T MAX xp500 - 2001
T MAX xp500 - 2001
T MAX xp500 - 2001
XP500 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00005
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the scooter.
1 2 SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
chapter.
3 4
1 General information
CHK 2 Specifications
ADJ CHAS 3 Periodic checks and adjustments
4 Chassis
5 6 5 Engine
6 Cooling system
ENG COOL 7 Carburetor(-s)
8 Electrical system
9 Troubleshooting
7 8
CARB ELEC
Symbols 10 to 17 indicate the following.
9 10
10 Serviceable with engine mounted
TRBL 11 Filling fluid
SHTG 12 Lubricant
13 Special tool
11 12 14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
13 14
15 16 17
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS
4
ENGINE ENG
5
COOLING SYSTEM COOL
6
CARBURETORS CARB
7
ELECTRICAL SYSTEM ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
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GEN
INFO
CHAPTER 1
GENERAL INFORMATION
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CRANKSHAFT AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1-2
CHAIN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SWINGARM AND REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL INFORMATION
SCOOTER IDENTIFICATION
EAS00017
EAS00018
MODEL CODE
The model code label 2 is affixed to the lug-
gage Box. This information will be needed to or-
der spare parts.
1-1
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GEN
FEATURES INFO
FEATURES
CRANKSHAFT AND BALANCER SHAFT
An integrated crankshaft of a new design is used Horizontally opposed reciprocating balancers are
used. Layout free from primary inertial force, secondary inertial force, and a couple of force, and signifi-
cant vibration reduction are implemented.
CHAIN DRIVE
The chain drive is newly designed. A non adjustable z-stage silent chain is used. A backlash free pivot
coaxial drive is used. The drive and the swingarm at the right are integrated to create rigidity. The rear
wheel swing system ensures high speed stability.
1-2
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GEN
FEATURES INFO
SWINGARM AND REAR SUSPENSION
A newly designed swingarm is used. A pull-type monocross suspension is used. These components
are located out under the engine.
1-3
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GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
1-4
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GEN
IMPORTANT INFORMATION INFO
EAS00023
EAS00024
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways 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
1-5
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GEN
CHECKING THE CONNECTIONS INFO
EAS00026
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
5. Check:
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.
1-6
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GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
90890-01362
This tool is used to remove the generator
rotor.
T-handle T-handle
90890-01326 Damper rod holder
Damper rod These tools are used to hold the cartridge
holder cylinder when loosening or tightening the
90890-01294 cartridge cylinder bolt.
Fuel level gauge
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Timing light
90890-03141
This tool is used to check the ignition
timing.
Locknut wrench
90890-03148
This tool is used to remove the sheave or
install the secondary sheave nut.
Fork seal Fork seal driver weight
driver weight Adapter
90890-01367
Adapter These tools are used to install the front
90890-01372 fork’s oil seal and dust seal.
Ignition checker
90890-06754
This tool is used to check the ignition
system components.
Valve spring compressor
90890-04019
This tool is used to remove or install the
valve assemblies.
1-7
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GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
Valve guide remover (4 mm)
90890-04111
This tool is used to remove or install the
valve guides.
Valve guide installer
90890-04112
90890-04113
This tool is used to rebore the new valve
guides.
Primary/secondary sheave holder
90890-01304
90890-03008
This tool is used to measure the piston skirt
diameter.
Cylinder bore gauge (50~100 mm)
90890-03017
90890-03112
This tool is used to check the electrical
system.
1-8
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GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
Compression Compression gauge
gauge
90890-03081
Compression
gauge adapter These tools are used to measure engine
90890-04082 compression.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Oil filter wrench
90890-01469
This tool is needed to loosen or tighten
the oil filter cartridge.
Engine tachometer
90890-03113
90890-85505
This sealant is used to seal two mating
surfaces (e.g., crankcase mating surfaces).
Oil pressure Oil pressure gauge
gauge
90890-03153
Adapter This tool is used to measure the engine oil
90890-03124 pressure.
Plane bearing installer/remover
90890-01439
This tool is used to install or remove the
bearing.
Sheave spring Sheave spring compressor
compressor Sheave fixed block
90890-04134
Sheave fixed
block
90890-04135 This tool is used to remove spring.
Radiator cap tester
90890-01325
1-9
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GEN
SPECIAL TOOLS INFO
Tool No. Tool name/Function Illustration
Clutch spring compressor
90890-01482
1-10
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SPEC
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code XP500 (N) : 5GJ1 (EUR)
5GJ2 (GBR)
5GJ3 (OCE)
Dimensions
Overall length 2235 mm
Overall width 775 mm
Overall height 1410 mm
Seat height 795 mm
Wheelbase 1575 mm
Minimum ground clearance 130 mm
Minimum turning radius 2800 mm
Weight
Wet (with oil and a full fuel tank) 205 kg
Dry (without oil and fuel) 197 kg
Maximum load (total of cargo, rider, 183 kg
passenger, and accessories)
2-1
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ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine tipe Liquid-cooled, 4-stroke, DOHC
Displacement 499 cm3
Cylinder arrangement
Bore stroke 66 73 mm
Compression ratio 10.1
Engine idling speed 1150 1250 r/min
Vacuum pressure at engine idling 35 kPa (3.5 kg/cm2)
speed
Standard compression pressure 1450 kPa (14.5 kg/cm2) at 360 r/min
(at sea level)
Fuel
Recommended fuel Regular unleaded gasoline
Fuel tank capacity
Total (including reserve) 14L
Engine oil
Lubrication system Dry sump
Recommended oil
SAE10W30 or SAE10W40
API service SE, SF, SG type or higher
Quantity
Total amount 3.6 L
Without oil filter cartridge 2.8 L
replacement
With oil filter cartridge replacement 2.9 L
Oil pressure (hot) 150 kPa at 1200 r/min
(1.50 kgf/cm2 at 1200 r/min)
Relief valve opening pressure 450 550 kPa (4.5 5.5 kgf/cm2)
2-2
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ENGINE SPECIFICATIONS SPEC
2-3
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ENGINE SPECIFICATIONS SPEC
2-4
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ENGINE SPECIFICATIONS SPEC
2-5
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ENGINE SPECIFICATIONS SPEC
Cylinders
Cylinder arrangement Forward-included parallel-2 cylinder SSS
Bore stroke 66.0 73.0 mm SSS
Compression ratio 10.1 SSS
Bore 66.00 66.01 mm SSS
Max. taper SSS 0.05 mm
Max. out-of-round SSS 0.05 mm
2-6
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ENGINE SPECIFICATIONS SPEC
Height H 9 mm
Piston pin bore (in the piston)
Diameter 16.002 16.013 mm
Offset 0.5 mm
Offset direction Intake side
Piston pins
Outside diameter 15.991 16.000 mm
Piston-pin-to-piston-pin-bore 0.002 0.022 mm 0.072 mm
clearance
Piston rings
Top ring
2-7
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ENGINE SPECIFICATIONS SPEC
2-8
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ENGINE SPECIFICATIONS SPEC
2-9
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CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond SSS
Caster angle 28_ SSS
Trail 95 mm SSS
Front wheel
Wheel type Cast wheel SSS
Rim
Size 14 MT3.50 SSS
Material Aluminum SSS
Wheel travel 120 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Rear wheel
Wheel type Cast wheel SSS
Rim
Size 14 MT4.50 SSS
Material Aluminum SSS
Wheel travel 120 mm SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
Max. lateral wheel runout SSS 0.5 mm
Front tire
Tire type Tubeless SSS
Size 120/70-14 SSS
Model (manufacturer) BRIDGESTONE HOOP B03 SSS
DUNLOP D305FA SSS
Tire pressure (cold)
0 90 kg 200 kPa (2.0 kg/cm2, 2.0 bar) SSS
90 197 kg 225 kPa (2.25 kg/cm2, 2.25 bar) SSS
High-speed riding 225 kPa (2.25 kg/cm2, 2.25 bar) SSS
Min. tire tread depth SSS 1.6 mm
2-10
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CHASSIS SPECIFICATIONS SPEC
2-11
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CHASSIS SPECIFICATION SPEC
2-12
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ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type T.C.I. SSS
Ignition timing 10_ BTDC at 1200 r/min SSS
Advancer type Digital SSS
Pickup coil resistance/color 189 231 Ω/Gy-B SSS
Transistorized coil ignition unit model J4T120 (MITSUBISHI) SSS
(manufacturer)
Ignition coils
Model J0313 SSS
Minimum ignition spark gap 6 mm SSS
Primary coil resistance 1.87 2.53 Ω SSS
Secondary coil resistance 12 18 kΩ SSS
Throttle position sensor standard 4 6 kΩ SSS
resistance
Charging system
System type AC magneto SSS
Model (manufacturer) F4T373 (MITSUBISHI) SSS
Nominal output 14 V/305W at 5,000 r/min SSS
Stator coil resistance 0.375 Ω SSS
Voltage regulator
Regulator type Semiconductor, short circuit type SSS
Model (manufacturer) SH650A-12 (SHINDENGEN) SSS
No-load regulated voltage 14.1 14.9 V SSS
Rectifier
Model SH650A-12 SSS
Rectifier capacity 18 A SSS
Withstand voltage 200 V SSS
Battery
Battery type GT9B-4 SSS
Battery voltage/capacity 12 V/8 Ah SSS
Headlight type Halogen bulb SSS
Bulbs (voltage/wattage quantity)
Headlight 12 V 60 W/55 W + 55 W SSS
Auxiliary light 12 V 5 W 2 SSS
Tail/brake light 12 V 5 W/21 W 2 SSS
Turn signal light (Front) 12 V 21 W/ 5 W 2 SSS
Turn signal light (Rear) 12 V 21 W 2 SSS
2-13
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ELECTRICAL SPECIFICATIONS SPEC
2-14
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ELECTRICAL SPECIFICATIONS SPEC
2-15
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CONVERSION TABLE/TIGHTENING TORQUES SPEC
EB201000 EB202001
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
mSkg 7.233 ftSlb
Tighten-
mSkg 86.794 inSlb
ing
cmSkg 0.0723 ftSlb
torque
cmSkg 0.8679 inSlb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km / hr 0.6214 mph
km 0.6214 mi
m 3.281 ft A: Width across flats
Distance m 1.094 yd B: Thread diameter
cm 0.3937 in
mm 0.03937 in
General tightening
cc (cm3) 0.03527 oz (IMP liq.) A B torques
Volume / cc (c(cm3) 0.06102 cuSin (nut) (bolt)
Capacity lt (liter) 0.8799 qt (IMP liq.) Nm mSkg
lt (liter) 0.2199 gal (IMP liq.)
10 mm 6 mm 6 0.6
kg / mm lb / in
kg / cm2
55.997
psi (lb / in2) 12 mm 8 mm 15 1.5
Misc. 14.2234
Centigrade Fahrenheit 14 mm 10 mm 30 3.0
9 / 5 + 32
(_C) (_F)
18 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
2-16
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TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Tightening
Thread torque
Item Part name Q’ty
y Remarks
size
Nm mkg
Spark plug – M10 2 12.5 1.25
Cylinder head cover Bolt M6 10 10 1.0
Camshaft cap Bolt M6 12 10 1.0
Cylinder head and cylinder body Nut M9 4 35 3.5
Cylinder head and cylinder body Nut M9 2 46 4.6
Cylinder head and cylinder body Bolt M6 2 10 1.0
Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5
Cylinder body Bolt M6 1 10 1.0
Cylinder head (AI System) Stud bolt M6 4 7 0.7
Connecting rod cap Nut M7 4 See NOTE*1
Connecting rod cap (balancer) Nut M9 2 60 6.0
Cylinder (balancer) Bolt M10 4 58 5.8
Generator rotor Nut M18 1 See NOTE*2
Chain tensioner Bolt M6 2 10 1.0
Chain tensioner cap bolt Bolt M6 1 10 1.0
Chain guide (intake side) Bolt M6 2 10 1.0
Water pump housing cover Bolt M6 2 10 1.0
Water pump assembly Bolt M6 2 10 1.0
Coolant pipe Bolt M6 2 10 1.0
Thermostat cover Bolt M6 2 10 1.0
Oil pump assembly Bolt M6 3 10 1.0
Oil strainer assembly Bolt M6 2 10 1.0
Oil cooler assembly Bolt M20 1 63 6.3
Oil filter – M20 1 17 1.7
Oil delivery pipe Bolt M6 1 10 1.0
Carburetor intake manifold Bolt M6 4 10 1.0
Silencer assembly Bolt M6 2 8.5 0.85
Air filter case assembly Bolt M6 3 8.5 0.85
Exhaust pipe Nut M8 4 20 2.0
2-17
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TIGHTENING TORQUES SPEC
Tightening
Thread torque
Item Part name Q’ty
y Remarks
size
Nm mkg
Muffler Nut M10 1 48 4.8
Muffler protector Bolt M6 3 7 0.7
A.I.System pipe Nut M6 4 10 1.0
A.I.System reed valve assembly Bolt M6 3 10 1.0
Air cut valve assembly Bolt M6 1 7 0.7
Crankcase Bolt M6 13 10 1.0
Crankcase Bolt M8 8 24 2.4
Engine oil drain bolt Bolt M14 1 43 4.3
Engine oil sub tank cover Bolt M6 7 10 1.0
Stator coil base Screw M6 3 12 1.2
Timing plug Plug M16 1 8 0.8
Generator cover Bolt M6 19 10 1.0
Belt drive cover Bolt M6 4 10 1.0
Belt drive cover Bolt M8 6 24 2.4
Plate Bolt M6 3 10 1.0
Crankcase cover Bolt M8 2 24 2.4
Protector cover Bolt M6 3 7 0.7
Belt drive filter Bolt M6 2 7 0.7
Starter clutch Bolt M8 3 30 3.0
Clutch boss nut Nut M36 1 90 9.0
Clutch housing assembly Nut M16 1 65 6.5
Chian drive holder assembly Bolt M8 3 30 3.0
Chian drive drain bolt Bolt M12 1 20 2.0
Chian drive caes (outer) Bolt M6 18 10 1.0
Chian drive case cover Bolt M6 2 7 0.7
Stopper Bolt M5 8 6 0.6
Primary sheave assembly Nut M20 1 160 16
Secondary sheave spring seat Nut M36 1 90 9.0
Secondary sheave assembly Nut M18 1 90 9.0
2-18
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TIGHTENING TORQUES SPEC
Tightening
Thread torque
Item Part name Q’ty
y Remarks
size
Nm mSkg
Primary bearing cover plate Screw M6 1 10 1.0
Secondary bearing cover plate Screw M6 1 12 1.2
Stator coil assembly Bolt M6 3 10 1.0
Pickup coil Bolt M5 2 7 0.7
Starter motor Bolt M6 2 10 1.0
Thermo switch – M18 2 18 1.8
Thermo unit – PT 1/8 1 8 0.8
Ignitor unit Screw M6 2 3 0.3
NOTE:
*1: After tightening to 16 Nm (1.6 mSkg), tighten another 90_.
*2: After tightening to 60 Nm (6,0 mSkg), tighten another 120_.
2-19
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TIGHTENING TORQUES SPEC
1 8 M8 Bolt
9 21 M6 Bolt
2-20
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TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
Tightening
Item Thread size torque Remarks
Nm mkg
Upper bracket pinch bolt M8 30 3.0
Steering stem nut M22 110 11.0
Lower ring nut M25 19 1.9 See NOTE
Front fork cap bolt 45 4.5
Handlebar upper holder M8 23 2.3
Brake hose union bolt M10 30 3.0
Brake master cylinder holder M6 10 1.0
Master cylinder reservoir cap M4 1 0.1
Handlebar grip end M16 26 2.6
Engine mounting
Front mounting nut (upper) M12 87 8.7
Front mounting bolt (lower) M10 48 4.8
Front wheel axle shaft M14 59 5.9
Front wheel axle shaft pinch bolt M8 20 2.0
Rear wheel axle nut M14 104 10.4
Rear wheel axle shaft pinch bolt M8 17 1.7
Front brake caliper bracket M10 27 2.7
Front brake caliper bolt M10 40 4.0
Front brake disc M6 18 1.8
Rear brake caliper bracket M10 27 2.7
Rear brake caliper bolt M10 40 4.0
Rear brake disc M6 18 1.8
Brake caliper bleed screw M7 6 0.6
Swingarm and pivot shaft M22 7 0.7
Pivot shaft and lock nut M22 100 10.0
Chain drive and swingarm M10 40 4.0
Rear shock absorber (front) M12 67 6.7
Rear shock absorber (rear) M16 52 5.2
2-21
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TIGHTENING TORQUES SPEC
Tightening
Item Thread size torque Remarks
Nm mkg
Fuel tank M6 10 1.0
Fuel sender M5 4 0.4
Grab bar M8 15 1.5
Seat lock M6 7 0.7
Box M6 10 1.0
Cover and panel M8 15 1.5
Cover and panel M6 7 0.7
Windshield M5 0.4 0.04
Coolant reservoir tank M6 4 0.4
Mainstand bracket M10 55 5.5
Mainstand M10 55 5.5
Sidestand (bolt and frame) M10 8 0.8
Sidestand (bolt and nut) M10 40 4.0
Rear footrest M8 23 2.3
NOTE:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
2-22
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC
2-23
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OIL FLOW DIAGRAMS SPEC
2-24
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OIL FLOW DIAGRAMS SPEC
1 Oil pan
2 Oil strainer
3 Crankshaft
2-25
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OIL FLOW DIAGRAMS SPEC
1 Clutch
2 Right main journal bearing
3 Main gallery bolt
2-26
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OIL FLOW DIAGRAMS SPEC
Exhaust camshaft
Intake camshaft
Piston cooler
Crankshaft
Oil filter
Oil tank
Oil cooler
Relief valve
Check valve
Strainer
Flush oil pump
2-27
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COOLANT FLOW DIAGRAMS SPEC
2-28
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CABLE ROUTING SPEC
CABLE ROUTING
1 Headlight lead F Connect the brake light switch from the handlebar
2 Horn (H mark on the back of the horn). switch side wiring.
G Route the throttle cables through the hole of the
A Attach the wireharness clamp (protector handle under cover.
terminal) to the T stud. H Fasten the handlebar switch lead to the handlebar
B Install the wireharness to the top of the steering using a plastic clamp.
after each coupler connection. The fastening location is the bend area on the
C Route the wireharness between brake hose and bottom of the handlebar.
upper bracket. I Connect the headlight sub-harness to the
D Route the throttle cables between handle under wireharness on top of the stay (left and right)
cover and upper bracket. After making the connection, push the coupler
E Install a wireharness guide to hold down the between the front cowling and the air filter case.
wireharness.
2-29
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CABLE ROUTING SPEC
J Connect the taped headlight lead coupler to the
headlight’s white marked side (left side: high beam
side).
(For UK, the right side is the high beam side.)
K Fasten the headlight sub-harness.
L Connect the turn signal light.
M Securely fasten the wire strap to the front cowling
hook to prevent it from being pulled out by the
headlight assembly.
N Route the horn lead through the wire guide.
O After passing the horn lead through the clamp,
crimp the clamp.
2-30
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CABLE ROUTING SPEC
1 Rectifier/ regulator A The wireharness pass-through is change.
2 Starting circuit cut-off relay B Fasten the starter motor lead, battery negative lead
3 Pump relay and seat lock cable (right side) to the frame with a
4 Flasher relay plastic clamp.
5 Fuel pump C Fasten the starter motor lead and battery negative
6 Main switch lead to the frame with a clamp.
7 Meter assembly
8 Horn lead
9 Ignition coil
10 Battery negative lead
11 Frame
12 Seat lock cable
13 Starter motor lead
14 Wireharness
15 Fuel hose
16 Sub harness
17 Fan motor lead
18 V-belt reset coupler
2-31
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CABLE ROUTING SPEC
D Fasten the starter motor lead, battery negative H Use the clamp on the back of the frame to hold the
lead, V-belt reset coupler, and seat lock cable to side stand switch lead and fan motor lead.
the frame with a plastic band. I Connect the wireharness (wire taped area) to the
Position the band clasp on the bottom of the frame side T stud.
frame and face the band end to the outside. J After connecting the main switch lead, push it
E Fasten the fuel sender lead and fuel pump lead between the seat lock cable adjustment area and
to the frame with a plastic clamp. the frame.
F Place the wireharness and seat lock cable in the K Through the main switch lead between frame and
frame holder. seat lock cable.
G Through the seat lock cable between L After connecting the wireharness and meter lead,
wireharness and frame. use a plastic clamp to connect them to stay 1.
M Connect to the headlight sub harness (left and
right)
2-32
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CABLE ROUTING SPEC
N Fasten the headlight sub harness with a plastic T Through the wireharness to the frame wireharness
clamp. holder.
O Fasten the igniter lead to the stay with a plastic U Route the wireharness and regulator lead through
clamp. the frame wire holder.
P Fasten the horn lead with a clamp. Place the regulator lead under the wireharness.
Q Fasten the fan motor lead, sidestand switch V The V-belt reset coupler position is change.
lead, and thermo switch lead to the frame with a W After making the connections, push the couplers
plastic clamp. into the space inside the frame above the
R Use a plastic band to connect the wireharness mudguard.
and relay lead to the frame. X To the tail / brake light.
Position the band clasp on the bottom of the Y Insert the tail / brake light cuplers between the
frame and face the band end to the outside. wireharness and the seat lock cable (left side).
S Insert the seat lock cable and the cylinder Z To the starter relay.
mounting rubber into the frame stay.
2-33
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CABLE ROUTING SPEC
AA After connecting the left headlight sub-harness
and wireharness (by matching the coupler
colors), fold back the lead facing to the right and
insert it into the air filter case rib.
AB Fasten the coolant reservoir hose to the stay with
a plastic clamp.
AC Route the ignition coil lead through the inside of
the bracket.
AD Route the seat lock cable through the frame
bracket side.
2-34
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CABLE ROUTING SPEC
1 Air vent hose A Route the wireharness through the frame guide.
2 Vacuum hose At this time, place the protector (for the handle
3 A.C. magneto lead cover inner side) on the bottom side.
4 Sidestand switch B Fasten the rear brake hose and vacuum hose with
5 Fan motor lead a plastic clamp.
6 Thermo switch lead The fastening position is 0 to 5 m from edge of the
7 Stay 1 frame bracket.
C Pass the wireharness by the outside of the rear
footrest mounting boss.
(When mounting the rear footrest, do not catch or
pinch the A.C. magneto lead in the bracket.)
2-35
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CABLE ROUTING SPEC
D Fasten the wireharness to the frame with a K Use this as a reference when adjusting the throttle
plastic clamp. cable.
E Fasten the wireharness to the frame with a L After adjusting the throttle cables, make sure the
plastic clamp. rubber cap is insert connectly.
F Pass the box light lead by the front of the frame
back stay pipe.
G Fasten the sidestand switch lead to the frame
with a plastic clamp.
H When adjusting the throttle cable, completely
tighten the hut on the throttle cable return side.
I Through the speed sensor lead to the lead
holder.
J Through the speed sensor lead between front
brake caliper and front brake caliper mounting
bolt.
2-36
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CABLE ROUTING SPEC
1 Fuel hose A Route the wireharness against the stay wire guide.
2 Battery negative lead B Fasten the wireharness branch wiring to the frame
3 Seat lock with a plastic clamp.
4 Starter motor lead C Fasten the wireharness to the frame with a plastic
5 Fuse box clamp.
6 Battery D Connect the black wire on the outside of the seat
7 Battery positive lead lock cable to the right seat lock.
8 Fuel sender E Install the starter relay to the mad guard.
9 Breather hose F Fasten the wireharness, battery positive lead and
10 Lean angle cut-off switch lead seat lock cable to the mad guard with a clamp.
11 Wireharness G Connect the gray wire on the outside of the seat
12 Seat lock cable lock cable to the left seat lock.
2-37
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CABLE ROUTING SPEC
H Install the box light to the box 1. N Route the wireharness through the guide.
I Fasten the auto choke leads (left and right) and O Place the speed sensor lead between the ribs of
throttle position sensor lead to the frame with a the air filter case.
clamp. P Fasten the lean angle cut-off switch lead to the stay
Leave some slack in the lead wires so that when (2 locations). Face the end of the band downward.
the vacuum hose is install it does not press Q Hang the wireharness and seat lock cable on the
against them. wire holder on the back of the fuel pump
J Fasten the auto choke leads (left and right) to the attachment stay.
frame with a plastic clamp. R Fasten the battery negative lead and the starter
K Pass the auto choke lead (right side) and throttle motor lead to the frame.
position sensor lead by the front bottom side of S Route the battery negative lead and the fuse box
the vacuum hose. lead from the box opening to the bottom of the
L Route the thermo switch lead through the guide. cross pipe.
M Insert the air vent hose through the hole on the T Pass the black seat lock cable beneath the battery
left side of the frame bracket. negative lead and starter motor lead and out to the
inside of the frame.
2-38
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CABLE ROUTING SPEC
U Align the plastic clamp with the white tape on the AA Pass the speed sensor lead under the stay and
wireharness and fasten the wireharness to the cross pipe and then over the brake hose guide.
frame.
V Fasten the wireharness to the seat lock cable.
W Pass the wireharnesses past the outside of the
frame bracket.
X Apply silicone when inserting the starter relay.
Y Fasten the wireharness to the frame with a
plastic clamp.
Z Use a plastic band to hold the auto choke leads
(left and right), throttle position sensor lead, and
rear brake hose in a loose bandle. (The band
should be loose enough so that it can be turned.)
Pull the band end to the bottom.
2-39
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CABLE ROUTING SPEC
1 Vacuum hose A Route the throttle cable through the cable holder.
2 Rear brake hose B Into the handle cover.
3 Switch assembly lead C Route the main switch lead through over the seat
4 Auto choke lead lock cable.
5 Throttle position sensor lead D Fasten the sidestand switch lead and thermo
6 Fan motor lead switch lead to the frame with a plastic clamp.
7 Air vent hose E Fasten the carburetor air vent hose to the frame
8 Drain hoses with a plastic clamp.
9 Sidestand switch lead F Fasten the carburetor air vent hose and drain
10 Thermo switch lead hoses (2 hoses) to the frame.
11 High tension code G Drop the carburetor drain hose.
2-40
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CABLE ROUTING SPEC
H Fasten the rear end of the carburetor air vent M Route the left carburetor drain hose through the
hose to the frame with a plastic clamp. (The outside of the left high tension cable.
distance from the end of clamp to the frame must
range from 0 to 5 mm.)
I Bundle the auto choke leads (left and right) and
the throttle position sensor lead with a plastic
clamp.
J Fasten the rear brake hose and vacuum hose
with a plastic clamp.
K Faster the rear brake hose to the stay 1 with a
plastic clamp.
L Pass the right carburetor drain hose and air vent
hose between the right and left high tension
cables.
2-41
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CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-8
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . 3-13
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-15
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-16
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-20
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 3-25
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-27
CLEANING THE V-BELT CASE AIR FILTER ELEMENT . . . . . . . . . 3-28
CHECKING THE CARBURETOR JOINTS AND INTAKE
MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . 3-29
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . 3-30
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-38
CHECKING THE CHAIN DRIVE OIL LEVEL . . . . . . . . . . . . . . . . . . . . 3-39
CHANGING THE CHAIN DRIVE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-40
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . 3-48
Fuel lilne
1 * Check fuel hoses and vacuum hose for cracks or damage.
(See page 3-29)
Fuel filter
2 * Check condition.
(See page 3-29)
Check condition.
Spark plugs
3 Clean and regap.
(See page 3-18)
Replace.
Check valve clearance.
4 * Valves (See page 3-8) Every 40,000 km
Adjust.
Front brake Check operation, fluid level and vehicle for fluid leakage.
7 * (See page 3
3-36)
36)
(See page 3-37) Repalce brake pads. Whenever worn to the limit
Rear brake Check operation, fluid level and vehicle for fluid leakage.
8 * (See page 3
3-36)
36)
(See page 3-37) Replace brake pads. Whenever worn to the limit
Steering
g bearings
g Check bearing play and steering for roughness.
13 *
(See page 3-40) Lubricate with lithium-soap-based grease. Every 20,000 km
Chassis fasteners Make sure that all nuts, bolts and screws are properly
14 *
(See page 2-21) tightened.
Sidestand switch
16 * Check operation.
(See page 8-9)
Front fork
17 * Check operation and for oil leakage.
(See page 3-43)
Rear shock absorber Check operation and shock absorber for oil leakage.
18 * assembly Lubricate the pivoting points with lithium-soap-based
(See page 3-49)
grease.
Carburetors
19 * Adjust engine idling speed and synchronization.
(See page 3-15)
3-1
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PERIODIC MAINTENANCE CHK
AND LUBRICATION INTERVALS ADJ
Cooling
g system
y S Check coolant level and vehicle for coolant leakage.
22 *
(See page 3-32) S Change. Every 3 years
Chain drive oil
S Check vehicle for oil leakage.
23 (See page 3-39)
S Change.
(See page 3-40)
When the V-Belt replacement indication light comes
24 * V-belt (See page 5-48) S Replace.
on (every 20,000 km)
EAU03541
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S Regularly check and, if necessary, correct the brake fluid level.
S Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
3-2
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CHK
SEAT AND FUEL LID ADJ
SEAT
SEAT AND FUEL LID
3-3
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CHK
FRONT COWLING ADJ
COVER AND PANEL
FRONT COWLING
3-4
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CHK
SIDE COVER MOLES ADJ
3-5
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CHK
REAR COVERS AND TAILLIGHT ADJ
15 Nm (1.5 mkg)
3-6
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CHK
FUEL TANK ADJ
FUEL TANK
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
3-7
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CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
footrest boards
front cowling
legshield
Refer to “COVER AND PANEL”.
2. Remove:
radiator
Refer to “RADIATOR” in chapter 6.
3. Remove:
carburetor
spark plug
cylinder head cover 1
cylinder head cover gasket 2
intake manfold
Refer to “CARBURETORS” in chapter 7.
4. Remove:
timing plug 1
5. Measure:
valve clearance
Out of specification ! Adjust.
3-8
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CHK
ADJUSTING THE VALVE CLEARANCE ADJ
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark a on the
generator rotor with the mark b on the gen-
erator cover.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
6. Remove:
CAUTION:
When removing the camshaft from the cylin-
der head, first tip up the chassis front side at
least 25_ from the chassis level position.
S intake camshaft
S exhaust camshaft
NOTE:
S Refer to “CAMSHAFTS” in chapter 5.
S When removing the timing chain and cam-
shafts, fasten a wire to the timing chain to re-
trieve it if it falls into the cramkcase.
7. Adjust:
S valve clearance
a. Remove the valve lifter 1 and the valve pad
2.
NOTE:
S Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
3-9
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CHK
ADJUSTING THE VALVE CLEARANCE ADJ
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
NOTE:
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.
3-10
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CHK
ADJUSTING THE VALVE CLEARANCE ADJ
NOTE:
Apply molybdenum disulfide to the valve pad.
Lubricate the valve lifter with molybdenum dis-
ulfide oil.
The valve lifter must turn smoothly when ro-
tated by hand.
Install the valve lifter and the valve pad in the
correct place.
3-11
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CHK
ADJUSTING THE VALVE CLEARANCE ADJ
VALVE PAD SELECTION TABLE
INTAKE
B MEASURED A ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08 X 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11 X 0.20 C STANDARD CLEARANCE
0.21 X 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.23 X 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28 X 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 X 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 185 190 195 200 205 210 215 220 225 230 235 240 Example:
0.83 X 0.87 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
0.88 X 0.92 195 200 205 210 215 220 225 230 235 240 0.11 X 0.20 mm
0.93 X 0.97 200 205 210 215 220 225 230 235 240 Rounded value 150
0.98 X 1.02 205 210 215 220 225 230 235 240
1.03 X 1.07 210 215 220 225 230 235 240
Measured valve clearance is 0.24 mm
1.08 X 1.12 215 220 225 230 235 240 Replace pad 150 with pad 160
1.13 X 1.17 220 225 230 235 240 Pad No. 150 = 1.50 mm
1.18 X 1.22 225 230 235 240 Pad No. 160 = 1.60 mm
1.23 X 1.27 230 235 240 Always install the valve pad with the
1.28 X 1.32 235 240
1.33 X 1.37 240
number facing down.
EXHAUST
B MEASURED A ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08 X 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 X 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18 X 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21 X 0.30 C STANDARD CLEARANCE
0.31 X 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 X 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 X 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 X 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 X 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 X 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 X 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 X 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 X 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 X 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 X 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 X 0.87 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88 X 0.92 185 190 195 200 205 210 215 220 225 230 235 240 Example:
0.93 X 0.97 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
0.98 X 1.02 195 200 205 210 215 220 225 230 235 240 0.21 X 0.30 mm
1.03 X 1.07 200 205 210 215 220 225 230 235 240
Rounded value 175
1.08 X 1.12 205 210 215 220 225 230 235 240
1.13 X 1.17 210 215 220 225 230 235 240 Measured valve clearance is 0.35 mm
1.18 X 1.22 215 220 225 230 235 240 Replace pad 150 with pad 185
1.23 X 1.27 220 225 230 235 240 Pad No. 175 = 1.75 mm
1.28 X 1.32 225 230 235 240 Pad No. 185 = 1.85 mm
1.33 X 1.37 230 235 240
Always install the valve pad with the
1.38 X 1.42 235 240
1.43 X 1.47 240 number facing down.
3-12
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ADJSTING THE VALVE CLEARANCE/ CHK
SYNCHRONIZING THE CARBURETORS ADJ
8. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
EAS00051
2. Remove:
center cover
side covers (left and right)
Refer to “COVER AND PANEL”.
4. Install:
engine tachometer 1
(onto the spark plug lead of cylinder. #1)
vacuum gauge 2
Engine tachometer
90890-03113
Vacuum gauge
90890-03094
3-13
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CHK
SYNCHRONIZING THE CARBURETORS ADJ
5. Start the engine and let it warm up for several
minutes.
6. Check:
engine idling speed
Out of specification ! Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
7. Adjust:
carburetor synchronization
NOTE:
The difference between the two carburetors
should not exceed 1.33 kPa (10 mm Hg, 0.4 in
Hg).
8. Measure:
engine idling speed (adjust while the air in-
duction system is operating)
Out of specification ! Adjust.
9. Stop the engine and remove the measuring
equipment.
10. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
11. Install:
side covers (left and right)
center cover
Refer to “COVER AND PANEL”.
3-14
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CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
EAS00052
Engine tachometer
90890-03113
4. Measure:
engine idling speed
Out of spcification ! adjust
5. Adjust:
engine idling speed
Pilot screw
2 turns out
3-15
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ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
c. Turn the throttle stop screw 2 in direction a
or b until the specified engine idling speed is
obtained.
6. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
7. Install:
side covers (left and right)
center cover
Refer to “COVER AND PANEL”.
EAS00055
1. Check:
throttle cable free play a
Out of specification ! Adjust.
2. Remove:
center cover
side cover (left)
Refer to “COVER AND PANEL”.
3. Adjust:
throttle cable free play
NOTE:
When the scooter is accelerating, the accelera-
tor cable 1 is pulled.
3-16
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CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
Carburetor side
a. Loosen the locknut 1 on the decelerator
cable.
b. Turn the adjusting nut 2 in direction a or b
to take up any slack on the decelerator cable.
c. Loosen the locknut 3 on the accelerator
cable.
d. Turn the adjusting nut 4 in direction a or b
until the specified throttle cable free play is
obtained.
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.
4. Install:
side cover (left)
center cover
Refer to “COVER AND PANEL”.
3-17
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CHK
CHECKING THE SPARK PLUGS ADJ
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
center cover
side cover (left and right)
Refer to “COVER AND PANEL”.
2. Disconnect:
spark plug cap
3. Remove:
spark plug
CAUTION:
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:
spark plug type
Incorrect ! Change.
Spark plug type (manufacturer)
CR7E (NGK)
5. Check:
electrode 1
Damage/wear ! Replace the spark plug.
insulator 2
Abnormal color ! Replace the spark plug.
Normal color is a medium-to-light tan color.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire gauge)
Out of specification ! Regap.
8. Install:
spark plug
Spark plug
12.5 Nm (1.25 mkg)
3-18
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CHECKING THE SPARK PLUGS/ CHK
CHECKING THE IGNITION TIMING ADJ
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
spark plug cap
10. Install:
center cover
side cover (left and right)
Refer to “COVER AND PANEL”.
EAS00062
1. Remove:
footrest board (left)
center cover
side cover (left)
Refer to “COVER AND PANEL”.
2. Remove:
timing plug 1
3. Install:
timing light 1
engine tachometer
(onto the spark plug lead of cylinder. #1)
Timing light
90890-03141
Engine tachometer
90890-03113
3-19
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CHECKING THE IGNITION TIMING/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
4. Check:
ignition timing
5. Install:
timing plug
footrest board (left)
side cover (left)
center cover
Refer to “COVER AND PANEL”.
EAS00065
1. Remove:
legshield.
inner fender (rear)
Refer to “COVER AND PANEL”.
2. Measure:
valve clearance
Out of specification ! Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
3-20
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CHK
MEASURING THE COMPRESSION PRESSURE ADJ
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Disconnect:
spark plug cap
5. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
6. Install:
compression gauge 1
Compression gauge
90890-03081
Adapter
90890-04082
7. Measure:
compression pressure
Out of specification ! Refer to steps (c) and
(d).
Compression pressure at
360 r/min (at sea level)
Minimum
1,400 kPa (14.0 kg/cm2,
14.0 bar)
Standard
1,450 kPa (14.5 kg/cm2,
14.5 bar)
Maximum
1,500 kPa (15.0 kg/cm2,
15.0 bar)
NOTE:
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa
(1 kg/cm2, 1 bar).
3-21
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MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL ADJ
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than Piston wear or
without oil damage ! Repair.
Piston ring(-s),
valve(-s), cylinder
Same as without head gasket or
oil piston possibly
defective !
Repair.
8. Install:
spark plug 12.5 Nm (1.25 mkg)
9. Install:
legshield
EB303070
3-22
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CHECKING THE ENGINE OIL LEVEL/ CHK
CHANGING THE ENGINE OIL ADJ
Recommended oil
SAE10W30 or SAE 10W40
API standard
SE, SF, SG or higher grade
(Non-Friction modified)
CAUTION:
Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and do
not use oils labeled “ENERGY CONSERV-
ING II” d or higher.
Do not allow foreign materials to enter the
crankcase.
3. Remove:
engine oil filler cap 1
engine oil drain bolt 2
(along with the gasket)
4. Drain:
engine oil
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.
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CHK
CHANGING THE ENGINE OIL ADJ
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
Oil filter cartridge
17 Nm (1.7 mkg)
6. Check:
engine oil drain bolt washer
Damage ! Replace.
7. Install:
engine oil drain bolt 43 Nm (4.3 mkg)
8. Fill:
crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
3.6 L
Without oil filter cartridge
replacement
2.8 L
With oil filter cartridge
replacement
2.9 L
9. Install:
engine oil filler cap
10. Start the engine, warm it up for several min-
utes, and then turn it off.
11. Check:
engine
(for engine oil leaks)
12. Check:
engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
13. Reset:
Oil change indicator light perform the follow-
ing procedure.
3-24
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CHK
MEASURING THE ENGINE OIL PRESSURE ADJ
EAS00077
4. Remove:
S main gallery bolt 1
WARNING
The engine, muffler and engine oil are ex-
tremely hot.
5. Install:
S oil pressure gauge 1
S adapter 2
6. Measure:
S engine oil pressure
(at the following conditions)
Out of specification ³ Replace.
3-25
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CHK
MEASURING THE ENGINE OIL PRESSURE ADJ
Engine oil pressure Possible causes
Faulty oil pump
Clogged oil filter
Below specification Leaking oil passage
Broken or damaged
oil seal
Leaking oil passage
Above specification Faulty oil filter
Oil viscosity too high
7. Install:
main gallery bolt 1 20 Nm (2.0 mkg)
3-26
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CHK
CLEANING THE AIR FILTER ELEMENT ADJ
CLEANING THE AIR FILTER ELEMENT
1. Remove:
front cowling upper cover
windshield
front cowling inner panel
Refer to “COVER AND PANEL”.
2. Remove:
air filter case cover 1
air filter element
3. Clean:
air filter element
Apply compressed air to the outer surface of
the air filter element.
4. Check:
air filter element
Damage ! Replace.
5. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor en-
gine performance and possible overheat-
ing.
NOTE:
When installing the air filter element into the air
filter case cover, be sure their sealing surfaces
are aligned to prevent any air leaks.
6. Install:
front cowling inner panel
windshield
front cowling upper cover
3-27
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CLEANING THE V-BELT CASE AIR FILTER ELEMENT/CHECKING CHK
THE CARBURETOR JOINTS AND INTAKE MANIFOLDS
ADJ
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
1. Remove:
upper side cover mole (left)
footrest board (left)
Refer to “COVER AND PANEL”.
2. Remove:
V-velt case air filter element 1 and 2
3. Clean:
V-velt case air filter element
Apply compressed air to the inner surface of
V-velt case air filter element.
4. Check:
V-velt case air filter element
Damage ! Replace.
CAUTION:
Since the V-belt case air filter element is a dry
type, do not let grease or water contact it.
5. Install:
footrest board (left)
upper side cover mole (left)
3-28
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CHECKING THE CARBURETOR JOINTS AND INTAKE CHK
MANIFOLDS/CHECKING THE FUEL HOSES AND FUEL FILTER
ADJ
2. Check:
carburetor joints 1
Cracks/damage ! Replace.
Refer to “CARBURETOR” in chapter 7.
3. Install:
legshield
EAS00097
2. Check:
fuel hose 1
Cracks/damage ! Replace.
fuel filter 2
Damage/dirt ! Replace.
NOTE:
Drain and flush the fuel tank if abrasive dam-
age to any components of the fuel line is evi-
dent.
The arrow mark on the fuel filter should face to
the side of the fuel pump 3 .
3. Install:
upper side cover mole (right)
footrest board
Refer to “COVER AND PANEL”.
3-29
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CHECKING THE CRANKCASE BREATHER HOSE/ CHK
CHECKING THE EXHAUST SYSTEM ADJ
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
legshield
Refer to “COVER AND PANEL”.
2. Check:
crankcase breather hose 1
Cracks/damage ! Replace.
Loose connection ! Connect properly.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
legshield
Refer to “COVER AND PANEL”.
EAS00099
4. Install:
lower side cover mole (right)
Refer to “COVER AND PANEL”.
3-30
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CHK
CHECKING THE COOLANT LEVEL ADJ
EAS00103
2. Remove:
lower side cover mole (right)
3. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
Below the minimum level mark ! Add the
recommended coolant to the proper level.
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
6. Install:
lower side cover mole (right)
3-31
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CHECKING THE COOLING SYSTEM/ CHK
CHANGING THE COOLANT ADJ
CHECKING THE COOLING SYSTEM
1. Remove:
footrest board (left and right)
legshield
Refer to “COVER AND PANEL”.
2. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
oil cooler inlet hose 4
oil cooler outlet hose 5
Cracks/damage ! Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
legshield
footrest board
Refer to “COVER AND PANEL”.
2. Disconnect:
coolant reservoir bolts 1
coolant reservoir cap 2
NOTE:
When draining the coolant from the coolant res-
ervoir, be sure to tilt the reservoir so that coolant
cannot flow through the coolant reservoir
breather hose.
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CHK
CHANGING THE COOLANT ADJ
3. Drain:
coolant (from the coolant reservoir)
4. Install:
coolant reservoir bolts
5. Remove:
front side cover mole (right)
Refer to “COVER AND PANEL”.
radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap, while still pressing down turn it
counterclockwise, and then remove it.
6. Remove:
coolant drain bolt 1
(along with the rubber washer)
7. Drain:
coolant
8. Check:
rubber washer 1
drain bolt 2
9. Install:
drain bolt 2 10 Nm (1.0 mkg)
3-33
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CHK
CHANGING THE COOLANT ADJ
10. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol anti
freeze containing corrosion inhibi
tors for aluminum engines
Mix ratio
50% antifreeze/50% water
Quantity
Total amount
1.5 L
Coolant reservoir capacity
0.6 L
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
Use only distilled water. Soft water may be
used if distilled water is not available.
If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
Do not mix different types of antifreeze.
11. Install:
radiator cap
3-34
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CHK
CHANGING THE COOLANT ADJ
12. Fill:
coolant reservoir
(with the recommended coolant to the maxi-
mum level mark a )
13. Install:
coolant reservoir cap
14. Start the engine, warm it up for several min-
utes, and then turn it off.
15. Check:
coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
16. Install:
lower side cover mole (right)
side cover mole (right)
3-35
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CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
CHASSIS
EAS00116
2. Check:
brake fluid level
A Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
A Front brake
B Rear brake
WARNING
Use only the designated brake fluid. Other
B brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reser-
voir is horizontal.
3-36
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CHECKING THE BRAKE PADS/ CHK
CHECKING THE BRAKE HOSES ADJ
EB304032
A
CHECKING THE BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
front brake pad
rear brake pad
Brake pad wear limit a
Wear limit reached ! Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
B
chapter 4.
A Front brake
B Rear brake
EAS00132
A
CHECKING THE BRAKE HOSES
The following procedure applies to all of the
brake hoses and clamps.
1. Check:
brake hose 1
A Front
B Rear
Cracks/damage/wear ! Replace.
2. Check:
brake hose clamp
Loose connection ! Tighten.
B
3. Hold the scooter upright and apply the brake.
4. Check:
brake hose
Activate the brake several times.
Brake fluid leakage ! Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00135
NOTE:
Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system,
make sure that there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the hydrau-
lic brake system, considerably lengthening the
bleeding procedure.
If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:
hydraulic brake system
3-38
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BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHK
CHECKING THE CHAIN DRIVE OIL LEVEL ADJ
Bleed screw
6 Nm (0.6 mkg)
2. Remove:
chain drive oil filler cap 1
3. Check:
chain drive oil level
The chain drive oil level should be between
the minimum level mark a and maximum
level mark b .
Below the minimum level mark ! Add the
recommended transfer oil to the proper level.
4. Install:
chain drive oil filler cap
3-39
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CHANGING THE CHAIN DRIVE OIL/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
CHANGING THE CHAIN DRIVE OIL
1. Place a container under the chain drive.
2. Remove:
chain drive oil drain bolt 1
chain drive oil filler cap
Completely drain the chain drive of its oil.
3. Check:
drain bolt gasket
Damage ! Replace.
4. Install:
chain drive oil drain bolt
20 Nm (2.0 mkg)
5. Fill:
chain drive oil
(with the specified amount of the recomen-
ded chain drive oil)
Quantity
0.7 L
6. Check:
chain drive oil level
Refer to “CHECKING THE CHAIN DRIVE
OIL LEVEL”.
EAS00146
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
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CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness or binding ! Adjust the steering
head.
3. Remove:
handlebar
Refer to “HANDLEBAR” in chapter 4.
4. Loosen:
upper bracket pinch bolts 1
5. Remove:
steering stem nut 1
upper bracket 2
6. Adjust:
steering head
3-41
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CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
c. Loosen the lower ring nut 4 completely, then
tighten it to specification.
WARNING
Do not overtighten the lower ring nut.
7. Install:
upper bracket 1
steering stem nut 2
8. Tighten:
upper bracket pinch bolt
30 Nm (3.0 mkg)
steering stem nut
110 Nm (11.0 mkg)
3-42
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CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
9. Measure:
S steering head tension
(with the motorcycle still on the stand)
NOTE:
Make sure that all of the cables and wires are
properly routed.
EAS00149
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CHK
CHECKING THE FRONT FORK ADJ
2. Check:
inner tube
Damage/scratches ! Replace.
oil seal
Oil leakage ! Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation ! Repair.
Refer to “FRONT FORK” in chapter 4.
3-44
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CHK
CHECKING THE TIRES ADJ
EB304170
Basic
weight
(with oil 217 kg
and a full
fuel tank)
Maximum
372 kg
load*
Cold tire
Front Rear
pressure
200 kPa 225 kPa
Up to 90 kg
(2.0 kgf/cm2, (2.25 kgf/cm2,
load*
2.0 bar) 2.25 bar)
90 kg X 225 kPa 250 kPa
maximum (2.25 kgf/cm2, (2.5 kgf/cm2,
load* 2.25 bar) 2.5 bar)
225 kPa 250 kPa
High-speed
(2.25 kgf/cm2, (2.5 kgf/cm2,
riding
2.25 bar) 2.5 bar)
* total of cargo, rider, passenger and accesso-
ries
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
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CHK
CHECKING THE TIRES ADJ
2. Check:
tire surfaces
Damage/wear ! Replace the tire.
Front tire
Manufacturer Size Model
120/70-14 HOOP
BRIDGESTONE
M/C 55S BO3
120/70-14
DUNLOP D305FA
M/C 55S
3-46
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CHK
CHECKING THE TIRES/CHECKING THE WHEELS ADJ
Rear tire
Manufacturer Size Model
150/70-14 HOOP
BRIDGESTONE
M/C 66S BO2
150/70-14
DUNLOP D305
M/C 66S
WARNING
After mounting a new tire, ride conservative-
ly for a while to become accustomed to the
“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 damage to the motor-
cycle.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
EB304180
NOTE:
After a tire or wheel has been changed or re-
placed, always balance the wheel.
3-47
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CHECKING AND LUBRICATING THE CABLES /LUBRICATING THE LEVERS CHK
LUBRICATING THE CENTERSTAND/ LUBRICATING THE SIDESTAND ADJ
EAS00170
1. Check:
cable sheath
Damage ! Replace.
2. Check:
cable operation
Unsmooth operation ! Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubing device.
EB304210
Recommended lubricant
Lithium soap base grease
EAS00173
Recommended lubricant
Engine oil
EB304220
Recommended lubricant
Lithium soap base grease
3-48
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CHK
LUBRICATING THE REAR SUSPENSION ADJ
EAS00174
Recommended lubricant
Molybdenum disulfide grease
3-49
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CHK
CHECKING AND CHARGING THE BATTERY ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin – Wash with water
Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
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CHK
CHECKING AND CHARGING THE BATTERY ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
3. Remove:
S battery
4. Measure:
S battery charge
5 6.5 10
Charging time (hours)
b. Check the charge of the battery, as shown in
These values vary with the temperature, the condition of the charts and the following example.
the battery plates, and the electrolyte level.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 X 30%
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CHECKING AND CHARGING THE BATTERY ADJ
Charging 5. Charge:
Ambient temperature 20_C
S battery
Open-circuit voltage (V)
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CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a variable-voltage charger
Charger
Ammeter
Measure the open-circuit NOTE:
voltage prior to charging. Leave the battery unused for more than
30 minutes before measuring its open-
circuit voltage.
NO
Leave the battery unused for more than 30 minutes before measur-
ing its open-circuit voltage.
12.8 V ! Charging is complete.
12.0 X 12.7 V ! Recharging is required.
Under 12.0 V ! Replace the battery.
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CHK
CHECKING AND CHARGING THE BATTERY ADJ
Charging method using a constant-voltage charger
Charge the battery until the charging This type of battery charger cannot
voltage reaches 15 V. charge an MF battery. A variable-
voltage charger is recommended.
NOTE:
Set the charging time to a maximum of
20 hours.
CAUTION:
Constant amperage chargers are not
suitable for charging MF battries.
3-54
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CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
8. Check:
battery terminals
Dirt ! Clean with a wire brush.
Loose connection ! Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10. Install:
seat
battery cover
EB305040
1. Remove:
seat
battery cover
2. Check:
continuity
Pocket tester
90890-03112
3-55
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CHK
CHECKING THE FUSES ADJ
3. Replace:
blown fuse
WARNING
Never use a fuse with an amperage other
than that specified. Improvising or using a
fuse with the wrong amperage rating may
cause extensive damage to the electrical
system, cause the lighting and ignition sys-
tems to malfunction and could possibly
cause a fire.
4. Install:
battery cover
seat
3-56
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CHK
REPLACING THE HEADLIGHT BULBS ADJ
EB305051
2. Detach:
headlight bulb holder 1
3. Remove:
headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:
headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Attach:
headlight bulb holder
6. Install:
headlight bulb holder cover
7. Connect:
headlight coupler
3-57
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CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
EAS00184
2. Adjust:
headlight beam (horizontally)
3-58
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CHAS
CHAPTER 4
CHASSIS
CHASSIS
FRONT WHEEL AND BRAKE DISC
59 Nm (5.9 mkg)
40 Nm (4.0 mkg)
20 Nm (2.0 mkg)
18 Nm (1.8 mkg)
4-1
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FRONT WHEEL AND BRAKE DISC CHAS
4-2
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FRONT WHEEL AND BRAKE DISC CHAS
EAS00520
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
front brake caliper
front wheel axle
NOTE:
Do not squeeze the brake lever when removing
the brake caliper.
3. Elevate:
front wheel
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
EB700110
4-3
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FRONT WHEEL AND BRAKE DISC CHAS
EAS00525
2. Check:
tire
front wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits Replace.
4. Check:
wheel bearings
Front wheel turns roughly or is loose Re-
place the wheel bearings.
oil seals
Damage/wear Replace.
5. Replace:
wheel bearings New
oil seals New
4-4
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FRONT WHEEL AND BRAKE DISC CHAS
c. Remove the wheel bearings 3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center race
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.
EAS00528
4-5
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FRONT WHEEL AND BRAKE DISC CHAS
3. Measure:
S brake disc thickness a
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
4. Adjust:
S brake disc deflection
4-6
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FRONT WHEEL AND BRAKE DISC CHAS
EB700711
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
2. Install:
oil seal New 1
EAS00542
Recommended lubricant
Lithium soap base grease
2. Install:
speed sensor
NOTE:
Make sure that the speed sensor unit and the
wheel hub are installed with the two projec-
tions meshed into the two slots respectively.
Make sure that the slot a in the speed sensor
fits over the stopper b on the outer tube.
4-7
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FRONT WHEEL AND BRAKE DISC CHAS
3. Install:
brake disc 18 Nm (1.8 mkg)
NOTE:
Apply LOCTITE 648 to the threads of the
brake disc bolts.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4. Install:
front wheel
front wheel axle
wheel axle pinch bolt
NOTE:
Make sure that the slot in the speedometer gear
unit fits over the stopper on the outer tube.
5. Tighten:
front wheel axle 1 59 Nm (5.9 mkg)
wheel axle pinch bolt 2
20 Nm (2.0 mkg)
CAUTION:
Before tightening the wheel axle pinch bolt,
push down hand on the handlebar several
times and check if the front fork rebounds
smoothly.
6. Install:
front brake caliper 1
WARNING
Make sure that the brake cable is routed
properly.
7. Tighten:
front brake caliper bolt 2
40 Nm (4.0 mkg)
4-8
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FRONT WHEEL AND BRAKE DISC CHAS
EAS00548
1. Remove:
S balancing weight(-s)
2. Find:
S front wheel’s heavy spot
3. Adjust:
S front wheel static balance
4-9
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FRONT WHEEL AND BRAKE DISC CHAS
4. Check:
front wheel static balance
4-10
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REAR WHEEL AND BRAKE DISC CHAS
17 Nm (1.7 mkg)
7 Nm (0.7 mkg)
40 Nm (4.0 mkg)
4-11
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REAR WHEEL AND BRAKE DISC CHAS
18 Nm (1.8 mkg)
4-12
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REAR WHEEL AND BRAKE DISC CHAS
EAS00565
EAS00567
EAS00575
1. Adjust:
rear wheel static balance
Refer to “FRONT WHEEL”.
4-13
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FRONT AND REAR BRAKES CHAS
40 Nm (4.0 mkg)
4-14
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FRONT AND REAR BRAKES CHAS
40 Nm (4.0 mkg)
4-15
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FRONT AND REAR BRAKES CHAS
EAS00579
CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt fluid immediately.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get im-
mediate medical attention.
EAS00581
1. Remove:
front brake caliper bolt 1
brake caliper 2
2. Remove:
brake pad spring 1
brake pads 2
4-16
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FRONT AND REAR BRAKES CHAS
3. Measure:
brake pad thickness a
Out of specification Replace the brake
pads as a set.
4. Install:
brake pad spring 1
brake pads 2
NOTE:
Always install new brake pads and a new brake
pad shim as a set.
Bleed screw
6 Nm (0.6 mkg)
5. Lubricate:
brake caliper bolts
Recommended lubricant
Lithium soap base grease
CAUTION:
Do not allow grease to contact the brake
pads.
Remove any excess grease.
4-17
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FRONT AND REAR BRAKES CHAS
6. Install:
brake caliper 1
brake caliper bolts 2 40 Nm (4.0 mkg)
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
1. Remove:
brake caliper bolt 1
brake caliper 2
2. Remove:
brake pads 1
brake pad shim 2
brake pad spring 3
4-18
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FRONT AND REAR BRAKES CHAS
3. Measure:
brake pad thickness a
Out of specification Replace the brake
pads as a set.
4. Install:
brake pads 1
brake pad spring 2
brake pad shim 3
NOTE:
Always install new brake pads and a brake pad
spring as a set.
Bleed screw
6 Nm (0.6 mkg)
5. Lubricate:
brake caliper bolts
Recommended lubricant
Lithium soap base grease
CAUTION:
Do not allow grease to contact the brake
pads.
Remove any excess grease.
4-19
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FRONT AND REAR BRAKES CHAS
6. Install:
brake caliper
brake caliper bolt 40 Nm (4.0 mkg)
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-20
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FRONT AND REAR BRAKES CHAS
10 Nm (1.0 mkg)
4-21
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FRONT AND REAR BRAKES CHAS
4-22
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FRONT AND REAR BRAKES CHAS
30 Nm (3.0 mkg)
4-23
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FRONT AND REAR BRAKES CHAS
4-24
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FRONT AND REAR BRAKES CHAS
EAS00588
1. Disconnect:
front brake light switch connector
(from the brake light switch)
2. Remove:
union bolt 1
copper washers 2
brake hoses 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
1. Disconnect:
rear brake light switch connector
(from the brake light switch)
2. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4-25
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FRONT AND REAR BRAKES CHAS
EAS00592
A
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
brake master cylinder 1
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
B A Front
B Rear
2. Check:
brake master cylinder kit 1
Damage/scratches/wear Replace.
3. Check:
front brake master cylinder reservoir cap 1
Cracks/damage Replace.
front brake master cylinder reservoir dia-
phragm 2
Damage/wear Replace.
4. Check:
rear brake master cylinder reservoir cap 1
Cracks/damage Replace.
rear brake master cylinder reservoir dia-
phragm 2
Damage/wear Replace.
4-26
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FRONT AND REAR BRAKES CHAS
5. Check:
brake hoses 1
Cracks/damage/wear Replace.
EAS00596
1. Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3
2. Install:
front brake light switch 1
3. Install:
brake lever
4-27
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FRONT AND REAR BRAKES CHAS
4. Install:
brake master cylinder 1
brake master cylinder holder 2
holder bolts 10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up a .
Align the end of the brake master cylinder hold-
er with the punch mark b in the handlebar.
First, tighten the upper bolt, then the lower bolt.
5. Install:
copper washers 2 New
brake hose 3
union bolt 1 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe scooter operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
4-28
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FRONT AND REAR BRAKES CHAS
6. Connect:
front brake light switch connector
7. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
8. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
10. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-29
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FRONT AND REAR BRAKES CHAS
EAS00600
1. Install:
brake master cylinder kit 1
circlip 2 New
dust boot 3
2. Install:
rear brake light switch 1
3. Install:
brake lever
4-30
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FRONT AND REAR BRAKES CHAS
4. Install:
brake master cylinder 1
brake master cylinder holder 2
holder bolts 10 Nm (1.0 mkg)
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up a .
Align the end of the brake master cylinder hold-
er with the punch mark b on the handlebar.
First, tighten the upper bolt, then the lower bolt.
5. Install:
copper washer 2 New
brake hose 3
union bolt 1 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe scooter operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebar to the left and to the right to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
4-31
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FRONT AND REAR BRAKES CHAS
6. Connect:
rear brake light switch connector
7. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
8. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
9. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
10. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-32
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FRONT AND REAR BRAKES CHAS
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
4-33
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FRONT AND REAR BRAKES CHAS
6 Nm (0.6 mkg)
40 Nm (4.0 mkg)
4-34
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FRONT AND REAR BRAKES CHAS
30 Nm (3.0 mkg)
40 Nm (4.0 mkg)
4-35
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FRONT AND REAR BRAKES CHAS
6 Nm
(0.6 mkg)
40 Nm (4.0 mkg)
4-36
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FRONT AND REAR BRAKES CHAS
EAS00619
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
EAS00626
4-37
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FRONT AND REAR BRAKES CHAS
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper piston 1
brake caliper piston seals 2
EAS00631
4-38
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FRONT AND REAR BRAKES CHAS
A 1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake cali-
per.
brake caliper body 3
Cracks/damage Replace the brake cali-
per.
brake fluid delivery passages
B (brake caliper body)
Obstruction Blow out with compressed air.
WARNING
Whenever a brake caliper is disassembled,
replace the piston seals.
A Front
B Rear
A 2. Check:
brake caliper bracket 1
Cracks/damage Replace.
A Front
B Rear
4-39
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FRONT AND REAR BRAKES CHAS
EAS00635
1. Install:
bleed screw
piston seals 1 New
dust seals 2 New
caliper pistons 3
2. Install:
brake pad spring 1
brake pads 2
NOTE:
Install the brake pad with the attached brake
pad spring.
4-40
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FRONT AND REAR BRAKES CHAS
3. Install:
brake caliper
brake caliper bolt 40 Nm (4.0 mkg)
4. Install:
brake hose 1
copper washers 2 New
union bolt 3 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe scooter operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
5. Fill:
brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
4-41
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FRONT AND REAR BRAKES CHAS
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
6. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00643
1. Install:
bleed screw
piston seals 1 New
dust seals 2 New
caliper piston
4-42
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FRONT AND REAR BRAKES CHAS
2. Install:
brake pad shim 1
brake pad spring 2
brake pad 3
NOTE:
Install the brake pad with the attached brake
pad shim.
3. Install:
brake caliper
brake caliper bolt 40 Nm (4.0 mkg)
4. Install:
brake hose 1
copper washers 2 New
union bolt 3 30 Nm (3.0 mkg)
WARNING
Proper brake hose routing is essential to in-
sure safe scooter operation. Refer to
“CABLE ROUTING”.
CAUTION:
When installing the brake hose onto the
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
4-43
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FRONT AND REAR BRAKES CHAS
5. Fill:
brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
6. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
7. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-44
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FRONT FORK CHAS
FRONT FORK
30 Nm
(3.0 mkg)
27 Nm (2.7 mkg)
4-45
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FRONT FORK CHAS
30 Nm
(3.0 mkg)
27 Nm (2.7 mkg)
4-46
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FRONT FORK CHAS
20 Nm (2.0 mkg)
4-47
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FRONT FORK CHAS
20 Nm (2.0 mkg)
4-48
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FRONT FORK CHAS
EAS00651
NOTE:
Place the scooter on a suitable stand so that the
front wheel is elevated.
2. Remove:
front cowling
handle cover
meter
legshield
front wheel
front fender
3. Loosen:
cap bolt 1
4. Loosen:
upper bracket pinch bolts 2
5. Loosen:
lower bracket pinch bolts. 1
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
6. Remove:
front fork leg
4-49
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FRONT FORK CHAS
EAS00652
2. Drain:
fork oil
NOTE:
Stroke the outer tube several times while drain-
ing the fork oil.
3. Remove:
damper rod assembly bolt
NOTE:
While holding the cartridge cylinder with the
damper rod holder 1 and T-handle 2 , loosen
the cartridge cylinder bolt.
4. Remove:
inner tube
4-50
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FRONT FORK CHAS
EAS00656
2. Measure:
spring free length a
Over the specified limit Replace.
3. Check:
damper rod 1
Damage/wear Replace.
Obstruction Blow out all of the oil pas-
sages with compressed air.
oil flow stopper 2
Damage Replace.
4. Check:
cap bolt O-ring
Damage/wear Replace.
4-51
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FRONT FORK CHAS
EAS00659
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
-inner tube bushing
-outer tube bushing
-oil seal
-dust seal
Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
damper rod 1
rebound spring 2
CAUTION:
Allow the damper rod to slide slowly down
the inner tube 3 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Install:
oil flow stopper 1
3. Lubricate:
inner tube’s outer surface 2
Recommended lubricant
Fork oil 5 W or equivalent
4. Install:
outer tube (onto the inner tube)
copper washer New
damper rod bolt
4-52
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FRONT FORK CHAS
5. Tighten:
damper rod bolt 1 20 Nm (2.0 mkg)
NOTE:
Apply the locking agent (LOCTITE 204) to
the threads of the damper rod bolt.
While holding the damper rod with the damper
rod holder 2 and T-handle 3 , tighten the
damper rod bolt.
6. Install:
outer tube bushing 1 New
washer 2
(with the fork seal driver weight 3 and adapt-
er 4 )
7. Install:
Oil seal 1 New
(with the fork seal driver weight 2 and adapt-
er 3 )
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, apply lithium soap
base grease onto its lips.
Apply fork oil onto the outer surface of the inner
tube.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to protect
the oil seal during installation.
4-53
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FRONT FORK CHAS
8. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
1 tube’s groove.
9. Install:
dust seal 1 New
(with the fork seal driver weight)
10. Fill:
front fork leg
(with the specified amount of the recom-
mended fork oil)
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.
11. Install:
fork spring
spacer
fork spring seat
O-ring New
NOTE:
Install the spring with the smaller pitch facing
down.
Before installing the cap bolt, lubricate its O-
ring with grease.
Temporarily tighten the cap bolt.
4-54
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FRONT FORK CHAS
EAS00663
2. Tighten:
cap bolt 1 45 Nm (4.5 mkg)
lower bracket pinch bolt 3
30 Nm (3.0 mkg)
upper bracket pinch bolt 2
30 Nm (3.0 mkg)
3. Install:
front fender
legshield
meter
handle cover
front cowling
front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
4-55
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HANDLEBAR CHAS
HANDLEBAR
26 Nm (2.6 mkg)
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
4-56
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HANDLEBAR CHAS
26 Nm (2.6 mkg)
23 Nm (2.3 mkg)
10 Nm (1.0 mkg)
26 Nm (2.6 mkg)
4-57
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HANDLEBAR CHAS
EAS00666
2. Remove:
right handlebar switch 1
throttle cable
throttle grip 2
front brake master cylinder 3
grip end 4
3. Remove:
left handlebar switch 1
left handlebar grip 2
rear brake master cylinder 3
grip end 4
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
4-58
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HANDLEBAR CHAS
EAS00671
2. Install:
handlebar 1
handlebar upper holders 2
23 Nm (2.3 mkg)
WARNING
First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
NOTE:
The upper handlebar holders should be
installed with the arrows a facing forward A .
Align the match marks b on the handlebar
with the upper surface of the lower handlebar
holders.
3. Install:
front brake master cylinder 1
front brake master cylinder holder 2
10 Nm (1.0 mkg)
holder bolt
NOTE:
Install the front brake master cylinder holder
with the “UP” a mark facing up.
4-59
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HANDLEBAR CHAS
First, tighten the upper bolt, then the lower bolt.
4. Install:
throttle cable
throttle grip
grip end
5. Install:
right handlebar switch 1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
6. Connect:
front brake light switch
7. Install:
rear brake master cylinder 1
rear brake master cylinder holder 2
10 Nm (1.0 mkg)
NOTE:
Install the rear brake master cylinder holder
with the “UP” mark facing up a .
Align the end of the rear brake master cylinder
holder with the punch mark b in the handle-
bar.
First, tighten the upper bolt, then the lower bolt.
8. Install:
left handlebar switch 1
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
4-60
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HANDLEBAR CHAS
9. Install:
left handlebar grip
grip end
10. Connect:
rear brake light switch
11. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
4-61
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STEERING HEAD CHAS
STEERING HEAD
LOWER BRACKET
4-62
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STEERING HEAD CHAS
4-63
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STEERING HEAD CHAS
EAS00678
2. Remove:
upper bracket
3. Remove:
lock washer 1
upper ring nut 2
rubber washer 3
lower ring nut 4
(with the special tool)
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
2. Check:
bearings 1
bearing races 2
Damage/pitting Replace.
4-64
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STEERING HEAD CHAS
3. Replace:
bearings
bearing races
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00684
Recommended lubricant
Lithium soap base grease
2. Install:
oil seal
lower bearing
outer race
3. Install:
lower bracket
4-65
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STEERING HEAD CHAS
4. Install:
upper bearing
bearing cover
5. Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
6. Install:
upper bracket 1
steering stem nut 2
7. Tighten:
steering stem nut 2 110 Nm (11.0 mkg)
4-66
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REAR SHOCK ABSORBER CHAS
52 Nm (5.2 mkg)
67 Nm (6.7 mkg)
4-67
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REAR SHOCK ABSORBER CHAS
EAS00687
EAS00689
4-68
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REAR SHOCK ABSORBER CHAS
EAS00693
NOTE:
Place the scooter on a suitable stand so that the
rear wheel is elevated.
2. Remove:
bolts 1
NOTE:
When removing the bolts 1 , hold the swin-
garm so that it does not drop down.
3. Remove:
rear shock absorber.
EAS00696
4-69
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REAR SHOCK ABSORBER CHAS
INSTALLING THE REAR SHOCK ABSORB-
ER
1. Lubricate:
spacer
bearings
Recommended lubricant
Molybdenum disulfide grease
2. Install:
bush 1
washer 2
bearings 3
spacer 4
3. Install:
rear shock absorber 1
bolt (rear side) 2 52 Nm (5.2 mkg)
4. Install:
bolt (front side) 1 67 Nm (6.7 mkg)
lock washer 2
NOTE:
When installing the bolt 1 , hold the swingarm
so that it does not drop down.
Bend the lock washer 2 tab along a flat side of
the bolt 1 .
4-70
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ENG
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
LEAD AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 5-11
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
CHECKING THE SPRINGS AND CLUTCH SPRINGS . . . . . . . . . . . 5-42
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
48 Nm (4.8 mkg)
20 Nm (2.0 mkg)
5-1
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ENGINE ENG
5-2
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ENGINE ENG
5-3
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ENGINE ENG
ENGINE
87 Nm (8.7 mkg)
87 Nm (8.7 mkg)
48 Nm (4.8 mkg)
5-4
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ENGINE ENG
INSTALLING THE ENGINE
1. Install:
front mounting bolt/nut 1
front mounting bolts (lower) 2
collar 3
rear mounting bolt/nut 4
NOTE:
Do not fully tighten the bolts.
2. Tighten:
front mounting nut (upper) 1
87 Nm (8.7 mkg)
front mounting bolts (lower) 2
48 Nm (4.8 mkg)
rear mounting nut 4 87 Nm (8.7 mkg)
5-5
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CAMSHAFTS ENG
CAMSHAFTS
CYLINDER HEAD COVER
10 Nm (1.0 mkg)
5-6
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CAMSHAFTS ENG
CAMSHAFTS
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
5 In take camshaft 1
6 Exhaust camshaft 1
For installation, reverse the removal
procedure.
5-7
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CAMSHAFTS ENG
REMOVING THE CAMSHAFTS
1. Remove:
S timing plug 1
2. Align:
S “I” mark a (with the stationary pointer b )
3. Remove:
S timing chain tensioner 1
S timing chain tensioner gasket 2
4. Remove:
CAUTION:
When removing the camshaft from the cylin-
der head, first tip up the chassis front side at
least 25_ from the chassis level position.
5-8
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CAMSHAFTS ENG
5. Remove:
intake camshaft 1
exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, faster it with a wire 3 .
6. Remove:
timing chain guide (exhaust side)
EAS00204
3. Measure:
camshaft runout
Out of specification Replace.
5-9
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CAMSHAFTS ENG
4. Measure:
S camshaft-journal-to-camshaft-cap clear-
ance
Out of specification Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.020 0.054 mm
5. Measure:
S camshaft journal diameter a
Out of specification Replace the cam-
shaft.
Within specification Replace the cylinder
head and the camshaft caps as a set.
5-10
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CAMSHAFTS ENG
CHECKING THE CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
camshaft sprocket
More than 1/4 tooth wear a Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
2. Check:
timing chain guide (exhaust side) 2
timing chain guide (intake side) 1
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
5-11
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CAMSHAFTS ENG
INSTALLING THE CAMSHAFTS
1. Install:
timing chain guide (exhaust side)
2. Install:
intake camshaft 1
exhaust camshaft 2
3. Install:
intake camshaft cap 1
exhaust camshaft cap 2
NOTE:
Make sure that camshaft sprocket timing hole
a are aligned with the cylinder head edge b .
Out of alignment Reinstall.
5-12
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CAMSHAFTS ENG
4. Install:
chair guide (exhaust side)
timing chain tensioner gasket
timing chain tensioner
Cap bolt
10 Nm (1.0 mkg)
5. Turn:
crankshaft (several turns counterclockwise)
6. Check:
TDC mark a
Make sure that the TDC mark is aligned with
the crankcase mating surface b .
camshaft sprocket timing mark c
Make sure that the camshaft sprocket timing
mark is aligned with the cylinder head edge
d.
Out of alignment Adjust.
Refer to the installation steps above.
7. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
5-13
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CAMSHAFTS ENG
8. Install:
cylinder head cover gasket
cylinder head cover
NOTE:
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
5-14
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CYLINDER HEAD ENG
CYLINDER HEAD
46 Nm (4.6 mkg)
10 Nm (1.0 mkg)
35 Nm (3.5 mkg)
5-15
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CYLINDER HEAD ENG
REMOVING THE CYLINDER HEAD
1. Remove:
cylinder head bolts 1
cylinder head nuts 2
NOTE:
Loosen the nuts in the proper sequence as
shown.
Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00229
2. Check:
cylinder head
Damage/scratches Replace.
cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
5-16
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CYLINDER HEAD ENG
INSTALLING THE CYLINDER HEAD
1. Install:
dowel pins
gasket New
2. Install:
cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
cylinder head nuts 1 35 Nm (3.5 mkg)
cylinder head nuts 2 46 Nm (4.6 mkg)
cylinder head bolts 3 10 Nm (1.0 mkg)
NOTE:
Apply engine oil onto the threads of the cylin-
der head nuts.
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
exhaust camshaft
intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
5-17
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VALVES AND VALVE SPRINGS ENG
5-18
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VALVES AND VALVE SPRINGS ENG
EAS00237
1. Remove:
valve lifter 1
valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
valve sealing
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
3. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
5-19
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VALVES AND VALVE SPRINGS ENG
4. Remove:
valve retainer 1
valve spring 2
oil seal 3
valve spring seat 4
valve 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Valve-stem-to-valve-guide
clearance
Intake
0.010 0.037 mm
<Limit>: 0.08 mm
Exhaust
0.025 0.052 mm
<Limit>: 0.10 mm
5-20
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VALVES AND VALVE SPRINGS ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_ in an oven.
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
S valve margin thickness a
Out of specification Replace the valve.
5-21
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VALVES AND VALVE SPRINGS ENG
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always re-
place the oil seal.
EAS00240
5-22
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VALVES AND VALVE SPRINGS ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
5-23
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VALVES AND VALVE SPRINGS ENG
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
2. Measure:
compressed spring force a
Out of specification Replace the valve
spring.
b Installed length
5-24
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VALVES AND VALVE SPRINGS ENG
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
EAS00242
EAS00245
2. Lubricate:
valve stem 1
oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
5-25
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VALVES AND VALVE SPRINGS ENG
3. Install:
valve 1
valve spring seat 2
oil seal 3 New
valve spring 4
valve retainer 5
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place.
Install the valve spring with the larger pich a
facing up.
b Smaller pitch
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
5-26
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VALVES AND VALVE SPRINGS ENG
6. Lubricate:
valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
valve pad
valve lifter
CAUTION:
After making sure that the valve pads are ful-
ly inserted, install the valve lifter taking care
so that the pads do not fall.
NOTE:
The valve lifter must move smoothly when ro-
tated with a finger.
Each valve lifter and valve pad must be rein-
stalled in its original position.
5-27
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STARTER CLUTCH AND GENERATOR ENG
10 Nm (1.0 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
30 Nm (3.0 mSkg) 60 Nm (6.0 mSkg) + 120_
5-28
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STARTER CLUTCH AND GENERATOR ENG
10 Nm (1.0 mSkg)
7 Nm (0.7 mSkg)
10 Nm (1.0 mSkg)
30 Nm (3.0 mSkg) 60 Nm (6.0 mSkg) + 120_
5-29
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STARTER CLUTCH AND GENERATOR ENG
REMOVING THE GENERATOR
1. Remove:
generator rotor cover
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 loosend, remove
them.
2. Remove:
generator rotor nut 1
spacer 2
NOTE:
While holding the generator rotor 3 with the
sheave holder 4 , loosen the generator rotor
nut.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
3. Remove:
generator rotor 1
(with the flywheel puller set 2 )
woodruff key
NOTE:
Remove the rotor 1 using the flywheel puller.
Center the flywheel puller over the rotor.
Make sure after installing the holding bolts that
the clearance between the flywheel puller and
the rotor is the same everywhere. If necessary,
one holding bolt maybe turned out slightly to
adjust the flywheel puuler’s position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
5-30
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STARTER CLUTCH AND GENERATOR ENG
CHECKING THE STARTER CLUTCH
1. Check:
starter clutch
Damage/wear Replace.
2. Check:
idle gear
idle gear shaft
starter clutch gear
Pitting/burrs/chips/roughness/wear Re-
place the defective parts.
3. Check:
starter clutch operation
5-31
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STARTER CLUTCH AND GENERATOR ENG
2. Tighten:
S generator rotor nut 1
60 Nm (6.0 mSkg) + 120_
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
CAUTION:
S When tightening the generator rotor nut, be
sure to use an F-type torque wrench.
S After tightening the generator rotor nut, to
the specified torque, turn the connecting
rod nut another + 120_.
3. Apply:
S sealant
(onto the stator coil assembly lead grommet)
4. Install:
S stator coil
5. Install:
S generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
5-32
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OIL PUMP ENG
OIL PUMP
10 Nm (1.0 mkg)
5-33
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OIL PUMP ENG
10 Nm (1.0 mkg)
5-34
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OIL PUMP ENG
5-35
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OIL PUMP ENG
CHECKING THE OIL PUMP
1. Check:
oil pump driven gear 1
oil pump housing 2
oil pump cover 3
Cracks/damage/wear Replace the de-
fective part(-s).
2. Measure:
inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-housing clearance
b
Out of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.04 0.12 mm
<Limit>: 0.20 mm
Outer-rotor-to-oil-pump-housing
clearance
0.045 0.085 mm
<Limit>: 0.15 mm
3. Check:
oil pump operation
Unsmooth Repear or replace the defec-
tive part(-s).
EAS00365
5-36
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OIL PUMP ENG
EAS00367
EAS00368
Recommended lubricant
Engine oil
2. Install:
oil pump housing 1
10 Nm (1.0 mkg)
outer rotor 2
inner rotor 3
pins 4
oil pump cover 5
oil pump driven gear 6
NOTE:
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove 2 on the in-
ner rotor 3 .
3. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
5-37
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CLUTCH ENG
CLUTCH
65 Nm (6.5 mkg)
5-38
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CLUTCH ENG
90 Nm (9.0 mkg)
5-39
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CLUTCH ENG
90 Nm (9.0 mkg)
5-40
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CLUTCH ENG
REMOVING THE CLUTCH
1. Remove:
generator cover 1
Refer to “STARTER CLUTCH AND GENER-
ATOR”.
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
nut 1
clutch assembly 2
clutch boss
NOTE:
Before removal, apply a and b alignment
marks.
Align these marks during reassembly.
3. Remove:
circlip 1
NOTE:
Install the clutch spring holder 2 onto the clutch
assembly as shown. Then, compress the
spring, and remove the circlip 1 .
4. Remove:
spring plate stopper
clutch spring
pressure plate
friction and clutch plates
weight thrust plate
weights
springs
5-41
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CLUTCH ENG
EAS00280
EAS00281
Spring Limit
25.4 mm
2. Measure:
clutch spring b
Out of specification Replace the clutch
spring
EAS00284
EAS00285
EAS00286
5-43
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BELT DRIVE ENG
BELT DRIVE
BELT DRIVE COVER
7 Nm (0.7 mkg)
24 Nm (2.4 mkg)
7 Nm (0.7 mkg)
5-44
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BELT DRIVE ENG
BELT DRIVE
: Shell BT grease 3
24 Nm (2.4 mSkg)
:
90 Nm (9.0 mSkg)
:
160 Nm (16.0 mSkg)
5-45
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BELT DRIVE ENG
: Shell BT grease 3
:
:
6 Nm (0.6 mSkg)
5-46
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BELT DRIVE ENG
: :
90 Nm (9.0 mSkg)
5-47
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BELT DRIVE ENG
REMOVING THE PRIMARY SHEAVE AS-
SEMBLY, SECONDARY SHEAVE AS-
SEMBLY AND V-BELT
1. Remove:
primary sheave nut 1
secondary sheave nut 2
NOTE:
While holding the primary and secondary
sheave with the sheave holder, loosen the nut.
Sheave holder
90890-01481
2. Install:
bolts 1
NOTE:
Insert M6 bolts (more than 45 mm) into the holes
of the secondary sheave assembly, and then
thighten the bolts to open the secondary sheave
assembly.
3. Remove:
primary sliding sheave 2
secondary sheave assembly 1
V-velt 3
NOTE:
Before removal, apply a and b alignment
marks.
Align these marks during reassembly.
Remove the primary sliding sheave, second-
ary sheave assembly and V-belt together.
4. Remove:
primary fixed sheave 1
5-48
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BELT DRIVE ENG
DISASSEMBLING THE PRIMARY SHEAVE
1. Remove:
cam 1
slider 2
weight 3
V-belt width
32 mm
<Limit>: 30.5 mm
5-49
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BELT DRIVE ENG
CHECKING THE PRIMARY SHEAVE
1. Check:
primary sliding sheave 1
primary fixed sheave 2
Cracks/damage/wear Replace the pri-
mary sliding sheave and primary fixed
sheave as a set.
EAS00322
5-50
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BELT DRIVE ENG
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
primary fixed sheave
primary sliding sheave
collar
weight
slider
cam
stopper
NOTE:
Remove any excess grease.
2. Install:
weight 1
slider 2
cam 3
NOTE:
Before installing the weights, lubricate the in-
side and outside of each weight with Shell BT
grease 3.
Put in approximately 80 g of grease.
Recommended lubricant
Shell BT grease 3
3. Install:
primary sliding sheave cap 1
6.0 Nm (0.6 mkg)
collar 2
5-51
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BELT DRIVE ENG
EAS00324
Recommended lubricant
BEL-RAY assembly lube
2. Install:
secondary sliding sheave 1
3. Install:
guide pin 2
4. Lubricate:
guide pin groove 3
oil seal New
(with the recommended lubricant)
Recommended lubricant
BEL-RAY assembly lube
5. Install:
spring seat 1
compression spring 2
upper spring seat 3
NOTE:
Attach the sheave spring compresser 2 onto
the secondary sheave as shown.
Then compress the spring, and tighten the sec-
ondary sheave nut 1 with locknut wrench 3 .
5-52
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BELT DRIVE ENG
6. Tighten:
nut 90 Nm (9.0 mkg)
NOTE:
When installing the belt, screw M6 (more than
45 mm) bolts 4 to spread apart the secondary
sheave and then install the belt. Make sure the
belt pullout direction is correct.
Install the V-belt and secondary sheave as-
sembly onto the primary sheave side.
Align the a and b during reassembly.
2. Tighten:
secondary sheave nut 1
90 Nm (9.0 mkg)
NOTE:
While holding the secondary sheave with the
primary /secondary sheave holder 2 , tighten
the secondary sheave nut 1 .
Sheave holder
90890-01481
3. Install:
primary sliding sheave 1
spacer
primary sheave nut 2
5-53
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BELT DRIVE ENG
4. Tighten:
primary sheave nut 1 160 Nm (16.0 mkg)
CAUTION:
Before tightening the nut to remount the
primary sheave, make sure that the serra-
tion of the cam brinells deeply into the
serration of the crankshaft.
Also, fully tighten the nut as far as the
clepths while holding down the cam so as
not to allow the serration to disengage.
Apply grease to the thread and seat of the
primary sheave nut.
Recommended lubricant
Shell BT grease 3
NOTE:
While holding the primary sheave with the pri-
mary/secondary sheave holder 2 , tighten the
primary sheave nut 1 .
Sheave holder
90890-01481
5-54
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CYLINDER AND PISTON ENG
5-55
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CYLINDER AND PISTON ENG
REMOVING THE CYLINDER AND PISTON
The following procedure applies to all of the pis-
tons.
1. Remove:
piston pin clip 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller 4 .
2. Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
5-56
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CYLILNDER AND PISTON ENG
EAS00261
2. Measure:
piston-to-cylinder clearance
Micrometer
90890-03008
5-57
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CYLILNDER AND PISTON ENG
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.020 0.045 mm
<Limit>: 0.15 mm
EAS00263
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the pis-
ton crown as shown.
a 10 mm
5-58
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CYLINDER AND PISTON ENG
3. Measure:
piston ring end gap
Out of specification Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
EAS00266
2. Measure:
piston pin outside diameter a
Out of specification Replace the piston
pin.
3. Measure:
piston pin bore diameter b (in the piston)
Out of specification → Replace the piston
pin.
5-59
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CYLINDER AND PISTON ENG
4. Calculate:
piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston
pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter (in the piston)
–
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.002 0.022 mm
<Limit>: 0.072 mm
EAS00271
2. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
A Intake side
5-60
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CYLINDER AND PISTON ENG
3. Lubricate:
piston
piston pin
Recommended lubricant
Engine oil
4. Install:
piston 3
piston pin 2
piston pin clip New 1
NOTE:
Apply engine oil onto the piston pin.
Make sure that the arrow mark a on the piston
points towards the exhaust side of the cylinder.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
5. Install:
gasket New 1
dowel pins
6. Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
cylinder
timing chain guide (exhaust side)
NOTE:
Pass the timing chain through the timing chain
cavity.
5-61
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CRANKCASE AND CRANKSHAFT ENG
58 Nm (5.8 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
5-62
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CRANKCASE AND CRANKSHAFT ENG
58 Nm (5.8 mkg)
10 Nm (1.0 mkg)
24 Nm (2.4 mkg)
5-63
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CRANKCASE AND CRANKSHAFT ENG
CONNECTING ROD
60 Nm (6.0 mSkg)
5-64
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CRANKCASE AND CRANKSHAFT ENG
EAS00385
2. Remove:
right crankcase
CAUTION:
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
3. Remove:
dowel pins
EAS00399
5-65
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CRANKCASE AND CRANKSHAFT ENG
EAS00387
NOTE:
Identify the position of each crankshaft main
journal bearing so that it can be reinstalled in its
original place.
EAS00391
EB413404
Crankshaft runout
Less than 0.05 mm
2. Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear Replace the crankshaft.
3. Measure:
crankshaft-pin-to-big-end-bearing clear-
ance
Out of specification Replace the big end
bearings.
5-66
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CRANKCASE AND CRANKSHAFT ENG
Crankshaft-pin-to-big-end-bearing
clearance
0.040 0.082 mm
5-67
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CRANKCASE AND CRANKSHAFT ENG
CAUTION:
S When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
S After tightening the connecting rod nut to
the specified torque, turn the connecting
rod nut another+90_.
4. Select:
S big end bearings (P1,P2,P3)
NOTE:
S The numbers 1 stamped into the crankshaft
web and the numbers 2 on the connecting
rods are used to determine the replacement
big end bearing sizes.
S “P1,P2” refer to the bearings shown in the
crankshaft illustration.
5-68
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CRANKCASE AND CRANKSHAFT ENG
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.04 0.082 mm
5-69
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CRANKCASE AND CRANKSHAFT ENG
e. If journal bearing inside diameter is “45.03”
and crankshaft journal outside diameter is
“44.98”, then the main journal oil clearance
is:
6. Select:
crankshaft journal bearings (J1, J2)
NOTE:
The numbers 1 stamped into the crankshaft
web and the numbers 2 on the crankcase are
used to determine the replacement crankshaft
journal bearing size.
“P1” refer to the bearings shown in the crank-
shaft illustration.
5-70
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CRANKCASE AND CRANKSHAFT ENG
INSTALLING THE CRANKSHAFT JOURNAL
BEARING
1. Attach:
crankshaft journal bearings
NOTE:
Attach the crankshaft journal bearing to the in-
staller 1 .
2. Install:
crankshaft journal bearings 2
NOTE:
align the projection a on the bearing with the
projection b on the crankcase.
Place an iron 3 plate beneath the crankcase
and press fit until the end of the plain bearing
installer touches the iron plate.
2. Install:
connecting rods 1
NOTE:
The stamped “Y” mark a on the connecting
rods should face towards the left side of the
crankcase.
Install each connecting rod in its original place.
5-71
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CRANKCASE AND CRANKSHAFT ENG
3. Install:
S Connecting rod cap 1
NOTE:
Be sure that the characters on the side of the
cap and connecting rod are aligned.
4. Tighten:
S nuts (connecting rod cap)
16 Nm (1.6 mSkg)+90_
NOTE:
Apply molybdenum disulfide grease to the rod
cap bolt threads and nut surfaces.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
5-72
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CRANKCASE AND CRANKSHAFT ENG
5. Install:
balancer connecting rod
connecting rod cap 60 Nm (6.0 mkg)
CAUTION:
When tightening the nuts be sure to use an
F-type torque wrench.
Without pausing, tighten to full torque
specification. Apply continuous torque be-
tween 57 and 63 Nm (5.7 6.3 mkg). Once
you reach 57 Nm (5.7 mkg) DO NOT STOP
TIGHTENING until final torque is reached. If
the tightening is interrupted between 57
and 63 Nm (5.7 6.3 mkg) loosen the nut
to less than 57 Nm (5.7 mkg) and start
again.
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, apply
grease onto the oil seal lips and apply en-
gine oil onto each bearing.
EAS00418
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
3. Install:
dowel pins
crankcase (left)
5-73
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TRANSMISSION ENG
TRANSMISSION
5-74
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TRANSMISSION ENG
REMOVING THE TRANSMISSION
1. Remove:
crankcase (left)
Refer to “CRANKCASE AND CRANK-
SHAFT”.
2. Remove:
secondary shaft 1
main axle 2
drive axle 3
primary driven gear 4
first pinion gear 5
first wheel gear 6
EAS00425
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
3. Measure:
secondary shaft runout
(with a centering device and dial gauge 1 )
Out of specification Replace the second-
ary shaft.
5-75
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TRANSMISSION ENG
4. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(-s).
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Damage/bends/looseness Replace.
EAS00418
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
3. Install:
dowel pins
crankcase (left)
5-76
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CHAIN DRIVE ENG
CHAIN DRIVE
7 Nm (0.7 mkg)
5-77
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CHAIN DRIVE ENG
7 Nm (0.7 mkg)
5-78
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CHAIN DRIVE ENG
10 Nm (1.0 mkg)
5-79
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TRANSFER ENG
CHECKING THE SWINGARM
1. Check:
swingarm 1
Damage/wear Replace.
2. Check:
pivot shaft 1
collar
bearing
oil seal
Damage/wear Replace.
2. Check:
primary /secondary drive gear 3
primary /secondary driven gear 4
Damage/wear Replace the respective
drive gears and respective drive chains as a
set.
5-80
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CHAIN DRIVE ENG
INSTALLING THE CHAIN DRIVE
1. Install:
chain drive assembly
swingarm
2. Tighten:
swingarm bolt 40 Nm (4.0 mkg)
3. Adjust:
pivot shaft
NOTE:
With your fingers, screw in the pivot shaft until
it touches the collar and then tighten the pivot
shaft to the tightening torque.
Tighten the nut to the tightening torque.
Install the shock absorber and rear wheel after
the swingarm is installed.
4. Fill:
chain drive oil
5. Check:
chain drive oil level
Refer to “CHECKING THE TRANSFER OIL
LEVEL” in chapter 3.
5-81
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COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
INSTALLILNG THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
INSTALLING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
COOLING SYSTEM
RADIATOR
RADIATOR AND OIL COOLER
63 Nm (6.3 mkg)
17 Nm (1.7 mkg)
6-1
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RADIATOR COOL
63 Nm (6.3 mkg)
17 Nm (1.7 mkg)
6-2
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RADIATOR COOL
EAS00455
2. Check:
radiator hoses
Cracks/damage Replace.
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
4. Check:
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6-3
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RADIATOR COOL
EAS00456
EAS00458
EAS00459
6-4
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RADIATOR COOL
3. Bend the lock washer tab along a flat side of
the bolt.
4. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Check:
cooling system
Leaks Repair or replace any faulty part.
6. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-5
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THERMOSTAT COOL
THERMOSTAT
10 Nm (1.0 mkg)
18 Nm (1.8 mkg)
6-6
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THERMOSTAT COOL
EAS00462
1 Thermostat
2 Thermometer
3 Water
4 Container
A Fully closed
B Fully opens
NOTE:
If the accuracy of the thermostat is in doubt, re-
mm place it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover
S thermostat housing
82 ± 2_C 95_C Cracks/damage Replace.
EAS00467
6-7
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THERMOSTAT COOL
2. Install
thermostat cover 10 Nm (1.0 mkg)
NOTE:
Befor installing the thermostat cover to the cylin-
der head, lubricate the O-ring with a thin coat of
litium soap base grease.
3. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:
cooling system
Leaks Repair or replace any faulty part.
5. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
6-8
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WATER PUMP COOL
WATER PUMP
10 Nm (1.0 mkg)
6-9
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WATER PUMP COOL
6-10
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WATER PUMP COOL
EAS00474
2. Check:
water pump seal 1
oil seal
Cracks/damage/wear Replace.
3. Check:
bearing
Roughness Replace.
EAS00475
2. Install:
bearing 1
6-11
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WATER PUMP COOL
3. Install:
water pump seal New 1
CAUTION:
Never apply oil or grease onto the water
pump seal surface.
NOTE:
Install the water pump seal with the water
pump seal installers.
Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .
A Push down
4. Install:
rubber damper New 1
rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
5. Measure:
tilt
Out of specification Repeat steps (3) and
(4).
CAUTION:
Make sure that the rubber damper and rub-
ber damper holder are flush with the impel-
ler.
1 Straightedge
2 Impeller
6-12
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CARB
CHAPTER 7
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
INSTALLILNG THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 7-9
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
CARBURETORS
CARBURETORS
10 Nm (1.0 mkg)
85 Nm (8.5 mkg)
7-1
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CARBURETORS CARB
7-2
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CARBURETORS CARB
1 Starter plunger 1
2 Vacuum chamber cover 1
3 Piston valve spring 1
4 Jet needle kit 1
5 Piston valve 1
6 Screw plug 1
7 Pilot screw 1
8 Fuel drain bolt 1
9 Float chamber cover 1
10 Float chamber gasket 1
11 Float pivot pin 1
7-3
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CARBURETORS CARB
7-4
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CARBURETORS CARB
EB600031
2. Check:
fuel passages
Obstruction Clean.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket 1
Cracks/damage/wear Replace.
5. Check:
float
Damage Replace.
6. Check:
needle valve 1
needle valve seat 2
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
7. Check:
O-ring 3
Damage/wear Replace the needle valve,
needle valve seat and O-ring as a set.
7-5
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CARBURETORS CARB
8. Check:
piston valve 1
Damage/scratches/wear Replace.
piston valve diaphragm 2
Cracks/tears Replace.
9. Check:
vacuum chamber cover 1
piston valve spring 2
Cracks/damage Replace.
10. Check:
jet needle 1
main jet 2
main jet holder 3
pilot jet 4
pilot screw 5
pilot air jet 6
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
11. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
12. Check:
pipes 1
hose joints 2
Cracks/damage Replace.
Obstruction Clean.
Blow out the pipes with compressed air.
7-6
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CARBURETORS CARB
13. Check:
fuel hoses
Cracks/damage/wear Replace.
Obstruction Clean.
Blow out the hoses with compressed air.
EAS00488
1. Install:
O-ring New
washer
pilot screw spring
pilot screw 1
Pilot screw
2 turns out
2. Install:
piston valve
jet needle kit
jet needle holder
piston valve spring
vacuum chamber cover
NOTE:
Insert the end of the piston valve spring onto
the spring guide on the vacuum chamber cov-
er.
Align the tab on the piston valve diaphragm
with the recess in the carburetor body.
7-7
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CARBURETORS CARB
3. Install:
pipe
fuel feed pipes
spring
float chamber air vent hoses
hose joint
copper washer
throttle stop screw
NOTE:
Install the throttle valve lever 1 onto carbure-
tors #1, and #2 between the spring 2 and syn-
chronizing screw 3 .
4. Install:
auto choke unit 1
EB600051
7-8
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CARBURETORS CARB
EAS00496
2. Adjust:
fuel level
7-9
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CARBURETORS CARB
EB600071
1. Check:
S throttle position sensor
2. Adjust:
S throttle position sensor angle
7-10
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CARBURETORS CARB
Closed-throttle resistance
0.56 0.84 kΩ at 20°C
(yellow – black)
7-11
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CARBURETORS CARB
CHECKING THE FUEL PUMP
1. Check:
fuel pump 1
7-12
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AIR INDUCTION SYSTEM CARB
EAS00507
EAS00508
7-13
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AIR INDUCTION SYSTEM CARB
EAS00509
10 Nm
(1.0 mkg)
1 Reed valve
2 Air filter
3 Air cutoff valve
7-14
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AIR INDUCTION SYSTEM CARB
EAS00510
2. Check:
reed valve 1
reed valve stopper
reed valve seat
Cracks/damage Replace the reed valve.
3. Measure:
reed valve bending a
Out of specification Replace the reed
valve.
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
7-15
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ELEC
CHAPTER 8
ELECTRICAL
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHECKING THE SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . 8-8
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
ELECTRICAL
ELECTRICAL COMPONENTS
1 Front brake light switch 13 Pickup coil
2 Rear brake light switch 14 Stator coil
3 Thermo unit 15 Thermo switch
4 Fuel sender 16 Radiator fan
5 Starting circuit cut-off relay 17 Speed sensor
6 Fuel pump relay 18 Horn
7 Flasher relay 19 Throttle position sensor
8 Battery 20 Ignition coil
9 Fuse box 21 Lean angle cut-off switch
10 Starter relay 22 Main switch
11 Rectifire/ regulator
12 Sidestand switch
8-1
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ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
8-2
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ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Main switch 6 Starting circuit cut-off relay
2 Ignition coils 7 Turn signal relay
3 Fuel sender 8 Pump relay
4 Fuel pump 9 Rectifier/ regulator
5 Reset coupler
8-3
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ARRANGEMENT OF THE ELECTRICAL
COMPONENTS AND COUPLERS ELEC
1 Fuse box 6 Box light
2 Battery negative lead
3 Battery positive lead
4 Tail / brake light coupler
5 Starter relay
8-4
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INSTRUMENT FUNCTIONS ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Engine oil change indicator light
(display functions based on the oil indicator)
The display functions based on the engine oil
change indicator can be divided into three major
types:
1. Bulbs disconnections confirmation (light ON)
by main switch ON.
Main switch on activates the oil indicator for
1.4 seconds to allow the user to check if bulb
disconnections have occurred.
2. Oil replacement timing notification (light on)
Turn the key to “ON”.
Hold the reset botton pushed for two to five
seconds.
Release the reset button, and the oil change
indicator light will go off.
NOTE:
If the engine oil is changed before the oil change
indicator light comes on (i.e. before the periodic
oil change interval has been reached), the indi-
cator light must be reset after the oil change for
the next periodic oil change to be indicated at
the correct time. To reset the oil change indica-
tor light before the periodic oil change interval
has been reached, follow the above procedure,
but note that the indicator light will come on for
1.4 seconds after releasing the reset button,
otherwise repeat the procedure.
8-5
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INSTRUMENT FUNCTIONS ELEC
Detection of the second and subsequent re-
set switch on operations with the indicator
light off when 2 5 second reset switch on is
cletected, the indicator will light on for 1.4 se-
conds and then after it has gone off, cumula-
tive distance data will be reset.
Detection of the second and subsequent re-
set switch on operations with the indicator on
when 2 5 second reset switch on is de-
tected, the indicator will go off and cumula-
tive distance data will be reset.
3. Fault code display (blinks) based on self
diagnostics.
If it detects the follwing faults, the igniter will
blink the display of a 5 second ON/OFF code
and then blink the engine oil chamge indica-
tor light at intervals of 3.0 seconds. If multiple
faults are detected, the appropriate faults
codes will be displayed in order of occur-
rence.
Detected fault
Throttle position sensor
Speed sensor
Lean angle cutt-off switch
NOTE:
The fault code is reset by main switch off (ignit-
er unit power off). Also, the display off the fault
code is terminated with the recovery of the cir-
cuits from the fault.
8-6
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INSTRUMENT FUNCTIONS ELEC
V-belt indicator light
Indicates V-belt change timing every 20,000 km
(the V-belt indicator light reset connecter is lo-
cated in the side cover at right).
When change the V-belt, temporarily discon-
nect the short connector of the double-pole for
about 2 5 seconds and then reconnect the
connecter to complete the resetting operation.
8-7
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SWITCHES ELEC
EAS00730
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
8-8
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CHECKING THE SWITCHES ELEC
EAS00731
8-9
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CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
Bulbs A and B are used for headlights and
usually use a bulb holder which must be de-
tached before removing the bulb. The majority
of these bulbs can be removed from their re-
spective socket by turning them counterclock-
wise.
Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.
Bulbs D and E are used for meter and indica-
tor lights and can be removed from their re-
spective socket by carefully pulling them out.
8-10
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CHECKING THE BULBS AND BULB SOCKETS ELEC
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bulb (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
8-11
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CHECKING THE BULBS AND BULB SOCKETS ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
bulb socket (for continuity)
(with the pocket tester)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
8-12
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IGNITION SYSTEM ELEC
DAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 Pickup coil
6 Main switch
7 Battery
8 Main fuse
19 Igniter unit
20 Ignition coil
21 Spark plug
23 Lean angle cut-off switch
35 Engine stop switch
71 Ignition fuse
8-13
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IGNITION SYSTEM ELEC
EAS00737 EAS00739
TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no S Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Check:
1. Main and ignition fuses Open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Spark plugs S Is the battery OK?
4. Ignition spark gap
5. Spark plug cap resistance YES NO
6. Ignition coil resistance
7. Pickup coil resistance
8. Main switch S Clean the battery
9. Engine stop switch terminals.
10. Sidestand switch S Recharge or replace
11. Lean angle cut-off switch the battery.
12. Wiring connections
(of the entire ignition system)
NOTE:
Before troubleshooting, remove the following EAS00741
part(-s):
1) Leg shield 3. Spark plugs
2) Footrest board S The following procedure applies to all of the
S Troubleshoot with the following special spark plugs.
tool(-s). S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Ignition checker Refer to “CHECKING THE SPARK PLUGS”
90890-06754 in CHAPTER 3.
Pocket tester
90890-03112 Standard spark plug
CR7E (NGK)
EAS00738 Spark plug gap
1. Main and ignition fuses 0.7 0.8 mm
S Check the main and ignition fuses for conti- S Is the spark plug in good condition, it is of the
nuity. correct type, and its gap within specifica-
Refer to “CHECKING THE FUSES” in tion?
CHAPTER 3.
S Are the main and ignition fuses OK? YES NO
8-14
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IGNITION SYSTEM ELEC
EAS00743
NO YES
S Measure the primary coil resistance.
EAS00745
S Connect the pocket tester (Ω 1k) to the
ignition coil as shown.
5. Spark plug cap resistance S Measure the secondary coil for the specified
resistance.
S The following procedure applies to all of the
spark plug caps. Tester posltlve probe red/black
S Remove the spark plug cap. Tester negative probe spark plug lead
S Connect the pocket tester (Ω 1k range) to
the spark plug cap as shown.
S Measure the spark plug cap resistance.
8-15
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IGNITION SYSTEM ELEC
EAS00750
S Disconnect the pickup coil coupler from the 10. Sidestand switch
wireharness.
S Check the neutral switch for continuity.
S Connect the pocket tester (Ω 100) to the
Refer to “CHECKING THE SWITCHES”.
pickup coil terminal as shown.
S Is the neutral switch OK?
Tester positive probe – gray 1
Tester negative probe – black/blue 2 YES NO
Replace the
sidestand switch.
EAS00754
YES NO
12. Wiring
8-16
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ELECTRIC STARTING SYSTEM ELEC
EAS00755
8-17
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ELECTORIC STARTING SYSTEM ELEC
6 Main switch
7 Battery
8 Main fuse
9 Starter relay
10 Starter motor
11 Diode
12 Starting circuit cut-off relay
18 Sidestand switch
34 Start switch
35 Engine stop switch
37 Front brake light switch
43 Rear brake light switch
69 Signal fuse
71 Ignition fuse
8-18
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ELECTRIC STARTING SYSTEM ELEC
EAS00756
8-19
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ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING 2. Battery
The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
Check: CHAPTER 3.
1. Main, signal and ignition fuses Open-circuit voltage
2. Battery 12.8 V or more at 20_C
3. Starter motor
4. Starting circuit cut-off relay S Is the battery OK?
5. Starter relay YES NO
6. Main switch
7. Engine stop switch
8. Brake light switch (front and rear) S Clean the battery
9. Sidestand switch terminals.
10. Start switch S Recharge or
11. Wiring connections replace the battery.
(of the entire starting system)
NOTE: EAS00758
Pocket tester
90890-03112
EAS00738
YES NO
8-20
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ELECTRIC STARTING SYSTEM ELEC
EAS00759
4. Starting circuit cut-off relay Does the starter relay have continuity be-
tween red and black?
Disconnect the starting circuit cut-off relay
coupler from the wireharness. YES NO
Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the starting circuit cut-off relay
coupler as shown. Replace the starter
relay.
Battery positive terminal
red/black 1
Battery negative terminal
EAS00749
YES NO
EAS00750
Does the starting circuit cut-off relay have 7. Engine stop switch
continuity between green/yellow 3 and Check the engine stop switch for continuity.
green/yellow 4 ? Refer to “CHECKING THE SWITCHES”.
YES NO
Replace the starting
circuit cut-off relay.
Replace the right
EAS00761
handlebar switch.
5. Starter relay
EAS00751
Disconnect the starter relay coupler from the
wireharness. 8. Brake light switch (front and rear)
Connect the pocket tester (Ω 1) and bat- Check the brake light switch for continuity.
tery (12 V) to the starter relay coupler as Refer to “CHECKING THE SWITCHES”.
shown. Is the brake switch OK?
Battery positive terminal green/yellow 1 YES NO
Battery negative terminal black 2
Tester positive probe red 3
Replace the brake
Tester negative probe black 4
light switch.
8-21
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ELECTRIC STARTING SYSTEM ELEC
EAS00752
9. Sidestand switch
Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the sidestand switch OK?
YES NO
Replace the
sidestand switch.
EAS00764
YES NO
11. Wiring
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly con-
nected and without defects?
YES NO
8-22
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ELECTRIC STARTING SYSTEM ELEC
STARTER MOTOR
10 Nm (1.0 mkg)
8-23
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ELECTRIC STARTING SYSTEM ELEC
8-24
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ELECTRIC STARTING SYSTEM ELEC
EAS00770
3. Measure:
S mica (insulation) undercut a
Out of specification Scrape the mica (in-
sulation) to the proper measurement with a
hacksaw blade which has been grounded to
fit the commutator.
NOTE:
The mica (insulation) of the commutator must
be undercut to ensure proper operation of the
commutator.
4. Measure:
S armature coil resistances (continuity and in-
sulation)
Out of specification Replace the starter
motor.
Pocket tester
90890-03112
6. Measure:
brush spring force
Fatigue/out of specification Replace the
brush springs as a set.
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing 1
oil seal 2
bushing 3
Damage/wear Replace the defective
part(-s).
EAS00772
2. Install:
washers 1
armature coil 2
o-ring 3
starter motor yoke 4
NOTE:
To prevent damaging the brushes during instal-
lation push down on the brush springs.
8-26
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ELECTRIC STARTING SYSTEM ELEC
3. Install:
o-ring 1 New
washers 2
front bracket 3
o-ring 4 New
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.
4. Install:
bolts 1 7 Nm (0.7 mkg)
8-27
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CHARGING SYSTEM ELEC
YP80400
CHARGING SYSTEM
CIRCUIT DIAGRAM
2 A.C. magneto
3 Rectifire/ regulator
7 Battery
8 Main fuse
8-28
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CHARGING SYSTEM ELEC
EAS00774 EAS00775
YES NO
8-29
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CHARGING SYSTEM ELEC
YES NO
5. Wiring
S Check the wiring connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly
connected and without defects?
YES NO
8-30
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LIGHTING SYSTEM ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4 Box light switch 46 Headlight (Hi)
5 Box light 47 Headlight (Lo)
6 Main switch 48 Auxiliary light
7 Battery 53 Tail / brake light
8 Main fuse 54 Licence plate ligtht
36 Light switch 57 Hi beam indicator light
39 Pass swtich 58 Meter light
40 Dimmer switch 70 Headlight fuse
8-31
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LIGHTING SYSTEM ELEC
EB805010 EB802401
TROUBLESHOOTING 2. Battery
Any of the following fail to light: headlight, Check the condition of the battery.
high beam indicator light, taillight, auxilia- Refer to “CHECKING AND CHARGING THE
ry light or meter light. BATTERY” in chapter 3.
1) Front cawling
3. Main switch
2) Handlebar cover
Troubleshoot with the following special Check the main switch for continuity.
tool(-s). Refer to “CHECKING THE SWITCHES”.
Is the main switch OK?
YES NO YES NO
8-32
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LIGHTING SYSTEM ELEC
EB805401
EB805403
6. Pass switch
Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the pass switch OK?
YES NO
EB805403
YES NO
EB805404
8. Wiring
Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the lighting system’s wiring properly con-
nected and without defects?
8-33
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LIGHTING SYSTEM ELEC
EB805410
YES NO
Replace the
headlight bulb,
socket or both.
2. High beam indicator light bulb and socket Set the main switch to “ON”.
Check the high beam indicator light bulb and Set the light switch to “ ”.
socket for continuity. Set the dimmer switch to “ ” or “ ”.
Refer to “CHECKING THE BULBS AND Measure the voltage (12 V) of yellow (green)
BULB SOCKETS”. 2 on the headlight coupler (headlight side).
Is the high beam indicator light bulb and sock- Is the voltage within specification?
et OK?
YES NO
YES NO
This circuit is OK. The wiring circuit
Replace the high from the main switch
beam indicator bulb, to the headlight
socket or both. coupler is faulty and
must be repaired.
3. Voltage
EB805411
Connect the pocket tester (DC 20 V) to the 2. Meter light fails to come on.
headlight and high beam indicator light cou-
plers as shown. 1. Meter light bulb and socket.
A When the dimmer switch is set to “ ” Check the meter light bulb and socket for
B When the dimmer switch is set to “ ” continuity.
Refer to “CHECKING THE BULBS AND
Headlight coupler (wireharness side) BULB SOCKETS”.
Are the meter light bulb and socket OK?
B A
YES NO
8-34
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LIGHTING SYSTEM ELEC
2. Voltage 2. Voltage
Connect the pocket tester (20 V) to the meter Connect the pocket tester (DC 20 V) to the
assembly coupler (wireharness side) as tail/brake light coupler (wireharness side) as
shown. shown.
Tester positive probe blue 1 Tester positive probe blue/red 1
Tester negative probe black 2 Tester negative probe black 2
Set the main switch to “ON”. Set the main switch to “ON”.
Set the light switch to “ ” or “ ”. Set the light switch to “ ” or “ ”.
Measure the voltage (12 V) of blue 1 on the Measure the voltage (12 V) of blue/red 1 on
meter assembly coupler (wireharness side). the tail/brake light coupler (wireharness
Is the voltage within specification? side).
Is the voltage within specification?
YES NO YES NO
This circuit is OK. The wiring circuit This circuit is OK. The wiring circuit
from the main switch from the main switch
to the meter to the tail/brake light
assembly coupler is coupler is faulty and
faulty and must must be repaired.
be repaired.
EB805412 EB805413
3. A tail/brake light fails to come on. 4. The auxiliary light fails to come on.
(for Europe)
1. Tail/brake light bulb and socket
1. Auxiliary light bulb and socket
Check the tail/brake light bulb and socket for
continuity. Check the auxiliary light bulb and socket for
Refer to “CHECKING THE BULBS AND continuity.
BULB SOCKETS”. Refer to “CHECKING THE BULBS AND
Are the tail/brake light bulb and socket OK? BULB SOCKETS”.
Are the auxiliary light bulb and socket OK?
YES NO
YES NO
Replace the tail/
brake light bulb, Replace the auxiliary
socket or both. light bulb, socket or
both.
8-35
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LIGHTING SYSTEM ELEC
2. Voltage 2. Voltage
Connect the pocket tester (DC 20 V) to the Connect the pocket tester (20 V) to the li-
auxiliary light couplers (wireharness side) as cence plate light coupler (wireharness side)
shown. as shown.
Tester positive probe blue/red 1 Tester positive probe blue/red 1
Tester negative probe black 2 Tester negative probe black 2
YES NO
8-36
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SIGNAL SYSTEM ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-37
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SIGNAL SYSTEM ELEC
6 Main switch
7 Battery
8 Main fuse
19 Igniter unit
24 Reset coupler
25 Speed sensor
37 Front brake light switch
41 Horn switch
42 Turn signal switch
43 Rear brake light switch
44 Horn
45 Flasher relay
49 Front turn signal light (Left)
50 Front turn signal light (Right)
51 Rear turn signal light (Left)
52 Rear turn signal light (Right)
53 Tail / brake light
56 Turn signal indicator light
59 V-belt indicator light
60 Engine oil change indicator light
61 Clock
62 Speedometer
63 Water temperature gauge
64 Fuel gauge
65 Thermo unit
66 Fuel level sender
68 Backup fuse
69 Signal fuse
71 Ignition fuse
8-38
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SIGNAL SYSTEM ELEC
EAS00794 EAS00749
8-39
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SIGNAL SYSTEM ELEC
Br P
Br P
YES NO YES NO
2. Brakelight switch
Check the brakelight switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Is the brake switch OK?
YES NO
YES NO
Replace the
Replace the horn. brakelight switch.
4. Voltage 3. Voltage
Connect the pocket tester (20 V DC) to the Connect the pocket tester (20 V DC) to the
horn at the pink terminal as shown. tail/brake light coupler (wireharness side)
as shown.
8-40
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SIGNAL SYSTEM ELEC
YES NO
5. Voltage
Connect the pocket tester (20 V DC) to the
turn signal light coupler (wireharness side)
as shown.
A Front turn signal light
B Rear turn signal light
Left turn signal light Set the main switch to “ON”.
Tester positive probe chocolate 1 Set the turn signal switch to “ ” or “ ”.
Tester negative probe ground Measure the voltage (12 V) of the choco-
Right turn signal light late 1 or dark green 2 on the meter as-
Tester positive probe dark green 2 sembly coupler (wireharness side).
Tester negative probe ground Is the voltage iwthin specification?
A B
YES NO
YES NO
8-42
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SIGNAL SYSTEM ELEC
4. The V-belt indicator light fails to come on. 5. Fuel gauge fails to operate
1. V-belt indicator light bulb and socket 1. Fuel sender
Check the V-belt indicator light bulb and Remove the fuel sender from the fuel tank.
socket for continuity. Disconnect the fuel sender coupler from the
Are the V-belt indicator light bulb and socket wireharness.
OK? Connect the pocket tester (Ω 10) to the
fuel sender coupler lead.
YES NO
Tester positive probe green 1
Tester negative probe ground
Replace the V-belt
indicator light bulb,
socket or both.
YES NO
8-43
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SIGNAL SYSTEM ELEC
Set the main switch to “ON”. 6. Water temperature gauge fails to operate
Measure the voltage (12 V) of brown 1 at 1. Thermo unit
the meter assembly coupler.
(wireharness side) Remove the thermo unit from the cylinder
Is the voltage within specification? head.
Connect the pocket tester (Ω 10) to the
YES NO thermo unit.
Tester positive probe
The wiring circuit Thermo unit terminal 1
from the signal fuse Tester negative probe
to the meter Thermo unit body 2
assembly coupler
(wireharness side) is
faulty and must be
repaired.
3. Fuel gauge
Connect the fuel sender coupler. Measure the thermo unit resistance.
Move the float to “UP” 1 or “DOWN” 2 . Thermo unit resistance:
69 Ω at 80C
22 Ω at 120C
Is the thermo unit OK?
YES NO
This circuit is OK. Replace the fuel Tester positive probe brown 1
gauge. Tester negative probe ground
8-44
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SIGNAL SYSTEM ELEC
YES NO
YES NO
8-45
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COOLING SYSTEM ELEC
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
6 Main switch
7 Battery
8 Main fuse
31 Thermo switch
32 Fan motor
63 Water temperature gauge
65 Thermo unit
69 Signal fuse
72 Radiator fan fuse
8-46
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COOLING SYSTEM ELEC
EB807010
Check:
Clean the battery
1. Main, and radiator fan motor fuses
terminals.
2. Battery
Recharge or
3. Main switch
replace the battery.
4. Radiator fan motor
5. Thermo switch EB802411
6. Wiring
3. Main switch
(the entire cooling system)
NOTE: Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Before troubleshooting, remove the following
Is the main switch OK?
part(-s):
1) Footrest board
YES NO
2) Legshield
Truobleshooting with the following special tool
(-s). Replace the main
switch.
YES NO
2. Battery
Check the condition of the battery. Does the radiator fan motor turn?
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. YES NO
Open-circuit voltage
12.8 V or more at 20C The radiator fan
motor is faulty and
must be replaced.
8-47
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COOLING SYSTEM ELEC
EB807400
YES NO
EB807402
6. Thermo switch
Remove the thermo switch from the radiator.
Connect the pocket tester (Ω 1) to the ther-
mo switch 1 as shown.
WARNING
Immerse the thermo switch in a container
filled with coolant 2 . Handle the thermo switch with special
NOTE: care.
Make sure that the thermo switch terminals Never subject the thermo switch to
do not get wet. strong shocks. If the thermo switch is
dropped, replace it.
Place a thermometer 3 in the coolant.
Slowly heat the coolant, then let it cool to the Thermo switch
specified temperature as indicated in the 23 Nm (2.3 mkg)
table. Three bond sealock 10
Check the thermo switch for continuity at the
temperatures indicated in the table. A The thermo switch circuit is open and the ra-
diator fan is off.
B The thermo switch circuit is closed and the
radiator fan is on.
8-48
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COOLING SYSTEM ELEC
92 ± 3 C 98 ± 3 C
YES NO
EB807403
7. Wiring
Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the cooling system’s wiring properly con-
nected and without defects?
YES NO
8-49
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FUEL PUMP SYSTEM ELEC
6 Main switch
7 Battery
8 Main fuse
13 Fuel pump relay
17 Fuel pump
19 Ignitor unit
35 Engine stop switch
71 Ignition fuse
8-50
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FUEL PUMP SYSTEM ELEC
EB808010
8-51
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FUEL PUMP SYSTEM ELEC
EAS00816 EAS00749
2. Battery
Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20C
Is the battery OK?
Does the fuel pump relay have continuity
YES NO between red/black and blue/black?
YES NO
Clean the battery
terminals.
Recharge or Replace the fuel
replace the battery. pump relay.
8-52
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FUEL PUMP SYSTEM ELEC
EAS00817
YES NO
YES NO
8. Wiring
Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the fuel pump system’s wiring properly
connected and without defects?
YES NO
8-53
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FUEL PUMP SYSTEM ELEC
EAS00819
1. Check:
fuel pump operation
8-54
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AUTO CHOKE SYSTEM ELEC
7 Battery
8 Main fuse
14 Thermo switch
15 Auto choke 1
16 Auto choke 2
19 Igniter
68 Backup fuse
8-55
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AUTO CHOKE SYSTEM ELEC
EAS00821
YES NO
EAS00739
2. Battery
Check the condition of the battery.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage
12.8 V or more at 20C
Is the battery OK?
YES NO
8-56
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AUTO CHOKE SYSTEM ELEC
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Thermo switch
23 Nm (2.3 mkg)
Three bond sealock 10 Measure the auto choke unit resistance.
YES NO
55 C 60 ± 3 C
5. Igniter unit
Does the thermo switch operate properly as When the engine is running at a speed of at
described above? least 800 r/min.
OK if one of the auto chokes is on.
YES NO
NO
EAS00826
6. Wiring
EAS00825
The following procedure applies to all to the Check the entire auto choke system’s wir-
auto choke unit. ing.
4. Auto choke unit Refer to “CIRCUIT DIAGRAM”.
Is the auto choke system’s wiring properly
Remove the auto choke unit from the carbu- connected and without defects?
retor.
Connect the pocket tester to the auto choke NO
unit coupler as shown.
Tester positive probe black 1 Properly connect or
Tester negative probe black 2 repair the auto choke
system’s wiring.
8-57
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SELF-DIAGNOSIS ELEC
SELF-DIAGNOSIS
The XP500 features a self-diagnosing system for following circuit (-s).
1. Throttle position sensor (TPS)
2. Speed sensor
3. Lean angle cut-off switch
1. ENGINE TROUBLE INDICATOR LIGHT
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the engine oil change indicator light (irrespective of whether the engine is running or not).
NOTE:
The XP500 features a self-diagnosing system.
In the XP500, when the main switch is turned on the “Engine oil change indicator light” in the meter
assembly comes on for 0.5 seconds then goes off. However, if there is a malfunction, it comes on for 0.5
seconds, goes off and then begins flashing. (However, it is on while the engine is running.)
8-58
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SELF-DIAGNOSIS ELEC
Display order on the engine warning light
When one item being monitored
Repetition
Repetition
Repetition
Light on
Light off
Repetition
8-59
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SELF-DIAGNOSIS ELEC
EAS00835
1. Wire harness
TROUBLESHOOTING
Check the wire harness for continuity.
The tachometer starts to display the self- Refer to “CIRCUIT DIAGRAM”.
diagnosis sequence. Is the wire harness OK?
Check: YES NO
1. Throttle position sensor
2. Speed sensor
3. Lean angle cut-off switch Repair or replace the
wire harness.
NOTE:
Before troubleshooting, remove the following
part(-s): EB812401
1) Front cowling
2. Throttle position sensor
2) Footrest board
Troubleshoot with the following special Check the throttle position sensor for conti-
tool(-s). nuity.
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR” in
Pocket tester chapter 6.
90890-03112 Is the throttle position sensor OK?
EAS00836 YES NO
1. Throttle position sensor
CIRCUIT DIAGRAM
Replace the igniter Replace the throttle
unit. position sensor.
19 Igniter unit
22 Throttle position sensor
8-60
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SELF-DIAGNOSIS ELEC
EB812401
2. Speed sensor
CIRCUIT DIAGRAM 2. Speedometer
Check the speedometer operation.
Is the speedometer OK?
YES NO
19 Igniter unit
23 Lean angle cut-off suitch
1. Wireharness
19 Igniter unit Check the wireharness for continuity.
25 Speed sensor Refer to “CIRCUIT DIAGRAM”.
Is the wireharness OK?
1. Wireharness
YES NO
Check the wireharness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wireharness OK? Repair or replace the
wireharness.
YES NO
8-61
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SELF-DIAGNOSIS ELEC
EB812401
YES NO
8-62
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TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLILNG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
inspection, adjustment, and replacement of parts.
9-1
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INCORRECT ENGINE IDLING SPEED/ POOR TRBL
MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG
Switches and wiring Starting system
Faulty main switch Faulty starter motor
Faulty engine stop switch Faulty starter relay
Broken or shorted wiring Faulty starting circuit cut-off relay
Faulty front, rear or both brake switches Faulty starter clutch
Faulty start switch
Faulty sidestand switch
Improperly grounded circuit
Loose connections
EAS00847
9-2
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FAULTY CLUTCH/OVERHEATING/ TRBL
OVERCOOLING SHTG
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT SCOOTER WILL POOR STARTING PERFORMANCE
NOT MOVE V-belt
V-belt V-belt slips
Bent, damaged or worn V-belt Oil or grease on the V-belt
Slipping V-belt Primary sliding sheave
Primary pulley cam and primary pulley slid- Faulty operation
er Worn pin groove
Damaged or worn primary pulley cam Worn pin
Damaged or worn primary pulley slider Clutch shoe(-s)
Clutch spring(-s) Bent, damaged or worn clutch shoe
Damaged clutch spring POOR SPEED PERFORMANCE
Transmission gear(-s) V-belt
Damaged transmission gear Oil or grease on the V-belt
CLUTCH SLIPS Primary pulley weight(-s)
Clutch shoe spring(-s) Faulty operation
Damaged, loose or worn clutch shoe spring Worn primary pulley weight
Clutch shoe(-s) Primary fixed sheave
Damaged or worn clutch shoe Worn primary fixed sheave
Primary sliding sheave Primary sliding sheave
Seized primary sliding sheave Worn primary sliding sheave
Secondary fixed sheave
Worn secondary fixed sheave
Secondary sliding sheave
Worn secondary sliding sheave
EAS00855
OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Carburetor(-s)
Cylinder head(-s) and piston(-s) Incorrect main jet setting
Heavy carbon buildup Incorrect fuel level
Engine oil Air leak at carburetor joint
Incorrect oil level Air filter
Incorrect oil viscosity Clogged air filter element
Inferior oil quality CHASSIS
COOLING SYSTEM Brake(-s)
Coolant Dragging brake
Low coolant level ELECTRICAL SYSTEMS
Radiator Spark plug(-s)
Damaged or leaking radiator Incorrect spark plug gap
Faulty radiator cap Incorrect spark plug heat range
Bent or damaged radiator fins Ignition system
Water pump Faulty ignitor unit
Damaged or defective water pump
Thermostat
Thermostat stays closed
Oil cooler
EAS00856
Clogged or damaged oil cooler
Hose(-s) and pipe(-s)
OVERCOOLING
COOLING SYSTEM
Damaged hose
Thermostat
Improperly connected hose
Thermostat stays open
Damaged pipe
Improperly connected pipe
9-3
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POOR BRAKING PERFORMANCE/FAULTY TRBL
FRONT FORK LEGS/UNSTABLE HANDLING SHTG
EAS00857 EAS00861
EAS00862
UNSTABLE HANDLING
Handlebar Tire(-s)
Bent or improperly installed handlebar Uneven tire pressures (front and rear)
Steering Incorrect tire pressure
Improperly installed upper bracket Uneven tire wear
Improperly installed lower bracket Wheel(-s)
(improperly tightened ring nut) Incorrect wheel balance
Bent steering stem Deformed cast wheel
Damaged ball bearing or bearing race Damaged wheel bearing
Front fork leg(-s) Bent or loose wheel axle
Uneven oil levels (both front fork legs) Excessive wheel runout
Uneven fork spring tension (both front fork Frame
legs) Bent frame
Broken fork spring Damaged steering head pipe
Bent or damaged inner tube Improperly installed bearing race
Bent or damaged outer tube
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
Rear shock absorber assembly(-ies)
Faulty rear shock absorber spring
Leaking oil or gas
9-4
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TRBL
FAULTY SIGNALING SYSTEM SHTG
EAS00866
9-5
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XP500 WIRING DIAGRAM (for EUR)
COLOR CODE
B ........ Black Br / G . . . . . Brown / Green
Br . . . . . . . Brown Br / L . . . . . Brown / Blue
Ch . . . . . . Chocolate Br / R . . . . . Brown / Red
Dg . . . . . . Dark green Br / Y . . . . . Brown / Yellow
G ....... Green Br / W . . . . . Brown / White
Gy . . . . . . Gray G/R . . . . . Green / Red
L ........ Blue G / Y. . . . . . Green / Yellow
Lg . . . . . . . Light green L/B . . . . . . Blue / Black
O ....... Orange L/G . . . . . . Blue / Green
P ........ Pink L/R . . . . . . Blue / Red
R........ Red L/Y . . . . . . Blue / Yellow
Y ........ Yellow L/W . . . . . Blue / White
W ....... White R/B. . . . . . Red / Black
B/R. . . . . . Black / Red R/Y. . . . . . Red / Yellow
B/Y . . . . . . Black / Yellow R/W . . . . . Red / White
B/W . . . . . Black / White Y/B . . . . . . Yellow / Black
B/L . . . . . . Black / Blue Y/R. . . . . . Yellow / Red
COLOR CODE
B ........ Black Br / G . . . . . Brown / Green
Br . . . . . . . Brown Br / L . . . . . Brown / Blue
Ch . . . . . . Chocolate Br / R . . . . . Brown / Red
Dg . . . . . . Dark green Br / Y . . . . . Brown / Yellow
G ....... Green Br / W . . . . . Brown / White
Gy . . . . . . Gray G/R . . . . . Green / Red
L ........ Blue G / Y. . . . . . Green / Yellow
Lg . . . . . . . Light green L/B . . . . . . Blue / Black
O ....... Orange L/G . . . . . . Blue / Green
P ........ Pink L/R . . . . . . Blue / Red
R........ Red L/Y . . . . . . Blue / Yellow
Y ........ Yellow L/W . . . . . Blue / White
W ....... White R/B. . . . . . Red / Black
B/R. . . . . . Black / Red R/Y. . . . . . Red / Yellow
B/Y . . . . . . Black / Yellow R/W . . . . . Red / White
B/W . . . . . Black / White Y/B . . . . . . Yellow / Black
B/L . . . . . . Black / Blue Y/R. . . . . . Yellow / Red