PDF At115 2002 Nouvo

AT115
SERVICEMANUAL
5MX-F8197-E0

EAS00000
AT115
SERVICE MANUAL
©2002 by Yamaha
Yamaha Motor Co., Ltd.
First edition, January 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs
rep airs 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 vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING 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
motorcycle.
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.

EASF0007
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic checks and adjustments” the 3rd title
appears.)
3rd title 3: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step fformat.
ormat. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “” with each proce-
dure preceded by “”.
IMPROTANT FEATURES
 Data and a special tool are framed in a box preceded by a relevant symbol 5.
 An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

 A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.

EASF0009
1 2
SYMBOLS
GEN The following symbols are not relevant to
SPEC
INFO every vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
CHK 1 General information
2 Specifications
ADJ ENG 3 Periodic checks and adjustments
4 Engine
5 6
5 Carburetor
6 Chassis
CARB CHAS 7 Electrical system
8 Troubleshooting
7 8
– + TRBL
ELEC SHTG
9 0 Symbols 9 to F indicate the following.
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data
C D

T
.
R
.
E F
G H I Symbols G to L in the exploded diagrams

indicate the types of lubricants and lubrication
points.
E G M G Engine oil
H Gear oil
J K L
I Molybdenum-disulfide oil
J Wheel-bearing grease
B LS M K Lithium-soap-based grease
L Molybdenum-disulfide grease
M N Symbols M to N in the exploded diagrams

indicate the following.
LT New M Apply locking agent (LOCTITE ® )

N Replace the part

EASF0011
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO
1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG
4
CARBURETOR CARB 5
CHASSIS CHAS 6
– +
ELECTRICAL SYSTEM ELEC

7
TROUBLESHOOTING TRBL
SHTG 8

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION..................................................................1-1
IDENTIFICATION ..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................
..................................... ................ 1-1
ENGINE SERIAL NUMBER ......................................................................
........................................ .............................. 1-1
FEATURES ......................................................................................................1-2
FEATURES......................................................................................................1-2
V-BELT POWERMATIC .....................................................................
................................ ............................................
....... 1-2
TORQUE CAM ..........................................................................
.................................... ......................................................
................ 1-5
IMPORTANT INFORMATION .........................................................................1-6

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-6
REPLACEMENT PARTS...........................................................................1-6
GASKETS, OIL SEALS AND O-RINGS ....................................................
................................... ................. 1-6
LOCK WASHERS/PLATES
WASHERS/PLATES AND COTTER PINS ..................................... 1-7
BEARINGS AND OIL SEALS ....................................................................
....................................... ............................. 1-7
CIRCLIPS ........................................................................
................................... ...............................................................
.......................... 1-7
CHECKING THE CONNECTIONS ..................................................................1-8
SPECIAL TOOLS ............................................................................................1-9

GEN
INFO

GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
1 EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification 1 is stamped into
the frame.
EASF0016
ENGINE SERIAL NUMBER
1 The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1-1

GEN
FEATURES INFO
EAS00019
FEATURES
V-BELT POWERMATIC
Mechanism
A variable ratio V-belt transmission, which is fully automatic, has been adopted.
To accommodate the engine speed, the optimum transmission ratio is automatically established. In
addition, shocks cannot be felt when changing speeds, and smooth acceleration and an excellent
climbing power can be achieved.
This transmission mechanism consists of a primary pulley and a secondary pulley, which are con-
nected by a V-belt. Also, the reduction ratio changes according to the movement of the V-belt.
1 2 3 4 5
C B A 0 9 8
1 Crankshaft 6 Secondary fixed sheave A Clutch carrier

2 Primary sliding sheave 7 Secondary sliding sheave B V-belt
3 Primary pulley weight 8 Spring C Primary fixed sheave
4 Main axle 9 Primary drive gear
5 Drive axle 0 Clutch housing
1-2

GEN
FEATURES INFO
Operation
1. Idl
Idle
e speed
speed operati
operation
on
When the engine speed is at idle, power is transmitted from the primary pulley, V-belt, and sec-
ondary pulley to the clutch carrier. However, power is not transmitted to the clutch housing
because the centrifugal force of the clutch carrier is weaker than the tension of the clutch springs,
thus the clutch carrier (shoe) does not come into contact with the clutch housing.
2. St
Start
artin
ing
g out
out
When engine speed reaches approximately 3,000 r/min, the centrifugal force of the clutch carrier
becomes stronger than the tension of the clutch springs. This causes the clutch carrier (shoe) to
come into contact with the clutch housing and to initiate frictional force (transmission torque).
When this occurs, the V-belt moves inward toward the inner diameter of the primary pulley and
outward toward the perimeter of the secondary pulley. Also, the reduction ratio is maximized and
sufficient driving force is transmitted to the rear wheel.
1 2 Clut
Clutch
ch--in re
revo
vollut
utio
ion
n 2,
2,55
550
0 ~ 2,
2,95
950
0 rpm
rpm
Clutch
Clutch-st
-stall
all revolut
revolution
ion 4,700
4,700 ~ 5,300
5,300 rpm
rpm
1 V-belt
2 Secondary pulley
3 Primary pulley
1-3

GEN
FEATURES INFO
3. Med
Medium
ium-sp
-speed
eed operati
operation
on
As engine speed increases, the primary pulley weight is moved outward by centrifugal force.
The primary pulley weight pushes the primary sliding sheave towards the primary fixed sheave,
which forces the V-belt toward the outer perimeter of the primary pulley. When this occurs, the
diameter of the V-belt is increased at the primary pulley. As the diameter of the V-belt increases,
the belt is pulled at the secondary pulley because the length of the belt is constant. As a result,
the belt is pushed toward the inner diameter of the secondary pulley until the tension of the V-belt
and clutch springs is balanced. When this occurs, the diameter of the V-belt is decreased at the
secondary pulley and the reduction ratio gradually decreases and the speed of the secondary
pulley gradually increases.
4. Hig
High-s
h-speed
peed operati
operation
on
As engine speed increases from medium-speed operation, the primary pulley weight moves fur-
ther outward, the primary sliding sheave is pushed closer toward the primary fixed sheave, and
the V-belt is forced further outward toward the perimeter of the primary pulley.
At the secondary pulley the V-belt is forced further inward and, as a result, the reduction ratio is
minimized.
1-4

GEN
FEATURES INFO
TORQUE CAM
When a powerful torque is needed
ne eded to climb hills, powerful climbing power is delivered from the
t he oper-
ation of the torque cam, not from driving skill of the rider.
Operation
When the motorcycle approaches a hill, the load of the rear wheel increases and traveling speed is
reduced. As the throttle is opened to increase speed, the torque of the engine increases and the
secondary sliding sheave forces the V-belt outward toward the perimeter of the secondary pulley.
As a result, the diameter of the V-belt increases at the secondary pulley, and at the same time a
large driving force, excellent operation, excellent acceleration ability, and powerful climbing capabil-
ities are achieved because the transmission ratio is also increased.
Normal operation Climbing hills or quick acceleration
1 2
3
È
É 3
1 Secondary fixed sheave È Small load on rear wheel
2
3 Secondary
V-belt sliding sheave É Large load on rear wheel
4 Torque cam
1-5

GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal
removal and disassembly,
disassembly, remov
remove e all
dirt, mud, dust and foreign material.
2. Use only
only the proper
proper tools and cleaning
cleaning
equipment.
Refer to the “SPECIAL TOOLS”
TOOLS”.
3. When disassemb
disassembling,
ling, alwa
always
ys keep
keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated
mated”” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassemb
disassembly ly,, clean all of the
the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all par ts.
5. Keep
Keep all parts away
away from
from any source
source of fire.
fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. 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
1. When overhaul
overhauling
ing the engine,
engine, replace
replace all
all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembl
reassembly y, properly oil all mating
mating
parts and bearings and lubricate the oil seal
lips with grease.
1-6

GEN
IMPORTANT INFORMATION INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’’s marks or numbers are visible. When
facturer
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.
1 Oil seal
_
CAUTION:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-7

GEN
CHECKING THE CONNECTIONS INFO
EAS00026
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disc
Disconn
onnec
ect:
t:
• lead
• coupler
• connector
2. Chec
Check:k:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Chec
Check:k:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it

up.
4. Conn
Connec
ect:
t:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Chec
Check:k:
• continuity
(with the 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.
1-8

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 inappropri-
ate 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/Usage Illustration
Weight
Weight Slide hammer bolt
90890-01084
Slide hammer bolt
90890-01085 These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight
90890-01184
This tool is used to installing the oil seal.

Fork seal driver attachment
90890-01186
This tool is used to installing the oil seal.

Flywheel puller
90890-01189
This tool is used for removing the rotor.

Rotor holding tool
90890-01235
This tool is used to hold the generator
rotor when removing or installing the
generator rotor bolt.
Valve spring compressor
90890-01253
These tools are used when removing or
installing the valve and the valve spring.
Ring nut wrench
90890-01268
This tool is used to loosen and tighten
the steering ring nut.
1-9

GEN
SPECIAL TOOLS INFO
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
T-handle
90890-01326
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
Clutch spring holder
90890-01337
This tool is used to disassembly and
assembly the secondary pulley.
Locknut wrench
90890-01348
the clutch carrier locknut of the second-
ary pulley.
Steering nut wrench
90890-01403
the steering ring nut.
Oil seal guide
90890-01384
This tool is used to install oil seals.

Sheave holder
90890-01701
This tool is used for holding the second-
ary pulley.
1 - 10

GEN
SPECIAL TOOLS INFO
Thickness gauge
90890-03079
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer
90890-03113
This tool is needed for detecting engine
rpm.
Valve guide remover (5 mm)
90890-04097
This tool is needed to remove and
install the valve guide.
Valve guide installer (5 mm)
90890-04098
This tool is needed to install the valve
guide.
Valve guide reamer (5 mm)
90890-04099
This tool is needed to rebore the new
valve guide.
Valve lapper
90890-04101
This tool is used for removing and
installing the lifter and for lapping the
valve.
1 - 11

GEN
SPECIAL TOOLS INFO
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
Yamaha bond No. 1215
90890-85505
This sealant (bond) is used for crank-
case mating surface, etc.
1 - 12

SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
MAINTENANCE SPECIFICATIONS ...............................................................2-4

ENGINE.....................................................................................................2-4
TIGHTENING TORQUES..........................................................................2-8
CHASSIS.................................................................................................2-10
TIGHTENING TORQUES........................................................................2-12
ELECTRICAL ..................................................................................
........................................ ..................................................
........ 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-16

SPECIFICATIONS ...............................2-16
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-17

ENGINE ..................................................................................................2-17
CHASSIS ................................................................................................2-18
CABLE ROUTING .........................................................................................2-19

SPEC

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AT115
Model code 5MX1
Dimensions
Overall length 1,935 mm

Overall width 675 mm
Overall height 1,070 mm
Seat height 755 mm
Wheelbase 1,280 mm
Minimum ground clearance 135 mm
Minimum turning radius 1,900 mm
Weight
Wet (with oil and full fuel tank) 103 kg
Engine
Engine type Forced-air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.1137 L
Bore × s
sttroke 50.0 × 57.9 mm
Compression ratio 8.8 : 1
Compression pressure (STD) 1,100 kPa (11 kgf/cm2) at 510 r/min
Starting system Kick and electric starter
Lubrication system Wet sump
Engine idling speed 1,500 ~ 1,700 r/min
Oil type or grade
Engine oil YAMALUBE 4, SAE 10W30 SE/F or
SAE 20W40 SE/F
Periodic oil change 0.8 L
Total amount 0.9 L
Transmission oil
Recommended oil Engine oil

Periodic oil change 0.1 L
Total amount 0.12 L
Air filter Dry type element
Fuel
Recommended fuel Regular gasoline
Fuel tank capacity 4.9 L
2-1


Model AT115
Carburetor
Type/quantity BS25/1
Manufacturer MIKUNI
Spark plug
Type CR7HSA
Manufacturer NGK
Spark plug gap 0.6 ~ 0.7 mm
Clutch type V-belt automatic
Transmission
Primary reduction system Helical gear
Primary reduction ratio 47/15 (3.133)
Secondary reduction system Spur gear
Secondary reduction ratio 43/12 (3.538)
Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Craasilter angle
T 21
152
° mm
Tire
Type With tube
Size front 70/90-16 36P
rear 80/90-16 43P
Model (manufacturer) front D110 (DUNLOP)
rear D110 (DUNLOP)
Min. tire tread depth front 0.8 mm
rear 0.8 mm
Tire pressure (cold tire)
Maximum load*-except motorcycle 116 kg
front 200 kPa (2.00 kg/cm2)
rear 225 kPa (2.25 kg/cm2)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2


Model AT115
Brake
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left ha
hand op
operation
Suspension
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 90 mm
Rear wheel travel 50 mm
Electrical
Ignition system DC. C.D.I.
Generator system A.C. magneto
B
Baatttte
erry
yctyappea/m
citaynufacturer Y
12B7
VB7-BA/H
YUASA
Headlight type Incandescence bulb
Bulbs (voltage/wattage × quantity)
Headlight 12 V 25 W/25 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Front turn signal light 12 V 10 W × 2
Rear turn signal light 12 V 10 W × 2
Meter light 12 V 3.4 W × 1
12 V 1.7 W × 1
High beam indicator light 12 V 1.7 W × 1
Turn indicator light 12 V 3.4 W × 2
2-3

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit

Cylinder head
Max. warpage “*” ---- 0.05 mm
Cylinder
Bore 50.000 ~ 50.010 mm 50.1 mm
Warp limit ---- 0.05 mm
Camshaft
Drive method Chain drive (left)
Cam dimensions
Intake “A” A 25.881 ~ 25.981 mm 25.780 mm
“B” 21.195 ~ 21.295 mm 21.095 mm
Exhaust “A” 25.841 ~ 25.941 mm 25.740 mm
“B” 21.050 ~ 21.150 mm 20.950 mm
B
Camshaft runout limit ---- 0.03 mm

Cam chain
Cam chain type/No. of links DID SCR-0404 SDH/90
Rocker arm/rocker armshaft
Rocker arm inside diameter 10.000 ~ 10.015 mm 10.030 mm
Rocker shaft outside diameter 9.981 ~ 9.991 mm 9.950 mm
Rocker arm-to-rocker arm shaft 0.009 ~ 0.034 mm 0.08 mm
clearance
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.08 ~ 0.12 mm ----
EX 0.08 ~ 0.12 mm ----
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness

“A” he
head diameter IN 22.9 ~ 23.1 mm ----
EX 19.9 ~ 20.1 mm ----
“B” fa
face width IN 1.20 ~ 2.50 mm ----
EX 1.30 ~ 2.40 mm ----
“C” s
seeat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.9 ~ 1.1 mm 1.6 mm
“D” m
ma
argin thickness IN 0.7 mm ----
EX 1.0 mm ----
2-4


Item Standard Limit
Stem outside diameter IN 4.970 ~ 4.985 mm 4.930 mm
EX 4.955 ~ 4.970 mm 4.920 mm
Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm
EX 5.000 ~ 5.012 mm 5.050 mm
Valve stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.080 mm
EX 0.030 ~ 0.057 mm 0.110 mm

Valve stem runout limit ---- 0.01 mm
Valve spring
Free length IN/EX 35.44 mm 34.00 mm
Tilt limit “*” I
INN/EX ---- 2.5° /1.5 mm
Winding direction IN/EX Clockwise ----

Piston
Piston to cylinder clearance 0.020 ~ 0.035 mm 0.150 mm
Piston size “D” 49.970 ~ 49.985 mm ----
Measuring point “H” 5.0 mm ----
Offset 0.5 mm ----
H
Offset direction D Intake side ----
Piston pin bore inside diameter 15.002 ~ 15.013 mm 15.043 mm
Piston pin outside diameter 14.995 ~ 15.000 mm 14.975 mm
Piston rings
Top ring
Ring type Barrel ----
Dimensions (B × T T)) B 1.00 × 1
1..85 mm ----
End gap (installed) T 0.10 ~ 0.25 mm 0.50 mm
Ring side clearance (installed) 0.03 ~ 0.07 mm 0.12 mm
2nd ring
Ring type Taper ----
Dimensions (B × T T)) B 1.0 × 2.0 mm ----
End gap (installed) T 0.10 ~ 0.25 mm 0.60 mm
Ring side clearance 0.02 ~ 0.06 mm 0.12 mm
Oil ring
B
Dimensions (B × T T)) 2.0 × 2.2 mm ----
End gap (installed) T 0.20 ~ 0.70 mm ----
2-5


Item Standard Limit
Crankshaft
C C
A
Crank width “A” 45.45 ~ 45.50 mm ----
Max. runout limit “C” ---- 0.03 mm
Big end side clearance “D” 0.15 ~ 0.45 mm ----
Big end radial clearance “E” 0.004 ~ 0.014 mm ----
Clutch
Clutch shoe thickness 2.0 mm 1.0 mm
Clutch shoe spring free length 28.8 mm
Clutch housing inside diameter 112 mm 112.5 mm
Compression spring free length 76 mm 73 mm
Weight outside diameter 15 mm 14.5 mm
Clutch - in revolution 2,550 ~ 2,950 r/min ----

Clutch - stall revolution 4,700 ~ 5,300 r/min ----
V-belt
V-belt width 18.2 mm 17.2 mm
Kick starter
Kick starter type Ratchet type ----
Kick clip friction force 1.5 ~ 2.5 N (0.15 ~ 0.25 kgf) ----
Carburetor
Type BS25
I.D. mark 5MX1 00 ----
Main jet (M.J) #100 ----
Main air jet (M.A.J) ø0.8 ----
Jet needle (J.N) 4DFZ03-2 ----
Needle jet (N.J) E-3M (906) ----
Pilot air jet 1 #90 ----
Pilot air jet 2 #90 ----
Pilot outlet (P.O) ø0.8 ----
Pilot jet (P.J) #17.5 ----
Bypass 1 0.7 ----
Bypass 2 0.7 ----
Bypass 3 0.7 ----
Bypass 4 0.7 ----
Pilot screw turns out 1-1/2 ----
Valve seat size ø1.8 ----
Starter jet 1 #30 ----
Starter jet 2 ø0.6 ----
Throttle valve size #115 ----
2-6


Item Standard Limit
Oil filter type Wire mesh ----
Oil pump
Oil pump type Trochoid type ----
Inner rotor to outer rotor tip clearance 0.15 mm 0.23 mm
Outer rotor to pump housing 0.13 ~ 0.18 mm 0.25 mm
clearance
Housing and rotor clearance 0.06 ~ 0.10 mm 0.17 mm
Rotor thickness 7.96 ~ 7.98 mm ----
Model AT115
Lubrication chart
OIL RING PISTON CYLINDER HEAD CAMSHAFT
CONNECTING
ROD BIG END
CRANKSHAFT
OIL PUMP
OIL STRAINER
OIL PAN
2-7


TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Spark plug — M10 1 13 1.3
Cylinder head Nut M8 4 22 2.2 E
Cylinder head (timing chain side) Bolt M6 2 10 1.0

Cylinder head stud bolt Bolt M8 2 13 1.3
Oil gallery bolt Bolt M6 1 7 0.7
Tappet cover (intake and exhaust side) — M45 2 18 1.8
Camshaft sprocket cover Bolt M6 2 12 1.2
Camshaft retainer Bolt M6 1 12 1.2
Camshaft sprocket cover breather plate Bolt M6 2 10 1.0
Camshaft sprocket Bolt M8 1 30 3.0
Valve adjusting locknut Nut M5 2 7 0.7
Chain guide retainer (intake side) Bolt M6 1 7 0.7
Timing chain tensioner Bolt M6 2 9 0.9
Timing chain tensioner cap bolt Bolt M8 1 8 0.8
Engine cooling fan cover Screw M6 3 7 0.7
Engine cooling fan Bolt M6 3 10 1.0
Generator rotor Nut M12 1 70 7.0
Oil pump cover Bolt M6 3 10 1.0
Oil pump Screw M5 2 4 0.4
Engine oil drain plug Plug M30 1 20 2.0
Engine oil drain bolt Bolt M12 1 20 2.0
Transmission oil drain bolt Bolt M8 1 22 2.2
Muffler and cylinder head Nut M8 2 20 2.0
Muffler and rear suspension arm Bolt M8 2 35 3.5
Muffler protector 1 Bolt M6 3 11 1.1 LT
Exhaust pipe protector Bolt M6 2 11 1.1

Muffler cap Bolt M6 3 11 1.1 LT
Muffler protector 2 Bolt M6 2 11 1.1 LT
Intake manifold Bolt M6 2 10 1.0

Air filter case Bolt M6 2 10 1.0
Kickstarter crank Bolt M6 1 11 1.1
V-belt case cover protector 1 Bolt M8 2 23 2.3
V-belt case air filter cover Bolt M6 3 10 1.0
V-belt case cover Bolt M6 13 10 1.0
V-belt case cover protector 2 Bolt M6 2 10 1.0
Kickstarter shaft plate Screw M6 4 9 0.9
Secondary pulley nut Nut M10 1 40 4.0
Clutch carrier nut Nut M28 1 75 7.5
Transmission case cover Bolt M6 6 13 1.3
Bearing retainer (primary drive gear) Bolt M6 1 10 1.0 LT
2-8


Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Primary pulley nut Nut M12 1 55 5.5
Idle gear plate Bolt M6 2 10 1.0
Starter wheel gear holder Bolt M6 1 10 1.0
Crankcase (left and right) Bolt M6 9 10 1.0
Crankcase stud bolt Bolt M8 4 13 1.3
Stator coil Bolt M6 3 11 1.1
Pickup coil bracket Screw M6 2 7 0.7
Starter motor Bolt M6 2 7 0.7
2-9


CHASSIS
Item Standard Limit

Steering system
Steering bearing type Angular bearing ----
Lock to lock angle left 50° ----
Lock to lock angle right 50° ----
Front suspension
Front fork travel 90 mm ----
Front absorber travel 50 mm ----
Fork spring free length 307.7 mm 301.5 mm
Installed length 287.7 mm ----
Spring rate (K1) 7.8 N/mm (0.8 kgf/mm) ----
(K2) 15.6 N/mm (1.59 kgf/mm) ----
Stroke (K1) 0 ~ 50 mm ----
(K2) 50 ~ 90 mm ----
Optional spring available No ----
Oil capacity 0.063 L (63.0 cm3) ----
Oil level 106 mm ----
Recommended oil Fork oil 10 W or equivalent ----

Inner tube outer diameter 26 mm ----
Inner tube vend limit ---- 0.2 mm
Rear suspension
Shock absorber stroke 50 mm ----
Spring free length 203.6 mm 199.5 mm
Installed length 198.6 mm ----
Spring rate (K1) 30 N/mm (3.06 kgf/mm) ----
(K2) 74.3 N/mm (7.58 kgf/mm) ----
Stroke (K1) 0 ~ 15 mm ----
(K2) 15 ~ 50 mm ----
Optional spring available No
Front wheel
Type Spoke wheel ----
Rim size 16 × 1
1..40 ----
Rim material Steel ----
Max. radial wheel runout ---- 2.0 mm
Max. lateral wheel runout ---- 2.0 mm
Rear wheel
Type Spoke wheel ----
Rim size 16 × 1
1..60 ----
Rim material Steel ----
Max. radial wheel runout ---- 2.0 mm
Max. lateral wheel runout ---- 2.0 mm
2 - 10


Item Standard Limit
Front brake
Disk brake type Single ----
Disc outside diameter × t
th
hickness 220.0 × 3
3..5 mm 3.0 mm
Pad thickness inner 5.3 mm 0.8 mm
Pad thickness outer 5.3 mm 0.8 mm
Master cylinder inside diameter 11 mm ----

Caliper cy
cylinder iin
nside di
diameter 22.22 mm
mm × 2 ----
Brake fluid type DOT 4 ----
Rear brake
Drum brake type Leading, trailing ----
Rear brake lever free play (lever end) 10 ~ 20 mm ----
Drum inside diameter 130 mm 131 mm
Lining thickness 4 mm 2 mm
Shoe spring free length 52 mm ----
(camshaft side)
Shoe spring free length (pivot side) 48 mm ----
Throttle cable free play 3 ~ 7 mm ----
2 - 11


TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Brake master cylinder M6 11 1.1
Rear bake lever holder M6 7 0.7
Handlebar nut M10 43 4.3
Steering ring nut (upper) M25 75 7.5 See NOTE
Steering ring nut (lower) M25 30 3.0 See NOTE
Engine mounting nut M12 59 5.9
Engine mounting rubber damper and engine
M8 16 1.6
bracket
Engine bracket and engine assembly M10 32 3.2
Rear shock absorber nut M10 30 3.0
Rear shock absorber lower bolt M8 16 1.6
Rear suspension arm and engine M8 30 3.0
Front wheel axle nut M10 40 4.0
Rear wheel axle nut M14 104 10.4
Disk brake and hub M8 23 2.3 LT
Front fork and brake hose holder M6 7 0.7

Brake hose holder and lower bracket M6 10 1.0
Brake hose/speed meter cable holder and lower
M6 10 1.0
bracket
Brake caliper bolt M10 35 3.5
Brake pad retaining bolt M10 27 2.7
Bleed screw M7 6 0.6
Brake hose union bolt M10 26 2.6
Brake camshaft lever pinch bolt M6 7 0.7
Front fender M6 7 0.7
Lower bracket pinch bolt M10 50 5.0
Front fork cap bolt M20 50 5.0
Damper rod bolt M10 23 2.3 LT
Rear view mirror M10 32 3.2

Sidestand (bracket and frame) M10 32 3.2
Sidestand bolt M8 26 2.6 LS
Sidestand nut M8 16 1.6

Rear brake cable holder M6 7 0.7
Storage compartment M6 8 0.8
Fuel tank M6 7 0.7
Fuel tank and fuel cock M6 7 0.7
Fuel sender M5 4 0.4
Seat M6 7 0.7
Side panel M6 4 0.4
Side panel/side cover and frame M6 7 0.7
2 - 12


Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Under cover M6 7 0.7
Ignition coil M6 7 0.7
Rectifier regulator M6 7 0.7
Battery box M6 7 0.7
NOTE:
1. First tighten
tighten the ring nut
nut (lower)
(lower) 30 Nm (3.0 m • kg) by using the torque wrench, then loosen the
ring nut quarter turn.
2. Then, hold the ring nuts (lower)
(lower) and tighten
tighten the ring nut (upper) 70 Nm (7.0 m • kg) by using the
torque wrench.
2 - 13


ELECTRICAL
Item Standard Limit

System voltage 12 V ----
Ignition system
Ignition timing (B.T.D.C.) 5° ----
Advanced type Digital ----
DC.C.D.I.
Pickup coil resistance/color 248 ~ 372 Ω at 20 °C/W/L
C/W/L––W/R ----
C.D.I. unit model/manufacturer 5LW/YIMM ----
Ignition coil
Model/manufacturer 5LW/YIMM ----
Minimum ignition spark gap 6 mm ----
Primary coil resistance 0.32 ~ 0.48 Ω at 20 °C ----
Secondary coil resistance 5.68 ~ 8.52 kΩ at 20 °C ----
Spark plug cap
Material Resin ----
Resistance 5 kΩ ----
Charging system
Type A.C. magneto ----

Model/manufacturer F5LW/YIMM ----
Nominal output 14 V 105 W at 5,000 r/min ----
Lighting coil resistance/color 0.24 ~ 0.36 Ω at 20 °C/Y/R
C/Y/R–
–B ----
Charging coil resistance/color 0.32 ~ 0.48 Ω at 20 °C/W
C/W––B ----
Rectifier/regulator
Regulator type Semi conductor-short circuit ----
Model/manufacturer SH656-12/SHINDENGEN ----
No load regulated voltage (DC) 14.1 ~ 14.9 V ----
(AC) 13.0 ~ 14.0 V ----
Rectifier capacity (DC) 8A ----
(AC) 12 A ----
2 - 14


Item Standard Limit
Battery
Type/manufacturer YB7B-B/YUASA
Voltage/capacity 12 V 7 AH ----
Specific gravity 1.280 ----
Electric starting system
Type Constant mesh
Starter motor
Model/manufacturer 5LW/YIMM ----
Power output 0.3 kW ----
Armature coil resistance 0.031 ~ 0.037 Ω at 20 °C ----
Brush overall length 10 mm 3.5 mm
Spring force 5.52 ~ 8.28 N (563 ~ 844 gf) 5.52 N
(563 gf)
Commutator diameter 22 mm 2 1 mm
Mica undercut (depth) 1.5 mm ----
Starter relay
Model/manufacturer 2768081-A/JIDECO ----
Amperage rating 180 A ----
Coil resistance 4.2 ~ 4.6 Ω at 20 °C ----
Horn
Type Plane ----
Quantity 1 pcs ----
Model/manufacturer LOCAL MADE ----
Max. amperage 1.5 A ----
Performance 95 ~ 105 db (2 m) ----
Coil resistance 4.30 ~ 4.80 Ω at 20 °C ----
Turn signal relay
Relay type Condenser ----
Model/manufacturer LOCAL MADE ----
Self-canceling device built-in No
Hazard flasher device No
Flasher frequency 75 ~ 95 cycle/min ----
Wattage 10 W × 2 + 3.4 W ----
Fuel gauge
Model/manufacturer 5LW/CHAO LONG ----
Sender unit resistance- full 4 ~ 10 Ω at 20 °C ----
- empty 90 ~ 100 Ω at 20 °C ----
Circuit breaker
Circuit breaker type Fuse ----
Main 10 A ----
Reserve 10 A ----
2 - 15

GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC

EAS00029
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Width across flats
B: 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 1 0 mm 30 3.0
17 mm 1 2 mm 55 5.5
19 mm 1 4 mm 85 8.5
22 mm 1 6 mm 130 13.0
2 - 16

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant

Oil seal lips LS
O-rings LS
Bearings E
Piston outside and ring groove E
Piston ring E
Piston pin E
Cylinder inner surface E
Timing chain E
Rocker arm shaft M
Rocker arm inner surfaces M
Camshaft lobes and camshaft journals E
Valve stem M
Valve stem seal M
Kickstarter pinion gear shaft LS
Idle gear shaft LS
Centerstand pivot LS
Sidestand pivot LS
Crankcase mating surfaces Yamaha bond No.1215
2 - 17

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

CHASSIS
Lubrication point Lubricant

Front wheel oil seal lips LS
Rear wheel oil seal lips LS
Front wheel axle LS
Speedometer gear fitting area LS
Brake pad retaining bolt and boot LS
Brake cam pivot shaft and cam surface LS
Brake cable (brake lever) LS
Tube guide (throttle grip) inner surface LS
Throttle cable (throttle grip) LS
Starter cable (starter lever) LS
Steering head pipe bearing (upper/lower) LS
2 - 18

CABLE ROUTING SPEC

EAS00035
CABLE ROUTING
1 Right handlebar switch lead È Pass the left handlebar switch Ë Fasten the starter cable, speed-
2 Left handlebar switch lead lead behind the handlebar and ometer cable, rear brake cable,
3 Starter cable over the rear brake cable, and and throttle cable to the handle-
4 Rear brake cable then connect it in front of the bar with a plastic locking tie. Be
5 Rear brake light switch lead meter assembly. sure to position the plastic lock-
6 Speedometer cable É Connect the brake light switch ing tie over the handlebar pro-
7 Wire harness coupler in front of the rear brake jection and to position the lock
8 Front brake hose cable. of the tie in the handlebar slit.
9 Throttle cable Ê Pass the right handlebar switch Ì Less than 1 mm
0 Front brake light switch lead lead behind the handlebar, and
then connect it in front of the
meter assembly.
2
1
A A
4 3
È
Ê 5
0 9 8 É
6
7
Ë
Ì
7 6
9 8
4
A-A
2 - 19

CABLE ROUTING SPEC

1 Rear brake cable 0 Horn lead
2 Throttle cable A Turn signal relay
3 Starter cable B Main switch lead
4 Air vent hose C Front brake hose
5 Fuel overflow hose
6 Battery È Do not pass the starter cable over the frame.
7 Speedometer cable É Fasten the wire harness with a plastic locking tie
8 Turn signal relay lead as shown.
9 Headlight unit assembly lead Ê Route the horn lead as shown.
C
Ê
B
A
8
0 É
A 7
9
1 3
B-B
2
B
B
8
A
C 1
2
C 3 4
È
3
1 C-C 2
2 - 20

CABLE ROUTING SPEC

1 Cylinder head breather hose È Use the holder to hold the vacuum hose and fuel
2 Fuel hose hose as shown.
3 Vacuum hose É Make sure that the metal clip does not interfere
4 Drain hose with the fuel hose, when clamping it to the vac-
5 A.C. magneto lead uum hose.
6 Rectifier/regulator lead Ê Make sure that the metal clip does not interfere
7 Rear brake cable with the vacuum hose, when clamping it to the
fuel hose.
3
2
Ê
A-A 2
3
É B
4
2 3
È
1
A B
6
5 É Ê
A
D C
E
E
D 7
C
7
7 7
E-E D-D C-C
2 - 21

CABLE ROUTING SPEC

1 Negative battery lead A Starter relay lead
2 Ground lead B Starter motor lead
3 Seat lock cable C Positive battery lead
4 Wire harness D Battery breather hose
5 Horn lead
6 Headlight unit assembly lead È Align the white tape of the wire harness with the
7 Main switch lead clamp.
8 Front brake hose
9 Starter relay
0 Main fuse
3
6
4 3 4
A-A B-B
4 A
7
3 8
2
1 B
E
D È
B
9
D
C C
B
C
D
1
4
1
D 4
B B
4 C B
E-E D-D C-C
2 - 22

CABLE ROUTING SPEC

1 Fuel sender lead A Starter motor
2 Seat lock cable B C.D.I. unit
3 Wire harness C Tail/brake light unit assembly lead
4 Rectifier/regulator
5 Ignition coil
6 Rectifier/regulator lead
7 Spark plug lead
8 A.C. magneto lead
9 Negative battery lead
0 Starter motor lead
2
9
7
6
0
3 C-C
A-A
È 8
B-B
1
23
4 É
C
A
5
Ì 6
Ê
7
8 9
B B 0
A
Ë
B
C
2 - 23

CABLE ROUTING SPEC

È Make sure that the rubber cover does not pinch Ë When installing the side cover (right), make sure
the seat lock cable and the fuel sender lead. that it does not pinch the wire harness.
É Pass the plastic locking tie between the rectifier/ Ì Place the tail/brake light unit assembly coupler
regulator bracket and ignition coil bracket, and between the frame and C.D.I. unit.
then fasten the wire harness and seat lock cable
with the tie.
Ê Make sure that the A.C. magneto coupler and
A.C. magneto lead are not pinched between the
rear fender and storage compartment.
2
9
7
6
0
3 C-C
A-A
È 8
B-B
1
23
4 É
C
A
5
Ì 6
Ê
7
8 9
B B 0
A
Ë
B
C
2 - 24

CABLE ROUTING SPEC

1 Air vent hose A Throttle cable
2 Wire harness B Starter cable
3 Seat lock cable
4 Starter motor lead
6 Starter motor
7 Fuel hose
8 Vacuum hose
9 Drain hose
0 Cylinder head breather hose
4 5
A-A
B
9
2
8
7
A A
3
5
6
2 - 25

CABLE ROUTING SPEC

1 Starter motor lead È Install the plastic clip in the direction shown.
3 A.C. magneto lead
4 Rectifier/regulator lead
5 Wire harness
6 Fuel sender lead
7 Seat lock cable
8 Rear turn signal light lead
9 Tail/brake light lead
0 Fuel sender
È 1 2
8 8
2 - 26

CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
INTRODUCTION ..............................................................................................3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....................3-1
SIDE COVER ...................................................................................................3-3

REMOVING THE SIDE COVER................................................................3-3
INSTALLING THE SIDE COVER ..............................................................
........................................ ...................... 3-3
LEG SHIELD....................................................................................................3-4
SHIELD....................................................................................................3-4
REMOVING THE LEG SHIELD.................................................................3-4
INSTALLING THE LEG SHIELD ...............................................................
................................... ............................ 3-5
AIR FILTER CASE ..........................................................................................3-6

REMOVING THE AIR FILTER CASE........................................................3-6
INSTALLING THE AIR FILTER CASE ......................................................

.................................... .................. 3-6
ENGINE ...........................................................................................................3-7
ADJUSTING THE VALVE CLEARANCE ..................................................
....................................... ........... 3-7
ADJUSTING THE ENGINE IDLING SPEED .............................................
..................................... ........ 3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-11
CHECKING THE SPARK PLUG .............................................................
................................ ............................. 3-13
MEASURING THE COMPRESSION PRESSURE..................................3-14
CHECKING THE ENGINE OIL LEVEL....................................................3-16
CHANGING THE ENGINE OIL ...............................................................
................................... ............................ 3-17
CHANGING THE TRANSMISSION OIL..................................................3-18
CLEANING THE AIR FILTER ELEMENT................................................3-19
CHECKING THE V-BELT........................................................................3-20
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ....................... 3-21
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD......3-22
CHECKING THE FUEL AND VACUUM HOSE.......................................3-23
CHECKING THE CYLINDERHEAD BREATHER HOSE ........................ 3-23
CHECKING THE EXHAUST SYSTEM....................................................3-24

CHK
ADJ
CHASSIS .......................................................................................................3-25
ADJUSTING THE REAR BRAKE............................................................3-25
CHECKING THE BRAKE FLUID LEVEL.................................................3-25
CHECKING THE FRONT FRONT BRAKE BRAKE PADS PADS ................................................
................................... ............. 3-26
CHECKING THE REAR BRAKE SHOES................................................3-26
CHECKING THE FRONT BRAKE HOSE................................................3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-27
CHECKING AND ADJUSTING THE STEERING HEAD HEAD ......................... 3-29
CHECKING THE FRONT FORK .............................................................
..................................... ........................ 3-30
CHECKING THE TIRES..........................................................................3-31
CHECKING AND TIGHTENING THE SPOKES......................................3-33
CHECKING AND LUBRICATING THE CABLES .................................... 3-34
LUBRICATING THE LEVERS .................................................................
....................................... .......................... 3-34
LUBRICATING THE SIDESTAND...........................................................3-34
LUBRICATING THE CENTERSTAND ....................................................
....................................... ............. 3-34
ELECTRICAL SYSTEM.................................................................................3-35
SYSTEM.................................................................................3-35
CHECKING AND CHARGING THE BATTERY.......................................3-35
CHECKING THE FUSE...........................................................................3-39
REPLACING THE HEADLIGHT BULBS .................................................
........................................ ......... 3-41
ADJUSTING THE HEADLIGHT BEAMS.................................................3-42

INTRODUCTION/PERIODIC
INTRODUCTION/PERIODIC MAINTENANCE AND CHK
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
ne ed for costly overhaul work. This information applies to vehicles
already in service
should be familiar as well
with thisasentire
to new vehicles that are being
chapter. b eing prepared for sale. All service technicians
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
• Check fuel hoses and vacuum hose for cracks or
1 * Fuel line
damage.
• Check condition.
2 Spark plug • Clean and regap.
• Replace if necessary.
• Check valve clearance.
3 * Valves
• Adjust.
4 Air filter element • Clean. Replace if necessary.
5 V-belt case air filter

elements • Clean. Replace if necessary.
• Check electrolyte level and specific gravity.

6 * Battery • Make sure that the breather hose is properly
routed.
• Check operation, fluid level and vehicle for fluid
7 * Front brake leakage. (See NOTE on page 3-2.)
• Replace brake pads if necessary.
• Check operation and adjust brake lever free play.
8 * Rear brake
• Replace brake shoes if necessary.
• Check runout, spoke tightness and for damage.
9 * Wheels
• Tighten spokes if necessary.
10 * Wheel be
bearings • Check bearing for looseness or damage.
• Check operation and for excessive play.
11 * Swingarm • Lubricate with lithium-soap based grease, every
24,
24,000
000 km.
• Check bearing play and steering for roughness.

12 * Steering b ea
earings • Lubricate with lithium-soap-based grease, every
12,000 km.
• Make sure that all nuts, bolts and screws are
13 * Chassis fasteners
properly tightened.
Sidestand/ • Check operation.
14
centerstand • Lubricate.
15 * Sidestand switch • Check operation.
16 * Front fork • Check operation and for oil leakage.
Shock absorber • Check operation and shock absorbers for oil
17 *
assemblies leakage.
• Check starter (choke) operation.
18 * Carburetor
• Adjust engine idling speed.
• Change.
19 Engine oil Every 2,000 km
• Check oil level and vehicle for oil leakage.
20 * E ng
ngine oil strainer • Clean.
Final transmission • Check vehicle for oil leakage.

21
oil • Change. Every 10,000 km
3-1

PERIODIC MAINTENANCE AND LUBRICATION CHK

INTERVALS ADJ
ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
• Check the damage and wear.
22 * V-belt
• Replace. Every 25,000 km
Front and rear brake
23 * • Check operation.
switches
Moving parts and
24 cables • Lubricate.
Lights, signals and • Check operation.
25 *
switches • Adjust headlight beam.
*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
_
• From 16,000 km, repeat the maintenance intervals starting from 4,000 km.
• Depending on riding conditions, the V-belt replacement interval may vary.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system
• After disassembling the brake master cylinder, and caliper cylinder, always change the fluid.
Regularly check the brake fluid level and fill reservoir as required.
• Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every
two years.
• Replace the brake hose every four years or if cracked or damaged.
3-2

CHK
SIDE COVER ADJ
SIDE COVER
1
REMOVING THE SIDE COVER
1. Remo
Remov ve:
• side panel (left and right) 1
2. Open
Open the
the seat
seat..
3. Remo
Remov ve:
• rear panel 1
1
NOTE:
Remove the rear panel by sliding it in the
direction of the arrow shown.
4. Remo
Remov ve:
1
• side cover (left and right) 1
INSTALLING THE SIDE COVER

1
1. In
Inst
stal
all:
l:
• side cover (left and right) 1
NOTE:
Before tightening the side cover screw and
bolts make sure that all hooks are securely fit-
ted.
2. In
Inst
stal
all:
l:
• rear panel 1
1
3-3

CHK
SIDE COVER/LEG SHIELD ADJ
3. In
Inst
stal
all:
l:
• side panel (left and right) 1
• side panel screws
NOTE:
Before tightening the side panel screws make
sure that all hooks are securely fitted.
LEG SHIELD
REMOVING THE LEG SHIELD
3 1. Remo
Remov ve:
• side cover (left and right)
Refer to “SIDE COVER”
COVER”.
2. Remo
Remov ve:
2 • footboard mat (left and right) 1
• footboard (left and right) 2
1
NOTE:
Remove the battery breather hose 3 that

passes through the hole in the right footboard.
3. Remo
Remov ve:
• front cover 1
NOTE:
Disconnect the headlight unit assembly cou-
pler 2.
2
1
3-4

CHK
LEG SHIELD ADJ
4. Remo
Removve:
• seat 1
1
5. Remo
Remov ve:
1 • center cover 1
6. Remo
Removve:
• hook 1
• main switch cover 2
2
7. Remo
Remov ve:
• leg shield 1
INSTALLING THE LEG SHIELD

1. In
Inst
stal
all:
l:
• leg shield
• main switch cover
• hook
• front cover 1
NOTE:
2 Connect the headlight unit assembly coupler
2.
1
2. In
Inst
stal
all:
l:
• seat
• seat nuts
T
.
R
.
7 Nm (0.7 m • kg)
3-5

CHK
LEG SHIELD/AIR FILTER CASE ADJ
3.Install:
• footboard (left and right) 1
• footboard mat (left and right) 2
3
NOTE:
Pass the battery breather hose 3 through the
hole in the right footboard.
1
EASF0043
AIR FILTER CASE

REMOVING THE AIR FILTER CASE
1. Remo
Remov ve:
• side panel (left and right)
COVER”.
• footboard (left and right)
Refer to “LEG SHIELD”
SHIELD”.
2. Loos
Loosen
en::
1
• screw (carburetor joint) 1
NOTE:
2 Remove the fuel overflow hose 2 and cylinder
head breather hose 3 that pass through the
hole in the air filter case.
3
3. Remo
Remov ve:
• air filter case 1
INSTALLING THE AIR FILTER CASE

1. In
Inst
stal
all:
l:
• air filter case
• air filter case bolts 10 Nm (1.0 m • kg)

T
.
R
.
3-6

CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00049
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. Remo
Remov ve:
• air filter case
Refer to “AIR FILTER CASE”
CASE”.
2. Remo
Remov ve:
1 • tappet cover (intake side) 1
• tappet cover (exhaust side) 2
• cam sprocket cover 3
3
3. Remo
Removve:
• engine cooling fan cover 1
1
3-7

CHK
ADJUSTING THE VALVE CLEARANCE ADJ
4. Meas
Measur
ure:
e:
• valve clearance
Out of specification → Adjust.
b
Valve clearance (cold)
Intake valve
0.08 ~ 0.12 mm
Exhaust valve
0.08 ~ 0.12 mm
a

a. Turn the crankshaft
crankshaft clockwise
clockwise..
b. When the piston
piston is
is at TDC on
on the compres-
compres-
d sion stroke, align the “I” mark a in the cam-
shaft sprocket with the stationary pointer b
on the cylinder head.
c. Alig
Align
n the TDC mark c on the generator
TDC mark
c
rotor with the stationary pointer d on the
crankcase.
d. Measure
Measure the valve
valve clearanc
clearance
e with a thick-
thick-
ness gauge 1.

5. Adju
Adjust
st::
• valve clearance

12 a. Loosen
Loosen the
the loc knutt 1.
locknu
b. Insert
Insert a thickne
thickness gauge 2 between the
ss gauge
end of the adjusting screw and the valve
valve tip.
c. Turn the adjusting screw 3 in direction a
adjusting screw
or b until the specified valve clearance is
obtained.
Valve clearance is
Direction a
increased.
Valve clearance is
Direction b
b decreased.
Tappet adjusting tool

90890-01311
a
3
3-8

ADJUSTING THE VALVE CLEARANCE/ CHK

ADJUSTING THE ENGINE IDLING SPEED ADJ
• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut

T
.
R
.
7 Nm (0.7 m • kg)
d. Measure
Measure the valve
valve clearance
clearance again.
again.
e. If the valve
valve clearance
clearance is still
still out of specifi
specifica-
ca-
tion, repeat all of
o f the valve clearance adjust-
ment steps until the specified clearance is
obtained.

6. In
Inst
stal
all:
l:
• engine cooling fan cover
• engine cooling fan cover screws

T
.
R
.
7 Nm (0.7 m • kg)
7. In
Inst
stal
all:
l:
1 New • cam sprocket cover
• cam sprocket cover bolts

T
.
R
.
12 Nm (1.2 m • kg)
• tappet cover (exhaust side)
• tappet cover (intake side)

T
.
R
.
18 Nm (1.8 m • kg)
• O-ring 1 New
8. In
Inst
stal
all:
l:
• air filter case
CASE”.
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
_
Prior to adjusting the engine idling speed, the

air filter element should be clean, and the
engine should have adequate compression.
1. Start the engine

engine and let
let it warm up for
for sev-
sev-
eral minutes.
3-9

CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
2. Remo
Remov ve:
• side panel (right)
COVER”.
3. Conn
Connecect:
t:
• engine tachometer
(onto the spark plug lead)
Engine tachometer
90890-03113
4. Chec
Check:
k:
• engine idling speed
Engine idling speed

1,500 ~ 1,700 r/min
5. Adju
Adjust
st::

screw 1 in or out until it is
a. Turn the pilot screw
lightly seated.
1 b. Turn the pilot screw
screw out the specified
specified num-
ber of turns.
Pilot screw setting

1-1/2 turns out
c. Remo
Remove ve th
the cap 2.
e cap
d. Turn the throttle
throttle stop
stop screw 3 in direction
screw
2 a b
speed is obtained.
or until the specified engine idling
3 b Engine idling speed is

Direction a
increased.
a Engine idling speed is
Direction b
decreased.
e. Instal the cap 2.

Installl the

3 - 10

ADJUSTING THE ENGINE IDLING SPEED/ CHK

ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
6. Adju
Adjust
st::
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” PLAY”.
Throttle cable free play (at the

flange of the throttle grip)
3 ~ 7 mm
7. In
Inst
stal
all:
l:
COVER”.
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
_
Prior to adjusting the throttle cable free play,

the engine idling speed should be adjusted.
1. Chec
Check:k:
• throttle cable free play a
a Out of specification → Adjust.

3 ~ 7 mm
2. Remo
Remov ve:
• side panel (left)
COVER”.
3 - 11

CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Adju
Adjust
st::
a2 1 
Carburetor side
a. Loosen
Loosen the the locknutt 1.
locknu
b adjusting nut 2 in direction a or
b. Turn the adjusting
b
is until the specified throttle cable free play
obtained.
Throttle cable free play

Direction a
is increased.
Direction b
is decreased.
c. Tighten
Tighten the lockn
locknut.
ut.
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. Pull
Pull the bo ot 1 off.
boot
b b. Loosen
Loosen the
the locknutt 2.
locknu
c. Turn the adjus
adjustin g nut 3 in direction a or
ting
b until the specified throttle cable free play
1 2 is obtained.
3
a
Direction a
is increased.
Direction b
is decreased.
d. Tighten
Tighten the loc
lockn
knut.
ut.
WARNING
_
After adjusting the throttle cable free play,

start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
e. Pull
Pull the boot 1 in.
boot

4. In
Inst
stal
all:
l:
COVER”.
3 - 12

CHK
CHECKING THE SPARK PLUG ADJ
EAS00060
CHECKING THE SPARK PLUG
1. Remo
Remov ve:
COVER”.
2. Disc
Disconn
onnec
ect:
t:
• spark plug cap
3. Remo
Remov ve:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away

any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
4. Chec
Check:
k:
• spark plug type
Incorrect → Replace.
Spark plug type (manufacturer)

CR7HSA (NGK)
5. Chec
Check:k:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clea
Clean:
n:
• spark plug
(with a spark plug cleaner or wire brush)
7. Meas
Measurure:
e:
• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.6 ~ 0.7 mm
3 - 13

CHECKING THE SPARK PLUG/ CHK

MEASURING THE COMPRESSION PRESSURE ADJ
8. In
Inst
stal
all:
l:
• spark plug
T
.
R
.
13 Nm (1.3 m • kg)
NOTE:
_
Before installing the spark plug, clean the

spark plug and gasket surface.
9. Conn
Connecect:
t:
• spark plug cap
10.Install:
COVER”.
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
_
Insufficient compression pressure will result in

a loss of performance.
1. Meas
Measurure:
e:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE””.
CLEARANCE
2. Start the engine,
engine, warm it up for
for several
several min-
min-
utes, and then turn it off.
3. Disc
Disconn
onnec
ect:
t:
• spark plug cap
4. Remo
Remov ve:
• spark plug
CAUTION:
_
Before removing the spark plug, use com-

pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.
3 14
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
5. In
Inst
stal
all:
l:
• compression gauge 1
1
Compression gauge
90890-03081
6. Meas
Measur
ure:
e:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea

level)
Minimum
900 kPa (9.0 kg/cm2)
Standard
1,100 kPa (11.0 kg/cm2)
Maximum
1,230 kPa (13.0 kg/cm2)

a. Set the
the main
main swit
switch
ch to “ON
ON””.
b. With the throttle
throttle wide
wide open,
open, crank
crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug

lead before cranking the engine.
c. If the compression
compression pressure
pressure is abov
above
e the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
3 15
MEASURING THE COMPRESSION PRESSURE/ CHK

CHECKING THE ENGINE OIL LEVEL ADJ
d. If the compres
compression
sion pressur
pressuree is below
below the
the
minimum specification, pour a teaspoonful
engine of oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Piston ring(s) wear
Higher than with-
or damage →
out oil
Repair.
Piston, valves, cyl-
Same as without inder head gasket
oil or piston possibly
defective → Repair.

7. In
Inst
stal
all:
l:
• spark plug 13 Nm (1.3 m • kg)

T
.
R
.
8. Conn
Connecect:
t:
• spark plug cap
9. In
Inst
stal
all:
l:
COVER”.
EASF0070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcy
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
Make sure the motorcycle is upright.

for several
several min-
min-
3. Remo
Remov ve:
• dipstick 1
4. Chec
Check:k:
• engine oil level
The engine oil level should be between the
b
minimum level mark a and maximum level
a mark b.
NOTE:
_
1 Before checking the engine oil level, wait a few

minutes until the oil has settled.
3 16
CHECKING THE ENGINE OIL LEVEL/ CHK

CHANGING THE ENGINE OIL ADJ
Below the minimum level mark → Add the
-20 -10 0 10 20 30 40 50 ˚C
recommended engine oil to the proper level.
SAE 10W-30
Recommended oil
Refer to the chart for the engine
SAE 10W-40
oil grade which is best suited
for certain atmospheric temper-
SAE 20W-40
atures.
API standard
SAE 20W-50
SE or higher grade
CAUTION:
_
Do not allow foreign materials to enter the

crankcase.

for several
several min-
min-
6. Check the engine
engine oil lev
level
el again.
again.
EAS00075
CHANGING THE ENGINE OIL
for several
several min-
min-
1
2. Place a container
container under the engine
engine oil drain
drain
bolt.
3. Remo
Remov ve:
• dipstick 1
• engine oil drain bolt 2
(along with the gasket)
• engine oil drain plug 3
• O-ring
• spring 4
• engine oil strainer 5

NOTE:
2 3 When only changing the engine oil, remove
engine oil drain bolt only.
4
3 17
CHANGING THE ENGINE OIL/ CHK

CHANGING THE TRANSMISSION OIL ADJ
4. Dr
Drai
ain:
n:
• engine oil
(completely from the crankcase)
5. Chec
Check:k:
• engine oil strainer
Dirt → clean.
Damage → Replace.
6. Chec
Check:k:
• engine oil drain bolt gasket
Damage → Replace.
7. In
Inst
stal
all:
l:
• engine oil drain bolt

T
.
R
.
20 Nm (2.0 m • kg)
• spring
• engine oil strainer
• engine oil drain plug

T
.
R
.
20 Nm (2.0 m • kg)
• O-ring
8. Fil
Fill:
• crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
0.9 L
Periodic replacement
0.8 L
9. In
Inst
stal
all:
l:
• dipstick
10.Start the engine, warm it up for several
several min-
11.Check:
• engine
(for engine oil leaks)
12.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL””.
LEVEL
CHANGING THE TRANSMISSION OIL
for several
several min-
min-
2. Place a containe
containerr under the transm
transmissio
ission
n oil
drain bolt.
3 18
CHANGING THE TRANSMISSION OIL/ CHK

CLEANING THE AIR FILTER ELEMENT ADJ
3. Remo
Remov ve:
• transmission oil filler plug 1
• transmission oil drain bolt 2
4. Dr
Drai
ain:
n:
1 • transmission oil
5. (completely
Chec
Check:k: from the transmission case)
• transmission oil drain bolt gasket
Damage → Replace.
6. In
Inst
stal
all:
l:
• transmission oil drain bolt
2 (along with the gasket)

T
.
R
.
22 Nm (2.2 m • kg)
7. Fill:
• transmission case
mended transmission oil)
Transmission oil
Engine oil
Quantity
Total amount
0.12 L
Periodic replacement
0.1 L
8. In
Inst
stal
all:
l:
• transmission oil filler plug
EAS00086
CLEANING THE AIR FILTER ELEMENT
NOTE:
On the bottom of the air filter case is a check
hose 1. If dust or water or both collects in this
hose, clean the air filter element and air filter
1
case.
1. Remo
Remov ve:
COVER”.
2 2. Remo
Remov ve:
• air filter case cover 1
• air filter element
1
3 - 19
CLEANING THE AIR FILTER ELEMENT/ CHK

CHECKING THE V-BELT ADJ
3. Clea
Clean: n:
Apply compressed air to the outer surface
of the air filter element.
4. Chec
Check: k:
→
5. Damage
In
Inst
stal
all:
l: Replace.
• 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
engine performance and possible overheat-
ing.
NOTE:
_
When installing the air filter element into the air

filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
6. In
Inst
stal
all:
l:
COVER”.
EAS00320
CHECKING THE V-BELT
1 1. Rem
Remove:
ove:
• V-belt case cover
Refer to “KICKSTARTER
KICKSTARTER”” in chapter 4.
2. Chec
Check:
k:
a
• V-belt 1
Cranks/damage/wear → Replace.
Grease/oil → Clean the primary and sec-
ondary pulleys.
Refer to “BELT DRIVE”
DRIVE” in chapter 4.
3. Meas
Measur
ure:
e:
• V-belt width a
Out of specification → Replace.
DRIVE” in chapter 4.
V-belt width
18.2 mm
<Limit>: 17.2 mm
3 - 20
CHK
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ADJ
EAS00091
CLEANING THE V-BELT CASE AIR FILTER
1
ELEMENT
NOTE:
On the bottom of the V-belt case cover is a
check hose 1. If dust or water or both collects
in this hose, clean the V-belt air filter elements.
1. Remo
Remov ve:
1
• V-belt case cover protector 1 1
• V-belt case air filter cover 2
• V-belt case air filter element 1 3

4 • V-belt case air filter element 2 4
3
2. Clea
Clean:
n:
• V-belt case air filter element 1
Blow the compressed air to the outer sur-
face of the V-belt case air filter element.
3 - 21
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHK

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD
ADJ
3. Chec
Check:
k:
Damage → Replace.
CAUTION:
_
Since the V-belt case air filter element is a

dry type, do not let grease or water contact
it.
4. In
Inst
stal
all:
l:
1 • V-belt case air filter element 1
• V-belt case air filter cover
• V-belt case air filter cover bolts

T
.
R
.
10 Nm (1.0 m • kg)
• V-belt case cover protector 1
• V-belt case cover protector 1 bolts

T
.
R
.
23 Nm (2.3 m • kg)
NOTE:
When installing the V-belt case cover protector
1, be sure to pass the V-belt case breather
hose 1 through the hole in the V-belt case
cover protector 1.
EAS00094
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Remo
Remov ve:
COVER”.
2. Chec
Check:
k:
1 • carburetor joint 1
2 • intake manifold 2
Cracks/damage → Replace.
Refer to “REMOVING THE ENGINE”
ENGINE” in
chapter 4.
3 - 22
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/

CHECKING THE FUEL AND VACUUM HOSE/ CHK
CHECKING THE CYLINDERHEAD BREATHER HOSE
ADJ
3. In
Inst
stal
all:
l:
COVER”.
EAS00096
CHECKING THE FUEL AND VACUUM HOSE
1. Remo
Remov ve:
• side cover (left)
COVER”.
2. Chec
Check:k:
1 2 • vacuum hose 1
• fuel hose 2
3. In
Inst
stal
all:
l:
• side cover (left)
COVER”.
EAS00098
CHECKING THE CYLINDERHEAD
BREATHER HOSE
1. Remo
Remov ve:
COVER”.
3 - 23
CHECKING THE CYLINDERHEAD BREATHER HOSE/ CHK

CHECKING THE EXHAUST SYSTEM ADJ
2. Chec
Check:k:
• cylinder head breather hose 1
1
CAUTION:
_
Make sure the cylinder head breather hose

is routed correctly.
3. In
Inst
stal
all:
l:
COVER”.
EAS00100
CHECKING THE EXHAUST SYSTEM
1. Remo
Remov ve:
• footboard (right)
SHIELD”.
2. Chec
Check:k:
• muffler 1
Exhaust gas leaks → Replace the gasket.
3. Chec
Check:k:
• tightening torque
Muffler nut 3
3 1 20 Nm (2.0 m • kg)

T
.
R
Muffler bolt 4
.
35 Nm (3.5 m • kg)
4. In
Inst
stal
all:
l:
3 • footboard (right)
SHIELD”.
2
3 - 24
ADJUSTING THE REAR BRAKE/ CHK

CHECKING THE BRAKE FLUID LEVEL ADJ
EAS00108
CHASSIS
EAS00114
ADJUSTING THE REAR BRAKE
1. Chec
Check:
k:
• rear brake lever free play a
Rear brake lever free play

10 ~ 20 mm
2. Adju
Adjust
st::
• rear brake lever free play

adjusting nut 1 in direction a or
a. Turn the adjusting
b until the specified brake lever free play is
obtained.
Brake lever free play is

Direction a
increased.
Direction b Brake lever free play is

decreased.
CAUTION:
_
After adjusting the brake lever free play,

make sure there is no brake drag.

EASF0115
CHECKING THE BRAKE FLUID LEVEL
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
2. Chec
Check:k:
LOWER • brake fluid level
a Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid

DOT 4
3 - 25
CHECKING THE BRAKE FLUID LEVEL/

CHECKING THE FRONT BRAKE PADS/ CHK
CHECKING THE REAR BRAKE SHOES
ADJ
WARNING
_
• Use only the designated brake fluid.

Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the 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
up any parts. fluid
spilt brake Therefore, always clean
imm ediately.
immediately.
NOTE:
_
In order to ensure a correct reading of the

brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
EASF0117
CHECKING THE FRONT BRAKE PADS
1. Operate
Operate the
the brake
brake..
2. Chec
Check:k:
• front brake pad
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as a set.
1 Refer to “REPLACING THE FRONT
BRAKE PADS”
PADS” in chapter 6.
EASF0126
CHECKING THE REAR BRAKE SHOES
1. Operate
Operate the
the brake
brake..
2. Chec
Check:
k:
• wear indicator 1
Reaches the wear limit line 2 → Replace
the brake shoes as a set.

Refer to “CHECKING THE BRAKE”
BRAKE” in
chapter 6.
1 2
3 - 26
CHECKING THE FRONT BRAKE HOSE/ CHK

BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00129
CHECKING THE FRONT BRAKE HOSE
1. Chec
Check:k:
• brake hose
Cracks/damage/wear → Replace.
2. Chec
Check:k:
• brake hose clamp
Loose Connection → Tighten the clamp
bolt.
3. Hold the
the motorcycle
motorcycle upright and apply
apply the
front brake several
several times.
4. Chec
Check:k:
• brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to “FRONT BRAKE”
BRAKE” in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system when-

ever:
• the system is disassembled.
• a brake hose is loosened, disconnected
or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
_
• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir to over-
flow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length-
ening 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 - 27
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
1. Blee
Bleed:
d:
• hydraulic brake system

1 2 a. Fill the
the brak
brake
e fluid reservoir
reservoir to the
the proper
level
level with the recommended brake fluid.
b. Install the
the brake
brake master cylind
cylinder
er reservoir
reservoir
diaphragm.
c. Connec
Connectt a clear
clear plasti
plastic
c hos
hosee 1 tightly to the
bleed screw 2.
d. Place the
the other end of the hose into
into a con-
tainer.
e. Slowly apply the brake lever
lever several
several times.
f. Fully pull the brake
brake lever
lever without
without releasing
releasing
it.
g. Loosen the bleed screw
screw.
NOTE:
_
Loosening the bleed screw will release the

pressure and cause the brake lever to contact
the throttle grip.
h. Tighten the bleed

bleed screw
screw and then release
release
the brake lever.
i. Repeat
Repeat stepsteps
s (e) to (h)
(h) until
until all of the
the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw

T
.
R
.
6 Nm (0.6 m • kg)
k. Fill the bra

brake
ke fluid
fluid reservoir
reservoir to the proper
proper
level
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL””.
LEVEL
WARNING
_
After bleeding the hydraulic brake system,

check the brake operation.

3 - 28
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EASF0146
CHECKING AND ADJUSTING THE
STEERING HEAD
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
• Place the motorcycle on a suitable stand so

that the front wheel is elevated.
• Make sure the motorcycle is upright.
2. Chec
Check:
k:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remo
Remov ve:
• front cover
• leg shield
SHIELD”.
4. Adju
Adjust
st::
1 • steering head

a. Loosen
Loosen the
the upper
upper ring nut 1.
ring nut
b. Loosen
Loosen the low lower ring nut 2 and then
er ring
tighten it to specification with a steering nut
wrench 3.
NOTE:
_
Set the torque wrench at a right angle to the

steering nut wrench.
3
Steering nut wrench
2 90890-01403
Lower ring nut

T
.
R
.
30 Nm (3.0 m • kg)
3 - 29
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK

CHECKING THE FRONT FORK ADJ
c. Loosen the lower
lower ring
ring nut a quarter
quarter turn.
turn.
5 d. Hold the lower
lower ring nut
nut with a ring nut
4 wrench 4 and tighten the upper ring nut 5
with a steering nut wrench.
Ring nut wrench

90890-01268
Upper ring nut

T
.
R
.
75 Nm (7.5 m • kg)
e. Check the steering

steering head for
for looseness
looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD”
HEAD” in chapter 6.

5. In
Inst
stal
all:
l:
• leg shield
• front cover
SHIELD”.
EASF0149
CHECKING THE FRONT FORK
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
2. Chec
Check:k:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the
the motorcycle
motorcycle upright and apply
apply the
front brake.
4. Chec
Check:k:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK”
FORK” in chapter 6.
3 - 30
CHK
CHECKING THE TIRES ADJ
EASF0166
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Chec
Check:k:
• 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 accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil and
103 kg
a full fuel
tank)
Maximum
116 kg
load*
Front Rear
Cold tire
200 kPa 225 kPa
pressure
(2.00 kgf/cm ) (2.25 kgf/cm2)
2
* Total w
weight
eight of rider,
rider, passenge
passenger,
r, cargo and
and
accessories
WARNING
_
It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit,
replace the tire immediately.
3 - 31
CHK
CHECKING THE TIRES ADJ
2. Chec
Check:k:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth

0.8 mm
1 Tire tread depth

2 Sidewall
3 Wear indicator
WARNING
_
• Do not use a tubeless tire on a wheel

designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, 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 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
replacement.
Tube wheel Tube tire only

Tube or tubeless
Tubeless wheel
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 manufacturer and of the same
design. No guarantee concerning han-
dling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
3 - 32
CHECKING THE TIRES/ CHK

CHECKING AND TIGHTENING THE SPOKES ADJ
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 high-speed riding is done.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.
NOTE:
_
For tires with a direction of rotation mark 2:

• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 3 with the valve installation
point.
EAS00169
CHECKING AND TIGHTENING THE
SPOKES
spokes.
1. Chec
Check:
k:
• spoke 1
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
_
A tight spoke will emit a clear, ringing tone, a

loose spoke will sound flat.
2. Tigh
Tighte
ten:
n:
• spoke
(with a spoke wrench 1)

T
.
R
.
3 Nm (0.3 m • kg)
NOTE:
_
Be sure to tighten the spokes before and after

break-in.
3 - 33
CHECKING AND LUBRICATING THE CABLES/

LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/ CHK
LUBRICATING THE CENTERSTAND ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
inner and outer cables.
WARNING
_
Damaged outer cable may cause the cable

to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Chec
Check:
k:
• outer cable
Damage → Replace.
2. Chec
Check:
k:
• cable operation
Rough movement → 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 suitable lubricating device.
EAS00171
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
moving parts of the sidestand.
EAS00173
LUBRICATING THE CENTERSTAND
moving parts of the centerstand.
3 - 34
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00176
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas

and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
3 - 35
CHK
1. Remo
Remov ve:
2 Refer to “SIDE COVER”
COVER”.
• battery band 1
2. Disc
Disconn
onnec
ect:
t:
3 • battery leads
(from the battery terminals)

CAUTION:
UP
UPPE
PERR LEVEL
LEVEL
LOW
LOWER LE
LEVE
VEL
L
First, disconnect the negative battery lead

2, and then the positive lead 3.
3. Remo
Remov ve:
• battery
4. Chec
Check: k:
• electrolyte level
The electrolyte level should be between the
minimum level mark a and the maximum
level mark b.
Below the minimum level mark → Add dis-
tilled water to the proper level.
CAUTION:
_
Add only distilled water. Tap water con-

tains minerals which are harmful to the bat-
tery.
5. Chec
Check:
k:
• specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20°
20°C
3 - 36
CHK
6. Char
Charge
ge::
• battery
Battery charging amperage and time

0.7 amps/10 hrs
_
WARNING
Do not quick charge a battery.
CAUTION:
_
• Loosen the battery sealing caps.

• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• 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.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charg-
ing has to be done with the battery
mounted on the motorcycle, disconnect
the negative lead from the battery termi-
nal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
3 - 37
CHK
NOTE:
_
Replace the battery whenever:

• battery voltage does not rise to specification
or bubbles fail to rise during charging.
• sulphation of one or more battery cells
occurs (as indicated by the battery plates
turning white or material accumulating in the
bottom of the battery cell).
• specific gravity readings after a long, slow
charge indicate that one battery cell’
cell’s charge
is lower than the rest.
• warpage or buckling of the battery plates or
insulators is evident.
7. Chec
Check:
k:
• battery breather hose and battery vent
Obstruction → Clean.
Damage → Replace.
8. Conn
Connecect:
t:
• battery breather hose 1
1 CAUTION:
UPPER
UPP ER LEVE
LEVELL _
LOWER
LOWERLLEVEL
EVEL
When checking the battery, make sure the

battery breather hose is properly installed
and routed correctly. If the battery breather
hose is positioned so as to allow electro-
lyte or hydrogen gas from the battery to
contact the frame, the motorcycle and its
finish may be damaged.
9. Chec
Check:
k:
• battery terminals
Dirt → Clean with a wire brush.
3 - 38
CHECKING AND CHARGING THE BATTERY/ CHK

CHECKING THE FUSE ADJ
10.Connect:
1 • battery leads
(to the battery terminals)

CAUTION:
UPPER
UPPER L
LEVEL
EVEL
LOWER
LOWER LEVE
LEVEL
L
First, connect the positive battery lead 1,

install the battery, and then connect the
negative battery lead 2.
NOTE:
Pass the battery breather hose 3 through the
hole in the footboard (right).
2
3

11.Lubricate:
• battery terminals
Dielectric grease
12.Install:
• battery band
COVER”.
EASF0181
CHECKING THE FUSE
CAUTION:
_
To avoid a short circuit, always set the

main switch to “OFF
OFF”
” when checking or
replacing a fuse.
1. Remo
Remov ve:
• battery (without disconnect the battery
leads)
Refer to “CHECKING AND CHARGING
THE BATTERY”
BATTERY”.
3 - 39
CHK
CHECKING THE FUSE ADJ
2. Chec
Check:
k:
• fuse

a. Connect the pocket
pocket tester to the fuse
fuse and
check the continuity.
NOTE:
_
Set the pocket tester selector to “Ω × 1

1””.
Pocket tester
90890-03112
b. If the pocket
pocket tester
tester indicat
indicates
es “∞”, replace
the fuse.

3. Repl
Replac
ace:
e:
• blown fuse
WARNING
_
Never use a fuse with an amperage rating
other
using athan
fusethat
withspecified.
the wrongImprovising or
amperage rat-
ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
4. In
Inst
stal
all:
l:
• battery
THE BATTERY”
BATTERY”.
3 - 40
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183
REPLACING THE HEADLIGHT BULBS
1 The following procedure applies to both of the
headlight bulbs.
1.Remove:
• front cover
SHIELD”.
2. Remo
Remov ve:
• headlight bulb holder 1
3. Remo
Remov ve:
• headlight bulb 2
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. In
Inst
stal
all:
l:
• headlight bulb New
Secure the new headlight bulb with the
headlight 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. In
Inst
stal
all:
l:
• headlight bulb holder
6. In
Inst
stal
all:
l:
• front cover
SHIELD”.
3 - 41
CHK
ADJUSTING THE HEADLIGHT BEAMS ADJ
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
1. Adju
Adjust
st::
1
• headlight beam (vertically)

a. Turn the adjuster 1 in direction a or b.
adjuster
Headlight beam is
Direction a
raised.
Headlight beam is low-
Direction b
ered.

a
3 - 42
ENG
CHAPTER 4
OVERHAULING THE ENGINE
REMOVING THE ENGINE...............................................................................4-1

ENGINE...............................................................................4-1
ENGINE OIL ..............................................................................
......................................... .....................................................
................ 4-1
CARBURETOR ..........................................................................
.................................... .....................................................
............... 4-2
MUFFLER..................................................................................................4-2
REAR SHOCK ABSORBER BOLTS .........................................................
..................................... .................... 4-2
WIRE, CABLE AND HOSE........................................................................4-3
SIDESTAND ....................................................................................
.......................................... ....................................................
.......... 4-3
ENGINE ASSEMBLY ................................................................................
....................................... ......................................... 4-4
ENGINE INSTALLATION ................................................................................4-4

ENGINE ASSEMBLY ...........................................................................
..................................... ...........................................
..... 4-4
SIDESTAND ..............................................................................
........................................ ......................................................
................ 4-4
WIRE, CABLE AND HOSE........................................................................4-4
REAR SHOCK ABSORBER BOLTS .........................................................
..................................... .................... 4-5
MUFFLER..................................................................................................4-5
CARBURETOR ..........................................................................
.................................... .....................................................
............... 4-5
UNDER COVER ............................................................................
.................................... ....................................................
............ 4-5
CYLINDER HEAD............................................................................................4-6
HEAD............................................................................................4-6
REMOVING THE CYLINDER HEAD.........................................................4-7
CHECKING THE CYLINDER HEAD .......................................................
......................................... .............. 4-10
CHECKING TIMING CHAIN GUIDE .......................................................
.................................... ................... 4-11
CHECKING THE TIMING CHAIN TENSIONER......................................4-12
INSTALLING THE CYLINDER HEAD .....................................................
...................................... ............... 4-12
CAMSHAFT ...................................................................................................4-16
REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-17
CHECKING THE CAMSHAFTS ..............................................................
............................................ .................. 4-18
CHECKING
CHECK ING THE ROCKER ARMS AND ROCKER ROCKER ARM SHAFTS ........ ........ 4-18
CHECKING THE CAMSHAFT SPROCKET............................................4-20
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER .........................................................
....................................... .................. 4-20
INSTALLING THE CAMSHAFTS AND ROCKER ARMS........................4-20
VALVES AND VALVE SPRINGS .................................................................4-22

REMOVING THE VALVES......................................................................4-23
CHECKING THE VALVES AND VALVE GUIDES .................................. 4-24
CHECKING THE VALVE SEATS ............................................................
....................................... ..................... 4-26
CHECKING THE VALVE SPRINGS........................................................4-28
INSTALLING THE VALVES ....................................................................
...................................... .............................. 4-29

ENG
CYLINDER AND PISTON..............................................................................4-31
PISTON..............................................................................4-31
REMOVING THE CYLINDER AND PISTON...........................................4-32
CHECKING THE PISTON PIN ................................................................
....................................... ......................... 4-33
CHECKING THE CYLINDER AND PISTON ...........................................
........................................ ...4-34
4-34
CHECKING THE PISTON RINGS...........................................................4-35
INSTALLING THE PISTON AND CYLINDER .........................................
..................................... ....4-36
4-36
KICKSTARTER .............................................................................................4-38
REMOVING THE KICKSTARTER...........................................................4-39
DISASSEMBLING THE KICKSTARTER SHAFT .................................... 4-39
CHECKING THE KICKSTARTER ...........................................................
............................................ ............... 4-40
ASSEMBLING THE KICKSTARTER.......................................................4-41
INSTALLING THE KICKSTARTER .........................................................
......................................... ................ 4-41
BELT DRIVE..................................................................................................4-42
DRIVE ..................................................................................................4-42
V-BELT, PRIMARY AND SECONDARY PULLEY .................................. 4-42
REMOVING THE SECONDARY PULLEY AND V-BELT V-BELT........................
........................ 4-44
REMOVING THE PRIMARY PULLEY.....................................................4-45
DISASSEMBLING THE SECONDARY PULLEY ....................................
................................... . 4-46
CHECKING THE CLUTCH HOUSING ....................................................
..................................... ............... 4-46
CHECKING THE CLUTCH SHOES ........................................................
....................................... ................. 4-47
CHECKING THE V-BELT........................................................................4-47
CHECKING THE PRIMARY PULLEY WEIGHTS ................................... 4-48
CHECKING THE SECONDARY PULLEY...............................................4-48
ASSEMBLING THE SECONDARY PULLEY .......................................... 4-49
ASSEMBLING THE PRIMARY PULLEY.................................................4-50
INSTALLING THE BELT DRIVE .............................................................
.................................... ......................... 4-52
STARTER CLUTCH ......................................................................................4-54

CHECKING THE STARTER CLUTCH ....................................................
....................................... ............. 4-55
INSTALLING THE STARTER CLUTCH ..................................................
.................................... .............. 4-56
GENERATOR ................................................................................................4-57
REMOVING THE GENERATOR .............................................................
..................................... ........................ 4-58
INSTALLING THE GENERATOR............................................................4-60
OIL PUMP......................................................................................................4-62
PUMP ......................................................................................................4-62
REMOVING THE OIL PUMP...................................................................4-63
DISASSEMBLING THE OIL PUMP.........................................................4-63
CHECKING THE OIL PUMP ...................................................................
......................................... .......................... 4-64
ASSEMBLING THE OIL PUMP...............................................................4-65
INSTALLING THE OIL PUMP .................................................................
....................................... .......................... 4-65
TRANSMISSION............................................................................................4-66
TRANSMISSION............................................................................................4-66
REMOVING THE TRANSMISSION .......................................
........................................................
................. 4-67
CHECKING THE TRANSMISSION .........................................................
....................................... .................. 4-68
INSTALLING THE TRANSMISSION .......................................................
.................................... ................... 4-68

ENG
CRANKSHAFT ..............................................................................................4-70
DISASSEMBLING THE CRANKCASE....................................................4-71
REMOVING THE CRANKSHAFT ASSEMBLY .......................................
.................................. ..... 4-73
CHECKING THE CRANKCASE ..............................................................
........................................... ................... 4-73
CHECKING THE BEARINGS..................................................................4-73
TIMING CHAIN GUIDE ...........................................................................
........................................ ................................... 4-74
CHECKING THE TIMING CHAIN............................................................4-74
CHECKING THE CRANKSHAFT
CRANKSHAFT AND AND CONNECTING ROD ................. 4-74
INSTALLING THE CRANKSHAFT ..........................................................
......................................... ................. 4-75
ASSEMBLING THE CRANKCASE..........................................................4-75

ENG

REMOVING THE ENGINE ENG

EASF0188
OVERHAULING THE ENGINE

REMOVING THE ENGINE
NOTE:
It is not necessary to remove the engine in
order to remove the following components.
• Cylinder head
• Cylinder
• Piston
• Starter clutch
• Starter motor
• Kickstarter shaft
• V-belt
• Primary pulley
• Secondary pulley
• Transmission
• Rear wheel assembly
• Oil pump
• Generator
1. Remo
Remov ve:
COVER” in chapter 3.
• leg shield
SHIELD” in chapter 3.
2. Remo
Removve:
• under cover 1
1 WARNING
Securely support the motorcycle so there
is no danger of it falling over.
ENGINE OIL
1. Dr
Drai
ain:
n:
• engine oil
Refer to “CHANGING THE ENGINE OIL”
OIL” in
chapter 3.
4-1

CARBURETOR
1. Remo
Remov ve:
• carburetor assembly
Refer to “CARBURETOR
CARBURETOR”” in chapter 5.
MUFFLER
1 1. Remo
Remov ve:
• muffler nuts 1
2. Remo
Remov ve:
• muffler bolts 1
• muffler 2
1 2
REAR SHOCK ABSORBER BOLTS

1. Remo
Remov ve:
2. Remo
Remov ve:
• rear shock absorber lower bolts 1
1 1
4-2

WIRE, CABLE AND HOSE
1. Remo
Remov ve:
• spark plug cap 1
2. Disc
Disconn
onnec
ect:
t:
• A.C. magneto couplers 1
• starter motor lead 2
• negative battery lead 3
1
3. Remo
Remov ve:
3 • plastic clip 4
2 4
4. Disc
Disconn
onnec
ect:
t:
2 • vacuum hose 2
5. Remo
Remov ve:
• rear brake cable 1
2
• rear brake cable holder
2 1
SIDESTAND
1. Remo
Remov ve:
• sidestand 1
1
4-3
ENGINE INSTALLATION ENG

ENGINE ASSEMBLY
1. Remo
Removve:
• nut 1
• mounting bolt 2
• washer
1 • engine assembly
2
ENGINE INSTALLATION
ENGINE ASSEMBLY
WARNING
Securely support the motorcycle so there
is no danger of it falling over when install-
ing engine.
1. In
Inst
stal
all:
l:
•• engine
washer assembly
• mounting bolt
• nut
T
.
R
.
59 Nm (5.9 m • kg)
SIDESTAND
1. In
Inst
stal
all:
l:
• sidestand
T
.
R
.
32 Nm (3.2 m • kg)
WIRE, CABLE AND HOSE

1. In
Inst
stal
all:
l:
•• rear
rear brake
brake cable
cable holder
holder screws

T
.
R
.
7 Nm (0.7 m • kg)
• rear brake cable
2. Conn
Connecect:
t:
• vacuum hose
• cylinder head breather hose
3. Conn
Connecect:
t:
• negative battery lead
• starter motor lead
• A.C. magneto couplers
4. In
Inst
stal
all:
l:
• plastic clip
5. In
Inst
stal
all:
l:
• spark plug cap
4-4
ENGINE INSTALLATION ENG

REAR SHOCK ABSORBER BOLTS
1. In
Inst
stal
all:
l:
• rear shock absorber lower bolts

T
.
R
.
16 Nm (1.6 m • kg)
2. In
Inst
stal
all:
l:

T
.
R
.
23 Nm (2.3 m • kg)
MUFFLER
1. In
Inst
stal
all:
l:
• muffler
• muffler bolts
T
.
R
.
35 Nm (3.5 m • kg)
• muffler nuts
T
.
R
.
20 Nm (2.0 m • kg)
CARBURETOR
1. In
Inst
stal
all:
l:
Refer to “CARBURETOR
UNDER COVER
1. In
Inst
stalall:
l:
• under cover
2. In
Inst
stalall:
l:
• leg shield
3. Fill:
• engine oil
Refer to “CHANGING THE ENGINE OIL” OIL” in
chapter 3.
4. Adju
Adjust
st::
• rear brake cable free play
CABLE FREE PLAY” PLAY” and “ADJUSTING
THE REAR BRAKE”
BRAKE” in chapter 3.

(at the flange of the throttle grip)
3 ~ 7 mm
10 ~ 20 mm
4-5
CYLINDER HEAD ENG

EASF0221
CYLINDER HEAD
1 Cylinder head 7 Timing chain guide C O-ring

2 Spark plug (exhaust side) D Intake manifold
3 O-ring 8 O-ring E Air shroud
4 Tappet cover 9 Camshaft sprocket cover F Rubber cover
5 Camshaft sprocket 0 Dowel pin G Air duct
6 Plate A Gasket H Timing chain tensioner
B Gasket I Gasket
G
T
.
R
.
m • kg)
8 Nm (0.8 m

T
.
R
.
m • kg)
9 Nm (0.9 m

T
.
R
.
10 Nm (1.0 m • kg)
H
I
E
New
D F
LS C
New E
B

T
.
R
.
13 Nm (1.3 m • kg)
18 Nm (1.8 m • kg)
4
T
.
R
.
3 New
2 A
1 0

T
.
R
.
30 Nm (3.0 m • kg)
3 5
4 6

T
.
R
10 Nm (1.0 m • kg) 7
22 Nm (2.2 m • kg)
.

T
.
R
.

T
.
R
.
10 Nm (1.0 m • kg)
LS 8
9

T
.
R
.
12 Nm (1.2 m • kg)
4-6
CYLINDER HEAD ENG

EASF0225
REMOVING THE CYLINDER HEAD

1. Remo
Remov ve:
• side cover
COVER”.
• center cover
SHIELD”.
2. Remo
Remov ve:
1 • fuel tank cap 1
2
• fuel tank cover 2
3
• storage compartment 3
NOTE:
• After removing the fuel tank cover, immedi-
ately install the fuel tank cap on fuel tank.
• Unfasten the A.C. magneto lead 4.
3. Remo
Removve:
4. Refer
Remo
Remov vtoe:“CARBURETOR
• muffler
ENGINE”.
5. Remo
Remov ve:
• engine cooling fan
Refer to “GENERATOR
GENERATOR””.
6. Remo
Remov ve:
• spark plug cap 1
• spark plug 2
1
2
4-7
CYLINDER HEAD ENG

7. Remo
Remov ve:
• tappet cover (intake side) 1
1
• tappet cover (exhaust side) 2
• camshaft sprocket cover 3
3
8. Remo
Remov ve:
• air duct 1
• rubber cover 2
1
9. Remo
Remov ve:
• intake manifold 1
10.Remove:
• air shroud (left) 1
2 • air shroud (right) 2
1
4-8
CYLINDER HEAD ENG

11.Align:
• “I” mark a on the generator rotor
b
(with the stationary pointer b on the crank-
case)


clockwise..
b. When the piston
piston is
is at TDC on
on the compres-
compres-
sion stroke, align the “I” mark c on the
a camshaft sprocket with the stationary
pointer d on the cylinder head.

12.Loosen:
• bolt 1
NOTE:
_
While holding the generator rotor with the rotor

holding tool 2, loosen the bolt 1.
2
1
Rotor holding tool
90890-01235
13.Remove:
• timing chain tensioner 1
1 • (along
bolt 2 with the gasket)
• camshaft sprocket plate 3
• camshaft sprocket 4
• timing chain 5
NOTE:
_
To prevent the timing chain from falling into the

t he
crankcase, fasten it with a wire.
5 4
4-9
CYLINDER HEAD ENG

14.Remove:
• cylinder head
2
NOTE:
6
_
4 • Loosen the bolts and nuts in the proper

sequence as shown.
• Loosen each bolt and nut a 1/2 turn at a time.
t ime.
3 5 1 After all of the bolts and nuts are fully loos-
ened, remove them.
15.Remove:
1 • dowel pins 1
• gasket 2
• timing chain guide (exhaust side) 3
2
EAS00227
CHECKING THE CYLINDER HEAD

1. Elim
Elimin
inat
ate:
e:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
_
Do not use a sharp instrument to avoid damag-

ing or scratching:
• spark plug bore threads
• valve seats
2. Chec
Check:k:
• cylinder head
Damage/scratches → Replace.
4 - 10
CYLINDER HEAD ENG

3. Meas
Measurure:
e:
• cylinder head warpage
Out of specification → Resurface the cylin-
der head.
Maximum cylinder head warpage

0.05 mm

a. Place
Place a stra
straigh
ightedge 1 and a thickness
tedge
gauge 2 across the cylinder head.
b. Measur
Measure e the warpage
warpage..
c. If the limit
limit is exceeded
exceeded,, resurface
resurface the cylin-
cylin-
der head as follows.
d. Place a 400 ~ 600 600 grit wet sandpaper
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.

CHECKING TIMING CHAIN GUIDE

1. Chec
Check:
k:
• timing chain guide

Damage/wear (exhaust side)
→ Replace.
4 - 11
CYLINDER HEAD ENG

EAS00210
CHECKING THE TIMING CHAIN

TENSIONER
1. Chec
Check:k:
• timing chain tensioner
2. Chec
Check:k:
• one-way cam operation
Rough movement → Replace the timing
chain tensioner housing.
3. Chec
Check:k:
• cap bolt
• spring
• one-way cam
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
EAS00231
INSTALLING THE CYLINDER HEAD

2 1. In
Inst
stal
all:
l:
• timing chain guide (exhaust side) 1
• dowel pins 2
New 3 • gasket 3 New
2. In
Inst
stal
all:
l:
• cylinder head
1 5 3.• cylinder
Tigh
Tighte
ten:
n: head nuts
3
T
.
R
.
22 Nm (2.2 m • kg)
• cylinder head bolts
T
.
R
.
10 Nm (1.0 m • kg)
NOTE:
4
_
6 • Lubricate the cylinder head nuts with engine

2
oil.
• Tighten the cylinder head nuts and bolts in
the proper tightening sequence as shown
and torque them in two stages.
4 - 12
CYLINDER HEAD ENG

4. In
Inst
stal
all:
l:
1 • camshaft sprocket 1
• timing chain 2
d

clockwise..
c b. Alig
Align the “I” mark a on the generator rotor
n the
2 with the stationary pointer b on the crank-

case.
c. Alig
Align the “I” mark c on the camshaft
n the
sprocket with the stationary pointer d on
the cylinder head.
d. Install
Install the timing
timing chain
chain onto the camshaf
camshaftt
b sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
_
• When installing the camshaft sprocket, be

sure to keep the timing chain as tight as pos-
sible on the exhaust side.
a • Align the projection e on the camshaft
sprocket with the slot in the camshaft.
e CAUTION:
_
Do not turn the crankshaft when installing

the camshaft to avoid damage or improper
valve timing.
e. While holding
holding the camshaft
camshaft,, temporarily
temporarily
tighten the camshaft sprocket bolt.
f. Remov
Remove e the wire
wire from
from the timi
timing
ng chain.
chain.

4 - 13
CYLINDER HEAD ENG

5. In
Inst
stal
alll
• timing chain tensioner

a. Remov
Remove bolt 1 and spring 2.
e the cap bolt
b. Release the
the timing
timing chain tensioner
tensioner one-wa
one-way
y
cam 3 and push the timing chain tensioner
rod 4 all the way into the timing chain ten-
sioner housing.
c. Install
Install the timing
timing chain
chain tensioner
tensioner and gasket
gasket
5 onto the
th e cylinder.
Timing chain tensioner bolt

T
.
R
.
9 Nm (0.9 m • kg)
d. Instal
Installl the
the spring 2 and cap bolt 1.
spring
Cap bolt

T
.
R
.
8 Nm (0.8 m • kg)

6. Tigh
Tighte
ten:
n:
• camshaft sprocket bolt

T
.
R
.
30 Nm (3.0 m • kg)
CAUTION:
_
Be sure to tighten the camshaft sprocket

bolt to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Turn:
urn:
• crankshaft
(several turns clockwise)

4 - 14
CYLINDER HEAD ENG

8. Chec
Check:k:
• “I” mark a
b
Align the “I” mark on the generator rotor
with the stationary pointer b on the crank-
case.
• “I” mark c
Align the “I” mark on the camshaft sprocket
with the stationary pointer d on the cylinder
a head.
Out of alignment → Correct.
Refer to the installation steps above.
9. Meas
Measurure:
e:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE”” in chapter 3.
CLEARANCE
10.Install:
• intake manifold
• intake manifold bolts

T
.
R .
10 Nm (1.0 m • kg)
11.Install:
• tappet cover (exhaust side)
• tappet cover (intake side)
T
.
R

• camshaft sprocket cover18 Nm (1.8 m • kg)

.
• camshaft sprocket cover bolts

T
.
R .
12 Nm (1.2 m • kg)
12.Install:
• spark plug
T
.
R .
13 Nm (1.3 m • kg)
4 - 15
CAMSHAFT ENG
EASF0193
CAMSHAFT
1 Locknut 5 Rocker arm shaft (intake side)

2 Adjusting screw 6 Rocker arm shaft (exhaust side)
3 Rocker arm (intake side) 7 Camshaft
4 Rocker arm (exhaust side) 8 Camshaft retainer
1 2
3

T
.
R
.
m • kg)
7 Nm (0.7 m
8
4
E 12 Nm (1.2 m • kg)
2

T
.
R
.
6
1
M
4 - 16
CAMSHAFT ENG
EASF0202
REMOVING THE ROCKER ARMS AND

2 CAMSHAFT
1 NOTE:
Prior to remove the rocker arms and camshaft,
remove the cylinder head.
1. Lo
Loos
osen
en::
• locknuts 1
• adjusting screws 2
2. Remo
Remov
ve:
• camshaft retainer 1
1
3. Remo
Remov
ve:
• camshaft assembly 1
1
NOTE:
_
Screw 8 mm bolt 2 into the threaded end of

2 the camshaft and then pull out the camshaft.
4. Remo
Remov ve:
• rocker arm shaft (intake side)
1 • rocker arm shaft (exhaust side)

• rocker arm (intake side)
• rocker arm(exhaust side)
NOTE:
_
Remove the rocker arm shafts with the slide

hammer 1.
Slide hammer bolt

90890-01085
Weight
90890-01084
4 - 17
CAMSHAFT ENG
EAS00205
CHECKING THE CAMSHAFTS

1. Chec
Check:
k:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Meas
Measur ure:
e:
• cam lobe dimensions a and b
Out of specification → Replace the cam-
shaft.
Cam lobe dimension

Intake
a 25.881 ~ 25.981 mm
<Limit>: 25.780 mm
b 21.195 ~ 21.295 mm
<Limit>: 21.095 mm
Exhaust
a 25.841 ~ 25.941 mm
<Limit>: 25.740 mm
b 21.050 ~ 21.150 mm
<Limit>: 20.950 mm
3. Chec
Check:
k:
• camshaft oil passage
→
Obstruction Blow out with compressed
air.
EAS00206
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Chec
Check:
k:
• rocker arm
Damage/wear → Replace.
4 - 18
CAMSHAFT ENG
2. Chec
Check:k:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrica-
tion system.
3. Meas
Measur
ure:
e:
• rocker arm inside diameter
Rocker arm inside diameter

10.000 ~ 10.015 mm
<Limit>: 10.030 mm
4. Meas
Measur
ure:
e:
• rocker arm shaft outside diameter
Rocker arm shaft outside diame-

ter
9.981 ~ 9.991 mm
<Limit>: 9.950 mm
5. Calcu
Calcula
late
te::
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
_
Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the
rocker arm inside diameter.
Above 0.08 mm → Replace the defective

part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm
<Limit>: 0.08 mm
4 - 19
CAMSHAFT ENG
EAS00207
CHECKING THE CAMSHAFT SPROCKET

1. Chec
Check:
k:
• camshaft sprocket
More than 1/4 tooth wear a → Replace the
camshaft sprocket and the timing chain as a
set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
EAS00212
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers and O-rings.
1. Chec
Check:k:
• tappet cover
• camshaft sprocket cover
• O-ring
part(s).
EAS00219
INSTALLING THE CAMSHAFTS AND

ROCKER ARMS
1. Lubric
Lubricat
ate:
e:
• camshaft journals
Recommended
Engine oil lubricant
4 - 20
CAMSHAFT ENG
2. In
Inst
stal
all:
l:
• camshaft assembly 1
1
3. Lubric
Lubricat
ate:
e:
• rocker arm shafts
Molybdenum disulfide oil
4. In
Inst
stal
all:
l:
• rocker arm (exhaust side)
• rocker arm (intake side)
M • rocker arm shaft (exhaust side)
• rocker arm shaft (intake side)
5. In
Inst
stal
all:
l:
• camshaft retainer 1
1
• camshaft retainer bolt

T
.
R
.
12 Nm (1.2 m • kg)
NOTE:
_
Install the camshaft retainer with the folded

side facing inward.
4 - 21
VALVES AND VALVE SPRINGS ENG

EASF0236
VALVES AND VALVE SPRINGS
1 Valve cotter
2 Upper spring seat
3 Valve spring
4
5 Valve
Lower stem seal
spring seat
6 Valve (intake side)
7 Valve (exhaust side)
1
2
4
New
5
M
7
New
5
4
3
2
1
4 - 22

EASF0237
REMOVING THE VALVES

NOTE:
Prior to remove the valves, remove the cylin-
der head, rocker arm and camshaft.

valves and related components.
NOTE:
_
Before removing the internal parts of the cylin-

der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Chec
Check:
k:
• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS” SEATS”.

a. Pour a clean
clean solvent a into the intake and
solvent
exhaust ports.
b. Check that the valves
valves properly
properly seal.
seal.
NOTE:
_
There should be no leakage at the valve seat

1.

2. Remo
Remov ve:
• valve cotters 1
NOTE:
_
Remove the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-01253
4 - 23

4. Remo
Remov ve:
• upper spring seat 1
• valve spring 2
• valve stem 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
valves and valve guides.
1. Meas
Measur
ure:
e:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve-stem-to-valve-guide
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve

guide.
Valve-stem-to-valve-guide
clearance
Intake
0.015 ~ 0.042 mm
<Limit>: 0.080 mm
Exhaust
0.030 ~ 0.057 mm
<Limit>: 0.110 mm
4 - 24

2. Repl
Replac
ace:
e:
• valve guide
NOTE:
_
To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder
head to 100°
100°C in an oven.

a. Remove
Remove the valve valve guide
guide with the valve
valve
guide remover 1.
b. Install
Install the new valvvalve
e guide with
with the valve
valve
guide installer 2 and valve guide remover
1.
c. After install
installing
ing the valv
valve
e guide,
guide, bore the
valve guide with the 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 (5 mm)

90890-04097
Valve guide installer (5 mm)
90890-04098
Valve guide reamer (5 mm)
90890-04099

3. Elim
Elimin
inat
ate:
e:
• carbon deposits
(from the valve face and valve seat)

4. Chec
Check:k:
• 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. Meas
Measurure:
e:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness

Intake: 0.7 mm
Exhaust: 1.0 mm
4 - 25

6. Meas
Measur
ure:
e:
• 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
replace the oil seal.
Valve stem runout

0.01 mm
EAS00240
CHECKING THE VALVE SEATS

valves and valve seats.
1. Elim
Elimin
inat
ate:
e:
• carbon deposits
(from the valve face and valve seat)
2. Chec
Check:k:
• valve seat
Pitting/wear → Replace the cylinder head.
3. Meas
Measur
ure:
e:
• valve seat width a
Out of specification → Replace the cylinder

head.
Valve seat width

Intake: 0.9 ~ 1.1 mm
Exhaust: 0.9 ~ 1.1 mm

a. Appl
Applyy Mecha
Mechani c’s blueing dye (Dykem) b
nic
onto the valve
valve face.
b. Install
Install the valve
valve into
into the cylinder
cylinder head.
c. Press the valv
valve
e through the valv
valve
e guide and
onto the valve seat to make a clear impres-
sion.
d. Measure
Measure the valve
valve seat width.
4 - 26

NOTE:
_
Where the valve seat and valve face contacted

one another, the blueing will have been
removed.

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
coarse lapping compound a to the
lapping compound
valve face.
CAUTION:
_
Do not let the lapping compound enter the

gap between the valve stem and the valve
guide.
b. Apply molybde
molybdenum
num disulfi
disulfide
de oil onto
onto the
valve
valv e stem.
c. Install
Install the valve
valve into the
the cylinder
cylinder head.
head.
d. Turn the valve until the valve
valve face
face and valve
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 between your hands.
e. Apply a fine
fine lapping
lapping compound
compound to the
the valve
valve
face and repeat the above steps.
f. After
After eve
everyry lapping
lapping proced
procedure
ure,, be sure
sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Appl
Applyy Mecha
Mechani c’s blueing dye (Dykem) b
nic
onto the valve
valve face.
4 - 27

h. Install
Install the valve
valve into
into the cylinder
cylinder head.
i. Press
Press the
the valv
valve
e through
through the
the valv
valve
e guide
guide and
onto the valve seat to make a clear impres-
sion.
valve seat width c again. If
j. Measure the valve
the valve seat width is out of specification,
reface and lap the valve seat.

EAS00241
CHECKING THE VALVE SPRINGS

valve springs.
1. Meas
Measurure:
e:
• valve spring free length a
spring.
Valve spring free length

Intake valve spring
35.44 mm
<Limit>: 34.00 mm
Exhaust valve spring
35.44 mm
<Limit>: 34.00 mm
2. Meas
Measur
ure:
e:
• compressed valve spring force a
spring.
b Installed length
Compressed valve spring force

(installed)
Intake and exhaust valve spring
14.9 ~ 17.1 kg at 24.10 mm
3. Meas
Measurure:
e:
• valve spring tilt a
spring.
Spring tilt limit

Intake and exhaust valve spring
2.5°° /1.5 mm
2.5
4 - 28

EAS00245
INSTALLING THE VALVES

valves and related components.
1. Deb
Debur
urr:
r:
• valve stem end
(with an oil stone)
2. Lubric
Lubricat
ate:
e:
• valve stem 1
• valve stem seal 2
(with the recommended lubricant)
Molybdenum disulfide oil
3. In
Inst
stal
all:
l:
• valve 1
• lower spring seat 2
• valve stem seal 3 New
• valve spring 4
• upper spring seat 5
(into the cylinder head)
NOTE:
_
Install the valve spring with the larger pitch a

facing up.
a Larger pitch
b Smaller pitch
4. In
Inst
stal
all:
l:
• valve cotters 1
NOTE:
_
Install the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-01253
90890 01253
4 - 29

5. To secure the valve
valve cotters onto the valve
valve
stem, lightly tap the valve
valve tip with a soft-face
hammer.
CAUTION:
_
Hitting the valve tip with excessive force
could damage the valve.

4 - 30
CYLINDER AND PISTON ENG

EASF0251
CYLINDER AND PISTON
1 Top ring 6 Piston pin circlip

2 2nd ring 7 Cylinder
3 Oil ring 8 Cylinder gasket
4 Piston 9 Dowel pin

5 Piston pin
New
8
E
6
New 7
3
2 6
1
4 5
New
E
4 - 31

EASF0253
REMOVING THE CYLINDER AND PISTON

NOTE:
Prior to remove the cylinder and piston,
1 remove the cylinder head.
1. Remo
Remov ve:
• cylinder 1
2. Remo
Removve:
1 • dowel pins 1
• gasket 2
3. Remo
Remov ve:
• piston pin clip 1
• piston pin 2
• piston 3
CAUTION:
_
Do not use a hammer to drive the piston

2 3
pin out.
1
NOTE:
_
• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the

crankcase.
• Before removing the piston pin, deburr the
piston pin clip’
clip’s groove and the piston’
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 set.
4. Remo
Remov ve:
• 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.
4 - 32

EAS00265
CHECKING THE PISTON PIN

1. Chec
Check:
k:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Meas
Measurure:
e:
• piston pin bore inside diameter
Out of specification → Replace the piston.
Piston pin bore inside diameter

15.002 ~ 15.013 mm
<Limit>: 15.043 mm
3. Meas
Measurure:
e:
• piston pin outside diameter
Out of specification → Replace the piston
pin.
Piston pin outside diameter

14.995 ~ 15.000 mm
<Limit>: 14.975 mm
4. Calcu
Calcula
late
te::
• piston-pin-to-piston-pin-bore clearance
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 ~ 0.018 mm
<Limit>: 0.068 mm
4 - 33

EAS00255
CHECKING THE CYLINDER AND PISTON

1. Chec
Check:k:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder,
rings as aand
set.replace the piston and piston
2. Meas
Measurure:
e:
• piston-to-cylinder clearance

a. Measur
Measuree cylind
cylinder
er bore
bore “C” with the cylinder
bore gauge.
NOTE:
_
Measure cylinder bore “C” by taking side-to-

side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements.
Cylinder bore “C” 50.000 ~ 50.010 mm

Taper limit “T” 0.05 mm
Out-of-round “R” 0.05 mm
“C” = maximum of D 1 ~ D2

“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 specificati
cylinder, specification,
on, the
and replace rebore
rebopiston
re or replace
replace
and the
the
piston
rings as a set.
c. Measur
Measure e piston
piston skirt
skirt diameter
diameter “P” with the
micrometer.
a 5 mm from the bottom edge of the piston
Piston size “P”

Standard 49.970 ~ 49.985 mm
d. If out of specifi
specification
cation,, replace
replace the piston
piston and
piston rings as a set.
e. Calculate
Calculate the piston-to-
piston-to-cylin
cylinder
der clearance
clearance
with the following formula.
formula.
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter P
4 - 34
Piston-to-cylinder clearance
0.015 ~ 0.040 mm
<Limit>: 0.15 mm
f. If out of spec
specifi
ificati
cation,
on, rebor
rebore
e or replace
replace the
the
cylinder, and replace the piston and piston
rings as a set.

EAS00263
CHECKING THE PISTON RINGS

1. Meas
Measurure:
e:
• piston ring side clearance
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
0.03 ~ 0.07 mm
<Limit>: 0.12 mm
2nd ring
0.02 ~ 0.06 mm
<Limit>: 0.12 mm
2. In
Inst
stal
all:
l:
• piston ring
(into the cylinder)
a NOTE:
_
Level the piston ring into the cylinder with the

piston crown.
a 5.0 mm
3. Meas
Measurure:
e:
• piston ring end gap
ring.
NOTE:
_
The oil ring expander spacer’

spacer’s end gap cannot
be measured. If the oil ring rail’
rail’s gap is exces-
sive, replace all three piston rings.
4 - 35
Piston ring end gap

Top ring
0.10 ~ 0.25 mm
<Limit>: 0.50 mm
2nd ring
0.10 ~ 0.25 mm
<Limit>:
Oil ring 0.60 mm
0.20 ~ 0.70 mm
EAS00267
INSTALLING THE PISTON AND CYLINDER

1. In
Inst
stal
all:
l:
• top ring 1
• 2nd ring 2
• oil ring 3
NOTE:
_
• Be sure to install the piston rings so that the

manufacturer’’s marks or numbers face up.
manufacturer
• The piston rings

be installed thattop
into the have and
ring “R” mark must
groove.
• The piston rings that have and “RN RN”” mark
must be installed into the 2nd ring groove.
2. In
Inst
stal
all:
l:
• piston 1
• piston pin 2
• piston pin clip 3 New
NOTE:
_
a • Apply engine oil the piston pin.

2 1 • Make sure the arrow mark a on the piston
points towards the exhaust side of the cylin-
3 New der.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the clip from falling into the crankcase.
4 - 36

3. In
Inst
stal
all:
l:
2 • gasket 1 New
• dowel pins 2
4. Lubric
Lubricat
ate:
e:
New 1 • piston
• piston rings
• cylinder
Engine oil
5. Offs
Offset
et::
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
È exhaust
6. In
Inst
stal
all:
l:
• cylinder 1
NOTE:
_
• While compressing the piston rings with one

1 hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
4 - 37
KICKSTARTER ENG
EASF0338
KICKSTARTER
1 V-belt case cover protector 1 8 V-belt case air filter cover E Washer
2 Dowel pin 9 Kickstarter pinion gear
3 V-belt case cover 0 Kickstarter pinion gear clip
4 V-belt case cover protector 2 A Spacer
5 Kickstarter crank B Kickstarter spring
6 Oil seal C Kickstarter shaft
7 Circlip D Kickstarter shaft plate

T
.
R
.
m • kg)
9 Nm (0.9 m

T
.
R .
23 Nm (2.3 m • kg)
D

T
.
R 10 Nm (1.0 m • kg)

A
.
2
E 3
C
T
.
R
10 Nm (1.0 m • kg)
.
4
B
0
9
LS
M 7
6
New 5
LS

T
.
R .
11 Nm (1.1 m • kg)

T
.
R
.
10 Nm (1.0 m • kg)
4 - 38
KICKSTARTER ENG
REMOVING THE KICKSTARTER
1
1. Remo
Remov ve:
• V-belt case air filter cover 2
2. Remo
Remov ve:
2 • kickstarter crank bolt
3 • kickstarter crank 1
• V-belt case cover 3
• dowel pins
1
DISASSEMBLING THE KICKSTARTER

SHAFT
1. Remo
Remov ve:
• kickstarter shaft plate 1
2. Remo
Remov ve:
1 • kickstarter pinion gear 1
• kickstarter pinion gear clip 2
2
4 - 39
KICKSTARTER ENG
3. Remo
Remov ve:
• oil seal 1
• circlip 2
1
4. Remo
Remov ve:
• kickstarter shaft 1
1 • kickstarter spring 2
• spacer
• washer
EAS00339
CHECKING THE KICKSTARTER

1. Chec
Check:
k:
• kickstarter shaft
• kickstarter pinion gear
2. Chec
Check:
k:
• kickstarter spring
3. Meas
Measurure:
e:
• kickstarter pinion gear clip force
(with the spring gauge)
Out of specification → Replace the kick-
starter pinion gear clip.
Kickstarter pinion gear clip force

0.7 ~ 2.0 N (0.07 ~ 0.20 kgf)
4 - 40
KICKSTARTER ENG
EAS00340
ASSEMBLING THE KICKSTARTER

1. In
Inst
stal
all:
l:
1
• washer
• spacer
• kickstarter spring
2
• kickstarter shaft
• circlip
• oil seal New
NOTE:
_
Install the kickstarter spring straight end on the

kickstarer shaft notch 1 and hook the spring
hooked end on the projection 2 as shown.
2. In
Inst
stal
all:
l:
• kickstarter pinion gear clip
• kickstarter pinion gear
• kickstarter shaft plate
• kickstarter shaft plate screws
T R

9 Nm (0.9 m • kg)
.
.
INSTALLING THE KICKSTARTER

1. In
Inst
stal
all:
l:
• dowel pins
• V-belt case cover bolts

T
.
R
.
10 Nm (1.0 m • kg)
T
R
.
.
10 Nm (1.0 m • kg)
• kickstarter crank
• kickstarter crank bolt
T
R
.
.
11 Nm (1.1 m • kg)
2. In
Inst
stal
all:
l:
• V-belt case air filter cover
• V-belt case air filter cover bolts
T
R
.
.
10 Nm (1.0 m • kg)
T
R
.
.
23 Nm (2.3 m • kg)
4 - 41
BELT DRIVE ENG

EASF0316
BELT DRIVE
V-BELT, PRIMARY AND SECONDARY PULLEY

1 O-ring 6 Spring seat A V-belt
2 Clutch housing 7 Oil seal B Conical spring washer
3 Clutch carrier 8 O-ring C Kickstarter one-way clutch
4 Clutch shoe 9 Secondary sliding sheave D Claw washer
5 Spring 0 Secondary fixed sheave E Primary fixed sheave
* Shell Dolium grease R ®
4
3

T
.
R .
75 Nm (7.5 m • kg)
7 New 9 2
*
New 1
8
7
T
.
R
.
40 Nm (4.0 m • kg)
New 6
0
K
*
J
I
L New
A
G
New H T
.
R .
55 Nm (5.5 m • kg)
G D
C
New F B
E
4 - 42
BELT DRIVE ENG

F Collar
G Oil seal
H Primary sliding sheave
I Primary pulley weight
J Slider
K Cam
L Gasket
M Guide pin
* Shell Dolium grease R ®
4
3

T
.
R .
75 Nm (7.5 m • kg)
7 New 9 2
*
New 1
8
7
T
.
R
.
40 Nm (4.0 m • kg)
New 6
0
K
*
J
I
L New
A
G
New H T
.
R .
55 Nm (5.5 m • kg)
G D
C
New F B
E
4 - 43
BELT DRIVE ENG

EASF0318
REMOVING THE SECONDARY PULLEY

3 AND V-BELT
1. Remo
Remov ve:
2 4
1 Refer to “KICKSTARTER
KICKSTARTER””.
2. Remo
Remov ve:
• O-ring 1
• secondary pulley nut 2
• clutch housing 3
NOTE:
_
While holding the clutch housing with the

sheave holder 4, loosen the secondary pulley
nut.
Sheave holder
90890-01701
3. Lo
Loos
osen
en::
• clutch carrier nut 1
CAUTION:
_
1 Do not remove the clutch carrier nut at this

3
stage.
2
NOTE:
_
While holding the clutch carrier with the rotor

holding tool 2, loosen the clutch carrier nut
one full turn with the locknut wrench 3.
Rotor holding tool

90890-01235
Locknut wrench
90890-01348
4. Remo
Remov ve:
2 • secondary pulley 1
• V-belt 2
NOTE:
_
Pull the secondary sliding sheave out as

shown, remove the V-belt along with the sec-
ondary pulley 1, and then remove the V-belt
1 2 from the primary pulley.
4 - 44
BELT DRIVE ENG

5. Remo
Removve:
1 • gasket 1
EASF0317
REMOVING THE PRIMARY PULLEY

3 1. Remo
Remov ve:
2 Refer to “GENERATOR
GENERATOR””.
2. Remo
Remov ve:
• primary pulley nut 1
• conical spring washer
1 • kickstarter one-way clutch
• claw washer
• primary fixed sheave 2
• washer
• primary sliding sheave
NOTE:
_
While holding the generator rotor with the rotor

holding tool 3, loosen the primary pulley nut.
Rotor holding tool

90890-01235
3. Remo
Removve:
3 3 1
2 • cams 1
• slider 2
• primary pulley weight 3
1 1
3
4 - 45
BELT DRIVE ENG

EAS00319
DISASSEMBLING THE SECONDARY
PULLEY
1. Remo
Remov ve:
1 • clutch carrier nut 1
NOTE:
_
Install the clutch spring holder 2 onto the sec-

2 ondary pulley as shown. Then, compress the
spring, and remove the clutch carrier nut 1.

90890-01337
2. Remo
Remov ve:
1 • spring seat
3. Remo
Remov ve:
• guide pins 1
EAS00290
CHECKING THE CLUTCH HOUSING

1. Chec
Check:
k:
• clutch housing
2. Meas
Measurure:
e:
a • clutch housing inside diameter a
Out of specification → Replace the clutch
housing.
Clutch housing inside diameter

112 mm
<Limit>: 112.5 mm
4 - 46
BELT DRIVE ENG

EAS00291
CHECKING THE CLUTCH SHOES

clutch shoes.
1. Chec
Check:
k:
• clutch shoe
Damage/wear → Replace the clutch shoes

and springs as a set.
Glazed areas → Sand with course sandpa-
per.
NOTE:
_
After sanding the glazed areas, clean the

clutch with a cloth.
2. Meas
Measurure:
e:
• clutch shoe thickness a
Out of specification → Replace the clutch
shoes and springs as a set.
Clutch shoe thickness

2.0 mm
<Limit>: 1.0 mm
EAS00320
CHECKING THE V-BELT

1. Chec
Check:
k:
1 • V-belt 1
Grease/oil → Clean the primary and sec-
a ondary pulley.
2. Meas
Measur
ure:
e:
• V-belt width a
V-belt width
18.2 mm
<Limit>: 17.2 mm
4 - 47
BELT DRIVE ENG

EAS00321
CHECKING THE PRIMARY PULLEY

WEIGHTS
primary pulley weights.
1. Chec
Check:
k:
• primary pulley weight

2. Meas
Measur
ure:
e:
• primary pulley weight outside diameter a
Primary pulley weight outside

diameter
15 mm
<Limit>: 14.5 mm
a
EAS00322
CHECKING THE SECONDARY PULLEY

1. Chec
Check:
k:
• secondary fixed sheave
• secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Chec
Check:
k:
• torque cam groove 1
2 Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Chec
Check:k:
• guide pin 2
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
1
4. Chec
Check:
k:
• spring free length
Out of specification → Replace the spring.
Spring free length

76 mm
<Limit>: 73 mm
4 - 48
BELT DRIVE ENG

EAS00324
ASSEMBLING THE SECONDARY PULLEY

1
1. Lubric
Lubricat
ate:
e:
• secondary fixed sheave 1
2
• secondary sliding sheave 2
• bearing

NOTE:
_
Do not get any grease on the surfaces of the

pulley. If any grease gets on the pulley, be
sure to wipe it off with alcohol, etc.
Shell Dolium grease R ®
2. In
Inst
stal
all:
l:
3
• oil seals New
• secondary sliding sheave 1
• secondary fixed sheave 2
NOTE:
1 _
2 Install the secondary sliding sheave onto the

secondary fixed sheave 2 with the oil seal
guide 3.
Oil seal guide

90890-01384
3. In
Inst
stal
all:
l:
1 • guide pin 1
4 - 49
BELT DRIVE ENG

4. Lubric
Lubricat
ate:
e:
• guide pin groove 1
• O-rings 2 New
2
New Recommended lubricant
1
5. In
Inst
stal
all:
l:
a
• spring seat 1
NOTE:
_
Do not get any grease on the surfaces a and

b of the pulley. If any grease gets on the pul-
ley, be sure to wipe it off with alcohol, etc.
1
b
6. In
Inst
stal
all:
l:
2
• spring
• clutch carrier 1 75 Nm (7.5 m • kg)
1
T
.
R
.
NOTE:
_
Attach the clutch spring holder 2 onto the sec-

3
ondary pulley as shown. Then, compress the
spring, and tighten the clutch carrier nut 3.

90890-01337
EAS00323
ASSEMBLING THE PRIMARY PULLEY

1. Clea
Clean:
n:
• primary fixed sheave
• collar
• primary pulley weights
4 - 50
BELT DRIVE ENG

2. In
Inst
stal
all:
l:
• oil seal
3. Lu
Lubr
bric
icat
ate:
e:
• collar
NOTE:
_
Fill the notch of the primary sliding sheave with

grease. Apply grease to the inside diameter of
the primary sliding sheave.
CAUTION:
_
Do not get any grease on the surfaces of

the pulley. If any grease gets on the pulley,
be sure to wipe it off with alcohol, etc.
4. In
Inst
stal
all:
l:
1 1 3
2 • primary pulley weights 1
• slider 2
• cams 3
3 3
1
5. In
Inst
stal
all:
l:
• primary sliding sheave 1
1
4 - 51
BELT DRIVE ENG

6. In
Inst
stal
all:
l:
• washer 1
• primary fixed sheave 2
4 5 • claw washer 3
• kickstarter one-way clutch 4
1
• conical spring washer 5
3 • primary pulley nut 6
2 4 5 55 Nm (5.5 m • kg)
6
T
.
R
.
NOTE:
_
• Install the conical spring washer 5 as shown

in the illustration.
• While holding the generator rotor with the
rotor holding tool, tighten the primary pulley
nut.
Rotor holding tool

90890-01235
EAS00325
INSTALLING THE BELT DRIVE

2 a
1. In
Inst
stal
all:
l:
• gasket 1 New
1 • V-belt 2
• secondary pulley 3
CAUTION:
_
3 Do not allow grease to contact the V-belt,

secondary pulley assembly.
NOTE:
_
• The V-belt must be installed, with the arrow

a forward.
• Install the V-belt on the primary pulley, then
install the secondary pulley 3 along with the
V-belt 2.
4 - 52
BELT DRIVE ENG

2. In
Inst
stal
all:
l:
• clutch carrier nut 1

T
.
R
.
50 Nm (5.0 m • kg)
1 NOTE:
_
3 While holding the clutch carrier with the rotor

holding tool 2, tighten the clutch carrier nut
2 with the locknut wrench 3.
Rotor holding tool

90890-01235
Locknut wrench
90890-01348
3. Pos
osit
itio
ion:
n:
• V-belt 1
1
2 NOTE:
_
3 Position the V-belt in the primary pulley 2

(when the pulley is at its widest position) and in
the secondary pulley 3 (when the pulley is at
its narrowest position), and make sure the V-
belt is tight.
4. In
Inst
stal
all:
l:
• clutch housing 1
1
• secondary pulley nut 2
3
T
.
R
.
40 Nm (4.0 m • kg)
2 • O-ring
NOTE:
_
Tighten the secondary pulley nut with the

sheave holder 3.
Sheave holder
90890-01701
5. In
Inst
stal
all:
l:
KICKSTARTER””.
4 - 53
STARTER CLUTCH ENG

EASF0341
STARTER CLUTCH
1 Idle gear plate

2 Idle gear
3 Starter clutch assembly
4 Starter wheel gear holder
5 Starter wheel gear
6 Bearing
2
1
LS

T
.
R
.
10 Nm (1.0 m • kg)

T
.
R
.
10 Nm (1.0 m • kg)
6
4

T
.
R
.
10 Nm (1.0 m • kg)
LT
4 - 54
STARTER CLUTCH ENG

1. Remo
Remov ve:
DRIVE”.
2. Remo
Remov ve:
1
• idle gear plate 1
• washer
• idle gear 2
2 • washer
3 • starter clutch assembly 3
3. Remo
Remov ve:
• starter wheel gear holder 1
• starter wheel gear 2
2
• bearing 3
3
EAS00348
CHECKING THE STARTER CLUTCH

1. Chec
Check:k:
• idle gear
• starter wheel gear
• starter clutch assembly
Burrs/chips/roughness/wear → Replace the
defective part(s).
2. Chec
Check:k:
• starter wheel gear contacting surface
Damage/pitting/wear → Replace the starter
wheel gear.
4 - 55
STARTER CLUTCH ENG

3. Chec
Check:k:
É È
• starter clutch operation

a. Install
Install the starter wheel
wheel gear
gear onto the
starter clutch and hold the starter clutch.
b. When turning
turning the starter
starter wheel gear clock-
clock-
wise È, the starter clutch and the starter
wheel gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter
starter wheel
wheel gear coun-
coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.

EAS00355
2 INSTALLING THE STARTER CLUTCH

1. In
Inst
stal
all:
l:
• starter wheel gear 1
• starter clutch assembly 2
1
NOTE:
_
• Install the starter wheel gear 1 while turning

the starter clutch assembly 2 counterclock-
wise.
• Apply a thin coat of grease to the needle
bearing.
2. In
Inst
stal
all:
l:
• starter wheel gear holder
• starter wheel gear holder bolt

T
.
R
.
10 Nm (1.0 m • kg)
3. In
Inst
stal
all:
l:
• idle gear plate
• idle gear plate bolts
T
.
R
.
10 Nm (1.0 m • kg)
4 - 56
GENERATOR ENG
GENERATOR
1 Stator coil assembly
2 Generator rotor
3 Engine cooling fan
4 Engine cooling fan cover

T
.
R
.
m • kg)
7 Nm (0.7 m

T
.
R
.
10 Nm (1.0 m • kg)

T
.
R
.
70 Nm (7.0 m • kg)
3
1

T
.
R
.
m • kg)
7 Nm (0.7 m

T
.
R
.
11 Nm (1.1 m • kg)
4 - 57
GENERATOR ENG
EASF0346
REMOVING THE GENERATOR

1. Remo
Remov ve:
• side cover (right)
2. Disc
Disconn
onnecect:
t:
• A.C. magnet couplers 1
1 3. Remo
Remov ve:
2 • plastic clip 2
4. Remo
Removve:
• engine cooling fan cover 1
1
5. Remo
Removve:
• engine cooling fan 1
1
4 - 58
GENERATOR ENG
6. Remo
Removve:
• generator rotor nut 1
2 • washer
NOTE:
_
1 While holding the generator rotor 2 with the

3
rotor
nut. holding tool , loosen the generator rotor
3
Rotor holding tool
90890-01235
7. Remo
Remov ve:
• generator rotor 1
(with the flywheel puller 2)
1
• woodruff key
Flywheel puller
90890-01189
8. Remo
Remov ve:
4
3 • stator coil 1
2 9. Disc
Disconn
onnec
ect:
t:
• stator coil coupler 2
10.Remove:
• pickup coil bracket 3
• pickup coil 4
1
4 - 59
GENERATOR ENG
EAS00354
INSTALLING THE GENERATOR

1
1. In
Inst
stal
all:
l:
• pickup coil
• pickup coil bracket 1
• pickup coil bracket screws

T
.
R
.
7 Nm (0.7 m • kg)
NOTE:
2
_
Pass the starter coil lead under the pickup coil

bracket.
2. Conn
Connecect:
t:
• stator coil coupler
3. In
Inst
stal
all:
l:
• stator coil 2
• stator coil bolts
T
.
R
.
11 Nm (1.1 m • kg)
4. In
Inst
stal
all:
l:
• woodruff key
• generator rotor 1
1 • washer
• generator rotor nut
NOTE:
_
• Clean the tapered portion of the crankshaft

and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
2 5. Tigh
Tighte
ten:
n:
• generator rotor nut 1
1
T
.
R
.
70 Nm (7.0 m • kg)
NOTE:
_
While holding the generator rotor 2 with the

rotor holding tool 3, tighten the generator
3 rotor nut.
Rotor holding tool

90890-01235
4 - 60
GENERATOR ENG
5. In
Inst
stal
all:
l:
• engine cooling fan bolts

T
.
R
.
10 Nm (1.0 m • kg)
6. In
Inst
stal
all:
l:
• engine cooling fan cover
• engine cooling fan cover screws

T
.
R
.
7 Nm (0.7 m • kg)
4 - 61
OIL PUMP ENG

EASF0357
OIL PUMP
1 Oil pump cover 7 Engine oil strainer

2 Oil seal 8 Spring
3 O-ring 9 O-ring
4 Gasket 0 Engine oil drain plug
5 Oil pump assembly
6 Gasket

T
.
R
.
10 Nm (1.0 m • kg)
2 New
LS

T
.
R
.
m • kg)
4 Nm (0.4 m

T
.
R
.
10 Nm (1.0 m • kg)
1
3 New
4 New
6
New
7
8
LS
9 New
0

T
.
R
.
20 Nm (2.0 m • kg)
4 - 62
OIL PUMP ENG

REMOVING THE OIL PUMP
1. Dr
Drai
ain:
n:
• engine oil
(completely from the crankcase)
Refer to “CHANGING THE ENGINE OIL”
OIL” in
chapter 3.
2. Remo
Remov ve:
• stator coil
GENERATOR””.
3. Remo
Remov ve:
• oil pump cover 1
• O-ring
1 • gasket
4. Remo
Remov ve:
• circlip 1
• plate washer 2
3 • driven gear 3
1
2
5. Remo
Remov ve:
• oil pump assembly 1
• gasket
DISASSEMBLING THE OIL PUMP

5 4
1. Remo
Remov ve:
• pin
3 • oil pump housing cover 1
• pin
1
• oil pump shaft 2
• inner rotor 3
2 • outer rotor 4
• oil pump housing 5
4 - 63
OIL PUMP ENG

EAS00364
CHECKING THE OIL PUMP

1. Chec
Check:k:
• oil pump drive gear
• oil pump driven gear 1
• oil pump housing 2
• oil pump housing cover 3
3 2 Cracks/damage/wear → Replace the defec-
1 tive part(s).
2. Meas
Measurure:
e:
• 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
0.15 mm
<Limit>: 0.23 mm
Outer-rotor-to-oil-pump-housing
clearance
0.13 ~ 0.18 mm
<Limit>: 0.25 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06 ~ 0.10 mm
<Limit>: 0.17 mm
3. Chec
Check:k:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
4 - 64
OIL PUMP ENG

EAS00375
ASSEMBLING THE OIL PUMP

1. Lubric
Lubricat
ate:
e:
• inner rotor
• outer rotor
• oil pump shaft
Engine oil
2. In
Inst
stal
all:
l:
1 • oil pump shaft
a • oil pump housing cover
• pin 1
• inner rotor 2
• outer rotor
• pin
• oil pump housing
2
NOTE:
_
When installing the inner rotor, align the pin 1

in the oil pump shaft with the groove a in the
inner rotor 2.
3. Chec
Check:k:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”
PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1.• In
Inst
stal
all:
gasket l: New
• oil pump assembly
• oil pump assembly screws

T
.
R
.
4 Nm (0.4 m • kg)
2. In
Inst
stal
all:
l:
• gasket New
• O-ring New
• oil pump cover
• oil pump cover bolts

T
.
R
.
10 Nm (1.0 m • kg)
4 - 65
TRANSMISSION ENG
EASF0419
TRANSMISSION
1 Drive axle 8 Oil seal

2 Oil seal 9 Transmission case cover
3 Conical spring washer 0 Gasket
4 Drive axle gear A Primary drive gear
5 Main axle
6 Conical spring washer
7 Dowel pin
2 New
3
4

T
.
R
.
10 Nm (1.0 m • kg)
7

T
.
R
.
13 Nm (1.3 m • kg)
0 New
LS
8 New
e
4 - 66
TRANSMISSION ENG
EASF0420
REMOVING THE TRANSMISSION

NOTE:
Prior to remove the transmission, remove the
muffler, rear wheel and secondary pulley.
1. Dr
Drai
ain:
n:
• transmission oil
(completely from the transmission case)
Refer to “CHANGING THE TRANSMIS-
SION OIL”
OIL” in chapter 3.
2. Remo
Remov ve:
• transmission case cover 1
1 (with primary drive gear, bearings)
• gasket
• dowel pins
3. Remo
Remov ve:
1 • oil seal 1
• circlip 2
4. Remo
Removve:
• primary drive gear 1
5. Remo
Remov ve:
• washer 1
2 • drive axle gear 2
• main axle 3
3
4 - 67
TRANSMISSION ENG
6. Remo
Remov ve:
• drive axle 1
(with circlip)
1
EAS00425
CHECKING THE TRANSMISSION

1. Chec
Check:k:
• drive axle
• main axle
• primary drive gear
2. Chec
Check:k:
• bearings
Rough movement → Replace.

3. Chec
Check: k:
• circlips
Bends/damage/looseness → Replace.
EAS00428
INSTALLING THE TRANSMISSION
1.• drive
In
Inst
stal
all:
l:
axle
a • circlip 1
1
NOTE:
_
• Make sure the circlip 1 is inserted into the

groove a in the drive axle.
• Always use a new gasket and O-ring.
4 2. In
Inst
stal
all:
l:
5 • main axle 1
3 • drive axle gear 3
3 2
• washer 5
1 NOTE:
_
Install the conical spring washers as shown in

5 the illustration.
4 - 68
TRANSMISSION ENG
3. In
Inst
stal
all:
l:
• primary drive gear bearing
• retainer bolt 10 Nm (1.0 m • kg)

T
.
R
.
4. In
Inst
stal
all:
l:
• circlip
• oil seal New
• dowel pins
• gasket New
• transmission case cover
(with primary drive gear, bearings)
• transmission case cover bolts

T
.
R
.
13 Nm (1.3 m • kg)
5. Chec
Check:
k:
• transmission
Rough movement → Repair.
NOTE:
_
Oil each gear, shaft, and bearing thoroughly.

4 - 69
CRANKSHAFT ENG
EASF0381
CRANKSHAFT
1 Crankcase (right) 9 Rubber damper
2 Crankshaft assembly 0 Collar
3 Timing chain A Engine bracket
4 Timing chain guide (intake side) B Spacer
5
6 Dowel pin (left)
Crankcase C
D Center
Center stand
stand shaft
spring
7 Oil seal E Center stand
8 Engine drain bolt

T
.
R
.
10 Nm (1.0 m • kg) 1
New
3
6
LS
E
2
09 7 New
LS

T
.
R
.
m • kg)
7 Nm (0.7 m
9 8
0
T
.
R
.
20 Nm (2.0 m • kg)
B
T 16 Nm (1.6 m • kg)
A
.
R
.
E C

T
.
R
.
32 Nm (3.2 m • kg)
D
LS
4 - 70
CRANKSHAFT ENG
EAS00385
DISASSEMBLING THE CRANKCASE

1. Remo
Remov ve:
• engine assembly
ENGINE”.
2. Remo
Remov ve:
• cylinder head
• cylinder
• piston
Refer to “CYLINDER HEAD”
HEAD” and “CYLIN-
DER AND PISTON”
PISTON”.
3. Remo
Remov ve:
KICKSTARTER””.
4. Remo
Remov ve:
• secondary pulley
• V-belt
• primary pulley
DRIVE”.
5.• Remo
Remov vclutch
starter e:
Refer to “STARTER CLUTCH”
CLUTCH”.
6. Remo
Remov ve:
• starter motor
Refer to “STARTER MOTOR”
MOTOR” in chapter 7.
7. Remo
Remov ve:
• generator
GENERATOR””.
8. Remo
Remov ve:
• oil pump
Refer to “OIL PUMP”
PUMP”.
9. Remo
Remov ve:
• rear wheel assembly
Refer to “REAR WHEEL AND BRAKE”
BRAKE” in
chapter 6.
10.Remove:
• rubber dampers 1
• collars
• engine bracket 2
1
2
4 - 71
CRANKSHAFT ENG
11.Remove:
2 3 • centerstand spring 1
• circlip 2
• washer
• centerstand shaft 3
4 1
• centerstand 4
12.Remove:
• timing chain guide (intake side) 1
1
13.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.
14.Remove:
• right crankcase
CAUTION:
_
Tap on one side of the crankcase with a

soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
4 - 72
CRANKSHAFT ENG
EASF0389
REMOVING THE CRANKSHAFT

ASSEMBLY
1 1. Remo
Remov ve:
• crankshaft assembly 1
2 • timing chain 2
NOTE:
_
• Before removing the crankshaft assembly,

remove the timing chain from the crankshaft
sprocket.
• The crankshaft assembly cannot be removed
if the timing chain is attached onto the crank-
shaft sprocket.
EAS00399
CHECKING THE CRANKCASE

1. Thoroughly
Thoroughly wash
wash the crankcas
crankcase
e halves
halves in a
mild solvent.
2. Thoroughly
Thoroughly clean
clean all the
the gasket
gasket surfaces
surfaces
and crankcase mating surfaces.
3. Chec
Check:k:
• crankcase
• oil delivery passages
Obstruction → Blow out with compressed
air.
EAS00401
CHECKING THE BEARINGS

1. Chec
Check:k:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
4 - 73
CRANKSHAFT ENG
TIMING CHAIN GUIDE
1. Chec
Check:
k:
• timing chain guide (intake side)
EAS00207
CHECKING THE TIMING CHAIN

1. Chec
Check:
k:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
EAS00394
CHECKING THE CRANKSHAFT AND

CONNECTING ROD
1. Meas
Measurure:
e:
• crankshaft runout 1
Out of specification → Replace the crank-
shaft, bearing or both.
NOTE:
_
Turn the crankshaft slowly.
Maximum crankshaft runout

0.03 mm
2. Meas
Measurure:
e:
• big end side clearance 2
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance

0.15 ~ 0.45 mm
3. Meas
Measur ure:
e:
• crankshaft width 3
Out of specification → Replace the crank-
shaft.
Crankshaft width
45.45 ~ 45.50 mm
4 - 74
CRANKSHAFT ENG
4. Chec
Check:k:
• crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
• bearing 2
Rough movement → Replace the crank-
shaft.
5. Chec
Check:
k:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
air.
EAS00408
INSTALLING THE CRANKSHAFT

1. In
Inst
stal
all:
l:
• timing chain
• crankshaft assembly
CAUTION:
_
To avoid scratching the crankshaft and to

ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
EAS00416
ASSEMBLING THE CRANKCASE

1. Appl
Apply:
y:
• 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.
4 - 75
CRANKSHAFT ENG
2. In
Inst
stal
all:
l:
• dowel pins 1
1 3. In
Inst
stal
all:
l:
• right crankcase
(onto the left crankcase)
NOTE:
_
1 Tap lightly on the right crankcase with a soft-

face hammer.
4. In
Inst
stal
all:
l:
• crankcase bolts 10 Nm (1.0 m • kg)

T
.
R .
5. In
Inst
stal
all:
l:
• timing chain guide (intake side)
• timing chain guide retainer bolt
T
R
.
.
7 Nm (0.7 m • kg)
6. In
Inst
stal
all:
l:
• engine bracket
• engine bracket bolts
• engine bracket nuts
T
R
.
.
32 Nm (3.2 m • kg)
• collars
• rubber dampers
• rubber damper bolts
• rubber damper nuts
T
R
.
.
16 Nm (1.6 m • kg)
4 - 76
CARB
CHAPTER 5
CARBURETOR
CARBURETOR................................................................................................5-1
CARBURETOR ................................................................................................5-1
REMOVING THE CARBURETOR.............................................................5-2
DISASSEMBLING THE CARBURETOR...................................................5-3
CHECKING THE CARBURETOR .............................................................
....................................... ...................... 5-5
ASSEMBLING THE CARBURETOR.........................................................5-7
INSTALLING THE CARBURETOR ...........................................................
....................................... .................... 5-9
MEASURING AND ADJUSTING
ADJUSTING THE FUEL LEVEL LEVEL ................................ 5-9
CHECKING THE FUEL COCK OPERATION..........................................5-11

CARB

CARBURETOR CARB
EASF0480
CARBURETOR
CARBURETOR
1 Vacuum chamber cover 9 Throttle stop screw set G Needle valve
2 Piston valve spring 0 Coasting enricher spring H Float
3 Jet needle set A Coasting enricher I Float pivot pin
4 Piston valve B Pilot jet J Accelerator plunger set
5 Air vent hose C Cap K Gasket
6 Pilot screw set D O-ring L Fuel drain screw
7 Starter plunger assembly E Needle jet M Float chamber
8 Gasket F Main jet N Fuel overflow hose
1
5
3
2
4 9
6
New
New D B
G E
C
K New F
H
J A
0
L I
M
N
5-1
CARBURETOR CARB
EASF0481
REMOVING THE CARBURETOR

WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
1. Remo
Remov ve:
• side panel (left and right)
2. Remo
Remov ve:
• air filter case
CASE” in chapter 3.
3. Loos
Loosenen::
• fuel drain screw 1
4. Dr
Drai
ain:
n:
• fuel (float chamber)
5. Loos
Loosenen::
• locknut (throttle cable) 1
• adjusting nut 2
6. Disc
Disconn
onnec ect:
t:
• throttle cable 3
3 4 7. Loos
Loosenen::
2 • screw (intake manifold) 4
1
8. Remo
Removve:
• carburetor assembly 1
1
5-2
CARBURETOR CARB
9. Remo
Remov ve:
10.Disconnect:
• fuel hose 2
1 • starter cable 3
4
•• fuel
air vent hose
overflow hose 5
4
2
5
11.Disconnect:
• starter plunger assembly 1
EASF0483
DISASSEMBLING THE CARBURETOR

NOTE:
The following parts can be cleaned and
inspected without disassembly.
• Starter plunger
• Throttle stop screw
• Pilot screw
1 1. Remo
Remov ve:
• float chamber 1
• float chamber rubber gascket
5-3
CARBURETOR CARB
2. Remo
Remov ve:
• accelerator plunger assembly 1
3. Remo
Remov ve:
• float pivot pin 1
• float 2
• needle valve 3
3 2 • float pin screw 4
1
4
4. Remo
Remov ve:
• main jet 1
• needle jet 2
4
• pilot jet 3
2 3 • O-ring 4
• cap 5
1
5
5. Remo
Remov ve:
3
1 • vacuum chamber cover 1
6. Remo
Remov ve:
2 • piston valve spring 2
• piston valve 3
1
7. Remo
Remov ve:
• jet needle set 1
1
5-4
CARBURETOR CARB
8. Remo
Remov ve:
• pilot screw set 1
9. Remo
Remov ve:
• fuel strainer 1
EAS00485
CHECKING THE CARBURETOR

1. Chec
Check:k:
• carburetor body
• float chamber
• jet housing
2. Chec
Check:k:
• fuel passages

a. Wash
Wash the carburet
carburetor
or in a petroleum
petroleum-based
-based
solvent. Do not use any caustic carburetor

cleaning solution.
b. Blow out
out all of the
the passages
passages and jets
jets with
compressed air.

3. Chec
Check:k:
• float chamber body
Dirt → Clean.
4. Chec
Check:k:
• fuel passages
5. Chec
Check:k:
• float chamber rubber gasket
5-5
CARBURETOR CARB
6. Chec
Check:k:
• float
Damage → Replace.
7. Chec
Check:
k:
• needle valve 1
• needle valve seat 2
Damage/obstruction/wear → Replace the
2 needle valve.
1
8. Chec
Check:
k:
• piston valve 1
Damage/scratches/wear → Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.
9. Chec
Check:
k:
2 • vacuum chamber cover 1
1 • piston valve spring 2
10.Check:
• jet needle set 1
2 3 4 5 6 • needle jet 2
• main jet 3
• pilot jet 4
• pilot screw 5
1 • fuel strainer 6
Bends/damage/wear → Replace.
Blow out the jets with compressed air.
5-6
CARBURETOR CARB
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:
• starter plunger 1
• starter plunger spring 2
Bends/cracks/damage → Replace.
1 2
13.Check:
• accelerator plunger 1
3
• O-ring 2
2 • accelerator plunger spring 3
1 14.Check:
• hose joints
15.Check:
• vacuum hose
• fuel hose
Blow out the hoses with compressed air.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
_
• Before assembling the carburetor, wash

all of the parts in a petroleum-based sol-
vent.
• Always use new gasket and o-ring.
5-7
CARBURETOR CARB
1. In
Inst
stal
all:
l:
• jet needle set
NOTE:
Push the jet needle holder 1 with a Phillips
screwdriver, and then turn it to secure it in
1 place.
2. In
Inst
stal
all:
l:
1 • piston valve 1
b
NOTE:
1 a • Install the piston valve into the carburetor
body as shown.
• Match the tab a on the piston diaphragm to
the matching recess b in the carburetor
body.
• To install the
chamber piston
cover, valve
push spring
the andvalve
piston vacuum
as
shown and make sure that the diaphragm is
not inserted into the carburetor body.
3. In
Inst
stal
all:
l:
• pilot screw 1
NOTE:
1
• Screw in the pilot screw 1 until it is lightly
seated.
• Back out by the specified number of turns.
4. Conn
Connecect:
t:
• fuel overflow hose 1
• air vent hose 2
3 • starter cable 3
• fuel hose 4
5. In
Inst
stal
all:
l:
4
WARNING
1
Proper hose and cable routing are essential
to insure safe motorcycle operation. Refer
to “CABLE ROUTING”
ROUTING” in chapter 2.
5
2
5-8
CARBURETOR CARB
EAS00492
INSTALLING THE CARBURETOR

a b 1. In
Inst
stal
all:
l:
NOTE:
Be sure to insert the projection a into the slot
b of intake manifold.
2. Adju
Adjust
st::
Engine idling speed

1,500 ~ 1,700 r/min
Refer to “ADJUSTING THE ENGINE

IDLING SPEED”
SPEED” in chapter 3.
3. Adju
Adjust
st::

3 ~ 7 mm

CABLE FREE PLAY”
PLAY” in chapter 3.
EAS00498
1 MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Remo
Removve:
• vacuum hose 1
NOTE:
Remove the vacuum hose from the intake
manifold.
5-9
CARBURETOR CARB
2. Meas
Measur ure:
e:
• fuel level a
Fuel level (above the float cham-

ber mating surface)
7 ~ 8 mm
1

a. Stand the motorcy
motorcycle
cle on a level
level surf
surface.
ace.
a b. Place the
the motorcycle
motorcycle on a suitab
suitable
le stand to
ensure that the motorcycle is standing
4
straight up.
2 c. Install
Install the
the fuel level gauge 1 onto the fuel
level
overflow pipe 2.
Fuel level gauge

90890-01312
d. Suck on the end

end of the
the vacuum
vacuum hose.
e. Loosen
Loosen the fuel
fuel drain screw 3.
drain screw
f. Hold the fuel
fuel level
level gauge vertically
vertically next to
the float chamber 4.
g. Measur
Measure e the fuel levell a.
fuel leve

3. Adju
Adjust
st::
• fuel level

a. Remove
Remove the the carbur
carburetor
etor..
b. Check the needle
needle valve
valve seat
seat and needle
needle
1 valve.
c. If either
either is worn, replace
replace the carburet
carburetoror
body and needle valve.
d. If both are fine, adjust
adjust the
the float lev
level
el by
slightly bending the float tang 1.
e. Install
Install the carburetor
carburetor..
f. Measur
Measure e the fuel le
leve
vell again
again..
g. Repeat steps
steps (a) to (g)
(g) until the
the fuel level
level is
is
within specification.

5 - 10
CARBURETOR CARB
EAS00506
CHECKING THE FUEL COCK OPERATION

1. Place a container
container under the end of the fuel
fuel
hose 1.
2. Chec
Check:k:
• fuel cock operation

1 a. Suck on the end
end of the vacuum hose 1.
the vacuum
Fuel flows. Fuel cock is OK.

Replace the fuel
Fuel does not flow.
cock.

5 - 11

CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC...............................................................6-1

DISC ...............................................................6-1
REMOVING THE FRONT WHEEL............................................................6-2
CHECKING THE FRONT WHEEL ............................................................
........................................ .................... 6-3
CHECKING THE BRAKE DISC.................................................................6-5
ASSEMBLING THE FRONT WHEEL........................................................6-7
INSTALLING THE FRONT WHEEL ..........................................................
..................................... ..................... 6-7
REAR WHEEL AND BRAKE ..........................................................................6-9

REMOVING THE REAR WHEEL ............................................................
........................................ .................... 6-10
CHECKING THE REAR WHEEL.............................................................6-10
REMOVING THE REAR BRAKE.............................................................6-11
CHECKING THE BRAKE ........................................................................
..................................... ................................... 6-12
ASSEMBLING THE BRAKE SHOE PLATE ............................................
...................................... ......6-13
6-13
INSTALLING THE REAR WHEEL...........................................................6-13
FRONT BRAKE .............................................................................................6-15

FRONT BRAKE CALIPER.......................................................................6-15
REPLACING THE FRONT BRAKE PADS ..............................................
......................................... ..... 6-16
DISASSEMBLING THE FRONT BRAKE CALIPER ................................ 6-19
CHECKING THE FRONT BRAKE CALIPER ..........................................
...................................... ....6-20
6-20
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER CALIPER ....... 6-21
FRONT BRAKE MASTER CYLINDER....................................................6-24
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 6-25
CHECKING THE FRONT BRAKE MASTER CYLINDER........................6-26
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER .............................................................................
....................................... ...................................... 6-27
FRONT FORK................................................................................................6-30
FORK................................................................................................6-30
REMOVING THE FRONT FORK LEGS..................................................6-31
DISASSEMBLING THE FRONT
FRONT FORK LEGS ........................................
..................................... ... 6-32
CHECKING THE FRONT FORK LEGS ..................................................
.......................................... ........ 6-33
ASSEMBLING THE FRONT FORK LEGS
LEGS ..............................................
......................................... ..... 6-34
INSTALLING THE FRONT FORK LEGS .......................................
................................................
......... 6-37
HANDLEBAR ................................................................................................6-38
REMOVING THE HANDLEBAR..............................................................6-39
CHECKING THE HANDLEBAR ..............................................................
.................................... .......................... 6-41
INSTALLING THE HANDLEBAR ............................................................
.................................... ........................ 6-41

CHAS
STEERING HEAD..........................................................................................6-45
HEAD..........................................................................................6-45
REMOVING THE LOWER BRACKET.....................................................6-46
CHECKING THE STEERING HEAD .......................................................
........................................ ............... 6-47
INSTALLING THE STEERING HEAD .....................................................
...................................... ............... 6-48
REAR SHOCK ABSORBER ASSEMBLY AND

REAR SUSPENSION ARM ..........................................................................6-50
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ASSEMBLIES ............... 6-51
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 6-52
CHECKING THE REAR SUSPENSION ARM.........................................6-52
CHECKING THE CRANKCASE (LEFT)..................................................6-53
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES..............6-53

FRONT WHEEL AND BRAKE DISC CHAS

EASF0512
CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle
2 Brake disc
3
4 Collar
Oil seal
5 Bearing
6 Spacer
7 Speedometer gear unit
1 LS 2
4 New
3
5
6
LT

T
.
R
.
23 Nm (2.3 m • kg) LS
5 7
LS

T
.
R
.
40 Nm (4.0 m • kg)
6-1

EAS00519
REMOVING THE FRONT WHEEL

motorcycle
cle on a level
level surf
surface.
ace.
WARNING
_
Securely support the motorcycle so that

there is no danger of it falling over.
NOTE:
_
Place the motorcycle on a suitable stand so

2. Remo
Remov ve:
• speedometer cable 1
• axle nut 2
• washer 3
1
2 3
3. Remo
Remov ve:
• front wheel axle 1
• spacer 2
• speedometer gear unit 3
• front wheel 4
3
1 2 4
4. Remo
Remov ve:
• brake disc 1
6-2

EAS00526
CHECKING THE FRONT WHEEL

1. Chec
Check:k:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent wheel

axle.
Wheel axle bending limit

0.25 mm
2. Chec
Check:k:
• tire
• front wheel
Refer to “CHECKING THE TIRES”
TIRES” in chap-
ter 3.
3. Chec
Check:
k:
• spokes
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
_
A tight spoke will emit a clear, ringing tone, a

loose spoke will sound flat.
4. Tigh
Tighte
ten:
n:
• spokes
T
.
R
.
3 Nm (0.3 m • kg)
NOTE:
_
After tightening the spokes, measure the front

wheel runout.
5. Meas
Measurure:
e:
• front wheel radial runout a
• front wheel lateral runout b
Over the specified limits → Replace.
Front wheel radial runout limit
2.0 mm
Front wheel lateral runout limit
2.0 mm
6-3
6. Chec
Check:k:
• collar
WARNING
_
• After mounting a new tire, ride conserva-

tively for a while to become accustomed
to the “feel
feel”
” of the new tire and to allow
the tire to seat itself properly in the rim.
Failure to do so could lead to an accident
with possible injury to the rider or dam-
age to the motorcycle.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.
7. Chec
Check:k:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seal
6-4
8. Repl
Replacace:
e:
2
• wheel bearings New
• oil seal New
1 
New a. Clean the outside
outside of the front
front wheel hub.
hub.
b. Remov
Removee the oil seal 1 with a flat-head
oil seal
screwdriver.
NOTE:
_
To prevent damaging the wheel, place a rag 2

between the screwdriver and the wheel sur-
face.
c. Remov
Remove e the wheel
wheel bearin gs 3 with a gen-
bearings
eral bearing puller.
puller.
d. Install the new
new wheel bearings and oil seal
in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race

4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
_
Use a socket 7 that matches the diameter of

the wheel bearing outer race and oil seal.

EAS00527
CHECKING THE BRAKE DISC

1. Chec
Check:
k:
• brake disc
Damage/galling → Replace.
2. Meas
Measurure:
e:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit

(maximum)
0.15 mm

a. Place the
the motorcycle
motorcycle on a suitable
suitable stand
stand so
6-5
b. Before
Before measuring
measuring thethe front brake
brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove
Remove the brake
brake caliper
caliper.
d. Hold the dial gauge at a right angle

angle against
against
the brake disc surface.
e. Measure
Measure the deflect
deflection
ion 14 mm below
below the
edge of the brake disc.

3. Meas
Measurure:
e:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Brake disc thickness limit

(minimum)
3.0 mm
4. Adju
Adjust
st::
• brake disc deflection

a. Remov
Remove e the brak
brakee disc.
disc.
b. Rotate thethe brake
brake disc by
by one bolt
bolt hole.
hole.
c. Instal
Installl the brake
brake disc
disc..
NOTE:
_
Tighten the brake disc bolts in stages and in a

crisscross pattern.
Brake disc bolt

T
23 Nm (2.3 m • kg)
LOCTITE ®
.
R
.
d. Measure
Measure the brak
brakee disc deflection.
deflection.
e. If out of specifi
specification
cation,, repeat the
the adjustment
adjustment
steps until the brake disc deflection is within
specification.
f. If the
the brake
brake disc
disc defl
deflect
ection
ion canno
cannott be
brought within specification, replace the
brake disc.

6-6

EAS00539
ASSEMBLING THE FRONT WHEEL

1. In
Inst
stal
all:
l:
• wheel bearings
• oil seal New

a. Install the new
new wheel bearings and oil seal
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 socket 4 that matches the diameter of

the wheel bearing outer race and oil seal.

EAS00542
INSTALLING THE FRONT WHEEL

1. Lubric
Lubricat
ate:
e:
• wheel axle
• wheel bearings
• oil seal lips
• speedometer gear unit
2. In
Inst
stal
all:
l:
• speedometer gear unit 1
NOTE:
_
Make sure the speedometer gear unit and the

wheel hub are installed with the two slots a
meshed into the two projections b respec-
tively.
6-7
3. In
Inst
stal
all:
l:
• speedometer gear unit
a • spacer
• front wheel
• wheel axle
• washer
NOTE:
_
Make sure the projection a in the speedome-

ter gear unit fits over the stopper on the outer
tube.
4. Tigh
Tighte
ten:
n:
• axle nut
T
.
R
.
40 Nm (4.0 m • kg)
WARNING
_
Make sure the brake hose is routed prop-

erly.
_
CAUTION:
Before tightening the axle nut, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
5. Conn
Connec
ect:
t:
NOTE:
_
Be sure that slit a on the speedometer cable

mesh with the projection b in the speedome-
ter gear unit 2.
6-8
REAR WHEEL AND BRAKE CHAS

EASF0554
REAR WHEEL AND BRAKE

1 Axle nut 9 Wave washer
2 Rear wheel 0 Adjusting nut
3 Brake shoe A Pin
4 Brake shoe spring (brake camshaft side) B Rear brake cable
5 Brake shoe spring (pivot side)
6 Brake camshaft
7 O-ring
8 Brake shoe wear indicator

T
.
R
.
104 Nm (10.4 m • kg)
2
4 New
LS

T
.
R
.
m • kg)
7 Nm (0.7 m
6
7 New
New 5
7 8
LS 9
New
0
A
B

T
.
R
.
m • kg)
7 Nm (0.7 m
6-9

EASF0563
REMOVING THE REAR WHEEL

motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_

that the rear wheel is elevated.
2. Remo
Remov ve:
• muffler
ENGINE” in
chapter 4.
3. Remo
Remov ve:
• rear suspension arm
Refer to “REAR SHOCK ABSORBER
1 ASSEMBLY AND REAR SUSPENSION
ARM””.
ARM
4. Remo
Remov ve:
• rear wheel 1
• washer
EAS00566
CHECKING THE REAR WHEEL

1. Chec
Check: k:
• rear wheel
Refer to “CHECKING THE FRONT
WHEEL””.
WHEEL
2. Chec
Check: k:
• tire
• rear wheel
Refer to “CHECKING THE TIRES”
TIRES” in chap-
ter 3.
3. Chec
Check:k:
• spokes
WHEEL””.
WHEEL
4. Meas
Measurure:
e:
• radial wheel runout
• lateral wheel runout
WHEEL””.
WHEEL
6 - 10
REMOVING THE REAR BRAKE

1. Remo
Remov ve:
4 • adjusting nut 1
• rear brake cable 2
• pin 3
5 • brake camshaft lever bolt 4

• brake camshaft lever 5
2
3 1
2. Remo
Remov ve:
• wave washer 1
• brake shoe wear indicator 2
12
3. Remo
Remov ve:
• brake shoes 1
• brake shoe spring (brake camshaft side) 2
3 • brake shoe spring (pivot side) 3
1 2
4. Remo
Remov ve:
• brake camshaft 1
1
6 - 11

EAS00569
CHECKING THE BRAKE

brake shoes.
1. Chec
Check:
k:
• brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with course sandpa-
per.
NOTE:
_
After sanding the glazed areas, clean the

brake shoe with a cloth.
2. Meas
Measur
ure:
e:
• brake shoe lining thickness a
Brake shoe lining thickness limit

2 mm
WARNING
_
Do not allow oil or grease to contact the

brake shoes.
NOTE:
_
Replace the brake shoes as a set, if either is

worn to the wear limit.
3. Chec
Check:k:
• brake drum inner surface
Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches → Repair.
Lightly and evenly polish the scratches with
an emery cloth.
4. Meas
Measurure:
e:
• brake drum inside diameter a
Out of specification → Replace the wheel.
Brake drum inside diameter limit

(maximum)
a
131 mm
5. Chec
Check:
k:
• brake camshaft
6 - 12

EAS00570
ASSEMBLING THE BRAKE SHOE PLATE

1. In
Inst
stal
all:
l:
a b • brake camshaft 1
• brake shoe wear indicator 2
• wave washer

1 a. Install the brake

brake camshaft
camshaft so
so its punch
punch mark
2 a is positioned as shown.
b. Ali
Align
gn the
the projec
projection b on the brake shoe
tion
wear indicator with the notch in the brake
camshaft.
c. Check
Check that thethe brake
brake shoes
shoes are
are properly
properly
positioned.

EAS00573
INSTALLING THE REAR WHEEL

1 1. In
Inst
stal
all:
l:
• brake camshaft lever
a WARNING
_
After installing the rear brake camshaft,

remove any excess grease.
2
NOTE:
_
• Align the punch mark on the brake camshaft

with the mark on the brake camshaft lever
positioned as shown a.
• Lubricate the brake camshaft 1 and pin 2
with lithium-soap-based grease.
A B 2. In
Inst
stal
all:
l:
• brake shoes
• brake shoe spring (pivot side)
• brake shoe spring (brake camshaft side)
•NOTE:
_
Do not to damage the springs during installa-

tion.
• Install the brake shoe spring as shown.
A B A A B B
6 - 13
3. Tigh
Tighte
ten:
n:
• brake camshaft lever pinch bolt

T
.
R
.
7 Nm (0.7 m • kg)
• axle nut
T
.
R
.
104 Nm (10.4 m • kg)
4. Adju
Adjust
st::
• brake lever free play
Refer to “ADJUSTING THE REAR BRAKE”
BRAKE”
in chapter 3.

10 ~ 20 mm
6 - 14
FRONT BRAKE CHAS
FRONT BRAKE
EASF0612
FRONT BRAKE CALIPER

1 Brake hose holder 6 Brake caliper seal
2 Brake caliper bolt 7 Brake caliper piston
3 Retaining bolt 8 Brake pad spring
4 Brake caliper 9 Brake pad
5 Bleed screw kit

T
.
R
.
m • kg)
7 Nm (0.7 m

T
.
R
.
35 Nm (3.5 m • kg)
27 Nm (2.7 m • kg)
2
T
.
R
.
LS 5
4
LS
9 6
8
6 - 15
FRONT BRAKE CHAS

EAS00579
CAUTION:
_
Disc brake components rarely require dis-

assembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless 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
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic
up any spiltparts.
brakeTherefore, always clean
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
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS

NOTE:
_
When replacing the brake pads, it is not neces-

1 sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Lo
Loos
osen
en::
• retaining bolts 1
2. Remove:
• brake caliper bolts
• washer
• brake caliper 1
1
6 - 16
FRONT BRAKE CHAS
3. Remove:
• retaining bolts
• brake pads 1
4. Meas
Measur
ure:
e:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit

0.8 mm
5. In
Inst
stal
all:
l:
• brake pads
• brake pad spring
NOTE:
_
Always install new brake pads and a new

brake pad spring as a set.

a. Connect
Connect a clear
clear plastic hose 1 tightly to the
plastic
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the
the bleed
caliper pistons screw
scre
into w and
the push
brake the
the brake
caliperbrake
with
your finger.
c. Tighten
Tighten the
the bleed
bleed screw
screw..
Bleed screw

T
.
R
.
6 Nm (0.6 m • kg)
d. Install new
new brake
brake pads
pads and a new brake
brake pad
spring.

6 - 17
FRONT BRAKE CHAS
6. Lubric
Lubricat
ate:
e:
• retaining bolts
CAUTION:
_
• Do not allow grease to contact the brake

pads.
• Remove any excess grease.
7. In
Inst
stal
all:
l:
• brake caliper
• brake caliper bolt
T
.
R
.
35 Nm (3.5 m • kg)
• retaining bolts
T
.
R
.
27 Nm (2.7 m • kg)
8. Chec
Check:k:
level.
LEVEL”” in chapter 3.
LEVEL
9. Chec
Check:
k:
• brake
Soft orlever operation
spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”
SYSTEM” in chapter 3.
6 - 18
FRONT BRAKE CHAS

EAS00619
DISASSEMBLING THE FRONT BRAKE

CALIPER
NOTE:
_
Before disassembling the brake caliper, drain

the brake fluid from the entire brake system.
1. Remo
Remov ve:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
_
Put the end of the brake hose into a container

1 and pump out the brake fluid carefully.
2
2. Remo
Remov ve:
• retaining bolts 1
• brake caliper 2
1
3. Remo
Remov
ve:
1
•• brake
brake caliper
caliper seals
pistons
2

a. Blow compres
compressed
sed air into
into the brake
brake hose
hose
joint opening to force out the pistons from
the brake caliper.
caliper.
WARNING
_
• Cover the brake caliper pistons with a

rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
• Never try to pry out the brake caliper pis-
tons.
b. Remove
Remove the brake
brake caliper
caliper seals.
seals.

6 - 19
FRONT BRAKE CHAS

EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component

replacement schedule
Brake pads If necessary

Piston seals Every two years
Brake hoses Every four years
Every two years
and whenever the
Brake fluid
brake is disassem-
bled
1. Chec
Check:
k:
• brake caliper pistons 1
Rust/scratches/wear → Replace the brake
caliper pistons.
• brake caliper cylinders 2

Scratches/wear → Replace the brake cali-
per assembly.
• brake caliper body 3
Cracks/damage → Replace the brake cali-
per assembly.
• brake fluid delivery passages
(brake caliper body)
air.
WARNING
_
Whenever a brake caliper is disassembled,

replace the piston seals.
6 - 20
FRONT BRAKE CHAS

EAS00634
ASSEMBLING AND INSTALLING THE

FRONT BRAKE CALIPER
WARNING
_
• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

DOT 4
1. In
Inst
stal
all:
l:
• brake caliper seals 1 New
• brake caliper pistons 2
2. In
Inst
stal
all:
l:
brake caliper 1
• (temporarily)
3
• copper washers 2 New
• brake hose 3
• union bolt 4
T
.
R
.
26 Nm (2.6 m • kg)
4 WARNING
2 _
1 Proper brake hose routing is essential to

New
insure safe motorcycle operation. Refer to
“CABLE ROUTING”
CAUTION:
_
b When installing the brake hose onto the

a
1
brake
a caliper
touches , make surebthe
the projection onbrake pipe
the brake
caliper.
1
6 - 21
FRONT BRAKE CHAS
3. Remo
Remov ve:
• brake caliper
4. In
Inst
stal
all:
l:
• brake pad springs
• brake pads
• brake caliper
• brake caliper bolts (with washer)

T
.
R
.
35 Nm (3.5 m • kg)
• retaining bolts
T
.
R
.
27 Nm (2.7 m • kg)
5. Fil
Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
imm ediately.
6. Blee
Bleed:
d:
• brake system
BRAKE SYSTEM”
6 - 22
FRONT BRAKE CHAS
7. Chec
Check:k:
level.
LEVEL
8. Chec
Check:
k:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
BRAKE SYSTEM”
6 - 23
FRONT BRAKE CHAS

EASF0584
FRONT BRAKE MASTER CYLINDER

1 Brake master cylinder 6 Brake master cylinder holder
2 Brake lever 7 Front brake light switch
3 Brake master cylinder kit 8 Copper washer
4 Brake master cylinder reservoir cap 9 Union bolt
5 Brake master cylinder reservoir diaphragm 0 Brake hose

T
.
R
.
11 Nm (1.1 m • kg)
3
6
2
1
7
New 8
9
T
.
•

26 Nm (2.6 m kg)
R
.
0

T
.
R
.
26 Nm (2.6 m • kg)
9
8 New
6 - 24
FRONT BRAKE CHAS

EAS00588
DISASSEMBLING THE FRONT BRAKE

MASTER CYLINDER
NOTE:
_
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire

brake system.
1. Remo
Remov ve:
• rear view mirror (left and right)
2. Remo
Removve:
• handlebar cover (front) 1
1
3. Remo
Removve:
• handlebar cover (rear) screws
4. Remo
Remov
ve:
•• meter assembly
handlebar cover screw
(rear) 1
1
5. Disc
Disconn
onnec
ect:
t:
• front brake light switch connectors 1
1
6 - 25
FRONT BRAKE CHAS
6. Remo
Remov ve:
• 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
2
1 end of the brake hose.
3
7. Remo
Remov ve:
• brake master cylinder holder
• brake master cylinder
EAS00590
CHECKING THE FRONT BRAKE MASTER

CYLINDER
1. Chec
Check:
k:
1
• brake master cylinder 1
Damage/scratches/wear → Replace.
• brake fluid delivery passages 2
2
(brake master cylinder body)
air.
2. Chec
Check:
k:
• brake master cylinder kit → Replace.

Damage/scratches/wear
3. Chec
Check:
k:
• brake master cylinder reservoir diaphragm
1
6 - 26
FRONT BRAKE CHAS
4. Check:
• brake hose 1
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.
components.

DOT 4
1. In
Inst
stal
all:
l:
•• brake
brake master cylinder 1
master cylinder
holder
• brake master cylinder holder bolts

T
.
R
.
11 Nm (1.1 m • kg)
NOTE:
_
• Install the brake master cylinder holder with

the “UP
UP”” mark facing up.
• Adjust the brake master cylinder to the
proper angle.
• First, tighten the upper bolt, then the lower
bolt.
6 - 27
FRONT BRAKE CHAS
2. In
Inst
stal
all:
l:
• copper washers 1 New
• brake hose 2
• union bolt 3
T
.
R
.
26 Nm (2.6 m • kg)
WARNING
_
Proper brake hose routing is essential to

New 1 insure safe motorcycle operation. Refer to
3 “CABLE ROUTING”
2
NOTE:
_
• While holding the brake hose, tighten the

union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3. Conn
Connecect:
t:
• front brake light switch connectors
4. In
Inst
stal
all:
l:
• rear view mirror (left and right)

T
.
R
.
32 Nm (3.2 m • kg)
5. Fil
Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
_

performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
6 - 28
FRONT BRAKE CHAS
CAUTION:
_

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
imm ediately.
6. Blee
Bleed:
d:
• brake system
BRAKE SYSTEM”
7. Chec
Check:k:
level.
LEVEL
8. Chec
Check:
k:
• brake
Soft orlever operation
spongy feeling → Bleed the brake
system.
BRAKE SYSTEM”
6 - 29
FRONT FORK CHAS
FRONT FORK
1 Front fork cap bolt 7 Dust seal
2 O-ring 8 Oil seal clip
3 Fork spring 9 Oil seal
4 Damper rod 0 Outer tube
5
6 Rebound
Inner tubespring A Front fender

T
.
R
.
50 Nm (5.0 m • kg)
1
2
New
4
7 New
5 8 New
9 New

T
.
R
.
50 Nm (5.0 m • kg)
6 0
New
LT
T
.
R
.
23 Nm (2.3 m • kg)
A

T
.
R
.
m • kg)
7 Nm (0.7 m
6 - 30
FRONT FORK CHAS

EASF0651
REMOVING THE FRONT FORK LEGS

front fork legs.
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_

2. Remo
Remov ve:
• front cover
3. Remo
Remov ve:
• brake hose holder
• brake caliper
BRAKE”.
4. Remo
Remov ve:
• front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC””.
DISC
5. Remo
Remov ve:
• front fender bolts 1
2
• washers
• front fender 2
1
6. Remo
Remov
ve:
• front fork cap bolt 1

(with a 10-mm hexagonal wrench)
7. Lo
Loos
osen
en::
• lower bracket pinch bolt 1
WARNING
_
Before loosening the lower bracket pinch

bolt, support the front fork leg.
6 - 31
FRONT FORK CHAS
8. Remo
Remov ve:
• front fork leg 1
EAS00652
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remo
Remov ve:
• fork spring
2. Dr
Drai
ain:
n:
• fork oil
3. Remo
Remov ve:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
Do not scratch the inner tube.
4. Remo
Remov
ve:
• damper rod assembly bolt

NOTE:
_
While holding the damper rod assembly with

the 10 mm hexagon nut/socket wrench 1 and
T-handle 2, loosen the damper rod assembly
bolt 3.
T-handle
90890-01326
6 - 32
FRONT FORK CHAS
5. Remo
Remov ve:
• inner tube
• damper rod
Pull out the inner tube with damper rod.
6. Remo
Remov ve:
• oil seal 1
CAUTION:
_
Never reuse the oil seal.
2 Rag
EAS00657
CHECKING THE FRONT FORK LEGS

1
front fork legs.
1. Chec
Check:
k:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
2
WARNING
_
Do not attempt to straighten a bent inner

tube as this may dangerously weaken it.
2. Meas
Measur
ure:
e:
• spring free length a
Spring free length

307.7 mm
<Limit>: 301.5 mm
3. Chec
Check:
k:
• damper rod 1
1 Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
6 - 33
FRONT FORK CHAS

EAS00659
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
WARNING
_
• Make sure 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:
- oil seal
- dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
1. In
Inst
stal
all:
l:
• damper rod assembly 1
2
• rebound spring
• inner tube 2
1 CAUTION:
_
Allow the damper rod assembly to slide

slowly down the inner tube 2 until it pro-
trudes from the bottom of the inner tube.
Be careful not to damage the inner
i nner tube.
6 - 34
FRONT FORK CHAS
2. Lubric
Lubricat
ate:
e:
• inner tube’
tube’s outer surface
Fork oil 10W or equivalent
3. Tigh
Tighte
ten:
n:
• damper rod assembly bolt 1
23 Nm (2.3 m • kg)

T
.
R
.
LOCTITE ®
NOTE:
_
While holding the damper rod assembly with

the 10 mm hexagon nut/socket wrench 2 and
T-handle 3, tighten the damper rod assembly
bolt.
T-handle
90890-01326
4. In
Inst
stal
all:
l:
• oil seal 1 New
(with the fork seal driver weight and fork
seal driver attachment)
Fork seal driver attachment 2

90890-01186
Fork seal driver weight 3
90890-01184
CAUTION:
_
Make sure the numbered side of the oil seal

faces up.
NOTE:
_
• Before installing the oil seal, lubricate its lips

with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to pro-
tect the oil seal during installation.
6 - 35
FRONT FORK CHAS
5. In
Inst
stal
all:
l:
• oil seal clip 1 New
NOTE:
_
Adjust the oil seal clip so that it fits into the

outer tube’
tube’s groove.
6. Fil
Fill:
• front fork leg
mended fork oil)
Quantity (each front fork leg)

0.063 L (63.0 cm3)
Recommended oil
Yamaha fork and shock oil 10W
or equivalent
Front fork leg oil level a (from

the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
106 mm
NOTE:
_
• While filling the front fork leg, keep it upright.

• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
7. In
Inst
stal
all:
l:
• spring 1
NOTE:
_
Install the spring with the smaller pitch facing

up.
6 - 36
FRONT FORK CHAS

EAS00663
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. In
Inst
stal
all:
l:
• front fork leg 1
• O-ring New
NOTE:
_
Pull up the inner tube until it stops, then install

the cap bolt.
1
2. Tigh
Tighte
ten:
n:

T
.
R
.
50 Nm (5.0 m • kg)
• lower bracket pinch bolt 2

T
.
R
.
50 Nm (5.0 m • kg)
3. In
Inst
stal
all:
l:
• front fender
• washers
• front fender bolts 7 Nm (0.7 m • kg)

T
.
R
.
4. In
Inst
stal
all:
l:
• front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC””.
DISC
5. In
Inst
stal
all:
l:
• brake caliper
• brake hose holder
Refer
6. In
Inst
stall:to “FRONT BRAKE”
all: BRAKE”.
• front cover
6 - 37
HANDLEBAR CHAS
EASF0664
HANDLEBAR
1 Rear view mirror
2 Throttle grip
3 Handlebar
4 Throttle cable
5 Rear brake cable
6 Starter cable
7 Rear brake lever
8 Handlebar grip
32 Nm (3.2 m • kg)
1
T
.
R
.
2
LS
3
LS
T
.
R
.
m • kg)
7 Nm (0.7 m
8
4
LS

T
.
R
.
43 Nm (4.3 m • kg)
5
6
LS
6 - 38
HANDLEBAR CHAS
EASF0666
REMOVING THE HANDLEBAR

motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
1. Remo
Remov ve:
• handlebar cover (left and right)
BRAKE”.
NOTE:
_
It is not necessary to disconnect the brake

hose when the brake fluid has been removed.
2. Remo
Remov ve:
1 • meter assembly 1
3. Disc
Disconn
onnec
ect:
t:
• meter assembly couplers 2
• right handlebar switch coupler 3
3 • left handlebar switch couplers 4
• rear brake light switch coupler 5
2 5
4
4. Remo
Remov
ve:
1 • plastic locking tie 1

• wire harness 2
5. Remo
Remov ve:
• right handlebar switch screws 1
2
• right handlebar switch 2
1
6 - 39
HANDLEBAR CHAS
6. Remo
Remov ve:
• throttle grip 2
2
7. Remo
Remov ve:
• starter lever screw 1
• starter lever washer
• starter lever 2
• starter cable 3
• spring washer
1 2
8. Remo
Remov ve:
2 1 • left handlebar switch screw 1
• left handlebar switch 2
9. Remo
Remov
ve:
• rear brake light switch 1
10.Remove:
1 • handlebar grip 1
NOTE:
_
Blow compressed air between the handlebar

and the handlebar grip, and gradually push the
grip off the handlebar.
6 - 40
HANDLEBAR CHAS
11.Remove:
1 • rear brake cable 1
• rear brake lever bolt 2
• rear brake lever holder 3
2 3
12.Remove:
• handlebar nut 1
• handlebar bolt 2
3 • handlebar 3
EAS00668
CHECKING THE HANDLEBAR

1. Chec
Check:
k:
• handlebar 1
1 WARNING
_
Do not attempt to straighten a bent handle-

bar as this may dangerously weaken it.
EASF0673
INSTALLING THE HANDLEBAR

motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
2. In
Inst
stal
all:
l:
• handlebar 1
NOTE:
_
Align the projection a on the handlebar with

1 a
b the slit on the under bracket b.
6 - 41
HANDLEBAR CHAS
3. Tigh
Tighte
ten:
n:
• handlebar bolt
• handlebar nut 43 Nm (4.3 m • kg)

T
.
R
.
4. In
Inst
stal
all:
l:
• rear brake lever holder
• rear brake lever holder bolt

T
.
R
.
7 Nm (0.7 m • kg)
• rear brake cable
5. In
Inst
stal
all:
l:
• handlebar grip

a. Apply a thin coat
coat of rubber
rubber adhesiv
adhesive e onto
the left end of the handlebar.
b. Slide the
the handlebar
handlebar grip
grip over
over the left
left end of
the handlebar.
c. Wipe off
off any excess
excess rubber
rubber adhesiv
adhesive e with a
clean reg.
WARNING
_
Do not touch the handlebar grip until the

rubber adhesive has fully dried.

6. In
Inst
stal
all:
l:
• rear brake light switch
7. In
Inst
stal
all:
l:
1
a • left handlebar switch 1
• left handlebar switch screws
NOTE:
_
• Align the projection a on the left handlebar

b switch with the hole b on the handlebar.
• Make sure that the left handlebar switch is in
full contact with the handlebar grip.
8. In
Inst
stal
all:
l:
0mm • spring washer
• starter cable
• starter lever
• starter lever washer
• starter lever screw
6 - 42
HANDLEBAR CHAS
9. In
Inst
stal
all:
l:
• throttle grip 2
NOTE:
_
Lubricate the inside of the throttle grip with a

thin coat of lithium-soap-based grease and
install it onto the handlebar.
1 2
10.Install:
b • right handlebar switch 1
• right handlebar switch screws
a
1 WARNING
_
Make sure the throttle grip operates

smoothly.
NOTE:
_
Align the projection a on the right handlebar

switch with the hole b on the handlebar.
11.Install:
BRAKE”.
12.Connect:
• rear brake light switch coupler
• left handlebar switch couplers
• right handlebar switch coupler
• meter assembly couplers
13.Install:
• meter assembly
14.Install:
• wire harness
• plastic locking tie
15.Install:
• handlebar cover (front and rear)
BRAKE”.
16.Adjust:
CABLE FREE PLAY” PLAY” in chapter 3.

3 ~ 7 mm
6 - 43
HANDLEBAR CHAS
18.Adjust:
• brake lever free play
Refer to “ADJUSTING THE REAR BRAKE”
BRAKE”
in chapter 3.
Brake lever free play

10 ~ 20 mm
6 - 44
STEERING HEAD CHAS
STEERING HEAD
1 Upper ring nut 6 Bearing inner race
2 Lower ring nut 7 Lower bearing
3 Ball race cover 8 Lower bracket
4 Bearing outer race 9 Inner fender
5 Upper bearing
LS 4
LS 4
7

T
.
R
.
10 Nm (1.0 m • kg) 6

T
.
R
.
10 Nm (1.0 m • kg) 9
6 - 45
STEERING HEAD CHAS

EASF0679
REMOVING THE LOWER BRACKET

motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_
2. Remo
Remov ve:
• front fork
Refer to “FRONT FORK”
FORK”.
• handlebar
Refer to “HANDLEBAR
HANDLEBAR””.
3. Remo
Remov ve:
• brake hose/speedometer cable bracket 1
4. Remo
Remov
ve:
• brake hose bracket 1
5. Remo
Remov ve:
• inner fender 1
1
6 - 46
STEERING HEAD CHAS
6. Remo
Remov ve:
• upper ring nut 1
• lower ring nut 2
• lower bracket
NOTE:
_
1 Hold the lower ring nut with the ring and steer-
ing nut wrench, and then remove the upper
2 ring nut with the ring nut wrench.
Ring nut wrench

90890-01268
Steering 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. Clea
Clean:
n:
• bearings
• bearing races
Recommended cleaning solvent

Kerosene
2. Chec
Check:
k:
2 1 • bearings 1
• bearing races 2
Damage/pitting → Replace.
6 - 47
STEERING HEAD CHAS
3. Repl
Replac
ace:
e:
• bearings
• bearing races

a. Remove
Remove the bearing
bearing races from the
the steering
steering
head pipe with a long rod 1 and hammer
h ammer..
b. Remove
Remove the bearing
bearing race from the
the lower
lower
bracket with a floor chisel 2 and hammer
ha mmer..
c. Instal
Installl the new beari
bearing
ng races
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.

4. Chec
Check:
k:
• lower bracket 1
(along with the steering stem)
1
EAS00683
INSTALLING THE STEERING HEAD

1. Lubric
Lubricat
ate:
e:
• upper bearing
• lower bearing
• bearing races
2. Tigh
Tighte
ten:
n:
• lower ring nut
• upper ring nut
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD”
6 - 48
STEERING HEAD CHAS
3. In
Inst
stal
all:
l:
• brake hose bracket
• brake hose bracket bolts
T

R
.
.
10 Nm (1.0 m • kg)
4. In
Inst
stal
all:
l:
• brake hose/speedometer cable bracket
• brake hose/speedometer cable bracket
bolts 10 Nm (1.0 m • kg)

T
.
R .
6 - 49

REAR SUSPENSION ARM CHAS
EASF0685
REAR SHOCK ABSORBER ASSEMBLY AND REAR SUSPENSION ARM

1 Rear shock absorber (right)
2 Rear shock absorber (left)
3 Axle nut
4 Collar
5 Oil seal
6 Bearing
7 Collar
8 Rear suspension arm

T
.
R
.
30 Nm (3.0 m • kg)

T
.
R
.
16 Nm (1.6 m • kg)

T
.
R
.
104 Nm (10.4 m • kg)
3
4
5
LS 2
30 Nm (3.0 m • kg)
9

T
.
R
.
6
5
7
LS

T
.
R
.
16 Nm (1.6 m • kg)
6 - 50

EASF0691
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLIES
motorcycle
cle on a level
level surf
surface.
ace.
NOTE:
_

that the rear wheel is elevated.
2. Remo
Remov ve:
3. Remo
Remov ve:
• storage compartment
Refer to “CYLINDER HEAD”
4. Remo
Remov ve:
KICKSTARTER”” in chapter 4.
5.• Remo
Remov ve:
muffler
ENGINE” in
chapter 4.
6. Remo
Remov
ve:
• axle nut 1
• rear shock absorber lower bolt (right) 2
1
2 • rear suspension arm bolts 3
• rear suspension arm 4
3 • collar
7. Remo
Remov ve:
2 • rear shock absorber nut (right) 1
1
• rear shock absorber upper bolt (right) 2
rear shock absorber (right) 3
6 - 51

8. Remo
Remov ve:
• rear shock absorber nut (left) 1
2 1 • rear shock absorber upper bolt (left) 2
• rear shock absorber lower bolt (left) 3
4 • rear shock absorber (left) 4
EAS00695
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Chec
Check:k:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bushings
Damage/wear → Replace the rear shock
absorber assembly.
• bolts
Bends/damage/wear → Replace.
CHECKING THE REAR SUSPENSION ARM

1. Chec
Check:
k:
• bushing (rear shock absorber assembly)
2. Chec
Check:k:
• oil seals
collar
→
Damage/wear Replace.
6 - 52

CHECKING THE CRANKCASE (LEFT)

1. Chec
Check:
k:
• bushing (rear shock absorber assembly)
EAS00699
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLIES
1. In
Inst
stal
all:
l:
• rear shock absorber (left and right)
• rear shock absorber nut (left and right)

T
.
R
.
30 Nm (3.0 m • kg)
• rear shock absorber lower bolt (left)
T
.
R
.
2. In
Inst
stal
all:
l: 16 Nm (1.6 m • kg)
• collar
• rear suspension arm
• rear suspension arm bolts

T
.
R
.
30 Nm (3.0 m • kg)
• rear shock absorber lower bolt
(right) 16 Nm (1.6 m • kg)

T
.
R
.
• axle nut 104 Nm (10.4 m • kg)

T
.
R
.
6 - 53

– +
ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................7-1
COMPONENTS........................................................................7-1
CHECKING SWITCH CONTINUITY................................................................7-3

CONTINUITY ................................................................7-3
CHECKING THE SWITCHES..........................................................................7-5

SWITCHES ..........................................................................7-5
CHECKING THE BULBS AND BULB SOCKETS ..........................................7-7

TYPES OF BULBS ..........................................................................
.................................. ..................................................
.......... 7-7
CHECKING THE CONDITION OF THE BULBS .......................................
.................................. ..... 7-8
CHECKING THE
THE CONDITION OF THE THE BULB SOCKETS ....................... 7-9
IGNITION SYSTEM .......................................................................................7-10
CIRCUIT DIAGRAM ................................................................................

TROUBLESHOOTING ........................................
.............................................................................
............................................................................ 7-10
....................................... 7-11
ELECTRIC STARTING SYSTEM ..................................................................7-15

CIRCUIT DIAGRAM ................................................................................
........................................ ........................................ 7-15
TROUBLESHOOTING ............................................................................
..................................... ....................................... 7-16
STARTER MOTOR........................................................................................7-18
MOTOR ........................................................................................7-18
REMOVING THE STARTER MOTOR.....................................................7-19
DISASSEMBLING THE STARTER MOTOR...........................................7-19
CHECKING THE STARTER MOTOR .....................................................
........................................ ............. 7-20
ASSEMBLING THE STARTER MOTOR.................................................7-22
INSTALLING THE STARTER MOTOR ...................................................
.................................. ................. 7-22
CHARGING SYSTEM....................................................................................7-23
SYSTEM ....................................................................................7-23
CIRCUIT DIAGRAM ................................................................................
........................................ ........................................ 7-23
..................................... ....................................... 7-24
LIGHTING SYSTEM ......................................................................................7-26

CIRCUIT DIAGRAM ................................................................................
....................................... ......................................... 7-26
.................................... ........................................ 7-27
CHECKING THE LIGHTING SYSTEM....................................................7-28
SIGNALING SYSTEM ...................................................................................7-32

CIRCUIT DIAGRAM ................................................................................
....................................... ......................................... 7-32
.................................... ........................................ 7-33
CHECKING THE SIGNALING SYSTEM .................................................

......................................... ........ 7-34
– +
ELEC

– +
ELECTRICAL COMPONENTS ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Wire harness
3 Battery
2
3
7-1
– +
ELECTRICAL COMPONENTS ELEC
1 Horn
2 Ignition coil
3 Rectifier/regulator
4 C.D.I. unit
5 Fuel sender
6 Starter relay
7 Turn signal relay
7 5
6
7-2
– +
CHECKING SWITCH CONTINUITY ELEC
EAS00730
“∞” “0”
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incor-
rect, check the wiring connections and if nec-
essary, replace the switch.
“Ω×1”
CAUTION:
_
Never insert the tester probes into the cou-

pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
1
the leads.
Pocket tester
90890-03112
NOTE:
_
• Before checking for continuity, set the

pocket tester to “0” and to the “Ω × 1
1”” range.
• When checking for continuity, switch back
b and forth between the switch positions a
few times.
Br R
OFF
a The terminal connections for switches (e.g.,
ON
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
Br R
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 red and brown
when the switch is set to “ON
ON””.
7-3
– +
CHECKING SWITCH CONTINUITY ELEC
7-4
– +
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”
CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1 2 3 4 5
Y P
P B Y / R L Y L G Ch Br/W Dg L Y / R
OFF OFF HI L
G B
B PUSH ON LO N
B R
Dg
(BLACK) Br / / W
Ch
6 7
L/W B
OFF
START L / W Br
B G / Y
8
Br R
R
OFF
Br
ON
9
7-5
– +
CHECKING THE SWITCHES ELEC
1 Rear brake light switch
2 Horn switch
3 Light switch
4 Dimmer switch
5 Turn signal switch
6 Start switch
7 Front brake light switch
8 Main switch
9 Main fuse
7-6
– +
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 con-
tinuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → 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 and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs D and E are used for meter and indi-
cator lights and can be removed from their
respective socket by carefully pulling them
out.
7-7
– +
CHECKING THE CONDITION OF THE
BULBS
bulbs.
1. Remo
Remov ve:
• 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

removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise 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.
2. Chec
Check:k:
• bulb (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1
1”” range.

a. Connect the
the positive
positive tester probe
probe to termi-
termi-
nal 1 and the negative tester probe to ter-
minal 2, and check the continuity.
continuity.
b. Connect thethe positive
positive tester
tester probe
probe to termi
termi
nal 1 and the negative tester probe to ter-
minal 3, and check the continuity.
continuity.
c. If either
either of the
the readings
readings indicate
indicate no continu-
continu-
ity, replace the bulb.

7-8
– +
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Chec
Check:k:
• bulb socket (for continuity)
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.
b. Install
Install a good
Connect the bulb
bul
pocbket
intotester
pocket the bulb
bulb
tester socket.
socket.
probes to
to the
respective leads of the bulb socket.
c. Check
Check the bulb socket
socket for continuity
continuity.. If any
of the readings indicate no continuity,
replace the bulb socket.

7-9

– +
IGNITION SYSTEM ELEC
EAS00736 EAS00739
TROUBLESHOOTING
2. Batt
Batter
ery
y
The ignition system fails to operate (no • Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING
Check: THE BATTERY”

BATTERY” in chapter 3.
1. main
main fuse
fuse Minimum open-circuit voltage
2. batt
batter
eryy 12.8 V or more at 20°
20°C
3. spar
spark k plug
plug
• Is the battery OK?
4. ign
igniti
ition
on spark
spark gap
5. spa
sparkrk plug
plug cap resist
resistanc
ance
e YES NO
6. ign
igniti
ition
on coil resist
resistanc
ancee
7. pic
pickup
kup coil
coil resist
resistanc
ancee
8. main
main swiswitc
tch
h • Clean the battery
9. wir
wiring
ing connect
connectionions
s terminals.
(of the entire ignition system) • Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the following EAS00740
part(s): 3. Spar
Spark
k plug
plug
1. re
rear
ar pa
pane
nell
• Check the condition of the spark plug.
2. sid
sidee panel
panel (right)
(right)
• Check the spark plug type.
3. sid
sidee panel
panel (left)
(left)
• Measure the spark plug gap.
4. sid
sidee cove
coverr (righ
(right)
t)
Refer to “CHECKING THE SPARK PLUG” PLUG”
5. fron
frontt cov
cover
in chapter 3.
• Troubleshoot with the following special
tool(s). Standard spark plug
CR7HSA (NGK)
Spark plug gap
Ignition checker 0.6 ~ 0.7 mm
90890-06754
Pocket tester • Is the spark plug in good condition, is it of
90890-03112 the correct type, and is its gap within spec-
EAS00738 ification?
1. Main
Main fuse
fuse YES NO
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSE”
FUSE” in chap- Re-gap or replace
ter 3. the spark plug.
• Is the main fuse OK?
YES NO
Replace the fuse.

7 - 11
– +
EAS00742 EAS00744
4. Ignitio
Ignition
n sp
spark
ark gap 5. Spark
Spark plug
plug cap resist
resistanc
ance
e
• Disconnect the spark plug cap from the • Remove the spark plug cap from the spark
spark plug. plug lead.
Ω×
• Connect
2 Spark plug ignition checker 1 as shown.
thecap • to
Connect the plug
the spark pocket
captester (“ 1k
(“
as shown. 1k”” range)
• Set the main switch to “ON
ON””. • Measure the spark plug cap resistance.
• Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
• Measure the ignition spark gap a. Ω×1k
Spark plug cap resistance

5 k Ω at 20°
20°C
• Is the spark plug cap OK?
Minimum ignition spark gap NO
YES
6 mm
• Is there a spark and is the spark gap within

Replace the spark
specification?
plug cap.
NO YES
The ignition system

is OK.
7 - 12
– +
EAS00746 EAS00748
6. Ignitio
Ignition
n coil res
resist
istanc
ance
e 7. Pickup
Pickup coil
coil resistanc
resistance
e
• Disconnect the ignition coil connector from • Disconnect the pickup coil coupler from
the ignition coil terminal. the wire harness.
Ω × Ω ×
• Connect the pocket tester ( 1) to the • Connect the pocket tester ( 100) to the
ignition coil as shown. pickup coil terminal as shown.
Positive tester probe → terminal 1 Positive tester probe → white/blue 1
Negative tester probe → Negative tester probe → white/red 2
ignition coil base 2
2
B Y / R W W / R W / L
1 2 1
• Measure the pickup coil resistance.
• Measure the primary coil resistance.
Pickup coil resistance
Primary coil resistance 248 ~ 372 Ω at 20°
20°C
0.32 ~ 0.48 Ω at 20°
20°C (between white/blue and white/
red)
• Connect the pocket tester ( Ω × 1k) to the
ignition coil as shown. • Is the pickup coil OK?
Negative tester probe → terminal 1 YES NO

Positive tester probe → spark plug lead 2
Replace the pickup

coil.
EAS00749
8. Main
Main swi
switc
tch
h
• Check the main switch for continuity.
1
2 Refer to “CHECKING THE SWITCHES”
SWITCHES”.
• Is the main switch OK?
• Measure the secondary coil resistance. YES NO
Secondary coil resistance

5.68 ~ 8.52 k Ω at 20°
20°C Replace the main
switch.
• Is the ignition coil OK?
YES NO
Replace the ignition

coil.
7 - 13
– +
EAS00754
9. Wiri
Wiring
ng
• Check the entire ignition system’
system’s wiring.
Refer to “CIRCUIT DIAGRAM”
DIAGRAM”.
• Is the ignition system’

system’s wiring properly
connected and without defects?
YES NO
Replace the C.D.I. Properly connect or

unit. repair the ignition
system’’s wiring.
system
7 - 14

– +
ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING
2. Batt
Batter
ery
y
The starter motor fails to turn. • Check the condition of the battery.
Check:
1. main
main fuse
fuse THE BATTERY”
2. batt
batter
ery
y Minimum open-circuit voltage
3. starte
starterr mot
motoror 12.8 V or more at 20°
20°C
4. starte
starterr rela
relayy
5. main
main swi
switc
tch
h
6. start
start swi
switc
tchh YES NO
7. fro
front
nt bra
brake
ke light
light swit
switch
ch
8. rear brake
brake light
light switch
switch
9. wir
wiring
ing connect
connection ions
s • Clean the battery
(of the entire starting system) terminals.
• Recharge or
NOTE:
• Before troubleshooting, remove the following replace the battery.
part(s): EAS00758
1. re
rear
ar pa
pane
nell 3. Starte
Starterr moto
motorr
2. sid
sidee panel
panel (right)
(right)
• Connect the positive battery terminal 1
3. sid
sidee panel
panel (left)
(left)
and starter motor lead 2 with a jumper
4. sid
sidee cove
coverr (righ
(right)
t)
lead 3.
5. fron
frontt cov
cover
6. han
handleb
dlebar
ar cove
coverr
tool(s).
Pocket tester
90890-03112
EAS00738
1. Main
Main fuse
fuse
• Check the main fuse for continuity. WARNING
_

FUSE” in chap- • A wire that is used as a jumper lead
ter 3. must have at least the same capacity or
• Is the main fuse OK? more as that of the battery lead, other-
wise the jumper lead may burn.
YES NO • This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
Replace the fuse.
• Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
7 - 16
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00761 EAS00764
4. St
Starte
arterr relay
relay 6. Start
Start swi
switc
tch
h
• Disconnect the starter relay coupler from • Check the start switch for continuity.
the coupler. Refer to “CHECKING THE SWITCHES”
SWITCHES”.
• Connect the pocket tester ( Ω × 1) and bat- • Is the start switch OK?
tery (DC 12 V) to the starter relay coupler
as shown. YES NO
Positive battery terminal →

brown/yellow 1 Replace the right
Negative battery terminal → blue/white 2 handlebar switch.
Positive tester probe → red 3
Negative tester probe → red 4 7. Front brake
brake light
light switch
switch
• Check the front brake light switch for conti-
3
nuity.
R
Refer to “CHECKING THE SWITCHES”
SWITCHES”.
• Is the front brake light switch OK?
R
L / W Br /
/ Y YES NO
R
1 2
Replace the front
4 brake light switch.
• Does the starter relay have continuity
between red and red? 8. Rear brak
brake
e light
light switch
switch
• Check the rear brake light switch for conti-
YES NO
nuity.
SWITCHES”.
Replace the starter • Is the rear brake light switch OK?
relay.
YES NO
EAS00749
5. Main
Main swi
switc
tch
h
Replace the rear
brake light switch.
SWITCHES”.
EAS00766
9. Wiri
Wiring
ng
YES NO
• Check the entire starting system’
system’s wiring.
DIAGRAM”.
Replace the main • Is the starting system’
switch. connected and without defects?
YES NO
The starting system Properly connect or
circuit is OK. repair the starting
system
7 - 17
– +
STARTER MOTOR ELEC
EASF0767
STARTER MOTOR
1 Starter motor side cover
2 Starter motor yoke
3 Armature
4
5 Bush
Starterholder
motor front cover

T
.
R
.
m • kg)
7 Nm (0.7 m
New
2
New
3
New
BRUSH LENGTH LIMIT:

A New
3.5 mm
COMMUTATOR WEAR LIMIT: 4
B LS
21 mm
MICA UNDER CUT: 5
C 1.5 mm
ARMATURE COIL RESISTANCE:
ARMATURE RESISTANCE:
D
0.031 ~ 0.037 Ω at 20°
20°C
7 - 18
– +
STARTER MOTOR ELEC
REMOVING THE STARTER MOTOR
2 1. Disc
Disconn
onnec
ect:
t:
2. Remo
Remov ve:
• starter motor 2
1
DISASSEMBLING THE STARTER MOTOR

1 1. Remo
Remov ve:
2 • starter motor front cover bolts
(with washer and O-ring)
2. Remo
Remov ve:
• starter motor front cover 1
• washer 2
3. Remo
Remov ve:
1
• starter motor yoke 1
• O-rings 2 New
2
New
2
New
4. Remo
Remov
ve:
• armature 1
1
7 - 19
– +
STARTER MOTOR ELEC
EAS00770
CHECKING THE STARTER MOTOR

1. Chec
Check:
k:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Meas
Measur
ure:
e:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit

21 mm
3. Meas
Measur
ure:
e:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.5 mm
NOTE:
_
The mica proper

to ensure of the commutator
operation ofmust be undercut
the commutator.
7 - 20
– +
STARTER MOTOR ELEC
4. Meas
Measurure:
e:
• armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.

a. Measure
Measure the armature assembly
assembly resis-
resis-
tances with the
th e pocket tester.
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.031 ~ 0.037 Ω at 20°
20°C
Insulation resistance 2
Above 1 MΩ at 20°
20°C
b. If any resist
resistance
ance is out
out of specifica
specification,
tion,
replace the starter motor.

5. Meas
Measurure:
e:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit

3.5 mm
6. Meas
Measur
ure:
e:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

5.52 ~ 8.28 N (563 ~ 844 gf)
7. Chec
Check:
k:
• gear teeth
Damage/wear → Replace the gear.
8. Chec
Check:
k:
• bearing
• oil seal
part(s).
7 - 21
– +
STARTER MOTOR ELEC
ASSEMBLING THE STARTER MOTOR
b a
b
WARNING
_
Always use a new O-ring.
1. In
Inst
stal
all:
l:
• starter motor assembly
NOTE:
_
Align the groove a on the starter motor

assembly with the groove b on the covers.
INSTALLING THE STARTER MOTOR

1 1. In
Inst
stal
all:
l:
• starter motor 1
• starter motor bolts 7 Nm (0.7 m • kg)

T
.
R
.
2. Conn
Connecect:
t:
2
7 - 22
– +
CHARGING SYSTEM ELEC
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
O B
r Y
B
)
/
G
K
C
O B
B B A
L
B
D (
)
) K
O B K r Y C
C B G /
A
B
L
/
A L
r
W
R L A B B
(
B
/
W B
(
L R r

W W B
/ /
r W W

B
E r
/
B
r
/
B
r
B L N R
W
L R
/ /
r
/
B K
W W
Y
/
0
G
r
B
I O
7 H L
B B
J
L
/
R
W Y B
W T
F R
/
R R
/
W F A /

Y
O T r Y
9 S B G /
H
F S
R
W Y
W B F
O U
/
R L
/
8
/
I P
R W
W Y
/
B
L r
/
B
W
W
L W B
/
L
/
r Y
F
B G /
P P
H
F S
F
O U
H P
W Y
P R B
/
Y g W
r
D B
/
Y L G
G
B Y Y L G g W
6
r
B R D B
/
P Y
/
B
W R
)
Y K
r C
/
B
A
R R W L Y
r W
L
B B
/ /
L
/
(
3
R B B
5 Y
S
4 g
D
T
h
r
R B
2
B B
C
T
R R
B B
U
r
R B B
U
r
o t
R a
l
r r u t o
B B
g V
e
F N e
r n
F e / g
O O y u
s )
K
i a
e
r
1 r f f
Y C
i m r
e
t
h n t
g A . B G
C i
t D L
c
a a (
R B e C
B .
M R A
)
h g
K
C D C
2 3 A 7
6 r
B G
Y L
B
(
7 - 23
– +
EAS00774 EAS00739
TROUBLESHOOTING
2. Batt
Batter
ery
y
The battery is not being charged. • Check the condition of the battery.
Check:
1. main
main fuse
fuse THE BATTERY”
2. batt
batter
ery
y Minimum open-circuit voltage
3. cha
chargi
rging
ng volta
voltage
ge 12.8 V or more at 20°
20°C
4. cha
chargi
rging
ng coil
coil resista
resistance
nce
5. wir
wiring
ing connect
connection
ions
s
(of the entire charging system) YES NO
NOTE:
_
• Before troubleshooting, remove the follow-

ing part(s): • Clean the battery
1. seat terminals.
2. re
rear
ar pa
pane
nell • Recharge or
3. sid
side
e panel
panel (right)
(right) replace the battery.
4. sid
side
e cove
coverr (righ
(right)
t)
tool(s).
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
1. Main
Main fuse
fuse
• Check the main fuse for continuity.
FUSE” in chap-
ter 3.
YES NO
Replace the fuse.

7 - 24
– +
EAS00775 EAS00776
3. Chargin
Charging
g volta
voltage
ge 4. Chargin
Charging
g coil resist
resistanc
ance
e
• Connect the engine tachometer to the • Connect the pocket tester (Ω × 1) to the
spark plug lead. charging coils as shown.
• Connect the pocket tester (DC 20 V) to the Positive tester probe → white 1
battery as shown. Negative tester probe → black 2
Positive tester probe →
positive battery terminal 1
Negative tester probe →
negative battery terminal 2
B Y / R W W / R W / L
2 1
• Measure the charging coil resistances.
Charging coilΩresistance
0.32 ~ 0.48 20°C (W – B)
at 20°
• Start the engine and let it run at approxi- • Is the charging coil OK?
mately 5,000 r/min.
• Measure the charging voltage. YES NO
Charging voltage
14 V at 5,000 r/min Replace the stator
coil assembly.
NOTE:
_
EAS00779
Make sure the battery is fully charged.
5. Wiri
Wiring
ng
• Is the charging voltage within specifica- • Check the wiring connections of the entire
tion? charging system.
DIAGRAM”.
NO YES • Is the charging system’
connected and without defects?
The charging circuit
YES NO
is OK.
Replace the rectifier/ Properly connect or

regulator. repair the charging
system
7 - 25

– +
LIGHTING SYSTEM ELEC
EAS00781 EAS00739
TROUBLESHOOTING
2. Batt
Batter
ery
y
Any of the following fail to light: head- • Check the condition of the battery.
light, high beam indicator light, taillight or Refer to “CHECKING AND CHARGING
meter light. THE BATTERY”
Check: Minimum open-circuit voltage
1. main
main fuse
fuse 12.8 V or more at 20°
20°C
2. batt
batter
ery
y
3. main
main swi
switc
tch
h
4. li
light
ght switc
witch
h YES NO
5. wir
wiring
ing connect
connection
ions
s
(of the entire lighting system)
• Clean the battery
NOTE:
_
• Before troubleshooting, remove the follow- terminals.

ing part(s): • Recharge or
1. re
rear
ar pa
pane
nell replace the battery.
2. sid
side
e panel
panel (right)
(right) EAS00783
3. sid
side
e panel
panel (left)
(left) 3. Main
Main swi
switc
tch
h
4. sid
side
e cove
coverr (righ
(right)t)
5. sid
side
e cove
coverr ((lef
left)
t)
SWITCHES”.
6. fron
frontt cov
cover
7. han
handleb
dlebarar cove
coverr
• Troubleshoot with the following special YES NO
tool(s).
Replace the main

Pocket tester switch.
90890-03112
EAS00738 4. Ligh
Lightt swit
switch
ch
1. Main
Main fuse
fuse • Check the light switch for continuity.
• Check the main fuse for continuity. Refer to “CHECKING THE SWITCHES”
SWITCHES”.
• Is the light switch OK?
FUSE” in chap-
ter 3. YES NO
YES NO Replace the light

switch.
Replace the fuse.
7 - 27
– +
EAS00787 EAS00788
CHECKING THE LIGHTING SYSTEM

5. Wiri
Wiring
ng
1. The headlight
headlight and
and the high
high beam indicator
indicator
• Check the entire lighting system’
system’s wiring. light fail to come on.
DIAGRAM”. EAS00784
• connected
Is the lighting systemdefects?
system’
and without ’s wiring properly 1. Dimmer
Dimmer switch
witch
• Check the dimmer switch for continuity.
YES NO Refer to “CHECKING THE SWITCHES”
SWITCHES”.
• Is the dimmer switch OK?
Check the condition Properly connect or YES NO

of each of the light- repair the lighting
ing system’
system’s circuits. system’’s wiring.
system
Refer to “CHECK- The dimmer switch is
ING THE LIGHTING faulty. Replace the
SYSTEM””.
SYSTEM left handlebar
switch.
2. Headlight
Headlight bulb
bulb and
and sock
socket
et
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
SOCKETS”
• Are the headlight bulb and socket OK?
YES NO
Replace the head-

light bulb, socket or
both.
7 - 28
– +
3. Volta
oltage
ge • Set the main switch to “ON
ON””.
• Start the engine.
• Connect the pocket tester (AC 20 V) to the
• Set the dimmer switch to “ ” or “ ”.
headlight and high beam indicator light
• Measure the voltage (AC 12 V) of green 1
couplers as shown.
(yellow 2) on the headlight coupler (wire
È When the dimmer switch is set to “ ”. harness side) and yellow 4 on the meter
É When the dimmer switch is set to “ ”. assembly coupler (wire harness side).
Headlight coupler (wire harness side) • Is the voltage within specification?
YES NO
É
AC20V 1 2 The wiring circuit
from the main switch
G Y to the headlight cou-
È B pler is faulty and
Dg Ch must be repaired.
3
Headlight
Positive tester probe →
green 1 or yellow 2
Negative tester probe → black 3
Meter light coupler (wire harness side)
Ch Ch
Dg Y Y Dg
4
Br Br
G G
B B
5
High beam indicator light
Positive tester probe → yellow 4
7 - 29
– +
EAS00776 EAS00789
2. The meter
meter light
light fails
fails to come
come on.
4. Lightin
Lighting
g coil resist
resistanc
ance
e
• Connect the pocket tester (Ω × 1) to the 1. Meter light bulb and socket
socket
lighting coils as shown. • Check the meter light bulb and socket for
Positive tester probe → yellow/red 1 continuity.
Negative tester probe → black 2 Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
SOCKETS”
• Are the meter light bulb and socket OK?
YES NO
Replace the meter

B Y / R W W / R W / L light bulb, socket or
both.
2 1
2. Vol
olta
tage
ge
• Measure the lighting coil resistances.
• Connect the pocket tester (DC 20 V) to the
Lighting coil resistance (Y/R – B) meter light coupler (wire harness side) as
0.24 ~ 0.36 Ω at 20°
20°C
shown.
• Is the lighting coil OK? Positive tester probe → brown 1
YES NO
This circuit is OK. Replace the stator 1

coil assembly.
Br Br
G G
B B

ON””.
• Measure the voltage (DC 12 V) of brown
1 on the meter light coupler (wire harness
side).
• Is the voltage within specification?
YES NO
This circuit is OK. The wiring circuit

to the meter light
coupler is faulty and
must be repaired.
7 - 30
– +
EAS00790 EAS00776
3. The tai
tail/bra
l/brake
ke light
light fails
fails to
to come on.
on.
3. Lighti
Lighting
ng coil resist
resistanc
ance
e
1. Tail/brake
ail/brake light
light bulb and socket
socket • Connect the pocket tester (Ω × 1) to the
• Check the tail/brake light bulb and socket lighting coils as shown.
for continuity. Positive tester probe → yellow/red 1
Refer to “CHECKING THE BULBS AND Negative tester probe → black 2
BULB SOCKETS”
SOCKETS”
• Are the tail/brake light bulb and socket
OK?
YES NO
Replace the tail/ B Y / R W W / R W / L

brake light bulb,
socket or both. 2 1
• Measure the lighting coil resistances.
2. Volta
oltage
ge
• Connect the pocket tester (AC 20 V) to the Lighting coil resistance (Y/R – B)
0.24 ~ 0.36 Ω at 20°
20°C
tail/brake light coupler (wire harness side)
as shown. • Is the lighting coil OK?
Positive tester probe → blue 1
YES NO
This circuit is OK. Replace the stator

1 2 coil assembly.
B L L B
Y G / Y
Ch Dg Dg Ch

ON””.
• Start the engine.
• Measure the voltage (AC 12 V) of blue 1
on the tail/brake light coupler (wire har-
ness side).
YES NO
wiring circuit from
the main switch to
the tail/brake light
must be repaired.
7 - 31

– +
SIGNALING SYSTEM ELEC
EAS00794 EAS00739
TROUBLESHOOTING
2. Batt
Batter
ery
y
• Any of the
the following
following fail
fail to light:
light: turn • Check the condition
condition of the b
battery.
attery.
signal light, brake light or an indicator Refer to “CHECKING AND CHARGING
• light.
The horn
horn fail
fails
s to sound
sound.. THE BATTERY” in chapter 3.
Minimum open-circuit voltage
Check: 12.8 V or more at 20°C
1. main
main fuse
fuse
• Is the battery
battery OK?
2. batt
batter
ery
y
3. main
main swi
switc
tch
h YES NO
4. wir
wiring
ing connect
connection
ions
s
(of the entire signaling system)
• Clean
Clean the battery
battery
NOTE:
_
 Before trouble
troubleshooti
shooting,
ng, remove
remove the follow-
follow- terminals.
ing part(s): • Recha
Recharg
rgee or
1. re
rear
ar pane
panell replace the battery.
2. sid
side
e panel
panel (right)
(right) EAS00783
3. sid
side
e panel
panel (left)
(left) 3. Main
Main swi
switc
tch
h
4. sid
side
e cove
coverr (righ
(right)t)
• Check tthe
he main switch
switch for
for continuity.
continuity.
5. sid
side
e cove
coverr ((lef
left)
t)
Refer to “CHECKING THE SWITCHES”.
6. fron
frontt cov
cover
• Is th
the
e main
main switch
switch OK?
OK?
7. han
handleb
dlebar ar cove
coverr
8. rubber
rubber cov
cover YES NO
• Troubleshoot
Troubleshoot with with the following
following special
special
tool(s).
Replace the main
switch.
Pocket tester
EAS00795
90890-03112
4. Wiri
Wiring
ng
EAS00738
1. Main
Main fuse
fuse • Refer
Checktothe e
entire
ntire signal
“CIRCUIT signal system’s
system’s wiring
DIAGRAM”. wiring..
• Check the main
main fuse for continui
continuity.
ty. • Is the sig
signaling
naling system
system’s’s wiring
wiring properly
properly
Refer to “CHECKING THE FUSE” in chap- connected and without defects?
ter 3.
• Is tthe
he main
main fuse
fuse OK? YES NO
YES NO
Check the condition Properly connect or
of each of the signal- repair the signaling
Replace the fuse. ing system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.
7 - 33
– +
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn

1. The h
horn
orn fail
fails
s to sound
sound.. • Disconnect the pink connector at the horn
1. Horn
Horn swi
switc
tch
h terminal.
• Connect a jumper lead 1 to the horn ter-
• Check the horn switch for continuity. minal and ground the jumper lead.
SWITCHES”.
ON””.
• Is the horn switch OK?
• Does the horn sound?
YES NO
Br
Replace the left han-

dlebar switch. 1
2. Volta
oltage
ge
horn connector at the horn terminal as
shown.
Positive tester probe → brown 1 NO YES
Negative tester probe → ground
The horn is OK.
Br P
4. Vol
olta
tage
ge
horn connector at the pink terminal as
1
shown.
Positive tester probe → pink 1

ON””.
Br P
• Push the horn switch.

• Measure the voltage (DC 12 V) of brown at
the horn terminal.
• Is the voltage within specification? 1
YES NO
The wiring circuit • Set the main switch to “ON

ON””.
from the main switch • Measure the voltage (DC 12 V) of pink 1
to the horn connec- at the horn terminal.
tor is faulty and must • Is the voltage within specification?
be repaired.
YES NO
Repair or replace the Replace the horn.

horn.
7 - 34
– +
EAS00797
2. The tai
tail/bra
l/brake
ke light
light fails
fails to
to come on.
on. 3. Vol
olta
tage
ge
1. Tail/brake
ail/brake light
light bulb and socket
socket • Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
• Check the tail/brake light bulb and socket
as shown.
for continuity.
Refer to “CHECKING THE BULBS AND Positive tester probe → green/yellow 1
BULB SOCKETS”
SOCKETS” Negative tester probe → black 2
• Are the tail/brake light bulb and socket
OK?
1 2
YES NO
B L L B
Y G / Y
Ch Dg Dg Ch
Replace the tail/
brake light bulb,
socket or both.
2. Brake
Brake light
light switc
switches
hes • Set the main switch to “ON
ON””.
• Check the brake light switches for continu- • Pull in the brake levers.
• Measure the voltage (DC 12 V) of green/
ity.
yellow 1 on the tail/brake light coupler
SWITCHES”.
(wire harness side).
• Is the brake light switch OK?
YES NO
YES NO
Replace the brake

This circuit is OK. The wiring circuit
light switch.
to the tail/brake light
must be repaired.
7 - 35
– +
EAS00799
3. The turn s signal

ignal light,
light, turn
turn signal indicator
indicator 3. Vol
olta
tage
ge
light or both fail to blink. • Connect the pocket tester (DC 20 V) to the
1. Turn signal indicator
indicator light bulb
bulb and socket
socket turn signal relay coupler (wire harness
side) as shown.
• Check the turn signal light bulb and socket
for continuity. Positive tester probe → brown 1
Refer to “CHECKING THE BULBS AND Negative tester probe → ground
BULB SOCKETS”
SOCKETS”
• Are the turn signal light bulb and socket
OK?
Br /
/ W
YES NO 1 Br
Replace the turn sig-

nal light bulb, socket
or both.
ON””.
2. Turn signal
signal switch
switch • Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
• Check the turn signal switch for continuity.
harness side).
SWITCHES”.
• Is the turn signal switch OK?
YES NO
YES NO
The wiring circuit

Replace the left han-
dlebar switch.
to the turn signal
relay coupler is faulty
and must be
repaired.
7 - 36
– +
4. Volta
oltage
ge 5. Vol
olta
tage
ge
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness turn signal light connector (wire harness
side) as shown. side) as shown.
Positive tester probe → brown/white 1 È Rear turn signal light
Negative tester probe → ground Left turn signal light
Positive tester probe → chocolate 1
Right turn signal light
1 Br /
/ W Positive tester probe → dark green 2
Br Negative tester probe → ground
É Front turn signal light
Left turn signal light
Positive tester probe → chocolate 3
ON””. Right turn signal light
• Measure the voltage (DC 12 V) on brown/ Positive tester probe → dark green 4
white 1 at the turn signal relay coupler Negative tester probe → ground
(wire harness side). Ê Turn signal indicator light
• Is the voltage within specification? Positive tester probe → chocolate 5
YES NO
Positive tester probe → dark green 7
The turn signal relay
is faulty and must be
replaced.
B L L B
Y G / Y
Ch Dg Dg Ch
2 1
Y G G Y
B B
Ch Dg Dg Ch
4 3
7 - 37
– +
EAS00804
Ê
5 4. The fuel level
level gauge
gauge fails
fails to operate.
operate.
Ch Ch
1. Fuel
Fuel sende
senderr
Dg Y Y Dg • Remove the fuel sender from the fuel tank.
7 • Connect the pocket tester to the fuel
Br Br sender coupler (fuel sender side) as
G G shown.
B B
Positive tester probe → green 1
6
• Set the main switch to “ONON””.
• Set the turn signal switch to “ ” or “ ”. 2 1
• Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn B G
signal light connector (wire harness side)
and chocolate 5 or dark green 7 at the
turn signal indicator light coupler (wire har- È
ness side).
• Is the voltage within specification? É

YES NO • Measure the fuel sender resistances.
Fuel sender resistance
This circuit is OK. The wiring circuit (up position È)
from the turn signal (Ω × 1)
4 ~ 10 Ω at 20°
20°C
switch to the turn
Fuel sender resistance
signal light connec- (down position É)
tor is faulty and must (Ω × 10)
be repaired. 90 ~ 100 Ω at 20°
20°C
• Is the fuel sender OK?
YES NO
Replace the fuel

sender.
7 - 38
– +
2. Volta
oltage
ge 3. Fuel le
leve
vell gauge
gauge
• Connect the pocket tester (DC 20 V) to the • Set the main switch to “ON
ON””.
meter coupler (wire harness side) as • Move the float up 1 or down 2.
shown. • Check that the fuel level gauge needle
Fuel level gauge moves to “F” or “E”.
Positive tester probe → brown 1 NOTE:
_
Negative tester probe → green 2 Before reading the fuel level gauge, leave the
float in one position (either up or down) for at
least three minutes.
E F
Br Br
G G
B B
2 1

ON””. 2
• Measure the voltage (DC 12 V) of brown
1 on the meter coupler (wire harness
side). • Does the fuel level gauge needle move
• Is the voltage within specification? appropriately?
YES NO YES NO
Check the wiring This circuit is OK. Replace the fuel

connections of the level gauge.
entire signaling sys-
tem.
7 - 39

TRBL
SHTG
CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
TROUBLESHOOTING.....................................................................................8-1
ELECTRICAL SYSTEM.............................................................................8-1
COMPRESSION SYSTEMS .....................................................................
.................................. ................................... 8-2
INTAKE AND EXHAUST SYSTEM ...........................................................
...................................... ..................... 8-3

TRBL
SHTG

TRBL
TROUBLESHOOTING SHTG
EASF0844
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM
CHECK ALL WIRE CONNECTIONS
IGNITION COIL (see page 7-12)

• Primary or secondary windings
are broken or faulty
• High tension lead is faulty
• Plug cap is faulty
C.D.I. unit
MAIN SWITCH (see page 7-5)
• C.D.I. unit is broken
• Main switch is shorted
SPARK
SPARK PLUG
PL UG
 Many carbon deposits
STARTER MOTOR (see page 7-18) • Electrodes are wet
• Starter motor is broken or faulty Improper gap
• Starter relay is broken • Broken
• Starter switch is broken
CHARGING COIL (see page 7-25) /
PICKUP COIL (see page 7-13)
• Windings are broken
8-1
TRBL
COMPRESSION SYSTEMS
WEAR/SCRATCH/DAMAGE
WEAR/STICK/BROKEN
INSUFFICIENT TIGHTENING TORQUE
WEAR/SCRATCH
WEAR/CARBON DEPOSITS DAMAGE
DAMAGE
INSUFFICIENT TIGHTENING TORQUE
8-2
TRBL
INTAKE AND EXHAUST SYSTEM
FUEL TANK
TANK CAP
• Clogged
SILENCER
• Clogged EXHAUST PIPE AIR CLEANER ELEMENT
• Cracked or broken • Dirty or clogged

• Carbon deposits
JET NEEDLE
• Improperly adjusted
(medium speed)
THROTTLE STOP SCREW

PILOT SCREW • Improperly adjusted
• Improperly adjusted (idling and starting)
(idling and starting)
STARTER
• Improperly adjusted
(starting)
NEEDLE
NEED LE VALVE
VALVE
• Wear
PILOT JET
MAIN JET • Clogged (low speed)
• Incorrect size
• Clogged (high speed) FLOAT
• Incorrect fuel level adjustment
• Puncture
FLOAT
FLOAT CHAMBER
• Accumulated dust and/or water
8-3

YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN

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Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

HOW TO USE THIS MANUAL

3rd title 3: This is a final title.

alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

G H I Symbols G to L in the exploded diagrams

M N Symbols M to N in the exploded diagrams

LT New M Apply locking agent (LOCTITE ® )

ELECTRICAL SYSTEM ELEC

IMPORTANT INFORMATION .........................................................................1-6

CHECKING THE CONNECTIONS ..................................................................1-8

SPECIAL TOOLS ............................................................................................1-9

1 Crankshaft 6 Secondary fixed sheave A Clutch carrier

Normal operation Climbing hills or quick acceleration

1 Secondary fixed sheave È Small load on rear wheel

CHECKING THE CONNECTIONS

If the pin 1 on the terminal is flattened, bend it

Make sure all connections are tight.

• If there is no continuity, clean the terminals.

This tool is used to installing the oil seal.

This tool is used to installing the oil seal.

This tool is used for removing the rotor.

Fuel level gauge

This tool is used to install oil seals.

Yamaha bond No. 1215

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

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

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-16

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-17

CABLE ROUTING .........................................................................................2-19

GENERAL SPECIFICATIONS SPEC

Overall length 1,935 mm

Recommended oil Engine oil

GENERAL SPECIFICATIONS SPEC

GENERAL SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Camshaft runout limit ---- 0.03 mm

Head Diameter Face Width Seat Width Margin Thickness

MAINTENANCE SPECIFICATIONS SPEC

EX 0.030 ~ 0.057 mm 0.110 mm

Winding direction IN/EX Clockwise ----

MAINTENANCE SPECIFICATIONS SPEC

Clutch - in revolution 2,550 ~ 2,950 r/min ----

MAINTENANCE SPECIFICATIONS SPEC

OIL RING PISTON CYLINDER HEAD CAMSHAFT

MAINTENANCE SPECIFICATIONS SPEC

Cylinder head (timing chain side) Bolt M6 2 10 1.0

Exhaust pipe protector Bolt M6 2 11 1.1

Muffler protector 2 Bolt M6 2 11 1.1 LT

Intake manifold Bolt M6 2 10 1.0

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Recommended oil Fork oil 10 W or equivalent ----

MAINTENANCE SPECIFICATIONS SPEC

Master cylinder inside diameter 11 mm ----

MAINTENANCE SPECIFICATIONS SPEC

Front fork and brake hose holder M6 7 0.7