Yamaha XJR1300 (L) '99 manual

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EAS00000 XJR1300(L) ’99 SERVICE MANUAL  1998 by Y amaha Motor Co., Ltd. 1st Edition, August 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressly prohibited.[...]

NOTE: CAUTION: EAS00002 NOTICE This manual was written by the Y amaha Motor Company primarily for use by Y amaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Y amaha motorcycle has a basic underst[...]

1 2 6 4 5 7 3 8 EAS00007 HOW T O USE THIS MANUAL This manual is intended as a handy , easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly , assembly , repair and check procedures are laid out with the individual steps in sequential order . 1 The manual is divided into chapters. An abbre[...]

21 1 3 5 7 9 2 4 8 6 23 24 22 20 18 19 17 16 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC CHAS CHK ADJ TRBL SHTG EAS00009 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter . 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis[...]

GEN INFO SPEC ENG CARB CHAS ELEC CHK ADJ TRBL SHTG GENERAL INFORMA TION SPECIFICA TIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURET ORS CHASSIS ELECTRICAL TROUBLESHOOTING 1 2 3 4 5 6 7 8 EAS00013 INDEX[...]

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GEN INFO 1[...]

GEN INFO CHAPTER 1. GENERAL INFORMA TION MOTORCYCLE IDENTIFICA TION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICA TION NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORT ANT INFORMA TION 1-[...]

GEN INFO[...]

1-1 GEN INFO MOTORCYCLE IDENTIFICA TION EAS00014 GENERAL INFORMA TION MOTORCYCLE IDENTIFICA TION EAS00017 VEHICLE IDENTIFICA TION NUMBER (For E) The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare p[...]

1-2 GEN INFO IMPORT ANT INFORMA TION EAS00020 IMPORT ANT INFORMA TION PREP ARA TION FOR REMOV AL AND DIS- ASSEMBL Y 1. Before removal and disassembly , remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together . This in[...]

1-3 GEN INFO IMPORT ANT INFORMA TION CAUTION: EAS00023 LOCK W ASHERS / PLA TES AND COTTER PINS After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1. Install be[...]

1-4 GEN INFO CHECKING THE CONNECTIONS NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect:  lead  coupler  connector 2. Check:  lead  coupler  connector Moisture  Dry with an air blower . Rust / stains  Connect and disconnect sev- eral t[...]

1-5 GEN INFO SPECIAL TOOLS EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly . Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order , refer to the list provided below to avoid an[...]

1-6 GEN INFO SPECIAL TOOLS T ool No. T ool name / Function Illustration 90890-031 13 Engine tachometer This tool is used to check engine speed. 90890-03141 T iming light This tool is used to check the ignition tim- ing. 90890-03158 Carburetor angle driver This tool is used to turn the pilot screw when adjusting the engine idling speed. 90890-04016 [...]

1-7 GEN INFO SPECIAL TOOLS T ool No. T ool name / Function Illustration 90890-06754 I gnition checker This tool is used to check the ignition sys- tem components. 90890-85505 Y amaha bond No. 1215 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces).[...]

GEN INFO[...]

SPEC 2[...]

SPEC CHAPTER 2. SPECIFICA TIONS GENERAL SPECIFICA TIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICA TIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-14 . [...]

SPEC[...]

2-1 SPEC GENERAL SPECIFICA TIONS SPECIFICA TIONS GENERAL SPECIFICA TIONS Model XJR1300(L) Model code: 5EA2 / 5EA3 / 5EA4 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2175 mm (GB) (D) (NL) (B) (F) (E) (P) (I) (GR) (SF) (AUS) 2250 mm (N) (SF) (G) (A) 775 mm 1 1 15 mm 775[...]

2-2 SPEC GENERAL SPECIFICA TIONS Model XJR1300(L) Carburetor: T ype / quantity Manufacturer BS36 / 4 MIKUNI Spark plug: T ype quantity Manufacturer Spark plug gap DPR8EA-9 / X24EPR-U9 4 NGK / DENSO 0.8 X 0.9 mm Clutch type: Wet, multiple-disc T ransmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduct[...]

2-3 SPEC GENERAL SPECIFICA TIONS Model XJR1300(L) Brake: Front brake type operation Rear brake type operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension: Front suspension Rear suspension T elescopic fork Swingarm Shock absorber: Front shock absorber Rear shock absorber Coil spring / Oil Damper Coil spring[...]

2-4 SPEC MAINTENANCE SPECIFICA TIONS MAINTENANCE SPECIFICA TIONS ENGINE Model Standard Limit Cylinder head: W arp limit  0.1 mm Cylinder: Bore size T aper limit Out of round limit Wear limit 79.00  79.01 mm     0.05 mm 0.05 mm 79.1 mm Camshaft: Drive method Cam cap inside diameter Camshaft outside dia[...]

2-5 SPEC MAINTENANCE SPECIFICA TIONS Head Dia. Face Width Seat Width Margin Thickness Model Standard Limit Cam chain: Cam chain type / No. of links Cam chain adjustment method 79RH2015 / 156 Automatic   V alve, valve seat, valve guide: V alve clearance (cold) IN EX V alve dimensions: 0.1 1  0.15 mm 0.16  0.20 mm  ?[...]

2-6 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit V alve spring: Inner spring Free length IN EX Set length (valve closed) IN EX Compressed pressure (installed) IN EX T ilt limit IN EX 39.65 mm 39.65 mm 32.8 mm 32.8 mm 61.7  72.5 N (6.29  7.39 kg) 61.7  72.5 N (6.29  7.39 kg)   37.5 mm 37.5 mm  ?[...]

2-7 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit Piston rings: T op ring: T ype Dimensions (B  T) End gap (installed) Side clearance (installed) 2nd ring: Barrel 1.00  3.05 mm 0.20  0.35 mm 0.045  0.080 mm   0.6 mm 0.1 mm T ype Dimensions (B  T) End gap (installed) Side clearance (installed) Oil ring: T ape[...]

2-8 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Clutch spring height Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit 2.9  3.1 mm 8 pcs 1.9  2.1 mm 7 pcs 6 mm 1 pc 0  0.2 mm 0.004  0.04[...]

2-9 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit Lubrication system: Oil filter type Oil pump type T ip clearance Housing and rotor clearance Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Pressure check location Paper type T rochoid type 0.12  0.17 mm 0.03  0.08 mm 0.03  0.08 mm 18[...]

2-10 SPEC MAINTENANCE SPECIFICA TIONS Tightening torques Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m  kg Camshaft cap Oil gallery bolt Spark plug Cylinder head Cylinder head cover Cylinder Cylinder Cylinder Connecting rod Cam sprocket T iming chain tensioner T iming chain tensioner cap bolt Chain gu[...]

2-1 1 SPEC MAINTENANCE SPECIFICA TIONS Part to be ti g htened Part name Thread size Q’ty T ightening torque Remarks g size y Nm m  kg Crankcase Crankcase Main gallery Oil buffle plate Stopper plate Bearing housing HY -VO chain guide Clutch boss Clutch pressure plate Push lever comp. Drive sprocket Shift shaft stopper Stopper plate (Starter clu[...]

2-12 SPEC MAINTENANCE SPECIFICA TIONS Tightening sequence Cylinder head Crankcase[...]

2-13 SPEC MAINTENANCE SPECIFICA TIONS Lubrication chart: Pressure feed Splashed Generator shaft Clutch T ransmission Ex. camshaft Lifter IN. camshaft Lifter T iming chain area Piston, Cylinder Connecting rod bearing Crankshaft bearings Main gallery Oil filter Relief valve Oil pump Oil cooler Oil pan / Oil strainer Model XJR1300(L)[...]

2-14 SPEC MAINTENANCE SPECIFICA TIONS CHASSIS Model Standard Limit Steering system: Steering bearing type Angular bearing  Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade 130 mm 407.3 mm 363.3 mm 150 mm 4.9 N / m[...]

2-15 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit Front disc brake: T ype Disc outside diameter  thickness Disc deflection limit Pad thickness Dual 298  5 mm  5.5 mm   0.2 mm 0.5 mm Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type 14 mm 30.2 mm and 27 mm DOT #4  [...]

2-16 SPEC MAINTENANCE SPECIFICA TIONS Tightening torques Part to be tightened Part name Thread size Q’ty T ightening torque Remarks g y Nm m  kg Handle crown and inner tube Handle crown and steering stem Handle crown and handlebar holder (lower) Upper handlebar holder Lower bracket and inner tube Steering stem and ring nut Front master cylinde[...]

2-17 SPEC MAINTENANCE SPECIFICA TIONS NOTE: Part to be ti g htened Part name Thread size Q’ty T ightening torque Remarks g y Nm m  kg Hook Helmet holder T ail light bracket Side stand Side stand Side stand switch Footrest bracket Rear footrest bracket Footrest and footrest bracket Rear brake reservoir tank Rear master cylinder and bracket Cent[...]

2-18 SPEC MAINTENANCE SPECIFICA TIONS ELECTRICAL Model Standard Limit V oltage: 12 V  Ignition system: Ignition timing (B.T .D.C.) Advanced timing (B.T .D.C.) Advancer type 5  / 1050 r / min 50  / 5000 r / min TPS & Electrical type    T .C.I.: Pickup coil resistance / color T .C.I. unit model / manufact[...]

2-19 SPEC MAINTENANCE SPECIFICA TIONS Model Standard Limit Mica undercut Starter relay: Model / manufacturer Amperage rating Coil winding resistance 0.7 mm MS5E-491 / JIDECO 100 A 4.2  4.6 Ω     Horn: T ype Quantity Model / manufacturer Maximum amperage Plane type 2 pcs YF12 / NIKKO 3 A   ?[...]

2-20 SPEC CONVERSION T ABLE / GENERAL TORQUE SPECIFICA TIONS EAS00028 CONVERSION T ABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MUL TIPLIER IMP ** mm x 0.03937 = ** in 2 mm x 0.03937 = 0.08 in CONVERSION T ABLE METRIC TO IMP Known Multiplie[...]

2-21 SPEC LUBRICA TION POINT AND GRADE OF LUBRICANT LUBRICA TION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring Bearing Piston surface Piston pin Crankshaft pin Crankshaft journal / big end Connecting rod bolt / nut Camshaft cam lobe / journal V alve stem (IN, EX) V alve stem end (IN, EX) V alve lifter Oil pump ro[...]

2-22 SPEC LUBRICA TION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Symbol Steering bearing (upper / lower) and bearing cover lip Front wheel oil seal (left / right) Rear wheel oil seal (left / right) Clutch hub fitting area Rear brake pedal shaft Shift pedal Centerstand sliding surface Sidestand sliding surface T ube guide (throttle grip[...]

2-23 1 Camshaft (intake) 2 Camshaft (exhaust) 3 Main gallery 4 Oil strainer 5 Oil pump 6 Main axle 7 Crankshaft SPEC LUBRICA TION DIAGRAMS LUBRICA TION DIAGRAMS[...]

2-24 1 Oil cooler 2 Starter clutch 3 Main axle 4 Drive axle 5 Oil pump 6 Oil pan 7 Relief valve 8 Main gallery SPEC LUBRICA TION DIAGRAMS[...]

2-25 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter SPEC LUBRICA TION DIAGRAMS[...]

2-26 A Fasten the wireharness to the seat rail with a plastic band. Make sure that the end of band down ward. B Align the white tape on the wire- harness with a plastic band and fasten them to the seat real. Make sure that the end of band down ward. C Fasten the wireharness with the steel clamp on the frame. 9 Throttle position sensor 10 Ignition c[...]

2-27 I Fasten the high tension cables and throttle cables with a plastic clamp. J Route the air ventilation hoses, air filter case drain hose, fuel tank drain hose and fuel tank bre- ather hose through the engine guide. K Fasten the AC generator lead, pick-up coil lead, sidestand swi- tch lead and starter motor cable with a plastic band. F Fasten t[...]

2-28 L Route the wireharness and start- er motor cable behind the side cover bracket and fasten them with a plastic band at front of the bracket. M Align the white paint marks of the fuel tank drain hose, fuel tank breather hose and air filter case drain hose. N T ouch the brake pipe to the brake caliper stopper . SPEC CABLE ROUTING[...]

2-29 E Fasten the high tension cables (#1 , 2) wi th a pl astic clamp. Posi- tion the clamp at 50 – 80 mm above the high tension cable number . F Fasten the horn lead to the frame with a plastic band. Make sure that the end of band down ward. G Install the frame ground and ig- niter unit together with screw . A Insert the plastic band through the[...]

2-30 N Route the speedometer cable through the guide. O T ouch the brake pipe to the bra- ke caliper stopper . P T ouch the brake pipe to the bra- ke hose joint. K Fasten the sidestand switch lead with steel clamp on the frame and then route it between the pickup cover , oil filter cover , AC generator and starter motor to the right side of motorcy[...]

2-31 24 T aillight lead 25 Starter cable A Position the horn (high) to right side. B Fasten the throttle cable (front side) to the frame with a plastic clamp. C Fasten the throttle position sen- sor with steel clamp on the car- buretor (#4). D T o fuel sender . 12 Starter relay 13 Seat lock cable 14 Seat lock 15 Battery positive (+) lead 16 Fuse bo[...]

2-32 J Position the seat lock cable in- side under the seat lock bracket. K Fasten the wireharness to the frame with a plastic band. Make sure that the end of band down ward. L Route the starter cable between the throttle cables. M Fasten the wireharness, starter cable to the frame with a plastic band. Make sure that end of ba- nd down ward. G Fast[...]

2-33 SPEC CABLE ROUTING N Fasten the wireharness, taillight lead and rear turn signal light leads (left and right) with steel clamp on the frame make sure that the end of clamp forward. O Route the rear turn signal light leads (left and right) through the each holes of the rear fender . P T ouch the starter cable to the stopper and position it vert[...]

2-34 D Route the handlebar switch lead (left) and front turn signal light lead (left) into the left under hole of the headlight body . E Route the front turn signal light leads (left and right) in front of the headlight stay . F Route the speedometer cable through the guide on the head- light stay . G T o front brake master cylinder . A Route the t[...]

2-35 H T ouch the brake pipe to the stop- per . I Route the handlebar switch lead (right) and front turn signal light lead (right) into the right under hole of the headlight stay . J Fasten the handlebar switch lead (right) and front brake hose with a plastic band. SPEC CABLE ROUTING[...]

SPEC[...]

CHK ADJ 3[...]

CHK ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANC E/ LUBRIC A TION INTE R V AL S 3- 1 . . . . . . . . . . . SEA T SIDE COVER AND FUEL T ANK 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 3-4 . . . [...]

CHK ADJ LUBRICA TING THE SIDE ST AND 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICA TING THE CENTERST AND 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICA TING THE REAR SUSPENSION 3-40 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 3-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

3-1 CHK ADJ INTRODUCTION / PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle opera- tion and a longer service life.[...]

3-2 PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS CHK ADJ NOTE: *: It is recommended that these items be serviced by a Y amaha dealer . **: Molybdenum disulfide grease. ***: Lithium soap base grease. Brake fluid replacement: 1. When disassembling the master cylinder , caliper cylinder or clutch release cylinder , replace the brake fluid. Normally [...]

3-3 CHK ADJ SEA T , SIDE COVER AND FUEL T ANK 19 Nm (1.9 m S kg) Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the seat, side cover and fuel tank Seat Side cover (left) Side cover (right) Fuel hose Fuel tank Fuel sender lead Drain hose Grab bar Rear fender cover 1 1 1 1/ 1 1 1 2 1 1 Remove the parts in the order listed. Disconnect the [...]

3-4 CHK ADJ ADJUSTING THE V AL VE CLEARANCE NOTE: ENGINE ADJUSTING THE V AL VE CLEARANCE the following procedure applies to all of the valves. S V alve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression st[...]

3-5 CHK ADJ ADJUSTING THE V AL VE CLEARANCE NOTE: NOTE: a. T urn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the timing plate with the mark b on the pickup coil base plate. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other . c. Mea[...]

3-6 ADJUSTING THE V AL VE CLEARANCE CHK ADJ EX IN NOTE: NOTE: 5. Adjust: S V alve clearance a. Align the intake and exhaust valve lifter slots with each other . b. Slowly turn the crankshaft until the cam lifted at maximum. c. Install the tappet adjusting tool 1 as shown. T appet adjusting tool: P / N 90890-041 10 Make sure that the tappet adjustin[...]

3-7 MEASURED CLEARANCE MEASURED CLEARANCE INST ALLED P AD NUMBER INST ALLED P AD NUMBER V AL VE CLEARANCE (cold): 0.1 1  0.15 mm Example: Installed is 250 Measured clearance is 0.23 mm Replace 250 pad with 260 pad Pad number: (example) Pad No. 250 = 2.50 mm Pad No. 260 = 2.60 mm Always install pad with number down. V AL VE CLEARANCE (cold): 0.16[...]

3-8 CHK ADJ ADJUSTING THE V AL VE CLEARANCE NOTE: NOTE: EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm (0.098 in)) Rounded value = 250 h. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row inter- sect is the new valve pad number . T[...]

3-9 CHK ADJ SYNCHRONIZING THE CARBURETORS NOTE: NOTE: NOTE: EAS00050 SYNCHRONIZING THE CARBURETORS Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. 2. Rem[...]

3-10 CHK ADJ SYNCHRONIZING THE CARBURETORS ADJUSTING THE ENGINE IDLING SPEED NOTE: NOTE: b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in ei- ther direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in ei- ther direction until both gauges [...]

3-1 1 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLA Y a b NOTE: Engine tachometer 90890-031 13 3. Measure: S engine idling speed Out of specification  Adjust. Engine idling speed 1,000  1,100 r / min 4. Adjust: S engine idling speed a. T urn the pilot screw 1 in or out until it is light- ly seated. b. T urn t[...]

3-12 ADJUSTING THE THROTTLE CABLE FREE PLA Y CHK ADJ NOTE: a b NOTE: a b W ARNING 2. Remove: S seat S fuel tank Refer to “SEA T , SIDE COVER AND FUEL T ANK”. 3. Adjust: S throttle cable free play When the motorcycle is accelerating, the acceler- ator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 3 on the decelerator cable. b. T urn[...]

3-13 CHECKING THE SP ARK PLUGS CHECKING THE IGNITION TIMING CHK ADJ CAUTION: NOTE: NOTE: EAS00059 CHECKING THE SP ARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect:  spark plug cap 2. Remove:  spark plug Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air[...]

3-14 CHK ADJ CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE NOTE: NOTE: 2. Install:  timing light 1  engine tachometer 2 (to the spark plug lead of cyl. #1) Timing light 90890-03141 Engine tachometer 90890-031 13 3. Check:  ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the sp[...]

3-15 CHK ADJ MEASURING THE COMPRESSION PRESSURE CAUTION: 3. Disconnect: S spark plug cap 4. Remove: S spark plug 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: S compression gauge 1 S adapter 2 Compression gauge 90890-03081 [...]

3-16 CHK ADJ MEASURING THE COMPRESSION PRESSURE / CHECKING THE ENGINE OIL LEVEL W ARNING NOTE: NOTE: a. T urn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. T o prevent sparking, ground all spark plug leads before cranking the engine. The difference in compression[...]

3-17 CHK ADJ CHECKING THE ENGINE OIL LEVEL / CHANGING THE ENGINE OIL CAUTION: NOTE: S 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 hig[...]

3-18 CHK ADJ CHANGING THE ENGINE OIL / MEASURING THE ENGINE OIL PRESSURE CAUTION: W ARNING Quantity T otal amount 4.2 L Without oil filter element re- placement 3 L With oil filter element replace- ment 3.35 L 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off. 1 1. Check; S engine (for [...]

3-19 MEASURING THE ENGINE OIL PRESSURE / ADJUSTING THE CLUTCH LEVER CHK ADJ NOTE: b a a c W ARNING Engine oil pressure 80 kPa (0.8 kg / cm 2 , 0.8 bar) Engine speed Approx. 1000 r / min Engine oil temperature 70  80 _ C (158  176 _ F) Out of specification  Adjust. Engine oil pressure Possible causes Below specification Faulty oil pump Clog[...]

3-20 CHK ADJ CHECKING THE CLUTCH FLUID LEVEL / BLEEDING THE HYDRAULIC CLUTCH SYSTEM NOTE: W ARNING CAUTION: NOTE: W ARNING EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. 2. Check: S clutch fluid level Below the minimum level mark a  Add the recommended clutch fluid t[...]

3-21 CHK ADJ BLEEDING THE HYDRAULIC CLUTCH SYSTEM NOTE: W ARNING S Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over- flow . S When bleeding the hydraulic clutch system, make sure that there is always enough clutch fluid before applying the clutch lever . Ignoring this precaution could allow air to enter[...]

3-22 CHK ADJ CLEANING THE AIR FIL TER ELEMENT CAUTION: NOTE: EAS00087 CLEANING THE AIR FIL TER ELEMENT 1. Remove: S side cover (right) Refer to “SEA T , SIDE COVER AND FUEL T ANK”. S air filter case cover 1 2. Remove: S air filter element 2 3. Clean: S air filter element 1 Apply compressed air to the inner surface of the air filter element. 4. [...]

3-23 CHK ADJ CHECKING THE CARBURETOR JOINTS AND INT AKE MANIFOLDS/ CHECKING THE FUEL AND V ACUUM HOSES EAS00095 CHECKING THE CARBURETOR JOINTS AND INT AKE MANIFOLDS The following procedure applies to all of the car- buretor joints and intake manifolds. 1. Remove: S seat S side cover S fuel tank Refer to “SEA T , SIDE COVER AND FUEL T ANK”. 2. C[...]

3-24 CHK ADJ CHECKING THE CRANKCASE BREA THER HOSE/ CHECKING THE EXHAUST SYSTEM CAUTION: EAS00098 CHECKING THE CRANKCASE BREA THER HOSE EAS00100 1. Check: S crankcase breather hose 1 Cracks / damage  Replace. Loose connection  Connect properly . Make sure that the crankcase breather hose is routed correctly . EAS00099 CHECKING THE EXHAUST SYS[...]

3-25 CHK ADJ ADJUSTING THE FRONT BRAKE / ADJUSTING THE REAR BRAKE NOTE: b a a c W ARNING a b W ARNING EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position[...]

3-26 CHK ADJ ADJUSTING THE REAR BRAKE / CHECKING THE BRAKE FLUID LEVEL A B W ARNING CAUTION: NOTE: W ARNING EAS001 10 c. T ighten the locknut 1 to specification. Locknut 18 Nm (1.8 m S kg) 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 blee[...]

3-27 CHK ADJ CHECKING THE BRAKE FLUID LEVEL / CHECKING THE BRAKE P ADS / ADJUSTING THE REAR BRAKE LIGHT SWITCH A B CAUTION: NOTE: NOTE: a b S When refilling, be careful that water does not enter the reservoir . W ater will signifi- cantly lower the boiling point of the brake fluid and could cause vapor lock. Brake fluid may damage painted surfaces [...]

3-28 A B CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM W ARNING NOTE: EAS00134 BLEEDING THE HYDRAULIC BRAKE SYS- TEM Bleed the hydraulic brake system whenev- er: S the system was disassembled, S a brake hose was loosened or removed, S the brake fluid level is very low , S brake operation is faulty . S Be careful not to spill any brake fluid or allow [...]

3-29 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK W ARNING a b NOTE: CAUTION: Bleed screw 6 Nm (0.6 m S kg) k. Fill the reservoir to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. After bleeding the hydraulic brake system, check the brake operation. EAS00136 ADJUSTING THE[...]

3-30 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK W ARNING NOTE: a b NOTE: W ARNING 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Rotate the rear wheel several times and check the drive chain to lo[...]

3-31 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK / LUBRICA TING THE DRIVE CHAIN CAUTION: Do not loosen the wheel axle nut after tight- ening it to the specified torque. If the groove in the wheel axle nut is not aligned with the cotter pin hole in the wheel axle, tighten the nut further until they are aligned. i. T ighten the tensionbar bolt to specifi[...]

3-32 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD W ARNING NOTE: EAS00146 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: S steering head G[...]

3-33 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD –0.2po NOTE: W ARNING 8. Remove: S upper handleber holder 1 S handleber 2 9. Remove: S handle crown 1 10. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut w[...]

3-34 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK NOTE: W ARNING e. Install the rubber washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary , hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Inst[...]

3-35 CHK ADJ ADJUSTING THE FRONT FORK LEGS W ARNING CAUTION: a b ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. S Always adjust both front fork legs evenly . Uneven adjustment can result in poor han- dling and loss of stability . S Securely support the motorcycle so that there is no danger of it fallin[...]

3-36 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES W ARNING CAUTION: NOTE: a b EAS00161 ADJUSTING THE REAR SHOCK ABSORB- ER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. S Securely support the motorcycle so that there is no danger of it falling over . S Always adjust both rear shock absorber assemb[...]

3-37 CHK ADJ CHECKING THE TIRES W ARNING EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification  Regulate. S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must b[...]

3-38 CHK ADJ CHECKING THE TIRES A B W ARNING W ARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately . 2. Check: S tire surfaces Damage / wear  Replace the tire. Minimum tire tread depth 1.6 mm 1 T ire tread depth 2 Side wall 3 Wear indicator S Do not use a tubeless tire on [...]

3-39 CHK ADJ CHECKING THE TIRES / CHECKING THE WHEELS W ARNING NOTE: W ARNING NOTE: Front tire Manufacturer Size T ype MICHELIN 120 / 70ZR17 MACADAM 90X DUNLOP 120 / 70ZR17 D207F BRIDGESTONE 120 / 70ZR17 BT57F Rear tire Manufacturer Size T ype MICHELIN 180/ 55ZR17 MACADAM 90X DUNLOP 180 / 55ZR17 D207 BRIDGESTONE 180 / 55ZR17 BT57R New tires have a [...]

3-40 CHK ADJ CHECKING ANDLUBRICA TING THE CABLES/LUBRICA TING THE LEVERS AND PEDALS LUBRICA TING THE SIDE ST AND/LUBRICA TING THE CENTERST AND LUBRICA TING THE REAR SUSPENSION W ARNING NOTE: EAS00170 CHECKING AND LUBRICA TING THE CABLES The following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may cause the cable[...]

3-41 CHK ADJ CHECKING AND CHARGING THE BA TTER Y W ARNING CAUTION: EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BA TTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling o[...]

3-42 CHK ADJ CHECKING AND CHARGING THE BA TTER Y NOTE: CAUTION: 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. Discon[...]

3-43 CHK ADJ CHECKING AND CHARGING THE BA TTER Y W ARNING CAUTION: Do not quick charge a battery . S Make sure that the battery vent is free of ob- structions. 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 batte[...]

3-44 Measure the open-circuit voltage prior to charging. Connect a charger and am- meter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 20  25 V . Adjust the voltage to obtain the standard charging amperage. Monitor the amperage for 3  5 minu[...]

3-45 CHK ADJ CHECKING AND CHARGING THE BA TTER Y Measure the open-circuit voltage prior to charging. Connect a charger and am- meter to the battery and start charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Is the amperage higher than the standard charging amperage written on the battery?[...]

3-46 CHK ADJ CHECKING AND CHARGING THE BA TTER Y/ CHECKING THE FUSES CAUTION: CAUTION: NOTE: 6. Check: S battery vent Obstruction  Clean. Damage  Replace. 7. Install: S battery 8. Connect: S battery leads (to the battery terminals) First, connect the positive lead 1 , then the negative lead 2 . 9. Check: S battery terminals Dirt  Clean wit[...]

3-47 CHK ADJ CHECKING THE FUSES W ARNING Pocket tester 90890-031 12 b. If the pocket tester indicates “ ∞ ”, replace the fuse. 3. Replace: S blown fuse a. T urn off the ignition. b. Install a new fuse of the correct amperage rating. c. T urn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows a[...]

3-48 CHK ADJ REPLACING THE HEADLIGHT BULB W ARNING CAUTION: EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S headlight unit 1 2. Disconnect: S headlight lead 1 S auxiliary light lead 2 3. Remove: S cover 3 4. Remove: S headlight bulb holder 1 5. Remove: S headlight bulb 2 Since the headlight bulb gets extremely hot, keep flammable products and yo[...]

3-49 CHK ADJ REPLACING THE HEADLIGHT BULB / ADJUSTING THE HEADLIGHT BEAM a b a b 7. Install: S headlight bulb holder 8. Install: S cover 9. Connect: S auxiliary light lead S headlight lead 10. Install: S headlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. T urn the adjusting screw 1 in direction a or b .[...]

CHK ADJ[...]

ENG 4[...]

ENG CHAPTER 4. ENGINE OVERHAUL ENGINE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS, HOSES AND EXHAUST PIPES 4-1 . . . . . . . . . . . . . . . . . . . . . . . LEADS AND DRIVE SPROCET 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 4-5 . . . . . . . . . [...]

ENG CHECKING THE PRESSURE PLA TE 4-37 . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PUSH RODS 4-38 . . . . . . . . . . . . . . . . . . . . . . . INST ALLING THE CLUTCH 4-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

ENG CHECKING THE BEARINGS AND OIL SEALS 4-79 . . . . . . . . . . . . . . . . . CHECKING THE CIRCLIPS AND W ASHERS 4-79 . . . . . . . . . . . . . . . . . . . INST ALLING THE CONNECTING RODS 4-79 . . . . . . . . . . . . . . . . . . . . . . INST ALLING THE CRANKSHAFT 4-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 4-82 . . [...]

ENG[...]

4-1 ENG ENGINE Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the leads, hoses and ex- haust pipes Seat, side cover , fuel tank Carburetor Engine oil Exhaust band Exhaust pipe Gasket Muffler left / right Exhaust chamber Exhaust chamber bracket Oil cooler Air duct left / right 6 4 4 1/1 1 1 1 1/1 Remove the parts in the order listed. Refer[...]

4-2 ENG ENGINE Order Job / Part Q’ty Remarks O-ring Ground lead Crankcase breather hose 2 1 1 For installation, reverse the removal pro- cedure. Disconnect ground lead. NOTE: 9 10 11 12 Nm (1.2 m  kg) 20 Nm (2.0 m  kg) 25 Nm (2.5 m  kg) 25 Nm (2.5 m  kg) 20 Nm (2.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 20 Nm (2.0 m  k[...]

4-3 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the leads and drive sprocket Starter motor lead Starter motor Pickup / neutral switch lead A.C. generator lead A.C. generator Clutch release cylinder comp. Shift arm Drive sprocket cover Dowel pins Gasket Nut 1 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed. Refer to “[...]

4-4 ENG ENGINE Order Job / Part Q’ty Remarks 12 13 14 Lock washer Drive sprocket Drive chain 1 1 1 For installation, reverse the removal procedure. 25 Nm (2.5 m  kg) 10 Nm (1.0 m  kg) 85 Nm (8.5 m  kg) 10 Nm (1.0 m  kg) 10.Nm (1.0 m  kg) New New[...]

4-5 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the engine Footrest Down tube Engine bracket (front) Spacer Engine bracket (rear upper) left, right Engine bracket (rear lower) Engine 1 1 2 1 2 1 1 Remove the parts in the order listed. For installation, reverse the removal procedure. Place a suitable stand under the frame and engine. NOTE[...]

4-6 ENG ENGINE NOTE: EAS00192 INST ALLING THE ENGINE 1. T ighten the bolts in the following order . Bolt 1 : 88 Nm (8.8 m  kg) Bolt 2 : 48 Nm (4.8 m  kg) Bolt 3 : 55 Nm (5.5 m  kg) Bolt 4 : 30 Nm (3.0 m  kg) Bolt 5 : 64 Nm (6.4 m  kg) Nut 6 : 64 Nm (6.4 m  kg) 2. Install:  shift arm 1  Align the punch mark b in the shift sha[...]

4-7 ENG CAMSHAFT Order Job / Part Q’ty Remarks 1 2 3 4 5 Removing the cylinder head covers Seat, fuel tank Bolts Air duct (left / right) Plug cap Cylinder head cover Gasket 2 1/1 4 1 1 Remove the parts in the order listed. Refer to “SEA T , SIDE COVER AND FUEL T ANK”. For installation, reverse the removal procedure. 10 Nm (1.0 m  kg) 10 Nm[...]

4-8 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the camshafts Spark plugs T iming plate cover / Gasket T iming chain guide (top side) T iming chain tensioner assembly T iming chain guide (exhaust side) Camshaft caps Dowel pins Camshaft (intake) Camshaft (exhaust) Camshaft sprockets 4 1/1 1 1 1 8 16 1 1 2 Remove the parts in the or[...]

4-9 ENG CAMSHAFTS NOTE: NOTE: NOTE: CAUTION: EAS00199 REMOVING THE CAMSHAFTS 1. Align:  “T” mark on the timing plate (with the stationary pointer on the pickup coil base plate) a. T urn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark a with the pickup coil mark b . TDC on the c[...]

4-10 ENG CAMSHAFTS NOTE: EAS000204 CHECKING THE CAMSHAFTS 1. Check:  camshaft lobes Blue discoloration / pitting / scratches  Re- place the camshaft. 2. Measure:  camshaft lobe dimensions a and b Out of specification  Replace the cam- shaft. Camshaft lobe dimension limit Intake / exhaust a Wear limit <28.15 mm> b Wear limit <35[...]

4-1 1 ENG CAMSHAFTS 5. Measure:  camshaft journal diameter a Out of specification  Replace the cam- shaft. Within specification  Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.967  24.980 mm EAS00208 CHECKING THE CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of[...]

4-12 A B ENG CAMSHAFTS NOTE: CAUTION: NOTE: NOTE: INST ALLING THE CAMSHAFTS 1. Install:  camshaft sprockets  Be sure to set the sprockets in the specified position as shown in the figure.  T emporarily tighten the bolts in this stage. A Exhaust side B Intake side 2. Install:  camshaft (exhaust)  camshaft (intake) a. T urn the cranksh[...]

4-13 ENG CAMSHAFTS CAUTION: CAUTION: NOTE: CAMSHAFTS ENG d. Check if the punched marks c on both cam- shafts are inside the holes of camshaft caps d . If they are not in the position, repeat the above steps. e. T ighten the bolts (camshaft cap) in a criss- cross pattern from the inside outwards. The bolts (camshaft caps) must be tight- ened evenly [...]

4-14 ENG CAMSHAFTS CAUTION: a. T urn the crankshaft counterclockwise sever- al times until the TDC mark on the timing plate is aligned with the stationary pointer . b. Check if both the camshaft timing punch marks a are aligning with the camshaft cap hole b . 5. T ighten:  Bolts (cam sprockets) Be sure to tighten the camshaft sprocket bolts to t[...]

4-15 Order Job / Part Q’ty Remarks 1 2 3 4 5 Removing the cylinder head Camshafts Cylinder head Gasket Dowel pins O-rings Intake manifold 1 1 2 2 4 Remove the parts in the order listed. Refer to “CAMSHAFTS”. For installation, reverse the removal procedure. NOTE: Refer to “REMOVING / INST ALLING THE CYLINDER HEAD”. Remove the engine mount [...]

4-16 ENG CYLINDER HEAD NOTE: NOTE: EAS00223 REMOVING THE CYLINDER HEAD 1. Remove:  cylinder head nuts 1  16  Loosen the nuts in the proper sequence as shown.  Loosen each nut 1 / 2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00228 CHECKING THE CYLINDER HEAD The following procedure applies to all of the[...]

4-17 NOTE: ENG CYLINDER HEAD NOTE: T o ensure an even surface, rotate the cylinder head several times. EAS00232 INST ALLING THE CYLINDER HEAD 1. Install:  gasket (New) 1  dowel pins 2 2. Install:  cylinder head  washers  copper washers  cylinder head nuts  Apply engine oil onto the threads of the cylin- der head nuts.  T igh[...]

4-18 ENG V AL VES AND V AL VE SPRINGS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the valves and valve springs Camshaft Cylinder head V alve pads V alve lifters V alve cotters Upper springs seats V alve springs (outer) V alve springs (inner) Intake valves Exhaust valves Lower spring seats Oil seals 16 16 32 16 16 16 8 8 16 16 Remo[...]

4-19 ENG V AL VES AND V AL VE SPRINGS NOTE: NOTE: NOTE: EAS00237 REMOVING THE V AL VES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove:  valve lifter 1  valve pad[...]

4-20 ENG V AL VES AND V AL VE SPRINGS NOTE: NOTE: 4. Remove: S upper spring seat 1 S valve springs 2 S oil seal 3 S lower spring seat 4 S valve 5 Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE V AL VES AND V AL VE GUIDES The following procedure applies to all of the valve[...]

4-21 302-013 ENG V AL VES AND V AL VE SPRINGS NOTE: NOTE: a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem to valve-guide clearance. A[...]

4-22 ENG V AL VES AND V AL VE SPRINGS NOTE: CAUTION: EAS00240 CHECKING THE V AL VE SEA TS The following procedure applies to all of the valves and valve seats. 1. Eliminate:  carbon deposits (from the valve face and valve seat) 2. Check:  valve seat Pitting / wear  Replace the cylinder head. 3. Measure:  valve seat width a Out of specif[...]

4-23 ENG V AL VES AND V AL VE SPRINGS NOTE: d. T urn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hand. e. Apply a fine lapping compound to the valve face and repeat the ab[...]

4-24 ENG V AL VES AND V AL VE SPRINGS V alve spring free length (intake and exhaust) Inner spring <Limit> 39.65 mm <37.5 mm> Outer spring <Limit> 41.1 mm <39 mm> 2. Measure: S compressed spring force a Out of specification  Replace the valve spring. b Installed length Compressed spring force Intake and exhaust inner sprin[...]

4-25 ENG V AL VES AND V AL VE SPRINGS NOTE: NOTE: CAUTION: NOTE: Recommended lubricant Molybdenum disulfide oil 2. Install:  valve 1  lower spring seat 2  oil seal 3  valve springs 4  upper spring seat 5 (into the cylinder head) Install the valve spring with the larger pitch a facing up. b Smaller pitch 3. Install:  valve cotters [...]

4-26 CYLINDERS AND PISTONS ENG Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the cylinders and pistons Cylinder head Cylinder block Dowel pins Gasket Piston pin clips Piston pins Pistons Oil ring sets Remove the parts in the order listed. Refer to “CYLINDER HEAD”. For installation, removal procedure. Refer to “REMOVING / INST ALLING [...]

4-27 ENG CYLINDERS AND PISTONS CAUTION: NOTE: NOTE: EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove:  piston pin clip 1  piston pin 2  piston 3 Do not use a hammer to drive the piston pin out.  Before removing the piston pin clip, cover the crankcase opening wi[...]

4-28 ENG CYLINDERS AND PISTONS NOTE: a. Measure cylinder bore “C” with the cylinder bore gauge. 1 20 mm from the top of the cylinder Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cyl- inder . Then, find the average of the measure- ments. Cylinder bore gauge Standard 79.00  79.01 mm Wear limit 79.[...]

4-29 ENG CYLINDERS AND PISTONS NOTE: NOTE: NOTE: EAS00263 CHECKING THE PISTON RINGS 1. Measure:  piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearan[...]

4-30 1 2 4 5 3 ENG CYLINDERS AND PISTONS NOTE: NOTE: EAS00270 INST ALLING THE PIST ONS AND CYLIN- DERS The following procedure applies to all of the pis- tons and cylinders. 1. Install:  top ring 1  2nd ring 2  lower oil ring rail 3  upper oil ring rail 4  oil ring expander 5  Be sure to install the piston rings so that the manufa[...]

4-31 ENG CYLINDERS AND PISTONS NOTE: 3. Install:  gasket (New) 1  dowel pins 2 4. Lubricate:  piston  piston rings  cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset:  piston ring end gaps a T op ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A forward 6. Install:  cylinder block [...]

4-32 Order Job / Part Q’ty Remarks 1 2 3 Removing the clutch cover . Engine oil Clutch cover Gasket Dowel pins 1 1 2 Remove the parts in the order listed. Drain For installation, reverse the removal procedure. 10 Nm (1.0 m  kg) New ENG CLUTCH EAS00273 CLUTCH CLUTCH COVER[...]

4-33 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Removing the clutch Pressure plate Clutch spring Spring housing Pressure plate Clutch push rod (short) Ball Clutch push rod (long) O-ring Friction plates Clutch plates Friction plates Clutch boss nut Lock washer 1 1 1 1 1 1 1 1 1 6 6 1 1 Remove the parts in the order listed. Refer t[...]

4-34 ENG CLUTCH Order Job / Part Q’ty Remarks 14 15 16 17 18 19 20 21 22 23 Clutch boss Stopper ring Clutch plate Clutch spring plate Clutch spring plate seat Friction plates (narrow) Thrust washer Spacer Bearing Clutch housing 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure. Refer to “REMOVING / INST ALLING THE CLUTCH”. 7[...]

4-35 ENG CLUTCH NOTE: NOTE: NOTE: EAS00275 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen:  clutch boss nut 1 While holding the clutch boss 2 with the univer- sal clutch holder , loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3. Remove:  clutch boss nut 1  lock washer 2  clutch boss 3  thrust wash[...]

4-36 ENG CLUTCH EAS00281 CHECKING THE CLUTCH PLA TES The following procedure applies to all of the clutch plates. 1. Check:  clutch plate Damage  Replace the clutch plates as a set. 2. Measure:  clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification  Replace the clutch plates as a set. Clutch plate warpa[...]

4-37 CLUTCH ENG NOTE: NOTE: EAS00284 CHECKING THE CLUTCH HOUSING 1. Check:  Clutch housing dogs Damage / pitting / wear  Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check:  bearing Damage / wear  Replace the clutch hous- ing. EAS00285 CHECKING[...]

4-38 ENG CLUTCH NOTE: NOTE: EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check:  O-ring 1  short clutch push rod 2  long clutch push rod 3  ball 4  bearing 5 Cracks / damage / wear  Replace the de- fective part(-s). 2. Measure:  long clutch push rod bending limit Out of specification  Replace the long clutch push rod. Long clut[...]

4-39 ENG CLUTCH NOTE: NOTE: 3. T ighten:  clutch boss nut 1 While holding the clutch boss with the universal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 Clutch boss nut 70 Nm (7.0 m  kg) 4. Bend the lock washer tab along a flat side of the nut. 5. Lubricate:  long clutch push rod 1  ball 2  shor[...]

4-40 ENG CLUTCH NOTE: NOTE: 7. Install:  Friction plates (narrow type) 1  Clutch plates 2  Stopper ring 3  Friction plates (wide type) 4 a. Install the friction plate of narrow contact face 1 and one of the clutch plate to the clutch boss. b. Install the stopper ring 3 . Install the stopper ring onto the groove around the clutch boss wi[...]

4-41 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the clutch master cylinder Clutch lever Clutch switch lead Clutch switch Union bolt Copper washers / Clutch hose Clutch lever holder Clutch master cylinder 1 1 1 1 2/1 1 1 Remove the parts in the order listed. Before removing the clutch master cylin- der , drain the clutch fluid from the e[...]

4-42 Order Job / Part Q’ty Remarks Disassembling the clutch master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 New ENG CLUTCH[...]

4-43 ENG CLUTCH CAUTION: W ARNING EAS00307 Clutch components rarely require disas- sembly . Therefore, always follow these preventive measures:  Never disassemble clutch components un- less absolutely necessary .  If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned,[...]

4-44 ENG CLUTCH W ARNING W ARNING W ARNING NOTE: 2. Check:  clutch master cylinder 1  clutch master cylinder kit 2 Rust / scratches / wear  Replace the clutch master cylinder and clutch master cylinder kit as a set.  clutch hose 3 Cracks / damage / wear  Replace. EAS00309 ASSEMBLING THE CLUTCH MASTER CYL- INDER  Before installatio[...]

4-45 CLUTCH ENG NOTE: W ARNING CAUTION: NOTE: Union bolt 30 Nm (3.0 m  kg) 3. Install:  clutch lever 1 Lubricate the clutch lever pivot bolt with lithium soap base grease. 4. Fill:  clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended clutch fluid Brake fluid DOT 4  Use only the desi[...]

4-46 ENG CLUTCH 6. Check:  clutch fluid level Below the minimum level mark a  Add the recommended clutch fluid to the proper lev- el. Refer to “CHECKING THE CLUTCH FLUID LEVEL” in chapter 3. 7. Check:  clutch lever operation Soft or spongy feeling  Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapt[...]

4-47 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 Removing the clutch release cylinder Bolt Union bolt Copper washer Spacer Clutch hose Clutch release cylinder 3 1 3 1 1 1 Remove the parts in the order listed. Refer to “INST ALLING THE CLUTCH RELEASE CYLINDER”. Before removing the clutch releace cylin- der , drain the clutch fluid from the entir[...]

4-48 ENG CLUTCH Order Job / Part Q’ty Remarks 1 2 3 4 5 Disassembling the clutch release cylinder Clutch release cylinder Piston seal Clutch release cylinder piston Piston seal Spring 1 1 1 1 1 Disassembly the parts in the order listed. Refer to “DISASSEMBLING THE CLUTCH RELEASE CYLINDER”. For assembly , reverse the disassembly procedure.[...]

4-49 ENG CLUTCH W ARNING EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove:  piston seal 1  clutch release cylinder piston 2  spring 3  piston seal 4 a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder .  Cover the clutch release cylinder with a rag. Be caref[...]

4-50 ENG CLUTCH W ARNING W ARNING CAUTION: EAS00315 INST ALLING THE CLUTCH RELEASE CYL- INDER 1. Check:  copper washers (New)  clutch hose 1  union bolt 2 Proper clutch hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. Union bolt 30 Nm (3.0 m  kg) 2. Fill:  clutch master cylinder reservoir[...]

4-51 ENG CLUTCH NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reser- voir is horizontal. 3. Bleed:  clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 4. Check:  clutch fluid level Below the minimum level mark a  Add the recommended clutch fluid to the prope[...]

4-52 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the oil pump. Clutch Oil pump drive gear Collar W asher Oil buffer plate Circlip Oil pump driven gear W asher Oil pump Dowel pin Collar O-ring 1 1 1 1 1 1 1 1 1 1 3 Remove the parts in the order listed. Refer to “INST ALLING THE CLUTCH”. Refer to “INST ALLING THE OIL PUMP?[...]

4-53 ENG OIL PUMP Order Job / Part Q’ty Remarks Disassembling the oil pump Oil pump housing Inner rotor Outer rotor Pin Dowel pin Oil pump housing Inner rotor Outer rotor Pin Oil pump shaft Oil pump cover 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed. Refer to “ASSEMBLING THE OIL PUMP”. For assembly , reverse the disassembly[...]

4-54 ENG OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check:  oil pump drive gear 1  oil pump driven gear 2  oil pump housing 3  oil pump housing cover 4 Cracks / damage / wear  Replace the de- fective part(-s). 2. Measure:  inner-rotor to outer-rotor tip clearance A  outer-rotor to oil-pump-housing clearance B  oil-pump-housi[...]

4-55 ENG OIL PUMP NOTE: CAUTION: NOTE: EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate:  inner rotor  outer rotor  oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install:  oil pump shaft 1 (to the oil pump cover 2 )  pin 3  inner rotor 4  outer rotor 5  pin 6  oil pump housing 7  scre[...]

4-56 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the shift shaft and stopper lever Oil pump Drive sprocket cover Circlip W asher Shift shaft W asher Shift lever spring Bolt Stopper lever Stopper lever spring 1 1 1 1 1 1 1 1 Remove the parts in the order listed. Refer to “OIL PUMP”. Refer to “ENGINE”. Refer to “INST ALLING THE[...]

4-57 ENG SHIFT SHAFT NOTE: EAS00328 CHECKING THE SHIFT SHAFT 1. Check:  shift shaft 1 Bends / damage / wear  Replace.  shift lever spring Damage / wear  Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check:  stopper lever 1 Bends / damage  Replace. Roller turns roughly  Replace the stopper lever . EAS00331 INST ALLING THE SHIF[...]

4-58 ENG SHIFT SHAFT NOTE:  Lubricate the oil seal lips with lithium soap base grease.  Hook the end of the shift lever spring onto the shift lever spring stopper 4 .[...]

4-59 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the timing plate and pickup coil Seat, side cover , fuel tank Pickup coil read T iming plate cover Gasket Pickup coil T iming plate Dowel pin Pickup base 1 1 1 1 1 1 1 Remove the parts in the order listed. For installation, reverse the removal procedure. 4 Nm (0.4 m  kg) 45 Nm (4.5 m ?[...]

4-60 10 Nm(1.0 m  kg) 10 Nm(1.0 m  kg) Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the oil pan Engine Oil level switch / O-ring Oil pan Dowel pin Gasket Relief valve / O-ring Relief valve / O-ring Oil strainer Oil strainer housing Gasket 1/1 1 2 1 1/1 1/1 1 1 1 Remove the parts in the order listed. Refer to “ENGINE”. Refer [...]

4-61 ENG OIL P AN NOTE: EAS00362 REMOVING THE OIL P AN 1. Remove:  oil level switch 1  oil pan 2  gasket  dowel pins 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. EAS00365 CHECKING THE RELIEF V AL VE 1. Check:  relief valve body 1  relief [...]

4-62 ENG OIL P AN NOTE: NOTE: W ARNING NOTE: EAS00378 INST ALLING THE OIL STRAINER 1. Install:  oil strainer housing 1 Oil strainer housing bolt 10 Nm (1.0 m  kg) LOCTITE  The arrow a on the oil strainer housing must point towards the front of the engine. 2. Install:  oil strainer cover 1  relief valve 2 The arrow a on the oil strain[...]

4-63 ENG CRANKCASE Order Job / Part Q’ty Remarks 1 2 3 Removing the oil pan Engine Camshafts Cylinder head Cylinder , piston Clutch Oil pump Shift shaft T iming plate, pickup coil Oil strainer Spring / rod Chain guide Cover 1/1 1 1 Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CAMSHAFTS”. Refer to “CYLINDER HEAD”.[...]

4-64 ENG CRANKCASE Order Job / Part Q’ty Remarks 4 5 6 Bearing cover Crankcase (lower) Dowel pin 1 1 2 Refer to “DISASSEMBLING / ASSEM- BLING THE CRANKCASE”. For installation, reverse the removal pro- cedure. 24 Nm (2.4 m  kg) 35 Nm (3.5 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 12 Nm (1.2 m  kg) 35 Nm (3.5 m  kg) 12 Nm (1.[...]

4-65 A B ENG CRANKCASE NOTE: CAUTION: NOTE: EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts S 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. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration). S Th[...]

4-66 ENG CRANKCASE NOTE: NOTE: EAS00399 CHECKING THE CRANKCASE 1. Throughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check:  crankcase Cracks / damage  Replace.  oil delivery passages Obstruction  Blow out with compressed air . EAS00412 ASSEMBLING THE CRAN[...]

4-67 A B ENG CRANKCASE CAUTION: NOTE: NOTE: 5. Set the shift drum assembly and transmis- sion gears in the neutral position. 6. Install: S lower crankcase 1 (onto the upper crankcase 2 ) Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. S Carefully position[...]

4-68 ENG ST ARTER CLUTCH Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 Removing the starter clutch Crankcase Bearing housing O-ring Oil seal Nozzle Generator shaft Bearing Starter clutch drive gear Starter clutch gear Collar Circlip Starter clutch roller Stopper plate 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed. Refer [...]

4-69 ENG ST ARTER CLUTCH Order Job / Part Q’ty Remarks 13 14 15 Idle gear shaft Starter clutch idle gear Bearing 1 1 1 For installation, reverse the removal pro- cedure. 7 Nm (0.7 m  kg) 10 Nm (1.0 m  kg) New[...]

4-70 ENG ST ARTER CLUTCH EAS00350 CHECKINHG THE ST ARTER CLUTCH 1. Check:  starter clutch rollers 1 Damage / wear  Replace. 2. Check:  starter clutch idle gear 2  starter clutch drive gear 3  starter clutch gear 4 Burrs / chips / roughness / wear  Replace the defective part(-s). 3. Check:  starter clutch gear ’s contacting su[...]

4-71 ENG ST ARTER CLUTCH CAUTION: EAS00352 CHECKING THE GENERA TOR SHAFT 1. Check:  generator shaft 1  generator shaft splines 2 Damage / wear  Replace the generator shaft.  oil passages 3 Dirt / obstruction  W ash the generator shaft and then blow out the oil passages with com- pressed air .  bearing 4 Rough movement  Replace.[...]

4-72 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the crankshaft assembly Crankcase Starter clutch Crankshaft Oil seal Cover T iming chain HY -VO chain Crankshaft journal bearings HY -VO chain guide 1 1 1 1 1 10 1 Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “ST ARTER CLUTCH”. Refer to “REMOVING / INST AL[...]

4-73 ENG CRANKSHAFT Order Job / Part Q’ty Remarks 1 2 3 4 5 Removing the connecting rod. Nut Connecting rod bolt Coonecting rod Connecting rod cap Connecting rod bearing 8 8 4 4 8 Remove the parts in the order listed For installation, reverse the removal procedur . Refer to ”REMOVING / INST ALLING THE CONNECTING RODS.” Refer to ”INST ALLING[...]

4-74 ENG CRANKSHAFT NOTE: NOTE: CAUTION: EAS00387 REMOVING THE CRANKSHAFT ASSEMBL Y 1. Remove:  crankshaft assembly 1  crankshaft journal upper bearings (from the upper crankcase) Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00391 REMOVING THE CONNECTING RODS 1. Remove:[...]

4-75 ENG CRANKSHAFT NOTE: NOTE: NOTE: NOTE: a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. Align the projections a of the crankshaft jour- nal u[...]

4-76 ENG CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings. h. Measure the compressed Plastigauge  width 1 on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 4. Select:  Crankshaft journal bearings (J 1 X J 5 ) For example, if the crankcase ?[...]

4-77 CAUTION: ENG CRANKSHAFT NOTE: NOTE: CAUTION: Do not interchange the big end bearings and connecting rods. T o obtain the correct crank- shaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bear- ings must be installed in their original posi- tions. a. Clean the big end bearings, crankshaft pins, and bearing portions of[...]

4-78 ENG CRANKSHAFT NOTE: Refer to “INST ALLING THE CONNECTING RODS”. Connecting rod nut 36 Nm (3.6 m  kg) f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS”. g. Measure the compressed Plastigauge  width 1 on the crankshaft pin. If the clearance is out of specification, select replacement big en[...]

4-79 ENG CRANKSHAFT CHECKING THE TIMING CHAIN 1. Check:  timing chain 1 Damage / stiffness  Replace the timing chain and camshaft sprockets as a set. 2. Check  timing chain guide (intake side) Damage / wear  Replace. EAS00400 CHECKING THE HY -VO CHAIN 1. Check:  HY -VO chain 1 Damage / stiffness  Replace the HY -VO chain and sproc[...]

4-80 ENG CRANKSHAFT NOTE: CAUTION: Recommended lubricant Engine oil 3. Install:  big end bearings 1  connecting rods 2  connecting rod caps 3 (onto the crankshaft pins)  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 orig[...]

4-81 ENG CRANKSHAFT NOTE: NOTE: EAS00407 INST ALLING THE CRANKSHAFT 1. Install:  crankshaft journal upper bearings (into the upper crankcase)  Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the crankcase.  Be sure to install each crankshaft journal up- per bearing in its original place. 2. Install:[...]

4-82 ENG TRANSMISSION Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the transmission, shift drum assembly , and shift forks. Crankcase Main axle assembly Oil seal Bearing Drive axle assembly Collar O-ring Oil seal Circlip Bearing 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed. Refer to “CRANKCASE”. For installation, reverse[...]

4-83 ENG TRANSMISSION Order Job / Part Q’ty Remarks Disassembling the transmission W asher 1st wheel gear/ Collar W asher 4th wheel gear Circlip W asher 3rd wheel gear / collar W asher 5th wheel gear Circlip W asher 2nd wheel gear / collar Drive axle 1 1/1 1 1 1 1 1/1 1 1 1 1 1/1 1 Disassembly the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 1[...]

4-84 ENG TRANSMISSION Order Job / Part Q’ty Remarks 2nd pinion gear 5th pinion gear / collar W asher 3rd pinion gear Circlip W asher 4th pinion gear Main axle (1st pinion gear) 1 1/1 1 1 1 1 1 1 For assembly , reverse the disassembly procedure. 14 15 16 17 18 19 20 21 New New New[...]

4-85 ENG TRANSMISSION Order Job / Part Q’ty Remarks 1 2 3 4 5 6 Removing the shift cam and shift fork. Crankcase Shif fork quide bar Shift fork (L) Shift fork (C) Shift fork (R) Stopper plate Shift drum 1 1 1 1 1 1 Remove the parts in the order listed. Refer to ”CRANKCASE” For installation, reverse the removal produre. Refer to ”INST ALLING[...]

4-86 ENG TRANSMISSION W ARNING EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check:  shift fork cam follower 1  shift fork pawl 2 Bends / damage / scoring / wear  Replace the shift fork. 2. Check:  shift fork guide bar Roll the shift fork guide bar on a flat surfac[...]

4-87 ENG TRANSMISSION NOTE: NOTE: 2. Measure:  drive axle runout (with a centering device and dial gauge 1 ) Out of specification  Replace the drive axle. Drive axle runout limit 0.06 mm 3. Check:  transmission gears Blue discoloration / pitting / wear  Replace the defective gear(-s).  transmission gear dogs Cracks / damage / rounded[...]

4-88 ENG TRANSMISSION NOTE: NOTE: EAS00429 INST ALLING THE TRANSMISSION 1. Install:  main axle assembly 1  drive axle assembly 2  Make sure that the drive axle bearing circlips 3 are inserted into the grooves 4 in the upper crankcase.  The drive axle bearing pin 5 must face to- wards the rear of the crankcase and the main axle bearing p[...]

CARB 5[...]

CARB CHAPTER 5. CARBURETORS CARBURETORS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURET ORS 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . INST ALLING THE CARBURETORS 5-7 . . . . . . .[...]

CARB[...]

5-1 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the carburetors Seat, fuel tank Battery negative lead Battery positive lead Battery Carburetor joint screws Air filter joint screws Bolts Air filter case Throttle position sensor lead Starter cable Throttle cables Carburetors 1 1 1 4 4 3 1 1 1 2 1 Remove the parts in the order lis[...]

5-2 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Disassembling the carburetor Starter shaft / Starter levers Upper bracket Lower bracket Throttle stop screw set Carburetors Throttle cable bracket Starter plunger set V acuum chamber cover Piston valve spring Piston valve Jet needle Pilot air jet Pilot screw 1/4 1 1 1 4 1 1 1 1 1 1 1[...]

5-3 Order Job / Part Q’ty Remarks 14 15 16 17 18 19 20 Float chamber Float chamber gasket Float pin Float Needle valve ass’y Pilot jet Main jet Needle jet 1/1 1 1 1 1 1 1 For assembly , reverse the disassembly procedure. Refer to “ASSEMBLING THE CARBURE- TORS”. New CARB CARBURET ORS EAS00484[...]

5-4 CARB CARBURET ORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check:  carburetor body  float chamber  jet housing Cracks / damage  Replace. 2. Check:  fuel passages Obstruction  Clean. a. W ash the carburetor in a petroleum-based solvent. Do not use any caustic-carburetor- [...]

5-5 CARB CARBURET ORS CAUTION: NOTE: 10. Check:  jet needle kit 1  needle jet 2  main jet 3  pilot jet 4  pilot screw 5 Bends / damage / wear  Replace. Obstruction  Clean. Blow out the jets with compressed air . 1 1. Check:  piston valve movement Insert the piston valve into the carburetor body and move it up and down. T igh[...]

5-6 CARB CARBURET ORS NOTE: NOTE: EAS00489 2. Measure:  float height a Out of specification  Adjust. Float height 21.3  23.3 mm a. Hold the carburetor upside down. b. Measure the distance from the mating sur- face of the float chamber (with the gasket re- moved) to the top of the float. The float arm should rest on the needle valve without[...]

5-7 CARB CARBURET ORS NOTE: EAS00493 INST ALLING THE CARBURETORS 1. Adjust:  carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in chapter 3. 2. Adjust:  engine idling speed Engine idling speed 1,000  1,100 r / min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3. Adjust:  throttle cable free play [...]

5-8 CARB CARBURET ORS NOTE: 1 2 1 2 a. Remove the carburetor assembly . b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slight- ly bending the float tang 1 . e. Install the carburetor assembly . f. Measure the fuel level again. g. Repeat steps (a) to (f) un[...]

5-9 CARB CARBURET ORS NOTE: NOTE: NOTE: Out of specification  Replace the throttle position sensor . Throttle position sensor resistance 0 to 4  6 k Ω at 20 _ C (68 _ F) (Y ellow – Black / Blue) 2. Adjust: S throttle position sensor angle a. T urn the main switch to “ON”. b. Disconnect the throttle position sensor cou- pler . c. Recon[...]

5-10 CARB CARBURET ORS NOTE: EAS00505 CHECKING THE FUEL COCK 1. Check:  fuel cock Cracks / damage / wear  Replace. EAS00506 CHECKING THE FUEL COCK OPERA TION After installing the fuel cock, check its opera- tion. 1. Check that the fuel cock lever is positioned to “ON” or “R”. 2. Place a container under the end of the fuel hose. 3. Che[...]

CHAS 6[...]

CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISCS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 6-4 . . . . . . . . . . . . . . . . . . .[...]

CHAS FRONT FORK 6-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 6-44 . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 6-44 . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 6-46 . . . . . . . . . . . . . . . . . . . . [...]

6-1 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the front wheel and brake discs Wheel axle pinch bolt Brake hose holder (left / right) Caliper (left / right) Wheel axle Front wheel Speedometer gear unit Collar Brake disc (left / right) 1 1/1 1/1 1 1 1 1 1/1 Remove the parts in the order listed. Place the motorcycle on a suitable stand [...]

6-2 Order Job / Part Q’ty Remarks Disassembling the front wheel. Oil seal Bearing Spacer Bearing 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518[...]

6-3 CHAS FRONT WHEEL AND BRAKE DISCS W ARNING NOTE: NOTE: NOTE: W ARNING EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. disconnect:  speedometer cable 1 3.[...]

6-4 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: CAUTION: NOTE: Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 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) a. Clean the o[...]

6-5 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: Brake disc deflection limit (maximum) Front: 0.2 mm Rear: 0.15 mm a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is station- ary . c. Remove the brake cali[...]

6-6 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: NOTE: NOTE: CAUTION: EAS00544 INST ALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate:  wheel axle  oil seal lips Recommended lubricant Lithium soap base grease 2. Install:  brake disc 1  Apply LOCTITE  648 to the threads of the brake disc bolts.  T i[...]

6-7 CHAS FRONT WHEEL AND BRAKE DISCS W ARNING NOTE: NOTE: 6. Install:  brake caliper Brake caliper bolt 40 Nm (4.0 m  kg) Make sure that the brake hose is routed properly . EAS00549 ADJUSTING THE FRONT WHEEL ST A TIC BALANCE  After replacing the tire, wheel or both, the front wheel static balance should be adjusted.  Adjust the front wh[...]

6-8 CHAS FRONT WHEEL AND BRAKE DISCS NOTE: 3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rim ex- actly opposite the heavy spot “X”. Start with the lightest weight. b. T urn the front wheel 90 _ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posi- tion, install a heavi[...]

6-9 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the rear wheel Chain adjusters Rear wheel axle nut Plate washer Chain puller (left) Wheel axle Chain Puller (right) Rear wheel 2 1 1 1 1 1 1 Remove the parts in the order listed. Place the motorcycle on a suitable stand so that the rear wheel is elevated. NOTE: Refer to “REMOVING / INST A[...]

6-10 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the brake disc and rear wheel sprocket Collar Brake disc Clutch hub Collar Rear wheel sprocket Clutch dampers Oil seal Bearing 1 1 1 1 1 5 1 1 Remove the parts in the order listed. For installation, the removal procedure. 20 Nm (2.0 m  kg) 60 Nm (6.0 m  kg) CHAS REAR WHEEL, BRAKE D[...]

6-1 1 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET W ARNING NOTE: NOTE: EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Loosen:  adjusting bolt 1  l[...]

6-12 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET NOTE: EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check:  rear wheel drive hub Cracks / damage  Replace.  rear wheel dive hub dampers Damage / wear  Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check:  rear wheel sprocket More than 1 / 4 tooth a wear ?[...]

6-13 CHAS REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET NOTE: EAS00572 INST ALLING THE REAR WHEEL 1. Lubricate:  wheel axle  wheel bearings  oil seal lips Recommended lubricant Lithium soap base grease 2. T ighten:  wheel axle nut Wheel axle nut 150 Nm (15.0 m  kg) EAS00575 ADJUSTING THE REAR WHEEL ST A TIC BALANCE  After replaci[...]

6-14 Order Job / Part Q’ty Remarks 1 2 3 4 Removing the front brake pads Clip Pad pin Pad support Brake pad 4 2 2 4 Remove the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE P ADS”. For installation, reverse the removal procedure. CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE P ADS[...]

6-15 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the rear brake pads Caliper Cover Clip Pad pin Pad spring Brake pad Caliper shim 1 1 2 2 1 2 2 Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE P ADS”. For installation, reverse the removal procedure. 40 Nm (4.0 m  kg) CHAS FRONT AND REAR BRAKES EAS00578 REAR[...]

6-16 CHAS FRONT AND REAR BRAKES CAUTION: NOTE: EAS00579 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, dra[...]

6-17 CHAS FRONT AND REAR BRAKES NOTE: NOTE: 3. Remove:  brake pads 7 4. Measure:  brake pad wear limit a Out of specification  Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install:  brake pads  brake pad spring Always install new brake pads, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly[...]

6-18 CHAS FRONT AND REAR BRAKES NOTE: 6. Install:  brake pad pins  brake pad clips  brake caliper Brake caliper bolt 40 Nm (4.0 m  kg) 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 lev[...]

6-19 CHAS FRONT AND REAR BRAKES NOTE: NOTE: 5. Install:  brake pad shims (onto the brake pads)  brake pads  brake pad spring Always install new brake pads, brake pad shims, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container . b. Loosen the b[...]

6-20 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 Removing the front brake master cylinder Brake fluid Brake lever Brake switch lead Front brake switch Union bolt Copper washers / Brake hose Master cylinder bracket Master cylinder 1 2 1 1 2/ 1 1 1 Remove the parts in the order listed. Drain Refer to “DISASSEMBLING / ASSEM- BLING AND INST ALLING [...]

6-21 CHAS FRONT AND REAR BRAKES Order Job / Part Q’ty Remarks Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 New[...]

6-22 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the rear brake master cylinder Brake fluid Bolts Brake pedal Brake switch Union bolt Copper washers / brake hose Clip / reservoir hose Cotter pin / copper washer Pin Master cylinder ass’y Reservoir tank 2 1 1 1 2/1 2/1 1/1 1 1 1 Remove the parts in the order listed. Drain Refer to[...]

6-23 CHAS FRONT AND REAR BRAKES Order Job / Part Q’ty Remarks Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 New[...]

6-24 CHAS FRONT AND REAR BRAKES NOTE: NOTE: NOTE: NOTE: EAS00588 DISASSEMBLING THE FRONT BRAKE MAS - TER CYLINDER Before disassembling the front brake master cylinder , drain the brake fluid from the entire brake system. 1. Remove:  rear view mirror (right)  brake lever 1 2. Disconnect:  brake switch coupler 2 (from the brake switch) 3. Re[...]

6-25 CHAS FRONT AND REAR BRAKES A B C D E F EAS00592 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 1 Damage / scratches / wear  Replace.  brake fluid delivery passages 2 (brake master cylinder body) Obstruction  Blow out with[...]

6-26 CHAS FRONT AND REAR BRAKES W ARNING NOTE: W ARNING CAUTION: NOTE: EAS00598 ASSEMBLING AND INST ALLING THE FRONT BRAKE MASTER CYLINDER  Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.  Never use solvents on internal brake com- ponents. Recommended brake fluid DOT 4 1. In[...]

6-27 CHAS FRONT AND REAR BRAKES W ARNING CAUTION: 3. Fill:  brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4  Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.  Refill with t[...]

6-28 CHAS FRONT AND REAR BRAKES W ARNING CAUTION: W ARNING CAUTION: EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install:  copper washers (New) 1  brake hose 2 Union bolt 3 30 Nm (3.0 m  kg) Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. When installing the brake hose on[...]

6-29 CHAS FRONT AND REAR BRAKES 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[...]

6-30 Order Job / Part Q’ty Remarks 1 2 3 4 Removing the front brake calipers Brake fluid Union bolts Copper washers Brake hoses Caliper ass’y 2 4 2 2 Remove the parts in the order listed. Drain For installation, reverse the removal procedure. Refer to “DISASSEMBLING / ASSEMBLING AND INST ALLING THE FRONT BRAKE CALIPERS”. 7 Nm (0.7 m  kg)[...]

6-31 CHAS FRONT AND REAR BRAKES 6 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 Disassembling the front brake cali- pers. The following procedure applies to both of the front brake calipers. Clips Pad pin Pad spring Brake pads / shims Caliper pistons Bleed screw Dust seals Piston seals 2 1 1 2/2 4 1 4 4 Disassembly the parts in the order listed. [...]

6-32 Order Job / Part Q’ty Remarks 1 2 3 4 Removing the rear brake caliper Brake fluid Union bolt Copper washers Brake hose Caliper ass’y 1 2 1 1 Remove the parts in the order listed. Drain For installation, reverse the removal procedure. Refer to “DISASSEMBLING / ASSEMBLING AND INST ALLING THE REAR BRAKE CALIPER”. 40 Nm (4.0 m  kg) 30 N[...]

6-33 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 Disassembling the rear brake caliper Cover Clips Pad pins Pad support Brake pads / shims Caliper pistons Dust seals Piston seals Bleed screws 1 2 2 1 2/2 2 2 2 2 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. Refer to “DISASSEMBLING THE REAR BRAKE[...]

6-34 CHAS FRONT AND REAR BRAKES NOTE: NOTE: W ARNING EAS00625 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. Before disassembling either brake caliper , drain the brake fluid from the entire brake system. 1. Remove:  union bolt 1  copper washers 2  brake hose Put the end of the brake[...]

6-35 CHAS FRONT AND REAR BRAKES NOTE: NOTE: W ARNING EAS00629 DISASSEMBLING THE REAR BRAKE CAL- IPER Before disassembling the brake caliper , drain the brake fluid from the entire brake system. 1. Remove:  union bolt 1  copper washers 2  brake hose 3 Put the end of the brake hose into a container and pump out the brake fluid carefully . 2.[...]

6-36 CHAS FRONT AND REAR BRAKES A B W ARNING W ARNING EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassembled. 1. Check:  brake caliper pistons 1 Rust / s[...]

6-37 CHAS FRONT AND REAR BRAKES W ARNING CAUTION:  Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.  Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install:  brake caliper 1 (temporarily)  copper washers (New) ?[...]

6-38 CHAS FRONT AND REAR BRAKES W ARNING CAUTION: Recommended brake fluid DOT 4  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 che[...]

6-39 CHAS FRONT AND REAR BRAKES W ARNING New 30 Nm (3.0 m  kg) W ARNING CAUTION: 40 Nm (4.0 m  kg) 7 Nm (7.0 m  kg) EAS00642 ASSEMBLING AND INST ALLING THE REAR BRAKE CALIPER  Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.  Never use solvents on internal brake com-[...]

6-40 CHAS FRONT AND REAR BRAKES W ARNING CAUTION: 4. Fill:  brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4  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 ty[...]

6-41 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 Removing the front fork Front wheel Brake calipers Brackets Front fender Bolts (upper bracket) Cap bolts Bolts (lower bracket) Front fork (left / right) 2 1 2 2 4 1/1 Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. For installation, reverse the removal procedure. Ref[...]

6-42 CHAS FRONT FORK Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Disassembling the front fork Cap bolts O-rings Plates Spacers Spring seats Fork springs Dust seals Oil seal clips Oil seals Seal spacers Outer tube bushings Bolts (damper rod) Gaskets 2 2 2 2 2 2 2 2 2 2 2 2 2 Disassembly the parts in the order listed. Refer to “DI[...]

6-43 CHAS FRONT FORK Order Job / Part Q’ty Remarks 14 15 16 17 18 19 Inner tubes Inner tube bushings Oil flow stoppers Damper rods Damper rod springs Outer tubes 2 2 2 2 2 2 For assembly , reverse the disassembly procedure. Refer to “DISASSEMBLING / ASSEMBLING THE FRONT FORK LEGS”. 23 Nm (2.3 m  kg) 23 Nm (2.3 m  kg)[...]

6-44 CHAS FRONT FORK W ARNING NOTE: W ARNING EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the front wheel is elevated. 2[...]

6-45 CHAS FRONT FORK CAUTION: NOTE: CAUTION: 4. Remove:  dust seal 1  oil seal clip 2 (with a flat-head screwdriver) Do not scratch the inner tube. 5. Remove:  damper rod bolt 1 While holding the damper rod with the damper rod holder 2 and T -handle 3 , loosen the damper rod bolt. Damper rod holder (30 mm) 90890-01327 T -Handle 90890-01326[...]

6-46 CHAS FRONT FORK W ARNING CAUTION: EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check:  inner tube 1  outer tube 2 Bends / damage / scratches  Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure:  spring free length a Over t[...]

6-47 CHAS FRONT FORK W ARNING NOTE: CAUTION: NOTE: EB703703 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.  Make sure that the oil levels in both front fork legs are equal.  Uneven oil levels can result in poor han- dling and a loss of stability .  When assembling the front fork leg, be sure [...]

6-48 CHAS FRONT FORK CAUTION: NOTE: NOTE: 4. Install:  outer tube bushing 1  seal spacer 2  oil seal 3 (with the fork seal driver weight 4 and adapter 5 ) Fork seal driver weight 90890-01367 Adapter 90890-01374 Make sure that the numbered side of the oil seal faces up.  Before installing the oil seal, apply lithium soap base grease onto[...]

6-49 CHAS FRONT FORK CAUTION: NOTE: 7. Fully compress the front fork leg. 8. Fill:  front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 538 cm 3 Recommended oil Fork oil 10w or equivalent  Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performanc[...]

6-50 CHAS FRONT FORK NOTE: NOTE: W ARNING  Install the fork spring with its smaller pitch up- ward.  Before installing the cap bolt, apply grease to the O-ring.  T emporarily tighten the cap bolt. EAS00662 INST ALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install:  front fork leg T empora[...]

6-51 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Removing the handlebar Master cylinder bracket Master cylinder (front brake) Throttle cable housing Handlebar switch (right) Throttle cable housing Throttle cables Grip end (right) Throttle grip Master cylinder bracket Master cylinder (clutch) Handlebar switch (left) Starter lever /[...]

6-52 Order Job / Part Q’ty Remarks 14 15 16 17 Handlebar grip Collar Upper handlebar holders Handlebar 1 1 2 1 Refer to “REMOVING THE HANDLEBAR”. 26 Nm (2.6 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 26 Nm (2.6 m  kg) 23 Nm (2.3 m  kg) Refer to “INST ALLING THE HANDLEBAR”. For installation, reverse the removal procedure. CH[...]

6-53 CHAS HANDLEBAR W ARNING NOTE: NOTE: W ARNING W ARNING EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . 2. Remove:  throttle cable housing 1 While removing the throttle cable housing, pull back the rubber cover 2 . 3. Remove:  handle[...]

6-54 CHAS HANDLEBAR W ARNING W ARNING CAUTION: NOTE: 3. Install:  handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar . b. Slide the handlebar grip over the left end of the handlebar . c. Wipe off any excess rubber adhesive with a clean rag. Do not touch the handlebar grip until the rubber adhesive has full[...]

6-55 CHAS THE HANDLEBAR NOTE: NOTE: NOTE: NOTE: W ARNING W ARNING 3. Install:  handlebar grip 1  left grip end 2 There should be 1  3 mm of clearance a be- tween the handlebar grip and the left grip end. 4. Install:  left handlebar switch 1 Align the pin on the left handlebar switch with the hole a in the handlebar . 5. Install:  mas[...]

6-56 CHAS THE HANDLEBAR NOTE:  Align the pin on the right handlebar switch with the hole a in the handlebar .  There should be 1  3 mm of clearance b be- tween the throttle grip and the right grip end. 8. Install:  master cylinder ass’y (front brake) 9. Adjust:  throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE[...]

6-57 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the lower bracket Front wheel Front fork Handlebar Steering stem nut / W asher Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Rubber seal Bearing cover Bearing 1/1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed. Refer to “FRONT WHEEL AN[...]

6-58 Order Job / Part Q’ty Remarks 11 12 13 Bearing Dust seal Lower handlebar holders 1 1 2 For installation, reverse the removal procedure. 1 10 Nm (1 1.0 m  kg) 40 Nm (4.0 m  kg) 1st 2nd 52 Nm (5.2 m  kg) 18 Nm (1.8 m  kg) CHAS STEERING HEAD[...]

6-59 CHAS STEERING HEAD W ARNING NOTE: W ARNING EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . 2. Remove:  upper ring nut 1  lower ring nut 2 Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper r[...]

6-60 CHAS STEERING HEAD CAUTION: NOTE: NOTE: NOTE: a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer . b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer . c. Install a new dust seal and new bearing races. If the bearing race is not installed properly , the steering head pipe could [...]

6-61 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the rear shock absorber , swingarm and drive chain. Rear wheel Drive sprocket Rear shock absorber (left / right) Chain case Brake hose holders T ension bar / Caliper bracket Pivot shaft Swingarm Drive chain guide Dust covers W ashers Bush 1 1 2 1/1 1 1 1 2 2 1 Remove the parts in th[...]

6-62 Order Job / Part Q’ty Remarks 11 12 Bearings Drive chain 2 1 For installation, reverse the removal procedure. 23 Nm (2.3 m  kg) 125 Nm (12.5 m  kg) 7 Nm (0.7 m  kg) 23 Nm (2.3 m  kg) 30 Nm (3.0 m  kg) 7 Nm (0.7 m  kg) CHAS REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN[...]

6-63 CHAS REAR SHOCK ABSORBER, SWINGARMAND DRIVE CHAIN W ARNING W ARNING EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder , read and make sure you under- stand the following information. The manufacture[...]

6-64 CHAS REAR SHOCK ABSORBER, SWINGARMAND DRIVE CHAIN W ARNING NOTE: NOTE: EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove:  rear shock absorber assembl[...]

6-65 CHAS REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN W ARNING EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBL Y AND GAS CYLINDER 1. Check:  rear shock absorber rod 1 Bends / damage  Replace the rear shock absorber assembly .  rear shock absorber Gas leaks / oil leaks  Replace the rear shock absorber assembly .  spring 2 Damage /[...]

6-66 CHAS REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN NOTE: CAUTION: 4. Check:  dust covers 1  washers 2 Damage / Wear  Replace.  bearings 3 Damage / Pitting  Replace.  bush 4 Damage / Scratches  Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure:  ten-link section a of the drive chain Out of specification  Replace t[...]

6-67 CHAS REAR SHOCK ABSORBER, SWINGARM AND 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- l[...]

CHAS[...]

ELEC 7 –+[...]

ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCHES 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCH CONTINUITY 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWITCHES 7-3 . .[...]

ELEC[...]

7-1 ELEC ELECTRICAL COMPONENTS Rear brake switch Oil level switch Horns Ignition coils Main switch Fuel sender Starter relay Starting circuit cutoff relay Battery Oil level relay Flasher relay Ignitior unit Neutral switch Sidestand switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EAS00729 ELECTRICAL ELECTRICAL COMPONENTS[...]

7-2 ELEC SWITCHES B B CAUTION: NOTE: NOTE: EAS0010 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester . If the continuity reading is incorrect, check the wiring connections and if necessary , replace the switch. Never insert the tester probes into the cou- pler terminal slots 1 . Always insert the probes fro[...]

7-3 ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear , proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage / wear  Repair or replace the switch. Improperly connected  Properly connect. Incorrect continuity reading  Replace the s[...]

7-4 Start switch Lights switch (for Europe) Rear brake switch Fuse Side stand switch Neutral switch Oil level switch * 1 : for Europe * 2 : for AUS Horn switch Clutch switch Dimmer switch Pass switch T urn signal switch Main switch Front brake switch Engine stop switch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ELEC CHECKING THE SWITCHES[...]

7-5 ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear , proper connections, and also for continu- ity between the terminals. Damage / wear  Repair or replace the bulb, bulb socket or both. Improperly connected  Properly connect. Incorrect continuity reading[...]

7-6 ELEC CHECKING THE BULBS AND BULB SOCKETS W ARNING CAUTION: NOTE: Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.  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 . ?[...]

7-7 ELEC CHECKING THE BULBS AND BULB SOCKETS NOTE: 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 90890-031 12 Check each bulb socket for continuity in the same manner as described in t[...]

7-8 2 3 5 6 9 10 11 12 14 15 18 Main fuse Battery Main switch Ignition fuse Ignitor unit Ignition coils Spark plugs Pickup coil Neutral switch Sidestand switch Engine stop switch ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM[...]

7-9 ELEC IGNITION SYSTEM NOTE: YES NO Replace the fuse(-s). 1. Main and ignition fuses S Check the main and ignition fuses for conti- nuity . Refer to “CHECKING THE FUSES” in chap- ter 3. S Are the main and ignition fuses OK? 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapter 3. Min. o[...]

7-10 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker as shown. S Spark plug cap S Set the main switch to “ON”. S Measure the ignition spark gap . S Crank the engine by pushing the start switch and gradually increase the spark gap[...]

7-1 1 Secondary coil resistance 9.5 X 14.3 k Ω at 20 _ C S Is the ignition coil OK? YES Replace the ignition coil. NO EAS00748 7. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester ( Ω 100) to the pickup coil terminal. Pickup coil resistance 248 X 372 Ω at 20 _ C (between white / red[...]

7-12 EAS00754  Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”.  Is the ignition system’s wiring properly con- nected and without defects? NO Replace the ignitor unit. YES 13. Wiring Properly connect or repair the ignition system’s wiring. ELEC IGNITION SYSTEM[...]

7-13 2 3 4 5 6 7 8 14 15 17 18 Main fuse Battery Starter relay Main switch Ignition fuse Starter motor Starting circuit cutoff relay Neutral switch Sidestand switch Start switch Engine stop switch Clutch switch 38 ELEC ELECTRIC ST ARTING SYSTEM EAS00755 ELECTRIC ST ARTING SYSTEM CIRCUIT DIAGRAM[...]

7-14 ELEC ELECTRIC ST ARTING SYSTEM EAS00756 ST ARTING CIRCUIT CUTOFF SYSTEM OPERA TION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met:  The transmission is in neutral (the neutral switch is closed[...]

7-15 ELEC ELECTRIC ST ARTING SYSTEM NOTE: YES NO Replace the fuse(-s). 1. Main and ignition fuses S Check the main and ignition fuses for conti- nuity . Refer to “CHECKING THE FUSES” in chap- ter 3. S Are the main and ignition fuses OK? 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapte[...]

7-16 4. Starting circuit cutoff relay  Disconnect the relay unit from the coupler .  Connect the pocket tester ( Ω  1) and bat- tery (12 V) to the relay unit terminals as shown. YES Replace the relay unit. NO Battery positive terminal  red / black Battery negative terminal  black / yellow 1 2 T ester positive probe  blue / white[...]

7-17 6. Starter relay  Disconnect the starter relay from the coupler .  Connect the pocket tester ( Ω  1) and bat- tery (12 V) to the starter relay coupler as shown. YES Replace the starter relay . NO Battery positive terminal  red / white Battery negative terminal  blue / white 2 EAS00750  Check the engine stop switch for conti[...]

7-18 EAS00766  Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.  Is the starting system’s wiring properly con- nected and without defects? NO The starting system circuit is OK. YES 13. Wiring  Check the start switch for continuity . Refer to “CHECKING THE SWITCHES”.  Is the start switch OK? YES Replace [...]

7-19 ELEC ELECTRIC ST ARTING SYSTEM Order Job / Part Q’ty Remarks 1 2 1 2 3 4 5 6 7 Removing the starter motor Starter motor lead Starter motor assembly Disassembling the starter motor Starter motor front cover W asher set Starter motor rear cover washer set Brush holder / brush Armature assembly Starter motor yoke 1 1 1 1 1 1 1/1 1 1 Remove the [...]

7-20 ELEC ELECTRIC ST ARTING SYSTEM NOTE: EAS00769 Checking The Starter Motor 1. Check: S commutator Dirt  Clean with 600 grit sandpaper . 2. Measure: S commutator diameter a Out of specification  Replace the starter motor . Min. commutator diameter 27 mm 3. Measure: S mica undercut a Out of specification  Scrape the mica to the proper mea[...]

7-21 ELECTRIC ST ARTING SYSTEM ELEC NOTE: New 5 Nm (0.5 m  kg) NOTE: 5. Measure:  brush length a Out of specification  Replace the brushes as a set. Min. brush length 5 mm 6. Measure:  brush spring force Out of specification  Replace the brush springs as a set. Brush spring force 7.65 X 10.01 N (0.780 X 1.021 kg) 7. Check:  gear t[...]

7-22 CHARGING SYSTEM ELEC 1 2 3 5 Generator Main fuse Battery Main switch EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM[...]

7-23 CHARGING SYSTEM ELEC NOTE: YES NO Replace the fuse. 1. Main fuse S Check the main fuse for continuity . Refer to “CHECKING THE FUSES” in chap- ter 3. S Is the main fuse OK? 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapter 3. Open-circuit voltage 12.8 V or more at 20 _ C S Is the[...]

7-24 NO The charging circuit is OK. YES NOTE: Make sure that the battery is fully charged. S Is the charging voltage within specification? EAS00776 4. Stator coil assembly resistances S Remove the generator cover . S Connect the pocket tester ( Ω 1) to the sta- tor coil assembly coupler as shown. Stator coil resistance 0.19 X 0.21 Ω at 20 _ C S[...]

7-25 6. Field coil resistance S Connect the pocket tester ( Ω 1) to the rotor as shown. Field coil resistance 2.8 X 3.0 Ω at 20 _ C S Measure the field coil resistance. S Is the field coil OK? YES Replace the field coil. NO EAS00749 S Check the mian switch for continuity . Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? YES Repla[...]

7-26 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Disassembling the A.C. Generator Cover Brush holder Regulator Rectifier cover Rectifier Rear cover Rotor assembly Bearing cover Bearing Bearing Stator assembly 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order list. For assembly , reverse the disassembly procedure. 7 Nm (0.7 m  [...]

7-27 2 3 5 21 32 37 41 42 44 45 46 Main fuse Battery Main switch Lights switch Meter light High beam indicator light Pass switch Dimmer switch Headlight fuse Auxiliary light T ail / brake light Headlight 47 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM[...]

7-28 LIGHTING SYSTEM ELEC NOTE: YES NO Replace the fuse(-s). 1. Main, and headlight fuses S Check the main, and headlight fuses for con- tinuity . Refer to “CHECKING THE FUSES” in chap- ter 3. S Are the main, and headlight fuses OK? 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapter 3.[...]

7-29  Check the dimmer switch for continuity . Refer to “CHECKING THE SWITCHES”.  Is the dimmer switch OK? YES The dimmer switch is faulty . Replace the left handlebar switch. NO 5. Dimmer switch EAS00786  Check the pass switch for continuity . Refer to “CHECKING THE SWITCHES”.  Is the pass switch OK? YES The pass switch is faul[...]

7-30 Headlight T ester positive probe  yellow or green T ester negative probe  black High beam indicator light T ester positive probe  yellow T ester negative probe  black  Set the main switch to “ON”.  Set the light switch to “ ”.  Set the dimmer switch to “ ” or “ ”.  Measure the voltage (12 V) of yellow (g[...]

7-31 2. V oltage  Connect the pocket tester (DC 20 V) to the tail / brake light coupler (wire harness side) as shown. T ester positive probe  blue / red T ester negative probe  black 1 2 YES The wiring circuit from the main switch to the tail / brake light coupler is faulty and must be repaired. NO This circuit is OK.  Set the main swit[...]

7-32 2 3 5 14 16 19 22 23 24 25 26 Main fuse Battery Main switch Neutral switch Oil level relay Front brake light switch Signaling system fuse Rear brake light switch Horn Flasher relay Oil level switch Fuel gauge 30 Fuel sender 31 Neutral indicator light 33 T urn signal indicator 34 T urn signal indicator 35 Oil level warning light 36 T urn signal[...]

7-33 Open-circuit voltage 12.8 V or more at 20 _ C YES Replace the fuse(-s). NO YES S Clean the battery terminals. S Recharge or re- place the battery . NO Replace the main switch. NO EAS00749 3. Main switch S Check the main switch for continuity . Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? YES 1. Main and signaling system fuses[...]

7-34 Replace the left han- dlebar switch. NO 1. Horn switch  Check the horn switch for continuity . Refer to “CHECKING THE SWITCHES”.  Is the horn switch OK? YES 2. V oltage  Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. T ester positive probe  brown T ester negative probe  ground 1 The [...]

7-35 Replace the tail / brake light bulb, sock- et or both. NO 1. T ail / brake light bulb and socket  Check the tail / brake light bulb and socket for continuity . Refer to “CHECKING THE BULBS AND BULB SOCKETS”.  Are the tail / brake light bulb and socket OK? YES 3. V oltage  Connect the pocket tester (DC 20 V) to the tail / brake lig[...]

7-36 A B Replace the left han- dlebar switch. NO 2. Turn signal switch  Check the turn signal for continuity . Refer to “CHECKING THE SWITCHES”.  Is the turn signal switch OK? YES The wiring circuit from the main switch to the flasher relay coupler (flasher relay side) is faulty and must be repaired. NO 3. V oltage  Connect the pocket [...]

7-37 SIGNALING SYSTEM ELEC Replace the neutral indicator light bulb, socket or both. NO YES The wiring circuit from the turn signal switch to the turn sig- nal light connector is faulty and must re- paired. NO This circuit is OK. EAS00800 4. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket  Check the neutr[...]

7-38 SIGNALING SYSTEM ELEC 4. V oltage  Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. T ester positive probe  brown T ester negative probe  sky blue 1 2  Set the main switch to “ON”.  Measure the voltage (12 V) of brown and sky blue at the meter assembly coupler .  Is the volta[...]

7-39 SIGNALING SYSTEM ELEC 4. Starting circuit cutoff relay S Disconnect the relay unit from the coupler . S Connect the pocket tester ( Ω 1) to the relay unit terminals as shown. Relay unit resistance 8.2 Ω at 20 _ C T ester positive probe  red / blue T ester negative probe  brack / red S Measure the relay unit resistance. S Is the relay[...]

7-40  Check that the fuel level gauge needle move to “F” to “E”. Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes.  Does the fuel level gauge needle move ap- propriately? 2. V oltage Connect the pocket tester (DC 20 V) to the me- ter assembly coupler (wire harness side[...]

7-41 SELF-DIAGNOSIS ELEC Revolution (  10 3 r / min) T achometer display T ime (seconds) Engine speed 0 r / min ... 3 seconds Condition code ... 2.5 seconds Engine speed ... 3 seconds 1 2 3 0 r / min ... 3 seconds Condition code ... 2.5 seconds 1 2 T achometer display T ime (seconds) Revolution (  10 3 r / min) EAS00834 SELF-DIAGNOSIS The XJR[...]

7-42 SELF-DIAGNOSIS ELEC Repair or replace the wire harness. NO 1. Wire harness  Check the wire harness for continuity . Refer to “CIRCUIT DIAGRAM”.  Is the wire harness OK? YES NO 2. Throttle position sensor  Check the throttle position sensor for conti- nuity . Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in cha[...]

7-43 Replace the main switch. NO 3. Main switch  Check the main switch for continuity . Refer to “CHECKING THE SWITCHES”.  Is the main switch OK? YES Repair or replace the wire harness. NO 4. Wire harness  Check the ire harness for continuity . Refer to “CIRCUIT DIAGRAM”.  Is the wire harness OK? YES 5. Starting circuit cutoff r[...]

7-44 Replace the relay unit. NO When you switch the “–” and “+” leads of the digital pocket tester the readings in the above chart will be reversed.  Are the tester readings correct? YES Replace the ignitor unit. NOTE: SELF-DIAGNOSIS ELEC[...]

TRBL SHTG 8[...]

TRBL SHTG CHAPTER 8. TROUBLESHOOTING ST ARTING PROBLEMS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

TRBL SHTG[...]

8-1 TRBL SHTG ST ARTING PROBLEMS NOTE: EAS00844 TROUBLESHOOTING 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. ST ARTING PROBLEMS ENGINE Cy[...]

8-2 INCORRECT ENGINE IDLING SPEED / POOR MEDIUM AND- HIGH-SPEED PERFORMANCE / F AUL TY GEAR SHIFTING TRBL SHTG EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head  Incorrect valve clearance  Damaged valve train components Air filter  Clogged air filter element FUEL SYSTEM Carburetors  Faulty starter plunger  Loo[...]

8-3 F AUL TY CLUTCH / OVERHEA TING TRBL SHTG EAS00852 F AUL TY CLUTCH CLUTCH SLIPS Clutch  Improperly assembled clutch  Improperly assembled clutch master cylinder  Improperly assembled clutch release cylinder  Loose or fatigued clutch spring  Loose union bolt  Worn friction plate  Worn clutch plate  Damaged clutch release c[...]

8-4 POOR BRAKING PERFORMANCE / F AUL TY FRONT FORK LEGS / UNST ABLE HANDLING TRBL SHTG EAS00857 POOR BRAKING PERFORMANCE  Worn brake pad  Worn brake disc  Air in hydraulic brake system  Leaking brake fluid  Faulty brake caliper piston seal  Loose union bolt  Damaged brake hose  Oil or grease on the brake disc  Oil or grea[...]

8-5 F AUL TY LIGHTING AND SIGNALING SYSTEMS TRBL SHTG EAS00866 F AUL TY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT  Wrong headlight bulb  T oo many electrical accessories  Hard charging  Incorrect connection  Incorrectly grounded circuit  Poor contacts (main or light switch)  Burnt-out headlight bulb HEADLIGHT BULB[...]

TRBL SHTG[...]

COLOR CODE B Black . . . . . Br Brown . . . . Ch Chocolate . . . Dg Dark green . . . G Green . . . . Gy Gray . . . L Blue . . . . . Lg Light green . . . . O Orange . . . . Sb Sky blue . . . . P Pink . . . . . R Red . . . . . Y Y ellow . . . . . B / L Black / Blue . . . B / R Black / Red . . . B / Y Black / Y ellow . . . Br / L Brown / Blue . . Br /[...]

COLOR CODE B Black . . . . . Br Brown . . . . Ch Chocolate . . . Dg Dark green . . . G Green . . . . Gy Gray . . . L Blue . . . . . Lg Light green . . . . O Orange . . . . Sb Sky blue . . . . P Pink . . . . . R Red . . . . . Y Y ellow . . . . . B / L Black / Blue . . . B / R Black / Red . . . B / Y Black / Y ellow . . . Br / L Brown / Blue . . Br /[...]