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Инструкция для YAMAHA XV16ATLC (1998), XV16ATL (1998), XV16ALC (1998), XV16AL (1998)

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5 - 118

ENG

CRANKSHAFT AND CONNECTING RODS

4. Select:

• big end bearings (P

1

 ~ P

2

)

NOTE:
• The numbers 

a stamped into the crank-

shaft web and the numbers 

b on the con-

necting rods are used to determine the
replacement big end bearing sizes.

• “P

1

” ~ “P

2

” refer to the bearings shown in

the crankshaft illustration.

▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼

For example, if the connecting rod “P

1

” and

the crankshaft web “P

1

” numbers are “6”

and “2” respectively, then the bearing size
for “P

1

” is:

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

“P

1

” (connecting rod) – “P

1

” (crank-

shaft web) =
6 – 2 = 4 (green)

BIG END BEARING COLOR CODE

1

blue

2

black

3

brown

4

green

5

yellow

5. Measure:

• crankshaft journal diameter 

a

Out of specification 

→ Replace the crank-

shaft.

NOTE:
Measure the diameter of each crankshaft
journal at two places.

Crankshaft journal diameter

49.968 ~ 49.980 mm
(1.967 ~ 1.968 in)

5

Страница:
(338 из 449)
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Оглавление инструкции
  • Страница 1 из 450
    XV16AL/XV16ALC XV16ATL/XV16ATLC SERVICE MANUAL LIT-11616-12-56 4WM-28197-E0
  • Страница 2 из 450
    EAS00001 XV16AL/XV16ALC XV16ATL/XV16ATLC SERVICE MANUAL  1998 by Yamaha Motor Corporation, U.S.A. First Edition, October 1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N
  • Страница 3 из 450
    EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
  • Страница 4 из 450
    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is
  • Страница 5 из 450
    ******** 1 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system 8 Troubleshooting
  • Страница 6 из 450
    ******** TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE CARBURETION GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 CARB 6 – ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 7 TRBL SHTG 8
  • Страница 7 из 450
    GEN INFO CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL CODE
  • Страница 8 из 450
    MOTORCYCLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. 1 EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This
  • Страница 9 из 450
    FEATURES GEN INFO EAS00019 FEATURES Twin spark plugs For this model, two spark plugs are incorporated in each cylinder. By using two spark plugs, the combustion time in the combustion chamber is shortened in an attempt to improve torque. Speed sensor The speed sensor is installed to the crankcase
  • Страница 10 из 450
    FEATURES GEN INFO Auto decompression mechanism The auto decompression mechanism occurs when the engine is started. When the engine is started, the decompression cam and pin raise the exhaust valve lifters, push the push rods, move the rocker arms, and lower the exhaust valves which compress the
  • Страница 11 из 450
    FEATURES GEN INFO Operation 1. When the starter switch is pushed, electricity is run to the decompression solenoid 1 causing it to push out the decompression solenoid rod 2. 2. When the decompression solenoid rod is pushed out, the decompression connector 3 moves the decompression levers 4 in the
  • Страница 12 из 450
    FEATURES GEN INFO Hydraulic valve lifters Since the hydraulic valve-lifting mechanism maintains a valve clearance of zero, periodic valve clearance adjustments are unnecessary. The advantages of this system as compared to conventional techniques include the following: mechanical noise is reduced,
  • Страница 13 из 450
    IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling, always
  • Страница 14 из 450
    IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. 1 EAS00024
  • Страница 15 из 450
    CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. • • • Disconnect: lead coupler connector 2. • • • Check: lead coupler connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect
  • Страница 16 из 450
    SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS 1 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
  • Страница 17 из 450
    SPECIAL TOOLS Tool No. Tool name/Function GEN INFO Illustration Valve guide remover (6 mm) YM-4064-A This tool is used to remove or install the valve guides. Valve guide installer YM-4065-A This tool is used to install the valve guides. Valve guide reamer YM-4066 This tool is used to rebore the new
  • Страница 18 из 450
    SPECIAL TOOLS Tool No. 1 Compression gauge YU-33223 Compression gauge adapter YU-33223-3 Tool name/Function Compression gauge These tools are used to measure engine compression. Steering nut wrench YU-33975 This tool is used to loosen or tighten the steering stem ring nuts. Oil filter wrench
  • Страница 19 из 450
    SPEC CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 ENGINE SPECIFICATIONS ........................................................................... 2-2 CHASSIS SPECIFICATIONS
  • Страница 20 из 450
    GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Dimensions Overall length Overall width Overall height 2 Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo,
  • Страница 21 из 450
    ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total
  • Страница 22 из 450
    ENGINE SPECIFICATIONS Item 2 SPEC Standard Engine oil pump Oil pump type Inner rotor to outer rotor tip clearance Inner rotor outer rotor 2 to oil pump housing clearance (feed pump) Inner rotor outer rotor 1 to oil pump housing clearance (scavenging pump) Transfer oil pump Oil pump type Inner rotor
  • Страница 23 из 450
    SPEC ENGINE SPECIFICATIONS Item Standard Measurement A Limit 36.594 ~ 36.649 mm (1.4407 ~ 1.4429 in) 31.950 ~ 32.050 mm (1.2579 ~ 1.2618 in) Measurement B 36.494 mm (1.4368 in) 31.850 mm (1.2539 in) Camshaft exhaust cam dimensions A 2 B Measurement A 36.554 ~ 36.654 mm (1.4391~ 1.4431 in) 31.950 ~
  • Страница 24 из 450
    ENGINE SPECIFICATIONS Item Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust 2 Valve guide inside diameter Intake Exhaust SPEC Standard 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 0.7 ~ 1.3 mm (0.028 ~ 0.051 in) 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.960 ~ 5.975 mm (0.2346 ~ 0.2352
  • Страница 25 из 450
    ENGINE SPECIFICATIONS Item Standard SPEC Limit Spring tilt Intake ---- Exhaust ---- Winding direction (top view) Intake Exhaust Outer springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust 2.5˚ /2.4 mm (2.5˚/0.094 in)
  • Страница 26 из 450
    ENGINE SPECIFICATIONS Item Standard Winding direction (top view) Intake Exhaust Limit Clockwise Clockwise ------- 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 22.990 ~ 23.010 mm (0.9051 ~ 0.9059 in) 0.0156 ~ 0.0420 mm (0.0006 ~ 0.0017 in) ---- 293.45 ~ 293.95 mm (11.553 ~ 11.573 in) 0.3 mm (0.012 in)
  • Страница 27 из 450
    ENGINE SPECIFICATIONS Item SPEC Standard Limit Piston rings Top ring B T Ring type Dimensions (B × T) End gap (installed) Barrel 1.2 × 3.8 mm (0.047 × 0.150 in) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) Ring side clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) ------0.65 mm (0.026 in) 0.12 mm (0.0047 in) 2nd
  • Страница 28 из 450
    ENGINE SPECIFICATIONS Item Big end radial clearance E 2 Crankshaft journal-to-crankshaftjournal bearing clearance Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever) Friction plates Thickness Plate quantity
  • Страница 29 из 450
    ENGINE SPECIFICATIONS Item Shifting mechanism Shift mechanism type Max. shift fork guide bar bending Shift fork thickness Air filter type Fuel pump Pump type Model (manufacturer) Output pressure Carburetor Model (manufacturer) × quantity Throttle cable free play (at the flange of the throttle grip)
  • Страница 30 из 450
    CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item 2 Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel
  • Страница 31 из 450
    CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Model (manufacturer) SPEC Standard With tube 150/80 B16 71H D404 (DUNLOP)/ G702 (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm2, 36 psi) 90 kg (198 lb) ~ Maximum load* 280 kPa (2.8 kg/cm2, 40 psi) High-speed riding
  • Страница 32 из 450
    CHASSIS SPECIFICATIONS SPEC Item 2 Standard Limit Master cylinder inside diameter Caliper cylinder inside diameter Steering Steering bearing type Front suspension Suspension type Front fork type Front fork travel Spring Free length 12.7 mm (0.5 in) 33.9 mm (1.33 in) and 30.2 mm (1.19 in) -------
  • Страница 33 из 450
    CHASSIS SPECIFICATIONS Item Drive belt Model (manufacturer) Drive belt slack (on a sidestand) Drive belt slack (on a suitable stand) Standard UBD-0568 7.5 ~ 13 mm (0.30 ~ 0.51 in) 14 ~ 21 mm (0.55 ~ 0.83 in) SPEC Limit ---------- 2 2 - 14
  • Страница 34 из 450
    ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item 2 System voltage Ignition system Ignition system type Ignition timing Advanced timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition
  • Страница 35 из 450
    ELECTRICAL SPECIFICATIONS Item Neutral indicator light Turn signal indicator light High beam indicator light Fuel level indicator light Engine trouble indicator light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Commutator
  • Страница 36 из 450
    ELECTRICAL SPECIFICATIONS Item Fuses (amperage × quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Carburetor heater fuse Backup fuse (odometer) Reserve fuse Standard 30 A × 1 15 A × 1 10 A × 1 15 A × 1 10 A × 1 5A×1 30 A, 15 A, 10 A, 5 A × 1 2 2 - 17 SPEC Limit
  • Страница 37 из 450
    TIGHTENING TORQUES SPEC TIGHTENING TORQUES GENERAL TIGHTENING TORQUES This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid
  • Страница 38 из 450
    TIGHTENING TORQUES SPEC ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Spark plug – M12 4 18 1.8 13 Cylinder head Nut M12 8 50 5.0 36 Cylinder head Nut M10 4 39 3.9 28 Stud bolt M8 4 15 1.5 11 Camshaft driven gear Nut M14 1 52 5.2 37 Camshaft drive
  • Страница 39 из 450
    TIGHTENING TORQUES SPEC Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Generator rotor Bolt M12 1 160 16.0 115 Generator shaft Bolt M8 1 28 2.8 20 LT Pickup coil rotor Bolt M12 1 115 11.5 85 LT Baffle plate Bolt M6 4 10 1.0 7.2 LT Clutch boss Nut M20 1 70 7.0 50 Clutch
  • Страница 40 из 450
    TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item 2 Thread size Upper bracket and inner tube Upper bracket and steering shaft Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) Brake hose joint and lower bracket Front brake master cylinder cap Handlebar holder
  • Страница 41 из 450
    TIGHTENING TORQUES Item Rear master cylinder and rear brake bracket Rear brake reservoir tank Union bolt (rear brake hose) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Front wheel axle Front wheel axle pinch bolt Rear wheel axle nut Front brake caliper Rear brake
  • Страница 42 из 450
    LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Connecting rod bolts and nuts M Connecting rod small end and big end 2 E Crankshaft pins E Crankshaft
  • Страница 43 из 450
    LUBRICATION POINTS AND LUBRICANT TYPES SPEC CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) LS Steering bearing cover LS Steering head pipe lower oil seal LS Front wheel oil seal (right and left) LS Rear wheel oil seal
  • Страница 44 из 450
    ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2 2 - 25 SPEC
  • Страница 45 из 450
    ENGINE OIL FLOW DIAGRAMS SPEC ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Oil strainer 3 Dipstick 4 Oil delivery pipe 5 Push rod 6 Oil filter cartridge 7 Engine oil drain bolt (oil tank) 2 2 - 26
  • Страница 46 из 450
    ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 2 2 - 27 SPEC
  • Страница 47 из 450
    ENGINE OIL FLOW DIAGRAMS SPEC 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt (engine) 2 2 - 28
  • Страница 48 из 450
    ENGINE OIL FLOW DIAGRAMS 1 Main axle 2 Drive axle 3 Engine oil pump 4 Oil strainer Å To oil tank ı From oil tank Ç To oil filter cartridge 2 2 - 29 SPEC
  • Страница 49 из 450
    TRANSFER GEAR OIL FLOW DIAGRAMS SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 2 - 30
  • Страница 50 из 450
    TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 2 - 31 SPEC
  • Страница 51 из 450
    CABLE ROUTING SPEC EB206000 CABLE ROUTING 1 Throttle cables 2 Brake hose 3 Clutch cable 4 Left handlebar switch lead 5 Vacuum hose (air induction system) 6 Rear brake light switch lead 7 Rectifier/regulator Å Route the rear brake light switch lead in front of the rectifier/regulator bracket on the
  • Страница 52 из 450
    CABLE ROUTING 1 Spark plug cap #3 2 Ignition coil (rear cylinder) 3 Spark plug cap #1 4 Fuse box 5 Starter relay 6 Thermo switch 7 Fuel tank breather hose 8 Horns 9 Fuel pump 0 Starter motor lead A Fuel pump lead SPEC B Carburetor heater lead C Throttle position sensor lead D Horn lead E Sidestand
  • Страница 53 из 450
    CABLE ROUTING 1 Battery 2 Turn signal relay 3 Relay unit 4 Oil tank breather hose 5 Ignition coil (front cylinder) 6 Main switch coupler 7 Meter assembly couplers 8 Right handlebar switch lead 9 Fuel tank breather hose 0 Spark plug cap #4 SPEC A Spark plug cap #2 B Sidestand switch coupler C Pickup
  • Страница 54 из 450
    CABLE ROUTING Å Fasten the fuel tank breather and oil tank breather hose with a plastic clamp and then insert the clamp into the frame. ı To the stator coil. Ç To the decompression solenoid. Î To the fuel tank. ‰ To the wire harness. SPEC Ï Fasten the starter motor lead, stator coil lead,
  • Страница 55 из 450
    CABLE ROUTING 1 Fuel tank breather hose 2 Oil tank breather hose 3 Relay unit 4 Turn signal relay 5 Tail/brake light and rear turn signal light subwire harness coupler 6 Thermo switch 7 Fuse box 8 Fuel sender lead 9 Vacuum hose (air induction system) 0 Solenoid valve lead (California only) A Spark
  • Страница 56 из 450
    CABLE ROUTING SPEC Evaporative emission control system (California only) 1 Main switch 2 Fuel tank breather hose 3 Charcoal canister to carburetor hose 4 Charcoal canister 5 Charcoal canister to rollover valve hose 6 Rollover valve 7 Solenoid valve coupler 8 Solenoid valve 9 Solenoid valve to air
  • Страница 57 из 450
    CHK ADJ CONTENTS PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART
  • Страница 58 из 450
    CHK ADJ CHECKING THE FRONT BRAKE PADS ............................................. 3-35 CHECKING THE REAR BRAKE PADS ................................................ 3-35 ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-35 CHECKING THE BRAKE HOSE
  • Страница 59 из 450
    CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS/ GENERAL MAINTENANCE AND LUBRICATION CHART EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance
  • Страница 60 из 450
    CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL No. ITEM ROUTINE Clutch 6 * (See page 328.) • Check operation and free play. • Correct if necessary. Transfer case oil 7 * (See page 326.) Control cable (See page 349.) 8 * Rear arm pivot bear9 * ing (See page 484.) TYPE ODOMETER READINGS
  • Страница 61 из 450
    SEATS AND SIDE COVERS CHK ADJ SEATS AND SIDE COVERS 3 Order 1 2 3 4 Job/Part Removing the seats and side covers Rider seat Passenger seat Left side cover Right side cover Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For installation, reverse the removal procedure. 3-3
  • Страница 62 из 450
    XV16AT ACCESSORY PARTS CHK ADJ XV16AT ACCESSORY PARTS 3 Order 1 2 3 Job/Part Accessory parts removal (front) Front windshield Chrome flasher bracket cover Windshield stay Q’ty Remarks Remove the parts in the order listed. 1 1 2 For installation, reverse the removal procedure. 3-4
  • Страница 63 из 450
    XV16AT ACCESSORY PARTS CHK ADJ 3 Order 1 2 3 4 5 6 7 8 Job/Part Accessory parts removal (rear) Emblem Backrest holder Backrest Backrest stay Saddlebag Passenger footrest Saddlebag stay Grip Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 2 2 2 2 For installation, reverse the removal
  • Страница 64 из 450
    FUEL TANK CHK ADJ EAS00040 FUEL TANK 1 2 6 1 3 3 5 4 Order 1 2 3 4 Job/Part Removing the fuel tank Rider seat Meter assembly Meter assembly coupler Fuel tank breather hose Fuel hose 5 6 Q’ty Fuel sender coupler Fuel tank 2 1 Remarks Remove the parts in the order listed. Refer to “SEATS AND SIDE
  • Страница 65 из 450
    AIR FILTER CASE CHK ADJ AIR FILTER CASE 3 Order 1 2 3 Job/Part Removing the air filter case Vacuum chamber breather hose (air filter case to solenoid valve hose) Cylinder head breather hose Air filter case Q’ty 1 1 1 Remarks Remove the parts in the order listed. Disconnect. Disconnect. For
  • Страница 66 из 450
    ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00047 Å ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times that the valve clearance is needed to be adjusted
  • Страница 67 из 450
    ADJUSTING THE VALVE CLEARANCE CHK ADJ 4. Remove: • shift rod 1 5. Remove: • rider footrest (left) bolts 1 3 6. Remove: • engine left side cover 1 7. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 8. Remove: • decompression solenoid cover 1 • camshaft sprocket cover 2 3-9
  • Страница 68 из 450
    ADJUSTING THE VALVE CLEARANCE CHK ADJ 9. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0 ~ 0.04 mm (0 ~ 0.0016 in) Exhaust valve 0 ~ 0.04 mm (0 ~ 0.0016 in) CAUTION: ACHTUNG: Be sure to check the intake and exhaust valves. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
  • Страница 69 из 450
    ADJUSTING THE VALVE CLEARANCE CHK ADJ 10.Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw 3 in direction a or b until the specified valve clearance is
  • Страница 70 из 450
    ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the
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    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 8. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4 ~ 8 mm (0.16 ~ 0.31 in) EAS00058 ADJUSTING THE THROTTLE CABLE
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    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS CHK ADJ e. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased. f. Tighten the
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    CHECKING THE SPARK PLUGS 2. • 3. • CHK ADJ Disconnect: spark plug cap Remove: spark plug CAUTION: ACHTUNG: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: • spark plug type Incorrect
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    CHECKING THE IGNITION TIMING CHK ADJ EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”. 2.
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    CHECKING THE IGNITION TIMING CHK ADJ 7. Remove: • timing mark accessing screw 1 8. Install: • timing light 1 • inductive tachometer 2 (onto the spark plug lead of cylinder #1) Timing light YU-33277-A Inductive tachometer YU-8036-A 3 9. Check: • ignition timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start
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    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE CHK ADJ 11.Adjust: • installed shift rod length Refer to “ADJUSTING PEDAL”. THE SHIFT EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure result
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    MEASURING THE COMPRESSION PRESSURE CHK ADJ 8. Install: • compression gauge 1 • compression gauge adapter 2 Compression gauge YU-33223 Compression gauge adapter YU-33223-3 9. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level)
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    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston wear or damage → Repair. Piston rings, valves, cylinder Same as without oil head gasket,
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    CHECKING THE ENGINE OIL LEVEL CHK ADJ 3. Remove: • rider seat Refer to “SEATS AND SIDE COVERS”. 4. Remove: • dipstick 1 5. Check: • engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → Add the recommended engine
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    CHANGING THE ENGINE OIL CHK ADJ EAS00073 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • dipstick 1 • engine oil drain bolt (oil tank) 2 • engine oil drain bolt (engine) 3 4. Drain:
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    CHANGING THE ENGINE OIL CHK ADJ c. Tighten the new oil filter cartridge to specification with an oil filter wrench. T. Oil filter cartridge 17 Nm (1.7 m • kg, 12 ft • lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: • engine oil drain bolt gasket Damage → Replace. 7. Install: • engine oil drain bolt
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    CHANGING THE ENGINE OIL CHK ADJ NOTE: After the engine has been disassembled, pour the specified amount of engine oil into the crankcase and the oil tank. When pouring engine oil into the crankcase, pour it into the hole of the removed bolt 1. 10.Install: • dipstick 11.Start the engine, warm it up
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    MEASURING THE ENGINE OIL PRESSURE CHK ADJ EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 2. Start the engine, warm it up for several minutes, and then turn it off. CAUTION: ACHTUNG: When the engine is cold, the engine oil will have
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    MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL CHK ADJ Out of specification → Adjust. Engine oil pressure Possible causes Below specification • Faulty oil pump • Clogged oil filter • Leaking oil passage • Leaking oil passage Broken or damaged • Faulty oil filter oil seal
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    CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL CHK ADJ CAUTION: ACHTUNG: Do not allow foreign materials to enter the transfer case. 4. Install: • checking bolt T. R. 8 Nm (0.8 m · kg, 5.8 ft · lb) CHANGING THE TRANSFER GEAR OIL 1. Place a container under the transfer gear oil
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    ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2. Adjust: • clutch cable free play
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    CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: • air filter case Refer to “AIR FILTER CASE”. 2. Remove: • air filter case cover 1 • air filter element 2 3 3. Clean: • air filter element Apply compressed air to the outer surface of the air filter element.
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    CHECKING THE CARBURETOR JOINT/ CHECKING THE FUEL HOSES AND FUEL FILTER CHK ADJ EAS00094 CHECKING THE CARBURETOR JOINT 1. Remove: • carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Check: • carburetor joint 1 Cracks/damage → Replace. Refer to “CARBURETOR” in chapter 6. 3. Install: •
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    CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00098 CHECKING THE CYLINDER HEAD BREATHER HOSE AND TRANSFER GEAR CASE BREATHER HOSE 1. Remove: • rider seat • fuel tank Refer to “SEATS AND SIDE COVERS” and “FUEL TANK”. 2. Check: •
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    ADJUSTING THE FRONT BRAKE CHK ADJ EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2. Adjust: • brake lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen
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    ADJUSTING THE REAR BRAKE CHK ADJ EAS00110 ADJUSTING THE REAR BRAKE 1. Measure: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 100 mm (3.9 in) 2. Adjust: •
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    CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Check: • brake fluid level Below the minimum level mark a → Add the recommended
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    CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ EAS00120 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • brake pad Wear indicator groove 1 almost disappeared → Replace
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    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSE CHK ADJ 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body 1 of the rear brake light switch so that it does not rotate and
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    BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING WARNING Bleed the hydraulic brake system whenever: • the brake system was disassembled, • a brake hose was loosened, disconnected, or replaced, • the brake fluid level is very low, • brake operation is
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    BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ c. Connect a clear plastic hose 1 tightly to the bleed screw 2. Å Front ı Rear d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in
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    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK CHK ADJ EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 374.4 ~ 378.4 mm (14.74 ~
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    ADJUSTING THE DRIVE BELT SLACK CHK ADJ 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated. 2. Rotate the
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    ADJUSTING THE DRIVE BELT SLACK/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ a. Loosen the brake caliper bracket bolt 1. b. Loosen the wheel axle nut 2. c. Loosen both locknuts 3. Å Right ı Left d. Turn both adjusting bolts 4 in direction a or b until the specified drive chain slack is
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    CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 2. Check: • steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: • meter assembly Refer to “FUEL TANK”. 4. • 5. • • • Loosen: upper bracket pinch bolts 1
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    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD”
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    CHECKING THE FRONT FORK/ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK 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: • front fork operation Push down hard on the handlebar several times
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    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHECKING THE TIRES CHK ADJ Adjusting length a Minimum 42.5 mm (1.67 in) Standard 42.5 mm (1.67 in) Maximum 51.5 mm (2.03 in) CAUTION: ACHTUNG: Never turn the adjusting ring beyond the maximum or minimum setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3 EAS00166
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    CHECKING THE TIRES CHK ADJ Basic weight 332 kg (732 lb): XV16A (with oil and a 347 kg (765 lb): XV16AT full fuel tank) Maximum load* 196 kg (432 lb): XV16A 181 kg (399 lb): XV16AT Cold tire pressure Up to 90 kg load* Front tire Rear tire 250 kPa 250 kPa 2, (2.5 kgf/cm2, (2.5 kgf/cm 36 psi) 36 psi)
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    CHECKING THE TIRES CHK ADJ • To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. • Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality
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    CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES CHK ADJ WARNING WARNING • After mounting a new tire, ride conservatively 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
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    CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES CHK ADJ 2. Tighten: • spokes (with a spoke wrench 1) T. R. 3 Nm (0.3 m · kg, 2.2 ft · lb) NOTE: Be sure to tighten the spokes before and after break-in. EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure
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    LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION CHK ADJ EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-tometal moving parts of the levers and pedals. Recommended lubricant Lithium soap base grease EAS00172 LUBRICATING
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    CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •
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    CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
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    CHECKING AND CHARGING THE BATTERY CHK ADJ 5. Charge: • battery (refer to the appropriate method illustration) charging WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a
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    CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a variable voltage charger 3 3 - 54
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    CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger 3 3 - 55 CHK ADJ
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    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. • • 7. • CHK ADJ Install: battery battery band Connect: battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: • battery terminals Dirt → Clean with a
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    CHECKING THE FUSES CHK ADJ NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester YU-03112 b. If the pocket tester indicates “∞”, replace the fuse. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of
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    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB CHK ADJ 4. Install: • left side cover Refer to “SEATS AND SIDE COVERS”. EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • screws 1 • headlight lens unit 2 3 2. • 3. • Disconnect: headlight coupler 1 Remove: headlight bulb holder cover 2 4. • 5. •
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    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ 6. Install: New • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: ACHTUNG: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass,
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    ADJUSTING THE HEADLIGHT BEAM CHK ADJ 2. Adjust: • headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob 2 in direction a or b. Direction a Headlight beam moves to the right. Direction b Headlight beam moves to the left. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3 3 - 60
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    INSTRUMENT FUNCTIONS CHK ADJ INSTRUMENT FUNCTIONS INDICATOR LIGHTS 1 Fuel indicator light “ ” 2 High beam indicator light “ ” 3 Turn indicator light “ ” 4 Neutral indicator light “ ” 5 Engine trouble indicator light “ ” Neutral indicator light “ ” This indicator comes on when the transmission is in
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    INSTRUMENT FUNCTIONS CHK ADJ To reset the trip meter to “0”, push the set button until it displays “TRIP A” or “TRIP B”, then push mode button and hold it down for at least one second. NOTE: This motorcycle does not have a tachometer. However, it is equipped with an engine revolution limiter, which
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    CHAS CONTENTS CHASSIS 4 FRONT WHEEL AND BRAKE DISCS ........................................................... 4-1 REMOVING THE FRONT WHEEL ........................................................ 4-3 DISASSEMBLING THE FRONT WHEEL .............................................. 4-3 CHECKING THE
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    CHAS FRONT AND REAR BRAKES ...................................................................... 4-22 REPLACING THE FRONT BRAKE PADS ............................................ 4-24 REPLACING THE REAR BRAKE PADS .............................................. 4-27 DISASSEMBLING THE FRONT BRAKE
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    CHAS DRIVE BELT AND DRIVE PULLEY ............................................................. 4-90 REMOVING THE DRIVE BELT AND DRIVE PULLEY ......................... 4-91 CHECKING THE DRIVE BELT ............................................................. 4-91 INSTALLING THE DRIVE BELT AND DRIVE
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    FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 4 Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 1 2 3 4 5 6 7 8 9 Reflector
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    FRONT WHEEL AND BRAKE DISCS CHAS 4 Order 1 2 3 Job/Part Disassembling the front wheel Oil seal (left and right) Wheel bearing (left and right) Spacer Q’ty Remarks Remove the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure. 4-2
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    FRONT WHEEL AND BRAKE DISCS CHAS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2.
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    FRONT WHEEL AND BRAKE DISCS CHAS EAS00526 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and
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    FRONT WHEEL AND BRAKE DISCS CHAS 6. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 7. Replace: • wheel bearings • oil seals New New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b. Remove the
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    FRONT WHEEL AND BRAKE DISCS CHAS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
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    FRONT WHEEL AND BRAKE DISCS CHAS NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. T. R. Brake disc bolt 23 Nm (2.3 m • kg, 17 ft • lb) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is
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    FRONT WHEEL AND BRAKE DISCS CHAS 2. Install: • brake discs • brake disc covers T. R. 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: • Apply locking agent (LOCTITE 648) to the threads of the brake disc bolts. • Tighten the brake disc bolts in stages and in a crisscross pattern. 3. • • • 4. • Install: collars
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    FRONT WHEEL AND BRAKE DISCS CHAS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel, or both, the front wheel static balance should be adjusted. • Adjust the front wheel static balance with the brake discs installed. 1. • 2. • Remove: balancing weight(s) Find:
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    FRONT WHEEL AND BRAKE DISCS CHAS c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY 4 Order 1 2 3 Job/Part Removing the rear fender and muffler Rider seat Q’ty Muffler Tail/brake light and turn signal light sub-wire harness Rear fender assembly 1 1 Remarks Remove the parts in
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00550 4 Order Job/Part Removing the rear wheel Q’ty Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 1 2 3 4 5 6 7 8 9 Upper drive belt cover Brake caliper Brake
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS 4 Order Job/Part 10 Rear wheel 11 Collar (left and right) 12 Brake caliper bracket Q’ty 1 2 1 Remarks For installation, reverse the removal procedure. 4 - 13
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00556 4 Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the brake disc and rear wheel pulley Brake disc Rear wheel pulley Oil seal Collar Circlip Bearing Collar Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel Q’ty Remarks
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00560 4 Order 1 2 3 4 Job/Part Disassembling the rear wheel Oil seal Bearing Spacer Bearing Q’ty Remarks Remove the parts in the order listed. 1 1 1 4 For assembly, reverse the disassembly procedure. 4 - 15
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS 3. Check: • spokes Refer to “FRONT WHEEL AND BRAKE DISCS”. 4. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISCS”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub 1 Cracks/damage →
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS T. Rear wheel pulley self-locking nut 95 Nm (9.5 m • kg, 68 ft • lb) R. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ASSEMBLING THE REAR WHEEL 1. Install: • bearings • spacer • bearing • oil
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS 4. Install: • rear wheel pulley 1 T. R. 95 Nm (9.5 m · kg, 68 ft · lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. 5. Install: • brake disc NOTE: • Apply locking agent (LOCTITE 648) to the threads of the brake disc
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS 9. Tighten: • wheel axle nut T. 150 Nm (15.0 m · kg, 110 ft · lb) R. • brake caliper bracket bolt T. R. 48 Nm (4.8 m · kg, 35 ft · lb) 10.Install: • brake caliper 1 T. R. 40 Nm (4.0 m · kg, 29 ft · lb) 11.Install: • upper drive belt cover 1 T. R. 10
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    REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS 17.Install: • rider seat Refer to “SEATS AND SIDE COVERS” in chapter 3. EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel, or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel
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    FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 4 Order 1 2 3 4 5 6 7 Job/Part Removing the front brake pads Q’ty Brake hose holder bolt Retaining bolt Brake caliper Brake pad Brake pad shim Brake pad spring Brake pad spring Remarks Remove the parts in the order listed.
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    FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS 4 Order 1 2 3 4 5 6 Job/Part Removing the rear brake pads Muffler Q’ty Brake caliper bolt Brake pad cover Brake pad clip Brake pad pin Brake pad spring Brake pad Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC AND
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    FRONT AND REAR BRAKES CHAS EAS00579 CAUTION: ACHTUNG: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire
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    FRONT AND REAR BRAKES CHAS 2. Remove: • brake pads 1 (along with the brake pad shim) • brake pad springs 3. Measure: • brake pad thickness a Out of specification → Replace the brake pads as a set. Minimum brake pad thickness 0.5 mm (0.02 in) 4. Install: • brake pads • brake pad springs 4 NOTE:
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    FRONT AND REAR BRAKES CHAS 5. Lubricate: • brake caliper retaining bolt Recommended lubricant Lithium soap base grease CAUTION: ACHTUNG: • Do not allow grease to contact the brake pads. • Remove any excess grease. 6. Install: • brake caliper • brake caliper retaining bolts T. R. 27 Nm (2.7 m · kg,
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    FRONT AND REAR BRAKES CHAS EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: • brake caliper 1 • brake pad cover 2 2. • • • 4 Remove: brake pad clips 1 brake pad pins 2 brake pad
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    FRONT AND REAR BRAKES CHAS b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. T. Bleed screw 6 Nm (0.6 m • kg, 4.3 ft • lb) R. d. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad
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    FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the front brake master cylinder Brake fluid Rear view mirror Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm
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    FRONT AND REAR BRAKES CHAS 4 Order Job/Part 11 Brake master cylinder holder 12 Brake master cylinder 13 Front brake light switch Q’ty 1 1 1 Remarks For installation, reverse the removal procedure. 4 - 30
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    FRONT AND REAR BRAKES CHAS EAS00585 4 Order 1 2 3 4 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure. 4 - 31
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    FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder Brake fluid Drain. Brake fluid reservoir cover 1 Brake fluid reservoir cap 1 Brake fluid reservoir
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    FRONT AND REAR BRAKES CHAS 4 Order 11 12 13 14 Job/Part Left footrest assembly Cotter pin Pin Brake master cylinder Q’ty 1 1 1 1 Remarks For installation, reverse the removal procedure. 4 - 33
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    FRONT AND REAR BRAKES CHAS EAS00587 4 Order 1 2 3 4 Job/Part Disassembling the rear brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure. 4 - 34
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    FRONT AND REAR BRAKES CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. • • • Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: To collect any remaining brake fluid,
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    FRONT AND REAR BRAKES CHAS EAS00592 Å CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →
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    FRONT AND REAR BRAKES CHAS 5. Check: • brake hoses • brake fluid reservoir hose Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new
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    FRONT AND REAR BRAKES Install: copper washers New brake hose 30 Nm (3.0 m · kg, 22 ft · lb) union bolt T. R. 4. • • • CHAS WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. NOTE: • While holding the brake hose, tighten the union
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    FRONT AND REAR BRAKES CHAS WARNING 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
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    FRONT AND REAR BRAKES CHAS EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • brake master cylinder kit 1 • circlip 2 New • dust boot 3 2. Install: • brake master cylinder 1 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) 3. Install: • left footrest assembly 1 T. R. 48 Nm (4.8 m ·
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    FRONT AND REAR BRAKES CHAS CAUTION: ACHTUNG: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. 6. Install: • brake fluid reservoir hose 1 • brake fluid reservoir 2 7. Fill: • brake fluid reservoir (to the maximum level mark) 4
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    FRONT AND REAR BRAKES CHAS 8. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 9. Install: • brake fluid reservoir diaphragm • brake fluid reservoir diaphragm holder • brake fluid reservoir cap • brake fluid reservoir cover 10.Check: • brake fluid level Below the
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    FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS 4 Order 1 2 3 4 5 6 7 8 Job/Part Removing the front brake calipers Q’ty Brake fluid Reflector Brake hose holder bolt Union bolt Copper washer Brake hose Retaining bolt Brake caliper bolt Brake caliper 1 1 1 2 1 2 2 1 Remarks Remove the parts
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    FRONT AND REAR BRAKES CHAS EAS00615 4 Order Job/Part Disassembling the front brake calipers Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 1 2 3 4 5 6 7 8 9 Retaining bolt Brake caliper Brake caliper bracket Brake pad Brake
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    FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER 4 Order 1 2 3 4 5 Job/Part Removing the rear brake caliper Muffler Q’ty Brake fluid Union bolt Copper washer Brake hose Brake caliper bolt Brake caliper Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC AND REAR
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    FRONT AND REAR BRAKES CHAS EAS00617 4 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad cover 1 Brake pad clip 2 Brake pad pin 2 Brake pad spring 1 Brake pad 2 Brake caliper piston 4 Brake caliper piston seal 8 Bleed
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    FRONT AND REAR BRAKES CHAS EAS00624 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. • • • Remove: union bolt 1 copper washers 2 brake hose 3
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    FRONT AND REAR BRAKES 1. • • • CHAS Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper pistons 1 • brake caliper piston seals 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the right
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    FRONT AND REAR BRAKES CHAS 1. Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper cylinders 2 Scratches/wear → Replace the brake caliper. • brake calipers Cracks/damage → Replace. • brake fluid delivery passages (brake caliper body) Obstruction → Blow
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    FRONT AND REAR BRAKES CHAS • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. • • • Install: bleed screw brake caliper piston
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    FRONT AND REAR BRAKES Install: copper washers New brake hose 30 Nm (3.0 m · kg, 22 ft · lb) union bolt T. R. 6. • • • CHAS WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. CAUTION: ACHTUNG: When installing the brake hose onto the
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    FRONT AND REAR BRAKES CHAS 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: •
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    FRONT AND REAR BRAKES CHAS 1. • • • Install: bleed screw brake caliper piston seals 1 brake caliper pistons 2 2. • • • • Install: brake pads brake pad spring 1 brake pad pins 2 brake pad clips 3 New NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. 3. • 4. • •
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    FRONT AND REAR BRAKES CHAS 6. Fill: • brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake
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    FRONT FORK CHAS EAS00647 FRONT FORK 4 Order Job/Part Removing the front fork legs Q’ty Front wheel 1 2 3 4 5 6 7 8 9 Meter assembly Front fender Brake hose holder Upper bracket pinch bolt Cap bolt Steering stem nut Upper bracket Upper fork cover Upper fork cover spacer Upper fork cover washer 1 1 4
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    FRONT FORK CHAS 4 Order 10 11 12 13 14 Job/Part Lower bracket pinch bolt Front fork leg Bolt Brake hose guide Lower fork cover Q’ty Remarks 2 Loosen. 1 3 1 1 For installation, reverse the removal procedure. 4 - 56
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    FRONT FORK CHAS EAS00648 4 Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the front fork leg Q’ty Cap bolt O-ring Fork spring Dust seal Oil seal clip Cartridge cylinder bolt Copper washer Cartridge cylinder Rebound spring Inner tube 1 1 1 1 1 1 1 1 1 1 4 - 57 Remarks Remove the parts in the order
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    FRONT FORK CHAS 4 Order A B C D E F Job/Part Oil seal Seal spacer Outer tube bushing Inner tube bushing Oil flow stopper Outer tube Q’ty 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure. 4 - 58
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    FRONT FORK CHAS EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable
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    FRONT FORK CHAS 3. Remove: • cartridge cylinder bolt NOTE: While holding the cartridge cylinder with the damper rod holder 1 and T-handle 2, loosen the cartridge cylinder bolt. Damper rod holder YM-1300-1 T-Handle YM-01326 4. Remove: • inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork
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    FRONT FORK CHAS 2. Measure: • spring free length a Out of specification → Replace. Spring free length limit 566 mm (22.3 in) 3. Check: • cartridge cylinder 1 Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • oil flow stopper 2 Damage → Replace. 4. Check: •
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    FRONT FORK CHAS 1. Install: • cartridge cylinder 1 CAUTION: ACHTUNG: Allow the cartridge cylinder to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. • 3. • Install: oil flow stopper 3 Lubricate: inner tube’s outer
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    FRONT FORK CHAS 6. Install: • outer tube bushing 1 New • seal spacer 2 (with the fork seal driver weight 3 and adapter 4) Fork seal driver weight YM-33963 Adapter YM-8020 7. Install: • oil seal 1 New (with the fork seal driver weight 2 and adapter 3) CAUTION: ACHTUNG: Make sure the numbered side of
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    FRONT FORK CHAS 10.Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 554 L (488 lmp qt, 589 US qt) Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) 110 mm (4.33
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    FRONT FORK CHAS 3. Install: • Upper bracket • Steering stem nut T. 130 Nm (13.0 m · kg, 94 ft · lb) R. NOTE: Make sure the inner fork tube is flush with the top of the upper bracket. 4. Tighten: • lower bracket pinch bolt 1 T. R. T. • cap bolt 20 Nm (2.0 m · kg, 14 ft · lb) R. 23 Nm (2.3 m · kg, 17
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    FRONT FORK CHAS 8. Tighten: • upper bracket pinch bolts 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 9. Install: • brake hose holder • front fender T. R. 23 Nm (2.3 m · kg, 17 ft · lb) 10.Install: • front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. 4 - 66 4
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    HANDLEBAR CHAS EAS00664 HANDLEBAR 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the handlebar Rear view mirror (left and right) Plastic clamp Front brake light switch connector Brake master cylinder holder Brake master cylinder Right handlebar switch Throttle cable holder Throttle cable Throttle
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    HANDLEBAR CHAS 4 Order 11 12 13 14 15 16 17 18 Job/Part Left handlebar switch Handlebar grip Clutch cable Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder Q’ty Remarks 1 1 1 Disconnect. 1 1 2 1 2 For installation, reverse the removal procedure. 4 - 68
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    HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and
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    HANDLEBAR CHAS NOTE: • The upper handlebar holders should be installed with the arrows a facing forward Å. • Align the match marks b on the handlebar with the upper surface of the lower handlebar holders. 3. Tighten: • lower handlebar holder nuts T. R. 40 Nm (4.0 m · kg, 29 ft · lb) 4. Install: •
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    HANDLEBAR CHAS 8. Install: • handlebar grip ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. WARNING WARNING Do not touch
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    HANDLEBAR CHAS • First, tighten the upper bolt, then the lower bolt. 13.Connect: • front brake light switch connector 14.Install: • plastic clamp • rear view mirrors 15.Adjust: • clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end
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    STEERING HEAD CHAS EAS00676 STEERING HEAD 4 Order 1 2 3 4 5 6 7 8 Job/Part Removing the lower bracket Meter assembly Front fork legs/fork covers Front wheel Q’ty Handlebar/handlebar holders Steering stem nut Upper bracket Headlight lens unit Lead (in the headlight body) Headlight body Headlight
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    STEERING HEAD CHAS 4 Order 9 10 11 12 13 14 15 16 17 18 Job/Part Brake hose joint Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Upper bearing Lower bearing Bearing outer race Q’ty 1 1 1 1 1 1 1 1 1 2 Remarks For installation, reverse the removal procedure. 4 -
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    STEERING HEAD CHAS EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • lower ring nut 1 (with the special tool 2) Ring nut wrench YU-33975 WARNING WARNING Securely
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    STEERING HEAD CHAS c. Install a new rubber seal and new bearing races. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CAUTION: ACHTUNG: 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
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    STEERING HEAD 3. • • • • CHAS 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. 4. Install: • brake hose joint 1 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) 5. Install: • turn signal light bracket assembly 1 • chrome
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    STEERING HEAD CHAS 10.Install: • upper bracket • steering stem nut • front fork legs Refer to “FRONT FORK”. 11.Install: • handlebar Refer to “HANDLEBAR”. • front fork legs Refer to “FRONT FORK”. • meter assembly Refer to “FUEL TANK” in chapter 3. 4 4 - 78
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    REAR SHOCK ABSORBER AND SWINGARM CHAS ******** REAR SHOCK ABSORBER AND SWINGARM 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear shock absorber and swingarm Rear wheel Adjusting bolt Locknut Mud guard Lower drive belt cover Horn coupler Horn Self-locking nut Bolt (shock absorber-connecting
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 4 Order Job/Part 11 Pivot shaft 12 Rear shock absorber and swingarm assembly Q’ty 1 1 Remarks For installation, reverse the removal procedure. 4 - 80
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 4 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear shock absorber and swingarm Self-locking nut/washer/bolt Self-locking nut/washer/bolt Connecting arm O-ring Rear shock absorber Spacer/O-ring Self-locking nut/washer/bolt Relay arm Spacer/oil seal/bearing
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 4 Order 11 12 13 14 15 16 Job/Part Spacer/bearing Swingarm Dust cover Washer Spacer Bearing Q’ty 1/1 1 2 2 1 2 Remarks For installation, reverse the removal procedure. 4 - 82
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    REAR SHOCK ABSORBER AND SWINGARM CHAS EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 2. Remove: • bolt (shock absorber - connecting arm frame) 1 NOTE: When removing the bolt (shock absorber connecting arm - frame) 1, hold the swingarm so that it does not drop down. 3. Measure: • swingarm free play • swingarm vertical movement
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    REAR SHOCK ABSORBER AND SWINGARM CHAS • spring Damage/wear → Replace the rear shock absorber assembly. • gas cylinder Damage/gas leaks → Replace. • bushings Damage/wear → Replace. • O-ring Damage/wear → Replace. • bolts Bends/damage/wear → Replace. CHECKING THE RELAY ARM AND CONNECTING ARM 1.
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    REAR SHOCK ABSORBER AND SWINGARM 3. • • • • CHAS Wash: pivot shaft dust covers spacer bearings Recommended cleaning solvent Kerosine 4. • • • Check: dust covers spacer oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 1.
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    REAR SHOCK ABSORBER AND SWINGARM 3. • • • CHAS Install: bearings oil seals 1 spacers 2 4. Install: • relay arm 1 (onto the swingarm) T. R. 59 Nm (5.9 m · kg, 43 ft · lb) 5. Install: • o-rings 1 • spacer 2 4 6. Install: • connecting arms 1 (onto the rear shock absorber) 7. Install: • connecting arms
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 8. Install: • rear shock absorber 1 (onto the relay arm) T. R. 40 Nm (4.0 m · kg, 29 ft · lb) 9. Install: • rear shock absorber and swingarm assembly • pivot shaft • washer • pivot shaft nut T. R. 125 Nm (12.5 m · kg, 90 ft · lb) • covers 10.Install: • bolt
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    REAR SHOCK ABSORBER AND SWINGARM CHAS 14.Install: • mud guard 1 15.Install: • locknut 1 • adjusting bolt 2 16.Install: • rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. 17.Adjust: • drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK” in chapter 3. 4 4 - 89
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    DRIVE BELT AND DRIVE PULLEY CHAS DRIVE BELT AND DRIVE PULLEY 4 Order 1 2 3 4 5 6 7 8 Job/Part Removing the drive belt and drive pulley Rear wheel Q’ty Rear shock absorber and swingarm assembly Drive pulley cover bracket Drive pulley cover Slider Dowel pin Drive belt Drive pulley nut Lock washer
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    DRIVE BELT AND DRIVE PULLEY CHAS REMOVING THE DRIVE BELT AND DRIVE PULLEY NOTE: Loosen the drive pulley nut before remove the rear wheel. 1. • • 2. 3. • Remove: drive pulley cover bracket 1 drive pulley cover 2 Straighten the lock washer tab. Loosen: drive pulley nut 1 NOTE: When loosening the
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    DRIVE BELT AND DRIVE PULLEY CHAS 3. Check: • drive pulley • rear wheel pulley Bent teeth → Replace the drive belt and pulleys as a set. INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1. Install: • drive pulley 1 • lock washer 2 New • drive pulley nut 3 2. Install: • drive belt 4 CAUTION: ACHTUNG:
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    DRIVE BELT AND DRIVE PULLEY CHAS 6. Install: • dowel pins 1 • sliders 2 7. Install: • drive pulley cover 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • drive pulley cover bracket 2 R. 4 - 93 T. 4 R. • bolts (M8) T. • bolts (M10) 53 Nm (5.3 m · kg, 38 ft · lb) 30 Nm (3.0 m · kg, 22 ft · lb)
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    ENG CONTENTS ENGINE 5 ENGINE ......................................................................................................... 5-1 INSTALLING THE ENGINE ................................................................... 5-8
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    ENG ROCKER ARMS, PUSH RODS AND VALVE LIFTERS .............................. 5-12 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS .............................................................................. 5-18 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS
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    ENG CLUTCH ...................................................................................................... 5-60 REMOVING THE CLUTCH .................................................................. 5-65 REMOVING THE PRIMARY DRIVE GEAR ......................................... 5-65 CHECKING
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    ENG ENGINE OIL PUMP ................................................................................... 5-108 CHECKING THE OIL PUMP .............................................................. 5-111 CHECKING THE RELIEF VALVE ....................................................... 5-111 CHECKING
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    ENGINE ENG EAS00188 ENGINE ENGINE 5 Order 1 2 3 4 Job/Part Removing the muffler and exhaust pipes Muffler Front exhaust pipe Rear exhaust pipe Gasket Q’ty Remarks Remove the parts in the order listed. 1 1 1 2 For installation, reverse the removal procedure. 5-1
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    ENGINE ENG 5 Order Job/Part Removing the oil filter bracket and horns Rider seat/side covers Q’ty Remarks Refer to “SEATS AND SIDE COVERS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “CARBURETOR” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in
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    ENGINE ENG 5 Order Job/Part Engine oil/oil filter cartridge Transfer gear oil Transfer gear case Rider footrest (left) Q’ty Drain. Drain. Refer to “TRANSFER GEAR CASE”. Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”. Refer to “GENERATOR AND STARTER CLUTCH”. Rider footrest (right) 1 2 3 4 5
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    ENGINE ENG 5 Order 1 2 3 4 5 6 7 8 9 Job/Part Disconnecting the leads and hoses Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Charcoal canister hose (carburetor to charcoal canister) Plastic clamp Stator coil coupler Decompression solenoid coupler Pickup coil
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    ENGINE ENG 5 Order Job/Part 10 Neutral switch cover 11 Neutral switch 12 Speed sensor Q’ty 1 1 1 Remarks For connecting, reverse the disconnection procedure. 5-5
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    ENGINE ENG EAS00191 ENGINE 5 Order Job/Part Removing the engine Q’ty Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. 1 2 3 4 5 6 7 8 Self-locking nut Upper front mounting bolt Front engine bracket bolt Horn bracket Front engine bracket
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    ENGINE ENG 5 Order 9 10 11 12 Job/Part Rear engine bracket Lower front mounting bolt Lower rear mounting bolt Engine Q’ty Remarks 2 1 1 1 Refer to “INSTALLING THE ENGINE”. For installation, reverse the removal procedure. 5-7
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    ENGINE ENG INSTALLING THE ENGINE 1. Install: • lower rear mounting bolt 1 • lower front mounting bolt 2 • rear engine brackets 3 • rear engine bracket bolts 4 • upper rear mounting bolt 5 • self-locking nuts 6 • front engine brackets 7 • horn bracket 8 • front engine bracket bolts 9 • upper front
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    ENGINE 5. • • • • • 6. • ENG Connect: speed sensor coupler neutral switch connector pickup coil coupler decompression solenoid coupler stator coil coupler Install: plastic clamp 1 7. Connect: • charcoal canister hose (carburetor to charcoal canister) 1 8. Connect: • clutch cable 1 5 9. • • •
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    ENGINE ENG 11.Install: • horns 1 12.Connect: • horn couplers 13.Install: • oil filter bracket 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • oil filter bolt 2 T. R. 70 Nm (7.0 m · kg, 50 ft · lb) NOTE: Apply locking agent (LOCTITE) to the threads of the oil filter bracket bolts. 14.Install: • rider
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    ENGINE ENG 18.Install: • starter motor Refer to “STARTER MOTOR” in chapter 7. • air induction system parts Refer to “AIR INDUCTION SYSTEM” in chapter 6. • carburetor joint • carburetor Refer to “CARBURETOR” in chapter 6. • air filter case Refer to “AIR FILTER CASE” in chapter 3. • fuel tank Refer
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 5 Order 1 2 3 4 5 6 7 8 Job/Part Removing the engine left side cover and camshaft sprocket cover Rider seat/fuel tank/air filter case Q’ty Engine oil Spark plug cap Spark plug Shift rod Charcoal canister hose
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 5 Order 9 10 11 12 Job/Part Decompression solenoid cover Camshaft sprocket cover Camshaft sprocket cover gasket Dowel pin Q’ty 1 1 1 2 Remarks For installation, reverse the removal procedure. 5 - 13
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 5 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing cylinder head covers Cylinder head breather hose Oil tank breather hose Bolt Bolt Bolt Bolt Rear cylinder head cover Front cylinder head cover Cylinder head cover gasket Dowel pin Q’ty 1 1 4 4 4 12 1 1 2 4 5
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 5 Order 11 12 13 14 Job/Part Rear cylinder head cover spacer Front cylinder head cover spacer Cylinder head cover spacer gasket Dowel pin Q’ty 1 1 2 4 Remarks For installation, reverse the removal procedure. 5 - 15
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 5 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the push rods and rocker arms Push rod Rear rocker arm base Front rocker arm base Rocker arm base gasket Dowel pin Rocker arm shaft Rocker arm 1 Rocker arm 2 Locknut Adjusting screw Q’ty Remarks Remove the
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 5 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the valve lifters Push rod cover Oil seal O-ring Throttle stop screw Throttle stop screw holder Rear valve lifter case cover Front valve lifter case cover Rear valve lifter case Front valve lifter case Valve
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark a on the pickup coil rotor (with the pointer b on the clutch/pickup coil rotor cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/scratches → Replace or check the lubrication system. 3. Measure: • rocker arm inside diameter a Out of specification → Replace. Rocker arm inside diameter 15.000 ~ 15.018 mm (0.5906 ~
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG CHECKING THE ROCKER ARM BASES 1. Check: • rocker arm base Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod • push rod end Bends/damage → Replace. 2. Measure: • push rod runout Out of specification → Replace. Push rod runout 0.3 mm
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 3. Measure: • valve lifter outside diameter a Out of specification → Replace. Valve lifter case outside diameter 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 4. Measure: • valve lifter case inside diameter a Out of specification → Replace. Valve lifter case
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 1. Bleed: • valve lifter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill a container with kerosene and place the valve lifter into the container as shown. Pump the plunger side of the valve lifter with a press a number of times to let in kerosene. CAUTION: ACHTUNG:
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG h. Rotate the crankshaft until the mark (on the camshaft driven gear) for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder #2 intake valve lifter, align mark 1 as shown. 1 Cylinder #2 intake
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 2. • • • Install: oil seals 1 O-rings 2 push rod covers 3 3. • • 4. • Install: valve lifter case covers 1 throttle stop screw holder 2 Hook: throttle stop screw 3 5. Install: • O-rings 1 • oil seals 2 5 INSTALLING THE ROCKER ARMS AND PUSH RODS The
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 2. Install: • dowel pins 1 • rocker arm gasket 2 New 3. Install: • rocker arm base (with rocker arms) • push rods Å ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Put the rocker arm base on the cylinder head. b. Install the push rods. NOTE: • Be sure to correctly
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG INSTALLING THE CYLINDER HEAD COVERS The following procedure applies to both cylinders. 1. Install: • dowel pins 1 • cylinder head cover spacer gasket 2 New 2. Install: • cylinder head cover spacer 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Install: •
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 1. Install: • dowel pins 1 • camshaft sprocket cover gasket 2 New 2. Install: • camshaft sprocket cover 1 • decompression solenoid cover 2 3. Install: • crankshaft end cover 1 • timing
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    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG 7. Install: • shift rod 1 8. • 9. • Install: spark plugs Connect: spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. Å Forward 10.Fill: • oil tank (with the specified amount of the recommended engine oil) Refer to “CHANGING THE ENGINE OIL” in
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    CAMSHAFTS ENG CAMSHAFTS 5 Order 1 2 3 4 5 6 7 8 Job/Part Removing the camshafts Valve lifters Q’ty Remarks Refer to “ROCKER ARMS, PUSH RODS AND VALVE LIFTERS”. Refer to “ENGINE”. Muffler/exhaust pipes Decompression solenoid Long decompression push rod Short decompression push rod Camshaft drive
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    CAMSHAFTS ENG 5 Order 9 10 11 12 13 14 Job/Part Camshaft cover Camshaft cover gasket Dowel pin Front cylinder camshaft end cover Front cylinder camshaft Rear cylinder camshaft Q’ty 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure. 5 - 30
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    CAMSHAFTS ENG REMOVING THE CAMSHAFTS 1. Loosen: • front cylinder camshaft end cover bolts 1 • camshaft drive gear bolt 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. • Do not damage the teeth of the camshaft
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    CAMSHAFTS ENG EAS00204 CHECKING THE CAMSHAFTS 1. Check: • cams Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • cam dimensions a and b Out of specification → Replace the camshaft. Minimum cam lobe dimensions Intake cam a 36.494 mm (1.4368 in) b 31.850 mm (1.2539 in)
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    CAMSHAFTS ENG 5. Measure: • crankcase hole inside diameter c Out of specification → Replace the crankcase. Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 6. Measure: • camshaft cover hole inside diameter d Out of specification → Replace the camshaft cover. Camshaft cover
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    CAMSHAFTS ENG 9. Check: • camshaft drive gears • camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the
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    CAMSHAFTS ENG CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. • O-rings 2 Damage/wear → Replace. INSTALLING THE CAMSHAFTS 1. Install: • camshafts (to the camshaft cover) • front cylinder camshaft end cover NOTE: •
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    CAMSHAFTS ENG 4. Install: • camshaft cover 1 (along with the camshafts) • oil delivery pipe 2 NOTE: Tighten the camshaft cover bolts in stages and in a crisscross pattern. 5. • • • Install: straight keys camshaft drive gear 1 camshaft driven gear 2 NOTE: • Cover the crankcase hole with a clean rag
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    CAMSHAFTS ENG 8. Tighten: • camshaft drive gear bolt 1 T. R. 30 Nm (3.0 m · kg, 22 ft · lb) • front cylinder camshaft end cover bolts 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. • Do not damage the teeth of
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    CAMSHAFTS ENG 12.Fill: • oil tank (with the specified amount of the recommended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 13.Install: • air filter case • fuel tank • rider seat Refer to “AIR FILTER CASE”, “FUEL TANK” and “SEATS AND SIDE COVERS” in chapter 3. 5 5 - 38
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    CYLINDER HEADS ENG CYLINDER HEADS 5 Order Job/Part Removing the cylinder head Rider seat/fuel tank/air filter case Q’ty Carburetor/carburetor joint Muffler/exhaust pipes Rocker arms/push rod cover 1 2 3 4 5 Reed valve case to rear cylinder pipe Reed valve case to front cylinder pipe Gasket Oil
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    CYLINDER HEADS ENG 5 Order 6 7 8 9 10 Job/Part Copper washer Rear cylinder head Front cylinder head Cylinder head gasket Dowel pin Q’ty 2 1 1 2 4 Remarks For installation, reverse the removal procedure. 5 - 40
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    CYLINDER HEADS ENG REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Follow the numerical order shown in the illustration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The
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    CYLINDER HEADS ENG d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE OIL DELIVERY PIPE 1. Check: • oil
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    CYLINDER HEADS 3. • • • ENG Install: copper washers New oil delivery pipe 1 oil delivery pipe bolts (M10) T. R. 21 Nm (2.1 m · kg, 15 ft · lb) • oil delivery pipe bolt (M8) T. R. 4. • • • 18 Nm (1.8 m · kg, 13 ft · lb) Install: gaskets reed valve case to front cylinder pipe 1 reed valve case to
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    VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS 5 Order 1 2 3 4 5 6 7 8 Job/Part Removing the valves and valve springs Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both cylinders. Refer to “CYLINDER HEADS”. Cylinder head Valve cotter Upper spring seat
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    VALVES AND VALVE SPRINGS ENG EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve (for
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    VALVES AND VALVE SPRINGS ENG NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • valve stem-to-valve guide
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    VALVES AND VALVE SPRINGS ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to
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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 replace the oil seal. Valve stem runout 0.01 mm (0.0004 in) EAS00240 CHECKING THE
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    VALVES AND VALVE SPRINGS ENG d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve
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    VALVES AND VALVE SPRINGS ENG 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 impression. j. Measure the valve seat width again. If the valve seat width is
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    VALVES AND VALVE SPRINGS ENG 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake and exhaust inner valve spring 6.3 ~ 7.3 kg at 29.0 mm (13.9 ~ 16.1 lb at 1.14 in) Intake and exhaust outer
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    VALVES AND VALVE SPRINGS ENG 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. • • • • • • Install: lower spring seat 1 oil seal 2 New valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 (into the cylinder
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    CYLINDERS AND PISTONS ENG EAS00251 CYLINDERS AND PISTONS 5 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the cylinders and pistons Cylinder heads Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring Q’ty Remarks Remove the parts in the order listed. Refer to
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    CYLINDERS AND PISTONS ENG EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: • piston pin clip 1 • piston pin 2 • piston 3 CAUTION: ACHTUNG: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston
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    CYLINDERS AND PISTONS ENG 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking sideto-side and front-to-back measurements of the cylinder. Then, find the average of the
  • Страница 276 из 450
    CYLINDERS AND PISTONS ENG Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) <Limit>: 0.15 mm (0.006 in) f. If out of specification, replace the cylinder, and the piston and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston
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    CYLINDERS AND PISTONS ENG Piston ring end gap Top ring 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) <Limit>: 0.65 mm (0.026 in) 2nd ring 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) <Limit>: 0.80 mm (0.031 in) Oil ring 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) EAS00266 CHECKING THE PISTON PINS The following procedure applies to
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    CYLINDERS AND PISTONS 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) b – Piston pin outside diameter a Piston pin-to-piston pin bore clearance 0.004 ~ 0.024
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    CYLINDERS AND PISTONS ENG 3. Install: • dowel pins 1 • gasket 2 New 4. • • • Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: • piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring Å Front of the
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    CLUTCH ENG EAS00273 CLUTCH 5 Order Job/Part Removing the clutch cover Left side cover Q’ty Engine left side cover 1 2 3 4 5 6 7 Engine oil Clutch cable Pull lever Pull lever spring Pickup coil coupler Shift arm Clutch cable holder Clutch cover 1 1 1 1 1 1 1 5 - 60 Remarks Remove the parts in the
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    CLUTCH ENG 5 Order Job/Part 8 Clutch cover gasket 9 Dowel pin Q’ty 1 1 Remarks For installation, reverse the removal procedure. 5 - 61
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    CLUTCH ENG 5 Order 1 2 3 4 5 6 Job/Part Removing the pull lever shaft and pickup coil Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Pickup coil lead holder Pickup coil Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 2 3 3 1 For installation, reverse the removal
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    CLUTCH ENG EAS00274 5 Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the clutch Generator rotor cover Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Clutch plate Lock washer Wire circlip Clutch plate Friction plate Clutch damper
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    CLUTCH ENG 5 Order 13 14 15 16 17 18 19 20 21 22 23 Job/Part Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key Q’ty 1 1 1 1 1 1 1 1 1 1 1 Remarks For installation, reverse the removal
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    CLUTCH ENG EAS00277 REMOVING THE CLUTCH 1. Remove: • clutch cable holder 1 • clutch cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the lock washer tab. 3. Loosen: • clutch boss nut
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    CLUTCH ENG NOTE: While holding the generator rotor 2 with the sheave holder 3, loosen the pickup coil rotor bolt. Sheave holder YS-01880 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: • friction plate Damage/wear → Replace the friction
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    CLUTCH ENG EAS00283 CHECKING THE CLUTCH SPRING PLATE 1. Check: • clutch spring plate 1 Damage → Replace. 2. Check: • clutch spring plate seat 2 Damage → Replace. EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the
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    CLUTCH ENG EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth a • pull rod teeth b Damage/wear → Replace the pull lever shaft and pull rod as a set. 2. Check: • pull rod bearing Damage/wear → Replace. EAS00292 CHECKING THE PRIMARY DRIVE 1. Check: •
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    CLUTCH ENG 3. Install: • bearings • oil seals 1 NOTE: Lubricate the oil seal lips with lithium soap base grease. 4. • • • Install: pull lever shaft 1 washer circlip EAS00303 INSTALLING THE PRIMARY DRIVE GEAR 1. Install: • straight key 1 • primary drive gear 2 • pickup coil rotor 3 • spacer 4 •
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    CLUTCH ENG EAS00296 INSTALLING THE CLUTCH 1. Install: • dowel pin 1 • oil pump drive gear 2 • plate 3 • circlip 4 2. Install: • clutch housing 1 • thrust washer 2 NOTE: • Lubricate the clutch housing bearings with engine oil. • Make sure that the primary driven gear teeth and primary drive gear
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    CLUTCH ENG Universal clutch holder YM-91042 5. Bend the lock washer tab along a flat side of the nut. 6. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • friction plates • clutch plates NOTE: • First, install a friction
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    CLUTCH 9. • • • ENG Install: clutch spring plate seat 1 clutch spring plate 2 clutch spring plate retainer 3 T. R. 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 10.Install: • dowel pins 1 • clutch cover gasket 2 New
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    CLUTCH ENG 14.Install: • pull lever spring • pull lever NOTE: If there is no free play in the clutch, install the pull lever to the pull lever shaft in order to get the distance a between the pull lever and clutch cable holder to 31.8 mm (1.25 in). 15.Connect: • clutch cable 1 16.Fill: • oil tank
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    SHIFT SHAFT ENG EAS00327 SHIFT SHAFT 5 Order 1 2 3 4 5 6 7 Job/Part Removing the shift shaft and stopper lever Engine oil Clutch housing Circlip Shift shaft spring Shift shaft Shift shaft spring stopper Lock washer Stopper lever Stopper lever spring Q’ty Remarks Remove the parts in the order
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    SHIFT SHAFT ENG EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift lever spring 2 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. EAS00331
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    SHIFT SHAFT 4. • • • ENG Install: shift shaft spring circlips shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2. 5. Install: • clutch housing Refer to “CLUTCH”. 6. Fill: • oil tank Refer to “CHANGING THE ENGINE OIL”. 5 5 - 76
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    GENERATOR AND STARTER CLUTCH ENG EAS00341 GENERATOR AND STARTER CLUTCH 5 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the stator coil assembly Rider seat/left side cover/fuel tank Q’ty Muffler/exhaust pipes Engine oil Plastic locking tie Rear brake light switch coupler Rider footrest (right) Stator
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    GENERATOR AND STARTER CLUTCH ENG 5 Order Job/Part 10 Stator coil assembly lead holder 11 Stator coil assembly Q’ty 1 1 Remarks For installation, reverse the removal procedure. 5 - 78
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    GENERATOR AND STARTER CLUTCH ENG EAS00343 5 Order 1 2 3 4 5 6 Job/Part Removing the generator rotor Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Starter clutch gear Q’ty Remarks Remove the parts in the
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    GENERATOR AND STARTER CLUTCH ENG EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor bolt 1 • washer NOTE: While
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    GENERATOR AND STARTER CLUTCH ENG c. When turning the starter clutch gear counterclockwise ı, it should turn freely, otherwise the starter clutch is faulty and must be replaced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS00354 INSTALLING THE GENERATOR 1. Install: • starter clutch gear 1 • generator rotor 2 •
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    GENERATOR AND STARTER CLUTCH ENG 4. Apply: • sealant (onto the stator coil assembly lead grommet) Quick Gasket ACC-11001-05-01 5. Install: • stator coil assembly 1 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) • stator coil assembly lead holder T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Apply locking agent
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    GENERATOR AND STARTER CLUTCH ENG 9. Connect: • decompression solenoid couplers • stator coil assembly coupler NOTE: Refer to “CABLE ROUTING” in chapter 2. 10.Install: • rider footrest (right) 1 T. R. 48 Nm (4.8 m · kg, 35 ft · lb) 11.Connect: • rear brake light switch coupler 1 NOTE: Refer to
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    GENERATOR AND STARTER CLUTCH ENG 14.Install: • exhaust pipes • muffler Refer to “ENGINE”. 15.Install: • fuel tank • left side cover • rider seat Refer to “FUEL TANK” and “SEATS AND SIDE COVERS” in chapter 3. 5 5 - 84
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    TRANSFER GEAR CASE ENG TRANSFER GEAR CASE 5 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the battery box Rider seat/side covers Q’ty Negative battery lead Positive battery lead Tool kit holder Tool kit Battery holder Battery Plastic bracket Ignitor unit coupler Ignitor unit holder 1 1 1 1 1 1 1 3 1 5
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    TRANSFER GEAR CASE ENG 5 Order 10 11 12 13 14 15 Job/Part Ignitor unit Battery box Relay unit coupler Turn signal relay coupler Plastic clamp Relay bracket Q’ty Remarks 1 1 1 Disconnect. 1 Disconnect. 1 1 For installation, reverse the removal procedure. 5 - 86
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    TRANSFER GEAR CASE ENG 5 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the oil tank cover Muffler/exhaust pipes Engine oil Oil tank breather hose Dipstick Dipstick joint Oil pipe #1 Oil pipe #2 Oil tank cover Oil tank cover gasket Dowel pin Oil strainer Q’ty 1 1 1 1 1 1 1 2 1 Remarks Remove the parts
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    TRANSFER GEAR CASE ENG 5 Order Job/Part Removing the transfer gear case Transfer gear oil Drive pulley Q’ty 1 2 3 4 5 6 7 8 9 10 Drive pulley case Dowel pin Cover Dowel pin Transfer gear oil pump Transfer gear oil pump gasket Transfer gear case cover Transfer gear case cover gasket Dowel pin Oil
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    TRANSFER GEAR CASE ENG 5 Order 11 12 13 14 15 16 17 18 19 Job/Part Lock washer Primary chain Middle drive gear Middle driven shaft Transfer gear case Spacer Dowel pin Oil seal Bearing Q’ty 1 1 1 1 1 1 2 1 2 Remarks For installation, reverse the removal procedure. 5 - 89
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    TRANSFER GEAR CASE ENG 5 Order 1 2 3 4 5 6 7 Job/Part Disassembling the transfer gear case oil pump Oil pump cover Pin Pin Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing Q’ty Remarks Remove the parts in the order listed. 1 2 1 1 1 1 1 For assembly, reverse the disassembly
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    TRANSFER GEAR CASE ENG REMOVING THE BATTERY 1. Disconnect: • battery leads (from the battery terminals) WARNING WARNING First, disconnect the negative battery lead, then the positive battery lead. REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before removing the drive
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    TRANSFER GEAR CASE ENG 2. Check: • primary chain 1 Damage/stiffness → Replace the primary chain, middle drive gear and middle driven shaft as a set. CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. CHECKING THE OIL PUMP 1. Check: • oil pump
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    TRANSFER GEAR CASE ENG 3. Check: • oil pump operation Unsmooth → Repair or replace the defective part(s). CHECKING THE OIL PIPE 1. Check: • oil pipe Damage → Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 5
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    TRANSFER GEAR CASE ENG 3. Install: • pins 1 • oil pump cover 2 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Apply locking agent (LOCTITE) to the threads of the oil pump cover screws. 4. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE TRANSFER GEAR CASE 1. Install: •
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    TRANSFER GEAR CASE ENG 4. Install: • transfer gear case cover 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 5. Install: • dowel pins 1 6. Install: • transfer gear case assembly 1 NOTE: • While installing the middle drive gear 2 onto the drive axle, install the transfer gear case assembly onto the engine.
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    TRANSFER GEAR CASE ENG 10.Remove: • drive pulley nut 11.Install: • transfer gear oil pump gasket • transfer gear oil pump 1 New T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply locking agent (LOCTITE) only to the threads of the transfer gear oil pump bolts 2 (M6 × 25 mm bolts). 12.Install: •
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    TRANSFER GEAR CASE ENG 15.Install: • drive pulley case 1 T. R. 30 Nm (3.0 m · kg, 22 ft · lb) 16.Install: • drive pulley Refer to “DRIVE BELT AND DRIVE PULLEY” in chapter 4. 17.Fill: • transfer gear case (with the specified amount of the recommended transfer gear oil) Refer to “CHANGING THE
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    TRANSFER GEAR CASE ENG 3. Install: • dipstick joint 1 • dipstick 2 NOTE: Finger tighten the dipstick joint bolt. 4. Connect: • oil tank breather hose 3 T. R. 5. Install: • oil pipes 1 10 Nm (1.0 m · kg, 7.2 ft · lb) INSTALLING THE BATTERY 1. Install: • relay bracket 1 • plastic clamp 2 2. Connect:
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    TRANSFER GEAR CASE ENG 6. Install: • plastic bracket 7. Install: • negative battery lead 1 (to the dipstick joint) 8. • • • • 9. • 5 Install: battery 1 battery holder 2 tool kit 3 tool kit holder 4 Connect: battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive
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    CRANKCASE ENG CRANKCASE 5 Order 1 2 3 Job/Part Separating the crankcase Engine Camshaft Piston Shift shaft Generator rotor Q’ty Generator shaft end cover Oil delivery pipe Engine oil pump driven gear stopper 1 1 1 5 - 100 Remarks Remove the parts in the order listed. Refer to “ENGINE”. Refer to
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    CRANKCASE ENG 5 Order 4 5 6 7 8 Job/Part Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase Q’ty 1 1 2 1 1 Remarks For installation, reverse the removal procedure. 5 - 101
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    CRANKCASE ENG 5 Order 1 2 3 Job/Part Removing the baffle plate and bearings Crankshaft Transmission Baffle plate Oil seal Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKSHAFT”. Refer to “TRANSMISSION”. 1 1 4 Installation, reverse the removal procedure. 5 - 102
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    CRANKCASE ENG EAS00386 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before removing the generator rotor. 1. Remove: • generator shaft bolt 1 NOTE: While the holding the generator rotor 2 with the sheave holder 3, loosen the generator shaft bolt. Sheave holder YS-01880 2.
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    CRANKCASE ENG 4. Remove: • right crankcase CAUTION: ACHTUNG: • First check that the shift drum segment’s teeth then remove the right crankcase. • Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work
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    CRANKCASE ENG CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. • O-rings 2 Damage/wear → Replace. CHECKING THE ENGINE OIL PUMP DRIVE 1. Check: • oil pump drive gear 1 • oil pump driven gear 2
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    CRANKCASE ENG 4. Install: • crankcase bolts Å NOTE: • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • Tighten the bolts in numerical order (refer to the numbers in the illustration). Å Left crankcase ı Right crankcase
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    CRANKCASE ENG 8. Install: • washer • generator shaft bolt 1 T. R. 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: • Apply locking agent (LOCTITE) to the threads of the generator shaft bolt. • While holding the generator rotor 2 with the sheave holder 3, tighten the generator shaft bolt. Sheave holder
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    ENGINE OIL PUMP ENG ENGINE OIL PUMP 5 Order 1 2 Job/Part Removing the engine oil pump Crankcase Oil strainer Engine oil pump assembly Q’ty Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. 1 1 Installation, reverse the removal procedure. 5 - 108
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    ENGINE OIL PUMP ENG 5 Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the engine oil pump Spring retainer Spring Relief valve Oil pump housing cover 1 Pin Spring Ball Oil pump outer rotor 1 Oil pump inner rotor 1 Pin Q’ty 1 1 1 1 2 1 1 1 1 1 5 - 109 Remarks Remove the parts in the order listed.
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    ENGINE OIL PUMP ENG 5 Order A B C D E F G H Job/Part Oil pump housing cover 2 Pin Oil pump shaft Pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil seal Oil pump housing Q’ty 1 2 1 1 1 1 2 1 Remarks For assembly, reverse the disassembly procedure. 5 - 110
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    ENGINE OIL PUMP ENG EAS00363 CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump housing covers 2 Cracks/damage/wear → Replace defective part(s). the 2. Measure: • inner rotor-to-outer rotor tip clearance a • outer rotor-to-oil pump housing clearance b Out of specification → Replace the
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    ENGINE OIL PUMP 2. • • • ENG Check: ball 1 spring 2 oil seal 3 Damage/wear → Replace the defective part(s). EAS00368 CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 Damage → Replace. Contaminants → Clean with engine oil. EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer
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    ENGINE OIL PUMP ENG • spring G • spring retainer H T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: When installing the inner rotor, align the pin in the oil pump shaft with the groove in the inner rotor. 3. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 T. INSTALLING THE OIL
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    CRANKSHAFT AND CONNECTING RODS ENG CRANKSHAFT AND CONNECTING RODS 5 Order 1 2 3 4 5 6 Job/Part Removing the crankshaft and connecting rods Crankcase Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing Q’ty Remarks Remove the parts in the order
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    CRANKSHAFT AND CONNECTING RODS ENG REMOVING THE CRANKSHAFT 1. Remove: • crankshaft journal bearing 1 NOTE: Remove the crankshaft journal bearing with the bearing remover and installer 2 and bearing driver 3. Bearing remover and installer YM-28898 Bearing driver YM-04058 EAS00391 REMOVING THE
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    CRANKSHAFT AND CONNECTING RODS ENG 3. Measure: • crankshaft pin-to-big end bearing clearance Out of specification → Replace the big end bearings. Crankshaft pin-to-big end bearing clearance 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) <Limit>: 0.09 mm (0.0035 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following
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    CRANKSHAFT AND CONNECTING RODS ENG e. Tighten the connecting rod bolts. CAUTION: ACHTUNG: • When tightening the connecting rod bolts, be sure to use an F-type torque wrench. • Without pausing, tighten the connecting rod bolts to the specified torque. Apply continuous torque between 3.3 and 4.0 m •
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    CRANKSHAFT AND CONNECTING RODS ENG 4. Select: • big end bearings (P1 ~ P2) NOTE: • The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. • “P1” ~ “P2” refer to the bearings shown in the crankshaft
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    CRANKSHAFT AND CONNECTING RODS ENG 6. Measure: • crankshaft journal bearing inside diameter a Out of specification → Replace the crankcase assembly. Crankshaft journal bearing inside diameter 50.01 ~ 50.03 mm (1.969 ~ 1.970 in) NOTE: Measure the inside diameter of each crankshaft journal bearing at
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    CRANKSHAFT AND CONNECTING RODS 2. • • • ENG Lubricate: crankshaft pins big end bearings connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. • • • Install: big end bearings connecting rods connecting rod caps (onto the crankshaft pins) NOTE: • Align the
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    CRANKSHAFT AND CONNECTING RODS ENG INSTALLING THE CRANKSHAFT 1. Install: • generator shaft 1 2. Install: • crankshaft NOTE: • Make sure that the generator shaft drive gear teeth and generator shaft driven gear teeth mesh correctly. • Align the right connecting rod with the front cylinder sleeve
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    TRANSMISSION ENG TRANSMISSION 5 Order 1 2 3 4 5 6 7 8 Job/Part Removing the shift forks, shift drum assembly and transmission Crankcase Shift fork guide bar Shift fork “L” Shift fork “R” Shift fork “C” Shift drum assembly Drive axle assembly Main axle assembly Spacer Q’ty Remarks Remove the parts
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    TRANSMISSION ENG 5 Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Disassembling the main axle assemRemove the parts in the order listed. bly Circrip 1 Washer 1 5th pinion gear 1 2nd/3rd pinion gear 1 Circlip 1 Washer 1 4th pinion gear 1 Main axle/1st pinion gear 1 For assembly, reverse the disassembly
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    TRANSMISSION ENG 5 Order 1 2 3 4 5 6 7 8 9 0 A B Job/Part Q’ty Remarks Disassembling the drive axle assemRemove the parts in the order listed. bly 5th wheel gear 1 Circlip 1 Washer 1 2nd wheel gear 1 Circlip 1 Washer 1 1st wheel gear 1 4th wheel gear 1 Circlip 1 Washer 1 3rd wheel gear 1 Drive axle
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    TRANSMISSION ENG EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat
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    TRANSMISSION ENG EAS00425 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge 1) Out of specification → Replace the main axle. Maximum main axle runout 0.08 mm (0.003 in) 2. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of
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    TRANSMISSION 2. • • • • • ENG Install: shift drum assembly 1 shift fork “R” shift fork “C” shift fork “L” shift fork guide bars NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. 3. Check: • transmission
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    CARB CONTENTS CARBURETOR 6 CARBURETOR .............................................................................................. 6-1 CHECKING THE CARBURETOR ........................................................... 6-6 CHECKING THE CARBURETOR JOINT
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    CARB CHECKING THE AIR INDUCTION SYSTEM ...................................... 6-26 INSTALLING THE AIR INDUCTION SYSTEM ................................... 6-26 6
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    CARBURETOR CARB EAS00480 CARBURETOR CARBURETOR 6 Order 1 2 3 4 5 6 7 8 Job/Part Removing the carburetor Rider seat Q’ty Fuel tank Air filter case Fuel (from the carburetor) Carburetor joint clamp screw Throttle stop screw Vacuum chamber breather hose (carburetor to solenoid valve hose) Throttle
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    CARBURETOR Order Job/Part 9 Charcoal canister hose (carburetor to charcoal canister) 10 Carburetor heater connector 11 Carburetor 12 Fuel pump bracket assembly (with fuel pump) 13 Vacuum hose 14 Carburetor joint Q’ty 1 Disconnect. 2 1 1 Remarks Disconnect. 1 1 CARB Disconnect. For installation,
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    CARBURETOR CARB EAS00483 6 Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the carburetor Throttle stop screw Vacuum chamber air vent hose Fuel strainer Throttle cable holder Throttle position sensor bracket Carburetor heater Coasting enricher cover Coasting enricher spring Coasting enricher Q’ty 1
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    CARBURETOR Order 0 A B C D E F G H I Job/Part Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit Piston valve Float chamber Float chamber rubber gasket Drain bolt Accelerator plunger Float pivot pin Q’ty 1 1 1 1 1 1 1 1 1 1 6-4 CARB Remarks 6
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    CARBURETOR 6 Order J K L M N O P Q R Job/Part Float Needle valve Needle valve seat Main jet Spacer Needle jet Pilot jet Starter jet Pilot air jet Q’ty 1 1 1 1 1 1 1 1 1 CARB Remarks For assembly, reverse the disassembly procedure. 6-5
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    CARBURETOR CARB EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic carburetor
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    CARBURETOR 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 jet needle holder 3 jet needle spring 4 Cracks/damage → Replace. 10.Check: • jet needle kit 1 • main jet 2 •
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    CARBURETOR CARB 13.Check: • coasting enricher cover 1 • coasting enricher spring 2 Cracks/damage → Replace. • coasting enricher 3 Cracks/tears/damage → Replace. 14.Check: • accelerator plunger 1 • accelerator plunger spring 2 Bends/cracks/damage → Replace. • O-ring 3 Damage/wear → Replace.
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    CARBURETOR CARB 1. Install: • pilot air jet 1 2. Install: • starter jet 1 • pilot jet 2 3. Install: • needle jet 1 NOTE: Align the slot a on the needle jet with the projection b on the carburetor body. 4. Install: • spacer 1 • main jet 2 6 5. Install: • needle valve seat 1 6-9
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    CARBURETOR CARB 6. • • • Install: needle valve float 1 float pin 2 7. • • • Install: accelerator plunger 1 drain bolt 2 float chamber rubber gasket 3 8. Install: • float chamber 1 9. • • • • • Install: piston valve 1 jet needle kit jet needle holder piston valve spring vacuum chamber cover 2 NOTE:
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    CARBURETOR CARB 10.Install: • coasting enricher 1 • coasting enricher spring • coasting enricher cover 2 NOTE: Align the tab a on the coasting enricher with the recess b in the carburetor body. 11.Install: • terminal 1 • washer • carburetor heater 2 T. R. 2.5 Nm (0.25 m · kg, 2.0 ft · lb) NOTE: Use
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    CARBURETOR CARB 13.Install: • throttle stop screw • drain hose INSTALLING THE CARBURETOR JOINT 1. Install: • carburetor joint 1 T. R. 12 Nm (1.2 m · kg, 8.7 ft · lb) 2. Connect: • vacuum hose 2 EAS00492 INSTALLING THE CARBURETOR 1. Connect: • carburetor heater connectors 1 • charcoal canister hose
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    CARBURETOR CARB 5. Connect: • fuel hose 1 6. Connect: • throttle cables 1 7. Connect: • float chamber breather hose (carburetor to solenoid valve) 1 8. Hook: • throttle stop screw 1 6 9. Install: • carburetor NOTE: Align the projection a of the carburetor with slot of the carburetor joint.
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    CARBURETOR CARB 11.Adjust: • engine idling speed Engine idling speed 850 ~ 950 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 12.Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 4 ~ 8 mm (0.16 ~ 0.31 in) Refer to “ADJUSTING THE
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    CARBURETOR CARB 2. Adjust: • fuel level ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1. e. Install the carburetor.
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    CARBURETOR CARB d. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → yellow terminal 3 Negative tester probe → black terminal 2 e. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. NOTE:
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    CARBURETOR CARB d. Measure the maximum throttle position sensor resistance. Out of specification → Replace the throttle position sensor. Maximum throttle position sensor resistance 4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F) (blue — black/blue) e. Connect the pocket tester (Ω × 1k) to the throttle position
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    CARBURETOR CARB 3. Adjust: • throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the throttle position sensor coupler from the wire harness. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor coupler. Positive tester probe → blue terminal 1 Negative tester
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    CARBURETOR CARB EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel hose (fuel pump to carburetor) 2 from the carburetor. b. Place a container under the end of the fuel hose. c. Set the fuel cock to “ON” or “RES”. d. Start the engine and check
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    CARBURETOR 6. • 7. • CARB Install: fuel cock Connect: fuel hose EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its operation. 1. Set the fuel cock to “OFF”. 2. Disconnect: • fuel hose (from the fuel cock) 3. Check: • fuel cock operation
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    AIR INDUCTION SYSTEM CARB EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens,
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    AIR INDUCTION SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cut valve 3 Air cleaner 4 Carburetor joint Å To the carburetor joint ı To the front cylinder head Ç To the rear cylinder head Î To the air cut valve 6 D FW 6 - 22
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    AIR INDUCTION SYSTEM 6 Order 1 2 3 4 5 6 7 8 Job/Part Removing the air induction system fuel tank Reed valve case to rear cylinder head hose Reed valve case to rear cylinder head pipe Reed valve case to front cylinder head hose Reed valve case to front cylinder head hose Gasket Rectifier/regulator
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    AIR INDUCTION SYSTEM Order 9 10 11 12 13 14 15 16 17 18 19 20 Job/Part Air filter Air filter cover Air filter hose Air cut valve to air filter hose Plastic locking tie Vacuum hose Bracket Air cut valve holder Air cut valve Air cut valve to reed valve cover hose Reed valve cover Reed valve case Q’ty
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    AIR INDUCTION SYSTEM 6 Order Job/Part 21 Reed valve base 22 Reed valve stopper 23 Reed valve Q’ty 1 2 2 CARB Remarks For installation, reverse the removal procedure. 6 - 25
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    AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. • • • Check: fibre reed 1 fibre reed stopper reed valve seat Cracks/damage → Replace the reed valve. 3. Measure: •
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    AIR INDUCTION SYSTEM CARB 2. • • • Install: reed valve case 1 reed valve cover bracket 2 3. • • • Install: air cut valve to reed valve cover hose 1 air cut valve 2 air cut valve holder 3 4. Install: • bracket (with the air cut valve and reed valve) 5. Install: • vacuum hose 1 • plastic locking tie
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    AIR INDUCTION SYSTEM 7. • • • CARB Install: air filter 1 air filter hose 2 air filter cover 3 8. Install: • air filter bracket 1 9. Install: • air filter case assembly 1 10.Install: • rectifier/regulator 1 11.Connect: • rectifier/regulator coupler 2 12.Install: • gaskets • reed valve case to front
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    AIR INDUCTION SYSTEM CARB 13.Install: • fuel tank Refer to “FUEL TANK” in chapter 3. 6 6 - 29
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    ELEC CONTENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...................................................................... 7-1 7 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ................................................................................................ 7-2 SWITCHES
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    ELEC – + IGNITION SYSTEM .................................................................................... 7-12 CIRCUIT DIAGRAM ............................................................................ 7-12 TROUBLESHOOTING
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    ELECTRICAL COMPONENTS ELEC ESA00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Wire harness 2 Main switch 3 Front brake light switch 4 Ignition coils 5 Throttle position sensor 6 Clutch switch 7 Decompression solenoid 8 Relay unit 9 Turn signal relay 0 Ignitor unit A Battery B Starter relay C Main
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    ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC – + ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Right handlebar switch coupler, left handlebar switch couplers and front turn signal connectors 2 Headlight coupler 1 Tail/brake light connectors and rear turn signal connectors 7
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    ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Spark plug cap #3 2 Rear brake light switch coupler 3 Ignition coil (front cylinder) 4 Meter assembly couplers 1 Rear brake light switch lead 2 Rectifier/regulator 3 Rectifier/regulator coupler 4 Starter motor 5 Starter motor lead 5 Carburetor
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    ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC – + 1 Fuse box 2 Stator coil coupler, decompression solenoid couplers, pickup coil coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler 3 Battery negative lead 4 Battery positive lead 5 Battery 6 Ignitor unit
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    ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC – 1 Carburetor heater 2 Throttle position sensor 3 Ignition coil (rear cylinder) 4 Main switch coupler 5 Main switch 6 Solenoid valve coupler 7 Solenoid valve 8 Spark plug cap #4 9 Rear brake light switch 1 Diode 2 Turn signal relay 3 Relay
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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: ACHTUNG: Never insert the tester probes into the coupler
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    CHECKING THE SWITCHES ELEC – + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect.
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    CHECKING THE SWITCHES 1 Dimmer switch 2 Horn switch 3 Turn signal switch 4 Clutch switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch ELEC – + 9 Fuse 0 Rear brake light switch A Sidestand switch B Neutral switch 7 7-8
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    CHECKING THE BULBS AND BULB SOCKETS ELEC – + EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected →
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    CHECKING THE BULBS AND BULB SOCKETS ELEC – + WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: ACHTUNG: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise
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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 YU-03112 NOTE: Check each bulb socket for
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    3 Main switch 4 Battery 5 Main fuse 9 Relay unit B Ignitor unit C Ignition coil D Spark plug F Pickup coil G Neutral switch a Engine stop switch i Ignition fuse k Sidestand switch l Diode IGNITION SYSTEM 7 - 12 ELEC – + EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 7
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    IGNITION SYSTEM – + EB802401 EB802011 TROUBLESHOOTING 2.Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. spark plugs 4.
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    IGNITION SYSTEM ELEC – + EB802405 4.Ignition spark gap The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the dynamic spark tester 1 as shown. 2 Spark plug cap • Set the main switch to “ON”. • Measure the ignition spark gap a. •
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    IGNITION SYSTEM – ELEC + EB802411 8.Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES NO Replace the main switch. Secondary coil resistance 12 ~ 18 kΩ at 20 ˚C (68 ˚F) • Is the ignition coil OK? EB802412 9.Engine stop switch NO YES •
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    IGNITION SYSTEM ELEC – + EB802415 12.Diode 13.Relay unit (diode) • Remove the diode from the coupler. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the diode for continuity as follows. • Remove the relay unit from the coupler. • Connect the pocket tester (Ω × 1) to
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    3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 9 Relay unit B Ignitor unit E Decompression solenoid 7 G Neutral switch Y Clutch switch a Engine stop switch b Start switch i Ignition fuse k Sidestand switch l Diode ELECTRIC STARTING SYSTEM 7 - 17 ELEC – + EB803000 ELECTRIC
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    ELECTRIC STARTING SYSTEM ELEC – + EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in
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    ELECTRIC STARTING SYSTEM ELEC – + EB802401 EB803020 TROUBLESHOOTING 2.Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. relay unit (starting
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    ELECTRIC STARTING SYSTEM ELEC – + EB803403 EB803402 4.Relay unit (starting circuit cutoff relay) 5.Relay unit (diode) • Disconnect the relay unit from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as shown. • Disconnect the relay unit from the
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    ELECTRIC STARTING SYSTEM – ELEC + EB802412 EB803404 6.Starter relay 8.Engine stop switch • Disconnect the starter relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminals as shown. • Check the engine stop switch for continuity. Refer to “CHECKING
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    ELECTRIC STARTING SYSTEM ELEC – + EB803406 11.Diode 13.Start switch • Remove the diode from the coupler. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the diode for continuity as follows. • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is
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    STARTER MOTOR ELEC – EB803500 STARTER MOTOR Order 7 1 2 Job/Part Removing the starter motor Starter motor lead Starter motor assembly Q’ty Remarks Remove the parts in the order listed. 1 1 For installation, reverse the removal procedure. 7 - 23 +
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    STARTER MOTOR ELEC – + EB803501 Order 1 2 3 4 5 6 7 8 9 0 A B C D Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Circlip 1 Starter motor 1 Starter motor rear cover 1 Lock washer 1 Oil seal 1 Bearing 1 Washer set 1 Starter motor front cover 1 Washer set 1
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    STARTER MOTOR ELEC – + EB803511 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Minimum commutator diameter 27 mm (1.06 in) 3. Measure: • mica undercut a Out of
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    STARTER MOTOR ELEC – + 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Minimum brush length 5 mm (0.20 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.65 ~ 10.01 N (765 ~ 1,001 gf, 27.0 ~ 35.3 oz)
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    STARTER MOTOR ELEC – + 3. Install: • armature assembly Install: bearing oil seal lock washer 1 5. • • • • Install: O-rings 1 New starter motor rear cover 2 starter motor front cover 3 bolts 7 Nm (0.7 m · kg, 5.1 ft · lb) T. 4. • • • R. NOTE: Align the match marks a on the starter motor yoke with
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    ELEC CHARGING SYSTEM – + EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM B R W W W W W W 1 W W W (BLACK) 2 8 R R R/G B W W W R W W R W 5 R R R 3 4 R Br/L L/Y L/B ON OFF (BLACK) Br/L L/Y L/B Br/L R L/B L/Y (BLACK) R R R R/W L L 6 R/W B B B B B B B 7 B 7 1 Generator 2 Rectifier/regulator 4 Battery 5 Main
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    CHARGING SYSTEM ELEC – + EB802401 EB804010 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil assembly resistance 5. wiring (of
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    CHARGING SYSTEM ELEC – + EB804404 NOTE: Make sure that the battery is fully charged. 5.Wiring • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? • Is the charging voltage within
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    3 Main switch 4 Battery 5 Main fuse O High beam indicator light P Meter light V Dimmer switch Z Front turn signal/position light \ Headlight c Tail/brake light h Headlight fuse LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 7 - 31 ELEC – +
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    LIGHTING SYSTEM ELEC – + EB802401 EB805010 TROUBLESHOOTING 2.Battery Any of the following fail to light: headlight, high beam indicator light, taillight, position light or meter light. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Open-circuit
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    LIGHTING SYSTEM EB805404 ELEC – + EB805410 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 5.Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? YES
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    LIGHTING SYSTEM ELEC – + EB805411 Headlight Tester positive probe → yellow 1 or green 2 Tester negative probe → black 3 High beam indicator light Tester positive probe → yellow 4 Tester negative probe → black 5 2. A meter light fails to come on. 1.Meter light bulb and socket • Check the meter light
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    LIGHTING SYSTEM – + 4. The front turn signal/position light fails to come on. EB805412 3. A tail/brake light fails to come on. 1.Tail/brake light bulb and socket 1.Front turn signal/position light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE
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    SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 7 - 37 ELEC – +
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    SIGNALING SYSTEM ELEC – + 3 Main switch 4 Battery 5 Main fuse 8 Backup fuse B Ignitor unit G Neutral switch J Engine trouble indicator light K Turn signal indicator light L Neutral indicator light M Speedometer assembly (speedometer, combination meter and fuel level meter) N Fuel level indicator
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    SIGNALING SYSTEM – + EB802401 EB806010 TROUBLESHOOTING 2.Battery • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Open-circuit voltage 12.8 V or
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    SIGNALING SYSTEM ELEC – + EB806410 3.Horn CHECKING THE SIGNALING SYSTEM 1.The horn fails to sound. • Disconnect the horn coupler at the horn. • Connect a jumper lead 1 to the brown terminal in the horn coupler and the horn terminal. • Connect a jumper lead 2 to the horn terminal and ground the
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    SIGNALING SYSTEM ELEC – + EB806411 • Set the main switch to “ON”. • Pull in the brake lever or push down on the brake pedal. • Measure the voltage (12 V) of yellow at the tail/brake light coupler (wire harness side). • Is the voltage within specification? 2. A tail/brake light fails to come on.
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    SIGNALING SYSTEM ELEC – + 3.Turn signal switch • Check the turn signal switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? YES NO Replace the left handlebar switch. • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage
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    SIGNALING SYSTEM ı ELEC – + 2.Neutral switch • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? YES Replace the neutral switch. • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (12 V) of chocolate
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    SIGNALING SYSTEM – ELEC + EB806417 3.Voltage 5. The fuel level indicator light, fuel level meter or both fail to come on. • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. 1.Fuel level indicator light LED • Check the LED of the fuel level indicator
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    SIGNALING SYSTEM EAS00843 2.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES Replace the ignitor unit. NO Repair or replace the wire harness. 7 7 - 45 ELEC – +
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    3 Main switch 4 Battery 5 Main fuse 9 Relay unit 0 Fuel pump B Ignitor unit a Engine stop switch i Ignition fuse FUEL PUMP SYSTEM 7 - 46 ELEC – + EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 7
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    FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump 7 D FW 7 - 47 ELEC – +
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    FUEL PUMP SYSTEM ELEC – + EAS00739 EB808020 TROUBLESHOOTING 2.Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. main switch 4. engine stop switch 5. relay unit
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    FUEL PUMP SYSTEM ELEC – + • Measure the fuel pump resistance. 5.Relay unit (fuel pump relay) • Disconnect the relay unit from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as shown. Fuel pump resistance 1.6 ~ 2.2 Ω at 20 ˚C (68 ˚F) • Is the fuel
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    FUEL PUMP SYSTEM ELEC – + EB808410 CHECKING THE FUEL PUMP WARNING WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refuelling. • Do not smoke and keep
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    3 Main switch 4 Battery 5 Main fuse e Carburetor heater f Thermo switch g Carburetor heater fuse CARBURETOR HEATING SYSTEM 7 7 - 51 ELEC – + EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM
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    CARBURETOR HEATING SYSTEM ELEC – + EAS00739 EAS00821 TROUBLESHOOTING 2.Battery The carburetor heating system fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. Main and carburetor heater fuses 2. Battery 3. Main switch 4.
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    CARBURETOR HEATING SYSTEM ELEC – + WARNING WARNING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. • Does the thermo switch operate properly? NO YES Replace the thermo switch. 5.Carburetor heater • Remove
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    CARBURETOR HEATING SYSTEM ELEC – + EAS00754 6.Wiring • Check the entire carburetor heating system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the carburetor heating system’s wiring properly connected and without defects? YES This circuit is OK. NO Properly connect or repair the carburetor heating
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    SELF-DIAGNOSIS ELEC – + EB812000 SELF-DIAGNOSIS The XV16AL/XV16ALC/XV16ATL/XV16ATLC features a self-diagnosing system for the following circuit(s): • throttle position sensor • speed sensor • decompression solenoid • fuel level meter If any of these circuits is defective, the respective condition
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    SELF-DIAGNOSIS ELEC – + Display order on the engine trouble indicator light and fuel level indicator light 1 Engine trouble indicator light 2 Fuel level indicator light 1 Indicator lights check...............................1.4 seconds 2 Light off
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    SELF-DIAGNOSIS EB812010 ELEC – + EAS00843 TROUBLESHOOTING 1.Wire harness The engine trouble indicator light or the fuel level indicator light starts to blink, display the self-diagnosis sequence. • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? Check:
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    SELF-DIAGNOSIS ELEC – + 2. Speed sensor CIRCUIT DIAGRAM B Ignitor unit H Speed sensor EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES 7 NO Replace the speed sensor. BAD Replace the ignitor unit. Repair or replace the wire
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    SELF-DIAGNOSIS ELEC – + 3. Decompression solenoid CIRCUIT DIAGRAM B Ignitor unit E Decompression solenoid EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES NO • Measure the decompression solenoid resistance. Repair or replace
  • Страница 439 из 450
    SELF-DIAGNOSIS ELEC – + EB812403 • Check the decompression solenoid for continuity. • Is the decompression solenoid OK? YES Replace the ignitor unit. 1.Fuel level indicator light LED • Check the LED of the fuel level indicator light. Refer to “CHECKING THE LEDs”. • Is the fuel level indicator light
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    SELF-DIAGNOSIS EAS00843 3.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES Replace the meter assembly. NO Replace or replace the wire harness. 7 7 - 61 ELEC – +
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    TRBL SHTG CONTENTS TROUBLESHOOTING STARTING PROBLEMS ................................................................................ 8-1 ENGINE ................................................................................................. 8-1 FUEL SYSTEM
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    TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM ........................................... 8-5 HEADLIGHT DOES NOT LIGHT ........................................................... 8-5 HEADLIGHT BULB BURNT OUT ......................................................... 8-5 TAIL/BRAKE LIGHT DOES NOT
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    STARTING PROBLEMS TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and
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    STARTING PROBLEMS/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery (See page 3-51 to 3-56) • Faulty battery • Discharged battery Fuses (See page 3-56 to 3-58) • Blown, damaged, or incorrect fuse • Incorrectly installed fuse Spark plugs (See page 3-14 to 3-15) • Incorrect spark plug gap •
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    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING/FAULTY CLUTCH TRBL SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE Air filter (See page 3-7 and 3-29) • Clogged air filter element FUEL SYSTEM Carburetor (See page 6-1 to 6-20) • Faulty diaphragm
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    OVERHEATING/POOR BRAKING PERFORMANCE/ FAULTY FRONT FORK LEGS TRBL SHTG EAS00855 OVERHEATING ENGINE Cylinder heads and pistons (See page 5-53 to 5-59) • Heavy carbon buildup Engine oil (See page 3-20 to 3-21) • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality FUEL SYSTEM
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    UNSTABLE HANDLING/FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00864 UNSTABLE HANDLING Handlebar (See page 4-67 to 4-72) • Bent or incorrectly installed handlebar Steering head components (See page 3-41 to 3-43 and 4-73 to 4-78) • Incorrectly installed upper bracket • Incorrectly installed
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    COLOR CODE B ........... black Br .......... brown Ch ......... chocolate Dg ......... dark green G ........... green Gy ......... gray L............ blue Lg.......... light green O ........... orange P............ pink R............ red Sb ......... sky blue W .......... white Y............ yellow
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    YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
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