup coil
41 Engine stop switch
58 Fuse (ignition)
8-13
IGNITION SYSTEM ELEC
EAS00737 EAS00739
TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no S Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Check:
1. Main and ignition fuses Minimum open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Spark plugs S Is the battery OK?
4. Ignition spark gap
5. Spark plug cap resistance YES NO
6. Ignition coil resistance
7. Main switch
8. Engine stop switch S Clean the battery
9. Pickup coil resistance terminals.
10. Wiring connections S Recharge or replace
(of the entire ignition system) the battery.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Seat EAS00741
2) Fuel tank
3) Side cover 3. Spark plugs
S Troubleshoot with the following special The following procedure applies to all of the
tool(-s). spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
Dynamic spark tester S Measure the spark plug gap.
YM-34487 Refer to “CHECKING THE SPARK PLUGS”
Ignition checker in CHAPTER 3.
90890-60754
Pocket tester Standard spark plug
90890-03112 CR9E (NGK)
U27ESR-N (DENSO)
EAS00738 Spark plug gap
1. Main and ignition fuses 0.7 X 0.8 mm
S Check the main and ignition fuses for conti- S Is the spark plug in good condition, it is of the
nuity. correct type, and is its gap within specifica-
Refer to “CHECKING THE FUSES” in tion?
CHAPTER 3.
YES NO
S Are the main and ignition fuses OK?
8-14
IGNITION SYSTEM ELEC
EAS00743
NO YES
S Measure the primary coil resistance.
8-15
IGNITION SYSTEM ELEC
EAS00748
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES NO
S Measure the pickup coil resistance.
Replace the main Pickup coil resistance
switch. 248 X 372 Ω at 20_C
(between gray and black)
EAS00750 S Is the pickup coil OK?
8. Engine stop switch
YES NO
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the pickup
S Is the engine stop switch OK? coil.
YES NO
EAS00754
NO YES
8-16
ELECTRIC STARTING SYSTEM ELEC
EAS00755
1 Main switch
5 Battery
6 Fuse (main)
7 Starter relay
8 Starter motor
9 Starting circuit cutoff relay
10 Side stand switch
19 Neutral switch
41 Engine stop switch
42 Start switch
48 Clutch switch
58 Fuse (ignition)
59 Alarm
8-17
ELECTRIC STARTING SYSTEM ELEC
EAS00756
8-18
ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING 2. Battery
The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
Check: CHAPTER 3.
1. Main and ignition fuses Minimum open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Starter motor
4. Starting circuit cutoff relay S Is the battery OK?
5. Starter relay YES NO
6. Main switch
7. Engine stop switch
8. Neutral switch S Clean the battery
9. Sidestand switch terminals.
10. Clutch switch S Recharge or re-
11. Start switch place the battery.
12. Wiring connections
(of the entire starting system) EAS00758
Pocket tester
90890-03112
EAS00738
YES NO
8-19
ELECTRIC STARTING SYSTEM ELEC
EAS00759
EAS00749
6. Main switch
Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Does the starting circuit cutoff relay have
Is the main switch OK?
continuity between blue/white and black?
YES NO YES NO
EAS00750
EAS00761
Disconnect the starter relay coupler from the Check the engine stop switch for continuity.
wireharness. Refer to “CHECKING THE SWITCHES”.
Connect the pocket tester (Ω 1) and bat- Is the engine stop switch OK?
tery (12 V) to the starter relay coupler as
shown. YES NO
Positive battery lead blue/white 1
Negative battery lead red/white 2 Replace the right
handlebar switch.
Positive tester probe red 3
Negative tester probe red 4
8-20
ELECTRIC STARTING SYSTEM ELEC
EAS00751 EAS00766
YES NO
YES NO
EAS00764
YES NO
8-21
ELECTRIC STARTING SYSTEM ELEC
EAS00767
STARTER MOTOR
8-22
ELECTRIC STARTING SYSTEM ELEC
EAS00768
5 Nm (0.5 mkg)
10 Nm (1.0 mkg)
8-23
ELECTRIC STARTING SYSTEM ELEC
EAS00769
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
3. Measure:
S mica undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commuta-
tor.
Mica undercut
0.7 mm
NOTE:
The mica must be undercut to ensure proper op-
eration of the commutator.
4. Measure:
S armature assembly resistances (commuta-
tor and insulation)
Out of specification Replace the starter
motor.
Pocket tester
90890-08112
Armature coil
Commutator resistance 1
0.025 X 0.035 Ω at 20_C
Insulation resistance 2
Above 1M Ω at 20_C
8-24
ELECTRIC STARTING SYSTEM ELEC
b. If any resistance is out of specification, re-
place the starter motor.
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
7. Check:
gear teeth
Damage/wear Replace the gear.
EAS00772
8-25
ELECTRIC STARTING SYSTEM ELEC
2. Install:
starter motor front cover 1
starter motor rear cover 2
O-ring 3 New
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear covers.
8-26
CHARGING SYSTEM ELEC
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
2 Rectifire/ reguretor
3 AC magneto
5 Battery
7 Fuse (main)
8-27
CHARGING SYSTEM ELEC
EAS00774
TROUBLESHOOTING YES NO
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
EAS00739
NO YES
2. Battery
S Check the condition of the battery. The charging circuit
Refer to “CHECKING THE BATTERY” in is OK.
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
8-28
CHARGING SYSTEM ELEC
EAS00776
YES NO
EAS00779
5. Wiring
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly
connected and without defects?
YES NO
8-29
LIGHTING SYSTEM ELEC
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
8-30
LIGHTING SYSTEM ELEC
EAS00781
TROUBLESHOOTING YES NO
2. Battery
The dimmer switch is
S Check the condition of the battery. faulty. Replace the
Refer to “CHECKING THE BATTERY” in left handlebar switch.
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
8-31
LIGHTING SYSTEM ELEC
EAS00786
YES NO
EAS00787
9. Wiring
Does the headlight relay (on/off) have conti-
nuity between red/yellow and black/blue? Check entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
YES NO Is the lighting system’s wiring properly con-
nected and without defects?
Replace the head- YES NO
light relay (on/off).
8-32
LIGHTING SYSTEM ELEC
EAS00788
CHECKING THE LIGHTING SYSTEM Set the main switch to “ON”.
1. The headlight and the high beam indicator Set the light switch to “ON”.
light fail to come on. Set the dimmer switch to “ ” or “ ”.
Measure the voltage (12 V) (wire harness
1. Headlight buld and scocket
side).
Check the headlight bulb and socket for
Is the voltage within specification?
continuity.
Are the headlight bulb and socket OK? YES NO
EAS00789
2. Voltage
2. The meter light fails to come on.
Connect the pocket tester (DC 20 V) to the
1. Meter light bulb and socket
headlight and high beam indicator light cou-
plers as shown. Check the meter light bulb and socket for
continuity.
A When the dimmer switch is set to “ ”.
B When the dimmer switch is seto to “ ”. Are the meter light bulb and socket OK?
Headlight YES NO
Positive tester probe
black/yellow 1 or black/green 2
Negative tester probe black 3 Replace the meter
High beam indicator light light bulb, socket of
Positive tester probe both.
black/yellow 4
Negative tester probe black 5
2. Vollage
Headlight coupler (wire harness side)
Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
Positive tester probe blue 1
Negative tester probe black 2
8-33
LIGHTING SYSTEM ELEC
Set the main switch to “ON”. Set the main switch to “ON”.
Set the light switch to “PO” or “ON”. Set the light switch to “PO” or “ON”.
Measure the voltage (12 V) of blue 1 on the Measure the voltage (12 V) of blue/red 1 on
meter light coupler (wire harness side). the tail/brake light coupler (tail/brake light
side).
Is the voltage within specification?
Is the voltage within specification?
YES NO
YES NO
This circuit is OK. The wiring circuit from
the main switch to the This circuit is OK. The wiring circuit from
meter light coupler is the main switch to the
faulty and must be re- tail/brake light coupler
paired. is faulty and must be
repaired.
EAS00790
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket
Chek the tail/brake light bulb and socket for
continuity.
Are the tail/brake light bulb and socket OK?
YES NO
2. Voltage
Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe blue/red 1
Negative tester probe black 2
8-34
SIGNAL SYSTEM ELEC
EAS00793
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-35
SIGNAL SYSTEM ELEC
1 Main switch
5 Battery
7 Fuse (main)
9 Starting circuit cutoff relay
19 Neutral switch
23 Fuel level warning light
24 Oil level warning light
25 Neutral indicator light
27 Combination meter
29 Fuel gauge
32 Turn signal indicator light (left)
33 Turn signal indicator light (right)
35 Oil level gauge
36 Fuel sender
37 Turn signal relay
39 Front brake light switch
43 Horn
47 Horn switch
49 Hazard switch
50 Turn signal switch
51 Front turn signal light (left)
52 Front turn signal light (right)
53 Rear turn signal light (left)
54 Rear turn signal light (right)
56 Tail/ brake light
57 Fuse (turn signal)
58 Fuse (ignition)
60 Fuse (alarm)
65 Rear brake light switch
8-36
SIGNAL SYSTEM ELEC
EAS00794 EAS00749
part(s): 4. Wiring
1) Seat S Check the entire signal system’s wiring.
2) Fuel tank Refer to “CIRCUIT DIAGRAM”.
3) Front cowling
4) Side cover S Is the signaling system’s wiring properly
S Troubleshoot with the following special tool(s). connected and without defects?
YES NO
Pocket tester
90890-03112
Check the condition Properly connect or
EAS00738 of each of the signal- repair the signaling
1. Main, signal, alarm and ignition fuses ing system’s circuits. system’s wiring.
Refer to “CHECK-
S Check the main, signal, alarm and ignition ING THE SIGNAL-
fuses for continuity. ING SYSTEM”.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main, signal, alarm and ignition
EAS00796
2. Battery
S Check the condition of the battery. YES NO
Refer to “CHECKING THE BATTERY” in
CHAPTER 3. Replace the left han-
Minimum open-circuit voltage dlebar switch.
12.8 V or more at 20_C
S Is the battery OK? 2. Voltage
YES NO S Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
S Clean the battery
terminals.
S Recharge or re-
place the battery.
8-37
SIGNAL SYSTEM ELEC
3. Horn EAS00797
2. Brake switches
Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake light switch OK?
NO YES
YES NO
The horn is OK.
Replace the brake
light switch.
8-38
SIGNAL SYSTEM ELEC
3. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
YES NO
3. The turn signal light, turn signal indicator Is the voltage within specification?
light or both fail to blink.
YES NO
1. Turn signal indicator light bulb and socket
Check the turn signal light bulb and socket The wiring circuit
for continuity. from the main switch
Are the turn signal light bulbs and socket OK? to the turn signal
relay coupler is faulty
YES NO and must be re-
paired.
8-39
SIGNAL SYSTEM ELEC
A B
4. Voltage
Connect the pocket tester (DC 20 V) to the
flasher relay coupler (wire harness side) as
shown.
Positive tester probe brown/white 1
Negative tester probe ground
The turn signal relay 4. The neutral indicator light fails to come on.
is faulty and must be
replaced. 1. Neutral indicator light bulb and socket
Check the neutral indicator light bulb and
socket for continuity.
5. Voltage
Are the neutral indicator light bulb and sock-
Connect the pocket tester (DC 20 V) to the et OK?
turn signal light connector (wire harness
side) as shown. YES NO
A Rear turn signal light
B Turn signal indicator light Replace the neutral
Left turn signal light indicator light bulb,
Positive tester probe chocolate 1 socket or both.
Negative tester probe ground
Right turn signal light 2. Neutral switch
Positive tester probe dark green 2 Check the neutral switch for continuity.
Negative tester probe ground Refer to “CHECKING THE SWITCHES”.
Is the neutral switch OK?
YES NO
8-40
SIGNAL SYSTEM ELEC
YES NO
EAS00795
3. Wiring
Set the main switch to “ON”.
Check the entire signal system’s wiring.
Measure the voltage (12 V).
Refer to “CIRCUIT DIAGRAM”.
Is the voltage within specification?
Is the signaling system’s wiring properly
connected and without defects?
YES NO
YES NO
This circuit is OK. The wiring circuit
from the main switch Replace the meter Properly connect or
to the meter light bulb unit. repair the signaling
coupler is faulty and system’s wiring.
must be repaired.
EAS00802
5. The oil level warning light fails to come on.
1. Oil level warning light bulb and socket
Check the oil level warning light bulb and
socket for continuity.
Are the oil level warning light bulb and sock-
et OK?
YES NO
8-41
SIGNAL SYSTEM ELEC
EAS00804
5. The fuel level gauge fails to operate. S Set the main switch to “ON”.
S Measure the voltage (12 V) of brown 1 on
1. Fuel sender
the meter light coupler (wire harness side).
S Remove the fuel sender from the fuel tank.
S Is the voltage within specification?
S Connect the pocket tester to the fuel sender
coupler (wire harness side) as shown. YES NO
Positive tester probe green 1
Negative tester probe black 2 Check the wiring
connections of the
entire signaling sys-
tem.
YES NO
NOTE:
Before reading the fuel level gauge, leave
Replace the fuel
the float in one position (either up or down)
sender.
for at least three minutes.
4. Wiring
S Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
8-42
COOLING SYSTEM ELEC
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
1 Main switch
5 Battery
7 Fuse (main)
21 Thermo unit
27 Combination meter
28 Water temp warning light
62 Fues (fan)
63 Fan motor relay
64 Fan motor
8-43
COOLING SYSTEM ELEC
EAS00808
EAS00809
Pocket tester
90890-03112 4. Radiator fan motor
S Disconnect the rediator fan motor coupler
EAS00738
from the wire harness.
1. Main and radiator fan motor fuses S Connect the battery (12 V) as shown.
S Check the main and radiator fan motor fuses Positive battery lead blue 1
for continuity. Negative battery lead black 2
Refert to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main and radiator fan motor fuses
OK?
YES NO
EAS00739
8-44
COOLING SYSTEM ELEC
EAS00812 EAS00759
YES NO
Termo unit resistance
80_C: 3.41 4.00 Ω Replace the fan mo-
105_C: 1.65 1.86 Ω tor relay.
WARNING
S Handle the termo unit with special care. EAS00813
8-45
FUEL PUMP SYSTEM ELEC
EAS00814
1 Main switch
5 Battery
7 Fuse (main)
9 Starting circuit cutoff relay
11 Fuel pump
15 Ignitor
41 Engine stop switch
51 Fuse (ignition)
8-46
FUEL PUMP SYSTEM ELEC
EAS00815
8-47
FUEL PUMP SYSTEM ELEC
EAS00816 EAS00749
S Check the main and ignition fuses for conti- S Disconnect the starting circuit cutoff relay
nuity. coupler from the wire harness.
Refer to “CHECKING THE FUSES” in S Connect the pocket tester (Ω 1) and bat-
CHAPTER 3. tery (12 V) to the starting circuit cutoff relay
coupler as shown.
S Are the main and ignition fuses OK?
Positive battery lead red/black 1
YES NO Negative battery lead blue/red 2
Positive tester probe red/black 3
Replace the fuse (s). Negative tester probe black/blue 4
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
S Does the starting circuit cutoff relay have con-
YES NO tinuity between red/black and black/blue?
YES NO
EAS00818
7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the fuel system’s wiring properly con-
nected and without defects?
YES NO
8-49
FUEL PUMP SYSTEM ELEC
EAS00819
1. Check:
fuel pump operation
8-50
EXUP SYSTEM ELEC
EAS00827
EXUP SYSTEM
CIRCUIT DIAGRAM
1 Main switch
5 Battery
7 Fuse (main)
12 EXUP servomotor
15 Ignitor
58 Fuse (ignition)
8-51
EXUP SYSTEM ELEC
EAS00828 EAS00829
TROUBLESHOOTING Procedure 1
When the engine speed changes, the 1. EXUP servomotor operation (with the
EXUP servomotor does not operate. EXUP servomotor coupler connected to
the wire harness)
Procedure 1 Disconnect the EXUP cables at the EXUP
Check: servomotor pulley side.
1. EXUP servomotor operation Start the engine and rev it to 5,000 r/min.
(with the EXUP servomotor coupler con-
nected to the wire harness) Does the EXUP servomotor pulley turn?
2. Voltage
3. EXUP servomotor operation YES NO
(with the EXUP servomotor coupler discon-
nected from the wire harness) Check that the EXUP
4. EXUP servomotor resistance cables are properly
(potentiometer resistance) installed.
5. Wiring connections If the connections are
(the entire EXUP system) correct, check the
Procedure 2 EXUP valve and
Check: cables. Refer to “EX-
1. Main and turn signal fuses HAUST SYSTEM” in
2. Battery chapter 5.
3. Main switch
4. Neutral switch EAS00830
Pocket tester
90890-03112
YES NO
Go to Procedure 2.
8-52
EXUP SYSTEM ELEC
EAS00831
YES NO
Check that the EXUP servomotor pulley ro-
tates several times.
The EXUP servomo-
CAUTION: tor is faulty and must
To prevent damaging the EXUP servomo- be replaced.
tor, perform this test within a few seconds
of connecting the battery. EAS00833
5. Wiring
Does the EXUP servomotor pulley turn?
Check the entire EXUP system’s wiring.
YES NO Refer to “CIRCUIT DIAGRAM”.
Is the EXUP system’s wiring properly con-
Replace the EXUP nected and without defects?
servomotor.
YES NO
EAS00832
Replace the ignitor Properly connect or
4. EXUP servomotor resistance unit. repair the EXUP sys-
(potentiometer resistance) tem’s wiring.
Disconnect the EXUP servomotor coupler
from the wire harness.
Connect the pocket tester (Ω 1 k) to the
EXUP servomotor coupler.
8-53
EXUP SYSTEM ELEC
EAS00750
Procedure 2
EAS00738
4. Engine stop switch
1. Main and ignition fuses
S Check the engine stop switch for continuity.
S Check the main and ignition fuses for conti- Refer to “CHECKING THE SWITCHES”.
nuity.
S Is the engine stop switch OK?
Refer to “CHECKING THE FUSES” in chap-
ter 3. YES NO
S Are the main and ignition fuses OK?
Replace the right
YES NO
handlebar switch.
5. Wiring
EAS00739
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES NO
8-54
SELF-DIAGNOSIS ELEC
SELF-DIAGNOSIS
The FZS1000 features a self-diagnosing system for the following circuit(-s):
Throttle position sensor
EXUP
Speed sensor
Emargency stop switch
If any of these circuits are defective, their respective condition codes will be displayed on the tachome-
ter when the main switch is set to “ON” (irrespective of whether the engine is running or not)
8-55
SELF-DIAGNOSIS ELEC
Tachometer display sequence
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
8-56
SELF-DIAGNOSIS ELEC
TROUBLESHOOTING
1. Wire harness
The tachometer starts to display the self- Check the wire harness for continuity.
diagnosis sequence. Refer to “CIRCUIT DIAGRAM”.
Check: Is the wire harness OK?
1. Throttle position sensor
2. EXUP YES NO
3. Speed sensor
4. Emargency stop switch Repair or replace the
NOTE: wire harness.
Before troubleshooting, remove the following
part(-s):
1) Rider seat 2. Throttle position sensor
2) Fuel tank
Check the throttle position sensor for conti-
3) Air filter case
nuity.
Troubleshoot with the following special
Refer to “CHECKING AND ADJUSTING
tool(-s).
THE THROTTLE POSITION SENSOR” in
chapter 6.
Pocket tester Is the throttle position sensor OK?
90890-03112
YES NO
8-57
SELF-DIAGNOSIS ELEC
2. EXUP
2. EXUP servomotor
CIRCUIT DIAGRAM
Check the EXUP servomotor for continuity.
Refer to “EXUP SYSTEM”.
Is the EXUP servomotor OK?
YES NO
12 EXUP servomotor
15 Ignitor unit
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES NO
8-58
SELF-DIAGNOSIS ELEC
3. Speed sensor
1. Wire harness
CIRCUIT DIAGRAM
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES NO
BAD
15 lgnitor unit
20 Speed sensor
8-59
SELF-DIAGNOSIS ELEC
4. Emargency stop switch
1. Wire harness
CIRCUIT DIAGRAM
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES NO
BAD
8-60
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING PROBLEMS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY CLUTCH
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
OVERHEATING
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
OVERCOOLING
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE
Cylinder(s) and cylinder head(s) Piston(s) and piston ring(s)
Loose spark plug Improperly installed piston ring
Loose cylinder head or cylinder Damaged, worn or fatigued piston ring
Damaged cylinder head gasket Seized piston ring
Damaged cylinder gasket Seized or damaged piston
Worn or damaged cylinder
Incorrect valve clearance Air filter
Improperly sealed valve Improperly installed air filter
Incorrect valve-to-valve-seat contact Clogged air filter element
Incorrect valve timing
Faulty valve spring Crankcase and crankshaft
Seized valve Improperly assembled crankcase
Seized crankshaft
FUEL SYSTEM
Fuel tank Carburetor(s)
Empty fuel tank Deteriorated or contaminated fuel
Clogged fuel filter Clogged pilot jet
Clogged fuel strainer Clogged pilot air passage
Clogged fuel tank drain hose Sucked-in air
Clogged rollover valve Damaged float
Clogged rollover valve hose Worn needle valve
Deteriorated or contaminated fuel Improperly installed needle valve seat
Incorrect fuel level
Fuel pump Improperly installed pilot jet
Faulty fuel pump Clogged starter jet
Faulty fuel pump relay Faulty starter plunger
Improperly adjusted starter cable
Fuel cock
Clogged or damaged fuel hose
9-1
TRBL
TROUBLESHOOTING SHTG
ELECTRICAL SYSTEMS
Battery Ignition system
Discharged battery Faulty ignitor unit
Faulty battery Faulty pickup coil
Broken generator rotor woodruff key
Fuse(s)
Blown, damaged or incorrect fuse Switches and wiring
Improperly installed fuse Faulty main switch
Faulty engine stop switch
Spark plug(s) Broken or shorted wiring
Incorrect spark plug gap Faulty neutral switch
Incorrect spark plug heat range Faulty start switch
Fouled spark plug Faulty sidestand switch
Worn or damaged electrode Faulty clutch switch
Worn or damaged insulator Improperly grounded circuit
Faulty spark plug cap Loose connections
EAS00846
9-2
TRBL
TROUBLESHOOTING SHTG
EAS00848
Fuel pump
Faulty fuel pump
EAS00850
9-3
TRBL
TROUBLESHOOTING SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
Clutch Clutch
Improperly assembled clutch Unevenly tensioned clutch springs
Improperly adjusted clutch cable Warped pressure plate
Loose or fatigued clutch spring Bent clutch plate
Worn friction plate Swollen friction plate
Worn clutch plate Bent clutch push rod
Broken clutch boss
Engine oil Burnt primary driven gear bushing
Incorrect oil level Match marks not aligned
Incorrect oil viscosity (low)
Deteriorated oil Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
EAS00855
OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Carburetor(s)
Cylinder head(s) and piston(s) Incorrect main jet setting
Heavy carbon buildup Incorrect fuel level
Damaged or loose carburetor joint
Engine oil
Incorrect oil level Air filter
Incorrect oil viscosity Clogged air filter element
Inferior oil quality
CHASSIS
COOLING SYSTEM Brake(s)
Coolant Dragging brake
Low coolant level
ELECTRICAL SYSTEMS
Radiator Spark plug(s)
Damaged or leaking radiator Incorrect spark plug gap
Faulty radiator cap Incorrect spark plug heat range
Bent or damaged radiator fin
Ignition system
Water pump Faulty ignitor unit
Damaged or faulty water pump
Thermostat
Thermostat stays closed
Oil cooler
Clogged or damaged oil cooler
Hose(s) and pipe(s)
Damaged hose
Improperly connected hose
Damaged pipe
Improperly connected pipe
9-4
TRBL
TROUBLESHOOTING SHTG
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
EAS00857
EAS00861
9-5
TRBL
TROUBLESHOOTING SHTG
EAS00862
UNSTABLE HANDLING
Handlebar Rear shock absorber assembly(-ies)
Bent or improperly installed handlebar Faulty rear shock absorber spring
Leaking oil or gas
Steering head components
Improperly installed upper bracket Tire(s)
Improperly installed lower bracket Uneven tire pressures (front and rear)
(improperly tightened ring nut) Incorrect tire pressure
Bent steering stem Uneven tire wear
Damaged ball bearing or bearing race
Wheel(s)
Front fork leg(s) Incorrect wheel balance
Uneven oil levels (both front fork legs) Deformed cast wheel
Unevenly tensioned fork spring Damaged wheel bearing
(both front fork legs) Bent or loose wheel axle
Broken fork spring Excessive wheel runout
Bent or damaged inner tube
Bent or damaged outer tube Frame
Bent frame
Swingarm Damaged steering head pipe
Worn bearing or bushing Improperly installed bearing race
Bent or damaged swingarm
9-6
TRBL
TROUBLESHOOTING SHTG
EAS00866
9-7
FZS1000 2001 WIRING DIAGRAM (EUR) 1 Main switch 35 Oil level gauge
2 Rectifier/ regulator 36 Fuel sender
3 AC magneto 37 Turn signal relay
4 Fuse (back up) 38 Handlebar switch (right)
5 Battery 39 Front brake light switch
6 Starter relay 40 Headlight switch
7 Fuse (main) 41 Engine stop switch
8 Starter motor 42 Start switch
9 Starting circuit cutoff relay 43 Horn
10 Sidestand switch 44 Handlebar switch (left)
11 Fuel pump 45 Pass switch
12 EXUP servo motor 46 Dimmer switch
13 T.P.S. 47 Horn switch
14 Emargency stop switch 48 Clutch switch
15 Igniter 49 Hazard switch
16 Ignition coil 50 Turn signal switch
17 Spark plug 51 Front turn signal light (left)
18 Pickup coil 52 Front turn signal light (right)
19 Neutral switch 53 Rear turn signal light (left)
20 Speed sensor 54 Rear turn signal light (right)
21 Thermo unit 55 Headlight
22 Meter assembly 56 Tail/ brake light
23 Fuel level warning light 57 Fuse (turn signal)
24 Oil level warning light 58 Fuse (ignition)
25 Neutral indicator light 59 Alarm
26 Tacho meter 60 Fuse (alarm)
27 Combination meter 61 Fuse (headlight)
28 Water temp warning light 62 Fuse (fan)
29 Fuel gauge 63 Fan motor relay
30 Speedometer 64 Fan motor
31 Hi-beam indicator light 65 Rear brake light switch
32 Turn signal indicator light (left) 66 Headlight relay (on / off)
33 Turn signal indicator light (right) 67 Head light relay (dimmer)
34 Meter light