Yamaha XVS 125 '00 - Service Manual

EB001000

NOTICE This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone any one who uses this book to perform perfor m maintenance and repairs repair s on Yamaha Yamaha motorcycles has a basic understanding understand ing of the mechanical ideas and the procedures of motorcycle motorcycl e repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving strivin g to improve all its models. Modifications Modifica tions and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

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, installa tion, removal, disassembly, disass embly, assembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS” on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“Periodic checks and Adjustments”), where the sub-section title(-s) appears. (In Chapter 3, “Periodic checks and Adjustments”, the sub-section title appears at the top of each page, instead of the section title.) 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequen-

1

EAS00009

2

GEN INFO 3

SYMBOLS

SPEC 4

CHK ADJ

ENG

5

6

CARB

CHAS

7

8

ELEC

TRBL SHTG

9

10

The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting

Symbols 9 to 16 indicate the following. 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant

EAS00011

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE

GEN INFO

1

SPEC

2

CHK ADJ

3 4

GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL PROCEDURES . . . . . . . . . . . . . . . 1-2 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHER/PLATE AND COTTER PINS . . . . . . . . . . . . . . . . . . . 1-3 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

GEN INFO

MOTORCYCLE IDENTIFICATION

GEN INFO

EB100000

GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB10010

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

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

IMPORTANT INFORMATION

GEN INFO

EB101000

IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly.

2. Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all

IMPORTANT INFORMATION

GEN INFO

EB101030

OR

LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/ plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1 Oil seal

CAUTION: Do not use compressed air to spin the bear-

CHECKING THE CONNECTIONS

GEN INFO

EB103000

CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector S S S

2. Check: lead coupler connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times. S S S

3. Check:

SPECIAL TOOLS

GEN INFO

EB102001

SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.

Tool name / How to use

Bolt 90890-01083

Slide hammer bolt/Weight

Weight 90890-01084

These tools are used to remove the rocker arm shaft.

Valve adjusting Tappet adjusting tool tool

90890-01311 Damper rod holder 90890-01365 T-handle

This tool is used to adjust the valve CLEARANCE. T-handle/ Damper rod holder

These tools are needed to loosen and

Illustration

SPECIAL TOOLS Tool No.

Tool name / How to use Sheave holder

90890-01701 This tool is needed to hold the rotor, when removing or installing the rotor bolt. Clutch holder 90890-04086 This tool is heed to hold the clutch when removing or installing the clutch boss nut. Valve spring compressor 90890-04019 This tool is needed to remove and install the valve assemblies. Valve guide remover (5.0 mm) 90890-04097 This tool is needed to remove the valve guide.

GEN INFO Illustration

SPECIAL TOOLS Tool No.

Tool name / How to use Ignition checker

90890-06754 This instrument is necessary for checking the ignition system components. Compression gauge set 90890-03081 These tools are needed to measure engine compression. Yamaha bond No.1215 90890-85505 This sealant (bond) is used for crankcase mating surfaces, etc.

GEN INFO Illustration

SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 ELECTRICAL SPECIFICATONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

LUBRICATIONS POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-20 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

SPEC

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Item

Standard

Model code

5JX1/5JX2

Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius

2,320 mm 910 mm 1,075 mm 670 mm 1,530 mm 150 mm 2,900 mm

Weight Wet (with oil and a full fuel tank) Dry (with out oil and fuel) Maximum load (total of cargo, rider, passenger, and accessaries)

156 kg 144 kg 183 kg

Limit SSS

SSS SSS SSS SSS SSS SSS SSS

SSS SSS SSS

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS Item 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 (including reserve) Reserve only Engine oil Lubrication system Recommended oil

Standard

Limit

Air-cooled, 4-stroke, SOHC 124 cm3 V-2 cylinder 41  47 mm 11.0 : 1 1,250 X 1,450 r/min 24 kPa (0.24 kg/ cm2)

SSS

1,200 kPa (12 kg/ cm2) at 400 r/min

SSS

Regular unleaded gasoline

SSS

11 L 3.4 L

SSS

Wet sump

SSS

SSS SSS SSS SSS SSS SSS

SSS

SSS

ENGINE SPECIFICATIONS Item

Standard

Limit

Electric starter

Starting system type Spark plugs Model (manufacturer)

SPEC



quantity

Spark plug gap Cylinder head Max. warpage

Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Camshaft lobe dimensions

CR7HSA (NGK), U22FSR-U  1 (DENSO) 0.6 X 0.7 mm SSS

Chain drive (left and right) 22.000 X 22.021 mm 21.96 X 21.98 mm 0.020 X 0.061 mm

SSS

SSS

0.05 mm

SSS SSS SSS SSS

ENGINE SPECIFICATIONS Item

Standard

Timing chain Model/number of links Tensioning system

SILENT CHAIN/110 Automatic

Rocker arm/rocker arm shaft Bearing inside diameter Shaft outside diameter Arm-to-shaft clearance

10.000 9.981 0.009

Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions

Head diameter

Valve head diameter A Intake

SPEC

X

X

0.08 0.10

X

X

Face width

10.015 mm 9.991 mm 0.034 mm

X

0.12 mm 0.14 mm

Seat width

19.9

X

20.1 mm

Limit SSS SSS

10.035 mm 9.961 mm 0.08 mm

SSS SSS

Margin thickness

SSS

ENGINE SPECIFICATIONS Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt

Intake Exhaust

SPEC

Standard

Limit

29.71 mm 29.71 mm

27.81 mm 27.81 mm

25.6 mm 25.6 mm

SSS

120.6 X 138.3 N (12.06 X 13.83 kg) 120.6 X 138.3 N (12.06 X 13.83 kg)

SSS

SSS

2.5_ /1.3 mm 2.5_ /1.3 mm

SSS

SSS

SSS

ENGINE SPECIFICATIONS Item Pistons Piston-to-cylinder clearance Diameter D

Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring

SPEC

Standard 0.02 X 0.04 mm 40.96 X 41.00 mm

3 mm

Limit 0.15 mm SSS

SSS

13.002 X 13.013 mm 0 mm Intake side

13.045 mm

12.996 X 13.000 mm 0.002 X 0.017 mm

12.976 mm

SSS SSS

SSS

ENGINE SPECIFICATIONS Item Connecting rods Crankshaft-pin-to-big-end-bearing clearance

SPEC

Standard 0.020

X

Limit

0.048 mm

SSS

68.00 mm

SSS

Crankshaft

Width A Max. runout C Big end side clearance D Crankshaft-journal-to-crankshaft journal-bearing clearance Clutch Clutch type Clutch release method Clutch release method operation Operation

67.95

X

0.03 mm 0.40 0.020

X

1.05 mm 0.048 mm

X

Wet, multiple disc Inner push, cam push Cable operation Left hand operation

SSS SSS

SSS SSS SSS SSS

ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Max. main axle runout Max. drive axle runout Shifting mechanism Shift mechanism type Max. shift fork guide bar bending installed shift rod length Air filter type

SPEC

Standard Constant mesh, 5-speed Spur gear 85/ 25 (3.400) Chain drive 59/ 16 (3.688) Left-foot operation 37/ 14 32/ 19 29/ 23 26/ 26 23/ 27

(2.643) (1.684) (1.261) (1.000) (0.852)

Limit SSS SSS SSS SSS SSS SSS

SSS SSS SSS SSS SSS

SSS

0.08 mm 0.08 mm

Cam drum

SSS

SSS

0.025 mm

267.8 mm

SSS

Dry element

SSS

SSS

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS Item 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

Standard

Limit

Double cradle 35_ 0’ 135 mm

SSS

Spoke wheel

SSS

18  1.60 Steel 140 mm

SSS

SSS SSS

2.0 mm 2.0 mm

Spoke wheel

SSS

15 M/ C  MT 3.00 Steel 100 mm

SSS

SSS SSS

SSS SSS

SSS SSS

CHASSIS SPECIFICATIONS Item Front brakes Brake type Operation Brake lever free play (at lever end) Recommended fluid Brake discs Diameter  thickness Min. thickness Max. deflection Brake pad lining thickness

Master cylinder inside diameter Caliper cylinder inside diameter Rear brake Brake type Operation Drum inside diameter Shoe thickness Shoe spring free length

SPEC

Standard Single-disc brake Right-hand operation 5 X 8 mm DOT 4 282  5 mm SSS SSS

6.2 mm

12.7 mm 25.4 mm and 30.1 mm Leading, trading brake Right-foot operation 130 mm 4 mm 50.5 mm

Limit SSS SSS SSS SSS

SSS

4.5 mm 0.15 mm 0.8 mm

SSS SSS

SSS SSS

131 mm 2 mm SSS

CHASSIS SPECIFICA SPECIFICATIONS TIONS Item Swingarm Free play (at the end of the swingarm) Radial Axial Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section

SPEC

Standard

Limit

1.0 mm 1.0 mm

SSS SSS

428 V (DID) 146 30 40 mm 129.5 mm X

SSS SSS SSS SSS

ELECTRICAL SPECIFICA SPECIFICATIONS TIONS

SPEC

ELECTRICAL SPECIFICATIONS Item

Standard

Limit

System voltage

12 V

SSS

Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer)

TCI 15_ BTDC at at 1,350 r/ min Throttle position sensor and electrical 192 X 288 Ω / /L L/Y X G/W TNDF60 (DENSO)

SSS

J0226, J0227 (DENSO) 6 mm 3.4 X 4.6 Ω 10.4 X 15.6 kΩ

SSS

4.0 X 6.0 kΩ

SSS

AC magneto TLMX20 (DENSO)

SSS

Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Throttle position sensor standard resistance Charging system System type Model (manufacturer)

SSS SSS SSS SSS

SSS SSS SSS

SSS

ELECTRICAL SPECIFICA SPECIFICATIONS TIONS Item

SPEC

Standard

Indicator light Meter light

12 V 1.7 W  4 12 V 1.7 W  1

Electric starting system System type Starter motor Model Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut

Constant mesh 5JX 0.4 kW 10 mm 5.52 X 8.28 N (563 X 844 gf) 0.0171 X 0.0209 Ω 22 mm 1.5 mm

Starter relay Model (manufacturer) Amperage Coil resistance

MS5F-561 (JIDENCO) 180 A 4.18 X 4.62 Ω

Horn Horn type Model (manufacturer) Max. amperage

Plain YF-12 (NIKKO)  1 3A



quantity

Limit SSS SSS

SSS

SSS SSS

3.5 mm SSS SSS

21 mm SSS

SSS SSS SSS

SSS SSS

GENERAL TORQUE SPECIFICA SPECIFICATIONS/ TIONS/ CONVERSION TABLE

SPEC

EB202001

EAS00028

GENERAL TORQUE SPECIFICATIONS

CONVERSION TABLE

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To To avoid warpage, tighten multi-fastenmulti-f astener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications specification s require clean, dry threads. Components should be at room temperature.

All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC

MULTIPLIER

IMP

** mm

x

0.03937

=

** in

2 mm

x

0.03937

=

0.08 in

CONVERSION TABLE METRIC TO IMP Known

M ul t i pl i er

Result

Torque

mSkg mSkg cmSkg cmSkg

7.233 86.794 0.0723 0.8679

ftSlb inSlb ftSlb inSlb

Weight

kg g

2.205 0.03527

lb oz

km/hr

0.6214

mph

MAINTENANCE SPECIFICA SPECIFICATIONS TIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Tightening torques Part to be tightened Cylinder head and cylinder Cylinder head (timing chain side, long) Cylinder head (timing chain side, short) Cam sprocket cover (hexagon) Cam sprocket cover Cylinder head (exhaust pipe) Cylinder head cover bracket Cylinder head cover Spark plug Tappet cover Valve clearance adjusting lock nut Stopper plate Camshaft sprocket Timing chain guide stopper Plate Timing chain tensioner

Part name Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Screw

Nut Bolt Bolt Bolt Bolt Bolt

Thread

M8 M6 M6 M6 M6 M6 M6 M6 M10 M45 M5 M6 M8 M6 M6 M6

Q’ty 8 4 4 4 2 4 2 4 2 4 4 2 2 4 2 4

Tightening torque Nm

m kg

22 12 12 10 10 7 7 0.7 13 18 7 12 26 10 10 10

2.2 1.2 1.2 1.0 1.0 0.7 0.7 0.07 1.3 1.8 0.7 1.2 2.6 1.0 1.0 1.0

S

Remarks

MAINTENANCE SPECIFICA SPECIFICATIONS TIONS

Part to be tightened Push lever axle Drive sprocket Shift drum segment Shift arm Shift pedal adjuster Neutral switch Stater coil Pickup coil Starter motor

Part name

Thread

Q’ty

SPEC


m kg

Remarks

S

Screw Nut Screw Bolt Nut

M8 M16 M5 M6 M8

1 1 1 1 2

12 60 3.8 8 10

1.2 6.0 0.38 0.8 1.0

Screw Screw Bolt

M10 M6 M5 M6

1 3 2 2

20 7 5 10

2.0 0.7 0.5 1.0

1 of 2 has LH thread

MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence:

SPEC

SPEC

MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques Thread size Upper bracket and inner tube Upper bracket and steering shaft Ring nut (steering shaft) Under bracket and inner tube Main switch and frame Front wheel axle shaft pinch bolt Front brake master cylinder and bracket Upper bracket and handle holder (under) Handlebar holder (upper and lower) Brake hose union bolt Brake hose holder and under bracket Front fender and front fork Headlight stay and under bracket Headlight body and unit Headlight stay and headlight Front turn signal light and under bracket Throttle cable and carburetor Engine mounting:

M8 M22 M25 M12 M8 M8 M6 M10 M8 M10 M6 M6 M6 M5 M6 M6 M6


m kg

20 110 18 30 23 20 7 32 23 30 9 7 7 3 8 7 4

2.0 11.0 1.8 3.0 2.3 2.0 0.7 3.2 2.3 3.0 0.9 0.7 0.7 0.3 0.8 0.7 0.4

S

See NOTE

SPEC

MAINTENANCE SPECIFICATIONS Thread size Fuel cock and tank Fuel tank bracket and frame Speedometer setting nut Speedometer cable Rides seat Passenger seat Front wheel axle shaft Rear wheel axle shaft Front brake caliper and front fork Brake disk Rear wheel sprocket Caliper bleed screw Brake hose union bolt Chain puller lock nut Sidestand bolt and nut Footrest assembly mounting Rear footrest bracket and frame Sidestand switch Sidestand switch panel and frame NOTE:

M6 M8 M5 M12 M6 M8 M16 M14 M10 M8 M10 M7 M10 M8 M10 M10 M8 M5 M6


m kg

7 23 3 3 7 16 59 104 40 23 40 6 30 16 40 40 26 4 7

0.7 2.3 0.3 0.3 0.7 1.6 5.9 10.4 4.0 2.3 4.0 0.6 3.0 1.6 4.0 4.0 2.6 0.4 0.7

S

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EB203000

LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Oil seal lips O-ring Bearing Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX)

Symbol

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

EB203010

CHASSIS Lubrication point Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface Tube guide (throttle grip) inner surface Brake lever pivot bolt, contact surface

Symbol

ENGINE OIL LUBRICATION CHART SPECIFICATIONS

ENGINE OIL LUBRICATION CHART SPECIFICATIONS Item Lubrication chart:

Standard

SPEC

ENGINE OIL FLOW DIAGRAMS EB205000

ENGINE OIL FLOW DIAGRAMS

SPEC


SPEC


SPEC

CABLE ROUTING

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10

Right handlebar switch lead Front brake light switch lead Main switch Brake hose Clutch switch lead Left handlebar switch lead Starter cable Clutch cable Headlight lead Throttle cables

A Install the coupler between left ignition coil and right ignition coil. B Insert rubber bracket, into the relay stay tightly for the relay and thermo switch. C Route the clutch cable through forward of head pipe and outside of throttle cable.

SPEC

CABLE ROUTING 1 2 3 4 5 6 7 8 9

Rectifier/regulator Ignition coil Front brake light switch lead Right handlebar switch lead Brake hose Throttle cables Clutch cable High tension code Rear brake light switch lead

A Connect the ignition coil read. (red lead: lower) (orange lead: upper) Connect the ignition coil lead terminal so that it faces the out side of the frame. B Route the right handlebar switch lead and front brake light switch lead through the hole of the frame from inside to outside. C Connect the rear brake light switch lead coupler between the band and the holder.

SPEC

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Clutch switch lead Left handlebar switch lead Clutch cable Starter cable Speedometer Speedometer cable Igniter unit Starting circuit cut-off relay Fuse box Sidestand switch lead Air filter breather hose High tension code Throttle position sensor lead Carburetor heater ground lead Carburetor heater lead Flasher relay Headlight relay

18 19 20 21 22 23 24 25

Thermo switch lead Thermo switch Horn lead Horn Ignition coil Headlight lead Wire harness Throttle cables

SPEC

CABLE ROUTING

SPEC

A Put in the speedometer lead cou- E Clamp the wire harness. K Clamp between the left handlepler into the fuel tank filler box. F Throttle position sensor coupler bar switch lead coupler and the B Route the speedometer cable under the wireharness. right handlebar switch lead couspeedometer lead and fuel tank G To the engine. pler. breather hose through the hole H Connect the ignition coil lead. L Line up the leads during installaof fuel tank. (red lead: lower) tion. C Clamp the white tape of wire har(gray lead: upper) M Run all leads along the frame. ness. (fix the position) Face the clamp end (extra posi- N Pass between the holder and enD Clamp the back sides of the left tion) toward the at side of the gine stay (left side). handlebar switch lead and clutch frame. switch lead couplers (3 loca- I Insert the front turn signal light tions). Face the end of the clamp leads and headlight lead from (extra position) toward the inside outside of headlight to inside. of the frame. Clamp immediately J Pass the throttle position sensor after the wireharness branch lead through the fuel hose down (leftand right hand lebar switch stream side. lead.)

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11

Throttle cables Brake hose Battery negative (–) lead Regulator lead Tail/brake light lead Starter relay Clutch cable Starter cable Alarm lead Inner panel Battery positive (+) lead

SPEC

A Through the speedometer cable H Fasten the wireharness, high between frame of tank rail and tension code, and throttle posiwireharness. tion sensor with a band. B Through the fuel tank breather I Fasten the wireharness, left hose between wireharness and handlebar switch lead, high tenleads. sion code, clutch switch lead, C Position an open side of clamp to right handlebar switch lead and rear frame and assemble. front brake light switch lead with D Face the end of the band (extra a band. portion) toward the bottom of the J To the fuel tank. frame. K Fasten the wireharness, left Items to be clamped with a band: handlebar switch lead clutch regulator lead, brake light lead. switch lead, right handlebar E To the rear fender. switch lead front brake switch F Cut the end of band position: lead, throttle cables, and starter Front upper band of frame. cable with a band. G To the engine.

CABLE ROUTING L Put an alarm coupler into this O Face the end of the band (extra position. portion) toward the bottom of the (surrounded part by vertical frame. Item to be clamped: regupanel inner wall.) lator lead, brake light lead, A, C. M To the starter motor. magneto lead, pickup coil lead, N Face the end of the clamp (extra side stand switch lead. portion) toward the inside of the P Berd the alarm lead once and frame. band to burdle it together with Item to be clamped: wireharthe wireharness. ness, battery negative leads (2 leads), starter motor lead, alarm read, A, C. magneto lead, side stand switch read.

SPEC

CHK ADJ CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE / LUBRICATON INTERVALS . . . . . . . . . . . . 3-1 RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 FUEL TANK AND AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-6 ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-11 CHECKING THE SPARK PUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-15 CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-19

CHK ADJ ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . 3-40 CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000

CHK ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS NO. 1

ITEM *

2 3

Fuel line Spark plugs

*

Valves

4

Air filter

5

Clutch

CHECKS AND MAINTENANCE JOBS

*

Front brake

√

Check condition. Clean, regap or replace if necessary.

√

S

Check valve clearance. Adjust if necessary.

√

S

Clean or replace if necessary.

√

S

S S

S

S S

S S

S

7

*

Rear brake

Every 6,000 km

Check fuel hoses and vacuum hose for cracks or damage. Replace if necessary.

S

S

6

Initial 1,000 km

S

Every 12,000 km

Annual check √

Check operation. Adjust or replace cable.

√

√

Check operation, fluid level and vehicle for fluid leakage. Correct accordingly. Replace brake pads if necessary.

√

√

√

Check operation. Adjust brake pedal freeplay and replace brake shoes if necessary.

√

√

√

CHK ADJ

PERIODIC MAINTENANCE/LUBRICATION INTERVALS NO.

ITEM

22

CHECKS AND MAINTENANCE JOBS

Initial 1,000 km

Engine oil filter element

S

Replace.

√ √

23

*

Front and rear brake switches

S S

Check operation. Correct accordingly.

24

*

Moving parts and cables

S

Lubricate if necessary.

*

Lights, signals and switches

S

25

Check operation. Correct if necessary. Adjust headlight beam if necessary.

S S

√

Every 6,000 km

Every 12,000 km

Annual check

√ √

√

√

√

√

√

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

NOTE: D The annual checks must be performed every year, except if a 6,000 km or 12,000 km maintenance is performed instead. D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. D Hydraulic brake service S Regularly check and, if necessary, correct the brake fluid level. S Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. S Replace the brake hoses every four years and if cracked or damaged.

CAUTION: The carburetor on this motorcycle has a built-in accelerator pump. Therefore, when engine is stopped or is operated without load, do not open and shut a throttle grip.

RIDER AND PASSENGER SEATS

CHK ADJ

RIDER AND PASSENGER SEATS

7 Nm (0.7 m kg) S

16 Nm (1.6 m kg) S

CHK ADJ

FUEL TANK AND AIR FILTER


7 Nm (0.7 m kg) S

23 Nm (2.3 m kg) S


CHK ADJ

REMOVAL 1. Remove: Ignitor plate S

NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out.

INSTALLATION

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

EAS00047

ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. S

S

1. Remove: rider and passenger seats Refer to “RIDER AND PASSENGER SEATS”. fuel tank Refer to “FUEL TANK”. 2. Disconnect: spark plug caps 3. Remove: spark plugs 4. Remove: air filter assembly 1 S

S

S

S


CHK ADJ

7. Remove: tappet covers 1 S

8. Remove: camshaft sprocket cover (front cylinder) 1 camshaft sprocket cover (rear cylinder) S S

9. Remove:


A

B

CHK ADJ

a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compression stroke, align either the alignment mark in the camshaft sprocket (front cylinder) a or alignment mark in the camshaft sprocket (rear cylinder) c , dependant on which cylinder you are checking, with the stationary pointer b on the cylinder head. When the hole in the camshaft sprocket plate or punch mark in the camshaft sprocket is aligned with the stationary pointer, the piston is at top dead center (TDC). c. Align the TDC mark d on the generator rotor with the stationary pointer e on the generator cover. A Front cylinder (“T” mark) B Rear cylinder (“I” mark)

d. Measure the valve clearance with a thick-

ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED

CHK ADJ

Locknut: 7 Nm (0.7 mkg) e. Measure the valve clearance again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 12. Install: all removed parts S

NOTE: Install all removed parts in the reverse order of their disassembly. Note the following points. S

camshaft sprocket covers 10 Nm (1.0 m kg) S

S

tappet covers 18 Nm (1.8 m kg) S

S

spark plugs 13 Nm (1.3 m kg) S

ADJUSTING THE IDLING SPEED

CHK ADJ

a. Turn the pilot screw in or out until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Pilot screw 2 turns out c. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a

Engine idling speed is increased.

Direction b

Engine idling speed is decreased.

5. Adjust: throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. S

Throttle cable free play (at the flange of the throttle grip)

ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK ADJ

EAS00058

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: throttle cable free play a Out of specification ! Adjust. S

Throttle cable free play (at the flange of the throttle grip) 3  5 mm 2. Remove: fuel tank 3. Adjust: throttle cable free play S

S

Carburetor side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b

ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS

CHK ADJ

WARNING After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

4. Install: fuel tank S

EAS00060

CHECKING THE SPARK PLUGS 1. Disconnect: spark plug cap 2. Remove: spark plug S

S

CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder.

CHECKING THE SPARK PLUGS 7. Install: spark plug S

CHK ADJ 13 Nm (1.3 m kg) S

NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: spark plug cap S

CHECKING THE IGNITION TIMING

CHK ADJ

EAS00062

CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: timing plug 1 2. Install: timing light 1 engine tachometer 2 (to the spark plug lead of cyl. #1) S

S S

Timing light 90890-03141 Engine tachometer 90890-03113 3. Check: ignition timing S

MEASURING THE COMPRESSION PRESSURE

CHK ADJ

EAS00065

MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: spark plug cap 4. Remove: spark plug S

S

S

CAUTION:

MEASURING THE COMPRESSION PRESSURE

CHK ADJ

Refer to the following table. Compression pressure (with oil applied into cylinder) Reading

Diagnosis

Higher than without oil

Piston wear or damage ! Repair.

Same as without oil

Piston ring(-s), valves, cylinder head gasket or piston possibly defective ! Repair. Compression pressure (at sea level)

Compression pressure (at sea level): Standard: 1.200 kPa (12 kg/cm2, 12 bar) Minimum: 1.100 kPa (11 kg/cm2, 11 bar) Maximum: 1.300 kPa (13 kg/cm2, 13 bar)

CHECKING THE ENGINE OIL LEVEL

CHK ADJ

EAS00069

CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. S S

2. Let the engine idle for a few minutes. 3. Check: engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b . Below the minimum level mark ! Add the recommended engine oil to the proper level. S

Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade

CHANGING THE ENGINE OIL

CHK ADJ

EAS00075

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:

WARNING Be careful not touch the exhaust pipe when removing or attaching the engine oil filler cap 1 or when adding oil. engine oil filler cap 1 engine oil drain bolt 2 (along with the gasket) 4. Drain: engine oil (completely from the crankcase) 5. If the oil filter element is also to be replaced, perform the following procedure. S S

S

a. Remove the oil filter element cover 1 and oil

CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY

CHK ADJ

Quantity Total amount 1.75 L Without oil filter element replacement 1.4 L With oil filter element replacement 1.6 L 9. Install: engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: engine (for engine oil leaks) 12. Check: engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. S

S

S

EAS00078

ADJUSTING THE CLUTCH CABLE FREE

ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT

CHK ADJ

b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a

Clutch cable free play is increased.

Direction b

Clutch cable free play is decreased

c. Tighten the locknuts 1 . CLEANING THE AIR FILTER ELEMENT 1. Remove: air filter case assembly 1 S

S

air filter element 2

CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD

CHK ADJ

CAUTION: Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks.

EAS00094

CHECKING THE CARBURETOR JOINT AND

CHECKING THE FUEL HOSES/ CHECKING THE CRANKCASE BREATHER HOSE

CHK ADJ

EAS00097

CHECKING THE FUEL HOSES The following procedure applies to all of the fuel hoses. 1. Remove: fuel tank silencer 2. Check: fuel hose 1 Cracks/damage ! Replace. Damage/dirt ! Replace. S S

S

NOTE: Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. S

3. Install: silencer fuel tank S S

EAS00098

CHECKING THE CRANKCASE BREATHER

CHK ADJ

CHECKING THE EXHAUST SYSTEM EAS00100

CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipe, muffler and gaskets. 1. Check: exhaust pipe 1 muffler 2 Cracks/damage ! Replace. gaskets 3 Exhaust gas leaks ! Replace. 2. Check: tightening torque S S

S

S

Exhaust pipe nut 4 10 Nm (1.0 m kg) Exhaust pipe and muffler bolt 5 10 Nm (1.0 m kg) Muffler and muffler bracket bolt 6 25 Nm (2.5 m kg) Front exhaust pipe and muffler 7 12 Nm (1.2 m kg) S

S

S

S

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE

CHK ADJ

EAS00108

CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: brake lever free play a Out of specification ! Adjust. S

Brake lever free play (at the end of the brake lever) 5  8 mm 2. Adjust: brake lever free play S

a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake lever free play is obtained. Direction a

Brake lever free play is increased.

Direction b

Brake lever free play is decreased.

CHK ADJ

ADJUSTING THE REAR BRAKE 2. Adjust: brake pedal position S

a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a

Brake pedal is raised.

Direction b

Brake pedal is lowered.

c. Tighten the locknut to specification. Locknut 10 Nm (1.0 m kg) S

3. Check: brake pedal free play a Out of specification ! Adjust. S

Brake pedal free play 20  30 mm

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 that the motorcycle is upright. S S

2. Check: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. S

Recommended brake fluid DOT 4 Front brake

WARNING S

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

CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHK ADJ

EAS00117

CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: brake pad Wear indicators 1 almost touch the brake disc ! Replace the brake pads as a set. Refer to “FRONT BRAKE” in chapter 6. S

EAS00126

CHECKING THE BRAKE SHOES 1. Operate the brake. 2. Check: wear indicator 1 Reaches the wear limit line 2 ! Replace the brake shoes as a set. Refer to “REAR WHEEL” in chapter 6. S

EAS00128

ADJUSTING THE REAR BRAKE LIGHT

CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK ADJ

EAS00129

CHECKING THE BRAKE HOSE 1. Check: brake hose 1 Cracks/damage/wear ! Replace. 2. Check: brake hose clamp Loose connection ! Tighten. 3. Hold the motorcycle upright and apply the front or rear brake. 4. Check: brake hose Activate the brake several times. Brake fluid leakage ! Replace the damaged hose. Refer to “FRONT BRAKE” in chapter 6. S

S

S

EAS00133

BLEEDING THE HYDRAULIC BRAKE SYS-

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK ADJ

1. Bleed: hydraulic brake system S

a. Add the recommended brake fluid to the proper level. b. Install the brake master cylinder reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . d. Place the other end of the hose into a container. e. Slowly squeeze the brake lever several times. f. Fully squeeze the brake lever without releasing it. g. Loosen the bleed screw. This will release the tension and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK

CHK ADJ

EAS00137

ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the ad justing bolt length a . 1. Measure: adjusting the length a Incorrect ! Adjust. S

Adjusting bolt length 276.8 mm 2. Adjust: adjusting bolt length a S

a. Loosen both locknuts 1 b. Turn the adjusting bolt 2 in direction b or c to obtain the correct shift pedal position. Direction b Direction c

!

shift pedal is raised.

!

shift pedal is lowered.

ADJUSTING THE DRIVE CHAIN SLACK

CHK ADJ

2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Check: drive chain slack a Out of specification ! Adjust. S

Drive chain slack 30  40 mm 4. Adjust: drive chain slack S

a. Loosen the wheel axle nut 1 . Loosen the locknut 3 . b. Turn the chain puller nut 2 in direction a or b until the specified drive chain slack is obtained. Direction a

Drive chain is tightened.

Direction b

Drive chain is loosened.

NOTE:

LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

EAS00142

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

CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

3. Remove: handlebar upper bracket pinch bolt 1 steering stem nut 2 upper bracket 3 S S S S

4. Adjust: steering head S

a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the ring nut wrench.

CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK

CHK ADJ

e. Install the rubber washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer 1 . NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b .

5. Install: upper bracket steering stem nut 110 Nm (11.0 m kg) upper bracket pinch bolt S S

S

S

20 Nm (2.0 m kg) S

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

CHK ADJ

EAS00156

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

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

CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: spring preload S

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

CHECKING THE TIRES

CHK ADJ

EAS00164

CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: tire pressure Out of specification ! Regulate. S

WARNING The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE. S

S

S

CHECKING THE TIRES

CHK ADJ

1 Tire tread depth 2 Side wall 3 Wear indicator

WARNING S

S

S

S

S

Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using tube tires, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure that 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 replacement. Tube wheel

Tube tire only

CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES

CHK ADJ

Rear tire Manufacturer

Type

Size

CHENG SHIN

C-915

130/90-15 M/ C 66P

MARBELLA NR31

130/90-15 M/ C 66P

INOUE

WARNING S

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

NOTE: For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in the direction of wheel rotation. Align the mark 2 with the valve installation point. S

S

CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION

CHK ADJ

EAS00170

CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.

WARNING Damaged cable sheaths may causes the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: cable sheath Damage ! Replace. 2. Check: cable operation Unsmooth operation ! Lubricate. S

S

Recommended lubricant Engine oil or a suitable cable lubricant

CHECKING AND CHARGING THE BATTERY

CHK ADJ

EB305020

ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY

WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. S

S S

S

S

S


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. 1. Remove: S battery cover 1

2. Disconnect: S battery leads (from the battery terminals)

CAUTION: First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: battery

CHECKING AND CHARGING THE BATTERY Ambient temperature 20_C ) V (

e g a t l o v t i u c r i c n e p O

WARNING Do not quick charge a battery.

CAUTION: Make sure that the battery breather hose and battery vent are free of obstructions. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.) S To reduce the chance of sparks, do not plug in the battery charger until the battery S

Condition of charge in battery (%)

Charging ) V ( e g a t l o v t i u c r i c n e p O

CHK ADJ

Ambient temperature 20_C

18 17 16 15 14 13 12 11 10

0

10

20

30

40

50

60 Time (Minutes)

Check the Open-circuit voltage


CHK ADJ

Charging method using a variable-current (voltage) type charger Charger AMP meter

Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery and start charging.

YES

Make sure the current is higher than the standard charging current written on the battery.

NOTE: Voltage should be measured 30 minutes after the machine is stopped.

NOTE: Set the charging voltage at 16  17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)

NO

By turning the charging voltage adjust dial, set the charging voltage at 20  25 V. Adjust the voltage so that cur-

YES

Monitor the amperage for 3 


CHK ADJ

Charging method using a constant-voltage type charger Measure the open-circuit voltage prior to charging.

NOTE: Voltage should be measured 30 minutes after the machine is stopped.

Connect a charger and AMP meter to the battery and start charging.

YES

Make sure the current is higher than the standard charging current written on the battery.

NO


CHK ADJ

6. Check: battery breather hose and battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: battery S

S

CAUTION: S

S

When inspecting the battery, make sure that the battery breather hose is properly attached and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the battery to contact the frame, the motorcycle and its finish may be damaged. Make sure that the battery breather hose is properly routed away from the drive chain and from below the swingarm.

8. Connect: battery leads (to the battery terminals) S

CHECKING THE FUSES

CHK ADJ

EAS00181

CHECKING THE FUSES The following procedure applies to all of the fuses.

CAUTION: To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a fuse. 1. Remove: left side cover 1 2. Check: fuse S

S

a. Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the pocket tester selector to “Ω  1”. Pocket tester 90890-03112 b. If the pocket tester indicates “ ”, replace the

CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB

CHK ADJ

WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: left side cover S

EAS00182

REPLACING THE HEADLIGHT BULB

REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM

CHK ADJ

CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: headlight bulb holder 7. Install: headlight bulb cover 8. Connect: leads S

S

S

EAS00184

ADJUSTING THE HEADLIGHT BEAM

ENG CHAPTER 4. ENGINE ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

DRIVE SPROCKET AND EXHAUST PIPES . . . . . . . . . . . . . . . . . . . . 4-1 LEADS, SHIFT PEDAL AND CLUTCH CABLE . . . . . . . . . . . . . . . . . . 4-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

FRONT CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 REAR CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 4-11 INSTALLILNG THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . 4-11 ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-16 CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 CHECKING THE ROCKER ARMS AND

ENG REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 REMOVING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . 4-43 CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . 4-46 CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . 4-46 INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-47 INSTALLILNG THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50

CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . 4-54 CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 CHECKING THE SHIFT LEVER 4 56

ENGINE REMOVAL

ENG

ENGINE ENGINE REMOVAL DRIVE SPROCKET AND EXHAUST PIPES

7 Nm (0.7 m kg) S

60 Nm (6.0 m kg) S

7 Nm (0.7 m kg) S

10 Nm (1.0 m kg) S

ENGINE REMOVAL

7 Nm (0.7 m kg) S

ENG

60 Nm (6.0 m kg) S

7 Nm (0.7 m kg) S

10 Nm (1.0 m kg) S

ENGINE REMOVAL LEADS, SHIFT PEDAL AND CLUTCH CABLE

ENG

ENGINE REMOVAL

ENG

EAS00191

ENGINE

35 Nm (3.5 m kg) S

35 Nm (3.5 m kg) S

35 Nm (3.5 m kg) S

ENGINE

ENG

EAS00192

INSTALLING THE ENGINE 1. Install: bolt (front under) 1 bolt (rear under) 2 bolt (rear upper) 3 bolt (front upper) 4 engine bracket 5 engine bracket 6 engine brackets 7 S S S S S S S

NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. 35 Nm (3.5 m kg) self locking nut 8 bolt (front upper) 4 35 Nm (3.5 m kg) 9 engine bracket bolts S

S

S

S

S

35 Nm (3.5 m kg) S

3. Install: chain cover S

CAUTION:

CYLINDER HEADS

ENG

CYLINDER HEADS FRONT CYLINDER HEAD

10 Nm (1.0 m kg) S

22 Nm (2.2 m kg) S

12 Nm (1.2 m kg) S

10 Nm (1.0 m kg) S

CYLINDER HEADS REAR CYLINDER HEAD 22 Nm (2.2 m kg) S

12 Nm (1.2 m kg) S

26 Nm (2.6 m kg) S

ENG

CYLINDER HEADS

ENG

REMOVING THE CYLINDER HEADS Front cylinder head 1. Remove: camshaft sprocket cover tappet cover timing plug straight plug S S S S

2. Align: “T” mark a on the generator rotor (with the stationary pointer b on the crank case cover) S

Turn the crankshaft counterclockwise.

CYLINDER HEADS

ENG

4. Remove: S timing chain tensioner 1 S gasket 2

5. Remove: S bolt (camshaft sprocket) 1 S camshaft sprocket 2 NOTE: To prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: S cylinder head NOTE: S Loosen the bolts in the proper sequence.

CYLINDER HEADS

ENG

EAS00228

CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 1. Eliminate: combustion chamber carbon deposits (with a rounded scraper) S

NOTE: Do not use a sharp instrument to avoid damaging or scratching: spark plug threads valve seats S S

2. Check: cylinder head Damage/scratches ! Replace. 3. Measure: cylinder head warpage Out of specification Resurface the cylinS

S

CYLINDER HEADS

ENG

EB401430

CHECKING THE TIMING CHAIN TENSIONER 1. Check: timing chain tensioner Cracks/damage/rough movement ! Replace. S

a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.

CYLINDER HEADS

ENG

3. Tighten: bolts (cylinder head) M8 1 22 Nm (2.2 m kg) M6 2 12 Nm (1.2 m kg) S

S

S

NOTE: Lubricate the cylinder head bolts with engine oil. Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages. S

S

4. Install:

ENG

CYLINDER HEADS WARNING Always use a new gasket.

Timing chain tensioner bolt 10 Nm (1.0 m kg) S

d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Cap bolt 8 Nm (0.8 m kg) S

6. Install: camshaft sprocket 1

CYLINDER HEADS

ENG

1. Install: S camshaft sprocket a. Turn the crankshaft counterclockwise 300_. b. Align the “I” mark a with the stationary pointer b on the generator cover. c. Install the camshaft sprocket with the timing mark c facing out. d. Turn the camshaft just enough to remove any slack from the intake side of the timing chain. e. Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward. f. While pushing the timing chain guide, be sure that the timing mark c and the stationary pointer d are properly aligned at TDC.

ENG

ROCKER ARMS AND CAMSHAFT


7 Nm (0.7 m kg) S

7 Nm (0.7 m kg) S

12 Nm (1.2 m kg) S


ENG

REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: lock nuts 1 adjusting screws 2 2. Remove: rocker arm shaft rocker arm 3 S S

S S

NOTE: Remove the rocker arm shafts with the slide hammer 1 and weight. Slide hammer bolt 90890-01083 Weight: 90890-01084 3. Remove:


ENG

4. Check: camshaft oil passage Obstruction ! Blow out with compressed air. S

EAS00206

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: rocker arm 1 Damage/wear ! Replace. 2. Check: rocker arm lobe 2 Excessive wear ! Replace the rockerarm. 3. Check: rocker arm shaft Blue discoloration/excessive wear/pitting/scratches ! Replace or check the luS

S

S


ENG

EAS00220

INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: camshaft S

Recommended lubricant Camshaft/Bushing Molybdenum disulfide oil 2. Install: camshaft 1 camshaft bushing 2 S S

NOTE:


ENG

5. Install: rocker arms rocker arm shafts S S

NOTE: Make sure that the rocker arm shafts is completely pushed into the cylinder head.

VALVES AND VALVE SPRINGS


ENG


ENG

EAS00237

REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Check: valve sealing Leakage at the valve seat ! Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. S

a. Pour a clean solvent 1 into the intake and exhaust ports. b. Check that the valves properly seal. There should be no leakage at the valve seat 2.

ENG

VALVES AND VALVE SPRINGS Out of specification guide.

!

Replace the valve

Valve-stem-to-valve-guide clearance Intake 0.010  0.037 mm : 0.08 mm Exhaust 0.025  0.052 mm : 0.1 mm

2. Replace. S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven.

a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide


ENG

5. Meas Measur ure: e: valve margin thickness a Out of specification ! Replace the valve. S

Valve margin thickness Intake 0.5  0.9 mm Exhaust 0.7  1.3 mm 6. Meas Measur ure: e: valve stem runout Out of specification ! Replace the valve. S

NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the valve stem seal. S

S

Valve stem runout 0.02 mm EAS00240

CHECKING THE VALVE SEATS


ENG

4. Lap: valve face valve seat S S

NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

a. Apply Apply a coarse lappin lapping g compound compound to the valve face.

CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply Apply molybdenu molybdenum m disulfide disulfide oil onto onto the valve stem. c. Insta Installll the valve valve into into the cylinde cylinderr head. head. d. Turn the valve until the valve face and valve valve seat are evenly polished, then t hen clean off all of


ENG

EAS00241

CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Me Meas asur ure: e: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length (intake and exhaust) 29.71 mm : 27.81 mm 2. Meas Measur ure: e: S compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force Compressed Intake and exhaust spring 129 N at 25.6 mm


ENG

NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch

4. Inst Instal all: l: valve cotters S

NOTE: Install the valve cotters by compressin compressing g the valve spring with the valve spring compressor 1 . Valve spring compressor 90890-04019 5. To secure the valve cotters onto the valve

CYLINDERS AND PISTONS


ENG


ENG

EAS00254

REMOVING THE PISTONS The following procedure applies appli es to all of the pistons. 1. Re Remo move ve:: piston pin clip 1 piston pin 2 piston 3 S S S

CAUTION: Do not use a hammer to drive the piston pin out. NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. For reference during installation, put an identification mark on each piston crown. Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston S

S

S


ENG

2. Measure: piston-to-cylinder clearance S

a. Measure cylinder bore “C” with the cylinder bore gauge. a 45 mm from the top of the cylinder NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.

Cylinder bore C:

Standard

Wear limit

40.99  41.03 mm

41.1 mm

C=

X+Y 2

b. If out of specification, rebore or replace the


ENG

EB404410

CHECKING THE PISTON RINGS 1. Measure: piston ring side clearance Out of specification ! Replace the piston and piston rings as a set. S

NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.02  0.08 mm : 0.12 mm 2nd ring 0.02  0.06 mm : 0.12 mm

2. Install:


ENG

EAS00266

CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Check: piston pin Blue discoloration/grooves ! Replace, then inspect the lubrication system. S

2. Measure: piston pin outside diameter a Out of specification ! Replace the piston pin. S

Piston pin outside diameter 12.996  13.000 mm 3. Measure: piston pin bore inside diameter b Out of specification ! Replace the piston S

Piston pin bore inside diameter 13.002  13.013 mm


ENG

2. Install: piston 1 piston pin 2 piston pin clip New 3 NOTE: Apply engine oil onto the piston pin. Make sure that the “EX” mark a on the piston faces towards the exhaust side of the engine. Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase. S S S

S S

S

3. Install: gasket New dowel pins 4. Lubricate: piston piston rings cylinder (with the recommended lubricant) S S

S S S

Recommended lubricant

GENERATOR AND STARTER CLUTCH

GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL

5 Nm (0.5 m kg) S

7 Nm (0.7 m kg) S

ENG

GENERATOR AND STARTER CLUTCH GENERATOR ROTOR AND STARTER CLUTCH

ENG


ENG

REMOVING THE GENERATOR 1. Remove: footrest/ shift pedal Refer to “ENGINE REMOVAL”. generator cover S

S

2. Remove: generator rotor nut 1 washer S S

NOTE: While holding the generator rotor 2 with the sheave holder 3 , loosen the generator rotor nut. Do not allow the sheave holder to touch the projection on the generator rotor. S

S

Sheave holder


ENG

EAS00351

CHECKING THE STARTER CLUTCH 1. Check: starter clutch idler gear 1 starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(-s). 2. Check: starter clutch gear’s contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear. S S

S

3. Check: starter clutch operation S

a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced.


ENG

INSTALLING THE GENERATOR 1. Install: starter clutch assembly woodruff key generator rotor washer generator nut S S S S S

NOTE: Clean the tapered portion of the crankshaft and the generator rotor hub. When installing the generator rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. S

S

2. Tighten: generator rotor nut 1 S

80 Nm (8.0 m kg) S

NOTE: While holding the generator rotor 2 with the sheave holder 3 , tighten the generator rotor nut. Do not allow the sheave holder to touch the projection on the generator rotor. S

S

CLUTCH

ENG

CLUTCH CLUTCH COVER

10 Nm (1.0 m kg) S

CLUTCH

ENG

10 Nm (1.0 m kg) S

CLUTCH

ENG

CLUTCH

80 Nm (8.0 m kg) S

CLUTCH

ENG

80 Nm (8.0 m kg) S

CLUTCH PUSH LEVER SHAFT

ENG

CLUTCH

ENG

EAS00276

REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: clutch boss nut 1 S

NOTE: While holding the clutch boss 2 with the universal clutch holder, loosen the clutch boss nut. Universal clutch holder 90890-04068 3. Remove: clutch boss nut 1 lock washer 2 clutch boss 3 S S S

EAS00279

REMOVING THE PRIMARY DRIVE GEAR

CLUTCH

ENG

EAS00280

CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: friction plate Damage/wear ! Replace the friction plates as a set. 2. Measure: friction plate thickness Out of specification ! Replace the friction plates as a set. S

S

NOTE: Measure the friction plate at four places. Friction plate thickness 2.9  3.1 mm : 2.5 mm

EAS00281

CHECKING THE CLUTCH PLATES

CLUTCH

ENG

EAS00282

CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: clutch spring Damage ! Replace the clutch springs as a set. S

2. Measure: clutch spring free length Out of specification ! Replace the clutch springs as a set. S

Clutch spring free length 34.6 mm : 33.6 mm

EAS00284

CHECKING THE CLUTCH HOUSING

CLUTCH

ENG

EAS00286

CHECKING THE PRESSURE PLATE 1. Check: pressure plate 1 Cracks/damage ! Replace. S

EAS00288

CHECKING THE CLUTCH PUSH RODS 1. Check: O-ring 1 short clutch push rod 2 long clutch push rod 3 ball 4 Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: long clutch push rod bending limit Out of specification ! Replace the long clutch push rod. S S S S

S

CLUTCH

ENG

INSTALLING THE PRIMARY DRIVE GEAR 1. Install: straight key primary drive gear 1 thrust washer lock washer 2 primary drive gear nut 3 S S S S S

80 Nm (8.0 m kg) S

NOTE: While holding the generator rotor with the sheave holder, tighten the primary drive gear nut. Sheave holder 90890-01701

EAS00298

INSTALLING THE CLUTCH

CLUTCH

ENG

5. Install: friction plates clutch plates S S

NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. Align the slot a in the friction plates with the marks b in the clutch housing. S

S

6. Install: long clutch push rod ball 7. Install: short clutch push rod 1 O-ring 2 New push plate 3 washer 4 nut 5 S S

S S S S S

8. Install:

ENG

CLUTCH 10. Adjust: push lever position S

a. Loosen the locknut 1 . b. Turn the adjusting screw 2 in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification.

CAUTION: Do not overtighten the locknut since this will remove the free play between both push rods. Push lever lock nut 8Nm (0.8m kg) S

11. Install:

OIL PUMP

ENG

OIL PUMP

7 Nm (0.7 m kg) S

7 Nm (0.7 m kg) S

OIL PUMP

7 Nm (0.7 m kg) S

ENG

OIL PUMP

ENG

CHECKING THE OIL PUMP 1. Check: oil pump drive gear 1 oil pump driven gear 2 oil pump housing oil pump housing cover Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance a outer-rotor-to-oil-pump-housing clearance b oil-pump-housing-to-inner-rotor-and-outerrotor clearance c Out of specification ! Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing S S S S

S S

S

Inner-rotor-to-outer-rotor-tip clearance 0.15 mm : 0.2 mm

OIL PUMP

ENG

2. Install: oil pump shaft 1 (to the oil pump cover 2 ) pin 3 inner rotor 4 outer rotor 5 pins 6 oil pump housing 7 screw 7 Nm (0.7 m kg) S

S S S S S S

S

NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4 . 3. Check: oil pump operation Refer to “CHECKING THE OIL PUMP”. S

SHIFT SHAFT

SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER

ENG

SHIFT SHAFT

ENG

SHIFT SHAFT

ENG

EAS00328

CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 stopper lever 2 Bends/damage/wear ! Replace stopper lever spring 3 Roller turns roughly ! Replace the shift lever. S S

S

EB408410

CHECKING THE SHIFT LEVER 1. Check: shift lever 1 Bends/damage/wear ! Replace. shift lever spring 2 Damage/wear ! Replace. S

S

INSTALLING THE SHIFT SHAFT

CRANKSHAFT AND CONNECTING RODS

CRANKSHAFT AND CONNECTING RODS CRANKSHAFT ASSEMBLY

10 Nm (1.0 m kg) S

ENG


10 Nm (1.0 m kg) S

ENG

CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS

ENG


ENG

EAS00386

DISASSEMBLING THE CRANKCASE 1. Remove: crankcase bolts S

NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence. S

S

S

2. Remove:


ENG

EAS00394

CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: crankshaft runout Out of specification ! Replace the crankshaft, bearing or both. S

NOTE: Turn the crankshaft slowly. Crankshaft runout Less than 0.03 mm 2. Measure: big end side clearance Out of specification ! Replace the big end bearing, crankshaft pin, or connecting rod. S

Big end side clearance 0.40  1.05 mm Limit 1.5 mm 3. Me


ENG

EAS00401

CHECKING THE BEARINGS AND OIL SEALS 1. Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2. Check: oil seals Damage/wear ! Replace. S

S

EAS00207

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1. Check: timing chain Damage/stiffness ! Replace the timing chain and camshaft sprocket as a set. S

2. Check:


ENG

EAS00408

INSTALLING THE CRANKSHAFT 1. Install: crankshaft assembly 1 S

CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing. EAS00418

ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: sealant (onto the crankcase mating surfaces) S

Yamaha bond No. 1215 90890-85505 NOTE:

TRANSMISSION TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

ENG

TRANSMISSION

ENG

TRANSMISSION

ENG

EAS00420

REMOVING THE TRANSMISSION 1. Remove: drive axle assembly 1 main axle assembly 2 Remove them at same the time. S S

EAS00421

CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: shift fork cam follower 1 shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork. S S

2. Check:

TRANSMISSION

ENG

EAS00424

CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. S

Main axle runout limit 0.08 mm 2. Measure: drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. S

Drive axle runout limit 0.08 mm

3. Check:

TRANSMISSION

ENG

EAS00426

INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: shift fork 3 “L” (left) 1 (face the “L” side for the clutch side.) shift fork 2 “R” (right) 2 (face the “R” side for the clutch side.) shift fork 1 “C” (center) 3 (face the “C” side for the magneto side.) shift fork guide bar 1 4 (long) shift fork guide bar 2 5 (short) S

S

S

S S

NOTE: Install the shift forks with the embossed mark to the right and in sequence (R, C, L) beginning from the right.

2. Check:

CARB CHAPTER 5. CARBURETOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 5-7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 DISASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 ASSEMBLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

CARB

CARBURETOR

CARB

CARBURETOR CARBURETOR

7 Nm (0.7 m kg) S

7 Nm (0.7 m kg) S

CARBURETOR

CARB

CARBURETOR

CARB

CARBURETOR

CARB

EB600031

CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 1. Check: carburetor body float chamber jet housing Cracks/damage ! Replace. 2. Check: fuel passages Obstruction ! Clean. S S S

S

a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic-carburetorcleaning solution. b. Blow out all of the passages and jets with compressed air.

CARBURETOR

CARB

7. Check: piston valve 1 Damage/scratches/wear ! Replace. rubber diaphragm 2 Cracks/tears ! Replace. S

S

8. Check: vacuum chamber cover 1 piston valve spring 2 plastic cap 3 plastic cap 4 spring 5 Cracks/damage ! Replace. S S S S S

9. Check:

CARBURETOR

CARB

EB600042

ASSEMBLING THE CARBURETOR NOTE: Before disassemblling the carburetor, make sure to note the number of times, the pilot screw is turned out from the seated position to its set position.

CAUTION: S

S

Before assembling the carburetors, wash all of the parts in a petroleum-based solvent. Always use a new gasket.

1. Install:

CARBURETOR

CARB

EB600051

INSTALLING THE CARBURETOR 1. Adjust: engine idling speed S

Engine idling speed 1,250  1,450 r/min Refer to “ADJUSTING THE ENGINE IDLLING SPEED” in chapter 3. 2. Adjust: throttle cable free play S

Throttle cable free play (at the flange of the throttle grip) 3  5 mm Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.

EB600063

MEASURING AND ADJUSTING THE FUEL

CARBURETOR

CARB

2. Adjust: fuel level S

a. Remove the carburetor assembly. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1 . e. Install the carburetor assembly. f. Measure the fuel level again. g. Repeat steps (a) to (f) until the fuel level is within specification.

CARBURETOR

CARB

EAS00502

CHECKING AND ADJUSTING THROTTLE POSITION SENSOR

THE

NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad justed. 1. Check: S throttle position sensor (installed on the carburetor) 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 probe ! black terminal 2 c. Measure the maximum throttle position sensor resistance. Out of specification ! Replace the throttle

CARBURETOR

CARB

2. Check: S throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sensor coupler from the wire harness. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω  1k) to the throttle position sensor. Positive tester probe ! blue terminal 1 Negative tester probe ! black terminal 2 d. Measure the maximum throttle position sensor resistance. Out of specification ! Replace the throttle position sensor. Maximum throttle position sensor resistance 4.0 X 6.0 kΩ at 20_C (blue – black)

CARBURETOR

CARB

3. Adjust: throttle position sensor angle S

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 probe ! black terminal 2 c. Measure the throttle position sensor maximum resistance. d. Calculate the throttle position sensor maximum resistance when the throttle is fully closed. Throttle position sensor maximum resistance (throttle is fully closed) = Maximum resistance (0.13 0.15) Example If the maximum resistance = 5 kΩ, then the throttle position sensor’s maximum resistance

FUEL PUMP

CARB

CHECKING THE FUEL PUMP 1. Check: fuel pump S

a. Turn the fuel cock “OFF”. b. Disconnect the fuel hose. (fuel pump-carburetor) c. Place a container under the fuel hose end. d. Turn the main switch to “ON”. e. Push the “START” switch. f. Check the fuel flows out from the fuel hose end. If fuel does not flow ! Clean or replace the fuel pump.

DISASSEMBLING THE FUEL PUMP

FUEL PUMP

CARB

4. Check: diaphragms and gaskets Turn/fatigue/cracks ! Replace fuel pump assembly. 5. Check: valves 1 Cracks/damage ! Replace fuel pump assembly. S

S

ASSEMBLING THE FUEL PUMP Reverse the disassembly procedure. NOTE: Be sure to connect the hoses correctly.

CHAS CHAPTER 6. CHASSIS FRONT WHEEL AND BRAKE DISC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 CHECKING THE SPEEDOMETER GEAR UNIT . . . . . . . . . . . . . . . . 6-7 INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE

. . . . . . . . . . 6-9

REAR WHEEL AND REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 REAR BRAKE AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . 6-12 REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . 6-16 CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 6-16 CHECKING THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 ASSEMBLILNG THE BRAKE SHOE PLATE . . . . . . . . . . . . . . . . . . . . 6-18 INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

CHAS STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . . 6-57 REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-57 SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 HANDLING THE REAR SHOCK ABSORBER

. . . . . . . . . . . . . . . . . . 6-59

DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 6-59 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES . . . . . 6-60 REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-62 CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64 INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

FRONT WHEEL AND BRAKE DISC

CHASSIS FRONT WHEEL AND BRAKE DISC 40 Nm (4.0 m kg) S

59 Nm (5.9 m kg) S

20 Nm (2.0 m kg) S

23 Nm (2.3 m kg) S

CHAS


CHAS


CHAS

EAS00519

REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: brake caliper 1 S

NOTE: Do not squeeze the brake lever when removing the brake caliper. 3. Remove: pinch bolt (front wheel axle) 2 front wheel axle 3 S S


CHAS

3. Check: spokes Bends/damage ! Replace. Loose ! Tighten. Tap the spokes with a screwdriver. S

NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: spokes S

3 Nm (0.3 m kg) S

NOTE: After tightening the spokes, measure the front wheel runout. 5. Measure: front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits ! Replace. S S

Front wheel radial runout limit


CHAS

a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface. c. Remove the wheel bearings with a general bearing puller 2 . d. Install the new wheel bearings and oil seals in the reverse order of disassembly.

CAUTION: Do not contact the wheel bearing center race 4 or balls 5 . Contact should be made only


CHAS

c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the center part of the brake disc that the brake pads touches.

3. Measure: brake disc thickness 1 Measure the brake disc thickness at a few different locations. Out of specification ! Replace. S

Brake disc thickness limit (minimum) Front: 4.5 mm 4. Adjust: brake disc deflection S


CHAS

CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: speedometer clutch Bends/damage/wear ! Replace. 2. Check: speedometer drive gear 1 speedometer driven gear 2 Damage/wear ! Replace. S

S S

EAS00542

INSTALLING THE FRONT WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips speedometer drive gear speedometer driven gear S S S S S

Recommended lubricant Lithium soap base grease 2. Install:

FRONT WHEEL AND BRAKE DISC 4. Tighten: wheel axle 1 wheel axle pinch bolt 2 S

CHAS 59 Nm (5.9 m kg) S

S

20 Nm (2.0 m kg) S

S

brake caliper bolts 3

40 Nm (4.0 m kg) S

WARNING Make sure that the brake cable is routed properly.

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


CHAS

EAS00549

ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1. Remove: S balancing weight (-s) NOTE: Place the front wheel on a suitable balancing stand. 2. Find: S front wheel’s heavy spot a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the “X ” mark


CHAS

4. Check: front wheel static balance S

a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.

REAR WHEEL AND REAR BRAKE

CHAS

REAR WHEEL AND REAR BRAKE REAR WHEEL 23 Nm (2.3 m kg) S

104 Nm (10.4 m kg) S

16 Nm (1.6 m kg) S

REAR WHEEL AND REAR BRAKE REAR BRAKE AND REAR WHEEL SPROCKET

CHAS


CHAS


CHAS

10 Nm (1.0 m kg) S


CHAS

EAS00563

REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: tension bar 1 3. Remove: wheel axle 2 rear wheel S

S S

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


CHAS

EAS00566

CHECKING THE REAR WHEEL 1. Check: wheel axle rear wheel wheel bearings oil seals Refer to “FRONT WHEEL”. 2. Check: tire rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Check: spokes Refer to “FRONT WHEEL”. 4. Measure: rear wheel radial runout rear wheel lateral runout Refer to “FRONT WHEEL”. S S S S

S S

S

S S

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB


CHAS

Rear wheel sprocket self-locking nut 40 Nm (4.0 m kg) S

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

EAS00569

CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: brake shoe lining Glazed areas ! Repair. Sand the glazed areas with course sandpaper. S

NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.


CHAS

4. Check: brake drum inner surface Oil deposits ! Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches ! Repair. Lightly and evenly polish the scratches with an emery cloth. 5. Check: brake camshaft Damage/wear ! Replace. S

S

EAS00570

ASSEMBLING THE BRAKE SHOE PLATE


CHAS

EAS00571

INSTALLING THE REAR WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips S S S

Recommended lubricant Lithium soap base grease 2. Adjust: drive chain slack S

Drive chain slack 30  40 mm Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 3. Tighten: wheel axle nut 104 Nm (10.4 m kg) S

S

WARNING Make sure that the brake hose is routed properly.

FRONT AND REAR BRAKES

FRONT AND REAR BRAKES FRONT BRAKE PADS

CHAS


CHAS

EAS00579

CAUTION: 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 brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. S

S

S

S

S

S


CHAS

EAS00581

REPLACING THE FRONT BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: retaining bolt 1 2. Remove: brake caliper 2 3. Remove: brake pad spring 1 brake pads 2 S

S

S S

4. Measure:


CHAS

Recommended lubricant Lithium soap base grease

CAUTION: S

S

Do not allow grease to contact the brake pads. Remove any excess grease.

7. Install: brake caliper retaining bolt 27 Nm (2.7 m kg) 8. 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. 9. Check: brake lever operation Soft or spongy feeling Bleed the brake S S

S

S

S


CHAS

FRONT BRAKE MASTER CYLINDER

7 Nm (0.7 m kg) S


CHAS


CHAS

EAS00588

REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before removing the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: rear view mirror (right) brake lever/compression spring brake switch 1 2. Remove: union bolt 2 copper washers brake hose 3 S S S

S S S

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


CHAS

EAS00592

CHECKING THE FRONT BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder 1 Damage/scratches/wear ! Replace. brake fluid delivery passages 2 (brake master cylinder body) Obstruction ! Blow out with compressed air. S

S

2. Check: brake master cylinder kit 1 Damage/scratches/wear ! Replace. S

3. Check:


CHAS

EAS00598

INSTALLING THE FRONT BRAKE MASTER CYLINDER

WARNING S

S

Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. Recommended brake fluid DOT 4

1. Install: brake master cylinder 1 brake master cylinder bracket 2 S S

7 Nm (0.7 m kg) S

NOTE: Install the brake master cylinder bracket with the “UP” mark facing up. Align the end of the brake master cylinder holder with the punch mark a on the handlebar. S

S


CHAS

WARNING S

S

S

Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4 Bl ed

FRONT AND REAR BRAKES EAS00612

FRONT BRAKE CALIPER

30 Nm (3.0 m kg) S

CHAS


CHAS

6 Nm (0.6 m kg) S


CHAS

EAS00619

DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose S S S

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 S S

a. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.


CHAS

EAS00633

CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule: Brake pads

If necessary

Piston seals

Every two years

Brake hoses

Every two years

Brake fluid

Every two years and whenever the brake is disassembled.

1. Check: brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. Piston assembly. brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. brake calipers 3 Cracks/damage ! Replace. brake fluid delivery passages S

S

S


CHAS

ASSEMBLING AND INSTALLING FRONT BRAKE CALIPER

THE

WARNING S

S

S

Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. 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: brake caliper 1 (temporarily) copper washers New 2 brake hose 3 union bolt 4 30 Nm (3.0 m kg) S

S S S

S


CHAS

3. Fill: brake master cylinder reservoir (with the specified amount of the recommended brake fluid) S

Recommended brake fluid DOT 4

WARNING S

S

S

Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

FRONT FORK

CHAS

EAS00646

FRONT FORK

20 Nm (2.0 m kg) S

23 Nm (2.3 m kg) S

7 Nm (0.7 m kg) S

30 Nm 3.0 m kg) S

FRONT FORK

CHAS

23 Nm (2.3 m kg) S

FRONT FORK

CHAS

23 Nm (2.3 m kg) S

FRONT FORK

CHAS

EAS00649

REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loosen: cap bolt 1 upper bracket pinch bolt 2 lower bracket pinch bolt 3 front turn signal pinch bolt 4 S S S S

WARNING Before loosening the upper and lower

FRONT FORK

CHAS

CAUTION: Do not scratch the inner tube. 4. Remove: damper rod bolt copper washer S S

NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the damper rod bolt 3 . Damper rod holder 90890-01365 T-Handle 90890-01326 5. Remove: damper rod inner tube S S

Hold the front fork leg horizontally

FRONT FORK

CHAS

EAS00657

CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: inner tube 1 outer tube 2 Bends/damage/scratches ! Replace. S S

WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: spring free length a Over the specified limit S

!

Replace.

Spring free length limit 299.4 mm

3. Check:

FRONT FORK

CHAS

NOTE: When assembling the front fork leg, be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal Before assembling the front fork leg, make sure that all of the components are clean. S

S

1. Install: damper rod 1 oil lock piece 2 S S

CAUTION: Allow the damper rod to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: inner tube’s outer surface S

FRONT FORK

CHAS

5. Install: washer oil seal 1 (with the fork seal driver weight and adapter) S S

CAUTION: Make sure that the numbered side of the oil seal faces up. NOTE: Before installing the oil seal, apply lithium soap base grease onto its lips. Apply fork oil onto the outer surface of the inner tube. Before installing the oil seal, cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation. S

S

2

S

6. Install:

FRONT FORK

CHAS

Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 112 mm NOTE: While filling the front fork leg, keep it upright. After filling, slowly pump the front fork leg up and down to distribute the fork oil. Be sure to stroke the inner tube slowly because the fork oil may spurt out. S S

S

9. Install:

FRONT FORK

CHAS

EAS00662

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: front fork leg Temporarily tighten the upper and lower bracket pinch bolts. S

NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: lower bracket pinch bolt 1 S

30 Nm (3.0 m kg) S

S

upper bracket pinch bolt 2 20 Nm (2.0 m kg) S

S S

cap bolt 3 23 Nm (2.3 m kg) front turn signal pinch bolt 4 S

7 Nm (0.7 m kg) S

WARNING

CHAS

HANDLEBAR

HANDLEBAR

7 Nm (0.7 m kg) S

23 Nm (2.3 m kg) S

CHAS

HANDLEBAR

7 Nm (0.7 m kg) S

23 Nm (2.3 m kg) S

HANDLEBAR

CHAS

EAS00666

REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: front brake master cylinder assembly 1 right handlebar switch 2 throttle grip 3 3. Remove: clutch lever assembly handlebar grip (left) 1 S S S

S S

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

HANDLEBAR

CHAS

3. Install: handlebar grip S

a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.

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

EAS00670

INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface.

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

HANDLEBAR

CHAS

NOTE: Install the right handlebar switch alignment surface position so that it is perpendicular ( a = 90_) to the master cylinder alignment surface.

4. Install: S master cylinder Refer to “FRONT AND REAR BRAKES”.

5. Install:

HANDLEBAR

CHAS

9. Adjust: clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. S

Clutch cable free play (at the end of the clutch lever) 5  10 mm 10. Adjust: throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. S

Throttle cable free play (at the flange of the throttle grip) 3  5 mm

STEERING HEAD

CHAS

STEERING HEAD LOWER BRACKET 110 Nm (11.0 m kg) S

1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) S S

7 Nm (0.7 m kg) S

STEERING HEAD

CHAS

110 Nm (11.0 m kg) S

1st 52 Nm (5.2 m kg) 2nd 18 Nm (1.8 m kg) S S

7 Nm (0.7 m kg) S

STEERING HEAD

CHAS

EAS00677

REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface.

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

2. Remove: upper ring nut 1 lower ring nut 2 S S

NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring nut with the ring nut wrench. Exhaust and steering nut wrench 90890-01268 Ring nut wrench

STEERING HEAD

CHAS

a. Remove the bearing reces from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing reces.

CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearings and bearing races as a set. Whenever the steering head is disassembled, replace the rubber seal. S

S

STEERING HEAD

CHAS

NOTE: Temporarily tighten the steering stem nut. 4. Install: front fork legs Refer to “FRONT FORK” S

NOTE: Temporarily tighten the upper and lower bracket pinch bolts.

REAR SHOCK ABSORBER AND SWINGARM

CHAS

EAS00685

REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY

23 Nm (2.3 m kg) S

REAR SHOCK ABSORBER AND SWINGARM SWINGARM

46 Nm (4.6 m kg) S

CHAS


CHAS

EAS00687

HANDLING THE REAR SHOCK ABSORBER

WARNING This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. If the rear shock absorber or both are damaged, damping performance will suffer. S

S

S


CHAS

EAS00691

REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: rear shock absorber (left and right) S

EAS00706

REMOVING THE DRIVE CHAIN


CHAS

EAS00703

REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface.

WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: rear shock absorber assembly bolt 1 S

NOTE: When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 3. Check: swingarm side play A S


CHAS

EAS00696

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. spring Damage/wear ! Replace the rear shock absorber assembly. bushings Damage/wear ! Replace. dust seals Damage/wear ! Replace. bolts Bends/damage/wear ! Replace. S

S

S

S

S

S

EAS00707

CHECKING THE SWINGARM


CHAS

4. Check: dust covers 1 spacer 2 oil seals 3 Damage/wear ! Replace. bearings Damage/pitting ! Replace. S S S

S


CHAS

EAS00709

CHECKING THE DRIVE CHAIN 1. Measure: ten-link section a of the drive chain Out of specification ! Replace the drive chain. S

Max. ten-link drive chain section 119.5 mm NOTE: While measuring the ten-link section, push down on the drive chain to increase its tension. Measure the length between drive chain roller 1 and 11 as shown. Perform this measurement at two or three different places. S

S

S

2. Check:


CHAS

c. Remove the drive chain from the kerosine and completely dry it.

CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain. Don’t soak drive drain in kerosine more them ten minutes. O-ring is damage by kerosine.

4. Check:


CHAS

EAS00711

INSTALLING THE SWINGARM 1. Lubricate: bearings spacers dust covers pivot shaft S S S S

Recommended lubricant Molybdenum disulfide grease 2. Install: rear shock absorber assembly rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” and “REAR WHEEL”. S S


CHAS

INSTALLING THE DRIVE CHAIN 1. Lubricate: drive chain S

Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: drive chain chain case chain cover S S S

CAUTION: Connecting the neutral switch lead, starter motor and A.C. generator leads should be through under the neutral switch . Face the terminal cover to right-under side, then assemble the chain cover without the both leads being caught. 3. Install: rear wheel S

ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHECKING THE BULBS AND SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . 7-5 TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 7-5 CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-7 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

ELEC

ELECTRICAL COMPONENTS EB800000

ELECTRICAL

ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8

Main switch Thermo switch Flasher relay Relay unit Front brake light switch Clutch switch Ignition coil Igniter unit

9 10 11 12 13 14 15 16

Fuse Starter relay Side stand switch Neutral switch Rectifier/regulator Battery Rear brake light switch Horn

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SWITCHES

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EAS0010

SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.

CAUTION: Never insert the tester probes into the coupler terminal slots 1 . Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Pocket tester 90890-03112 NOTE: Before checking for continuity, set the pocket tester to “0” and to the “Ω  1” range. When checking for continuity, switch back and S

S

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. Incorrect continuity reading ! Replace the switch.

CHECKING THE SWITCHES 1 2 3 4 5 6 7 8

Clutch switch Pass switch Horn switch Dimmer switch Turn switch Front brake switch Main switch Lights switch

9 10 11 12 13 14

Engine stop switch Start switch Fuse Rear brake switch Sidestand switch Neutral switch

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CHECKING THE BULBS AND BULB SOCKETS

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EAS00732

CHECKING THE BULB SOCKETS

BULBS

AND

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 ! Properly connect. Incorrect continuity reading ! Repair or replace the bulb, bulb socket or both.

TYPES OF BULBS


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

CAUTION: S

S

Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

2. Check:


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. S

Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.

a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity.

IGNITION SYSTEM

IGNITION SYSTEM CIRCUIT DIAGRAM

ELEC

ELEC

IGNITION SYSTEM EAS00737

TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. engine stop switch 10. neutral switch 11. sidestand switch 12. relay unit (diode) 13. wiring (of the entire ignition system) NOTE: S Before troubleshooting, remove the following

EAS00739

2. Battery S

Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Min. open-circuit voltage 12.8 V or more at 20 _C

S

Is the battery OK? YES

NO Clean the battery terminals. S Recharge or replace the battery. S

EAS00741

3. Spark plugs

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IGNITION SYSTEM EAS00743

Spark plug cap resistance 10 kΩ at 20_C

4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 as shown. S 2 Spark plug cap S Set the main switch to “ON”. S Measure the ignition spark gap a . S Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs.

S

Is the spark plug cap OK? YES

NO Replace the spark plug cap.

EAS00747

6. Ignition coil resistance The following procedure applies to all of the ignition coils. S Disconnect the ignition coil connectors from the ignition coil terminals. S Connect the pocket tester (Ω  1) to the ignition coil as shown. Tester positive probe ! red/black Tester negative probe ! orange (gray)

IGNITION SYSTEM

ELEC

EAS00749

8. Main switch Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the main switch OK? S

YES Replace switch.

Secondary coil resistance 10.4 X 15.6 kΩ 20_C S

the

main

EAS00750

Is the ignition coil OK? YES

NO

9. Engine stop switch NO

Replace the ignition coil.

Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? S

YES

NO

EAS00748

7. Pickup coil resistance

Replace the right handlebar switch.

IGNITION SYSTEM

NOTE: When you switch the “–” and “+” leads of the digital pocket tester the readings in the above chart will be reversed.

EAS00760

12. Relay unit (Diode) S S

S

Disconnect the relay unit from the coupler. Connect the pocket tester (Ω  1) to the starting circuit cutoff relay terminals as shown. Measure the relay unit for continuity as follws.

Tester positive probe ! blue/green 1 Tester negative probe ! blue/yellow 2 Tester positive probe ! blue/yellow 2 Tester negative probe ! blue/green 1 Tester positive probe ! light green 3 Tester negative probe

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S

Are the tester readings correct? YES

NO Replace the starting circuit cut-off relay.

Continuity EAS00754

13. Wiring No continuity

S

S

Continuity

Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the ignition system’s wiring properly connected and without defects? NO

YES

ELECTRIC STARTING SYSTEM

ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

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ELEC

EB803010

STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed). or if The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter from operating when neither of these conditions have been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions have been met however, the starting circuit cut-off

ELEC

ELECTRIC STARTING SYSTEM EAS00757

TROUBLESHOOTING The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. relay unit (starting circuit cutoff relay) 5. relay unit (diode) 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. start switch 13. wiring (of the entire starting system) NOTE: S Before troubleshooting, remove the following part(-s):

EAS00739

2. Battery S

Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Open-circuit voltage 12.8 V or more at 20 _C

S



EAS00758

3. Starter motor S

Connect the battery positive terminal 1 and starter motor lead 2 with a jumper lead


4. Relay unit (starting eircuit cutoff relay) S

S

Disconnect the relay unit (starting circuit cutoff relay) from the coupler. Connect the pocket tester (Ω  1) and battery (12 V) to the relay unit terminals as shown.

Battery positive terminal

!

red/black 1 Battery negative terminal

!

black/yellow 2 Tester positive probe ! blue 3 Tester negative probe ! black 4

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Tester positive probe ! light green 1 Tester negative probe ! blue/yellow 3

Continuity

Tester positive probe ! blue/yellow 3 Tester negative probe ! light green 1

No continuity

Tester positive probe ! blue/green 4 Tester negative probe ! blue/yellow 3

Continuity

Tester positive probe ! blue/yellow 3 Tester negative probe ! blue/green 4

No continuity


6. Starter relay S

S

Disconnect the starter relay from the coupler. Connect the pocket tester (Ω  1) and battery (12 V) to the starter relay coupler as shown.

ELEC

EAS00750

8. Engine stop switch S

S

Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the engine stop switch OK? YES

Battery positive terminal ! red/white 1 Battery negative terminal ! blue 2

NO Replace the right handlebar switch.

Tester positive probe ! red 3 Tester negative probe ! black 4 EAS00751

9. Neutral switch S

S

Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the neutral switch OK? YES

NO Replace the neutral


12. Start switch S

S

Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the start switch OK? YES

NO Replace the right handlebar switch.

EAS00766

13. Wiring S

S

Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. Is the starting system’s wiring properly connected and without defects? NO

Properly connect or

YES The starting system

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ELECTRIC STARTING SYSTEM STARTER MOTOR

5 Nm (0.5 m kg) S

ELEC


ELEC

EAS00769

CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Min. commutator diameter 22 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 1.5 mm NOTE:


ELEC

5. Measure: brush length a Out of specification ! Replace the brushes as a set. S

Min. brush length 3.5 mm

6. Measure: brush spring force free length a Out of specification ! Replace the brush springs as a set. S

Brush spring force 5.52 8.28 N (563 X

7. Check:

X

844 gf)


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3. Install: Starter motor front cover 1 S

NOTE: Align the match marks a on the rear cover with the match marks b on the front cover.

CHARGING SYSTEM

CHARGING SYSTEM CIRCUIT DIAGRAM

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CHARGING SYSTEM EAS00774

EAS00739

TROUBLESHOOTING The battery is not being charged. Check: 1. main fuses 2. battery 3. charging voltage 4. stator coil assembly resistance 5. wiring (of the entire charging system)

2. Battery S


S

Is the battery OK YES

NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) rider’s seat 3) left side cover S Troubleshoot with the following special tool(-s).


EAS00775

3. Charging voltage Engine tachometer

S

Connect the engine tachometer to the spark

CHARGING SYSTEM

ELEC

EAS00779

NOTE: Make sure that the battery is fully charged. S

Is the charging voltage within specification? NO

YES The charging circuit is OK.

EAS00776

4. Stator coil assembly resistances Remove the generator cover. S Connect the pocket tester ( Ω  1) to the stator coil assembly coupler as shown. S

Tester positive probe ! white 1 Tester negative probe ! white 2 Tester positive probe ! white 1 Tester negative probe ! white 3

5. Wiring Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. S Is the charging system’s wiring properly connected and without defects? S

NO Properly connect or repair the charging system’s wiring.

YES Replace the rectifier/regulator.

LIGHTING SYSTEM

LIGHTING SYSTEM CIRCUIT DIAGRAM

ELEC

ELEC

LIGHTING SYSTEM EAS00781

TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. main and headl headlight ight fuse fuses s 2. ba batt tter ery y 3. ma main in swi switc tch h 4. lig lights hts swi switch tch 5. dim dimme merr sw switc itch h 6. pa pass ss swi switc tch h 7. wi wiri ring ng (of the entire lighting system) NOTE: S Before troubleshooting, remove the following part(-s). 1) ba batte ttery ry cove coverr 2) rid rider’s er’s se seat at 3) fu fuel el ta tank nk 4) steer steering ing head head side side covers covers

EAS00739

2. Ba Batt tter ery y S


S



EAS00749

3. Ma Main in swi switc tch h S

Check the main switch for continuity.

LIGHTING SYSTEM EAS00784

EAS00788

5. Dim Dimmer mer swi switch tch S

S

Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the dimmer switch OK? YES

NO The dimmer switch is faulty. Replace the left handlebar switch.

CHECKING THE LIGHTING SYSTEM 1. The headlight headlight and and the high beam beam indicator indicator light fail to came on. 1. Head Headligh lightt bulb and socke sockett S

S

Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the headlight bulb and socket OK? YES

6. Pa Pass ss swi switc tch h

S

NO Replace the headlight bulb, socket or both.

EAS00786

S

ELEC

Check the pass switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the pass switch OK? 2. Vol olta tage ge YES

NO

S

Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light cou-

LIGHTING SYSTEM

ELEC

2. Vol olta tage ge S

Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown.

Tester positive probe ! blue 1 Tester negative probe ! black 2

S S S S

S

S

Set the main switch to “ON”. Set the lig light ht swi switch tch to “ ”. Set the dimm dimmer er switc switch h to “ ” or “ ”. 1 Measure the voltage (12 V) of yellow or green 2 on the headlight coupler (headlight side). Measure the voltage (12 V) of yellow 4 on the meter assembly coupler. Is the voltage within specification?

S S S

YES

NO S

Set the main switch to “ON”. Set the light switch to “ ” or “ ”. Measure the voltage (12 V) of blue 1 on the meter assembly coupler (wire harness side). Is the voltage within specification?

LIGHTING SYSTEM 2. Vol olta tage ge S

Connect the pocket tester (DC 20 V) to the tail// brake light coupler tail coupler (wire harness side) as shown.

Tester positive probe ! blue 1 Tester negative probe ! black 2

S S S

S

Set the main switch to “ON” Sett th Se the e liligh ghtt sw swit itch ch to “ ” or “ ”. Measure the voltage (12 V) of blue 1 on the tail// brake light coupler tail coupler (wire harness side). Is the voltage within specification?

ELEC


Connect the pocket tester (DC 20 V) to the auxiliary light couplers (wire harness side) as shown.

Tester positive probe ! blue/red 1 Tester negative probe ! black 2

S S S

Set the main switch to “ON” Set the ligh lightt swit switch ch to “ ” or “ ”. Measure the voltage (12 V) of blue/ red 1 on the auxiliary light couplers (wire harness side).

SIGNALING SYSTEM

SIGNALING SYSTEM CIRCUIT DIAGRAM

ELEC

SIGNALING SYSTEM 3 4 6 9 18 21 23 32 33 34 35 38 39 40 41 43 44 45 46

Main switch Fuse (main) Battery Relay unit (Diode) Neutral switch Neutral indicator light Turn signal indicator light Horn switch Turn signal switch Horn Flasher relay Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Fuse (signal) Rear stop switch Front stop switch Tail/ brake light

ELEC

ELEC

SIGNALING SYSTEM EB806010

TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. S The forn fails to sound. S

Check: 1. main and signaling system fuses 2. battery 3. main switch 4. wiring (of the entrire signaling system) NOTE: S Before troubleshooting, remove the following part(-s): 1) battery cover 2) rider’s seat 3) fuel tank 4) steering head side covers 5) headlight lens unit 6) tool box cover 7) left side cover

EAS00739

2. Battery S

Check the condition of the battery. Refer to “CHECKING AND CHRGING THE BATTERY” in chapter 3. Open-circuit voltage 12.8 V or more at 20_C

S



EAS00749

3. Main switch S

Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”.

SIGNALING SYSTEM

ELEC

EAS00796

CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch S

S

3. Horn S

S

Check the forn switch for continuity. Refer to “CHECKING THE SWITCHES”. Is the horn switch OK? YES

NO

S S

Disconnect the pink connector at the horn terminal. Connect a jumper lead 1 to the horn terminal and ground the jumper lead. Set the main switch to “ON”. Does the horn sound? Br

Replace the left handlebar switch.

2. Voltage S

Connect the pocket tester (DC 20 V) to the horn connecter at the horn terminal as shown.

Tester positive probe ! brown 1 Tester negative probe ! ground

NO

YES The horn is OK.

SIGNALING SYSTEM

ELEC

EAS00797

2. A tail/brake light fails to come on.

S S

1. Tail/ brake light bulb and socket S

S

Check the tail/ brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. Are the tail/brake light bulb and socket OK? YES

NO

S

S

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? YES

This circuit is OK.

Replace the tail/ brake light bulb, socket or both.

NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must bne repaired.

2. Brake light switches S

S

Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. Is the brake light switch OK?

EAS00799

3. A turn signal light, turn signal indicator light or both fail to blink.

SIGNALING SYSTEM 2. Turn signal switch S

S

Check the turn signal for continuity. Refer to “CHECKING THE SWITCHES”. Is the turn signal switch OK? YES

ELEC

Tester positive probe ! brown/white 1 Tester negative probe ! ground

NO Replace the left handlebar switch.

3. Voltage S

Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown.

Tester positive prove ! brown 1 Tester negative prove ! ground

S S S

S

Set the main switch to “ON”. Set the turn signal switch to “ ” or “ ”. Measure the voltage (12 V) of brown/ white at the flasher relay coupler (wire harness side). Is the voltage within specification? YES

NO The flasher relay is faulty and must be re-

SIGNALING SYSTEM S S S

S

Set the main switch to “ON”. Set the turn signal switch to “ ” or “ ”. Measure the voltage (12 V) of chocolate 1 or dark green 2 at the turn signal light connector (wire harness side). Is the voltage within specification? YES

This circuit is OK.

NO

ELEC


Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown.

Tester positive probe ! brown 1 Tester negative probe ! sky blue 2

The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must repaired.

EAS00800

4. The neutral neutral indicator indicator light light fails to come on. 1. Neutral indicator light bulb bulb and and socket socket S

Check the neutral indicator light bulb and socket for continuity.

S S

S

Set the main switch to “ON”. Measure the voltage (12 V) of brown 1 and sky blue 2 at the meter assembly coupler. Is the voltage with specification specification? ?

CARBURETOR HEATER SYSTEM

CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM

ELEC

ELEC

CARBURETOR HEATER SYSTEM EAS00781

TROUBLESHOOTING The carburetor heater fails to operate. Check: 1. main main,, and carburet carburetor or heater heater fuses fuses 2. ba batt tter ery y 3. ma main in swi switc tch h 4. the thermo rmo swi switch tch 5. car carbur bureto etorr heater heater 6. wi wiri ring ng (of the entire carburetor heater system) NOTE: S Before troubleshooting, remove the following part(-s): 1) ba batte ttery ry cove coverr 2) rid rider’s er’s se seat at 3) fu fuel el ta tank nk 4) steer steering ing head head side side covers covers 5) too tooll box box cove coverr S Troubleshoot with the following special tool (-s).

EAS00739

2. Ba Batt tter ery y S


S



EAS00749

3. Ma Main in swi switc tch h S

Check the main switch for continuity.

CARBURETOR HEATER SYSTEM

ELEC

5. Ca Carbu rburet retor or heater heater S Remove the carburetor heater from the car-

buretor body. S Connect the pocket tester to the carburetor heater. Tester (+) lead ! Heater terminal Tester (–) lead ! Heater body 2

1

S Immerse the thermo switch in the water 3 . S Check the thermo switch for continuity.

Note the temperatures while heating the water with the temperature gauge 4 . Tes estt ste step p

Wat ater er te temp mper erat atur ure e

Good condition

S Measure the heater resistance.

Carburetor heater resistance: 12 V 30 W : 6 X 10 Ω at 20_C

SELF-DIAGNOSIS

ELEC

SELF-DIAGNOSIS The XVS125 features self-diagnosis. When the main switch is turned to “ON”, the following followi ng items are monitored and the condition codes are displayed on the engine indicator light (irrespective of whether the engine is running or not). NOTE: The XVS125 features a self-diagnosing system. In the XVS125, when the main switch is turned on the “Engine indicator light” in the speedometer comes on for 1.4 seconds then goes off. However, if there is a malfunction, it comes come s on for 1.4 seconds, goes off and then begins flashing. (However, it is on while the engine is running.) Display condition code Item

Throttle position sensor (TPS)

Condition

Disconnected Short-circuit Locked

Response

S

S

Enables the motorcycle to run so that the ignition timing is fixed when the throttle is fully opened. Displays the condition code on the engine indicator light.

When engine is stationary Blinks in Fault code: 3

When engine is running Light on

SELF-DIAGNOSIS

ELEC

EAS00835

TROUBLESHOOTING The engine warning light starts to display the self-diagnosis sequence.

1. Wi Wire re harn harnes ess s S

S

Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK?

Check: 1. throt throttle tle posit position ion sens sensor or NOTE: Before troubleshooting, remove the following part(-s): 1) ride riderr seat and passe passenger nger seat seat 2) fu fuel el ta tank nk 3) air filte filterr assemb assembly ly 4) sile silencer ncer asse assembly mbly Troubleshoot with the following special tool(-s).

YES

Repair or replace the wire harness.

S

EB812401

2. Thro Throttle ttle posi position tion sens sensor or S

S

Pocket tester 90890-03112

S

Check the throttle position sensor for continuity. Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in chapter 6. Is the throttle position sensor OK? YES

EAS00836

1. Throt Throttle tle posit position ion senso sensorr

NO

NO

SELF-DIAGNOSIS 2. Speed sensor (5JX2) CIRCUIT DIAGRAM NOTE: The speed sensor into the speedometer.

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1. Wire harness S

S

Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? YES

Replace the speed meter.

NO Repair or replace the wire harness.

TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2 FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY FRONT LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

TRBL SHTG

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 replacement of parts.

STARTING PROBLEMS ENGINE Cylinders and cylinder head(-s) Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valve clearance Incorrectly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve Pistons and piston rings Incorrectly installed piston ring S S S S S S S S S S

S

FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank breather hole Deteriorated or contaminated fuel Fuel cock Clogged or damaged fuel hose Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Damaged float S S S S

S

S S S S S

INCORRECT ENGINE IDLING SPEED/POOR MEDIUM ANDHIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING

TRBL SHTG

EAS00846

INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element S S

S

ELECTRICAL SYSTEMS Battery Faulty battery Discharged battery Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coil Broken or shorted primary or secondary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty CDI unit Faulty pickup coil S S

S S

FUEL SYSTEM Carburetor Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Incorrectly adjusted engine idling speed (throttle stop screw) Incorrect throttle cable free play Flooded carburetor S S S S S

S S

S S S S

S

S S

S S

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

FAULTY CLUTCH/OVERHEATING

TRBL SHTG

EAS00851

FAULTY CLUTCH CLUTCH SLIPS Clutch Incorrectly assembled clutch Incorrectly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil S S S S S

S S S

CLUTCH DRAGS Clutch Unevenly tensioned clutch spring Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Damaged clutch boss Burnt primary driven gear bushing Match marks not aligned Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil S S S S S S S S

S S S

EAS00854

OVERHEATING ENGINE Cylinder head(-s) and piston(-s) Heavy carbon buildup Engine oil S

CHASSIS Brakes Dragging brake S

POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING

TRBL SHTG

EAS00859

POOR BRAKING PERFORMANCE Front brake Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level S S S S S S S S S S

Rear brake Improper brake pedal adjustment Worn brake shoe Improper brake shoe contact Worn camshaft Worn brake drum Mud or water into brake drum inside Oily or greasy brake lining Faulty brake cable Broken or fatigued tension spring Faulty camshaft, cam lever S S S S S S S S S S

EAS00861

FAULTY FRONT FORK LEGS LEAKING OIL Bent, damaged or rusty inner tube Damaged outer tube Incorrectly installed oil seal Damaged oil seal lip Incorrect oil level (high) S S S S S

MALFUNCTION Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube busing Bent or damaged damper rod S S S S S

FAULTY LIGHTING AND SIGNALING SYSTEMS

TRBL SHTG

EAS00866

FAULTY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Incorrectly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb S S S S

TURN SIGNAL BLINKS SLOWLY Faulty flasher relay Faulty main switch Faulty turn signal switch Wrong turn signal bulb S S S S

S S S

TURN SIGNAL REMAINS LIT Faulty flasher relay Burnt-out-turn signal bulb S S

HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier/regulator Incorrectly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired S S S S

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulb Faulty flasher relay Burnt-out turn signal bulb S S S

S S S

HORN DOES NOT SOUND Incorrectly adjusted horn Damaged or faulty horn Faulty main switch S S

TAIL/BRAKE LIGHT DOES NOT LIGHT

Yamaha XVS 125 '00 - Service Manual

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