EAS00000

FZS1000 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, December 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
EAS00003

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve-
hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed-
eral environmental quality objectives.

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

NOTE:

This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.

Designs and specifications are subject to change without notice.

EAS00004

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.

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

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

EAS00007

HOW TO USE THIS MANUAL

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

3
4

5
8

7
 EAS00008

1 2 SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ADJ CHAS 3 Periodic checks and adjustments
4 Chassis
5 Engine
5 6
6 Cooling system
7 Carburetor(-s)
ENG COOL 8 Electrical system
9 Troubleshooting
7 8

CARB ELEC
Symbols 10 to 17 indicate the following.
9 10 10 Serviceable with engine mounted
11 Filling fluid
TRBL 12 Lubricant
SHTG 13 Special tool
14 Tightening torque
11 12 15 Wear limit, clearance
16 Engine speed
17 Electrical data

13 14

15 16 17

Symbols 18 to 23 in the exploded diagrams indi-

cate the types of lubricants and lubrication
18 19 20
points.
18 Engine oil
19 Gear oil
20 Molybdenum disulfide oil
21 22 23
21 Wheel bearing grease
22 Lithium soap base grease
23 Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following:
24 25 24 Apply locking agent (LOCTITER)
25 Replace the part
EAS00012

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS
4
ENGINE ENG
5
COOLING SYSTEM COOL
6
CARBURETORS CARB
7
ELECTRICAL SYSTEM ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
 GEN
INFO
CHAPTER 1
GENERAL INFORMATION

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

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-2
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

GEN
INFO
 GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped
into the right side of the steering head.

EAS00018

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

1-1
 GEN
IMPORTANT INFORMATION INFO
EAS00020

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
”mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

lip
1. When overhauling the engine, replace all
lip gaskets, seals and O-rings. All gasket sur-
spring
faces, oil seal lips and O-rings must be
cleaned.
oil 2. During reassembly, properly oil all mating
grease parts and bearings and apply grease onto
the oil seal lips with greace.

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS
1. After removal, replace all lock wash-
ers/plates 1 and cotter pins. After the bolt or
nut has been tightened to specification, bend
the lock tabs along a flat of the bolt or nut.

1-2
 GEN
IMPORTANT INFORMATION INFO
EAS00024

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coat of lithium soap base grease onto the oil
seal lips. Oil bearings liberally when instal-
ling, if appropriate.
1 Oil seal

CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.

1 Bearing

EAS00025

CIRCLIPS
1. Before reassembly, check all circlips careful-
ly and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positioned op-
posite the thrust 3 that the circlip receives.
4 Shaft

1-3
 GEN
CHECKING THE CONNECTIONS INFO
EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:

lead 1

coupler 2

connector 3
2. Check:

lead

coupler

connector
Moisture
Dry with an air blower.
Rust/stains
Connect and disconnect sev-
eral times.
3. Check:

all connections
Loose connection
Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.

4. Connect:

lead

coupler

connector
NOTE:
Make sure that all connections are tight.

5. Check:

continuity
(with a pocket tester)

Pocket tester
90890-03112

NOTE:

If there is no continuity, clean the terminals.

When checking the wire harness, perform
steps 1 to 3.

As a quick remedy, use a contact revitalizer
available at most part stores.

1-4
 GEN
SPECIAL TOOLS INFO
EAS00027

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Function Illustration

Rotor puller

90890-01080
This tool is used to remove the generator
rotor.
Rotor holding tool

90890-01235 This tool is used to hold the generator rotor

when removing or installing the generator
rotor bolt or pickup coil rotor bolt.
Piston pin puller set

90890-01304

This tool is used to remove the piston pins.

Fuel level gauge

90890-01312
This tool is used to measure the fuel level in
the float chamber.
Radiator cap Radiator cap tester
tester Adapter
90890-01325
Adapter These tools are used to check the cooling
90890-01352 system.
Steering nut wrench

90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Damper rod holder

90890-01447 This tool is used to hold the damper rod as-

sembly when loosening or tightening the
damper rod assembly bolt.

1-5
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Function Illustration

Oil filter wrench

90890-01426
This tool is needed to loosen or tighten the
oil filter cartridge.
Rod holder

90890-01434
This tool is used to support the damper ad-
justing rod.
Rod puller Rod puller
90890-01437 Rod puller attachment
Rod puller
attachment These tools are used to pull up the front
90890-01436 fork damper rod.
Fork seal driver Fork seal driver weight
weight Fork seal driver attachment (ø43)
90890-01367
Fork seal driver
attachment (ø43) This tool is used to install the front fork’s oil
90890-01374 seal and dust seal.
Micrometer (50
75 mm)

90890-03008
This tool is used to measure the piston skirt
diameter.
Vacuum gauge
Vacuum gauge
90890-03094
This guide is used to synchronize the car-
buretors.
Compression Compression gauge
gauge Compression gauge adapter
90890-03081
Compression
gauge adapter These tools are used to measure engine
90890-04136 compression.
Pocket tester

90890-03112
This tool is used to check the electrical sys-
tem.
Engine tachometer

90890-03113

This tool is used to check engine speed.

1-6
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Function Illustration

Timing light

90890-03141
This tool is used to check the ignition tim-
ing.
Carburetor angle driver 2

90890-03173
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring com- Valve spring compressor
pressor Valve spring compressor attachment
90890-04019
Attachmenht
90890-04108 These tools are used to remove or install
90890-04114 the valve assemblies.
Middle driven shaft Middle driven shaft bearing driver
bearing driver Mechanical seal installer
90890-04058
Mechanical seal
installer These tools are used to install the water
90890-04078 pump seal.
Universal clutch holder

90890-04086 This tool is used to hold the clutch boss

when removing or installing the clutch boss
nut.
Valve guide remover (ø4)
Valve guide remover (ø4.5)
90890-04111
90890-04116
This tool is used to remove or install the
valve guides.
Valve guide installer (ø4)
Valve guide installer (ø4.5)
90890-04112
90890-04117
This tool is used to install the valve guides.
Valve guide reamer (ø4)
Valve guide reamer (ø4.5)
90890-04113
90890-04118
This tool is used to rebore the new valve
guides.
Ignition checker

90890-06754
This tool is used to check the ignition sys-
tem components.

1-7
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name/Function Illustration

Yamaha bond No. 1215

90890-85505
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).

1-8
 SPEC
CHAPTER 2.
SPECIFICATIONS

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

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

SPEC
 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I)



(N) (NL) (S) (SF) (CH) (P)
5LV2 (F)



5LV3 (D)



5LV4 (AUS)



Dimensions
Overall length 2,125 mm



Overall width 765 mm



Overall height 1,190 mm



Seat height 820 mm



Wheelbase 1,450 mm



Minimum ground clearance 140 mm



Minimum turning radius 2,900 mm



Weight
Wet (with oil and a full fuel tank) 231 kg



Dry (without oil and fuel) 208 kg



Maximum load (total of cargo, rider, 189 kg



passenger, and accessories)

2-1
 ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC



Displacement 998 cm3



Cylinder arrangement Forward-inclined parallel 4-cylinder



Bore
stroke 74
58 mm



Compression ratio 11.4 : 1



Engine idling speed 1,050  1,150 r/min



Vacuum pressure at engine idling 30 kPa (225 mm Hg)



speed
Standard compression pressure 1,450 kPa (14.5 kg/cm2) at 400 r/min



(at sea level)
Fuel
Recommended fuel Regular unleaded gasoline



Fuel tank capacity
Total (including reserve) 21 L



Reserve only 4.0 L



Engine oil
Lubrication system Wet sump



Recommended oil

SAE20W40SE or SAE10W30SE

Quantity



Total amount 3.7 L



Without oil filter cartridge 2.8 L



replacement
With oil filter cartridge replacement 3.0 L



Oil pressure (hot) 45 kPa at 1,100 r/min



(0.45 kg/cm2 at 1,100 r/min)
Relief valve opening pressure 490  570 kPa (4.9  5.7 kg/cm2)

2-2
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Oil filter
Oil filter type Cartridge (paper)



Bypass valve opening pressure 180  220 kPa (1.8  2.2 kg/cm2)



Oil pump
Oil pump type Trochoid



Inner-rotor-to-outer-rotor-tip 0.09  0.15 mm



clearance
Outer-rotor-to-oil-pump-housing 0.03  0.08 mm



clearance
Cooling system
Radiator capacity 2.4 L
Radiator cap opening pressure 95  125 kPa (0.95  1.25 kg/cm2)



Radiator core
Width 340 mm



Height 238 mm



Depth 24 mm



Coolant reservoir
Capacity 0.3 L



Water pump
Water pump type Single-suction centrifugal pump



Reduction ratio 68/43
28/28 (1.581)



Max. impeller shaft tilt


0.15 mm
Starting system type Electric starter
Spark plugs
Model (manufacturer)
quantity CR9E/U27ESR-N (NGK/DENSO)
4



Spark plug gap 0.7  0.8 mm



Cylinder head
Max. warpage


0.1 mm

2-3
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Camshafts
Drive system Chain drive (right)



Camshaft cap inside diameter 24.500
24.521 mm



Camshaft journal diameter 24.459
24.472 mm



Camshaft-journal-to-camshaft- 0.028
0.062 mm



cap clearance
Intake camshaft lobe dimensions

Measurement A 32.5
32.6 mm 32.4 mm

Measurement B 24.95
25.05 mm 24.85 mm
Measurement C 7.45
7.65 mm



Exhaust camshaft lobe dimensions

Measurement A 32.95
33.05 mm 32.85 mm

Measurement B 24.95
25.05 mm 24.85 mm
Measurement C 7.75
7.95 mm



Max. camshaft runout


0.03 mm

2-4
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Timing chain
Model/number of links RH2015/130



Tensioning system Automatic



Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.11
0.20 mm



Exhaust 0.21
0.25 mm



Valve dimensions

Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter A

Intake 22.9
23.1 mm



Exhaust 24.4
24.6 mm



Valve face width B
Intake 1.76
2.90 mm



Exhaust 1.76
2.90 mm



Valve seat width C
Intake 0.9
1.1 mm



Exhaust 0.9
1.1 mm



Valve margin thickness D
Intake 0.5
0.9 mm



Exhaust 0.5
0.9 mm



Valve stem diameter
Intake 3.975
3.990 mm 3.945 mm
Exhaust 4.465
4.480 mm 4.43 mm
Valve guide inside diameter
Intake 4.000
4.012 mm 4.05 mm
Exhaust 4.500
4.512 mm 4.55 mm
Valve-stem-to-valve-guide clearance
Intake 0.010
0.037 mm 0.08 mm
Exhaust 0.020
0.047 mm 0.10 mm
Valve stem runout


0.01 mm

Valve seat width

Intake 0.9
1.1 mm



Exhaust 0.9
1.1 mm

2-5
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Valve springs
Free length
Intake 38.9 mm SSS
Exhaust 40.67 mm SSS
Installed length (valve closed)
Intake 34.5 mm SSS
Exhaust 35 mm SSS
Compressed spring force
(installed)
Intake 82  96 N (8.36  9.79 kg) SSS
Exhaust 110  126 N (11.22  12.85 kg) SSS
Spring tilt

Intake SSS 2.5_/

1.7 mm
Exhaust SSS 2.5_/
1.8 mm
Winding direction (top view)
Intake Clockwise SSS
Exhaust Clockwise SSS

Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder SSS
Bore
stroke 74
58 mm SSS
Compression ratio 11.4 : 1 SSS
Bore 74.00  74.01 mm SSS
Max. taper SSS 0.05 mm
Max. out-of-round SSS 0.05 mm

2-6
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Piston
Piston-to-cylinder clearance 0.030  0.055 mm 0.12 mm
Diameter D 73.955  73.970 mm

Height H 5 mm



Piston pin bore (in the piston)
Diameter 17.002  17.013 mm 17.043
Offset



Offset direction Intake side



Piston pins
Outside diameter 16.991  17.000 mm 16.971
Piston-pin-to-piston-pin-bore 0.002  0.022 mm 0.072 mm
clearance
Piston rings
Top ring

Ring type Barrel

Dimensions (B
T) 0.90
2.75 mm



End gap (installed) 0.32  0.44 mm



Ring side clearance 0.030  0.065 mm



2nd ring

Ring type Taper

Dimensions (B
T) 0.8
2.8



End gap (installed) 0.43  0.58 mm



Ring side clearance 0.020  0.055 mm



Oil ring

Dimensions (B
T) 1.5
2.6 mm

End gap (installed) 0.10  0.35

2-7
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Connecting rods
Crankshaft-pin-to-big-end-bearing 0.031
0.055 mm



clearance
Bearing color code –1 = Violet 0 = White 1 = Blue 2 = Black



Crankshaft

Width A 52.40
57.25 mm

Width B 300.75
302.65 mm



Max. runout C


0.03 mm
Big end side clearance D 0.160
0.262 mm



Crankshaft-journal-to-crankshaft- 0.029
0.053 mm



journal-bearing clearance
Bearing color code –1 = Pink/violet 0 = Pink/white



1 = Pink/blue 2 = Pink/black
3 = Pink/brown
Clutch
Clutch type Wet, multiple disc



Clutch release method Cam (pull rod type)



Clutch release method operation Cable operation



Operation Left-hand operation



Clutch cable free play (at the end 10
15 mm



of the clutch lever)
Friction plates
Thickness 2.92
3.08 mm 2.82 mm
Plate quantity 8



Thickness 3.42
3.58 mm 3.32 mm
Plate quantity 1



Clutch plates
Thickness 1.9
2.1 mm



Plate quantity 8



Max. warpage


0.1 mm
Clutch springs
Free length 50 mm



Spring quantity 6

2-8
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Transmission
Transmission type Constant mesh, 6-speed



Primary reduction system Spur gear



Primary reduction ratio 68/43 (1.581)



Secondary reduction system Chain drive



Secondary reduction ratio 44/16 (2.750)



Operation Left-foot operation



Gear ratios
1st gear 35/14 (2.500)



2nd gear 35/19 (1.842)



3rd gear 30/20 (1.500)



4nd gear 28/21 (1.333)



5th gear 30/25 (1.200)



6th gear 29/26 (1.115)



Max. main axle runout


0.08 mm
Max. drive axle runout


0.08 mm
Shifting mechanism
Shift mechanism type Guide bar



Max. shift fork guide bar bending


0.1 mm
Installed shift rod length 260 mm



Air filter type Dry element



Fuel pump
Pump type Electrical



Model (manufacturer) 4SV (MITSUBISHI)



Output pressure 20 kPa (0.2 kg/cm2)

2-9
 ENGINE SPECIFICATIONS SPEC

Item Standard Limit

Carburetors
Model (manufacturer)
quantity BSR37 (MIKUNI)
4



Throttle cable free play (at the 3  5 mm



flange of the throttle grip)
ID mark 5LV1 00



Main jet Carburetors 1 and 4: #132.5



Carburetors 2 and 3: #130



Main air jet #80



Jet needle Carburetor 1 and 4: 5D129-3/5



Carburetor 2 and 3: 5D130-3/5



Needle jet P-OM



Pilot air jet #85



Pilot outlet 1.0



Pilot jet #15



Bypass 1 0.9



Bypass 2 0.9



Bypass 3 0.9



Pilot screw turns out 2.0



Valve seat size 1.5



Starter jet 1 #42.5



Starter jet 2 0.8



Throttle valve size #115



Fuel level (above the line on the 3.0  4.0 mm



float chamber)
Max. EXUP cable free play (at the 1.5 mm



EXUP valve pulley)

2-10
 CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Double cradle SSS
Caster angle 26_ SSS
Trail 104 mm SSS
Front wheel
Wheel type Cast wheel SSS
Rim
Size 17
MT3.50 SSS
Material Aluminum SSS
Wheel travel 140 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Rear wheel
Wheel type Cast wheel SSS
Rim
Size 17
MT5.50 SSS
Material Aluminum SSS
Wheel travel 135 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Front tire
Tire type Tubeless SSS
Size 120/70 ZR17 (58W) SSS
Model (manufacturer) MEZ4Y FRONT (METZELER) SSS
BT020F U (BRIDGESTONE)
Tire pressure (cold)
0  90 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
90  201 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
High-speed riding 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
Min. tire tread depth SSS 1.6 mm

2-11
 CHASSIS SPECIFICATIONS SPEC

Item Standard Limit

Rear tire
Tire type Tubeless



Size 180/55 ZR17 (73W)



Model (manufacturer) MEZ4Y (METZELER)



BT020R U (BRIDGESTONE)
Tire pressure (cold)
0  90 kg 270 kPa (2.7 kgf/cm2, 2.7 bar)



90  201 kg 290 kPa (2.9 kgf/cm2, 2.9 bar)



High-speed riding 290 kPa (2.9 kgf/cm2, 2.9 bar)



Min. tire tread depth


1.6 mm
Front brakes
Brake type Dual-disc brake



Operation Right-hand-operation



Recommended fluid DOT 4



Brake discs
Diameter
thickness 298
5 mm



Min. thickness


4.5 mm
Max. deflection


0.1 mm
Brake pad lining thickness 5.5 mm 0.5 mm

Master cylinder inside diameter 14 mm

Caliper cylinder inside diameter 30.2 mm and 27 mm



Rear brake
Brake type Single-disc brake



Operation Right-foot operation



Brake pedal position (from the top 35  40 mm



of the brake pedal to the top of the
rider footrest)
Recommended fluid DOT 4



Brake discs
Diameter
thickness 267
5 mm



Min. thickness


4.5 mm
Max. deflection


0.1 mm
Brake pad lining thickness 5.5 mm 0.5 mm

Master cylinder inside diameter 12.7 mm

Caliper cylinder inside diameter 42.9 mm

2-12
 CHASSIS SPECIFICATIONS SPEC

Item Standard Limit

Front suspension
Suspension type Telescopic fork



Front fork type Coil spring/oil damper



Front fork travel 140 mm



Spring
Free length 344.0 mm



Spacer length 78.5 mm



Installed length 320.0 mm



Spring rate (K1) 8.1 N/mm (0.83 kg/mm)



Spring rate (K2) 11.8 N/mm (1.2 kg/mm)



Spring stroke (K1) 0
55 mm



Spring stroke (K2) 55
140 mm



Optional spring available No



Fork oil
Recommended oil Suspension oil “01” or equivalent



Quantity (each front fork leg) 440 cm3



Level (from the top of the inner 140 mm



tube, with the inner tube fully
compressed, and without the
fork spring)
Spring preload adjusting positions
Minimum 5 (fully turned out position)



Standard 2



Maximum 1



Rebound damping adjusting
positions
Minimum* 17



Standard* 7



Maximum* 1



Compression damping adjusting
positions
Minimum* 21



Standard* 6



Maximum* 1



*from the fully turned-in position

2-13
 CHASSIS SPECIFICATIONS SPEC

Item Standard Limit

Steering
Steering bearing type Angular ball bearings



Rear suspension
Suspension type Swingarm (link suspension)



Rear shock absorber assembly Coil spring/gas-oil damper



type
Rear shock absorber assembly 65 mm



travel
Spring
Free length 182.5 mm



Installed length 163 mm



Spring rate (K1) 73.6 N/mm (7.5 kgf/mm)



Spring stroke (K1) 0
65 mm



Optional spring available No



Standard spring preload gas/air 1,200 kPa (12 kgf/cm2)



pressure
Spring preload adjusting positions
Minimum 1



Standard 6



Maximum 11



Rebound damping adjusting
positions
Minimum* 20



Standard* 10



Maximum* 3



Compression damping adjusting
positions
Minimum* 1



Standard* 7



Maximum* 12



*from the fully turned-in position
Swingarm
Free play (at the end of the
swingarm)
Radial


1 mm
Axial


1 mm
Drive chain
Model (manufacturer) 50ZVM (DAIDO)



Link quantity 116



Drive chain slack 40
50 mm



Maximum ten-link section 150.1 mm 152.5 mm

2-14
 ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type Transistorized coil ignition SSS
Ignition timing 5_ BTDC at 1,100 r/min SSS
Advanced timing 55_ BTDC at 5,000 r/min SSS
Advancer type Throttle position sensor and electrical SSS
Pickup coil resistance/color 248  372 Ω/Gy-B SSS
Transistorized coil ignition unit TNDF66 (DENSO) SSS
model (manufacturer)
Ignition coils
Model (manufacturer) J0313 (DENSO) SSS
Minimum ignition spark gap 6 mm SSS
Primary coil resistance 1.87  2.53 Ω SSS
Secondary coil resistance 12  18 kΩ SSS
Spark plug caps
Material Rubber SSS
Resistance 10 kΩ SSS
Throttle position sensor standard
resistance 4  6 kΩ SSS
Charging system
System type AC magneto SSS
Model (manufacturer) F4T361 (MITSUBISHI) SSS
Normal output 14 V/365 W at 5,000 r/min SSS
Stator coil resistance/color 0.27  0.33 Ω at 20_C/W-W SSS
Rectifier/regulator
Regulator type Semiconductor short circuit SSS
Model ((manufacture)) SH650C-11 ((SHINDENGEN)) SSS
No-load regulated voltage 14.1  14.9 V SSS
Rectifier capacity 18 A SSS
Withstand voltage 200 V SSS
Battery
Battery type GT14B-4 SSS
Battery voltage/capacity 12 V/12AH SSS
Headlight type Halogen bulb
Bulbs (voltage/wattage
quantity)
Headlight 12 V 60 W/55 W
2 SSS
Auxiliary light 12 V 5 W
2 SSS
Tail/brake light 12 V 5 W/21 W
2 SSS
Turn signal light 12 V 21 W
4 SSS
Meter light 12 V 2 W
3 SSS

2-15
 ELECTRICAL SPECIFICATIONS SPEC

Item Standard Limit

Indicator light
(voltage /wattage
quantity)
Neutral indicator light 14 V 1.4 W
1 SSS
High beam indicator light 14 V 1.4 W
1 SSS
Oil level indicator light 14 V 1.4 W
1 SSS
Turn signal indicator light 14 V 1.4 W
2 SSS
Fuel indicator light 12 V 2 W
1 SSS
Water temperature indicator light LED SSS
Electric starting system
System type Constant mesh SSS
Starter motor
Model (manufacturer) SM-13 (MITSUBA) SSS
Power output 0.8 kW SSS
Brushes
Overall length 12.5 mm 4 mm
Spring force 7.65  10.01 N (780  1,021 gf) SSS
Commutator resistance 0.025  0.035 Ω SSS
Commutator diameter 28 mm 27 mm
Mica undercut 0.7 mm SSS
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) SSS
Amperage 180 A SSS
Coil resistance 4.18  4.62 Ω SSS
Horn
Horn type Plain SSS
Model (manufacturer)
quantity YF-12 (NIKKO)
1 SSS
Max. amperage 3A SSS
Turn signal relay
Relay type Full-transistor SSS
Model (manufacturer) FE246BH (DENSO) SSS
Self-cancelling device built-in No SSS
Turn signal blinking frequency 75  95 cycles/min. SSS
Wattage 21 W
2 + 3.4 W SSS
Oil level switch
Model (manufacturer) 5LV (DENSO) SSS
Fuel sender
Model (manufacturer) 5LV (NIPPON SEIKI) SSS
Resistance 4  100 Ω at 25_C SSS
Sidestand /fuel pump relay
Model (manufacturer) 5EB-20 (OMRON) SSS
Coil resistance 180 Ω SSS
Fuel pump maximum amperage 1.2 A SSS
Radiator fan
Model (manufacturer) 4XV (TOYO RADIATOR) SSS
Thermo switch
Model (manufacturer) 5JJ (NIPPON THERMOSTAT) SSS

2-16
 ELECTRICAL SPECIFICATIONS SPEC

Item Standard Limit

Fuses (amperage
quantity)
Main fuse 30 A
1



Headlight fuse 20 A
1



Signaling system fuse 20 A
1



Ignition fuse 20 A
1



Radiator fan fuse 10 A
1



Turn signal relay fuse 10 A
1



Backup fuse (odometer) 10 A
1



Reserve fuse 30 A
1



20 A
1



10 A
1

2-17
 TIGHTENING TORQUES SPEC
EAS00029

TIGHTENING TORQUE
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special
components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Compo-
nents should be at room temperature.

A: Distance between flats

B: Outside thread diameter
General tightening
A B torques
(Nut) (Bolt)
Nm m
kg
10 mm 6 mm 6 0.6
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0

2-18
 TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mSkgf
Spark plugs – M10 4 13 1.3
Cylinder head Nut M10 8 50 5.0
Cylinder head Cap nut M10 2 50 5.0
Cylinder head Bolt M6 2 12 1.2
Camshaft caps Bolt M6 28 10 1.0
Cylinder head cover Bolt M6 6 12 1.2
Cylinder head (exhaust pipe) Stud bolt M8 8 15 1.5
Connecting rod caps Nut M8 8 36 3.6
Generator rotor Bolt M10 1 65 + 60_ 6.5 + 60_
Crankshaft sprocket Bolt M10 1 60 6.0
Cap bolt (timing chain tensioner) Bolt M6 1 6.4 0.64
Camshaft sprocket Bolt M7 4 24 2.4
Water pump inlet pipe Bolt M6 1 10 1.0
Water pump outlet pipe Bolt M6 1 10 1.0
Oil/water pump assembly driven
Bolt M6 1 15 1.5
sprocket
Oil pump Bolt M6 1 12 1.2
Oil cooler Bolt M20 1 35 3.5
Engine oil drain bolt – M14 1 43 4.3
Oil strainer housing Bolt M6 2 10 1.0
Oil/water pump assembly driven
Bolt M6 1 12 1.2
sprocket cover
Oil delivery pipe Bolt M6 1 10 1.0
Oil filter bolt Bolt M20 1 70 7.0
Oil filter cartridge – M20 1 17 1.7
Oil pipe Bolt M6 2 10 1.0
Air cleaner cap and air cleaner Screw M6 4 6 0.6
Frame and air cleaner Bolt M6 3 7 0.7
Air cleaner cover and air cleaner Screw M6 6 2 0.2
Ring nut and cylinder head Nut M8 8 20 2.0
Exhaust pipe and muffler Bolt M8 3 20 2.0
Emission check bolt Bolt M8 4 10 1.0
EXUP pulley cover Bolt M6 3 10 1.0
EXUP cable bracket Bolt M6 3 10 1.0
EXUP pulley and shaft arm Bolt M5 1 10 1.0
Exhaust joint Bolt M4 2 3 0.3
Exhaust pipe assembly Bolt M8 1 20 2.0
Air induction system pipe Band – 4 3.5 0.35
Crankcase (cylinder head) Stud bolt M10 10 10 1.0
Crankcase Bolt M9 10 See note
Crankcase Bolt M6 2 14 1.4
Crankcase Bolt M6 14 12 1.2
Crankcase Bolt M8 2 24 2.4

2-19
 TIGHTENING TORQUES SPEC

Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mSkgf
AC magneto cover Bolt M6 9 12 1.2
Drive sprocker cover Bolt M6 4 10 1.0
Plate Bolt M6 2 10 1.0
Clutch cover Bolt M6 8 12 1.2
Timing chain cap bolt Bolt M6 8 12 1.2
Shift shaft cover Bolt M6 5 12 1.2
Breather plate Bolt M6 5 10 1.0
Timing mark accessing screw Bolt M8 1 15 1.5
Starter clutch idle gear shaft Bolt M6 1 10 1.0
Starter one-way clutch Bolt M6 3 12 1.2
Use a lock
Clutch boss Nut M20 1 90 9.0
washer.
Clutch spring Bolt M6 6 8 0.8
Use a lock
Drive sprocket Nut M22 1 85 8.5
washer.
Main axle bearing housing Screw M6 3 12 1.2
Shift lever stopper Bolt M6 2 10 1.0
Stopper screw Screw M8 1 22 2.2
Shift rod Nut M6 1 6.5 0.65 Left thread
Shift rod Nut M6 2 6.5 0.65
Shift rod joint Bolt M6 1 10 1.0
Shift arm Bolt M6 1 10 1.0
AC magneto stator coil Screw M6 3 14 1.4
Ignitor unit Screw M5 2 7 0.7
Neutral switch – M10 1 20 2.0
Pick up coil Bolt M6 2 10 1.0
Thermo unit – – 1 15 1.5
NOTE:
1. First, tighten the bolt to approximately 14.7 Nm (1.5 mSkg) with a torque wrench.
2. Retighten the bolt to 14.7 Nm (1.5 mSkg), and tighten another 45
50_.

2-20
 TIGHTENING TORQUES SPEC

Crankcase tightening sequence:

2-21
 TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
Tightening
Item Thread size Remarks
Nm m
kgf
Upper bracket pinch bolt M8 30 3.0
Upper bracket cap nut M22 110 11
Upper bracket and handlebar holder M10 32 3.2
Handlebar holder M8 23 2.3
Lower bracket pinch bolt – 23 2.3
Lower bracket ring nut M25 18 1.8 See note
Front brake master cylinder M6 10 10
Front brake hose union bolt M10 30 3.0
Engine mounting
Engine mounting bolt/nut M10 55 5.5
Engine mounting bolt/nut M8 33 3.3
Frame and down tube M10 89 8.9
Clutch cable lock nut M8 7 0.7
Ignition coil and stay M6 7 0.7
Pivot shaft M18 125 12.5
Rear shock absorber (upper) M10 40 4.0
Rear shock absorber and relay arm M10 40 4.0
Relay arm and frame M10 40 4.0
Relay arm and connecting arm M12 48 4.8
Connecting arm and swing arm M12 48 4.8
Drive chain guard M6 7 0.7
Drive chain case M6 7 0.7
Fuel cock M6 7 0.7
Fuel sender M5 4 0.4
Side cover M6 4 0.4
Coolant reservoir tank M6 4 0.4
Front wheel axle M16 72 7.2
Front wheel axle pinch bolt M8 23 2.3
Front brake caliper M10 40 4.0
Front brake disk M6 18 1.8
Front brake bleed screw M8 6 0.6
Rear brake torque rod M8 23 2.3
Rear wheel sprocket M10 69 6.9
Drive chain adjusting nut M8 16 1.6
Rear brake caliper M10 40 4.0
Rear wheel axle M24 150 15
Rear brake hose union bolt M10 30 3.0
Rear brake bleed screw M8 6 0.6
Rear brake disk M8 23 2.3
Rider footrest bracket and frame M8 30 3.0
Rear brake reservoir tank M6 4 0.4
Rear brake master cylinder M8 23 2.3
Rider footrest and bracket M10 55 5.5
Passenger footrest bracket and frame M8 28 2.8
Passenger footrest bracket and muffler M10 48 4.8
NOTE:
1. First, tighten the ring nut to approximately 52 Nm (5.2 m
kg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.

2-22
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00031

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point Lubricant

Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Connecting rod bolts and nuts
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil strainer
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Yamaha bond
Cylinder head cover mating surface
No.1215
Yamaha bond
Crankcase mating surface
No.1215
Yamaha bond
Clutch cover (crankcase mating surface)
No.1215
Yamaha bond
Generator rotor cover (crankcase mating surface)
No.1215

2-23
 LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EAS00032

CHASSIS
Lubrication point Lubricant
Steering bearings, steering seal lips and ball race cover lips
Pivot shaft
Swing arm pivoting points and connecting arm bearings
Connecting arm oil seal lips
Swing arm oil seal lips
Relay arm bearings
Relay arm oil seal lips
Rear shock absorber upper bolt
Front wheel oil seal lips
Rear wheel oil seal lips
Clutch hub oil seal lips
Throttle cable end
Starter cable end and starter lever
Rear brake pedal moving point
Shift pedal moving point
Side stand moving point
Passenger footrest ball joint and moving point
Engine mounting bracket collar and oil seal lips
Mainstand moving point

2-24
 COOLING SYSTEM DIAGRAMS SPEC
EAS00033

COOLING SYSTEM DIAGRAMS

1 Radiator cap
2 Thermostat housing
3 Radiator
4 Water pump

2-25
 COOLING SYSTEM DIAGRAMS SPEC
1 Radiator cap
2 Thermostat housing
3 Radiator
4 Oil cooler
5 Water jacket joint

2-26
 COOLING SYSTEM DIAGRAMS SPEC
1 Radiator cap
2 Thermostat
3 Thermo unit

2-27
 COOLING SYSTEM DIAGRAMS SPEC
1 Radiator

2-28
 ENGINE OIL LUBRICATION CHART SPEC

ENGINE OIL LUBRICATION CHART

Exhaust
camshaft

Intake
camshaft

Main gallery

Oil filter

Main axle

Oil
cooler

Relief
Strainer
valve Drive axle

2-29
 LUBRICATION DIAGRAMS SPEC
EAS00034

LUBRICATION DIAGRAMS
1 Oil cooler
2 Oil filter cartridge
3 Drain bolt
4 Oil level switch
5 Oil strainer
6 Oil pump

2-30
 LUBRICATION DIAGRAMS SPEC
1 Intake camshaft
2 Exhaust camshaft
3 Oil cooler
4 Oil strainer
5 Oil pump

2-31
 LUBRICATION DIAGRAMS SPEC
1 Intake camshaft
2 Exhaust camsahft
3 Oil filter cartridge
4 Oil level switch

2-32
 LUBRICATION DIAGRAMS SPEC
1 Cylinder head
2 Crankshaft

2-33
 LUBRICATION DIAGRAMS SPEC
1 Main axle
2 Oil delivery pipe
3 Drive axle

2-34
 CABLE ROUTING SPEC
EAS00035

CABLE ROUTING
A Fasten the handlebar switch lead (right) and han- F Route the horn lead outside the motorcycle body,
dlebar with a plastic band. and fasten with the under bracket. Do not loose be-
B Route the handlebar switch lead (right) backward tween the horn and under bracket.
the throttle cable and right side the brake hose G Route the brake hose through the brake hose
guide. guide.
C Fasten the handlebar switch lead (left) and handle- H Route the throttle cable 1 and 2 backward the brake
bar with a plastic band. hose, and left side the brake hose guide.
D Fasten the handlebar switch lead (left), main switch
lead, clutch cable and starter cable with a plastic
band. Clamp beneath the horn lead branching posi-
tion. Do not fasten the horn lead.
E Route the main switch lead front and left side the
another leads.

2-35
 CABLE ROUTING SPEC
1 Fuel pump lead 17 Handle crown
2 Fuel pump 18 Handlebar switch lead
3 EXUP cable 19 Brake hose guide
4 Handlebar switch lead (right)
5 Throttle cable 1 A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed
6 Throttle cable 2 sensor lead, rear brake light switch lead and fuel pump with a plastic
7 Water-carburetor hose clamp.
8 Fan motor lead B Fasten the fuel hose, pickup coil lead, neutral switch lead and speed
9 Coolant reservoir tank over flow sensor lead with a plastic clamp under the fuel hose.
hose C Put the EXUP cable into the air box cover.
10 Fuel tank drain hose D Route the T.P.S. lead inward the EXUP cable.
11 Fuel tank breather hose E Fasten the water-carburetor hose with a plastic band.
12 White paint mark F Route the coolant hose over the frame.
13 Rear brake light switch lead G Fasten the handlebar switch lead and frame with a plastic guide.
14 Neutral switch lead H Align the white tape mark of the handlebar switch lead (right) with the
15 Speedo sensor lead tank rail welding bead and clamp down throttle cables 1 and 2.
16 Pickup coil lead

2-36
 CABLE ROUTING SPEC
I Route the water-carburetor hose between the Q Insert the all couplers into the rubber cover.
frame cross pipe and fan motor lead. R Route the rear brake light switch lead inside the
J To the carburetor another leads.
K Fasten the T.P.S. lead with a steel clamp. S Route the neutral switch lead and speed sensor
L Fasten the coolant hose with a plastic band. lead left side the coolant reservoir hose.
M Fasten the pickup coil lead with a steel clamp. T Route the coolant reservoir hose left side the en-
N Pass the coolant reservoir tank overflow hose, fuel gine mounting bracket.
tank drain hose and fuel tank breather hose through U Route the coolant reservoir hose forward the neu-
the frame hose holder from the inside of the vehicle tral switch lead and speed sensor lead.
to the outside. At this time, pull the fuel tank drain V Route the coolant reservoir hose backward the
hose and fuel tank breather hose so that the white another hoses.
paint marks are within a 20 mm range. W Route the EXUP cable forward the another hoses.
O Route the EXUP cable forward the another hoses, X Route the EXUP cable forward the frame cross
and upward the engine mounting bracket. pipe.
P Fasten the rear brake light switch lead with a plastic Y Route the fuel tank drain hose and fuel tank breath-
guide. er hose forward the neutral switch lead and speed
sensor lead.

2-37
 CABLE ROUTING SPEC
1 Starter cable A Fasten the main switch lead and handlebar switch lead with a plastic
2 Clutch cable guide.
3 Handlebar switch lead (left) B Fasten the water-head hose and water-carburetor hose with a plastic
4 Main switch lead band.
5 EXUP servo motor C Fasten the clutch cable with a plastic band.
6 Starting circuit cutoff relay D Fasten the clutch cable with a steel clamp.
7 Starter motor lead E Fasten the wire harness with a plastic band.
8 Fan motor relay F To the fuel sender.
9 Air cleaner case drain hose G Route the fuel sender lead inside the seat rail.
10 Sidestand switch lead H Route the battery negative lead forward the frame stay.
11 oil level switch lead I Route the main harness inside the rear fender groove.
12 ACgenerator lead J Fasten the wire harness, sidestand switch lead, oil level switch and
13 Water-head pipe flame with a plastic band. Do not fasten the Acgenerator lead (white).
14 Water-carburetor hose K Route the starter motor lead and battery negative lead inside the plastic
15 Throttle cable 2 band.
16 Throttle cable 1 L Route the all hoses outside the fuel hose.
17 EXUP cable M Route the fuel hose through the steel guide.

2-38
 CABLE ROUTING SPEC
N Fasten the sidestand switch lead, oil level switch lead, and rectifier regulator lead.
ACgenerator lead, starter motor lead, battery negative U Route the water carburetor hose outside the coolant
lead and air cleaner case drain hose with a plastic clamp. hose.
O Fasten the sidestand switch lead, oil level switch lead, V Route the starter cable outside the coolant hose, and up-
ACgenerator lead and air filter case drain hose with a per the water-carburetor hose.
plastic clamp. W Route the high tension cable (#2, 3) forward the EXUP
P Fasten the sidestand switch lead and frame with a plastic cable and high tension cable (#4).
clamp. X Route the throttle cable between the water-head hose,
Q Route the air cleaner box drain hose inside the sidestand and upper the EXUP cable.
switch lead, and put the end of the hose backward. Y Route the high tension cable (#4) between the water-
R Fasten the sidestand switch lead and frame with a plastic head hose.
clamp. Z Taillight lead and flasher light lead (right) should not be
S Fasten the sidestand switch lead, oil level switch lead and stick out from the gap between the rear fender and tail-
air filter case drain hose with a plastic clamp. Do not crush light.
the air filter case drain hose. AA Route the flasher light lead through the hole on the rear
T Route the high tension cable (#1) outside the starter cable fender.
and water-carburetor hose, and under the clutch cable AB Route the wire harness in the groove.

2-39
 CABLE ROUTING SPEC
1 Clutch cable 17 Ignition coil lead
2 Handlebar switch lead 18 Battery
3 Main switch lead 19 Emergency engine stop switch
4 Starter cable 20 Flasher relay
5 Thermo unit lead 21 Fuse box
6 Throttle cable 1 22 Igniter unit
7 Throttle cable 2 23 Flasher light lead
8 Handlebar switch lead (right) 24 Taillight lead
9 Coolant reservoir hose 25 Alarm coupler (free)
10 Ignition coil 26 Starter relay
11 Fuel hose 27 Battery positive lead
12 Fan motor lead 28 Fan motor lead
13 EXUP servo motor lead 29 Battery negative lead
14 Rectifier/ regulator lead 30 Starting circuit cutoff relay
15 White paint mark
16 Main harness

2-40
 CABLE ROUTING SPEC
A Fasten the flasher light lead and headlight lead with K Fasten the fuel hose and air induction system hose
a plastic clamp. with a plastic clamp.
B Route the rectifier / regulator lead upper the fan mo- L Route the coolant reservoir hose under the frame
tor lead and EXUP servomotor lead. cross pipe.
C Route the throttle cable right side the fan motor M Fasten the fuel hose and frame with a plastic band.
lead, EXUP servo motor lead and thermo unit lead. N Put the fuel tank drain hose into the frontward nipple
D Fasten the flasher light lead with a plastic clamp. on the fuel tank.
E Route the all leads between the frame cross pipe O Put the fuel tank breather hose into the backward
and bracket. nipple on the fuel tank.
F Do not excessively bend the throttle cable. P Route the coolant reservoir hose under the air vent
G Route the coolant reservoir hose under the frame hose and air induction system hose.
cross pipe. Q Route the air vent hose upper the main harness.
H Fasten the ignition coil and ignition coil lead with a R All coupler into the rubber cover.
plastic clamp. S Fasten the Rectifier / regulator lead with a plastic
I Route the T.P.S. lead under the air vent hose. band in the main harness.
J Fasten the EXUP cable with a plastic band.

2-41
 CABLE ROUTING SPEC
T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear
with a plastic clamp. Do not fasten the red / black fender.
lead and orange lead. AB Fasten the battery positive lead with a plastic band.
U Fasten the handlebar switch lead (left / right), main
switch lead, EXUP servo motor lead, fan motor lead
and thermo unit lead with a plastic clamp.
V Fasten the rectifier / regulator stay and rectifier / reg-
ulator lead with a plastic clamp.
W Route the wire harness under the rectifier / regula-
tor.
X Fasten the battery negative lead with a battery
band.
Y Insert the ground lead coupler in the battery band.
Z Fasten the taillight lead and flasher light lead, and
put in the groove on the taillight bracket.

2-42
 CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

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

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

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK . . . . . . . . . . . . . . 3-3

FRONT COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
SEAT, SIDE COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . 3-4

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-5
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . 3-10
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-12
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-13
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-17
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-22
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-23
CHECKING THE CARBURETOR JOINTS AND
INTAKE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . 3-24
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . 3-25
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ADJUSTING THE EXUP CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . 3-36
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-37
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . 3-39
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-41
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 3-43
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 3-45
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
 CHK
ADJ
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-50

ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . 3-51
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . . 3-58
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . . 3-59
ADJUSTING THE DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
 INTRODUCTION CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.

From 50,000 km, repeat the maintenance intervals starting from 10,000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.

ODOMETER READING (
1,000 km) ANNUAL

NO
NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK

Fuel line
1 *  Check fuel hoses for cracks or damage. √ √ √ √ √
(See page 3-24)
Fuel filter
2 *  Check condition. √ √
(See page 3-24)
 Check condition.
Spark plugs  Clean and regap.
√ √
3
(See page 3
3-15)
15)
 Replace. √ √
Valves  Check valve clearance.
4 * Every 40,000 km
(See page 3-5)  Adjust.

Air filter element  Clean. √ √

5
(See page 3-23)  Replace. √ √
Clutch  Check operation.
6 √ √ √ √ √
(See page 3-22)  Adjust.
 Check operation, fluid level and vehicle
Front brake
for fluid leakage. (See NOTE)
√ √ √ √ √ √
7 * (See page 3-35)
3 35)
(See page 3-36)  Replace brake pads. Whenever worn to the limit
 Check operation, fluid level and vehicle
Rear brake
for fluid leakage. (See NOTE)
√ √ √ √ √ √
8 * (See page 3-35)
3 35)
(See page 3-36)  Replace brake pads. Whenever worn to the limit

Brake hoses  Check for cracks or damage. √ √ √ √ √

9 * (See page 3-37)  Replace. (See NOTE) Every 4 years
Wheels
10 *  Check runout and for damage. √ √ √ √
(See page 4-4)
 Check tread depth and for damage.
Tires  Replace if necessary.
11 *
(See page 3-47)  Check air pressure.
√ √ √ √
 Correct if necessary.
Wheel bearings
12 *  Check bearing for looseness or damage. √ √ √ √
(Seep age 4-4)
Swingarm  Check operation and for excessive play. √ √ √ √
13 * (See page 4
4-68)
68)
(See page 4-69)  Lubricate with lithium-soap-based grease. Every 50,000 km
 Check chain slack.
Drive chain
 Make sure that the rear wheel is properly Every 1,000 km and after washing the
14 (See page 3-39)
aligned. motorcycle or riding in the rain.
(See page 4-69)
 Clean and lubricate.
 Check bearing play and steering for
Steering bearings
roughness.
√ √ √ √ √
15 * (See page 3-41)
3 41)
(See page 4-59)  Lubricate with lithium-soap-based grease. Every 20,000 km

3-1
 CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
ODOMETER READING (
1,000 km) ANNUAL
NO
NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
Chassis fasteners  Make sure that all nuts, bolts and
16 * √ √ √ √ √
(See page 2-22) screws and properly tightened.
Sidestand /
 Check operation.
17 centerstand
 Lubricate.
√ √ √ √ √
(Seep age 3-50)
Sidestand switch
18 *  Check operaiton. √ √ √ √ √ √
(See page 8-21)
Front fork
19 *  Check operation and for oil leakage. √ √ √ √
(See page 3-43)
Rear shock
absorber  Check operation and shock absorber for
20 *
assembly oil leakage.
√ √ √ √
(See page 4-64)
Rear suspension
relay arm and  Check operation. √ √ √ √
21 * connecting arm
pivoting points
(See page 4-69)
 Lubricate with lithium-soap-based grease. √ √

Carburetors  Check starter (choke) operation.

22 * (See page 3-10)  Adjust engine idling speed and √ √ √ √ √ √
(See page 3-12) synchronization.
Engine oil
23  Change. √ √ √ √ √ √
(See page 3-20)
Engine oil filter
24 cartridge  Replace. √ √ √
(See page 3-20)
 Check coolant level and vehicle. for
Cooling system
coolant leakage
√ √ √ √ √
25 * (See page 3-29)
3 29)
(See page 3-30)  Change. Every 3 years
Front and rear
brake switches
26 *
(See page 3-36)
 Chck operation. √ √ √ √ √ √
(See page 8-38)
Moving parts and
cables
27
(See page 2-24)
 Lubricate. √ √ √ √ √
(See page 3-50)
 Check the air cut valve and reed valve for
Air induction
damage.
28 * system
 Replace the entire air induction system if
√ √ √ √ √
(See page 7-16)
necessary.
Lights, signals
and switches
 Check operation.
29 * (See page 3-59)
 Adjust headlight beam.
√ √ √ √ √ √
(See page 8-30)
(See page 8-35)

*: It is recommended that these items be serviced by a Yamaha dealer.

NOTE:

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

Hydraulic brake service
 Regularly check and, if necessary, correct the brake fluid level.
 Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
 Replace the brake hoses every four years and if cracked or damaged.

3-2
 CHK
FRONT COWLING ADJ
EAS00038

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK

FRONT COWLING

Order Job/Part Q’ty Remarks

Removing the fron cowling Remove the4 parts in the order listed.
1 Inner panel 2
2 Headlight/meter coupler 1/1 Disconnect.
3 Front cowling assembly 1
4 Back view mirror 2
5 Meter unit 1
6 Headlight unit 1
For installation, reverse the removal
procedure.

3-3
 CHK
SEAT, SIDE COVER AND FUEL TANK ADJ
EAS00040

SEAT, SIDE COVER AND FUEL TANK

19 Nm (1.9 m
kg)

10 Nm (1.0 m
kg)

4 Nm (0.4 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the seat, side cover and Remove the parts in the order listed.
fuel tank
1 Seat 1
2 Side cover (left and right) 2
3 Fuel sender coupler 1 Disconnect.
4 Fuel tank 1
5 Fuel tank breather hose 1
6 Fuel tank drain hose 1 NOTE:
7 Fuel hose 1 Befor disconnecting the fuel hose, turn
the fuel cock off.

8 Grab bar 1
9 Rear cowling 1
For installation, reverse the removal
procedure.

3-4
 CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00045

ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:

Valve clearance adjustment should be made
on a cold engine, at room temperature.

When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.

1. Remove:

cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.

2. Measure:

valve clearance
Out of specification
Adjust.

Valve clearance (cold)

Intake valve
0.11 X 0.20 mm
Exhaust valve
0.21 X 0.25 mm

a. Turn the crankshaft clockwise.

b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark a on the
pickup rotor with the crankcase mating sur-
face b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.

c. Measure the valve clearance with a thick-

ness gauge 1 .
NOTE:

If the valve clearance is incorrect, record the
measured reading.

Measure the valve clearance in the following
sequence.

Valve clearance measuring sequence

Cylinder #1
#2
#4
#3
3-5
 CHK
ADJUSTING THE VALVE CLEARANCE ADJ
A Front
d. For each cylinder, starting with cylinder #1 at
TDC, turn the crankshaft clockwise as speci-
fied in the following table.
B Degrees that the crankshaft is turned clockwise
C Cylinder
D Combustion cycle

#2 Cylinder 180_
#4 Cylinder 360_
#3 Cylilnder 540_

3. Remove:
S intake camshaft
S exhaust camshaft
NOTE:
S Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chap-
ter 5.
S When removing the timing chain and cam-
shafts, fasten a wire to the timing chain to re-
trieve it if it falls into the crankcase.

4. Adjust:
S valve clearance

a. Remove the valve lifter 1 and the valve pad

2 with a valve lapper 3 .

Valve lapper
90890–04101

3-6
 CHK
ADJUSTING THE VALVE CLEARANCE ADJ
NOTE:

Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.

Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.

b. Select the proper valve pad from the follow-

ing table.

Valve pad Available valve

thickness range pads
25 thicknesses
Nos. 1.20 X
in 0.05 mm
120 X 240 2.40 mm
increments

NOTE:

The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.

Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.

c. Round off the original valve pad number ac-

cording to the following table.

Last digit Rounded value

0 or 2 0
5 5
8 10
EXAMPLE:
Original valve pad number = 148 (thickness
=1.48 mm (0.058 in))
Rounded value = 150
d. 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 intersect is the
new valve pad number.
NOTE:
The new valve pad number is only an approxi-
mation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.

3-7
 CHK
ADJUSTING THE VALVE CLEARANCE ADJ
VALVE PAD SELECTION TABLE
INTAKE
Measured INSTALLED PAD NUMBER
clearance
# 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08 X 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11 X 0.20 Specification
exa 0.21 X 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
! 0.23 X 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28 X 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 X 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 185 190 195 200 205 210 215 220 225 230 235 240
0.83 X 0.87 190 195 200 205 210 215 220 225 230 235 240
0.88 X 0.92 195 200 205 210 215 220 225 230 235 240
0.93 X 0.97 200 205 210 215 220 225 230 235 240 EXAMPLE:
0.98 X 1.02 205 210 215 220 225 230 235 240 VALVE CLEARANCE: 0.11 X 0.20 mm
1.03 X 1.07 210 215 220 225 230 235 240 Installed is 150
1.08 X 1.12 215 220 225 230 235 240 Measured clearance is 0.25 mm
1.13 X 1.17 220 225 230 235 240 Replace 150 pad with 160 pad
1.18 X 1.22 225 230 235 240
1.23 X 1.27 230 235 240
1.28 X 1.32 235 240
1.33 X 1.37 240

EXHAUST
Measured INSTALLED PAD NUMBER
clearance
# 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08 X 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 X 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18 X 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21 X 0.30 Specification
exa 0.31 X 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
! 0.33 X 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 X 0.87 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88 X 0.92 185 190 195 200 205 210 215 220 225 230 235 240
0.93 X 0.97 190 195 200 205 210 215 220 225 230 235 240
0.98 X 1.02 195 200 205 210 215 220 225 230 235 240
1.30 X 1.07 200 205 210 215 220 225 230 235 240 EXAMPLE:
1.08 X 1.12 205 210 215 220 225 230 235 240 VALVE CLEARANCE: 0.21 X 0.30 mm
1.13 X 1.17 210 215 220 225 230 235 240 Installed is 175
1.18 X 1.22 215 220 225 230 235 240 Measured clearance is 0.35 mm
1.23 X 1.27 220 225 230 235 240 Replace 175 pad with 185 pad
1.28 X 1.32 225 230 235 240
1.33 X 1.37 230 235 240
1.38 X 1.42 235 240
1.43 X 1.47 240

3-8
 CHK
ADJUSTING THE VALVE CLEARANCE ADJ
e. Install the new valve pad 1 and the valve lift-
er 2 .
NOTE:

Apply molybdenum disulfide to the valve pad.

Lubricate the valve lifter with molybdenum dis-
ulfide oil.

The valve lifter must turn smoothly when ro-
tated by hand.

Install the valve lifter and the valve pad in the
correct place.

f. Install the exhaust and intake camshafts,

timing chain and camshaft caps.

Camshaft cap bolt

10 Nm (1.0 m
kg)

NOTE:

Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 4.

Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.

First, install the exhaust camshaft.

Align the camshaft marks with the camshaft
cap marks.

Rotate the crankshaft clockwise several turns
to seat the parts.

g. Measure the valve clearance again.

h. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.

5. Install:

cylinder head cover
Refer to “CYLINDER HEAD COVER” in
chapter 5.
6. Install:

all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.

3-9
 CHK
SYNCHRONIZING THE CARBURETORS ADJ
EAS00050

SYNCHRONIZING THE CARBURETORS

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

1. Stand the motorcycle on a level surface.

NOTE:
Place the motorcycle on a suitable stand.

2. Remove:

vacuum cap

3. Install:

vacuum gauge 1

engine tachometer 2
(to the spark plug lead of cyl. #1)

Vacuum gauge
90890-03094
Engine tachometer
90890-03113

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

minutes.
5. Check:

engine idling speed
Out of specification
Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.

Engine idling speed

1,050
1,150 r/min

3-10
 CHK
SYNCHRONIZING THE CARBURETORS ADJ
6. Adjust:

carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2

by turning the synchronizing screw 1 in ei-
ther direction until both gauges read the
same.
NOTE:
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.

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 read the
same.

Vacuum pressure at engine idling

speed
30 kPa (225 mm Hg)

NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa (10
mm Hg).

7. Measure:

engine idling speed
Out of specification
Adjust.
8. Stop the engine and remove the measuring
equipment.
9. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

Throttle cable free play (at the

flange of the throttle grip)
3 X 5 mm

10. Install:

vacuum cap

3-11
 CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00052

ADJUSTING THE ENGINE IDLING SPEED

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

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

minutes.
2. Install:

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

Engine tachometer
90890-03113

3. Measure:

engine idling speed
Out of specification
Adjust.

Engine idling speed

1,050 X 1,150 r/min

4. Adjust:

engine idling speed

a. Turn the pilot screw 1 in or out until it is light-

ly seated.
b. Turn the pilot screw out the specified number
of turns.

Carburetor angle driver 2

908900-03173

Pilot screw
2 turns out

3-12
 ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
c. Turn the throttle stop screw 2 in direction a
or b until the specified engine idling speed is
obtained.

Engine idling speed is in-

Direction a
creased.
Engine idling speed is
Direction b
decreased.
5. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.

Throttle cable free play (at the

flange of the throttle grip)
3 X 5 mm

EAS00055

ADJUSTING THE THROTTLE CABLE FREE

PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and carburetor synchro-
nization should be adjusted properly.

1. Check:

throttle cable free play a
Out of specification
Adjust.

Throttle cable free play (at the

flange of the throttle grip)
3 X 5 mm

2. Remove:

seat

fuel tank

3-13
 CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Adjust:

throttle cable free play

NOTE:
When the motorcycle is accelerating, the accel-
erator cable 1 is pulled.

Carburetor side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 4 on the accelerator
cable.
d. Turn the adjusting nut 5 in direction a or b
until the specified throttle cable free play is
obtained.

Throttle cable free play is

Direction a
increased.
Throttle cable free play is
Direction b
decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot be
obtained on the carburetor side of the cable, use
the adjusting nut on the handlebar side.

Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.

Throttle cable free play is

Direction a
increased.
Throttle cable free play is
Direction b
decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.

3-14
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUGS ADJ
4. Install:

fuel tank

seat

EAS00059

CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Disconnect:

spark plug cap
2. Remove:

spark plug
CAUTION:
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.

3. Check:

spark plug type
Incorrect
Change.
Spark plug type (manufacturer)
CR9E (NGK)
U27ESR-N (DENSO)

4. Check:

electrode 1
Damage/wear
Replace the spark plug.

insulator 2
Abnormal color
Replace the spark plug.
Normal color is a medium-to-light tan color.
5. Clean:

spark plug
(with a spark plug cleaner or wire brush)

6. Measure:

spark plug gap a
(with a wire gauge)
Out of specification
Regap.

Spark plug gap

0.7
0.8 mm

3-15
 CHECKING THE SPARK PLUGS/ CHK
CHECKING THE IGNITION TIMING ADJ
7. Install:

spark plug 13 Nm (1.3 m
kg)
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.

8. Connect:

spark plug cap

EAS00063

CHECKING THE IGNITION TIMING

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

1. Remove:

timing plug 1

2. Install:

timing light 1

engine tachometer 2
(to the spark plug lead of cyl. #1)

Timing light
90890-03141
Engine tachometer
90890-03113

3. Check:

ignition timing

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

utes, and then let it run at the specified en-
gine idling speed.

Engine idling speed

1,050 X 1,150 r/min

3-16
 CHECKING THE IGNITION TIMING/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
b. Check that the mark a is within the required
firing range b on the pickup coil rotor.
Incorrect firing range
Check the ignition
system.
NOTE:
The ignition timing is not adjustable.

4. Remove:

timing light

engine tachometer
5. Install:

timing plug
EAS00065

MEASURING THE COMPRESSION PRES-

SURE
The following procedure applies to all of the cyl-
inders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.

1. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:

spark plug cap
4. Remove:

spark plug
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.

5. Install:

compression gauge 1

Compression gauge
90890-03081
Compression gauge adapter
90890-04136

3-17
 CHK
MEASURING THE COMPRESSION PRESSURE ADJ
6. Measure:

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

Compression pressure
(with oil applied into cylinder)
Reading Diagnosis
Higher than Piston ring(-s) wear or
without oil damage
Repair.
Piston valves, cylinder
head gasket or piston
Same as possibly defective

without oil Repair.
Compression pressure
(at sea level)

Compression pressure (at sea

level):
Standard:
1,450 kPa (14.5 kg/cm2)
Minimum:
1,260 kPa (12.6 kg/cm2)
Maximum:
1,620 kPa (16.2 kg/cm2)

a. Turn the main switch to “ON”.

b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.

NOTE:
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1
kg/cm2).

7. Install:

spark plug 13 Nm (1.3 m
kg)
8. Connect:

spark plug cap

3-18
 CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EAS00069

CHECKING THE ENGINE OIL LEVEL

1. Stand the motorcycle on a level surface.
NOTE:

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

3. Check:

engine oil level
The engine oil level should be between the
minimum level marks a and maximum level
marks b .
Below the minimum level mark
Add the
recommended engine oil to the proper level.

Recommended engine oil

Refer to the chart for the engine
oil grade which is best suited
for certain atmospheric temper-
atures.
API standard
SE or higher grade
ACEA standard
G4 or G5

CAUTION:

Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD a or higher and do
not use oils labeled “ENERGY CONSERV-
ING II” b or higher.

Do not allow foreign materials to enter the
crankcase.

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

utes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.

3-19
 CHK
CHANGING THE ENGINE OIL ADJ
EAS00073

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.

3. Remove:

engine oil filler cap 1

engine oil drain bolt 2
(along with the gasket)
4. Drain:

engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.

a. Remove the oil filter cartridge 1 with an oil

filter wrench 2 .

Oil filter wrench

90890-01426

b. Apply a thin coat of engine oil onto the O-ring

1 of the new oil filter cartridge.

CAUTION:
Make sure that the O-ring 1 is positioned
correctly in the groove of the oil filter car-
tridge.

3-20
 CHK
CHANGING THE ENGINE OIL ADJ
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.

Oil filter cartridge

17 Nm (1.7 m
kg)

6. Check:

engine oil drain bolt gasket
Damage
Replace.
7. Install:

engine oil drain bolt 43 Nm (4.3 m
kg)
8. Fill:

crankcase
(with the specified amount of the recom-
mended engine oil)

Quantity
Total amount
3.7 L
Without oil filter cartridge
replacement
2.8 L
With oil filter cartridge replace-
ment
3.0 L

9. Install:

engine oil filler cap
10. Start the engine, warm it up for several min-
utes, and then turn it off.
11. Check:

engine
(for engine oil leaks)
12. Check:

engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
13. Check:

engine oil pressure

a. Slightly loosen the oil gallery bolt 1 .

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

3-21
 CHANGING THE ENGINE OIL/ CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
Oil gallery bolt
10 Nm (1.0 m
kg)

EAS00078

ADJUSTING THE CLUTCH CABLE FREE

PLAY
1. Check:

clutch cable free play a
Out of specification
Adjust.

Clutch cable free play (at the end

of the clutch lever)
10 X 15 mm

2. Adjust:

clutch cable free play

Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is ob-
tained.

Clutch cable free play is

Direction a
increased.
Clutch cable free play is
Direction b
decreased
c. Tighten the locknut.
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.

Engine side
a. Loosen the locknuts 1 .
b. Turn the adjusting bolt 2 in direction a or b
until the specified clutch cable free play is ob-
tained.

Clutch cable free play is

Direction a
increased.
Clutch cable free play is
Direction b
decreased
c. Tighten the locknuts.

3-22
 CHK
CLEANING THE AIR FILTER ELEMENT ADJ
EAS00086

CLEANING THE AIR FILTER ELEMENT

1. Remove:

seat

fuel tank

side cover

cover 1

2. Remove:

air filter case cover 1

air filter element

3. Clean:

air filter element
Apply compressed air to the outer surface of
the air filter element.

4. Check:

air filter element
Damage
Replace.
5. Install:

air filter element

air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor en-
gine performance and possible overheat-
ing.

3-23
 CLEANING THE AIR FILTER ELEMENT / CHK
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS /
CHECKING THE FUEL HOSES AND FUEL FILTER ADJ
NOTE:
When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.

6. Install:

cover

side cover

fuel tank

seat
EAS00095

CHECKING THE CARBURETOR JOINTS

AND INTAKE MANIFOLDS
The following procedure applies to all of the car-
buretor joints and intake manifolds.
1. Remove:

seat

fuel tank

air filter case panel 1

2. Check:

carburetor joint 1

intake manifold 2
Cracks/damage
Replace.
Refer to “CARBURETOR” in chapter 6.
3. Install:

air chamber cover

fuel tank

seat

EAS00097

CHECKING THE FUEL HOSES AND FUEL

FILTER
The following procedure applies to all of the fuel
hoses.
1. Remove:

seat

fuel tank

side cover

2. Check:

fuel hose 1
Cracks/damage
Replace.

fuel filter 2
Damage/dirt
Replace.

3-24
CHECKING THE FUEL HOSES AND FUEL FILTER/ CHK
CHECKING THE CRANKCASE BREATHER HOSE /
CHECKING THE EXHAUST SYSTEM ADJ
NOTE:

Drain and flush the fuel tank if abrasive dam-
age to any components of the fuel line is evi-
dent.

The arrow mark a on the fuel filter should face
to the side of the fuel pump 1 .

3. Install:

side cover

fuel tank

seat

EAS00098

CHECKING THE CRANKCASE BREATHER

HOSE
1. Remove:

seat

fuel tank
2. Check:

crankcase breather hose 1
Cracks/damage
Replace.
Loose connection
Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.

3. Install:

fuel tank

seat
EAS00099

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Check:

exhaust pipe 1

muffler 2
Cracks/damage
Replace.

gasket 3
Exhaust gas leaks
Replace.
2. Check:

tightening torque

Exhaust pipe nut 4

20 Nm (2.0 m
kg)
Exhaust pipe and muffler bolt 5
20 Nm (2.0 m
kg)
Exhaust pipe and bracket bolt 6
20 Nm (2.0 m
kg)
Muffler and muffler bracket bolt 7
48 Nm (4.8 m
kg)

3-25
 CHK
ADJUSTING THE EXUP CABLES ADJ
EAS00101

ADJUSTING THE EXUP CABLES

1. Remove:

seat

fuel tank

2. Remove:

EXUP valve pulley cover 1

3. Check:

EXUP operation

a. Disconnect the EXUP servomotor connector

1.

b. Connect the battery to the EXUP servomotor

connector and check if the servomotor oper-
ates properly.

Battery positive lead
black/yellow 2

Battery negative lead
black/red 3

CAUTION:
To avoid damaging the servomotor, do not
leave the battery connected to it for more
than a few seconds.

c. Check that the EXUP valve operates properly.

d. Connect the EXUP servomotor connector.

3-26
 ADJUSTING THE EXUP CABLES/ CHK
CHECKING THE COOLANT LEVEL ADJ
4. Check:

EXUP cable free play a

EXUP cable free play

1.5 mm max.

5. Adjust:

EXUP cable free play

a. Loosen both locknuts 1 .

b. Insert a 4 mm long pin through the notch in
the EXUP valve pulley and into the hole in the
EXUP valve cover.
c. Turn both adjusting bolts 2 counterclock-
wise until there is no EXUP cable free play.
d. Turn both adjusting bolts 1/2 of a turn clock-
wise.
e. Tighten both locknuts and then remove the
pin.

6. Install:

EXUP valve pulley cover
10 Nm (1.0 m
kg)
7. Install:

fuel tank

seat

EAS00102

CHECKING THE COOLANT LEVEL

1. Stand the motorcycle on a level surface.
NOTE:

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Check:

coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
Below the minimum level mark
Add the
recommended coolant to the proper level.

3-27
 CHK
CHECKING THE COOLANT LEVEL ADJ
CAUTION:

Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.

Use only distilled water. Soft water may be
used if distilled water is not available.

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

utes, and then turn it off.
4. Check:

coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.

3-28
 CHK
CHECKING THE COOLING SYSTEM ADJ
EAS00104

CHECKING THE COOLING SYSTEM

1. Check:

radiator 1

radiator inlet hose 2

radiator outlet hose 3

oil cooler inlet hose 4

oil cooler outlet hose 5

water jacket inlet joint 6

water pump outlet joint 7
Cracks/damage
Replace.
Refer to “COOLING SYSTEM” in chapter 5.

3-29
 CHK
CHANGING THE COOLANT ADJ
EAS00105

CHANGING THE COOLANT

1. Remove

seat

fuel tank

front cowling

rear suspension
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” in chapter 4.
2. Disconnect:

coolant reservoir hose 1
3. Drain:

coolant
(from the coolant reservoir)

4. Remove:

radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap, while still pressing down turn it
counterclockwise, and then remove it.

The following procedure applies to all of the

coolant drain bolts and copper washers.

5. Remove:

coolant drain bolt 1
(along with the copper washer)
6. Drain:

coolant
(from the engine and radiator)

3-30
 CHK
CHANGING THE COOLANT ADJ
7. Check:

copper washer 1

coolant drain bolt 2
Damage
Replace.
8. Install:

coolant drain bolt
7 Nm (0.7 m
kg)
9. Connect:

coolant reservoir hose
10. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)

Recommended antifreeze
High-quality ethylene glycol anti
freeze containing corrosion inhibi
tors for aluminum engines
Mix ratio
50% antifreeze/50% water

Quantity
Total amount
2.4 L
Coolant reservoir capacity
0.3 L
From minimum to maximum
level mark
0.2 L

Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
WARNING

If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.

If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.

If coolant is swallowed, induce vomiting
and get immediate medical attention.

3-31
 CHK
CHANGING THE COOLANT ADJ
CAUTION:

Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. Soft water may be
used if distilled water is not available.

If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.

Do not mix different types of antifreeze.

11. Install:

radiator cap

12. Fill:

coolant reservoir
(with the recommended coolant to the maxi-
mum level mark a )
13. Install:

coolant reservoir cap
14. Start the engine, warm it up for several min-
utes, and then turn it off.
15. Check:

coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.

16. Install:

rear suspension
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” in chapter 4.

fuel tank

seat

3-32
 CHK
ADJUSTING THE FRONT BRAKE ADJ
EAS00107

CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:

brake lever position
(distance a from the throttle grip to the brake
lever)

a. While pushing the brake lever forward, turn

the adjusting dial 1 until the brake lever is in
the desired position.
NOTE:
Be sure to align the setting on the adjusting dial
with the arrow mark 2 on the brake lever hold-
er.

Distance a is the larg-

Position #1
est.
Distance a is the small-
Position #4
est.

WARNING

After adjusting the brake lever position,
make sure that the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.

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

CAUTION:
After adjusting the brake lever position,
make sure that there is no brake drag.

3-33
 CHK
ADJUSTING THE REAR BRAKE ADJ
EAS00110

ADJUSTING THE REAR BRAKE

1. Check:

brake pedal position
(distance a from the top of the rider footrest
to the top of the brake pedal)
Out of specification
Adjust.

Brake pedal position (below the

top of the rider footrest)
40 mm

2. Adjust:

brake pedal position

a. Loosen the locknut 1 .

b. Turn the adjusting bolt 2 in direction a or b
until the specified brake pedal position is ob-
tained.

Direction a Brake pedal is raised.

Direction b Brake pedal is lowered.

WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt 2 is
visible through the hole c .

c. Tighten the locknut 1 to specification.

Locknut
18 Nm (1.8 m
kg)

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

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

3-34
 ADJUSTING THE REAR BRAKE/ CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
3. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
EAS00115

CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.
NOTE:

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.
A
2. Check:

brake fluid level
Below the minimum level mark a
Add the
recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4

A Front brake
B Rear brake
B WARNING

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.

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

NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser-
voir is horizontal.

3-35
 CHECKING THE BRAKE PADS/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00122
A
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:

front brake pad

rear brake pad
Wear indicator groove 1 almost disap-
peared
Replace the brake pads as a set.
Refer to “REPLACING THE FRONT BRAKE
B PADS” and “REPLACING THE REAR
BRAKE PADS” in chapter 4.
A Front brake
B Rear brake
EAS00128

ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1. Check:

rear brake light operation timing
Incorrect
Adjust.

2. Adjust:

rear brake light operation timing

a. Hold the main body 1 of the rear brake light

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

Brake light comes on

Direction a
sooner.
Brake light comes on lat-
Direction b
er.

3-36
 CHECKING THE BRAKE HOSES/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00131

CHECKING THE BRAKE HOSES

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

brake hose 1
Cracks/damage/wear
Replace.
2. Check:

brake hose clamp 2
Loose connection
Tighten.
3. Hold the motorcycle upright and apply the
brake.
4. Check:

brake hose 1
Activate the brake several times.
Brake fluid leakage
Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS-

TEM
WARNING
Bleed the hydraulic brake system whenev-
er:

the system was disassembled,

a brake hose was loosened or removed,

the brake fluid level is very low,

brake operation is faulty.

1. Remove:

reservoir cap 1

diaphragm 2
NOTE:

Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.

When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydrau-
lic brake system, considerably lengthening the
bleeding procedure.

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.

3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM / CHK
ADJUSTING THE SHIFT PEDAL ADJ
2. Bleed:

hydraulic brake system

a. Add the recommended brake fluid to the

proper level.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
A Front
B Rear
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-
press the brake pedal and hold it in position.
g. Loosen the bleed screw.
This will release the tension and cause the
brake lever to contact the throttle grip or the
brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.

Bleed screw
6 Nm (0.6 m
kg)

k. Fill the reservoir to the proper level.

Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.

EAS00110

ADJUSTING THE SHIFT PEDAL

1. Check:

shift pedal position
(distance a from the top of the rider footrest
to the top of the shift pedal)
Out of specification
Adjust.

Shift pedal position (below the

top of the rider footrest)
40 mm
3-38
 ADJUSTING THE SHIFT PEDAL/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
2. Adjust:

adjusting bolt length

a. Loosen both locknuts 1 .

b. Turn the adjusting bolt 2 in direction a or b
to obtain the correct shift pedal position.

Direction a Shift pedal is raised.

Direction b Shift pedal is lowered.

Tighten both locknuts.

EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:
The drive chain slack must be checked at the
tightest point on the chain.

CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.

1. Stand the motorcycle on a level surface.

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

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

2. Rotate the rear wheel several times and

check the drive chain to locate its tightest
point.

3. Check:

drive chain slack a
Out of specification
Adjust.

Drive chain slack

40
50 mm

3-39
 CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
4. Adjust:

drive chain slack

a. Loosen the brake caliper bracket bolt.

b. Loosen the wheel axle nut 1 .
c. Loosen both locknuts 2 .
d. Turn both adjusting nuts 3 in direction a or
b until the specified drive chain slack is ob-
tained.

Direction a Drive chain is tightened.

Direction b Drive chain is loosened.

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

e. Tighten both locknuts to specification.

Locknut
16 Nm (1.6 m
kg)

f. Tighten the wheel axle nut to specification.

Wheel axle nut

150 Nm (15 m
kg)

3-40
 LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EAS00142

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain sol-
vents, and the use of a coarse brush can dam-
age these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that
could damage the O-rings.

Recommended lubricant
Engine oil or chain lubricant
suitable forO-ring chains

EAS00146

CHECKING AND ADJUSTING THE STEER-

ING HEAD
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Check:

steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding
Adjust the steering
head.
3. Remove:

front cowling assembly
Refer to “FRONT COWLING”.

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:

steering head

a. Remove the lock washer 1 , the upper ring

nut 2 , and the rubber washer 3 .

3-41
 CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
b. Loosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5 .
NOTE:
Set the torque wrench at a right angle to the ring
nut wrench.

Ring nut wrench

90890-01403

Lower ring nut (initial tightening

torque)
52 Nm (5.2 m
kg)

c. Loosen the lower ring nut 6 completely, then

tighten it to specification.
WARNING
Do not overtighten the lower ring nut.

Lower ring nut (final tightening

torque)
18 Nm (1.8 m
kg)

d. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to “STEERING HEAD AND HAN-
DLEBAR” in chapter 4.

e. Install the rubber washer 7 .

f. Install the upper ring nut 8 .
g. Finger tighten the upper ring nut 8 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 9 .

NOTE:
Make sure that the lock washer tabs a sit cor-
rectly in the ring nut slots b .

5. Install:

upper bracket

front cowling assembly

3-42
 CHECKING AND ADJUSTING THE STEERING HEAD / CHK
CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS
ADJ
Steering stem nut
110 Nm (11 m
kg)
Upper bracket pinch bolt
30 Nm (3.0 m
kg)
Handlebar holder bolt
23 Nm (2.3 m
kg)

EAS00149

CHECKING THE FRONT FORK

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Check:

inner tube
Damage/scratches
Replace.

oil seal
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation
Repair.
Refer to “FRONT FORK” in chapter 4.
EAS00155

ADJUSTING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
WARNING

Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.

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

Spring preload
CAUTION:

Grooves are provided to indicate the ad-
justment position.

Never go beyond the maximum or mini-
mum adjustment positions.

3-43
 CHK
ADJUSTING THE FRONT FORK LEGS ADJ
1. Adjust:

spring preload

a. Turn the adjusting bolt 1 in direction a or

b.

Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).

Adjusting positions
Standard: 2
Minimum: 5*
Maximum: 1

*fully turned out position

Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

rebound damping

a. Turn the adjusting screw 1 in direction a or

b.

Rebound damping
p g is
Direction a increased (suspension is
harder).
Rebound damping
p g is
Direction b decreased (suspension is
softer).

Adjusting positions
Standard: 7 clicks out*
Minimum: 17 clicks out*
Maximum: 1 clicks out*

*: from the fully turned-in position

3-44
 ADJUSTING THE FRONT FORK LEGS/ CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

compression damping

a. Turn the adjusting screw 1 in direction a or

b.

Compression damping is
Direction increased (suspension is
harder).
Compression damping is
Direction decreased (suspension is
softer).

Adjusting positions
Standard: 6 clicks out*
Minimum: 21 clicks out*
Maximum: 1 clicks out*

*: from the fully turned-in position

EAS00158

ADJUSTING THE REAR SHOCK ABSORB-

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

Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the own-
er’s tool kit.

3-45
 CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
a. Turn the adjusting ring 1 in direction a or
b.
b. Align the desired position on the adjusting
ring with the stopper 2 .

Spring preload is
Direction a (s spension is
increased (suspension
harder).
Spring preload is de-
Direction b (s spension is
creased (suspension
softer).

Adjusting positions
Standard: 6
Minimum: 1
Maximum: 11

Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

rebound damping

a. Turn the adjusting knob 1 in direction a or

b.

Rebound damping is
Direction a (s spension is
increased (suspension
harder).
Rebound damping is
Direction b (s spension is
decreased (suspension
softer).

Adjusting positions
Standard: 20 clicks out*
Minimum: 10 clicks out*
Maximum: 3 clicks out*

*: from the fully turned-in position

3-46
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHK
CHECKING THE TIRES ADJ
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

compression damping

a. Turn the adjusting screw 1 in direction a or

b.

Compression damping is
Direction a increased (suspension is
harder).
Compression damping is
Direction b decreased (suspension is
softer).

Adjusting positions
Standard: 7 clicks in
Minimum: 1 clicks in
Maximum: 12 clicks in

*: from the fully turned-out position

EAS00162

CHECKING THE TIRES

The following procedure applies to both of the
tires.
1. Measure:

tire pressure
Out of specification
Regulate.
WARNING

The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.

The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.

Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.

3-47
 CHK
CHECKING THE TIRES ADJ
Basic weight
(with oil and a 231 kg
full fuel tank)
Maximum
189 kg
load*
Cold tire
Front tire Rear tire
pressure
Up to 90 kg 250 kPa 270 kPa
load* (2.5 kgf/cm2) (2.7 kgf/cm2)
90 kg
250 kPa 290 kPa
maximum load* (2.5 kgf/cm2) (2.9 kgf/cm2)
High 250 kPa 290 kPa
speed riding (2.5 kgf/cm2) (2.9 kgf/cm2)
*: total of cargo, rider, passenger and accesso-
ries
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

2. Check:

tire surfaces
Damage/wear
Replace the tire.

Minimum tire tread depth

1.6 mm

1 Tire tread depth

2 Side wall
3 Wear indicator

WARNING

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
A Tire B Wheel

3-48
 CHK
CHECKING THE TIRES ADJ
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire

After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufactur-
er and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.

Front tire

Manufacturer Type Size

120/70
BRIDGESTONE Tubeless
ZR17 (58 W)
120/70
METZELER Tubeless
ZR17 (58 W)
Rear tire

Manufacturer Type Size

180/55
BRIDGESTONE Tubeless
ZR17 (73 W)
180/55
METZELER Tubeless
ZR17 (73 W)

WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any highspeed riding is done.

NOTE:
For tires with a direction of rotation mark 1 :

Install the tire with the mark pointing in the
direction of wheel rotation.

Align the mark 2 with the valve installation
point.

3-49
 CHECKING AND LUBRICATING THE CABLES / CHK
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION ADJ
EAS00170

CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the
cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its move-
ment. Replace damaged cable sheaths and
cables as soon as possible.

1. Check:

cable sheath
Damage
Replace.
2. Check:

cable operation
Unsmooth operation
Lubricate.

Recommended lubricant
Engine oil or a suitable cable
lubricant

NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.

EAS00171

LUBRICATING THE LEVERS AND PEDALS

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

Recommended lubricant
lithium soap base grease

EAS00172

LUBRICATING THE SIDESTAND

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

Recommended lubricant
lithium soap base grease

EAS00174

LUBRICATING THE REAR SUSPENSION

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

Recommended lubricant
lithium soap base grease

3-50
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00178

ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

Wear protective eye gear when handling or
working near batteries.

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).

DO NOT SMOKE when charging or han-
dling batteries.

KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External

SKIN – Wash with water.

EYES – Flush with water for 15 minutes and
get immediate medical attention.
Internal

Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.

CAUTION:

This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.

Charging time, charging amperage and
charging voltage for a MF battery are differ-
ent from those of conventional batteries.
The MF battery should be charged as ex-
plained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.

3-51
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.

1. Remove:
S seat
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .

3. Remove:
S battery
4. Check:
S battery charge

a. Connect a pocket tester to the battery termi-

nals.

Tester positive lead
battery positive

Tester positive lead
terminal
Tester negative lead
battery negative
Tester negative lead
terminal

NOTE:
13.0 Relationship between the open-circuit voltage
S The charge state of a MF battery can be
Open-circuit voltage (V)

and the charging time at 20_C

12.5 checked by measuring its open-circuit voltage

12.0
(i.e., the voltage when the positive terminal is
disconnected).
11.5
S No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
5 6.5 10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%

3-52
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging 5. Charge:
Ambient temperature 20_C
S battery
Open-circuit voltage (V)

(refer to the appropriate charging method il-

lustration)
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage. CAUTION:
S Make sure that the battery vent is free of ob-
Ambient
structions.
Open-circuit voltage (V)

temperature
20_C
S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
S If it is impossible to regulate the charging
current on the battery charger, be careful
Charging condition of the battery (%) not to overcharge the battery.
S When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative lead
from the battery terminal.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure that the battery charger lead
clips are in full contact with the battery ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate heat in the contact area and a weak clip
spring may cause sparks.
S If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
S As shown in the following illustration, the
open-circuit voltage of a MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.

3-53
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a variable voltage charger

Measure the open-circuit NOTE:

voltage prior to charging. Voltage should be measured 30
minutes after the machine is stopped.

Connect a charged and NOTE:

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

Make sure that the current

YES is higher than the standard NO
charging current written on
the battery.

By turning the charging

voltage adjust dial, set the
charging voltage at 20
24 V.

Adjust the voltage so that the Monitor the amperage for

YES
current is at the standard 3
5 minutes to check if the
charging level. standard charging current is
reached.

NO

Set the time according to the If the current does not

charging time suitable for the exceed the standard
open-circuit voltage. charging current after 5
Refer to “Battery condition minutes, replace the battery.
checking steps”.

If charging requires more than 5 hours, it is advisable to check the

charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.

Measure the battery open-circuit voltage after leaving the battery

unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

3-54
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a constant voltage charger

Measure the open-circuit NOTE:

voltage prior to charging. Voltage should be measured 30
minutes after the machine is stopped.

Connect a charger and

AMP meter to the battery
and start charging.

Make sure that the current

YES is higher than the standard NO
charging current written on
the battery.

Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 V. Charge the charge the MF battery. A variable
battery until the battery’s charging voltage charger is recommended.
voltage is 15 V.

NOTE:
Set the charging time at 20 hours
(maximum).

Measure the battery open-circuit

voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.

3-55
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Check:

battery vent
Obstruction
Clean.
Damage
Replace.
7. Install:

battery

8. Connect:

battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .

9. Check:

battery terminals
Dirt
Clean with a wire brush.
Loose connection
Connect properly.
10. Lubricate:

battery terminals

Recommended lubricant
Dielectric grease

11. Install:

seat
EAS00181

CHECKING THE FUSES

The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.

1. Remove:

seat
2. Check:

fuse

a. Connect the pocket tester to the fuse and

check the continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.

3-56
 CHK
CHECKING THE FUSES ADJ
Pocket tester
90890-03112

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

fuse.

3. Replace:

blown fuse

a. Turn off the ignition.

b. Install a new fuse of the correct amperage
rating.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.

Fuses Amperage rating Quantity

Main fuse 30A 1
Headlight fuse 20A 1
Signaling
20A 1
system fuse
Ignition fuse 20A 1
Turn signal
10 A 1
relay fuse
Digital clock
10A 1
fuse
Radiator fan
10A 1
fuse
Reserve fuse 30A 1
Reserve fuse 20 A 1
Reserve fuse 10 A 1

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

4. Install:

seat

3-57
 CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183

REPLACING THE HEADLIGHT BULBS

The following procedure applies to both of the
headlight bulbs.
1. Disconnect:

headlight coupler 1

bulb cover 2

2. Remove:

headlight bulb holder 1
3. Remove:

headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.

4. Install:

headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

5. Install:

headlight bulb holder
6. Install:

bulb cover
7. Connect:

headlight coupler

3-58
ADJUSTING THE HEADLIGHT BEAMS/ CHK
ADJUSTING THE DIGITAL CLOCK ADJ
EAS00185

ADJUSTING THE HEADLIGHT BEAMS

The following procedure applies to both of the
headlights.
1. Adjust:

headlight beam (vertically)

a. Turn the adjusting screw 1 in direction a or

b.

Direction a Headlight beam is raised.

Direction b Headlight beam is lowered.
2. Adjust:

headlight beam (horizontally)

a. Turn the adjusting knob 1 in direction a or

b.
Left headlight

Headlight beam moves to

Direction a
the right.
Headlight beam moves to
Direction b
the left.
Right headlight

Headlight beam moves to

Direction a
the left.
Headlight beam moves to
Direction b
the right.

EAS00187

ADJUSTING THE DIGITAL CLOCK

NOTE:
This digital clock constantly displays the time.

1. Adjust:

digital clock 1

a. Hold down the “RESET” button 2 and “SE-

LECT” button 3 .
b. Push the “RESET” button 2 to set the hour.
And push the “SELECT” button.
c. Push the “RESET” button 2 to set the min-
utes. And push the “SELECT” button.
NOTE:
When setting the time (e.g., after reconnecting
the battery), first set the clock to 1:00 AM, then
set it to the correct time.

3-59
 CHAS
CHAPTER 4
CHASSIS

FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DISASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . 4-3
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
ASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . 4-7

REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . 4-13
CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 4-13
CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . 4-15

FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 4-18
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . 4-20
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . . 4-27
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . 4-27
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . 4-31
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . 4-37
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . 4-38
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . 4-39
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
ASSEMBLING AND INSTALLING THE REAR BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
 CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 4-46
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . 4-46
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 4-48
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . 4-49
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 4-53

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . 4-63
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . 4-64
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 4-64

SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
 FRONT WHEEL AND BRAKE DISCS CHAS
EAS00514

CHASSIS
FRONT WHEEL AND BRAKE DISCS

72 Nm (7.2 m
kg)

40 Nm (4.0 m
kg)

18 Nm (1.8 m
kg)

Order Job/Part Q’ty Remarks

Removing the front wheel and brake Remove the parts in the order listed.
discs NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.

1 Brake hose holder (left and right) 2

2 Brake caliper (left and right) 2
3 Wheel axle pinch bolt 1 Loosen.
4 Front wheel axle 1
5 Front wheel 1
6 Collar (left and right) 2
7 Oil seal cover (left and right) 2
8 brake disc (left and right) 2
For installation, reverse the removal
procedure.

4-1
 FRONT WHEEL AND BRAKE DISCS CHAS
EAS00518

FRONT WHEEL

Order Job/Part Q’ty Remarks

Disassembling the front wheel Disassemble the parts in the order listed.
1 Oil seal (left and right) 2
2 Wheel bearing (left and right) 2
3 Spacer 1
For assembly, reverse the disassembly
procedure.

4-2
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00521

REMOVING THE FRONT WHEEL

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Remove:

left brake caliper

right brake caliper
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.

3. Elevate:

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

EAS00523

DISASSEMBLING THE FRONT WHEEL

1. Remove:

oil seals

wheel bearings

a. Clean the outside of the front wheel hub.

b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.

c. Remove the wheel bearings with a general

bearing puller.

4-3
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00525

CHECKING THE FRONT WHEEL

1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends
Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.

2. Check:

tire

front wheel
Damage/wear
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

3. Measure:

front wheel radial runout 1

front wheel lateral runout 2
Over the specified limits
Replace.

Front wheel radial runout limit

1 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 outside of the front wheel hub.

b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
4-4
FRONT WHEEL AND BRAKE DISCS CHAS
c. Remove the wheel bearings 3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.

CAUTION:
Do not contact the wheel bearing center race
1 or balls 2 . Contact should be made only
with the outer race 3 .

NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.

EAS00531

CHECKING THE BRAKE DISCS

The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage/galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.

Brake disc deflection limit

(maximum)
0.1 mm

a. Place the motorcycle on a suitable stand so

that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2
3 mm below the
edge of the brake disc.

4-5
FRONT WHEEL AND BRAKE DISCS CHAS
3. Measure:
S brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.

Brake disc thickness limit

(minimum)
4.5 mm

4. Adjust:
S brake disc deflection

a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc bolt

18 Nm (1.8 mSkg)
LOCTITER

d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.

EAS00539

ASSEMBLING THE FRONT WHEEL

1. Install:
S wheel bearings
S oil seals New

a. Install the new wheel bearings and oil seals

in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
1 or balls 2 . Contact should be made only
with the outer race 3 .

NOTE:
Use a shocket 4 that matches the diameter of
the wheel bearing outer race and oil seal.

4-6
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00544

INSTALLING THE FRONT WHEEL

The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips

Recommended lubricant
Lithium soap base grease

2. Tighten:

wheel axle 1 72 Nm (7.2 m
kg)

wheel axle pinch bolt 2
23 Nm (2.3 m
kg)

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

3. Install:

brake caliper 40 Nm (4.0 m
kg)

WARNING
Make sure that the brake hose is routed
properly.

EAS00549

ADJUSTING THE FRONT WHEEL STATIC

BALANCE
NOTE:

After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.

Adjust the front wheel static balance with the
brake discs installed.

1. Remove:

balancing weight(-s)
NOTE:
Place the front wheel on a suitable balancing
stand.

4-7
FRONT WHEEL AND BRAKE DISCS CHAS
2. Find:
S front wheel’s heavy spot

a. Spin the front wheel.

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

3. Adjust:
S front wheel static balance

a. Install a balancing weight 1 onto the rim ex-

actly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.

b. Turn the front wheel 90_ so that the heavy

spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.

4. Check:
S front wheel static balance

a. Turn the front wheel and make sure that it

stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.

4-8
 REAR WHEEL AND BRAKE DISC CHAS
EAS00551

REAR WHEEL AND BRAKE DISC

REAR WHEEL

150 Nm (15 m
kg)

40 Nm (4.0 m
kg)

Order Job/Part Q’ty Remarks

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

1 Brake caliper 1
2 Brake torque rod 1 Loosen.
3 Nut 1
4 Washer 1
5 Wheel axle 1
6 Rear wheel assembly 1
For installation, reverse the removal
procedure.

4-9
 REAR WHEEL AND BRAKE DISC CHAS
EAS00560

Order Job/Part Q’ty Remarks

Disassembling the rear wheel Disassemble the parts in the order listed.
1 Spacer 1
2 Bearing 1
3 Spacer 1
4 Oil seal 1
5 Circlip 1
6 Bearing 1
For assembly, reverse the disassembly
procedure.

4-10
 REAR WHEEL AND BRAKE DISC CHAS

18 Nm (1.8 m
kg)

69 Nm (6.9 m
kg)

Order Job/Part Q’ty Remarks

Removing the brake disc and rear Remove the parts in the order listed.
wheel sprocket
1 Brake disc 1
2 Rear wheel sprocket 1
3 Collar (left and right) 2
4 Oil seal 1
5 Bearing 1
6 Rear wheel drive hub 1
7 Rear wheel drive hub damper 6
For installation, reverse the removal
procedure.

4-11
REAR WHEEL AND BRAKE DISC CHAS
EAS00561

REMOVING THE REAR WHEEL

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Remove:

brake caliper 1
NOTE:
Do not depress the brake pedal when removing
the brake caliper.

3. Loosen:

locknut 1

adjusting nut 2
4. Remove:

wheel axle nut 3

wheel axle

rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.

5. Remove:

left collar 1

rear wheel drive hub 2

rear wheel drive hub damper

right collar

4-12
REAR WHEEL AND BRAKE DISC CHAS
EAS00565

CHECKING THE REAR WHEEL

1. Check:

wheel axle

rear wheel

wheel bearings

oil seals
Refer to “FRONT WHEEL”.
2. Check:

tire

rear wheel
Damage/wear
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:

rear wheel radial runout

rear wheel lateral runout
Refer to “FRONT WHEEL”.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB

1. Check:

rear wheel drive hub 1
Cracks/damage
Replace.

rear wheel drive hub dampers 2
Damage/wear
Replace.

EAS00568

CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:

rear wheel sprocket
More than 1/4 tooth a wear
Replace the
rear wheel sprocket.
Bent teeth
Replace the rear wheel sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:

rear wheel sprocket

a. Remove the self-locking nuts and the rear

wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.

4-13
REAR WHEEL AND BRAKE DISC CHAS

Rear wheel sprocket self-locking

nut
69 Nm (6.9 m
kg)

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

EAS00531

CHECKING THE BRAKE DISC

1. Check:

brake disc
Damage/galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.

Brake disc deflection limit

(maximum)
0.1 mm

a. Place the motorcycle on a suitable stand so

that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2
3 mm below the
edge of the brake disc.

3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.

Brake disc thickness limit

(minimum)
4.5 mm

4-14
REAR WHEEL AND BRAKE DISC CHAS
4. Adjust:
S brake disc deflection

a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.

Brake disc bolt

18 Nm (1.8 mSkg)
LOCTITER

d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.

EAS00572

INSTALLING THE REAR WHEEL

1. Lubricate:
S wheel axle
S wheel bearings
S oil seal lips

Recommended lubricant
Lithium soap base grease

2. Tighten:
S wheel axle nut 150 Nm (15 mSkg)
S brake caliper bolts 40 Nm (4.0 mSkg)

EAS00575

ADJUSTING THE REAR WHEEL STATIC

BALANCE
NOTE:
S After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
S Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.

1. Adjust:
S rear wheel static balance
Refer to “FRONT WHEEL”.

4-15
 FRONT AND REAR BRAKES CHAS
EAS00577

FRONT AND REAR BRAKES

FRONT BRAKE PADS

40 Nm (4.0 m
kg) 6 Nm (0.6 m
kg)

Order Job/Part Q’ty Remarks

Removing the front brake pads Remove the parts in the order listed.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 brake pad 2
5 Brake pad shim 2
6 Bleed scrw 1
For installation, reverse the removal
procedure.

4-16
 FRONT AND REAR BRAKES CHAS

40 Nm (4.0 m
kg)

6 Nm (0.6 m
kg)

Order Job/Part Q’ty Remarks

Removing the rear brake pads Remove the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 2
For installation, reverse the removal
procedure.

4-17
FRONT AND REAR BRAKES CHAS
EAS00579

CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

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

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:

Flush with water for 15 minutes and get im-
mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove:

brake hose holder 1

brake caliper 2

4-18
FRONT AND REAR BRAKES CHAS
2. Remove:

brake pad clips 1

brake pad pins 2

brake pad spring 3

3. Remove:

brake pads 1
(along with the brake pad shims)

4. Measure:

brake pad wear limit
Out of specification
Replace the brake
pads as a set.

Brake pad wear limit

0.5 mm

5. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to the

bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.

Bleed screw
6 Nm (0.6 m
kg)

4-19
FRONT AND REAR BRAKES CHAS
d. Install new brake pad shims onto the new
brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must point
in the direction of disc rotation.

6. Install:

brake pad cover

brake pad pins

brake pad clips

brake caliper 40 Nm (4.0 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 lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove:

brake caliper 1
2. Remove:

brake pad clips 1

brake pad pins 2

brake pad spring 3

brake pads
(along with the brake pad shims)

4-20
FRONT AND REAR BRAKES CHAS
3. Measure:

brake pad wear limit
Out of specification
Replace the brake
pads as a set.

Brake pad wear limit

0.5 mm

4. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, brake pad pins, brake pad clips, and a
brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to the

bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.

Bleed screw
6 Nm (0.6 m
kg)

d. Install a new brake pad shim 3 onto each

new brake pad 4 .
e. Install new brake pads and a new brake pad
spring.

4-21
FRONT AND REAR BRAKES CHAS
5. Install:

brake pad cover

brake pad pins

brake pad clips

brake caliper 40 Nm (4.0 m
kg)

6. Check:

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

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

4-22
 FRONT AND REAR BRAKES CHAS
EAS00584

FRONT BRAKE MASTER CYLINDER

10 Nm (1.0 m
kg)

30 Nm (3.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the front brake master Remove the parts in the order listed.
cylinder
Brake fluid Drain.
1 Brake lever 1
2 Brake switch lead 2
3 Brake switch 1
4 Union bolt 1
5 Brake hose/copper washer 1/2 Refer to “REMOVING/ASSEMBLING
6 Master cylinder bracket 1 AND INSTALLING THE FRONT BRAKE
7 Master cylinder 1 MASTER CYLINDER” section.
For installation, reverse the removal
procedure.

4-23
 FRONT AND REAR BRAKES CHAS
EAS00585

Order Job/Part Q’ty Remarks

Disassembling the front brake Disassemble the parts in the order listed.
master cylinder
1 Master cylinder boot 1
2 Circlip 1
3 Master cylinder kit 1
4 Spring 1
For assembly, reverse the disassembly
procedure.

4-24
 FRONT AND REAR BRAKES CHAS
EAS00586

REAR BRAKE MASTER CYLINDER

30 Nm (3.0 m
kg)

4 Nm (0.4 m
kg)

23 Nm (2.3 m
kg)

Order Job/Part Q’ty Remarks

Removing the rear brake master Remove the parts in the order listed.
cylinder
Side cover (right)
Brake fluid Drain.
1 Master cylinder bolt 2
2 Union bolt 1 Refer to “REMOVING/ASSEMBLING
3 Brake hose/copper washer 1/2 AND INSTALLING THE REAR BRAKE
MASTER CYLINDER” section.
4 Clip/hose 2/1
5 Cotter pin 1
6 Pin 1
7 Washer 1
8 Master cylinder 1
For installation, reverse the removal
procedure.

4-25
 FRONT AND REAR BRAKES CHAS
EAS00587

Order Job/Part Q’ty Remarks

Disassembling the rear brake master Disassemble the parts in the order listed.
cylinder
1 Master cylinder boot 1
2 Circlip 1
3 Master cylinder kit 1
4 Spring 1
For assembly, reverse the disassembly
procedure.

4-26
FRONT AND REAR BRAKES CHAS
EAS00588

DISASSEMBLING THE FRONT BRAKE MAS-

TER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.

1. Disconnect:

brake switch coupler
(from the brake switch)
2. Remove:

union bolt 1

copper washers 2

brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.

EAS00589

DISASSEMBLING THE REAR BRAKE MAS-

TER CYLINDER
1. Remove:

side cover (right)

2. Remove:

union bolt 1

copper washers 2

brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.

4-27
 FRONT AND REAR BRAKES CHAS
EAS00592
A B
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:

brake master cylinder
Damage/scratches/wear
Replace.

brake fluid delivery passages
(brake master cylinder body)
Obstruction
Blow out with compressed air.
C D A Front
B Rear
2. Check:

brake master cylinder kit 1
Damage/scratches/wear
Replace.
C Front
D Rear

3. Check:

rear brake fluid reservoir 1
Cracks/damage
Replace.

rear brake fluid reservoir diaphragm 2
Cracks/damage
Replace.

4. Check:

front brake master cylinder reservoir 1
Cracks/damage
Replace.

front brake master cylinder reservoir dia-
phragm 2
Damage/wear
Replace.

5. Check:

brake hoses
Cracks/damage/wear
Replace.

4-28
 FRONT AND REAR BRAKES CHAS
EAS00598

ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER
WARNING

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. Install:

brake master cylinder 1
10 Nm (1.0 m
kg)
NOTE:

Install the brake master cylinder holder with
the “UP” mark facing up.

Align the end of the brake master cylinder hold-
er with the punch mark a on the handlebar.

First, tighten the upper bolt, then the lower bolt.

2. Install:

copper washers 1 New

brake hose 2

union bolt 3 30 Nm (3.0 m
kg)

CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
a brake pipe touches the projection a on the
brake master cylinder.

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

NOTE:

While holding the brake hose, tighten the
union bolt as shown.

Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.

4-29
FRONT AND REAR BRAKES CHAS
3. Fill:

brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid

DOT 4

WARNING

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.

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

4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:

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

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

4-30
FRONT AND REAR BRAKES CHAS
EAS00608

ASSEMBLING THE REAR BRAKE MASTER

CYLINDER
1. Install:

copper washers 1 New

brake hose 2

union bolt 3 30 Nm (3.0 m
kg)

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

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

2. Fill:

brake fluid reservoir
(to the maximum level mark a )

Recommended brake fluid

DOT 4

WARNING

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.

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

4-31
FRONT AND REAR BRAKES CHAS
3. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4. Check:

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

5. Adjust:

brake pedal position a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.

Brake pedal position (below the

top of the rider footrest)
40 mm

6. Adjust:

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

4-32
 FRONT AND REAR BRAKES CHAS
EAS00613

FRONT BRAKE CALIPERS

6 Nm (0.6 m
kg)

40 Nm (4.0 m
kg)

30 Nm (3.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the front brake calipers Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
For installation, reverse the removal
procedure.

4-33
 FRONT AND REAR BRAKES CHAS
EAS00615

6 Nm (0.6 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the front brake calipers Disassemble the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal 8
7 Bleed screw 1
For assembly, reverse the disassembly
procedure.

4-34
 FRONT AND REAR BRAKES CHAS
EAS00616

REAR BRAKE CALIPER

30 Nm (3.0 m
kg)

40 Nm (4.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the rear brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
For installation, reverse the removal
procedure.

4-35
 FRONT AND REAR BRAKES CHAS
EAS00617

6 Nm (0.6 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the rear brake caliper Disassemble the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 2
6 Brake caliper piston seal 4
7 Bleed screw 2
For assembly, reverse the disassembly
procedure.

4-36
FRONT AND REAR BRAKES CHAS
EAS00625

DISASSEMBLING THE FRONT BRAKE CAL-

IPERS
The following procedure applies to both of the
brake calipers.
NOTE:
Before disassembling either brake caliper, drain
the brake fluid from the entire brake system.

1. Remove:

union bolt 1

copper washers 2

brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.

2. Remove:

brake caliper pistons 1

brake caliper piston seals 2

a. Secure the right side brake caliper pistons

with a piece of wood a .
b. Blow compressed air into the brake hose
joint opening b to force out the left side pis-
tons from the brake caliper.

WARNING

Never try to pry out the brake caliper pis-
tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.

d. Repeat the previous steps to force out the
right side pistons from the brake caliper.

4-37
FRONT AND REAR BRAKES CHAS
EAS00628

DISASSEMBLING THE REAR BRAKE CAL-

IPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.

1. Remove:

union bolt 1

copper washers 2

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

2. Remove:

brake caliper pistons 1

brake caliper piston seals 2

a. Secure the right side brake caliper piston

with a piece of wood a .
b. Blow compressed air into the brake hose
joint opening b to force out the left side pis-
ton from the brake caliper.

WARNING

Never try to pry out the brake caliper pis-
tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.

d. Repeat the previous steps to force out the
right side piston from the brake caliper.

4-38
 FRONT AND REAR BRAKES CHAS
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
Every two years
and whenever the
Brake fluid
brake is disas-
sembled.

A 1. Check:

brake caliper pistons 1
Rust/scratches/wear
Replace the brake
caliper.

brake caliper cylinders 2
Scratches/wear
Replace the brake cali-
per.

brake calipers
Cracks/damage
Replace.

brake fluid delivery passages
(brake caliper body)
B Obstruction
Blow out with compressed Air.
WARNING
Whenever a brake caliper Is disassembled,
replace the brake caliper piston seals.

A Front
B Rear

2. Check:

brake caliper brackets 1
Cracks/damage
Replace.

4-39
FRONT AND REAR BRAKES CHAS
EAS00638

ASSEMBLING AND INSTALLING THE

FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
WARNING

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 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
(temporarily)

copper washers 1 New

brake hose 2

union bolt 3 30 Nm (3.0 m
kg)

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

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

2. Remove:

brake caliper
3. Install:

brake pads

brake pad pins

brake pad clips

brake hose holder 6 Nm (0.6 m
kg)

brake caliper 40 Nm (4.0 m
kg)
Refer to “REPLACING THE BRAKE PADS”.

4-40
FRONT AND REAR BRAKES CHAS
4. Fill:

brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid

DOT 4

WARNING

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.

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

5. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6. Check:

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

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

4-41
FRONT AND REAR BRAKES CHAS
EAS00644

ASSEMBLING AND INSTALLING THE REAR

BRAKE CALIPER
WARNING

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solevents 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

brake hose 2

union bolt 3 30 Nm (3.0 m
kg)

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

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

2. Remove:

brake caliper
3. Install:

brake pads

brake pad pin

brake pad clips

brake caliper 40 Nm (4.0 m
kg)
Refer to “REPLACING THE BRAKE PADS”.
4. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)

Recommended brake fluid

DOT 4

4-42
FRONT AND REAR BRAKES CHAS

WARNING

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.

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

5. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

6. Check:

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

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

4-43
 FRONT FORK CHAS
EAS00647

FRONT FORK

30 Nm (3.0 m
kg)

25 Nm (2.5 m
kg)

23 Nm (2.3 m
kg)

Order Job/Part Q’ty Remarks

Removing the front fork Remove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
1 Front fender 1
2 Bolt (upper bracket) 2 Loosen. Refer to “REMOVING/
3 Cap bolt 2 Loosen. INSTALLING THE FRONT
4 Bolt (lower bracket) 4 Loosen. FORK LEGS” section.
5 Front fork assembly (left/right) 1/1
For installation, reverse the removal
procedure.

4-44
 FRONT FORK CHAS
EAS00648

25 Nm (2.5 m
kg)

35 Nm (3.5 m
kg)

Order Job/Part Q’ty Remarks

Disassembly the front fork Disassemble the parts in the order listed.
1 Cap bolt 1
2 O-ring 1
3 Spacer 1
4 Spring seat 1
5 Fork spring 1
6 Damper adjusting rod 1
7 Dust seal 1
8 Oil seal clip 1
9 Damper rod bolt 1
10 Copper washer 1
11 Damper rod 1
12 Inner tube 1
13 Oil seal 1
14 Washer 1
15 Slide metal 1
16 Oil flow stopper 1
For assembly, reverse the disassembly
procedure.

4-45
 FRONT FORK CHAS
EAS00649

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Loosen:

upper bracket pinch bolt 1

cap bolt 2

lower bracket pinch bolt 3
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.

3. Remove:

front fork leg

EAS00653

DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Remove:

cap bolt 1
(from the damper adjusting rod)

nut 2
NOTE:
Remove the cap bolt with the piston rod holder
3.

Piston rod holder

90890-01434

4-46
 FRONT FORK CHAS
2. Remove:

spacer 1

spring seat 2

spring 3

damper adjusting rod 4
3. Drain:

fork oil

4. Remove:

oil seal clip 1
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.

5. Remove:

damper rod bolt

damper rod 1
NOTE:
While holding the damper rod with the damper
rod holder 2 , loosen the damper rod bolt.

Damper rod holder

90890-01447

6. Remove:

inner tube

a. Hold the front fork leg horizontally.

b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.

4-47
 FRONT FORK CHAS

CAUTION:

Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.

Avoid bottoming the inner tube into the
outer tube during the above procedure, as
the oil flow stopper will be damaged.

EAS00657

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check:

inner tube 1

outer tube 2
Bends/damage/scratches
Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2. Measure:

spring free length a
Over the specified limit
Replace.

Spring free length limit

347.0 mm

3. Check:

damper rod
Damage/wear
Replace.
Obstruction
Blow out all of the oil pas-
sages with compressed air.

oil flow stopper
Damage
Replace.
CAUTION:

The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.

When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.

4. Check:

cap bolt O-ring
Damage/wear
Replace.

4-48
 FRONT FORK CHAS
EAS00660

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
WARNING

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.

NOTE:

When assembling the front fork leg, be sure to
replace the following parts:
-inner tube bushing
-outer tube bushing
-oil seal
-dust seal

Before assembling the front fork leg, make
sure that all of the components are clean.

1. Install:

damper rod 1
CAUTION:
Allow the damper rod to slide slowly down
the inner tube 2 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.

NOTE:
Install the oil flow stopper with a flat surface part
a downward.

2. Lubricate:

inner tube’s outer surface

Recommended lubricant
Fork oil 5W or equivalent

3. Tighten:

damper rod bolt 1 35 Nm (3.5 m
kg)
LOCTITE
NOTE:
While holding the damper rod with the damper
rod holder 2 , tighten the damper rod bolt.

Damper rod holder

90890-01447

4-49
 FRONT FORK CHAS
4. Install:

oil seal 1
(with the fork seal driver weight 2 and fork
seal driver attachemt 3 )

Fork seal driver weight

90890-01367
Fork seal driver attachment
90890-01374

CAUTION:
Make sure that the numbered side of the oil
seal faces up.

NOTE:

Before installing the oil seal, apply lithium soap
base grease onto its lips.

Apply fork oil onto the outer surface of the inner
tube.

Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.

5. Install:

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

6. Fill:

front fork leg
(with the specified amount of the recom-
mended fork oil)

Quantity (each front fork leg)

0.44 L (440 cm3)
Recommended oil
Yamaha suspension oil “01” or
equivalent

CAUTION:

Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.

When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.

NOTE:
Be sure to bleed the front fork.

4-50
 FRONT FORK CHAS
7. Install:

rod puller 1

rod puller attachment 2
(onto the damper rod 3 )

Rod puller
90890-01437
Rod puller attachment
90890-01436

8. After filling the front fork leg, slowly stroke the

damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.

9. Slowly stroke the inner tube 2 up and down

to distribute the fork oil once more (1 stroke =
about 150 mm).
NOTE:
Be careful not to stroke the inner tube over 150
mm as this will cause air to enter. If the inner
tube is stroke more than 150 mm, repeat steps
(10) and (11).

10. Before checking the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.

11. Measure:

front fork leg oil level a
Out of specification
Correct.

Front fork leg oil level (from the

top of the inner tube and damper
rod, with the inner tube fully
compressed, and without the
spring)
140 mm

4-51
 FRONT FORK CHAS
12. Install:

spring 1

spring seats 2

spacer 3

nut 4

damper adjusting rod 5

cap bolt 6

a. Install the fork spring, spring seats, and

spacer.
NOTE:
Install the fork spring with the larger pitch a fac-
ing up.

b smaller pitch
b. Install the rod puller and the rod puller attach-
ment onto the damper rod.
c. Pull up the rod puller and install the rod hold-
er 1 between the rod puller attachment 2
and the spacer.
NOTE:
Use the side of the rod holder that is marked “B”.

Piston rod holder

90890-01434

d. Remove the rod puller and the rod puller at-

tachment.
e. Install the damper adjusting rod locknut.
f. Tighten the damper adjusting rod locknut.

Damper adjusting rod locknut

25 Nm (2.5 m
kg)

g. Install the damper adjusting rod and cap bolt,

and finger tighten it.
h. Remove the rod holder.
CAUTION:
The spring is compressed.

4-52
 FRONT FORK CHAS
EAS00662

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Install:

front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar holder.

2. Tighten:

lower bracket pinch bolt 1
23 Nm (2.3 m
kg)

cap bolt 2 25 Nm (2.5 m
kg)

upper bracket pinch bolt 3
30 Nm (3.0 m
kg)

WARNING
Make sure that the brake hoses are routed
properly.

3. Adjust:

spring preload

rebound damping

compression damping
Refer to “ADJUSTING THE FRONT FORK”
in chapter 3.

4-53
 HANDLEBAR CHAS
EAS00664

HANDLEBAR

23 Nm (2.3 m
kg)

26 Nm (2.6 m
kg)
10 Nm (1.0 m
kg)

26 Nm (2.6 m
kg)

Order Job/Part Q’ty Remarks

Removing the handlebar Remove the parts in the order listed.
1 Front brake master cylinder 1
2 Right handlebar switch 1
3 Throotle cable 1
4 Grip end (right) 1
5 Throttle grip 1
6 Grip end (left) 1
7 Left grip 1
8 Left handlebar switch 1
9 Starter cable 1
10 Clutch cable 1
11 Clutch lever 1
12 Handlebar holder 2
13 Handlebar 1
For installation, reverse the removal
procedure.

4-54
 HANDLEBAR CHAS
EAS00666

REMOVING THE HANDLEBAR

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Remove:

throttle cable housing 1

throttle grip 2

3. Remove:

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

EAS00668

CHECKING THE HANDLEBAR

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Check:

handlebar
Bends/cracks/damage
Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

4-55
 HANDLEBAR CHAS
3.Install:

handlebar grip

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

EAS00672

INSTALLING THE HANDLEBAR

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Install:

handlebar 1

upper handlebar holders 2
23 Nm (2.3 m
kg)

CAUTION:

First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.

Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.

NOTE:
Align the match marks a in the handlebar with
the upper surface of the lower handlebar hold-
ers.

3. Install:

throttle grip 1

throttle cables
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.

4-56
 HANDLEBAR CHAS
5. Install:

left handlebar switch
NOTE:
Align the pins a on the right handlebar switch
with the holes b in the handlebar.

6. Install:

clutch lever holder
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the left handlebar.

7. Install:

brake master cylinder
Refer to “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYL-
INDER”.
8. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the

flange of the throttle grip)
3
5 mm

4-57
 STEERING HEAD CHAS
EAS00676

STEERING HEAD

110 Nm (11.0 m
kg)

1st 52 Nm (5.2 m
kg)

2nd 18 Nm (1.8 m
kg)

Order Job/Part Q’ty Remarks

Removing the steering head Remove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL”
Front fork Refer to “FRONT FORK”
Handlebar Refer to “HANDLEBAR”
1 Front brake hose bracket 1
2 Horn/bracket 1/1
3 Brake hose joint 1
4 Upper bracket cap nut 1
5 Upper bracket 1
6 Lock washer 1
7 Upper ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Dust cover 1
11 Steering bearing (upper) 1
12 Lower bracket 1
13 Steering bearing (lower) 1
For installation, reverse the removal
procedure.

4-58
 STEERING HEAD CHAS
EAS00677

REMOVING THE LOWER BRACKET

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

2. Remove:

lower ring nut 1
(with the special tool 2 )

Ring nut wrench

90890-01403

WARNING
Securely support the lower bracket so that
there is no danger of it falling.

EAS00681

CHECKING THE STEERING HEAD

1. Wash:

bearings

bearing races

Recommended cleaning solvent

Kerosine

2. Check:

bearings 1

bearing races 2
Damage/pitting
Replace.

3. Replace:

bearings

bearing races

a. Remove the bearing races 1 from the steer-

ing head pipe with a long rod 2 and hammer.

4-59
 STEERING HEAD CHAS
b. Remove the bearing race 3 from the lower
bracket with a floor chisel 4 and hammer.
c. Install a new rubber seal and new bearing
races.

CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.

NOTE:

Always replace the bearings and bearing
races as a set.

Whenever the steering head is disassembled,
replace the rubber seal.

4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends/cracks/damage
Replace.
EAS00683

INSTALLING THE STEERING HEAD

1. Lubricate:

upper bearing

lower bearing

bearing races

Recommended lubricant
Lithium soap base grease

2. Install:

lower ring nut 1

rubber washer 2

upper ring nut 3

lock washer 4
Refer to “INSPECTING THE STEERING
HEAD” in chapter 3.
3. Install:

upper bracket

steering stem nut
NOTE:
Temporarily tighten the steering stem nut.

4. Install:

front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.

4-60
 REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00685

REAR SHOCK ABSORBER ASSEMBLY

40 Nm (4.0 m
kg)

40 Nm (4.0 m
kg)

48 Nm (4.8 m
kg)

48 Nm (4.8 m
kg)

40 Nm (4.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the rear shock absorber Remove the parts in the order listed.
assembly
Rear wheel Refer to “REAR WHEEL”
1 Side cover (left/right) 1/1
2 Connecting arm 1
3 Relay arm 1
4 Rear shock absorber 1
For installation, reverse the removal
procedure.

4-61
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00687

HANDLING THE REAR SHOCK ABSORBER

AND GAS CYLINDER
WARNING
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
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt to open the rear
shock absorber or gas cylinder.

Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.

Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORB-

ER AND GAS CYLINDER

a. Gas pressure must be released before dis-

posing of a rear shock absorber and gas cyl-
inder. To release the gas pressure, drill a 2

3 mm hole through the gas cylinder at a point
15
20 mm from its end as shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.

4-62
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00694

REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Remove:

connecting arm bolt 1

relay arm bolt 2

rear shock absorber assembly lower bolt 3
NOTE:
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.

3. Remove:

rear shock absorber assembly upper bolt 1

rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.

4-63
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00696

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:

rear shock absorber rod
Bends/damage
Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks/oil leaks
Replace the rear
shock absorber assembly.

spring
Damage/wear
Replace the rear shock ab-
sorber assembly.

bushings
Damage/wear
Replace.

dust seals
Damage/wear
Replace.

bolts
Bends/damage/wear
Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORB-

ER ASSEMBLY
1. Lubricate:

spacers

bearings

Recommended lubricant
Molybdenum disulfide grease

2. Install:

rear shock absorber assembly

Rear shock absorber assembly

upper nut
40 Nm (4.0 m
kg)
Rear shock absorber assembly
lower nut
40 Nm (4.0 m
kg)
Relay-arm-to-frame-nut
40 Nm (4.0 m
kg)

NOTE:

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.

4-64
 SWINGARM AND DRIVE CHAIN CHAS
EAS00700

SWINGARM AND DRIVE CHAIN

125 Nm (12.5 m
kg)

85 Nm (8.5 m
kg)

23 Nm (2.3 m
kg)

Order Job/Part Q’ty Remarks

Removing the swing arm and drive Remove the parts in the order listed.
chain
Rear wheel Refer to “REAR WHEEL”
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER
ASSEMBLY”
1 Rear brake caliper 1
2 Brake hose holder 2
3 Side protector (left/right) 1/1 NOTE:
Remove the side protector assembly.
Do not remove the center cap.

4 Pivot shaft 1
5 Swing arm 1
6 Drive chain case 1
7 Drive chain guard 1
8 Dust cover 2
9 Oil seal 2

4-65
 SWINGARM AND DRIVE CHAIN CHAS

125 Nm (12.5 m
kg)

85 Nm (8.5 m
kg)

23 Nm (2.3 m
kg)

Order Job/Part Q’ty Remarks

10 Bearing 2
11 Spacer 1
12 Shoft pedal assembly 1
13 Drive sprocket cover 1
14 Drive chain guide 1
15 Drive sprocket 1
16 Drive chain 1
For installation, reverse the removal
procedure.

4-66
SWINGARM AND DRIVE CHAIN CHAS
EAS00703

REMOVING THE SWINGARM

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Remove:

connecting arm bolt 1

relay arm bolt 2

rear shock absorber assembly lower bolt 3
NOTE:
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.

3. Check:

swingarm side play A

swingarm vertical movement B

a. Check the tightening torque of the pivot shaft

nut.

Pivot shaft nut

125 Nm (12.5 m
kg)

b. Check the swingarm side play A by moving

the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.

Swingarm side play (at the end

of the swingarm)
1.0 mm

d. Check the swingarm vertical movement B

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.

4-67
SWINGARM AND DRIVE CHAIN CHAS
EAS00704

REMOVING THE DRIVE CHAIN

1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

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

2. Remove:

foot rest (left)

drive sprocket cover

drive chain guide 1

drive sprocket 2

EAS00707

CHECKING THE SWINGARM

1. Check:

swingarm
Bends/cracks/damage
Replace.

2. Check:

pivot shaft
Roll the pivot shaft on a flat surface.
Bends
Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.

3. Wash:

pivot shaft

dust covers

spacer

washers

bearings

Recommended cleaning solvent

Kerosine

4-68
SWINGARM AND DRIVE CHAIN CHAS
4. Check:

dust covers 1

spacer 2

oil seals 3
Damage/wear
Replace.

bearings 4
Damage/pitting
Replace.

5. Check:

connecting arms 1

relay arm 2
Damage/wear
Replace.

bearings 3

oil seals 4
Damage/pitting
Replace.

spacers 5
Damage/scratches
Replace.

EAS00709

CHECKING THE DRIVE CHAIN

1. Measure:

ten-link section a of the drive chain
Out of specification
Replace the drive
chain.

Ten-link drive chain section limit

(maximum)
150.1 mm

NOTE:

While measuring the ten-link section, push
down on the drive chain to increase its tension.

Measure the length between drive chain roller
1 and 11 as shown.

Perform this measurement at two or three dif-
ferent places.

2. Check:

drive chain
Stiffness
Clean and lubricate or replace.

4-69
SWINGARM AND DRIVE CHAIN CHAS
3. Clean:

drive chain

a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosine and remove
any remaining dirt.
c. Remove the drive chain from the kerosine
and completely dry it.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosine to
clean the drive chain.

4. Check:

O-rings 1
Damage
Replace the drive chain.

drive chain rollers 2
Damage/wear
Replace the drive chain.

drive chain side plates 3
Damage/wear
Replace the drive chain.
Cracks
Replace the drive chain and make
sure that the battery breather hose is proper-
ly routed away from the drive chain and be-
low the swingarm.
5. Lubricate:

drive chain

Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains

6. Check:

drive sprocket

rear wheel sprocket
More than 1/4 tooth a wear
Replace the
drive chain sprockets as a set.
Bent teeth
Replace the drive chain sprock-
ets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket

4-70
SWINGARM AND DRIVE CHAIN CHAS
EAS00713

INSTALLING THE DRIVE CHAIN

1. Lubricate:

drive chain

Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains

2. Install:

drive chain 1

drive sprocket 2

washer 3 New

drive sprocket nut 4 85 Nm (8.5 m
kg)

drive chain guide 5
NOTE:
While applying the rear brake, tighten the drive
sprocket nut.

3. Bend the lock washer tab a along a flat side

of the nut.
EAS00711

INSTALLING THE SWINGARM

1. Lubricate:

bearings

spacers

dust covers

pivot shaft

Recommended lubricant
Molybdenum disulfide grease

2. Install:

relay arm 48 Nm (4.8 m
kg)

left connecting arm

right connecting arm 48 Nm (4.8 m
kg)

4-71
SWINGARM AND DRIVE CHAIN CHAS
NOTE:
Install the connecting arm front bolt 1 from the
right.

3. Install:

rear shock absorber assembly

rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and ”REAR
WHEEL”.
4. Adjust:

drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.

Drive chain slack

40
50 mm

CAUTION:
A drive chain that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swingarm
or cause an accident. Therefore, keep the
drive chain slack within the specified limits.

4-72
 ENG
CHAPTER 5
OVERHAULING THE ENGINE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
DRIVE SPROCKET AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . 5-1
LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 5-11
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . 5-22
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
INSTATLLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

REMOVING THE PLCKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34
 ENG
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
CHECKING THE PULL LEVER AND PULL ROD . . . . . . . . . . . . . . . . 5-43
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

GENERATOR ROTOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
CHECKING THE OIL DELIVERY PIPE . . . . . . . . . . . . . . . . . . . . . . . . 5-54
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . . 5-62
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . 5-63
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . 5-64
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . . 5-67
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . 5-72
CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . . 5-73
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . . . 5-74
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
 ENG
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 5-84
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
ENG
 ENGINE ENG
EAS00188

OVERHAULING THE ENGINE

ENGINE
DRIVE SPROCKET AND EXHAUST PIPE

10 Nm (1.0 m
kg)

20 Nm (2.0 m
kg)
85 Nm (8.5 m
kg)
20 Nm (2.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the drive sprocket and Remove the parts in the order listed.
exhaust pipe
Carburetor Refer to “CARBURETOR” in chapter 6.
Plug code
Ignition coil
Radiator Refer to “RADIATOR” in chapter 7.
Water hose
Air iduction system Refer to “AIR INDUCTION SYSTEM” in
chapter 6.
1 Side cover (left) 1
2 Stator coil coupler/oil level switch 1/1
3 Shit rod 1
4 Drive sprocket cover 1
5 Drive sprocket 1
6 Water outlet hose 1
7 Exhaust pipe 1
For installation, reverse the removal
procedure.
5-1
 ENGINE ENG
EAS00189

LEADS AND HOSES

Order Job/Part Q’ty Remarks

Removing the leads and hoses Remove the parts in the order listed.
1 Cover 1
2 Clutch cable 1
3 Nuetral switch/speed sensor/pickup 1/1/1 Disconnect.
coil lead
4 Water head pipe 1
5 Coolant outlet hose 1
For installation, reverse the removal pro-
cedure.

5-2
 ENGINE ENG
EAS00191

ENGINE

55 Nm (5.5 m
kg)

55 Nm (5.5 m
kg)

24 Nm (2.4 m
kg)

24 Nm (2.4 m
kg)
33 Nm (3.3 m
kg)

Order Job/Part Q’ty Remarks

Removing the engine Remove the parts in the order listed.
1 Down tube 1
2 Engine mounting bolt (front) 2
3 Engine bracket 1
4 Engine mounting bolt (rear upper) 1
5 Engine mounting bolt (rear lower) 1
6 Engine 1
For installation, reverse the removal
procedure.

5-3
 ENGINE ENG
EAS00192

INSTALLING THE ENGINE

1. Install:

engine mount bolt 1

engine mount bolt 2

engine mount bolt 3

engine bracket 4

engine mount bolt 5

down tube 6
NOTE:
Do not fully tighten the bolts.

2. Tighten the bolts in the following order.

Engine mount bolt 1

55 Nm (5.5 m
kg)
Engine mount bolt 2
55 Nm (5.5 m
kg)
Engine mount bolt 3
33 Nm (3.3 m
kg)
Engine mount bolt 5
55 Nm (5.5 m
kg)
Down tube 6
24 Nm (2.4 m
kg)

3. Install:

shift arm 1 10 Nm (10 m
kg)
NOTE:

Align the punch mark a in the shift shaft with
the slot in the shift arm.

Align the bottom edge of the shift pedal with
the mark on the frame-to-swingarm bracket.

5-4
 CAMSHAFT ENG
EAS00194

CAMSHAFT
CYLINDER HEAD COVERS

13 Nm (1.3 m
kg)

12 Nm (1.2 m
kg)

Order Job/Part Q’ty Remarks

Removing the cylinder head cover Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Radiator assembly and thermostat Refer to “RADIATOR” and
assembly “THERMOSTAT ASSEMBLY” in chapter 7.
1 Spark plug 4
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Timing chain guide (top side) 1
For installation, reverse the removal
procedure.

5-5
 CAMSHAFT ENG
EAS00196

CAMSHAFTS

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the camshafts Remove the parts in the order listed.
Pickup coil rotor cover Refer to “PICKUP COIL”.
1 Float chamber air vent hose holder 1
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Timing chain guide (exhaust side) 1
5 Intake camshaft cap 3 NOTE:
6 Dowel pin 6 During removal, the dowel pins may still
7 Exhaust camshaft cap 3 be connected to the camshaft caps.
8 Dowel pin 6
9 Intake camshaft 1
10 Exhaust camshaft 1

5-6
 CAMSHAFT ENG

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

24 Nm (2.4 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

11 Intake camshaft sprocket 1
12 Exhaust camshaft sprocket 1
13 Pin 1
14 Timing chain guide (intake side) 1
For installation, reverse the removal
procedure.

5-7
 CAMSHAFT ENG
EAS00198

REMOVING THE CAMSHAFTS

1. Remove:

pickup rotor coil cover
2. Align:

“T” mark on the pickup coil rotor a
(with the crankcase mating surface b )

a. Turn the crankshaft clockwise.

b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark a with the
crankcase mating surface b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.

3. Loosen:

camshaft sprocket bolts 1

4. Loosen:

cap bolt 1
5. Remove:

timing chain tensioner 2

gasket

6. Remove:

camshaft sprocket 1
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 2 .

5-8
 CAMSHAFT ENG
7. Remove

timing chain guide (exhaust side) 1

camshaft caps

dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.

8. Remove:

intake camshaft 1

exhaust camshaft 2

EAS00204

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
a 32.4 mm
b 24.85 mm
Exhaust
a 32.85 mm
b 24.85 mm

5-9
 CAMSHAFT ENG
3. Measure:
S camshaft runout
Out of specification
Replace.

Camshaft runout
Less than 0.03 mm

4. Measure:
S camshaft-journal-to-camshaft-cap clear-
ance
Out of specification ³ Measure the camshaft
journal diameter.

Camshaft-journal-to-camshaft-
cap clearance
0.028 X 0.062 mm

a. Install the camshaft into the cylinder head

(without the dowel pins and camshaft caps).
b. Position a strip of PlastigaugeR 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
NOTE:
S Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
S Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the PlastigaugeR.

Camshaft cap bolt

10 Nm (1.0 mSkg)

d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge 1 .

5. Measure:
S camshaft journal diameter a
Out of specification
Replace the cam-
shaft.
Within specification
Replace the cylinder
head and the camshaft caps as a set.

Camshaft journal diameter

24.459 X 24.472 mm

5-10
 CAMSHAFT ENG
EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:

timing chain 1
Damage/stiffness
Replace the timing
chain and camshaft sprockets as a set.

2. Check:

camshaft sprocket
More than 1/4 tooth a wear
Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket

3. Check:

timing chain guide (exhaust side) 1

timing chain guide (intake side) 2

timing chain guide (top side) 3
Damage/wear
Replace the defective
part(-s).

EAS00210

CHECKING THE TIMING CHAIN TENSIONER

1. Check:

timing chain tensioner
Cracks/damage
Replace.

5-11
 CAMSHAFT ENG
2. Check:

one-way cam operation
Rough movement
Replace the timing
chain tensioner housing.

a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.

b. Remove the screwdriver and slowly release

the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.

3. Check:

cap bolt

copper washer

spring

gasket

timing chain tensioner rod
Damage/wear
Replace the defective
part(-s).

EAS00217

INSTALLING THE CAMSHAFTS

1. Install:

exhaust camshaft 1

intake camshaft 2
NOTE:
Install the camshafts with the punch mark a
facing up.

2. Install:

dowel pins

intake camshaft caps

exhaust camshaft caps
NOTE:
Make sure that the punch marks a on the cam-
shafts are aligned with the arrow marks b on
the camshaft caps.
Out of alignment
Reinstall.

5-12
 CAMSHAFT ENG
3. Install:

camshaft cap bolts 10 Nm (1.0 m
kg)
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, cam-
shaft caps, and camshafts will result.

4. Install:

intake camshaft sprocket

exhaust camshaft sprocket

a. Turn the crankshaft clockwise.

b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark a on the pick-
up coil rotor with the crankcase mating sur-
face b .
c. Place the timing chain onto both camshaft
sprockets and then install the camshaft
sprockets onto the camshafts.
NOTE:
When installing the camshaft sprockets, start
with the exhaust camshaft and be sure to keep
the timing chain as tight as possible on the ex-
haust side.

CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

5-13
 CAMSHAFT ENG
d. Turn both camshafts opposite each other so
that the punch marks c in the camshaft are
aligned with the arrow marks d in the cam-
shaft caps as shown.
e. While holding the camshafts, temporarily
tighten the camshaft sprocket bolts.

5. Install:

timing chain tensioner

a. While lightly pressing the timing chain ten-

sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver 1 .
b. With the timing chain tensioner rod turned all
the way into the timing chain tensioner hous-
ing (with the thin screwdriver still installed),
install the gasket and the timing chain ten-
sioner 2 onto the cylinder block.
WARNING
Always use a new gasket.

c. Tighten the timing chain tensioner bolts 3 to

the specified torque.

Timing chain tensioner bolt

10 Nm (1.0 m
kg)

d. Remove the screwdriver, make sure that the

timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.

Timing chain cap bolt

12 Nm (1.2 m
kg)

6. Turn:

crankshaft
(several turns clockwise)

5-14
 CAMSHAFT ENG
7. Check:

“T” mark a
Make sure that the “T” mark a on the pickup
coil rotor is aligned with the crankcase mat-
ing surface b .

camshaft punch marks c

Make sure that the marks c on the camshaft
are aligned with the arrow marks d in the
comshaft caps.
Out of alignment
Adjust.
Refer to the installation steps above.

8. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
9. Install:

timing mark accessing screw
15 Nm (15 m
kg)

crankshaft end cover

5-15
 CYLINDER HEAD ENG
EAS00221

CYLINDER HEAD

1st 20 Nm (2.0 m
kg)

2nd 50 Nm (5.0 m
kg)
1st 20 Nm (2.0 m
kg)
2nd 50 Nm (5.0 m
kg)

12 Nm (1.2 m
kg)

Order Job/Part Q’ty Remarks

Removing the cylinder head Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Intake and exhaust camshafts Refer to “CAMSHAFTS”.
1 Cylinder head 1
2 Cylinder head gasket 1
3 Dowel pin 2
For installation, reverse the removal
procedure.

5-16
 CYLINDER HEAD ENG
EAS00223

REMOVING THE CYLINDER HEADS

1. Remove:

cylinder head nuts

cylinder head cap nuts

cylinder head bolts
NOTE:

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.

EAS00230

CHECKING THE CYLINDER HEADS

The following procedure applies to all of the cyl-
inder heads.
1. Eliminate:

carbon deposits
(from the combustion chambers with a
rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug threads

valve seats

2. Check:

cylinder head
Damage/scratches
Replace.

cylinder head water jacket
Mineral deposits/rust
Eliminate.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.

Cylinder head warpage

Less than 0.1 mm

a. Place a straightedge 1 and a thickness

gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 X 600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.

5-17
 CYLINDER HEAD ENG
EAS00233

INSTALLING THE CYLINDER HEAD

1. Install:

gasket New 1

dowel pins 2
2. Install:

cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.

3. Tighten:

cylinder head nuts 1 X 10
1st 20 Nm (2.0 m
kg)
2nd 50 Nm (5.0 m
kg)

cylinder head bolt 11 12
NOTE:

First, tighten the nuts 1 X 10 to approximate-
ly 20 Nm (2.0 m
kg) with a torque wrench.

Retighten the nuts to 50 Nm (5.0 m
kg).

NOTE:

Apply engine oil onto the threads of the cylin-
der head nuts.

Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.

4. Install:

exhaust camshaft

intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.

5-18
 VALVES AND VALVE SPRINGS ENG
EAS00236

VALVES AND VALVE SPRINGS

Order Job/Part Q’ty Remarks

Removing the valves and valve Remove the parts in the order listed.
springs
Cylinder head Refer to “CYLINDER HEAD”.
1 Intake valve lifter 12
2 Intake valve pad 12
3 Intake valve cotter 24
4 Intake valve upper spring seat 12
5 Intake valve spring 12
6 Intake valve oil seal 12
7 Intake valve lower spring seat 12
8 Intake valve 12
9 Intake valve guide 12

5-19
 VALVES AND VALVE SPRINGS ENG

Order Job/Part Q’ty Remarks

10 Exhaust valve lifter 8
11 Exhaust valve pad 8
12 Exhaust valve cotter 16
13 Exhaust valve upper spring seat 8
14 Exhaust valve spring 8
15 Exhaust valve oil seal 8
16 Exhaust valve lower spring seat 8
17 Exhaust valve 8
18 Exhaust valve guide 8
For installation, reverse the removal
procedure.

5-20
VALVES AND VALVE SPRINGS ENG
EAS00237

REMOVING THE VALVES

The following procedure applies to all of the
valves and related components.
NOTE:
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 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.

2. Check:

valve sealing
Leakage at the valve seat
Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent a into the intake and

exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat 1 .

3. Remove:

valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .

Valve spring compressor

90890-04019
Valve spring compressor
attachment
Intake valve
90890-04114
Exhaust valve
90890-04108

5-21
VALVES AND VALVE SPRINGS ENG
4. Remove:

upper spring seat 1

valve spring 2

oil seal 3

lower spring seat 4

valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVE

GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:

valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =
Valve guide inside diameter A –
Valve stem diameter B

Out of specification
Replace the valve

guide.

Valve-stem-to-valve-guide
clearance
Intake
0.010 X 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.020 X 0.047 mm
<Limit>: 0.1 mm

5-22
VALVES AND VALVE SPRINGS ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C in an oven.

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.
NOTE:
After replacing the valve guide, reface the valve
seat .

Valve guide remover

Intake (4.0 mm)
90890-04111
Exhaust (4.5 mm)
90890-04116
Valve guide installer
Intake (4.0 mm)
90890-04112
Exhaust (4.5 mm)
90890-04117
Valve guide reamer
Intake
90890-04113
Exhaust
90890-04118

5-23
VALVES AND VALVE SPRINGS ENG
3. Eliminate:

carbon deposits
(from the valve face and valve seat)
4. Check:

valve face
Pitting/wear
Grind the valve face.

valve stem end
Mushroom shape or diameter larger than the
body of the valve stem
Replace the valve.

5. Measure:

valve margin thickness a
Out of specification
Replace the valve.

Valve margin thickness

0.5 X 0.9 mm

6. Measure:

valve stem runout
Out of specification
Replace the valve.
NOTE:

When installing a new valve, always replace
the valve guide.

If the valve is removed or replaced, always re-
place the oil seal.

Valve stem runout

0.01 mm

EAS00240

CHECKING THE VALVE SEATS

The following procedure applies to all of the
valves and valve seats.
1. Eliminate:

carbon deposits
(from the valve face and valve seat)
2. Check:

valve seat
Pitting/wear
Replace the cylinder head.
3. Measure:

valve seat width a
Out of specification
Replace the cylinder
head.

Valve seat width

Intake: 0.9 X 1.1 mm
Exhaust: 0.9 X 1.1 mm

5-24
VALVES AND VALVE SPRINGS ENG

a. Apply Mechanic’s blueing dye (Dykem) 1

onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.

4. Lap:

valve face

valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.

a. Apply a coarse lapping compound a to the

valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.

e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
5-25
VALVES AND VALVE SPRINGS ENG
EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length a
Out of specification
Replace the valve
spring.

Valve spring free length

Intake spring
38.9 mm
Exhaust spring
40.67 mm

2. Measure:

compressed spring force a
Out of specification
Replace the valve
spring.
b Installed length

Compressed spring force

Intake
8.2 X 9.6 kg at 34.5 mm
Exhaust
11.0 X 12.6 kg at 35.0 mm

3. Measure:

valve spring tilt a
Out of specification
Replace the valve
spring.

Spring tilt limit

Intake
1.7 mm
Exhaust
1.8 mm

5-26
VALVES AND VALVE SPRINGS ENG
EAS00242

CHECKING THE VALVE LIFTERS

The following procedure applies to all of the
valve lifters.
1. Check:

valve lifter
Damage/scratches
Replace the valve lift-
ers and cylinder head.

EAS00245

INSTALLING THE VALVES

The following procedure applies to all of the
valves and related components.
1. Deburr:

valve stem end
(with an oil stone)

2. Lubricate:

valve stem 1

oil seal 2
(with the recommended lubricant)

Recommended lubricant
Molybdenum disulfide oil

3. Install:

valve 1

lower spring seat 2

oil seal 3

valve spring 4

upper spring seat 5
(into the cylinder head)
NOTE:
Install the valve spring with the larger pitch a
facing up.

b Smaller pitch
NOTE:
Make sure that each valve is installed in its origi-
nal place. Refer to the following embossed
marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “5LV”

5-27
VALVES AND VALVE SPRINGS ENG
4. Install:

valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .

Valve spring compressor

90890-04019
Attachment
Intake valve
90890-04114
Exhaust valve
90890-04108

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

6. Install:

valve pad 1

valve lifter 2
NOTE:

Apply molybdenum disulfide oil onto the valve
lifter and valve pad.

The valve lifter must move smoothly when ro-
tated with a finger.

Each valve lifter and valve pad must be rein-
stalled in its original position.

5-28
 GENERATOR ENG
EB410000

GENERATOR

14 Nm (1.4 mSkg)

65 Nm (6.5 mSlkg) + 60_

12 Nm (1.2 mSkg)

Order Job/Part Q’ty Remarks

Removing the stator coil assembly Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Bottom cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
1 Generator rotor cover 1
2 Generator rotor cover gasket 1
3 Dowel pin 2
4 Generator rotor bolt 1
5 Generator rotor 1
6 Stator coil assembly coupler 1 Disconnect.
7 Stator coil assembly lead holder 1
8 Stator coil assembly 1
For installation, reverse the removal
procedure.

5-29
 GENERATOR ENG
REMOVING THE GENERATOR
1. Remove:

generator rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.

2. Remove:

generator rotor bolt 1

washer
NOTE:
While holding the generator rotor 2 with the rotor
holding tool 3 , loosen the generator rotor bolt.

Rotor holding tool

90890-01235

3. Remove:

generator rotor 1
(with the flywheel puller 2 and rotor holding
tool 3 )

Flywheel puller
90890-01080

INSTALLING THE GENERATOR

1. Apply:

sealant
(onto the stator coil assembly lead grommet)

Yamaha bond No. 1215

90890-85505

2. Install:

generator rotor

washer

generator rotor bolt
WARNING
Always use a new generator rotor bolt.

CAUTION:

Clean the tapered portion of the crankshaft
and the generator rotor hub with lacquer
thinner.

Lubricate the generator rotor bolt threads
with engine oil.

5-30
 GENERATOR ENG
3. Tighten:
S generator rotor bolt 1 New
65 Nm (6.5 mSkg) + 60_
NOTE:
S While holding the generator rotor 2 with the
rotor holding tool 3 , tighten the generator ro-
tor bolt.
S After tightening to 65 Nm (6.5 mSkg), tighten
another 60_.

Rotor holding tool

90890-01235

4. Install:
S generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.

5-31
 PICKUP COIL ENG

PICKUP COIL

60 Nm (6.0 m
kg)

12 Nm (1.2 m
kg)

15 Nm (1.5 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the pickup coil and Remove the parts in the order listed.
pickup coil rotor
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Bottom cowling and right side cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Generator rotor cover Refer to “GENERATOR”.
1 Pickup coil lead holder 1
2 Pickup coil rotor cover 1
3 Pickup coil rotor cover gasket 1
4 Dowel pin 2

5-32
 PICKUP COIL ENG

60 Nm (6.0 m
kg)

12 Nm (1.2 m
kg)

15 Nm (1.5 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

5 Pickup coil coupler 1 Disconnect.
6 Pickup coil 1
7 Pickup coil rotor 1
For installation, reverse the removal
procedure.

5-33
 PICKUP COIL ENG
REMOVING THE PICKUP COIL ROTOR
1. Remove:

pickup coil lead holder 1

pickup coil rotor cover 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.

2. Remove:

pickup coil rotor bolt 1

washer

pickup coil rotor 2
NOTE:
While holding the generator rotor 3 with the ro-
tor holding tool 4 , loosen the pickup coil rotor
bolt.

Rotor holding tool

90890-01235

INSTALLING THE PICKUP COIL ROTOR

1. Install:

pickup coil rotor 1

washer

pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor, align the
pin 2 in the crankshaft sprocket with the groove
a in the pickup coil rotor.

5-34
 PICKUP COIL ENG
2. Tighten:

pickup coil rotor bolt 1
60 Nm (6.0 m
kg)
NOTE:
While holding the generator rotor 2 with the ro-
tor holding tool 3 , tighten the pickup coil rotor
bolt.

Rotor holding tool

90890-01235

3. Apply:

sealant
(onto the pickup coil lead grommet)

Yamaha bond No. 1215

90890-85505

4. Install:

pickup coil rotor cover

pickup coil lead holder
NOTE:

When installing the pickup coil rotor cover,
align the timing chain guide (intake side) pin 1
with the hole 2 in the pickup coil rotor cover.

Tighten the pickup coil rotor cover bolts in
stages and in a crisscross pattern.

5-35
 CLUTCH ENG
EAS00273

CLUTCH
CLUTCH COVER

12 Nm (1.2 m
kg)

12 Nm (1.2 m
kg)

Order Job/Part Q’ty Remarks

Removing the clutch cover Remove the parts in the order listed.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
1 Clutch cable 1
2 Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
For installation, reverse the removal
procedure.

5-36
 CLUTCH ENG
EB405010

Order Job/Part Q’ty Remarks

Removing the pull lever shaft Remove the parts in the order listed.
1 Circlip 2
2 Pull lever 1
3 Pull lever spring 1
4 Pull lever shaft 1
5 Oil seal 1
6 Bearing 2
For installation, reverse the removal
procedure.

5-37
 CLUTCH ENG
EAS00274

CLUTCH

12 Nm (1.2 m
kg)

70 Nm (7.0 m
kg)

8 Nm (0.8 m
kg)

Order Job/Part Q’ty Remarks

Removing the clutch Remove the parts in the order listed.
1 Clutch cover 1
2 Pull rod 1
3 Friction plate 1
4 Clutch plate 2 Select.
5 Friction plate 4 Color code: Black
6 Clutch plate 6
7 Friction plate 3 Color code: Blue
8 Friction plate 1 Refer to “INSTALLING THE CLUTCH”.
9 Clutch damper spring 1
10 Clutch damper spring seat 1

5-38
 CLUTCH ENG

12 Nm (1.2 m
kg)

70 Nm (7.0 m
kg)

8 Nm (0.8 m
kg)

Order Job/Part Q’ty Remarks

11 Clutch boss nut 1
12 Lock washer 1
13 Clutch boss 1
14 Thrust washer 1
15 Clutch housing 1
16 Bearing 1
17 Starter clutch gear 1
18 Bearing 1
19 Starter clutch assembly 1
20 Circlip 1
21 Starter clutch idle gear 1
For installation, reverse the removal
procedure.

5-39
 CLUTCH ENG
EAS00277

REMOVING THE CLUTCH

1. Straighten the lock washer tab.
2. Loosen:

clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3 , loosen the clutch boss nut.

Universal clutch holder

90890-04086

3. Remove:

clutch boss nut 1

lock washer 2

clutch boss 3

EAS00280

CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:

friction plate
Damage/wear
Replace the friction plates
as a set.

5-40
 CLUTCH ENG
2. Measure:

friction plate thickness
Out of specification
Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.

Friction plate thickness

Friction plate a
3.42
3.58 mm
<Limit>: 3.32 mm
Friction plate b
2.92
3.08 mm
<Limit>: 2.82 mm

3. Measure:

assembly width a
Out of specification
Adjust.

Assembly width
43.1
43.9 mm

a. Assembly width adjusted by clutch plate 1

and 2 .
b. Select the clutch plate from the following
table.
Clutch plate 1

Part No. Thickness

168-16325-00 1.6 mm
31A-16325-00 2.0 mm STD
168-16324-00 2.3 mm
Clutch plate 2

Part No. Thickness

31A-16325-00 2.0 mm STD
168-16324-00 2.3 mm

NOTE:
When adjusting the clutch assembly width [by
replacing the clutch plate(s)], be sure to replace
the clutch plate 1 first. After replacing the
clutch plate 1 , if specifications cannot be met,
replace the clutch plate 2 .

5-41
 CLUTCH ENG
EAS00281

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the
clutch plates.
1. Check:

clutch plate
Damage
Replace the clutch plates as a
set.

2. Measure:

clutch plate warpage
(with a surface plate and thickness gauge 1 )
Out of specification
Replace the clutch
plates as a set.

Clutch plate warpage limit

Less than 0.1 mm

EAS00282

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the
clutch springs.
1. Check:

clutch spring
Damage
Replace the clutch springs as a
set.

2. Measure:

clutch spring free length
Out of specification
Replace the clutch
springs as a set.

Clutch spring free length

50 mm
<Limit>: 47.5 mm

5-42
 CLUTCH ENG
EAS00284

CHECKING THE CLUTCH HOUSING

1. Check:

clutch housing dogs
Damage/pitting/wear
Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.

2. Check:

bearing
Damage/wear
Replace the clutch hous-
ing.

EAS00285

CHECKING THE CLUTCH BOSS

1. Check:

clutch boss splines
Damage/pitting/wear
Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE

1. Check:

pressure plate 1
Cracks/damage
Replace.

bearing 2
Damage/wear
Replace.

EAS00287

CHECKING THE PULL LEVER AND PULL

ROD
1. Check:

pull lever 1

pull rod 2
Damage/wear
Replace the pull rod and
pull lever pinion gear as a set.

5-43
 CLUTCH ENG
2. Check:

pull rod bearing
Damage/wear
Replace.

EAS00351

CHECKING THE STARTER CLUTCH

1. Check:

starter clutch rollers
Damage/wear
Replace.

2. Check:

starter clutch idle gear

starter clutch drive gear

starter clutch gear
Burrs/chips/roughness/wear
Replace
the defective part(-s).

3. Check:

starter clutch gear’s contacting surfaces
Damage/pitting/wear
Replace the starter
clutch gear.

5-44
 CLUTCH ENG
4. Check:

starter clutch operation

a. Install the starter clutch drive gear 1 onto

the starter clutch 2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the start-
er clutch drive gear should engage.
If the starter clutch drive gear and starter
clutch do not engage, the starter clutch is
faulty and must be replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely.
If the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.

EAS00299

INSTALLING THE CLUTCH

1. Install:

clutch housing
NOTE:

Make sure that the slots a in the clutch hous-
ing align with the tabs b on the oil/water pump
assembly drive sprocket.

Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.

Make sure that the starter clutch gear teeth and
starter clutch idle gear teeth mesh correctly.

2. Install:

lock washer New

clutch boss nut 1 90 Nm (9.0 m
kg)
NOTE:
While holding the clutch boss 2 with the univer-
sal clutch holder 3 , tighten the clutch boss nut.

Universal clutch holder

90890-04086

5-45
 CLUTCH ENG
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)

Recommended lubricant
Engine oil

5. Install:

friction plates

clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.

a. Install the clutch damper spring seat 1 ,

clutch damper spring 2 and friction plate
(smaller size) 3 .
b. Install the clutch plate and friction plate at fol-
lowing the illustrated.
Friction plate 4 : Color code/Blue
Friction plate 5 : Color code/Black
Clutch plate 6 : 20 mm
Clutch plate 7 : Select. Refer to “CHECKING
THE FRICTION PLATE”

6. Measure:

assembly width a
Out of specification
Adjust.
Refer to “CHECKING THE FRICTION
PLATE”.

Assembly width
43.1
43.9 mm

5-46
 CLUTCH ENG
7. Install:

pressure plate 1
NOTE:
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.

8. Install:

clutch springs

clutch spring bolts 8 Nm (0.8 m
kg)
NOTE:
Tighten the clutch spring bolts in stages and in a
crisscross pattern.

9. Install:

pull lever
NOTE:
Align the punch mark a in the pull lever shaft
with the mark b on the clutch cover.

10. Install:

dowel pins

gasket New

clutch cover 12 Nm (1.2 m
kg)
NOTE:

When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod groove c
and pull lever shaft groove d are engaged.

Tighten the clutch cover bolts in stages and in
a crisscross pattern.

5-47
 SHIFT SHAFT ENG
EAS00326

SHIFT SHAFT
GENERATOR ROTOR COVER

12 Nm (1.2 m
kg)

Order Job/Part Q’ty Remarks

Removing the shift shaft and stopper Remove the parts in the order listed.
lever
Drive sprocket cover Refer to “ENGINE”.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3 Dowel pin 2
4 Shift shaft 1
5 Shift shaft spring 1
6 Spacer 1
7 Stopper lever spring 1
8 Stopper lever 1
9 Collar 1
10 Shift shaft spring stopper 1
For installation, reverse the removal
procedure.

5-48
 SHIFT SHAFT ENG
EAS00328

CHECKING THE SHIFT SHAFT

1. Check:

shift shaft 1
Bends/damage/wear
Replace.

shift shaft spring 3
Damage/wear
Replace.

EAS00330

CHECKING THE STOPPER LEVER

1. Check:

stopper lever 1
Bends/damage
Replace.
Roller turns roughly
Replace the stopper
lever.

EAS00331

INSTALLING THE SHIFT SHAFT

1. Install:

shift shaft spring stopper 1
22 Nm (2.2 m
kg)

stopper lever spring 2

stopper lever 3
NOTE:

Apply LOCTITE to the threads of the shift
shaft spring stopper.

Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss.

Mesh the stopper lever with the shift drum seg-
ment assembly.

2. Install:

shift shaft 1

spacer
NOTE:

Lubricate the oil seal lips with lithium soap
base grease.

Install the end of the shift shaft spring onto the
shift shaft spring stopper 2 .

5-49
 OIL PAN AND OIL PUMP ENG
EAS00356

OIL PAN AND OIL PUMP

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)
10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

43 Nm (4.3 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the oil pan and oil pump Remove the parts in the order listed.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Radiator assembly and water pump Refer to “RADIATOR” and “OIL COOLER”
outlet pipe in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch connector 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2

5-50
 OIL PAN AND OIL PUMP ENG
EB411001

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)
10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

43 Nm (4.3 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

7 Drain pipe 1
8 Oil strainer 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Oil/water pump assembly drive 1
sprocket cover
12 Dowel pin 1
13 Oil/water pump assembly 1
14 Relief valve assembly 1
For installation, reverse the removal pro-
cedure.

5-51
 OIL PAN AND OIL PUMP ENG
EAS00360

10 Nm (1.0 m
kg)

15 Nm (1.5 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the oil pump Disassemble the parts in the order listed.
1 Oil/water pump assembly driven 1
sprocket
2 Washer 1
3 Oil pump housing 1
4 Bearing 1
5 Pin 2
6 Oil pump outer rotor 1
7 Oil pump inner rotor 1
8 Pin 1
For assembly, reverse the disassembly
procedure.

5-52
OIL PAN AND OIL PUMP ENG
EAS00362

REMOVING THE OIL PAN

1. Remove:

oil level switch 1

oil pan 2

engine oil drain bolt 3

gasket

dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

EAS00364

CHECKING THE OIL PUMP

1. Check:

oil pump drive gear 1

oil pump driven gear 2

oil pump housing

oil pump housing cover
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-housing-to-inner-rotor-and-outer-
rotor clearance c
Out of specification
Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing

Inner-rotor-to-outer-rotor-tip
clearance
0.09
0.15 mm
<Limit>: 0.23 mm
Outer-rotor-to-oil-pump-housing
clearance
0.03
0.08 mm
<Limit>: 0.15 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06
0.11 mm
<Limit>: 0.18 mm

3. Check:

oil pump operation
Unsmooth
Repeat steps (1) and (2) or re-
place the defective part(-s).

5-53
OIL PAN AND OIL PUMP ENG
EAS00365

CHECKING THE RELIEF VALVE

1. Check:

relief valve body 1

relief valve 2

spring 3

O-ring 4
Damage/wear
Replace the defective
part(-s).

EAS00366

CHECKING THE OIL DELIVERY PIPE

1. Check:

oil delivery pipe 1

oil pipe 2
Damage
Replace.
Obstruction
Wash and blow out with com-
pressed air.

EAS00368

CHECKING THE OIL STRAINER

1. Check:

oil strainer 1
Damage
Replace.
Contaminants
Clean with engine oil.

EAS00374

ASSEMBLING THE OIL PUMP

1. Lubricate:

inner rotor

outer rotor

oil pump shaft
(with the recommended lubricant)

Recommended lubricant
Engine oil

5-54
OIL PAN AND OIL PUMP ENG
2. Install:

pin 1

inner rotor 2

outer rotor 3

oil pump housing 4

Oil pump housing screw

10 Nm (1.0 m
kg)

NOTE:
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove a on the in-
ner rotor 2 .

3. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP

1. Install:

oil pump 12 Nm (1.2 m
kg)
NOTE:
Install the oil/water pump drive chain 1 onto
the oil/water pump driven sprocket 2 .

EAS00378

INSTALLING THE OIL STRAINER

1. Install:

oil strainer housing 1 10 Nm (1.0 m
kg)
LOCTITE

NOTE:
The arrow a on the oil strainer housing must
point towards the front of the engine.

5-55
OIL PAN AND OIL PUMP ENG
EAS00380

INSTALLING THE OIL PAN

1. Install:

dowel pins

gasket New

oil pan 1 10 Nm (10 m
kg)

oil level switch 2 10 Nm (10 m
kg)

engine oil drain bolt 3
43 Nm (4.3 m
kg)

WARNING
Always use new copper washers.

NOTE:

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch’s O-ring with en-
gine oil.

5-56
 CRANKCASE ENG
EAS00381

CRANKCASE
CRANKCASE

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the crankcase Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Cylinder head Refer to “CYLINDER HEAD”.
Pickup coil and pickup coil rotor Refer to “PICKUP COIL”.
Stator coil assembly Refer to “GENERATOR”.
Clutch housing and starter clutch idle Refer to “CLUTCH”.
gear
Oil/water pump assembly Refer to “OIL PAN AND OIL PUMP”.
1 Timing chain 1
2 Crankshaft sprocket 1
3 Pin 1
4 Oil/water pump assembly drive chain 1
guide
5 Oil/water pump assembly drive chain 1

5-57
 CRANKCASE ENG

10 Nm (1.0 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

6 Oil/water pump assembly drive 1
sprocket
7 Washer 1
8 Plate 1
9 Lower crankcase 1
10 Dowel pin 3
For installation, reverse the removal
procedure.

5-58
 CRANKCASE ENG
EAS00382

CONNECTING RODS AND PISTONS

36 Nm (3.6 m
kg)

Order Job/Part Q’ty Remarks

Removing the connecting rods and Remove the parts in the order listed.
pistons
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Piston pin clip 8
4 Piston pin 4
5 Piston 4
6 Connecting rod 4
7 Big end upper bearing 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
For installation, reverse the removal
procedure.

5-59
 CRANKCASE ENG

CRANKSHAFT

Order Job/Part Q’ty Remarks

Removing the crankshaft assembly Remove the parts in the order listed.
Crankcase Separate.
Refer to “CRANKCASE”.
Connecting rod caps Refer to “CONNECTING RODS AND
PISTONS”.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
For installation, reverse the removal
procedure.

5-60
 CRANKCASE ENG
EAS00384

DISASSEMBLING THE CRANKCASE

1. Place the engine upside down.
2. Remove:

crankcase bolts
NOTE:

Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.

3. Remove:

lower crankcase
CAUTION:
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.

M9 125 mm bolts: 1 X 10
M8 125 mm bolts: 21 X 22
M6 100 mm bolts: 11 X 20 , 23 X 28
4. Remove:

dowel pins

O-ring
5. Remove:

crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.

5-61
 CRANKCASE ENG
EAS00393

REMOVING THE CONNECTING RODS AND

PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap 1

big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.

2. Remove:

piston pin clips 1

piston pin 2

piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.

NOTE:

For reference during installation, put identifica-
tion marks on the piston crown.

Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 1 .

Piston pin puller

90890-01304

5-62
 CRANKCASE ENG
3. Remove:

top ring

2nd ring

oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

EAS00387

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:

crankshaft assembly 1

crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.

5-63
 CRANKCASE ENG
EAS00256

CHECKING THE CYLINDERS AND PISTONS

The following procedure applies to all of the cyl-
inders and pistons.
1. Check:

piston wall

cylinder wall
Vertical scratches
Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:

piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinder

bore gauge.
NOTE:
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 “C” 74.00
74.01 mm

Wear limit 74.06 mm
Taper limit “T” 0.05 mm
Out of round “R” 0.05 mm

“C” = maximum of D1
D6
“T” = maximum of D1 or D2 – maximum of
D5 or D6
“R” = maximum of D1 D3 or D5 – minimum of
D2 D4 or D6

b. If out of specification, replace the cylinder,

and the piston and piston rings as a set.

5-64
 CRANKCASE ENG
c. Measure piston skirt diameter “P” with the
micrometer.
a 0.5 mm from the bottom edge of the piston.

Piston size “P”

73.955
73.970 mm

d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.

Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”

Piston-to-cylinder clearance
0.030
0.055 mm
<Limit>: 0.12 mm

f. If out of specification, replace the cylinder,

and the piston and piston rings as a set.

EAS00263

CHECKING THE PISTON RINGS

1. Measure:

piston ring side clearance
Out of specification
Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.

Piston ring side clearance

Top ring
0.030
0.065 mm
2nd ring
0.020
0.055 mm

5-65
 CRANKCASE ENG
2. Install:

piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the pis-
ton crown as shown.

a 5 mm
3. Measure:

piston ring end gap
Out of specification
Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.

Piston ring end gap

Top ring
0.32
0.44 mm
2nd ring
0.43
0.58 mm
Oil ring
0.10
0.35 mm

EAS00266

CHECKING THE PISTON PINS

The following procedure applies to all of the pis-
ton pins.
1. Check:

piston pin
Blue discoloration/grooves
Replace the
piston pin and then check the lubrication sys-
tem.

2. Measure:

piston pin outside diameter
Out of specification
Replace the piston
pin.

Piston pin outside diameter

16.991
17.000 mm

5-66
 CRANKCASE ENG
3. Measure:

piston pin bore inside diameter
Out of specification → Replace the piston.

Piston pin bore inside diameter

17.002
17.013 mm

4. Calculate:

piston-pin-to-piston clearance
Out of specification
Replace the piston pin
and piston as a set.

Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002
0.022 mm
<Limit>: 0.072 mm

EAS00395

CHECKING THE CRANKSHAFT AND CON-

NECTING RODS
1. Measure:

crankshaft runout
Out of specification
Replace the crank-
shaft.

Crankshaft runout
Less than 0.03 mm

2. Check:

crankshaft journal surfaces

crankshaft pin surfaces

bearing surfaces
Scratches/wear
Replace the crankshaft.
3. Measure:

crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification
Replace the crank-
shaft journal bearings.

Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.029
0.053 mm

5-67
 CRANKCASE ENG

CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.

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.
NOTE:
Align the projections a of the crankshaft journal
upper bearings with the notches b in the crank-
case.

d. Put a piece of Plastigauge 2 on each

crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole in
the crankshaft journal.

e. Install the crankshaft journal lower bearings

1 into the lower crankcase and assemble
the crankcase halves.
NOTE:

Align the projections a of the crankshaft jour-
nal lower bearings with the notches b in the
crankcase.

Do not move the crankshaft until the clearance
measurement has been completed.

5-68
 CRANKCASE ENG
f. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase.

Crankcase bolt
Bolt 1
10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45
50_
Bolt 11
15 , 17
20 , 23 ,
25
28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21
22
24 Nm (24 mSkg)

NOTE:
Lubricate the crankcase bolt threads with en-
gine oil.

g. Remove the lower crankcase and the crank-

shaft journal lower bearings.
h. Measure the compressed Plastigauge
width c on each crankshaft journal.
If the clearance is out of specification, select
replacement crankshaft journal bearings.

4. Select:
S crankshaft journal bearings (J1
J5)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 stamped into the low-
er crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
S “J1
J5” refer to the bearings shown in the
crankshaft illustration.
S If “J1
J5” are the same, use the same size
for all of the bearings.

For example, if the crankcase “J1” and crank-

shaft web “J1” numbers are “6” and “2” respec-
tively, then the bearing size for “J1” is:

Bearing size for J1:

J1 (crankcase) – J1 (crankshaft web) –2 =
6 – 2 – 2 = 2 (Pink/black)

5-69
 CRANKCASE ENG

CRANKSHAFT JOURNAL BEARING

COLOR CODE
–1 Pink/violet
0 Pink/white
1 Pink/blue
2 Pink/black
3 Pink/brown
5. Measure:

crankshaft-pin-to-big-end-bearing clear-
ance
Out of specification
Replace the big end
bearings.

Crankshaft-pin-to-big-end-bearing
clearance
0.031
0.055 mm

The following procedure applies to all of the

connecting rods.
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.

a. Clean the big end bearings, crankshaft pins,

and bearing portions of the connecting rods.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.

NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.

5-70
 CRANKCASE ENG
c. Put a piece of Plastigauge 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.
NOTE:

Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.

Apply molybdenum disulfide grease onto the
bolts, threads, and nut seats.

Make sure that the “Y” mark c on the connect-

ing rod faces towards the left side of the crank-
shaft.

Make sure that the characters d on both the
connecting rod and connecting rod cap are
aligned.

e. Tighten the connecting rod nuts.

CAUTION:

When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.

Without pausing, tighten the connecting
rod nuts to the specified torque. Apply con-
tinuous torque between 2.0 and 3.6 m
kg.
Once you reach 2.0 m
kg, DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted be-
tween 2.0 and 3.6 m
kg, loosen the con-
necting rod nut to less than 2.0 m
kg and
start again.

Refer to “INSTALLING 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 on the crankshaft pin.
If the clearance is out of specification, select
replacement big end bearings.

5-71
 CRANKCASE ENG
6. Select:

big end bearings (P1
P4)
NOTE:

The numbers A stamped into the crankshaft
web and the numbers 1 on the connecting
rods are used to determine the replacement
big end bearing sizes.

“P1”
“P5” refer to the bearings shown in the
crankshaft illustration.

For example, if the connecting rod “P1” and the

crankshaft web “P1” numbers are “4” and “1” re-
spectively, then the bearing size for “P1” is:

Bearing size for “P1”:

“P1” (connecting rod) – “P1”
(crankshaft) –2 =
4 – 1 – 2 = 1 (Blue)

BIG END BEARING COLOR CODE

–1 Violet
0 White
1 Blue
2 Black

EAS00399

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks/damage
Replace.

oil delivery passages
Obstruction
Blow out with compressed air.
EAS00401

CHECKING THE BEARINGS AND OIL

SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement
Replace.
2. Check:

oil seals
Damage/wear
Replace.
5-72
 CRANKCASE ENG
CHECKING THE SPROCKETS AND CHAINS
1. Check:

crankshaft sprocket 1

oil/water pump assembly drive sprocket 2
Cracks/damage/wear
Replace the de-
fective part(-s).

2. Check:

timing chain 1
Damage/stiffness
Replace the timing
chain and crankshaft sprocket as a set.

oil/water pump assembly drive chain 2
Damage/stiffness
Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.

EAS00407

INSTALLING THE CRANKSHAFT

1. Install:

crankshaft journal upper bearings 1
(into the upper crankcase)
NOTE:

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:

crankshaft

5-73
 CRANKCASE ENG
EAS00268

INSTALLING THE CONNECTING ROD AND

PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring 1

2nd ring 2

upper oil ring rail 3

oil ring expander 4

lower oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers a face up.

2. Install:

piston 1
(onto the respective connecting rod 2 )

piston pin 3

piston pin clip New 4
NOTE:

Apply engine oil onto the piston pin.

Make sure that the “Y” mark a on the connect-
ing rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustra-
tion.

Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).

3. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)

Recommended lubricant
Engine oil

4. Offset:

piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
e Oil ring expander

5-74
 CRANKCASE ENG
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)

Recommended lubricant
Engine oil

6. Install:

big end bearings

connecting rod assembly
(into the cylinder and onto the crankshaft
pin).

connecting rod cap
(onto the connecting rod)
NOTE:

Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.

Be sure to reinstall each big end bearing in its
original place.

While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.

Make sure that the “Y” marks a on the con-
necting rods face towards the left side of the
crankshaft.

Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.

7. Align:

bolt heads
(with the connecting rod caps)
8. Tighten:

connecting rod nuts
36 Nm (3.6 m
kg)

CAUTION:

When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.

Without pausing, tighten the connecting
rod nuts to the specified torque. Apply con-
tinuous torque between 2.0 and 3.6 m
kg.
Once you reach 2.0 m
kg DO NOT STOP
TIGHTENING until the specified torque is
reached. If the tightening is interrupted be-
tween 2.0 and 3.6 m
kg, loosen the con-
necting rod nut to less than 2.0 m
kg and
start again.

5-75
 CRANKCASE ENG
EAS00414

ASSEMBLING THE CRANKCASE

1. Lubricate:

crankshaft journal bearings
(with the recommended lubricant)

Recommended lubricant
Engine oil

2. Apply:

sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505

NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2
3 mm of
the crankshaft journal bearings.

3. Install:

dowel pin

4. Install:

crankshaft journal lower bearings 1
(into the lower crankcase)
NOTE:

Align the projections a on the crankshaft jour-
nal lower bearings with the notches b in the
crankcase.

Install each crankshaft journal lower bearing in
its original place.

5. Set the shift drum assembly and transmis-

sion gears in the neutral position.

5-76
 CRANKCASE ENG
6. Install:
S upper crankcase 1
(onto the lower crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.

7. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Tighten the bolts in increasing numerical order.
S Install washers on bolts 1 X 10 .

M9 125 mm bolts: 1 X 10
M8 125 mm bolts: 21 X 22
M6 100 mm bolts: 11 X 20 , 23 X 28

Crankcase bolt
Bolt 1 X 10
1st: 15 Nm (1.5 mSkg)
2nd: 15 Nm (1.5 mSkg) +
45 X 50_
Bolt 11 X 15 , 17 X 20 , 23 ,
25 X 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 X 22
24 Nm (24 mSkg)

5-77
 TRANSMISSION ENG
EAS00419

TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

12 Nm (1.2 m
kg)

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Removing the transmission, shift Remove the parts in the order listed.
drum assembly, and shift forks
Crankcase Separate.
Refer to “CRANKCASE”.
Stopper lever Refer to “SHIFT SHAFT”.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 1
6 Shift fork guide bar 2
7 Spring 4
8 Shift fork “L” 1
9 Shift fork “R” 1
For installation, reverse the removal
procedure.

5-78
 TRANSMISSION ENG

Order Job/Part Q’ty Remarks

Disassembling the main axle Disassembly the parts in the order listed.
assembly
1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Toothed spacer 1
6 Toothed washer 2
7 Circlip 2
8 3rd/4th pinion gears 1
9 5th pinion gear 1
10 Collar 1

5-79
 TRANSMISSION ENG

Order Job/Part Q’ty Remarks

11 Main axle/1st pinion gear 1
12 Bearing 1
13 Main axle bearing housing 1
For assembly, reverse the disassembly
procedure.

5-80
 TRANSMISSION ENG

Order Job/Part Q’ty Remarks

Disassembling the drive axle Disassembly the parts in the order listed.
assembly
1 Washer 1
2 1st wheel gear 1
3 Spacer 1
4 5th wheel gear 1
5 Circlip 3
6 Washer 3
7 3rd wheel gear 1
8 Toothed spacer 2
9 Toothed lock washer 1
10 Toothed lock washer retainer 1

5-81
 TRANSMISSION ENG

Order Job/Part Q’ty Remarks

11 4th wheel gear 1
12 6th wheel gear 1
13 2nd wheel gear 1
14 Spacer 1
15 Drive axle 1
16 Bearing 1
17 Spacer 1
For assembly, reverse the disassembly
procedure.

5-82
 TRANSMISSION ENG
EAS00420

REMOVING THE TRANSMISSION

1. Remove:

main axle assembly 1
(with the Torx wrench T30)

a. Insert two bolts 2 of the proper size, as

shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.

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 surface.
Bends
Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.

3. Check:

shift fork movement
(on the shift fork guide bar)
Rough movement
Replace the shift forks
and shift fork guide bar as a set.

5-83
 TRANSMISSION ENG
EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:

shift drum grooves
Damage/scratches/wear
Replace the
shift drum.

shift drum segment 1
Damage/wear
Replace.

shift drum bearing 2
Damage/pitting
Replace.

EAS00425

CHECKING THE TRANSMISSION

1. Measure:

main axle runout
(with a centering device and dial gauge 1 )
Out of specification
Replace the main
axle.

Main axle runout limit

0.08 mm

2. Measure:

drive axle runout
(with a centering device and dial gauge 1 )
Out of specification
Replace the drive
axle.

Drive axle runout limit

0.08 mm

3. Check:

transmission gears
Blue discoloration/pitting/wear
Replace
the defective gear(-s).

transmission gear dogs
Cracks/damage/rounded edges
Replace
the defective gear(-s).
4. Check:

transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect
Reassemble the transmission
axle assemblies.
5. Check:

transmission gear movement
Rough movement
Replace the defective
part(-s).
6. Check:

circlips
Damage/bends/looseness
Replace.

5-84
 TRANSMISSION ENG
EAS00428

INSTALLING THE TRANSMISSION

main axle assembly

shift fork “C”

shift drum assembly

shift fork “R”

shift fork “L”

springs

shift fork guide bars

drive axle assembly
NOTE:

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.

Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip is
inserted into the grooves in the upper crank-
case.

2. Check:

transmission
Rough movement
Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.

5-85
 COOL
CHAPTER 6
COOLING SYSTEM

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
COOL
 RADIATOR COOL
EAS00454

COOLING SYSTEM
RADIATOR

Order Job/Part Q’ty Remarks

Removing the radiator Remove the parts in the order listed.
Coolant Drain.
1 Water inlet hose 1
2 Carburetor hose 1
3 Oil cooler hose 1
4 Water outlet hose 1
5 Radiator 1
6 Fan motor 1
For installation, reverse the removal
procedure.

6-1
 RADIATOR COOL
EAS00455

CHECKING THE RADIATOR

1. Check:

radiator fins
Obstruction
Clean.
Apply compressed air to the rear of the radia-
tor.
Damage
Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-
head screwdriver.

2. Check:

radiator hoses

radiator pipes
Cracks/damage
Replace.

3. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.

Radiator cap opening pressure

95
125 kPa
(0.95
1.25 kg/cm2)

a. Install the radiator cap tester 1 and adapter

2 to the radiator cap 3 .

Radiator cap tester

90890-01325
Adapter
90890-01352

b. Apply the specified pressure for ten seconds

and make sure that there is no drop in pres-
sure.

4. Check:

radiator fan
Damage
Replace.
Malfunction
Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.

6-2
 RADIATOR COOL
EAS00456

INSTALLING THE RADIATOR

1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.

2. Check:

cooling system
Leaks
Repair or replace any faulty part.

a. Attach the radiator cap tester 1 to the radia-

tor.

Radiator cap tester:

90890-01325

b. Apply 100 kPa (1.0 kg/cm2) of pressure.

c. Measure the indicated pressure with the
gauge.

6-3
 THERMOSTAT COOL
EAS00460

THERMOSTAT

Order Job/Part Q’ty Remarks

Removing the thermostat Remove the parts in the order listed.
Front cowling Refer to “FRONT COWLING” in chapter 3.
1 Coolant reservoir hose 1
2 Water inlet hose 1
3 Water outlet hose 1
4 Thermostat housing 1
For installation, reverse the removal
procedure.

6-4
 THERMOSTAT COOL
EAS00461

15 Nm (1.5 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the thermostat housing Disassemble the parts in the order listed.
1 Thermostat housing cover 1
2 Thermostat /O-ring 1/1
3 Thermostat housing 1
4 Thermo unit 1
For assembly, reverse the disassembly
procedure.

6-5
 THERMOSTAT COOL
EAS00462

CHECKING THE THERMOSTAT

1. Check:
S thermostat
Does not open at 71
85_C
Replace.

a. Suspend the thermostat in a container filled

with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the ther-
mometer’s indicated temperature.

1 Thermometer
2 Water
3 Thermostat
4 Container
A Closes
B Opens
NOTE:
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.

2. Check:
S thermostat housing cover 1
S thermostat housing 2
Cracks/damage
Replace.

EAS00464

ASSEMBLING THE THERMOSTAT

1. Install:
S thermostat housing 1
S thermostat 2
S O-ring New
S thermostat housing cover
NOTE:
Install the thermostat with its breather hole a
facing up.

6-6
 THERMOSTAT COOL
2. Install:

thermo unit 1 15 Nm (1.5 m
kg)

CAUTION:
Use extreme care when handling the thermo
unit. Replace any part that was dropped or
subjected to a strong impact.

EAS00466

INSTALLING THE THERMOSTAT

1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks
Repair or replace any faulty part.

6-7
 WATER PUMP COOL
EAS00469

WATER PUMP

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the water pump Disassemble the parts in the order listed.
NOTE:

The water pump and oil pump are
combined into one unit (oil/water pump
assembly).

It is not necessary to remove the
impeller shaft unless the coolant level
is extremely low or coolant leaks from
the oil pan.

Oil/water pump assembly and oil Refer to “OIL PAN AND OIL PUMP” in
pump rotor chapter 5.
1 Water pump cover 1
2 O-ring 1
3 Pin 2
4 Impeller shaft (along with the impeller) 1

6-8
 WATER PUMP COOL

10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

5 Water pump seal 1
6 Oil seal 1
7 Bearing 1
For assembly, reverse the disassembly
procedure.

6-9
 WATER PUMP COOL
EAS00470

DISASSEMBLING THE WATER PUMP

1. Remove:

water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.

2 Water pump housing

2. Remove:

oil sesal 1

bearing 2
NOTE:
Tap out the bearing and oil seal from the outside
of the water pump housing.

3 Water pump housing

3. Remove:

rubber damper holder 1

rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.

EAS00473

CHECKING THE WATER PUMP

1. Check:

water pump housing cover 1

water pump housing 2

impeller 3

rubber damper 4

rubber damper holder 5
2. Check:

water pump seal

oil seal

water pump inlet pipe
Crack/damage/wear ! Replace

bearing
Roughness ! Replace.

6-10
 WATER PUMP COOL
EAS00475

ASSEMBLING THE WATER PUMP

1. Install:

oil seal New 1
(to the water pump housing 2 )
NOTE:

Install the oil seal with a socket that matches its
outside diameter.

Before installing the oil seal, apply tap water or
coolant onto its outer surface.

2. Install:

water pump seal New 1
CAUTION:
Never apply oil or grease onto the water
pump seal surface.

NOTE:

Install the water pump seal with the water
pump seal installers.

Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .

Water pump seal installer 4

90890-04078
Middle driven shaft bearing
driver 5
90890-04058
Yamaha bond No.1215
90890-85505

A Push down

6-11
 WATER PUMP COOL
3. Install:

rubber damper New 1

rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.

4. Measure:

tilt
Out of specification
Repeat steps (3) and
(4).
CAUTION:
Make sure that the rubber damper and rub-
ber damper holder are flush with the impel-
ler.

Tilt limit
0.15 mm

1 Straightedge
2 Impeller

6-12
 CARB
CHAPTER 7
CARBURETORS

CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 7-10
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 7-15
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . 7-16
CARB
 CARBURETORS CARB

CARBURETORS
CARBURETORS
AIR FILTER CASE

Order Job/Part Q’ty Remarks

Removing the air filter case Remove the parts in the order listed.
Seat, fueltank and sidecovers Refer to “FRONT COWLING/SEAT/
SIDE COVER/FUEL TANK” section in
chapter 3.
Drain the coolant Refer to “CHANGING THE COOLANT”
section.
1 Air filter case panel (left/right) 1/1
2 Battery negative lead 1
3 Battery positive lead 1
4 Battery 1
5 Stay 1
For installation, reverse the removal
procedure.

7-1
 CARBURETORS CARB
EAS00481

Order Job/Part Q’ty Remarks

Removing the carburetors Remove the parts in the order listed.
Throttle position sensor lead Disconnect.
1 Air filter joint screw 4
2 Carburetors joint screw 4
3 Carburetor inlet/outlet hose 1/1
4 Carburetors assembly 1
5 Starter cable 1
6 Throttle cable 2
For installation, reverse the removal
procedure.

7-2
 CARBURETORS CARB
EAS00482

Order Job/Part Q’ty Remarks

Separating the carburetor Remove the parts in the order listed.
1 Throttle stop screw 1
2 Coolant hose 1
3 Starter plunger link 1
4 Connecting bolt 1
5 Spacer 1
6 Connecting bolt 1
7 Spacer 3
8 Fuel inlet pipe 1
9 Fuel feed pipe 2
10 Spring 2
11 Vacuum chamber air vent hose 2
12 Float chamber air vent hose 2
13 Throttle position sensor 1
14 Throttle position sensor bracket 1
15 Carburetor 4
For installation, reverse the removal
procedure.
7-3
 CARBURETORS CARB
EAS00484

Order Job/Part Q’ty Remarks

Disassembling the carburetor Disassemble the parts in the order listed.
NOTE:
The following procedure applies to all of
the carburetors.

1 Starter plunger 1
2 Pilot air jet 1
3 Vacuum chamber cover 1
4 Piston valve spring 1
5 Piston valve 1
6 Jet needle holder 1
7 Jet needle kit 1
8 Pilot screw 1
9 Fuel drain bolt 1
10 Float pin 1

7-4
 CARBURETORS CARB

Order Job/Part Q’ty Remarks

11 Float 1
12 Needle valve 1
13 Needle valve seat 1
14 Main jet 1
15 Main jet holder 1
16 Pilot jet 1
17 Needle jet 1
For assembly, reverse the disassembly
procedure.

7-5
 CARBURETORS CARB
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. Wash the carburetor in a petroleum-based

solvent. Do not use any caustic-carburetor-
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.

3. Check:

float chamber body 1
Dirt
Clean.
4. Check:

float chamber rubber gasket 2
Cracks/damage/wear
Replace.

5. Check:

float 1
Damage
Replace.

6. Check:

needle valve 1

needle valve seat 2
Damage/obstruction/wear
Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:

O-ring 3
Damage/wear
Replace the needle valve,
needle valve seat and O-ring as a set.

7-6
 CARBURETORS CARB
8. Check:

piston valve 1
Damage/scratches/wear
Replace.

rubber diaphragm 2
Cracks/tears
Replace.

9. Check:

vacuum chamber cover 1

piston valve spring 2

jet needle holder 3
Cracks/damage
Replace.

10. Check:

jet needle kit 1

needle jet 2

main jet 3

main jet holder 4

pilot jet 5

pilot screw 6
Bends/damage/wear
Replace.
Obstruction
Clean.
Blow out the jets with compressed air.

11. Check:

piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness
Replace the piston valve.
12. Check:

fuel feed pipes

hose joint
Cracks/damage
Replace.
Obstruction
Clean.
Blow out the pipes with compressed air.
13. Check:

fuel feed hoses

fuel hoses
Cracks/damage/wear
Replace.
Obstruction
Clean.
Blow out the hoses with compressed air.

7-7
 CARBURETORS CARB
EAS00489

ASSEMBLING THE CARBURETORS

The following procedure applies to both of the
carburetors.
CAUTION:

Before assembling the carburetors, wash
all of the parts in a petroleum-based sol-
vent.

Always use a new gasket.

1. Install:

jet needle kit

2. Install:

needle jet 1

pilot jet 2

main jet 3

3. Measure:

float height a
Out of specification
Adjust.

Float height
12.5
13.5 mm

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.
NOTE:
The float arm should rest on the needle valve
without depressing it.

c. If the float height is not within specification,

check the needle valve seat and needle
valve.

7-8
 CARBURETORS CARB
d. If either the needle valve seat or needle valve
is worn, replace them both.
e. If both the needle valve seat and needle
valve are fine, adjust the float height by bend-
ing the float tang 1 .
f. Check the float height again.

4. Install:

piston valve

piston valve spring

vacuum chamber cover
NOTE:
Align the tab a on the piston valve diaphragm
with the recess b in the carburetor body.

5. Install:

connecting bracket
NOTE:
After installing the connecting bracket, check
that the throttle cable lever and starter plunger
link operate smoothly.

EAS00493

INSTALLING THE CARBURETORS

1. Adjust:

carburetor synchronization
Refer to “SYNCHRONIZING THE CARBU-
RETORS” in chapter 3.
2. Adjust:

engine idling speed

Engine idling speed

1,050
1,150 r/min

Refer to “ADJUSTING THE ENGINE IDLING

SPEED” in chapter 3.

3. Adjust:

throttle cable free play

Throttle cable free play (at the

flange of the throttle grip)
3
5 mm

Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.

7-9
 CARBURETORS CARB
EAS00495

MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:

fuel level a
Out of specification
Adjust.

Fuel level (below the line on the

float chamber)
3.0
4.0 mm

a. Stand the motorcycle on a level surface.

b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 to the fuel drain
pipe 2 .

Fuel level gauge

90890-01312

d. Loosen the fuel drain screw.

e. Hold the fuel level gauge vertically next to the
line on the float chamber 3 .
f. Measure the fuel level a on both sides of the
carburetor assembly.
NOTE:
The fuel level readings should be equal on both
sides.

2. Adjust:

fuel level

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) until the fuel level is
within specification.

7-10
 CARBURETORS CARB
EAS00500

CHECKING AND ADJUSTING THE

THROTTLE POSITION SENSOR
NOTE:
S Before adjusting the throttle position sensor,
the engine idling speed should be properly ad-
justed.
S When installing the throttle position sensor,
adjust its angle according to the RPM which is
displayed on the tachometer. Refer to the ad-
justment procedure below.

1. Check:
S throttle position sensor

a. Disconnect the throttle position sensor cou-

pler.
b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω 1k) to the
throttle position sensor.

Tester positive lead
Black/blue 1

Tester negative lead
Blue 2

d. Check the throttle position sensor maximum

resistance.
Out of specification
Replace the throttle
position sensor.

Throttle position sensor

maximum resistance
4 X 6 kΩ at 20_C

e. Install the throttle position sensor onto the

carburetor.
f. Connect the pocket tester (Ω 1k) to the
throttle position sensor.

Tester positive lead
Yellow 3

Tester negative lead
Blue 2

g. While slowly opening the throttle, check that

the throttle position sensor resistance is with-
in the specified range.
Out of specification
Replace the throttle
position sensor.

Throttle position sensor

resistance
0.4 X 5.4 kΩ at 20_C

7-11
 CARBURETORS CARB
2. Adjust:

throttle position sensor angle

a. Turn the main switch to “ON”.

b. Disconnect the throttle position sensor cou-
pler.
c. Reconnect the throttle position sensor cou-
pler.
NOTE:
After reconnecting the throttle position sensor
coupler, the tachometer switches to the throttle
position sensor adjustment mode.

d. Loosen the throttle position sensor screws

1.
e. Adjust the throttle position sensor angle ac-
cording to the following table:
NOTE:
The angle of the throttle position sensor is indi-
cated by the RPM which are displayed on the
tachometer.

Throttle position
Tachometer reading
sensor angle
0 r/min 1 Too small
5,000 r/min 2 Correct
10,000 r/min 3 Too large

f. After adjusting the throttle position sensor

angle, tighten the throttle position sensor
screws.
NOTE:
To exit the throttle position sensor adjustment
mode, start the engine or turn the main switch to
“OFF”.

7-12
 CARBURETORS CARB
EAS00504

CHECKING THE FUEL PUMP

1. Check:

fuel pump 1

a. Place a container under the end of the fuel

hose.
b. Start the engine and check if fuel flows from
the fuel hose 2 .

Fuel flows. Fuel pump is OK.

Replace the fuel
Fuel does not flow.
pump.
c. Stop the engine and check if the fuel stops
flowing from the fuel hose 2 .

Fuel stops flowing. Fuel pump is OK.

Replace the fuel
Fuel flows.
pump.

7-13
 AIR INDUCTION SYSTEM CARB
EAS00507

AIR INDUCTION SYSTEM

AIR INJECTION
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700_C.

EAS00508

AIR CUTOFF VALVE

The air cutoff valve is operated by the intake gas
pressure through the piston valve diaphragm.
Normally, the air cutoff valve is open to allow
fresh air to flow into the exhaust port. During
sudden deceleration (the throttle valve sudden-
ly closes), negative pressure is generated and
the air cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cutoff valve au-
tomatically closes to guard against a loss of per-
formance due to self-EGR.
VIEW 1. (NO FLOW) VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the valve will
close.
VIEW 2. (FLOW)
During normal operation the valve is open.
A From the air cleaner
B To the reed valve
C To the carburetor joint

VIEW 2. (FLOW)

7-14
 AIR INDUCTION SYSTEM CARB
EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

1 Reed valve
2 Air cleaner
3 Air cutoff valve
4 Carburetor joint (cylinder #4)
A To the air cutoff valve
B To cylinder #1
C To cylinder #2
D To cylinder #3
E To cylinder #4

7-15
AIR INDUCTION SYSTEM CARB
EAS00510

CHECKING THE AIR INDUCTION SYSTEM

1. Check:

hoses
Loose connection
Connect properly.
Cracks/damage
Replace.

pipes
Cracks/damage
Replace.

2. Check:

fibre reed 1

fibre reed stopper

reed valve seat
Cracks/damage
Replace the reed valve.

3. Measure:

fibre reed bending limit a
Out of specification
Replace the reed
valve.

Fibre reed bending limit

0.2 mm

1 Surface plate

4. Check:

air cutoff valve
Cracks/damage
Replace.

7-16
 ELEC
CHAPTER 8
ELECTRICAL

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
INSTRUMENT FUENCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . 8-10

TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 8-11
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 8-12

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . . 8-18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8-25

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
 ELEC
EXUP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
CIRCUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
 ELECTRICAL COMPONENTS ELEC
EAS00729

ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch 7 Starting circuit cutoff relay 12 Oil level gauge
2 Fuel sender 8 Flasher relay 13 Ignition coil
3 Rear brake switch 9 Speed sensor 14 Rectifier/ Regulator
4 Battery 10 Sidestand switch 15 Thermo unit
5 Ignitor unit 11 Neutral switch 16 Horn
6 Starter relay 17 Emargency stop switch
18 Fan motor relay

8-1
 ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS

1 Thermo unit
2 T.P.S.
3 Starter motor
4 Pickup rotor
5 Pickup coil

8-2
 ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Ignitor unit
2 Fuse box
3 Battery
4 Fuel pump
5 Fuel pump coupler
6 Brake light switch coupler
7 Newtral switch coupler
8 Pickup coil coupler
9 Speed sensor coupler

8-3
 ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Ignition coil #2.3
2 Ignition coil #1.4
3 Rectifier/ regulator
4 Stator coil

8-4
 ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Emargency stop switch
2 Flasher relay
3 Starter relay
4 Fan motor relay
5 Starting circuit cutoff relay
6 Stator coil coupler
7 Sidestand switch coupler
8 Fuel sender coupler
9 Oil level switch coupler

8-5
 INSTRUMENT FUNCTIONS ELEC

INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Turn indicator light “ ” “ ”
This indicator flashes when the turn switch is
moved to the left or right, and the hazard
switch is on.
Neutral indicator light “ ”
This indicator comes on when the transmis-
sion is in neutral.
High beam indicator light “ ”
This indicator comes on when the headlight
high beam is used.
1 Turn indicator light (left) “ ”
2 Turn indicator light (right) “ ”
3 Neutral indicator light “ ”
4 High beam indicator light “ ”

WARNING LIGHT
Oil evel warning light “ ”
This warning light comes on when the engine
oil level is low. If this symbol flashes, stop the
engine immediately and fill it with oil to the
specified level.
Coolant temperature warning light “ ”
This warning light comes on when the cool-
ant temperature is too high.
Fuel level warning light “ ”
When the fuel level drops below approxi-
1 Oil level warning light “ ”
mately 5.5 L, this light will come on.When this
light comes on, fill the fuel tank at the first op-
2 Coolant temperature warning light “ ”
portunity.
3 Fuel level warning light “ ”
CAUTION:

Do not run the motorcycle until you know it
has sufficient engine oil.

Do not run the motorcycle if the engine is
overheated.

NOTE:
Even if the oil is filled to the specified level, the
warning light may flicker when riding on a slope
or during sudden acceleration or deceleration,
but this is normal.

8-6
 INSTRUMENT FUNCTIONS ELEC
DIGITAL CLOCK
Clock
To set the clock:
1. Push both the “SELECT” 1 and “RESET” 2
buttons for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button 2 to set the hours.
3. Push the “SELECT” button 1 to change the
minutes.
4. When the minute digits start flashing, push
the “RESET” button 2 to set the minutes.
1 “SELECT” button
5. Push the “SELECT” button 1 to start the
clock.
2 “RESET” button
NOTE:
After setting the clock, be sure to push the “SE-
LECT” button 1 before turning the main switch
to “OFF”, otherwise the clock will not be set.

8-7
CHECKING SWITCH CONTINUITY ELEC
EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.

Pocket tester
90890-03112

NOTE:

Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.

When checking for continuity, switch back and
forth between the switch positions a few times.

The terminal connections for switches (e.g.,

main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).

The example illustration on the left shows

that:
There is continuity between blue/red and red
when the switch is set to “P”.
There is continuity between blue/red and blue
when the switch is set to “ON”.

8-8
 CHECKING THE SWITCHES ELEC
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 switch.

1 Main switch 7 Turn signal switch 12 Rear brake switch

2 Pass switch 8 Front brake switch 13 Fuse
3 Dimmer switch 9 Light switch 14 Side stand switch
4 Horn switch 10 Engine stop switch 15 Neutral switch
5 Clutch switch 11 Start switch 16 Oil level switch
6 Hazard switch

8-9
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732

CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage/wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
Incorrect continuity reading
Repair or replace
the bulb, bulb socket or both.

TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs A are used for headlights and usually
use a bulb holder which must be detached be-
fore removing the bulb. The majority of these
bulbs can be removed from their respective
socket by turning them counterclockwise.

Bulb B is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.

Bulbs C are used for meter and indicator lights
and can be removed from their respective
socket by carefully pulling them out.

8-10
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

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

CAUTION:

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

2. Check:

bult (for continuity)
(with the pocket tester)
No continuity
Replace.

Pocket tester
90890-03112

NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.

a. Connect the tester positive probe to terminal

1 and the tester negative probe to terminal
2 , and check the continuity.
b. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.

8-11
CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity
Replace.

Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.

a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,
replace the bulb socket.

CHECKING THE LEDs

The following procedures applies to all of the
LEDs.
1. Check:

LED (for proper operation)
Improper operation
Replace.

a. Disconnect the meter assembly coupler (me-

ter assembly side).
b. Connect two jumper leads 1 from the bat-
tery terminals to the respective coupler ter-
minal as shown.
WARNING

A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.

This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.

c. When the jumper leads are connected to the

terminals the respective LED should illumi-
nate.
Does not light
Replace the meter assem-
bly.

8-12
 IGNITION SYSTEM ELEC
EAS00735

IGNITION SYSTEM
CIRCUIT DIAGRAM

1 Main switch
5 Battery
7 Fuse (main)
15 Ignitor
16 Ignition coil
17 Spark plug
18 Pickup coil
41 Engine stop switch
58 Fuse (ignition)

8-13
 IGNITION SYSTEM ELEC
EAS00737 EAS00739

TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no S Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Check:
1. Main and ignition fuses Minimum open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Spark plugs S Is the battery OK?
4. Ignition spark gap
5. Spark plug cap resistance YES NO
6. Ignition coil resistance
7. Main switch
8. Engine stop switch S Clean the battery
9. Pickup coil resistance terminals.
10. Wiring connections S Recharge or replace
(of the entire ignition system) the battery.
NOTE:
Before troubleshooting, remove the following
part(-s):
1) Seat EAS00741
2) Fuel tank
3) Side cover 3. Spark plugs
S Troubleshoot with the following special The following procedure applies to all of the
tool(-s). spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
Dynamic spark tester S Measure the spark plug gap.
YM-34487 Refer to “CHECKING THE SPARK PLUGS”
Ignition checker in CHAPTER 3.
90890-60754
Pocket tester Standard spark plug
90890-03112 CR9E (NGK)
U27ESR-N (DENSO)
EAS00738 Spark plug gap
1. Main and ignition fuses 0.7 X 0.8 mm

S Check the main and ignition fuses for conti- S Is the spark plug in good condition, it is of the
nuity. correct type, and is its gap within specifica-
Refer to “CHECKING THE FUSES” in tion?
CHAPTER 3.
YES NO
S Are the main and ignition fuses OK?

YES NO Re-gap or replace

the spark plug.

Replace the fuse(s).

8-14
 IGNITION SYSTEM ELEC
EAS00743

Spark plug cap resistance

4. Ignition spark gap
10 kΩ at 20_C
The following procedure applies to all of the S Is the spark plug cap OK?
spark plugs.
S Disconnect the spark plug cap from the YES NO
spark plug.
S Connect the ignition checker 1 as shown.
2 Spark plug cap Replace the spark
plug cap.
S Set the main switch to “ON”.
S Measure the ignition spark gap a . EAS00747
S Crank the engine by pushing the starter
6. Ignition coil resistance
switch and gradually increase the spark gap
until a misfire occurs. The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil leads from the
wire harness.
S Connect the pocket tester (Ω 1) to the
ignition coil as shown.
Positive tester probe
red/black
Negative tester probe
orange (gray)

Minimum ignition spark gap

6.0 mm
S Is there a spark and is the spark gap within
specification?

NO YES
S Measure the primary coil resistance.

The ignition system Primary coil resistance

is OK. 1.87 X 2.53 Ω at 20_C

EAS00745 S Connect the pocket tester (Ω 1k) to the

ignition coil as shown.
5. Spark plug cap resistance
The following procedure applies to all of the Posltlve tester probe
spark plug lead
Negative tester probe
spark plug lead
spark plug caps.
S Remove the spark plug cap from the spark
plug lead.
S Connect the pocket tester (“Ω 1k”) to the
spark plug cap as shown.
S Measure the spark plug cap resistance.

S Measure the secondary coil resistance.

8-15
 IGNITION SYSTEM ELEC
EAS00748

Secondary coil resistance 9. Pickup coil resistance

12 X 18 kΩ at 20_C
S Disconnect the pickup coil coupler from the
S Is the ignition coil OK?
wire harness.
S Connect the pocket tester (Ω 100) to the
YES NO
pickup coil terminal as shown.
Positive tester probe
gray 1
Replace the ignition Negative tester probe
black 2
coil.

EAS00749

7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?

YES NO
S Measure the pickup coil resistance.
Replace the main Pickup coil resistance
switch. 248 X 372 Ω at 20_C
(between gray and black)
EAS00750 S Is the pickup coil OK?
8. Engine stop switch
YES NO
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the pickup
S Is the engine stop switch OK? coil.
YES NO
EAS00754

Replace the right 10. Wiring

handlebar switch. S Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the ignition system’s wiring properly con-
nected and without defects?

NO YES

Properly connect or Replace the ignitor

repair the ignition unit.
system’s wiring.

8-16
 ELECTRIC STARTING SYSTEM ELEC
EAS00755

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

1 Main switch
5 Battery
6 Fuse (main)
7 Starter relay
8 Starter motor
9 Starting circuit cutoff relay
10 Side stand switch
19 Neutral switch
41 Engine stop switch
42 Start switch
48 Clutch switch
58 Fuse (ignition)
59 Alarm

8-17
ELECTRIC STARTING SYSTEM ELEC
EAS00756

STARTING CIRCUIT CUTOFF SYSTEM OP-

ERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:

The transmission is in neutral (the neutral
switch is closed).

The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the side-
stand is up (the sidestand switch is closed).

The starting circuit cutoff relay prevents the

starter motor from operating when neither of
these conditions has been met. In this instance,
the starting circuit cutoff relay is open so current
cannot reach the starter motor. When at least
one of the above conditions has been met the
starting circuit cutoff relay is closed and the en-
gine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS IN

NEUTRAL

WHEN THE SIDESTAND IS UP AND

THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1 Battery
2 Fuse (main)
3 Main switch
4 Fuse (ignition)
5 Engine stop switch
6 Starting circuit cutoff relay
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor

8-18
 ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739

TROUBLESHOOTING 2. Battery
The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
Check: CHAPTER 3.
1. Main and ignition fuses Minimum open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Starter motor
4. Starting circuit cutoff relay S Is the battery OK?
5. Starter relay YES NO
6. Main switch
7. Engine stop switch
8. Neutral switch S Clean the battery
9. Sidestand switch terminals.
10. Clutch switch S Recharge or re-
11. Start switch place the battery.
12. Wiring connections
(of the entire starting system) EAS00758

NOTE: 3. Starter motor

S Before troubleshooting, remove the following S Connect the positive battery terminal 1 and
part(-s): starter motor lead 2 with a jumper lead 3 .
1) Seat
2) Fuel tank
3) Side cover
S Troubleshoot with the following special tool(-s).

Pocket tester
90890-03112

EAS00738

1. Main and ignition fuses

S Check the main and ignition fuses for conti- WARNING
nuity. S A wire that is used as a jumper lead must
Refer to “CHECKING THE FUSES” in have at least the same capacity or more as
CHAPTER 3. that of the battery lead, otherwise the
S Are the main and ignition fuses OK? jumper lead may burn.
S This check is likely to produce sparks,
YES NO therefore make sure nothing flammable is
in the vicinity.
Replace the fuse (s).
S Does the starter motor turn?

YES NO

Repair or replace the

starter motor.

8-19
 ELECTRIC STARTING SYSTEM ELEC
EAS00759

4. Starting circuit cutoff relay

Disconnect the starting circuit cutoff relay
coupler from the wire harness.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the starting circuit cutoff relay
coupler as shown.

Positive battery lead
red/black 1

Negative battery lead
black/yellow 2

Does the starter relay have continuity be-
Positive tester probe
blue/white 3
tween red and red?
Negative tester probe
black 4
YES NO

Replace the starter

relay.

EAS00749

6. Main switch

Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Does the starting circuit cutoff relay have

Is the main switch OK?
continuity between blue/white and black?

YES NO YES NO

Replace the starting Replace the main

circuit cutoff relay. switch.

EAS00750
EAS00761

5. Starter relay 7. Engine stop switch

Disconnect the starter relay coupler from the
Check the engine stop switch for continuity.
wireharness. Refer to “CHECKING THE SWITCHES”.

Connect the pocket tester (Ω
1) and bat-
Is the engine stop switch OK?
tery (12 V) to the starter relay coupler as
shown. YES NO
Positive battery lead
blue/white 1
Negative battery lead
red/white 2 Replace the right
handlebar switch.
Positive tester probe
red 3
Negative tester probe
red 4

8-20
 ELECTRIC STARTING SYSTEM ELEC
EAS00751 EAS00766

8. Neutral switch 12. Wiring

Check the neutral switch for continuity.
Check the entire starting system’s wiring.
Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.

Is the neutral switch OK?
Is the starting system’s wiring properly con-
nected and without defects?
YES NO
YES NO
Replace the neutral
switch. The starting system Properly connect or
circuit is OK? repair the starting
EAS00752
system’s wiring.
9. Sidestand switch

Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES NO

Replace the side-

stand switch.
EAS00763

10. Clutch switch

Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES NO

Replace the clutch

switch.

EAS00764

11. Start switch

Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?

YES NO

Replace the right

handlebar switch.

8-21
 ELECTRIC STARTING SYSTEM ELEC
EAS00767

STARTER MOTOR

Order Job/Part Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.
Carburetor Refer to “CARBURETOR” in chapter 7.
1 Starter motor lead 1
2 Starter motor/O-ring 1/1
For installation, reverse the removal
procedure.

8-22
 ELECTRIC STARTING SYSTEM ELEC
EAS00768

5 Nm (0.5 m
kg)
10 Nm (1.0 m
kg)

Order Job/Part Q’ty Remarks

Disassembling the starter motor Disassemble the parts in the order listed.
1 Starter motor front cover 1
2 Lock washer 1
3 Oil seal 1 Refer to “ASSEMBLING THE STARTER
4 Bearing 1 MOTOR”.
5 Washer set 1 NOTE:
6 Starter motor rear cover 1 Be sure to remove the installation nut on
7 Washer set 1 brush #1 first.
8 Brush seat (along with the brushes) 1
9 Armature assembly 1
10 Brush holder (along with the brushes) 1
11 O-ring 2
12 Starter motor yoke 1
For assembly reverse the disassembly
procedure.

8-23
ELECTRIC STARTING SYSTEM ELEC
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.

Commutator wear limit

27 mm

3. Measure:
S mica undercut a
Out of specification
Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commuta-
tor.

Mica undercut
0.7 mm

NOTE:
The mica must be undercut to ensure proper op-
eration of the commutator.

4. Measure:
S armature assembly resistances (commuta-
tor and insulation)
Out of specification
Replace the starter
motor.

a. Measure the armature assembly resistances

with the pocket tester.

Pocket tester
90890-08112

Armature coil
Commutator resistance 1
0.025 X 0.035 Ω at 20_C
Insulation resistance 2
Above 1M Ω at 20_C

8-24
ELECTRIC STARTING SYSTEM ELEC
b. If any resistance is out of specification, re-
place the starter motor.

5. Measure:

brush length a
Out of specification
Replace the brushes
as a set.

Brush length wear limit

4 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

7. Check:

gear teeth
Damage/wear
Replace the gear.

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:

armature

brush seat 1
NOTE:
Align the tab a on the brush seat with the slot b
in the starter motor rear cover.

8-25
ELECTRIC STARTING SYSTEM ELEC
2. Install:

starter motor front cover 1

starter motor rear cover 2

O-ring 3 New
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear covers.

8-26
 CHARGING SYSTEM ELEC
EAS00773

CHARGING SYSTEM
CIRCUIT DIAGRAM

2 Rectifire/ reguretor
3 AC magneto
5 Battery
7 Fuse (main)

8-27
 CHARGING SYSTEM ELEC
EAS00774

TROUBLESHOOTING YES NO

The battery is not being charged.

S Clean the battery
Check: terminals.
1. Main fuse S Recharge or re-
2. Battery place the battery.
3. Charging voltage
4. Stator coil resistance EAS00775

5. Wiring connections 3. Charging voltage

(of the entire charging system) S Connect the engine tachometer to the spark
NOTE: plug lead of cylinder #1.
S Before troubleshooting, remove the following S Connect the pocket tester (DC 20 V) to the
part(-s): battery as shown.
1) Seat
Positive tester probe

2) Fuel tank
positive battery terminal
3) Side cover
Negative tester probe

S Troubleshoot with the following special
negative battery terminal
tool(-s).

Engine tachometer
90890-03113
Pocket tester
90890-03112

EAS00738

1. Main fuses S Start the engine and let it run at approxi-

S Check the fuses for continuity. mately 5,000 r/min.
Refer to “CHECKING THE FUSES” in S Measure the charging voltage.
CHAPTER 3. Charging voltage
S Are the fuses OK? 14 V at 5,000 r/min
NOTE:
YES NO
Make sure the battery is fully charged.

Replace the fuse (s). S Is the charging voltage within specification?

EAS00739
NO YES
2. Battery
S Check the condition of the battery. The charging circuit
Refer to “CHECKING THE BATTERY” in is OK.
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?

8-28
 CHARGING SYSTEM ELEC
EAS00776

4. Stator coil resistance

S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the sta-
tor coils as shown.
Positive tester probe
white 1
Negative tester probe
white 2
Positive tester probe
white 3
Negative tester probe
white 1

S Measure the stator coil resistances.

Stator coil resistance
0.27 X 0.33 Ω at 20_C
S Is the stator coil OK?

YES NO

Replace the stator

coil assembly.

EAS00779

5. Wiring
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly
connected and without defects?

YES NO

Replace the rectifi- Properly connect or

er/regulator. repair the charging
system’s wiring.

8-29
 LIGHTING SYSTEM ELEC
EAS00780

LIGHTING SYSTEM
CIRCUIT DIAGRAM

1 Main switch 46 Dimmer switch

5 Battery 55 Headlight
7 Fuse (main) 56 Tail/ brake light
31 Hi-beam indicator light 60 Fuse (Alarm)
34 Meter light 61 Fuse (headlight)
40 Headlight switch 66 Headlight relay (on / off)
45 Pass switch 67 Headlight relay (dimmer)

8-30
 LIGHTING SYSTEM ELEC
EAS00781

TROUBLESHOOTING YES NO

Any of the following fail to light: headlight,

high beam indicator light, taillight, auxilia- S Clean the battery
ry light or meter light. terminals.
S Recharge or re-
Check: place the battery.
1. Main, headlight and alarm fuses
2. Battery EAS00749

3. Main switch 3. Main switch

4. Headlight switch
5. Dimmer switch S Check the main switch for continuity.
6. Pass switch Refer to “CHECKING THE SWITCHES”.
7. Headlight relay (on/off) (for EUR) S Is the main switch OK?
8. Headlight relay (dimmer)
9. Wiring connections YES NO
(of the entire charging system)
NOTE:
S Before troubleshooting, remove the following Replace the main
part(-s): switch.
1) Seat
EAS00783
2) Fuel tank
3) Side cover 4. Headlight switch
S Troubleshoot with the following special S Check the headlight switch for continuity
tool(-s). Refer to “CHECKING THE SWITCHES”.
S Is the headlight switch OK?
Pocket tester
90890-03112 YES NO
EAS00738

1. Main, headlight and alarm fuses The headlight switch

S Check the main, headlight and alarm fuses is faulty. Replace the
for continuity. right handlebar
Refer to “CHECKING THE FUSES” in switch.
CHAPTER 3.
EAS00784

S Are the main, headlight and alarm fuses 5. Dimmer switch

OK?
S Check the dimmer switch for continuity.
YES NO Refer to “CHECKING THE SWITCHES”.
S Is the dimmer switch OK?
Replace the fuse (s).
YES NO
EAS00739

2. Battery
The dimmer switch is
S Check the condition of the battery. faulty. Replace the
Refer to “CHECKING THE BATTERY” in left handlebar switch.
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?

8-31
 LIGHTING SYSTEM ELEC
EAS00786

6. Pass switch Low-beam

Positive tester probe
black/blue 1

Check the pass switch for continuity. Negative tester probe
black/green 2
Refer to “CHECKING THE SWITCHES”.

Is the pass switch OK?

YES NO

The pass switch is

faulty.
Replace the left han-
dlebar switch. Hi-beam
Positive battery lead
yellow 1
Negative battery lead
black 2
7. Headlight relay (on/off) (for EUR) Positive tester probe
black/blue 3

Disconnect the headlight relay (on/off) from Negative tester probe
black/yellow 4
the coupler.

Connect the pocket tester (Ω
1) and bat-
tery (12 V) to the headlight relay (on/off)
coupler as shown.
Positive battery lead
blue/black 1
Negative battery lead
black 2
Positive tester probe
red/yellow 3
Negative tester probe
black/blue 4
Does the headlight rrelay (dimmer) have
continuity?
YES NO

Replace the head-

light relay (dimmer).

EAS00787

9. Wiring

Does the headlight relay (on/off) have conti-
nuity between red/yellow and black/blue?
Check entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
YES NO
Is the lighting system’s wiring properly con-
nected and without defects?
Replace the head- YES NO
light relay (on/off).

Check the condition Properly connect or

8. Headlight relay (dimmer) of each of the lighting repair the lighting
system’s circuits. system’s wiring.

Disconnect the headlight relay (dimmer) Refer to “CHECK-
from the coupler. ING THE LIGHTING

Connect the pocket tester (Ω
1) and bat- SYSTEM”.
tery (12 V) to the headlight relay (dimmer)
coupler as shown.

8-32
 LIGHTING SYSTEM ELEC
EAS00788
CHECKING THE LIGHTING SYSTEM
Set the main switch to “ON”.
1. The headlight and the high beam indicator
Set the light switch to “ON”.
light fail to come on.
Set the dimmer switch to “ ” or “ ”.

Measure the voltage (12 V) (wire harness
1. Headlight buld and scocket
side).

Check the headlight bulb and socket for

Is the voltage within specification?
continuity.

Are the headlight bulb and socket OK? YES NO

YES NO The wiring circuit

This circuit is OK.
from the main switch
Replace the headlight to the headlight cou-
bulb, socket or both pler is faulty and
must be repaired.

EAS00789
2. Voltage
2. The meter light fails to come on.

Connect the pocket tester (DC 20 V) to the
1. Meter light bulb and socket
headlight and high beam indicator light cou-
plers as shown.
Check the meter light bulb and socket for
continuity.
A When the dimmer switch is set to “ ”.
B When the dimmer switch is seto to “ ”.
Are the meter light bulb and socket OK?
Headlight YES NO
Positive tester probe

black/yellow 1 or black/green 2
Negative tester probe
black 3 Replace the meter
High beam indicator light light bulb, socket of
Positive tester probe
both.
black/yellow 4
Negative tester probe
black 5
2. Vollage
Headlight coupler (wire harness side)

Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as
shown.
Positive tester probe
blue 1
Negative tester probe
black 2

Meter light coupler (wire harness side)

8-33
 LIGHTING SYSTEM ELEC

Set the main switch to “ON”.
Set the main switch to “ON”.

Set the light switch to “PO” or “ON”.
Set the light switch to “PO” or “ON”.

Measure the voltage (12 V) of blue 1 on the
Measure the voltage (12 V) of blue/red 1 on
meter light coupler (wire harness side). the tail/brake light coupler (tail/brake light
side).

Is the voltage within specification?

Is the voltage within specification?
YES NO
YES NO
This circuit is OK. The wiring circuit from
the main switch to the This circuit is OK. The wiring circuit from
meter light coupler is the main switch to the
faulty and must be re- tail/brake light coupler
paired. is faulty and must be
repaired.
EAS00790
3. The tail/brake light fails to come on.
1. Tail/brake light bulb and socket

Chek the tail/brake light bulb and socket for
continuity.

Are the tail/brake light bulb and socket OK?

YES NO

Replace the tail/brake

light bulb, socket or
both.

2. Voltage

Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe
blue/red 1
Negative tester probe
black 2

8-34
 SIGNAL SYSTEM ELEC
EAS00793

SIGNAL SYSTEM
CIRCUIT DIAGRAM

8-35
 SIGNAL SYSTEM ELEC
1 Main switch
5 Battery
7 Fuse (main)
9 Starting circuit cutoff relay
19 Neutral switch
23 Fuel level warning light
24 Oil level warning light
25 Neutral indicator light
27 Combination meter
29 Fuel gauge
32 Turn signal indicator light (left)
33 Turn signal indicator light (right)
35 Oil level gauge
36 Fuel sender
37 Turn signal relay
39 Front brake light switch
43 Horn
47 Horn switch
49 Hazard switch
50 Turn signal switch
51 Front turn signal light (left)
52 Front turn signal light (right)
53 Rear turn signal light (left)
54 Rear turn signal light (right)
56 Tail/ brake light
57 Fuse (turn signal)
58 Fuse (ignition)
60 Fuse (alarm)
65 Rear brake light switch

8-36
 SIGNAL SYSTEM ELEC
EAS00794 EAS00749

TROUBLESHOOTING 3. Main switch

S Any of the following fail to come on: turn S Check the main switch for continuity.
signal light, brake light or indicator light. Refer to “CHECKING THE SWITCHES”.
S The horn fails to sound.
S Is the main switch OK?
Check:
1. Main, signal, alarm and clock fuses YES NO
2. Battery
3. Main switch
4. Wiring connections Replace the main
(of the entire signal system) switch.
NOTE:
S Before troubleshooting, remove the following
EAS00795

part(s): 4. Wiring
1) Seat S Check the entire signal system’s wiring.
2) Fuel tank Refer to “CIRCUIT DIAGRAM”.
3) Front cowling
4) Side cover S Is the signaling system’s wiring properly
S Troubleshoot with the following special tool(s). connected and without defects?

YES NO
Pocket tester
90890-03112
Check the condition Properly connect or
EAS00738 of each of the signal- repair the signaling
1. Main, signal, alarm and ignition fuses ing system’s circuits. system’s wiring.
Refer to “CHECK-
S Check the main, signal, alarm and ignition ING THE SIGNAL-
fuses for continuity. ING SYSTEM”.
Refer to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main, signal, alarm and ignition
EAS00796

fuses OK? CHECKING THE SIGNAL SYSTEM

1. The horn fails to sound.
YES NO 1. Horn switch
S Check the horn switch for continuity.
Replace the fuse (s). Refer to “CHECKING THE SWITCHES”.
S Is the horn switch OK?
EAS00739

2. Battery
S Check the condition of the battery. YES NO
Refer to “CHECKING THE BATTERY” in
CHAPTER 3. Replace the left han-
Minimum open-circuit voltage dlebar switch.
12.8 V or more at 20_C
S Is the battery OK? 2. Voltage
YES NO S Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
S Clean the battery
terminals.
S Recharge or re-
place the battery.

8-37
 SIGNAL SYSTEM ELEC

Positive tester probe
pink 1 4. Voltage

Negative tester probe
black

Connect the pocket tester (DC 20 V) to the
horn connector at the black terminal as
shown.
Positive tester probe
black 1
Negative tester probe
ground

Set the main switch to “ON”.

Push the horn switch.

Measure the voltage (12 V) of pink at the
horn terminal.

Is the voltage within specification?

Set the main switch to “ON”.
YES NO
Measure the voltage (12 V) of black 1 at the
horn terminal.

The wiring circuit
Is the voltage within specification?

from the main switch
YES NO
to the horn connector
is faulty and must be
repaired. Repair or replace the Replace the horn.
horn.

3. Horn EAS00797

2. The tail/brake light fails to come on.

Disconnect the black connector at the horn
terminal. 1. Tail/brake light bulb and socket.

Connect a jumper lead 1 to the horn termi-
Check the tail/brake light bulb and socket for
nal and ground the jumper lead. continuity.

Set the main switch to “ON”.

Push the horn switch.
Are the tail/brake light bulb and socket OK?

Does the horn sound? YES NO

Replace the tail/brake

light bulb, socket or
both.

2. Brake switches

Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the brake light switch OK?
NO YES
YES NO
The horn is OK.
Replace the brake
light switch.
8-38
 SIGNAL SYSTEM ELEC

3. Voltage 2. Turn signal switch

Connect the pocket tester (DC 20 V) to the
Check the turn signal switch for continuity.
tail/brake light coupler (wire harness side) Refer to “CHECKING THE SWITCHES”.
as shown.

Is the turn signal switch OK?
Positive tester probe
yellow 1
Negative tester probe
black 2 YES NO

Replace the left han-

dlebar switch.

3. Voltage

Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.

Set the main switch to “ON”. Positive tester probe
brown 1

Pull in the brake lever or push down on the Negative tester probe
ground
brake pedal.

Measure the voltage (12 V) of yellow 1 on the
tail/brake light coupler (wire harness side).

Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit from

the main switch to the
tail/brake light coupler
Set the main switch to “ON”.
is faulty and must be
Measure the voltage (12 V) on brown 1 at
repaired. the turn signal relay coupler (wire harness
side).
EAS00799

3. The turn signal light, turn signal indicator
Is the voltage within specification?
light or both fail to blink.
YES NO
1. Turn signal indicator light bulb and socket

Check the turn signal light bulb and socket The wiring circuit
for continuity. from the main switch

Are the turn signal light bulbs and socket OK? to the turn signal
relay coupler is faulty
YES NO and must be re-
paired.

Replace the turn sig-

nal light bulb, socket
or both.

8-39
 SIGNAL SYSTEM ELEC
A B
4. Voltage

Connect the pocket tester (DC 20 V) to the
flasher relay coupler (wire harness side) as
shown.
Positive tester probe
brown/white 1
Negative tester probe
ground

Set the main switch to “ON”.

Set the turn signal switch to “ ” or “ ”.

Measure the voltage (12 V) of the chocolate
1 or dark green 2 at the turn signal light
connector (wire harness side).

Is the voltage within specification?

Set the main switch to “ON”. YES NO

Set the turn signal switch to “ ” or “ ”.

Measure the voltage (12 V) on brown/white
1 at the turn signal relay coupler (wire har- This circuit is OK. The wiring circuit
ness side). from the turn signal
switch to the turn sig-

Is the voltage within specification? nal light connector is
faulty and must be
YES NO repaired.
EAS00800

The turn signal relay 4. The neutral indicator light fails to come on.
is faulty and must be
replaced. 1. Neutral indicator light bulb and socket

Check the neutral indicator light bulb and
socket for continuity.
5. Voltage

Are the neutral indicator light bulb and sock-

Connect the pocket tester (DC 20 V) to the et OK?
turn signal light connector (wire harness
side) as shown. YES NO
A Rear turn signal light
B Turn signal indicator light Replace the neutral
Left turn signal light indicator light bulb,
Positive tester probe
chocolate 1 socket or both.
Negative tester probe
ground
Right turn signal light 2. Neutral switch
Positive tester probe
dark green 2
Check the neutral switch for continuity.
Negative tester probe
ground Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

YES NO

Replace the neutral

switch.

8-40
 SIGNAL SYSTEM ELEC

3. Voltage 2. Engine oil level switch

Connect the pocket tester (DC 20 V) to the
Drain the engine oil and remove the engine
meter light bulb coupler (wire harness side) oil level switch from the oil pan.
as shown.
Check the engine oil level switch for conti-
nuity.
Positive tester probe
brown 1
Refer to “CHECKING THE SWITCHES”.
Negative tester probe
ground

Is the engine oil level switch OK?

YES NO

Replace the engine

oil level switch.

EAS00795

3. Wiring

Set the main switch to “ON”.

Check the entire signal system’s wiring.

Measure the voltage (12 V).
Refer to “CIRCUIT DIAGRAM”.

Is the voltage within specification?

Is the signaling system’s wiring properly
connected and without defects?
YES NO
YES NO
This circuit is OK. The wiring circuit
from the main switch Replace the meter Properly connect or
to the meter light bulb unit. repair the signaling
coupler is faulty and system’s wiring.
must be repaired.

EAS00802
5. The oil level warning light fails to come on.
1. Oil level warning light bulb and socket

Check the oil level warning light bulb and
socket for continuity.

Are the oil level warning light bulb and sock-
et OK?

YES NO

Replace the oil level

warning light bulb,
socket or both.

8-41
 SIGNAL SYSTEM ELEC
EAS00804

5. The fuel level gauge fails to operate. S Set the main switch to “ON”.
S Measure the voltage (12 V) of brown 1 on
1. Fuel sender
the meter light coupler (wire harness side).
S Remove the fuel sender from the fuel tank.
S Is the voltage within specification?
S Connect the pocket tester to the fuel sender
coupler (wire harness side) as shown. YES NO
Positive tester probe
green 1
Negative tester probe
black 2 Check the wiring
connections of the
entire signaling sys-
tem.

3. Fuel level gauge

S Set the main switch to “ON”.
S Move the float up 1 or down 2 .
S Check that the fuel level gauge needle
moves to “F” or “E”.
S Measure the fuel sender resistances.
Fuel sender resistance (up position
3 ) (Ω
1)
4  10 Ω at 20_C
Fuel sender resistance (down posi-
tion 4 ) (Ω
10)
90  100 Ω at 20_C
S Is the fuel sender OK?

YES NO
NOTE:
Before reading the fuel level gauge, leave
Replace the fuel
the float in one position (either up or down)
sender.
for at least three minutes.

2. Voltage S Does the fuel level gauge needle move ap-

propriately?
S Connect the pocket tester (DC 20 V) to the
meter light coupler (wire harness side) as YES NO
shown.
Positive tester probe
brown 1 Replace the fuel lev-
Negative tester probe
black 2 el gauge.

4. Wiring
S Check the entire signaling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.

8-42
 COOLING SYSTEM ELEC
EAS00807

COOLING SYSTEM
CIRCUIT DIAGRAM

1 Main switch
5 Battery
7 Fuse (main)
21 Thermo unit
27 Combination meter
28 Water temp warning light
62 Fues (fan)
63 Fan motor relay
64 Fan motor

8-43
 COOLING SYSTEM ELEC
EAS00808

TROUBLESHOOTING S Is the battery OK?

S The radiator fan motor fails to turn. YES NO

S The water temperature gauge needle
fails to move when the engine is warm. S Clean the battery
terminals.
Check:
S Recharge or re-
1. Main and radiator fan motor fuses
place the battery.
2. Battery
3. Main switch EAS00749
4. Radiator fan motor
3. Main switch
5. Thermo unit
6. Wiring connections S Check the main switch for continuity.
(the entire cooling system) Refer to “CHECKING THE SWITCHES”.
NOTE: S Is the main switch OK?
S Before troubleshooting, remove the following
part(-s). YES NO
1) Seat
2) Fuel tank
Replace the main
S Troubleshoot with the following special tool(s).
switch.

EAS00809
Pocket tester
90890-03112 4. Radiator fan motor
S Disconnect the rediator fan motor coupler
EAS00738
from the wire harness.
1. Main and radiator fan motor fuses S Connect the battery (12 V) as shown.
S Check the main and radiator fan motor fuses Positive battery lead
blue 1
for continuity. Negative battery lead
black 2
Refert to “CHECKING THE FUSES” in
CHAPTER 3.
S Are the main and radiator fan motor fuses
OK?

YES NO

Replace the fuse (s).

EAS00739

S Does the rediator fan motor turn?

2. Battery
S Check the condition of the battery. YES NO
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
The radiator fan mo-
Minimum open-circuit voltage tor is faulty and must
12.8 V or more at 20_C be replaced.

8-44
 COOLING SYSTEM ELEC
EAS00812 EAS00759

5. Thermo unit 6. Fan motor relay

S Remove the thermo unit from the thermostat S Disconnect the fan motor relay coupler from
housing. the wire harness.
S Connect the pocket tester (Ω  1) to the ter- S Connect the pocket tester (Ω
1) and bat-
mo unit 1 as shown. tery (12 V) to the fan mtor relay coupler as
S Immerse the termo unit in a container filled shown.
with coolant 2 .
NOTE: Positive battery terminal ! brown 1
Make sure the termo unit terminals do not Negative battery terminal !
get wet. green/black 2
Positive tester probe ! brown 3
S Place a thermometer 3 in the coolant.
Negative tester probe ! blue 4
S Slowly heat the coolant, and then let it cool
to the specified temperature indicated in the
table.
S Check the thermo unit for continuity at the
temperatures indicated in the table.

S Does the fan motor relay have continuity be-

tween brown and blue?

YES NO
Termo unit resistance
80_C: 3.41  4.00 Ω Replace the fan mo-
105_C: 1.65  1.86 Ω tor relay.

WARNING
S Handle the termo unit with special care. EAS00813

S Never subject the thermo unit to strong 7. Wiring

shocks. If the thermo unit is dropped, re-
S Check the entire cooling system’s wiring.
place it.
Refer to “CIRCUIT DIAGRAM”.
S Is the cooling system’s wiring properly con-
Thermo unit nected and without defects?
15 Nm (1.5 mSkg)
Three bond sealock 10 YES NO
S Does the thetmo unit operate properly?
This circuit is OK. Properly connect or
YES NO repair the cooling
system’s wiring.
Replace the thermo
unit.

8-45
 FUEL PUMP SYSTEM ELEC
EAS00814

FUEL PUMP SYSTEM

CIRCUIT DIAGRAM

1 Main switch
5 Battery
7 Fuse (main)
9 Starting circuit cutoff relay
11 Fuel pump
15 Ignitor
41 Engine stop switch
51 Fuse (ignition)

8-46
 FUEL PUMP SYSTEM ELEC
EAS00815

FUEL PUMP CIRCUIT OPERATION

The ignitor unit includes the control unit for the 1 Battery
fuel pump. 2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Ignitor unit
7 Fuel pump relay
8 Fuel pump

8-47
 FUEL PUMP SYSTEM ELEC
EAS00816 EAS00749

TROUBLESHOOTING 3. Main switch

If the fuel pump fails to operate. S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Check:
1. Main and ignition fuses S Is the main switch OK?
2. Battery
3. Main switch YES NO
4. Engine stop switch
5. Starting circuit cutoff relay
(the fuel pump relay) Replace the main
6. Fuel pump switch.
7. Wiring connections
(the entire fuel system) EAS00750

NOTE: 4. Engine stop switch

S Before troubleshooting, remove the following S Check the engine stop switch for continuity.
part(-s): Refer to “CHECKING THE SWITCHES”.
1) Seat
2) Fuel tank S Is the engine stop switch OK?
3) Side cover NO
YES
Troubleshoot with the following special tool(s).

Replace the right

Pocket tester handlebar switch.
90890-03112
EAS00759
EAS00738

1. Main, and ignition fuses 5. Starting circuit cutoff relay

S Check the main and ignition fuses for conti- S Disconnect the starting circuit cutoff relay
nuity. coupler from the wire harness.
Refer to “CHECKING THE FUSES” in S Connect the pocket tester (Ω
1) and bat-
CHAPTER 3. tery (12 V) to the starting circuit cutoff relay
coupler as shown.
S Are the main and ignition fuses OK?
Positive battery lead
red/black 1
YES NO Negative battery lead
blue/red 2
Positive tester probe
red/black 3
Replace the fuse (s). Negative tester probe
black/blue 4
EAS00739

2. Battery
S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
S Does the starting circuit cutoff relay have con-
YES NO tinuity between red/black and black/blue?

S Clean the battery YES NO

terminals.
S Recharge or re- Replace the starting
place the battery. circuit cutoff relay.
8-48
 FUEL PUMP SYSTEM ELEC
EAS00817

6. Fuel pump resistance

S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω
1) to the fuel
pump coupler as shown.
Positive tester probe
black/blue 1
Negative tester probe
black 2

S Measure the fuel pump resistance.

Fuel pump resistance
4  30 Ω at 20_C
S Is the fuel pump OK?

YES NO

Replace the fuel

pump.

EAS00818

7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the fuel system’s wiring properly con-
nected and without defects?

YES NO

Replace the ignitor Properly connect or

unit. repair the fuel sys-
tem’s wiring.

8-49
 FUEL PUMP SYSTEM ELEC
EAS00819

CHECKING THE FUEL PUMP

WARNING
Gasoline is extremely flammable and under
certain circumstances there can be a danger
of an explosion or fire. Be extremely careful
and note the following points:

Stop the engine before refuelling.

Do not smoke, and keep away from open
flames, sparks, or any other source of fire.

If you do accidentally spill gasoline, wipe it
up immediately with dry rags.

If gasoline touches the engine when it is
not, a fire may occur. Therefore, make sure
that the engine is completely cool before
performing the following test.

1. Check:

fuel pump operation

a. Fill the fuel tank.

b. Put the end of the fuel hose into an open con-
tainer.
c. Turn the fuel cock to “ON”.
d. Connect the battery (12 V) to the fuel pump
coupler as shown.

Positive battery lead
black/blue 1

Negative battery lead
black 2
e. If fuel flows out of the fuel hose, the fuel pump
is OK.
If fuel does not flow, replace the fuel pump.
B/L

8-50
 EXUP SYSTEM ELEC
EAS00827

EXUP SYSTEM
CIRCUIT DIAGRAM

1 Main switch
5 Battery
7 Fuse (main)
12 EXUP servomotor
15 Ignitor
58 Fuse (ignition)

8-51
 EXUP SYSTEM ELEC
EAS00828 EAS00829

TROUBLESHOOTING Procedure 1

When the engine speed changes, the 1. EXUP servomotor operation (with the
EXUP servomotor does not operate. EXUP servomotor coupler connected to
the wire harness)
Procedure 1
Disconnect the EXUP cables at the EXUP
Check: servomotor pulley side.
1. EXUP servomotor operation
Start the engine and rev it to 5,000 r/min.
(with the EXUP servomotor coupler con-
nected to the wire harness)
Does the EXUP servomotor pulley turn?
2. Voltage
3. EXUP servomotor operation YES NO
(with the EXUP servomotor coupler discon-
nected from the wire harness) Check that the EXUP
4. EXUP servomotor resistance cables are properly
(potentiometer resistance) installed.
5. Wiring connections If the connections are
(the entire EXUP system) correct, check the
Procedure 2 EXUP valve and
Check: cables. Refer to “EX-
1. Main and turn signal fuses HAUST SYSTEM” in
2. Battery chapter 5.
3. Main switch
4. Neutral switch EAS00830

5. Engine stop switch 2. Voltage

6. Wiring connections

Connect the pocket tester (DC 20 V) to the
(the entire EXUP system)
EXUP servomotor coupler as shown.
NOTE:
Positive tester probe
black/red 1

Before troubleshooting, remove the following
Negative tester probe
black/yellow 2
part(s):
1) Seat
2) Fuel tank

Troubleshoot with the following special tool(s).

Pocket tester
90890-03112

Set the main switch to “ON”.

Measure the voltage (12 V) between
black/red 1 and black/yellow 2 .

Is the voltage within specification?

YES NO

Go to Procedure 2.

8-52
 EXUP SYSTEM ELEC
EAS00831

3. EXUP servomotor operation (with the

servomotor coupler disconnected to the
wire harness)

Disconnect the EXUP cables from the EXUP
servomotor pulley.

Disconnect the EXUP servomotor coupler
from the wire harness.

Connect the battery leads to the EXUP ser-
vomotor coupler as shown.
Positive tester probe
blue 1
Positive battery lead
black/yellow 1 Negative tester probe
white/red 2
Negative battery lead
black/red 2

While slowly turning the EXUP servomotor
pulley, measure the EXUP servomotor re-
sistance.
EXUP servomotor resistance
(when the pulley is turned once)
0  approximately 7.5 k Ω
(blue – white/red)

Is the EXUP servomotor OK?

YES NO

Check that the EXUP servomotor pulley ro-
tates several times.
The EXUP servomo-
CAUTION: tor is faulty and must
To prevent damaging the EXUP servomo- be replaced.
tor, perform this test within a few seconds
of connecting the battery. EAS00833

5. Wiring

Does the EXUP servomotor pulley turn?

Check the entire EXUP system’s wiring.
YES NO Refer to “CIRCUIT DIAGRAM”.

Is the EXUP system’s wiring properly con-
Replace the EXUP nected and without defects?
servomotor.
YES NO

EAS00832
Replace the ignitor Properly connect or
4. EXUP servomotor resistance unit. repair the EXUP sys-
(potentiometer resistance) tem’s wiring.

Disconnect the EXUP servomotor coupler
from the wire harness.

Connect the pocket tester (Ω
1 k) to the
EXUP servomotor coupler.

8-53
 EXUP SYSTEM ELEC
EAS00750
Procedure 2
EAS00738
4. Engine stop switch
1. Main and ignition fuses
S Check the engine stop switch for continuity.
S Check the main and ignition fuses for conti- Refer to “CHECKING THE SWITCHES”.
nuity.
S Is the engine stop switch OK?
Refer to “CHECKING THE FUSES” in chap-
ter 3. YES NO
S Are the main and ignition fuses OK?
Replace the right
YES NO
handlebar switch.

Replace the fuse(s). EAS00833

5. Wiring
EAS00739

2. Battery S Check the entire EXUP system’s wiring.

Refer to “CIRCUIT DIAGRAM”.
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING S Is the EXUP system’s wiring properly con-
THE BATTERY” in chapter 3. nected and without defects?

Minimum open-circuit voltage YES NO

12.8 V or more at 20_C
S Is the battery OK? Replace the ignitor Properly connect or
unit. repair the EXUP sys-
YES NO tem’s wiring.

S Clean the battery

terminals.
S Recharge or re-
place the battery.

EAS00749

3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?

YES NO

Replace the main

switch.

8-54
 SELF-DIAGNOSIS ELEC

SELF-DIAGNOSIS
The FZS1000 features a self-diagnosing system for the following circuit(-s):

Throttle position sensor

EXUP

Speed sensor

Emargency stop switch
If any of these circuits are defective, their respective condition codes will be displayed on the tachome-
ter when the main switch is set to “ON” (irrespective of whether the engine is running or not)

Circuit Defect(-s) System response Condition code

Throttle posi-
Disconnected
The ignitor unit stays set to the 3,000 r/min
tion sensor
Short-circuit wide-open throttle ignition timing.

Locked The motorcycle can be ridden.

The tachometer displays the
condition code.
EXUP
Improper
The EXUP valve stays in the open 7,000 r/min
connection position for three seconds and

Short-circuit then the servomotor shuts off. The
motorcycle can be ridden.

The tachometer displays the
condition code.

Servomotor is
The servomotor’s power supply is
locked. constantly inteerupted so that it
will not burn out. The motorcycle
can be ridden.

The tachometer displays the
condition code.
Speed sensor
Improper
The tachometer displays the 4,000 r/min
connection condition code.
Emargency
Disconnected
The tachometer displays the 9,000 r/min
stop switch
Short-circuit condition code.

Fail angle
Ignition system cutoff.

8-55
 SELF-DIAGNOSIS ELEC
Tachometer display sequence

Revolution 1 0 r / min ... 3 seconds

(
103 r / min) 2 Condition code ... 2.5 seconds Tachometer display
3 Engine speed ... 3 seconds

Engine speed

Time (seconds)

When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.

8-56
 SELF-DIAGNOSIS ELEC
TROUBLESHOOTING
1. Wire harness
The tachometer starts to display the self-
Check the wire harness for continuity.
diagnosis sequence. Refer to “CIRCUIT DIAGRAM”.
Check:
Is the wire harness OK?
1. Throttle position sensor
2. EXUP YES NO
3. Speed sensor
4. Emargency stop switch Repair or replace the
NOTE: wire harness.

Before troubleshooting, remove the following
part(-s):
1) Rider seat 2. Throttle position sensor
2) Fuel tank

Check the throttle position sensor for conti-
3) Air filter case
nuity.

Troubleshoot with the following special
Refer to “CHECKING AND ADJUSTING
tool(-s).
THE THROTTLE POSITION SENSOR” in
chapter 6.
Pocket tester
Is the throttle position sensor OK?
90890-03112
YES NO

1. Throttle position sensor

CIRCUIT DIAGRAM Replace the ignitor Replace the throttle
unit. position sensor.

13 Throttle position sensor

15 Ignitor unit

8-57
 SELF-DIAGNOSIS ELEC
2. EXUP
2. EXUP servomotor
CIRCUIT DIAGRAM

Check the EXUP servomotor for continuity.
Refer to “EXUP SYSTEM”.

Is the EXUP servomotor OK?

YES NO

Replace the ignitor Replace the EXUP

unit. servomotor.

12 EXUP servomotor
15 Ignitor unit

1. Wire harness

Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES NO

Repair or replace the

wire harness.

8-58
 SELF-DIAGNOSIS ELEC
3. Speed sensor
1. Wire harness
CIRCUIT DIAGRAM

Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES NO

Replace the speed

sensor.

BAD

Replace the ignitor Repair or replace the

unit. wire harness.

15 lgnitor unit
20 Speed sensor

8-59
 SELF-DIAGNOSIS ELEC
4. Emargency stop switch
1. Wire harness
CIRCUIT DIAGRAM

Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES NO

Replace the emar-

gency stop switch.

BAD

Replace the ignitor Repair or replace the

unit. wire harness.

14 Emargency stop switch

15 lgnitor unit

8-60
 TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING

STARTING PROBLEMS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

INCORRECT ENGINE IDLING SPEED

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

FAULTY CLUTCH
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

OVERHEATING
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

OVERCOOLING
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

FAULTY FRONT FORK LEGS

LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

 TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . 9-7
TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . 9-7
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
 TRBL
TROUBLESHOOTING SHTG
EAS00844

TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.

STARTING PROBLEMS
ENGINE
Cylinder(s) and cylinder head(s) Piston(s) and piston ring(s)

Loose spark plug
Improperly installed piston ring

Loose cylinder head or cylinder
Damaged, worn or fatigued piston ring

Damaged cylinder head gasket
Seized piston ring

Damaged cylinder gasket
Seized or damaged piston

Worn or damaged cylinder

Incorrect valve clearance Air filter

Improperly sealed valve
Improperly installed air filter

Incorrect valve-to-valve-seat contact
Clogged air filter element

Incorrect valve timing

Faulty valve spring Crankcase and crankshaft

Seized valve
Improperly assembled crankcase

Seized crankshaft

FUEL SYSTEM
Fuel tank Carburetor(s)

Empty fuel tank
Deteriorated or contaminated fuel

Clogged fuel filter
Clogged pilot jet

Clogged fuel strainer
Clogged pilot air passage

Clogged fuel tank drain hose
Sucked-in air

Clogged rollover valve
Damaged float

Clogged rollover valve hose
Worn needle valve

Deteriorated or contaminated fuel
Improperly installed needle valve seat

Incorrect fuel level
Fuel pump
Improperly installed pilot jet

Faulty fuel pump
Clogged starter jet

Faulty fuel pump relay
Faulty starter plunger

Improperly adjusted starter cable
Fuel cock

Clogged or damaged fuel hose

9-1
 TRBL
TROUBLESHOOTING SHTG
ELECTRICAL SYSTEMS
Battery Ignition system

Discharged battery
Faulty ignitor unit

Faulty battery
Faulty pickup coil

Broken generator rotor woodruff key
Fuse(s)

Blown, damaged or incorrect fuse Switches and wiring

Improperly installed fuse
Faulty main switch

Faulty engine stop switch
Spark plug(s)
Broken or shorted wiring

Incorrect spark plug gap
Faulty neutral switch

Incorrect spark plug heat range
Faulty start switch

Fouled spark plug
Faulty sidestand switch

Worn or damaged electrode
Faulty clutch switch

Worn or damaged insulator
Improperly grounded circuit

Faulty spark plug cap
Loose connections

Ignition coil(s) Starting system

Cracked or broken ignition coil
Faulty starter motor

Broken or shorted primary or secondary
Faulty starter relay
coils
Faulty starting circuit cutoff relay

Faulty spark plug lead
Faulty starter clutch

EAS00846

INCORRECT ENGINE IDLING SPEED

ENGINE ELECTRICAL SYSTEMS
Cylinder(s) and cylinder head(s) Battery

Incorrect valve clearance
Discharged battery

Damaged valve train components
Faulty battery

Air filter Spark plug(s)

Clogged air filter element
Incorrect spark plug gap

Incorrect spark plug heat range
FUEL SYSTEM
Fouled spark plug
Carburetor(s)
Worn or damaged electrode

Faulty starter plunger
Worn or damaged insulator

Loose or clogged pilot jet
Faulty spark plug cap

Loose or clogged pilot air jet

Damaged or loose carburetor joint Ignition coil(s)

Improperly synchronized carburetors
Broken or shorted primary or secondary

Improperly adjusted engine idling speed coils
(throttle stop screw)
Faulty spark plug lead

Improper throttle cable free play
Cracked or broken ignition coil

Flooded carburetor

Faulty air induction system Ignition system

Faulty ignitor unit

Faulty pickup coil

Broken generator rotor woodruff key

9-2
 TRBL
TROUBLESHOOTING SHTG
EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to “STARTING PROBLEMS”.

ENGINE FUEL SYSTEM

Air filter Carburetor(s)

Clogged air filter element
Faulty diaphragm

Incorrect fuel level

Loose or clogged main jet

Fuel pump

Faulty fuel pump

EAS00850

FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT JUMPS OUT OF GEAR
Refer to “CLUTCH DRAGS”. Shift shaft

Incorrect shift pedal position
SHIFT PEDAL DOES NOT MOVE
Improperly returned stopper lever
Shift shaft

Improperly adjusted shift rod Shift forks

Bent shift shaft.
Worn shift fork

Shift drum and shift forks Shift drum

Foreign object in a shift drum groove
Incorrect axial play

Seized shift fork
Worn shift drum groove

Bent shift fork guide bar
Transmission
Transmission
Worn gear dog

Seized transmission gear

Foreign object between transmission
gears

Improperly assembled transmission

9-3
 TRBL
TROUBLESHOOTING SHTG
EAS00851

FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
Clutch Clutch

Improperly assembled clutch
Unevenly tensioned clutch springs

Improperly adjusted clutch cable
Warped pressure plate

Loose or fatigued clutch spring
Bent clutch plate

Worn friction plate
Swollen friction plate

Worn clutch plate
Bent clutch push rod

Broken clutch boss
Engine oil
Burnt primary driven gear bushing

Incorrect oil level
Match marks not aligned

Incorrect oil viscosity (low)

Deteriorated oil Engine oil

Incorrect oil level

Incorrect oil viscosity (high)

Deteriorated oil

EAS00855

OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Carburetor(s)

Cylinder head(s) and piston(s)
Incorrect main jet setting

Heavy carbon buildup
Incorrect fuel level

Damaged or loose carburetor joint
Engine oil

Incorrect oil level Air filter

Incorrect oil viscosity
Clogged air filter element

Inferior oil quality
CHASSIS
COOLING SYSTEM Brake(s)
Coolant
Dragging brake

Low coolant level
ELECTRICAL SYSTEMS
Radiator Spark plug(s)

Damaged or leaking radiator
Incorrect spark plug gap

Faulty radiator cap
Incorrect spark plug heat range

Bent or damaged radiator fin
Ignition system
Water pump
Faulty ignitor unit

Damaged or faulty water pump

Thermostat

Thermostat stays closed

Oil cooler

Clogged or damaged oil cooler

Hose(s) and pipe(s)

Damaged hose

Improperly connected hose

Damaged pipe

Improperly connected pipe

9-4
 TRBL
TROUBLESHOOTING SHTG
EAS00856

OVERCOOLING
COOLING SYSTEM
Thermostat

Thermostat stays open

EAS00857

POOR BRAKING PERFORMANCE

Worn brake pad

Worn brake disc

Air in hydraulic brake system

Leaking brake fluid

Faulty brake caliper seal

Loose union bolt

Damaged brake hose

Oil or grease on the brake disc

Oil or grease on the brake pad

Incorrect brake fluid level

EAS00861

FAULTY FRONT FORK LEGS

LEAKING OIL MALFUNCTION

Bent, damaged or rusty inner tube
Bent or damaged inner tube

Cracked or damaged outer tube
Bent or damaged outer tube

Improperly installed oil seal
Damaged fork spring

Damaged oil seal lip
Worn or damaged outer tube bushing

Incorrect oil level (high)
Bent or damaged damper rod

Loose damper rod bolt
Incorrect oil viscosity

Damaged damper rod bolt copper washer
Incorrect oil level

Cracked or damaged cap bolt O-ring

9-5
 TRBL
TROUBLESHOOTING SHTG
EAS00862

UNSTABLE HANDLING
Handlebar Rear shock absorber assembly(-ies)

Bent or improperly installed handlebar
Faulty rear shock absorber spring

Leaking oil or gas
Steering head components

Improperly installed upper bracket Tire(s)

Improperly installed lower bracket
Uneven tire pressures (front and rear)
(improperly tightened ring nut)
Incorrect tire pressure

Bent steering stem
Uneven tire wear

Damaged ball bearing or bearing race
Wheel(s)
Front fork leg(s)
Incorrect wheel balance

Uneven oil levels (both front fork legs)
Deformed cast wheel

Unevenly tensioned fork spring
Damaged wheel bearing
(both front fork legs)
Bent or loose wheel axle

Broken fork spring
Excessive wheel runout

Bent or damaged inner tube

Bent or damaged outer tube Frame

Bent frame
Swingarm
Damaged steering head pipe

Worn bearing or bushing
Improperly installed bearing race

Bent or damaged swingarm

9-6
 TRBL
TROUBLESHOOTING SHTG
EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEM

HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT

Wrong headlight bulb
Faulty turn signal switch

Too many electrical accessories
Faulty turn signal relay

Hard charging
Burnt-out turn signal bulb

Incorrect connection
Incorrect connection

Improperly grounded circuit
Damaged or faulty wire harness

Poor contacts (main or light switch)
Improperly grounded circuit

Burnt-out headlight bulb
Faulty battery

Blown, damaged or incorrect fuse
HEADLIGHT BULB BURNT OUT

Wrong headlight bulb TURN SIGNAL BLINKS SLOWLY

Faulty battery
Faulty turn signal relay

Faulty rectifier/regulator
Faulty main switch

Improperly grounded circuit
Faulty turn signal switch

Faulty main switch
Incorrect turn signal bulb

Faulty light switch

Headlight bulb life expired TURN SIGNAL REMAINS LIT

Faulty turn signal relay
TAIL/BRAKE LIGHT DOES NOT LIGHT
Burnt-out turn signal bulb

Wrong tail/brake light bulb

Too many electrical accessories TURN SIGNAL BLINKS QUICKLY

Incorrect connection
Incorrect turn signal bulb

Burnt-out tail/brake light bulb
Faulty turn signal relay

Burnt-out turn signal bulb
TAIL/BRAKE LIGHT BULB BURNT OUT

Wrong tail/brake light bulb HORN DOES NOT SOUND

Faulty battery
Improperly adjusted horn

Incorrectly adjusted rear brake light switch
Damaged or faulty horn

Tail/brake light bulb life expired
Faulty main switch

Faulty horn switch

Faulty battery

Blown, damaged or incorrect fuse

Faulty wire harness

9-7
FZS1000 2001 WIRING DIAGRAM (EUR) 1 Main switch 35 Oil level gauge
2 Rectifier/ regulator 36 Fuel sender
3 AC magneto 37 Turn signal relay
4 Fuse (back up) 38 Handlebar switch (right)
5 Battery 39 Front brake light switch
6 Starter relay 40 Headlight switch
7 Fuse (main) 41 Engine stop switch
8 Starter motor 42 Start switch
9 Starting circuit cutoff relay 43 Horn
10 Sidestand switch 44 Handlebar switch (left)
11 Fuel pump 45 Pass switch
12 EXUP servo motor 46 Dimmer switch
13 T.P.S. 47 Horn switch
14 Emargency stop switch 48 Clutch switch
15 Igniter 49 Hazard switch
16 Ignition coil 50 Turn signal switch
17 Spark plug 51 Front turn signal light (left)
18 Pickup coil 52 Front turn signal light (right)
19 Neutral switch 53 Rear turn signal light (left)
20 Speed sensor 54 Rear turn signal light (right)
21 Thermo unit 55 Headlight
22 Meter assembly 56 Tail/ brake light
23 Fuel level warning light 57 Fuse (turn signal)
24 Oil level warning light 58 Fuse (ignition)
25 Neutral indicator light 59 Alarm
26 Tacho meter 60 Fuse (alarm)
27 Combination meter 61 Fuse (headlight)
28 Water temp warning light 62 Fuse (fan)
29 Fuel gauge 63 Fan motor relay
30 Speedometer 64 Fan motor
31 Hi-beam indicator light 65 Rear brake light switch
32 Turn signal indicator light (left) 66 Headlight relay (on / off)
33 Turn signal indicator light (right) 67 Head light relay (dimmer)
34 Meter light

B ....... Black Br/ R . . . . Brown/ Red

Br . . . . . . Brown Br/ W . . . Brown/ White
Ch . . . . . Chocolate G/B . . . . Green / Black
Dg . . . . . Dark green G/R . . . . Green / Red
G ...... Green G/W . . . . Green / White
Gy . . . . . Gray G/Y . . . . Green / Yellow
L ....... Blue L/B . . . . . Blue/ Black
Lg . . . . . . Light green L/R . . . . . Blue/ Red
O ...... Orange
L/W . . . . Blue/ White
P ....... Pink
L/Y . . . . . Blue/ Yellow
R....... Red
O/R . . . . Orange / Red
Sb . . . . . . Sky blue
R/ B . . . . . Red/ Black
W ...... White
Y ....... Yellow R/ G . . . . Red/ Green
B/ G . . . . Black/ Green R/ W . . . . Red/ White
B/ L . . . . . Black/ Blue R/ Y . . . . . Red/ Yellow
B/ R . . . . . Black/ Red Sb/ W . . . Sky blue / White
B/ W . . . . Black/ White W/ R . . . . White/ Red
B/ Y . . . . . Black/ Yellow W/ Y . . . . White/ Yellow
Br/ B . . . . Brown/ Black Y/ B . . . . . Yellow/ Black
Br/ L . . . . Brown/ Blue Y/ G . . . . Yellow/ Green
FZS1000 N 2001 WIRING DIAGRAM (OCE)
1 Main switch 32 Turn signal indicator light (left)
2 Rectifier/ regulator 33 Turn signal indicator light (right)
3 AC magneto 34 Meter light
4 Fuse (back up) 35 Oil level gauge
5 Battery 36 Fuel sender
6 Starter relay 37 Turn signal relay
7 Fuse (main) 38 Handlebar switch (right)
8 Starter motor 39 Front brake light switch
9 Starting circuit cutoff relay 40 Engine stop switch
10 Sidestand switch 41 Start switch
11 Fuel pump 42 Horn
12 EXUP servo motor 43 Handlebar switch (left)
13 T.P.S. 44 Pass switch
14 Emargency stop switch 45 Dimmer switch
15 Igniter 46 Horn switch
16 Ignition coil 47 Clutch switch
17 Spark plug 48 Turn signal switch
18 Pickup coil 49 Front turn signal light (left)
19 Neutral switch 50 Front turn signal light (right)
20 Speed sensor 51 Rear turn signal light (left)
21 Thermo unit 52 Rear turn signal light (right)
22 Meter assembly 53 Headlight
23 Fuel level warning light 54 Tail/ brake light
24 Oil level warning light 55 Fuse (ignition)
25 Neutral indicator light 56 Fuse (turn signal)
26 Tacho meter 57 Fuse (headlight)
27 Combination meter 58 Fuse (fan)
28 Water temp warning light 59 Fan motor relay
29 Fuel gauge 60 Fan motor
30 Speedometer 61 Rear brake light switch
31 Hi-beam indicator light 62 Head light relay (dimmer)

B ....... Black Br/ R . . . . Brown/ Red

Br . . . . . . Brown Br/ W . . . Brown/ White
Ch . . . . . Chocolate G/B . . . . Green / Black
Dg . . . . . Dark green G/R . . . . Green / Red
G ...... Green G/W . . . . Green / White
Gy . . . . . Gray G/Y . . . . Green / Yellow
L ....... Blue L/B . . . . . Blue/ Black
Lg . . . . . . Light green L/R . . . . . Blue/ Red
O ...... Orange
L/W . . . . Blue/ White
P ....... Pink
L/Y . . . . . Blue/ Yellow
R....... Red
O/R . . . . Orange / Red
Sb . . . . . . Sky blue
R/ B . . . . . Red/ Black
W ...... White
Y ....... Yellow R/ G . . . . Red/ Green
B/ G . . . . Black/ Green R/ W . . . . Red/ White
B/ L . . . . . Black/ Blue R/ Y . . . . . Red/ Yellow
B/ R . . . . . Black/ Red Sb/ W . . . Sky blue / White
B/ W . . . . Black/ White W/ R . . . . White/ Red
B/ Y . . . . . Black/ Yellow W/ Y . . . . White/ Yellow
Br/ B . . . . Brown/ Black Y/ B . . . . . Yellow/ Black
Br/ L . . . . Brown/ Blue Y/ G . . . . Yellow/ Green